Inspection of honeycomb structures using bi-refringent plastic coatings
Visual observation inspection device for bonded honeycomb sandwich structures using birefringent plastic coatings
PLASTIC COATING↗
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Development and demonstration of manufacturing processes for fabricating graphite/PMR-15 polyimide structures
The work included establishing controls on the polymer, the prepreg, composite fabrication, and quality assurance, as well as fabrication of structural elements to demonstrate the developed materials and processes. The fabricated structures were hat sections, I-beam sections, honeycomb sandwich structures, and molded graphite-reinforced fittings. The graphite/PMR-15 polyimide system was shown to be well suited for use in the 550-600 F temperature range; the processing techniques developed were proved and found potentially useful for other commercially available systems.
Sheppard, C. H.↗
Apparatus permits flexure testing of specimens at cryogenic temperatures
Cryostat with support structure for test specimen allows flexure fatigue testing of honeycomb composite sandwich structures at cryogenic temperatures. The cryostat consists of a cryogen container enclosing two pairs of yokes which support two rotating end clamps.
Denaburg, C. R.↗
Manufacturing processes for fabricating graphite/PMR 15 polyimide structural elements
Investigations were conducted to obtain commercially available graphite/PMR-15 polyimide prepreg, develop an autoclave manufacturing process, and demonstrate the process by manufacturing structural elements. Controls were established on polymer, prepreg, composite fabrication, and quality assurance, Successful material quality control and processes were demonstrated by fabricating major structural elements including flat laminates, hat sections, I beam sections, honeycomb sandwich structures, and molded graphite reinforced fittings. Successful fabrication of structural elements and simulated section of the space shuttle aft body flap shows that the graphite/PMR-15 polyimide system and the developed processes are ready for further evaluation in flight test hardware.
Sheppard, C. H.↗
Approaches to Design and Evaluation of Sandwich Composites
This report describes research during the period June 15, 1997 to October 31, 2000. This grant yielded a low cast manufacturing of composite sandwich structures technology and characterization interfacial and subinterfacial cracks in foam core sandwich panels. The manufacturing technology is called the vacuum assisted resin transfer (VARTM). The VARTM is suitable for processing composite materials both at ambient and elevated temperatures and of unlimited component size. This technology has been successfully transferred to a small business fiber preform manufacturing company 3TEX located in Cary, North Carolina. The grant also supported one Ph.D, one M.S and a number of under graduate students, and nine publications and Presentations.
Shivakumar, Kunigal↗
End Effects and Load Diffusion in Composite Structures
The research carried out here builds on our previous NASA supported research on the general topic of edge effects and load diffusion in composite structures. Further fundamental solid mechanics studies were carried out to provide a basis for assessing the complicated modeling necessary for large scale structures used by NASA. An understanding of the fundamental mechanisms of load diffusion in composite subcomponents is essential in developing primary composite structures. Specific problems recently considered were focussed on end effects in sandwich structures and for functionally graded materials. Both linear and nonlinear (geometric and material) problems have been addressed. Our goal is the development of readily applicable design formulas for the decay lengths in terms of non-dimensional material and geometric parameters. Analytical models of load diffusion behavior are extremely valuable in building an intuitive base for developing refined modeling strategies and assessing results from finite element analyses. The decay behavior of stresses and other field quantities provides a significant aid towards this process. The analysis is also amenable to parameter study with a large parameter space and should be useful in structural tailoring studies.
Horgan, Cornelius O.↗
Nondestructive testing techniques used in analysis of honeycomb structure bond strength
DOT /Driver-Displacement Oriented Transducer/, applicable to both lap shear type application and honeycomb sandwich structures, measures the displacement of the honeycomb composite face sheet. It incorporates an electromagnetic driver and a displacement measuring system into a single unit to provide noncontact bond strength measurements.
Erdman, D. C.↗
Stainless-Steel-Foam Structures Evaluated for Fan and Rotor Blades
The goal of this project is to use a sandwich structure design, consisting of two stainlesssteel face sheets and a stainless-steel-foam core, to fabricate engine fan and propeller blades. Current fan blades are constructed either of polymer matrix composites (PMCs) or hollow titanium alloys. The PMC blades are expensive and have poor impact resistance on their leading edges, thereby requiring a metallic leading edge to satisfy the Federal Aviation Administration s impact requirements relating to bird strikes. Hollow titanium blades cost more to fabricate because of the intrinsically difficult fabrication issues associated with titanium alloys. However, both these current concepts produce acceptable lightweight fan blades.
