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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Fiber Reinforcement Architectures of PMCs on the Hygrothermal-Mechanical Performance for Aeropropulsion Applications

A rigid lightweight sandwich support structure, for the combustor chamber of a new generation liquid propellant rocket engine, was designed and fabricated using Polymer Matric Composite (PMC) facesheet on a Ti honeycomb or Carbon foam core. The facesheet consisted of high stiffness carbon fiber, M40JB, and high temperature Polyimides, such as PMR-11-50 and HFPE-II. Six different fiber architectures; 4HS woven fabric, uni-fabric, woven-uni hybrid, stitched woven fabric, stitched uni-fabric and tri-axial braided structures have been investigated for optimum stiffness-thickness-weight-performance design criteria for the hygrothermal-mechanical propulsion service exposure conditions including rapid heating up to 200 F/sec, maximum operating temperature of 600 F, internal pressure up to 100 psi. An extensive property and performance database including dry-wet mechanical properties at both 25 F and 600 F in various loading modes, thermal and physical properties including blistering onset condition was developed for fiber architecture down-selection and design guidelines. Various optimized process methods including vacuum bag compression molding, solvent assistant RTM (SaRTM), resin film infusion (RFI) were utilized for PMC panel fabrication depending on the architecture type. In the case of stitched woven fabric architecture, the optimal stitch pattern was chosen in terms of stitch density and yarn size, based on both in-plane mechanical properties and blistering performance. Potential reduction of the in-plane properties transverse to the line of stitching was also evaluated. Attempt to correlate the experimental results with theoretical micro-mechanics predictions will be presented.

Shin, Eugene↗
NASA NTRS2003

Effects of Fiber Reinforcement Architecture on the Hygrothermal-Mechanical Performance of Polyimide Matrix Composites for Aeropropulsion Applications

A lightweight sandwich support structure, for the combustor chamber of a new generation liquid propellant rocket engine, was designed and fabricated using a polymer matrix composite (PMC) facesheet on a Ti honeycomb core. The PMC facesheet consisted of high stiffness carbon fiber, M40JB, and high temperature Polyimides, such as PMR-II-50 and HFPE-II-52. Six different fiber architectures; four harness satin (4HS) woven fabric, uni-tape, woven-uni hybrid, stitched woven fabric, stitched uni-tape and triaxial braided structures have been investigated for optimum stiffness-thickness-weight-hygrothermal performance design criteria for the hygrothermal-mechanical propulsion service exposure conditions including rapid heating up to 200 F/sec, maximum operating temperature of 600 F, internal pressure up to 100 psi. One of the specific objectives in this study is to improve composite blistering resistance in z-direction at minimum expense of in-plane mechanical properties. An extensive property-performance database including dry-wet mechanical properties at various temperatures, thermal-physical properties, such as blistering onset condition was generated for fiber architecture down-selection and design guidelines. Various optimized process methods such as vacuum bag compression molding, solvent assistant resin transfer molding (SaRTM), resin film infusion (RFI) and autoclaving were utilized for PMC panel fabrication depending on the architecture type. In the case of stitched woven fabric architecture, the stitch pattern in terms of stitch density and yarn size was optimized based on both in-plane mechanical properties and blistering performance. Potential reduction of the in-plane properties transverse to the line of stitching was also evaluated. Efforts have been made to correlate the experimental results with theoretical micro-mechanics predictions. Changes in deformation mechanism and failure sequences in terms of fiber architecture will be discussed.

Shin, E. Eugene↗
NASA NTRSDate not supplied

ISAAC Integrated Structural Assembly of Advanced Composites

The NASA Langley Research Center obtained the Integrated Structural Assembly of Advanced Composites (ISAAC) robotic system in 2014 to add state-of-the-art automated manufacturing of composites to our traditional in-house design, analysis, and experimentation capabilities. ISAAC is used to explore fabrication of parts with novel designs and for research into new composite manufacturing techniques. Automated fiber placement (AFP) was the initial manufacturing capability on ISAAC and has been used to support a range of aeronautics and space projects including the Advanced Composites Project (ACP), Composites for Exploration Upper Stage (CEUS), and Advanced Air Transportation Technologies (AATT). In addition to AFP, ISAAC can now provide through-thickness reinforcement of composites by adding stitches through dry fabric prior to resin infusion. Stitching is of interest since it can improve damage tolerance, reduce final assembly time, and reduce inspection requirements. ISSAC can stitch traditional single-needle seams and perform stitching operations using two needles when access is only available to one side of the part. Stitching capability is being advanced in the High-Rate Composites Aircraft Manufacturing (HiCAM) project today. This lecture will describe the work with ISAAC today and new exciting plans for the future.

automated fiber placement↗
NASA NTRS2004

Hybrid Inflatable Pressure Vessel

Figure 1 shows a prototype of a large pressure vessel under development for eventual use as a habitable module for long spaceflight (e.g., for transporting humans to Mars). The vessel is a hybrid that comprises an inflatable shell attached to a rigid central structural core. The inflatable shell is, itself, a hybrid that comprises (1) a pressure bladder restrained against expansion by (2) a web of straps made from high-strength polymeric fabrics. On Earth, pressure vessels like this could be used, for example, as portable habitats that could be set up quickly in remote locations, portable hyperbaric chambers for treatment of decompression sickness, or flotation devices for offshore platforms. In addition, some aspects of the design of the fabric straps could be adapted to such other items as lifting straps, parachute straps, and automotive safety belts. Figure 2 depicts selected aspects of the design of a vessel of this type with a toroidal configuration. The bladder serves as an impermeable layer to keep air within the pressure vessel and, for this purpose, is sealed to the central structural core. The web includes longitudinal and circumferential straps. To help maintain the proper shape upon inflation after storage, longitudinal and circumferential straps are indexed together at several of their intersections. Because the web is not required to provide a pressure seal and the bladder is not required to sustain structural loads, the bladder and the web can be optimized for their respective functions. Thus, the bladder can be sealed directly to the rigid core without having to include the web in the seal substructure, and the web can be designed for strength. The ends of the longitudinal straps are attached to the ends of the rigid structural core by means of clevises. Each clevis pin is surrounded by a roller, around which a longitudinal strap is wrapped to form a lap seam with itself. The roller is of a large diameter chosen to reduce bending of the fibers in the strap. The roller also serves to equalize the load in the portions of the strap on both sides of the clevis pin. The lap seam is formed near the clevis by use of a tapered diamond stitch: This stitch is designed specifically to allow fibers in the stitch and strap to relax under load in such a manner that the load becomes more nearly evenly distributed among all fibers in the stitch region. Thus, the tapered diamond stitch prevents load concentrations that could cause premature failure of the strap and thereby increases the strength of the strap/structural-core joint. The lap seam can be rated at >90 percent of the strength of the strap material.

Raboin, Jasen↗
NASA NTRS2013

NDE Evidence for the Damage Arrestment Performance of PRSEUS Composite Cube During High-Pressure Load Test

As an approach to light-weight, cost-effective and manufacturable structures required to enable the hybrid wing body aircraft, The Boeing Company, Inc. and NASA have developed the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. A PRSEUS pressure cube was developed as a risk reduction test article to examine a new integral cap joint concept as part of a building block approach for technology development of the PRSEUS concept. The overall specimen strength exceeded the 18.4 psi load requirement as testing resulted in the cube reaching a final pressure load of around 48 psi prior to catastrophic failure. The cube pressure test verified that the joints and structure were capable of sustaining the required loads, and represented the first testing of joined PRSEUS structure. This paper will address the damage arrestment performance of the stitched PRSEUS structure. Following catastrophic failure of the cube, ultrasonic pulse-echo inspection found that the localized damage, surrounding a barely-visible impact damage site, did not change noticeably between just after impact and catastrophic failure of the cube, and did not play a role in the catastrophic failure event. Ultrasonic inspection of the remaining intact cube panels presented three basic types of indications: delaminations between laminae parallel to the face sheets, lying between face sheet and tear strap layers, or between tear strap and flange layers; delaminations above the noodles of stringers, frames or integral caps, lying within face sheet or tear strap layers; and delaminations between the laminae in the inner fillets of the integral caps, where pulloff stresses were expected to be highest. Delaminations of all three types were predominantly contained by the first row of stitches encountered. For the small fraction of delaminations extending beyond the first row of stitches, all were contained by the second stitch row.