Lerch, Bradley A.↗
Deflections of anisotropic sandwich beams with variable face sheets and core thicknesses
A sandwich construction consists of a low-density core material with high strength face sheets bounded to the top and bottom surfaces. The construction has been widely used in the aerospace and marine industries due to its outstanding characteristics such as noise absorption, weight minimization, heat insulation, and better bending stiffness. In sandwich structures used in high-performance aircraft, the face sheets are often made of fiber-reinforced composite materials and the core is made of honeycomb. The structures may also have variable thickness so as to satisfy aerodynamic requirements. In the stress analysis, the constant-thickness face sheets are usually considered as membrane and the core is assumed to be inextensible but deformable in the thickness direction. The static behavior of variable-thickness, isotropic and homogeneous sandwich beams was successfully studied by employing a constant-thickness theory but allowing stiffnesses to vary in accordance with local thickness variations. It has been recently found in a refined theory that the analyses based on the constant thickness theory locally can lead to significant errors in structural responses if the sandwich beam is thickness-tapered and the cores are deformable in transverse shear. The errors arise mainly from two factors: (1) the transverse shear components of the membrane forces in the face sheets alter the transverse shears carried by the core; and (2) the face-sheet membrane strains arise from transverse shear deformation of the core. In practice the variable thickness may not only exist in core but also in face sheets. The thickness-variations may even be a type of step function. In this case the transverse shear stress in the face sheets and bending stress in the core should be taken into account in the refined theory mentioned. In the present study, energy principles are employed in deriving governing equations for general bending of anisotropic sandwich beams with variable thickness in both face sheets and cores. Solutions to these equations are based on a finite difference scheme. As an example in application, a simply supported thickness-tapered sandwich beam subject to a concentrated load at its center is considered. Let W' be the maximum deflection of the beam in which face sheets are considered as membrane, while W'' is that based on using the modified refined theory. It is found that W' is always larger than W'', however, the magnitude of (W'- W'') appears to be insensitive to the change of the taper of the beam.
Lu, Chu-Ho↗
Preparation for foam composites
Methods were developed for the fabrication of fire resistant panels utilizing polybenzimidazole (PBI) and Kerimid 601 resins along with glass, quartz, and Kevlar reinforcements. Stitched truss structure, both unfilled and filled with PBI foam, were successfully fabricated and tested. Second generation structures were then selected, fabricated, and tested, with a PBI/glass skin/PBI foam sandwich structure emerging as the optimum panel concept. Mechanical properties, smoke generation, and fire resistance were determined for the candidate panels.
Maximovich, M. G.↗
2nd Generation RLV Airframe Structures and Materials
The goals and objectives of the project summarized in this viewgraph presentation are the following: (1) Develop and demonstrate verified airframe and cryotank structural design and analysis technologies, including damage tolerance, safety, reliability, and residual strength technologies, robust nonlinear shell and cryotank analysis technologies, high-fidelity analysis and design technologies for local structural detail features and joints, and high-fidelity analysis technologies for sandwich structures; (2) Demonstrate low cost, robust materials and processing, including polymeric matrix composite (PMC) and metallic materials and processing, and refractory composite and metallic hot structures materials and processing; (3) Develop and demonstrate robust airframe structures and validated integrated airframe structural concepts, including low cost fabrication and joining, operations efficient designs and inspection techniques (non-destructive evaluation), scale-up and integrated thermal structure tests, and airframe structures IVHM; (4) Demonstrate low cost, robust repair techniques; and (5) Develop verified integrated airframe structural concepts, including integrated structural concepts.
Johnson, Theodore F.↗
Ultra-Lightweight Self-Deployable Nanocomposite Structure for Habitat Applications
A document discusses self-deployable, rigidized structures that are ultra-lightweight and have gas barrier properties, space durability, and high impact resistance. Developed here are microcellular-foamed sandwich structures made from nanocomposite shape memory polymers (SMPs) with Cold-Hibernated Elastic Memory (CHEM) deployed technique for space structural components including space habitats. This type of foam sandwich also does not suffer from the toxicity problems of conventional foams, and has higher mechanical properties than those processed with conventional techniques. This design can be compacted into a very small volume for launch. Once deployed, the microcellular structure can use the heat from the Sun to recover 98 to 100 percent of its shape.
Tan, Seng C.↗
Technology development status at McDonnell Douglas
The significant technology items of the Concorde and the conceptual MCD baseline advanced supersonic transport are compared. The four major improvements are in the areas of range performance, structures (materials), aerodynamics, and in community noise. Presentation charts show aerodynamic efficiency; the reoptimized wing; low scale lift/drag ratio; control systems; structural modeling and analysis; weight and cost comparisons for superplasticity diffusion bonded titanium sandwich structures and for aluminum brazed titanium honeycomb structures; operating cost reduction; suppressor nozzles; noise reduction and range; the bicone inlet; a market summary; environmental issues; high priority items; the titanium wing and fuselage test components; and technology validation.