Johnston, Patrick H.↗
NASA NTRS1995

Evaluation of the impact response of textile composites

An evaluation of the impact damage resistance and impact damage tolerance of stitched and unstitched uniweaves, 2-D braids, and 3-D weaves was conducted. Uniweave laminates were tested at four thicknesses to determine the sensitivity of the tests to this parameter. Several braid and weave parameters were also varied to establish their velocity (large mass) impacts and then loaded in tension or compression to measure residual strength. Experimental results indicate that stitching significantly improves the uniweaves' damage resistance. The 2-D braids and 3-D weaves offered less damage resistance than the stitched materials. Stitching also improved the compression after impact (CAI) and tension after impact (TAI) strengths of the uniweave materials.

Portanova, M. A.↗
NASA NTRS2013

Notched Strength Allowables and Inplane Shear Strength of AS4/VRM-34 Textile Laminates

Notched and unnotched strength allowables were developed for a textile composite to provide input data to analytical structural models based on the Pultruded Rod Stiffened Efficient Unitized Structure (PRSEUS) concept. Filled-hole tensile strength, filled-hole compressive strength, and inplane shear strength along stitch lines have been measured. The material system evaluated in this study is based on warp-knitted preforms of AS4 carbon fibers and VRM-34 epoxy resin, which have been processed via resin infusion and oven curing. All specimens were tested in as-fabricated (dry) condition. Filled-hole strengths were evaluated with and without through-thickness stitching. The effects of scaling on filled-hole tensile strength were evaluated by testing specimens in two widths, but with identical width / hole-diameter ratios. Inplane shear specimens were stitched in two configurations, and two specimen thicknesses were tested for each stitch configuration.

Grenoble, Ray W.↗
NASA NTRS2014

PRSEUS Panel Fabrication Final Report

NASA and the Boeing Company have been working together under the Environmentally Responsible Aviation Project to develop stitched unitized structure for reduced weight, reduced fuel burn and reduced pollutants in the next generation of commercial aircraft. The structural concept being evaluated is PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure). In the PRSEUS concept, dry carbon fabric, pultruded carbon rods, and foam are stitched together into large preforms. Then these preforms are infused with an epoxy resin into large panels in an out-of-autoclave process. These panels have stiffeners in the length-wise and width-wise directions but contain no fasteners because all stiffeners are stitched to the panel skin. This document contains a description of the fabrication of panels for use in the 30-foot-long Multi-Bay Box test article to be evaluated at NASA LaRC.

Linton, Kim A.↗
NASA NTRS2015

Fabrication of Lower Section and Upper Forward Bulkhead Panels of the Multi-Bay Box and Panel Preparation

NASA and the Boeing Co. have been working together under the Environmentally Responsible Aviation Project to develop stitched unitized structure for reduced weight, reduced fuel burn and reduced pollutants in the next generation of commercial aircraft. The structural concept being evaluated is PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure). In the PRSEUS concept, dry carbon fabric, pultruded carbon rods, and foam are stitched together into large preforms. Then these preforms are infused with an epoxy resin into large panels in an out-of-autoclave process. These panels have stiffeners in the length-wise and width-wise directions but contain no fasteners because all stiffeners are stitched to the panel skin. This document contains a description of the fabrication of panels for use in the 30-foot-long Multi-Bay Box test article to be evaluated at NASA LaRC. The document also describes a panel which explores new PRSEUS concepts for applications beyond the Multi-Bay Box.

Velicki, Alexander↗
NASA NTRS2012

TPSAS-NF1676L-13678-DND

An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is integral stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The goal of the PRSEUS concept is to provide damage-containment capability for composite structures while reducing overall structural weight. The National Aeronautics and Space Administration, the Boeing Company, and the Federal Aviation Administration (FAA) have partnered in an effort to assess the damage-containment features of a full-scale curved PRSEUS panel using the FAA Full-Scale Aircraft Structural Test Evaluation and Research facility. The background, test plan, fixture modifications, pre-test analysis, and planned experimental procedure were presented at the 2011 Aircraft Airworthiness and Sustainment Conference. This follow-on paper and presentation will provide details of the experimental procedure, test results, nondestructive inspection results, and preliminary test analysis comparison. The test program included three phases of loading and inspections: Phase I, as-built; Phase II, with barely visible impact damage (BVID); and Phase III, with a two-bay notch severing the central stiffener. Axial tension, internal pressure, and combined axial tension and internal pressure load conditions were applied during each phase using load levels that demonstrate compliance with the strength, deformation, and damage-tolerance requirements of Title 14 Code of Federal Regulations Part 25. Pressure loads were based on an operating pressure of 9.2 psi, designated as 1P, and the axial loads were based on a design limit load (DLL) of 227 kip. The Phase I test results provided a baseline. First, 50 percent limit-load levels were applied for each of the three load cases to verify proper load introduction and repeatability by examining strain and displacement results. Next, three limit-load cases were applied: limit pressure of 12.2 psi (1.33 P), axial DLL of 227 kip, and combined 1P pressure and axial DLL. Linear strain and displacement results were observed in all load cases. For Phase-II testing, the panel was impacted to introduce BVID with an energy of 40 ft-lb, with the impact located between the central stringer stitch line and flange edge. The impact created non-penetrating visual damage with fiber breaks and delamination between the skin and stringer flange. Limit-load conditions were applied followed by pressure overload of 18.4 psi (2P) and ultimate load conditions, defined as 1.5 times DLL. Inspections were performed after each load case; no damage growth was observed. For Phase-III testing, a two-bay notch was machined severing the central stiffener. The panel was then subjected to limit-load conditions, followed by combined 1P pressure while increasing axial tension load to catastrophic failure. As limit combined loads were approached, damage initiation was observed in the form of 45? splitting at 1P + 79% DLL. Axial loading was increased to 1P + 150 percent DLL causing damage to propagate to the adjacent stringer flanges. Damage was contained within the two-bay region by the stitching rows up to 1P + 176% DLL. Axial load was further increased until catastrophic failure, when a stringer rod failed at 1P + 192% DLL. These test results further verify the damage containment features of the PRSEUS concept and suggest its appropriateness for future flight vehicles.

Andrew Bergan↗
NASA NTRS1991

Load limiting energy absorbing lightweight debris catcher

In the representative embodiment of the invention disclosed, a load limiting, energy absorbing net is arranged to overlay a normally-covered vent opening in the rear bulkhead of the space orbiter vehicle. Spatially-disposed flexible retainer straps are extended from the net and respectively secured to bulkhead brackets spaced around the vent opening. The intermediate portions of the straps are doubled over and stitched together in a pattern enabling the doubled-over portions to progressively separate at a predicable load designed to be well below the tensile capability of the straps as the stitches are successively torn apart by the forces imposed on the retainer members whenever the cover plate is explosively separated from the bulkhead and propelled into the net. By arranging these stitches to be successively torn away at a load below the strap strength in response to forces acting on the retainers that are less than the combined strength of the retainers, this tearing action serves as a predictable compact energy absorber for safely halting the cover plate as the retainers are extended as the net is deployed. The invention further includes a block of an energy-absorbing material positioned in the net for receiving loose debris produced by the explosive release of the cover plate.

Kahn, Jon B.↗
NASA NTRS1991

Ultrasonic detection and identification of fabrication defects in composites

Methods for deliberate fabrication of porosity into carbon/epoxy composite panels and the influence of three-dimensional stitching on the detection of porosity were investigated. Two methods of introducing porosity were investigated. Porosity was simulated by inclusion of glass microspheres, and a more realistic form of porosity was introduced by using low pressure during consolidation. The panels were ultrasonically scanned and the frequency slope of the ultrasonic attenuation coefficient was used to evaluate the two forms of porosity. The influence of stitching on the detection of porosity was studied using panels which were resin transfer molded from stitched plies of knitted carbon fabric and epoxy resin.

Long, Edward R., Jr.↗
NASA NTRS1992

Development of stitched/RTM composite primary structures

The goal of the NASA Advanced Composites Technology (ACT) Program is to provide the technology required to gain the full benefit of weight savings and performance offered by composite primary structures. Achieving the goal is dependent on developing composite materials and structures which are damage tolerant and economical to manufacture. Researchers at NASA Langley and Douglas Aircraft Co. are studying stitching reinforcement combined with resin transfer molding (RTM) to create structures meeting the ACT program goals. The research is aimed at materials, processes, and structural concepts for application in both transport wings and fuselages. Empirical guidelines are being established for stitching reinforcement in primary structures and test data are reported in another paper. New data are presented herein from evaluation tests of thick (96 ply) and thin (16 ply) stitched laminates and from selection tests of RTM composite resins. Tension strength, compression strength, and post impact compression strength data are reported. Elements of a NASA Langley program to expand the science base for stitched/RTM composites are discussed.