Rowe, W. T.↗
Face Sheet/Core Disbond Growth in Honeycomb Sandwich Panels Subjected to Ground-Air-Ground Pressurization and In-Plane Loading
Typical damage modes in light honeycomb sandwich structures include face sheet/core disbonding and core fracture, both of which can pose a threat to the structural integrity of a component. These damage modes are of particular interest to aviation certification authorities since several in-service occurrences, such as rudder structural failure and other control surface malfunctions, have been attributed to face sheet/core disbonding. Extensive studies have shown that face sheet/core disbonding and core fracture can lead to damage propagation caused by internal pressure changes in the core. The increasing use of composite sandwich construction in aircraft applications makes it vitally important to understand the effect of ground-air-ground (GAG) cycles and conditions such as maneuver and gust loads on face sheet/core disbonding. The objective of the present study was to use a fracture mechanics based approach developed earlier to evaluate the loading at the disbond front caused by ground-air-ground pressurization and in-plane loading. A honeycomb sandwich panel containing a circular disbond at one face sheet/core interface was modeled with three-dimensional (3D) solid finite elements. The disbond was modeled as a discrete discontinuity and the strain energy release rate along the disbond front was computed using the Virtual Crack Closure Technique (VCCT). Special attention was paid to the pressure-deformation coupling which can decrease the pressure load within the disbonded sandwich section significantly when the structure is highly deformed. The commercial finite element analysis software, Abaqus/Standard, was used for the analyses. The recursive pressure-deformation coupling problem was solved by representing the entrapped air in the honeycomb cells as filled cavities in Abaqus/Standard. The results show that disbond size, face sheet thickness and core thickness are important parameters that determine crack tip loading at the disbond front. Further, the pressure-deformation coupling was found to have an important load decreasing effect [6]. In this paper, a detailed problem description is provided first. Second, the analysis methodology is presented. The fracture mechanics approach used is described and the specifics of the finite element model, including the fluid-filled cavities, are introduced. Third, the initial model verification and validation are discussed. Fourth, the findings from a closely related earlier study [6] are summarized. These findings provided the basis for the current investigation. Fifth, an aircraft ascent scenario from 0 to 12192 m (0 to 40000 ft) is considered and the resulting crack tip loading at the disbond front is determined. In-plane loading to simulate maneuvers and gust conditions are also considered. Sixth, the results are shown for a curved panel, which was used to simulate potential fuselage applications. Finally, a brief summary of observations is presented and recommendations for improvement are provided.
Chen, Zhi M.↗
Plasmon and exciton superconductivity mechanisms in layered structures
Plasmon and exciton superconductivity mechanisms are discussed. Superconductivity in a three layer metal semiconductor metal and insulator semimetal insulator sandwich structure was described in terms of the temperature dependent Green function of the longitudinal (Coulomb) field. The dependences of the superconducting transition temperature on structure parameters were obtained. In a semiconducting film, as a result of interactions of degenerate free carriers with excitons, superconductivity exists only in a certain range of parameter values, and the corresponding critical temperature is much lower than in the plasmon mechanism of superconductivity.
Gabovich, A. M.↗
Reusable structure for the Advanced Launch System
The U.S. Advanced Launch System (ALS) effort has been established to reduce the cost of payload mass to orbit and increase launch reliability. One approach to reducing costs of primarily expendable launch vehicles is to recover and reuse the most costly elements (i.e., the main engines and the avionics hardware); this is the mission of the propulsion/avionics (P/A) module. This study was conducted to identify material and design options for P/A module structure. A critical structural element is the aeroshell which: (1) provides the reentry aerodynamic surface, (2) shields other subcomponents from reentry heating, and (3) absorbs touchdown loads. Two P/A module types are required for the ALS: one that flies a high-temperature return from orbit profile and another that flies a cooler suborbital profile. For system cost benefits, common structure is desired for both types. A design concept is developed for a honeycomb sandwich structure that can survive the suborbital-reentry heating rates and the return-from-orbit heating rates with an ablative thermal protection system. Thermal analyses show that structural temperatures from aerodynamic heating are within material capabilities. Stress analyses indicate the structural design can support the critical loads.
Gibbins, Martin N.↗
Parametric Study of an Ablative TPS and Hot Structure Heatshield for a Mars Entry Capsule Vehicle
The National Aeronautics and Space Administration is planning to send humans to Mars. As part of the Evolvable Mars Campaign, different en- try vehicle configurations are being designed and considered for delivering larger payloads than have been previously sent to the surface of Mars. Mass and packing volume are driving factors in the vehicle design, and the thermal protection for planetary entry is an area in which advances in technology can offer potential mass and volume savings. The feasibility and potential benefits of a carbon-carbon hot structure concept for a Mars entry vehicle is explored in this paper. The windward heat shield of a capsule design is assessed for the hot structure concept as well as an ablative thermal protection system (TPS) attached to a honeycomb sandwich structure. Independent thermal and structural analyses are performed to determine the minimum mass design. The analyses are repeated for a range of design parameters, which include the trajectory, vehicle size, and payload. Polynomial response functions are created from the analysis results to study the capsule mass with respect to the design parameters. Results from the polynomial response functions created from the thermal and structural analyses indicate that the mass of the capsule was higher for the hot structure concept as compared to the ablative TPS for the parameter space considered in this study.
Langston, Sarah L.↗
Development of a low expansion, composite antenna subreflector with a frequency selective surface
A Kevlar-49 epoxy, composite frequency-selective-surface subreflector was developed for the high gain antenna used on the Voyager spacecraft. The Kevlar-49 material was selected for this sandwich structure because a dielectric material was required, and the use of Kevlar-49 resulted in a composite sandwich with a low thermal coefficient of expansion and reduced weight over an equivalent fiberglass construction. A detailed description and the results of the development program are given and include the design requirements for the structure, the development testing of the materials that led to the final design configuration, and the processes used to fabricate this advanced composite spacecraft antenna component.
Stonier, R. A.↗