Kullerd, Susan M.↗
NASA NTRS1992

Test and analysis results for composite transport fuselage and wing structures

Automated tow placement (ATP) and stitching of dry textile composite preforms followed by resin transfer molding (RTM) are being studied as cost effective manufacturing processes for obtaining damage tolerant fuselage and wing structures for transport aircraft. Data are presented to assess the damage tolerance of ATP and RTM fuselage elements with stitched-on stiffeners from compression tests of impacted three J-stiffened panels and from stiffener pull-off tests. Data are also presented to assess the damage tolerance of RTM wing elements which had stitched skin and stiffeners from impacted single stiffener and three blade stiffened compression tests and stiffener pull-off tests.

Deaton, Jerry W.↗
NASA NTRS1992

Development of stitched/RTM composite primary structures

The goal of the NASA Advanced Composites Technology (ACT) Program is to provide the technology required to gain the full benefit of weight savings and performance offered by composite primary structures. Achieving the goal is dependent on developing composite materials and structures which are damage tolerant and economical to manufacture. Researchers at NASA LaRC and Douglas Aircraft Company are investigating stitching reinforcement combined with resin transfer molding (RTM) to create structures meeting the ACT program goals. The Douglas work is being performed under a NASA contract entitled Innovative Composites Aircraft Primary Structures (ICAPS). The research is aimed at materials, processes and structural concepts for application in both transport wings and fuselages. Empirical guidelines are being established for stitching reinforcement in primary structures. New data are presented in this paper for evaluation tests of thick (90-ply) and thin (16-ply) stitched laminates, and from selection tests of RTM composite resins. Tension strength, compression strength and post-impact compression strength data are reported. Elements of a NASA LaRC program to expand the science base for stitched/RTM composites are discussed.

Kullerd, Susan M.↗
NASA NTRS1992

Test and analysis results for composite transport fuselage and wing structures

Automated tow placement (ATP) and stitching of dry textile composite preforms followed by resin transfer molding (RTM) are being investigated by researchers at NASA LaRC and Douglas Aircraft Company as cost-effective manufacturing processes for obtaining damage tolerant fuselage and wing structures for transport aircraft. The Douglas work is being performed under a NASA contract entitled 'Innovative Composites Aircraft Primary Structures (ICAPS)'. Data are presented in this paper to assess the damage tolerance of ATP and RTM fuselage elements with stitched-on stiffeners from compression tests of impacted three-J-stiffened panels and from stiffener pull-off tests. Data are also presented to assess the damage tolerance of RTM wing elements which had stitched skin and stiffeners from impacted single stiffener and three blade-stiffened compression tests and stiffener pull-off tests.

Deaton, Jerry W.↗
NASA NTRS2000

Resin Film Infusion (RFI) Process Modeling for Large Transport Aircraft Wing Structures

Resin film infusion (RFI) is a cost-effective method for fabricating stiffened aircraft wing structures. The RFI process lends itself to the use of near net shape textile preforms manufactured through a variety of automated textile processes such as knitting and braiding. Often, these advanced fiber architecture preforms have through-the-thickness stitching for improved damage tolerance and delamination resistance. The challenge presently facing RFI is to refine the process to ensure complete infiltration and cure of a geometrically complex shape preform with the high fiber volume fraction needed for structural applications. An accurate measurement of preform permeability is critical for successful modeling of the RFI resin infiltration process. Small changes in the permeability can result in very different infiltration behavior and times. Therefore, it is important to accurately measure the permeabilities of the textile preforms used in the RFI process. The objective of this investigation was to develop test methods that can be used to measure the compaction behavior and permeabilities of high fiber volume fraction, advanced fiber architecture textile preforms. These preforms are often highly compacted due to through-the-thickness stitching used to improve damage tolerance. Test fixtures were designed and fabricated and used to measure both transverse and in-plane permeabilities. The fixtures were used to measure the permeabilities of multiaxial warp knit and triaxial braided preforms at fiber volume fractions from 55% to 65%. In addition, the effects of stitching characteristics, thickness, and batch variability on permeability and compaction behavior were investigated.

Knott, Tamara W.↗
NASA NTRS2011

Full-Scale Test and Analysis of a PRSEUS Fuselage Panel to Assess Damage-Containment Features

Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program.

Bergan, Andrew↗