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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Rapid Tools for an AFP Manufacturing Defects Assessment Framework

This work formulates an automated fiber placement (AFP) defects assessment framework. Such framework assumes AFP manufacturing processes are able to identify manufacturing defects via automated inspection systems and intends to provide rapid analysis tools to create a defect assessment loop. The defect assessment loop defines an automated analysis process during AFP manufacturing to minimize the number of manual repairs on the part, thus accelerating AFP manufacturing of composite structures. This defects assessment loop advantages automated inspection data to evaluate the influence of encountered AFP defects on a ply-by-ply basis. Structural evaluation is based on strength criteria using local-global finite element models. Local models affect the global part model via material property reductions. Schemes to reduce material properties using the local models are the main enablers of this framework’s automated assessment capability. Finally, we discuss the main technical challenges to realize the feasibility of this framework.

Bahamonde Jacome, Luis G.↗
NASA NTRS2018

Numerical Simulation of AFP Nip Point Temperature Prediction for Complex Geometries

Material placement at the ideal nip point temperature over complex surfaces with uniformity across the width of the compaction rollers results in optimized part properties for Automated Fiber Placement (AFP) processes. However, current AFP systems utilize heat control models and methodologies, based on multiple process parameters such as feed-rate and orientation, that are mostly open-loop. Here, infrared (IR) heater input is calibrated as a function of process parameters during machine qualification. This work presents a numerical simulation to predict arrayed-infrared (AIR) emitter radiation onto a substrate that includes view factor implementation, IR radiative heat flow calculation, energy rate balance, and a transient heat transfer model. The purpose of this numerical model is to predict nip point temperature on complex surfaces, serving as a baseline for a new arrayed-infrared (AIR) thermoset heater to improve AFP process control. It is anticipated that this simulation will accurately control the temperature for high-speed AFP layup of complex geometries. An anticipated result of an AIR heater system is that material calibration and testing will be reduced as temperature is instantaneously monitored and controlled. Therefore, temperature across the roller width will be uniform during placement of complex parts, independent of their geometry.

Xia, Kaishu↗
NASA NTRS2018

Experimental Calibration of a Numerical Model of Prepreg Tack for Predicting AFP Process Related Defects

Wrinkles, puckers, and fiber bridging are among the major defects encountered in the Automated Fiber Placement (AFP) process, and are all different manifestations of fiber misalignment. The main driver for these defects are the residual stresses introduced in the tow during the deposition stage by the AFP head. In contrast, the tack between the deposited tape and the substrate is the resisting force against the formation of such defects. Tack may be defined as the ability of a material to form a bond immediately on contact with another surface. Tack is a very complex phenomenon that is influenced by a variety of process parameters including temperature, head pressure and speed, as well as degree of cure, moisture content, and surface roughness A physics-based modeling framework for simulation of tack was developed in this study that allows for prediction of tack response. The developed tack model is incorporated in the AFP placement modelling framework developed to simulate AFP defects.

Forghani, Alireza↗
NASA NTRS2019

Machine Learning Based AFP Inspection: A Tool for Characterization and Integration

Automated Fiber Placement (AFP) has become a standard manufacturing technique in the creation of large scale composite structures due to its high production rates. However, the associated rapid layup that accompanies AFP manufacturing has a tendency to induce defects. We forward an inspection system that utilizes machine learning (ML) algorithms to locate and characterize defects from profilometry scans coupled with a data storage system and a user interface (UI) that allows for informed manufacturing. A Keyence LJ-7080 blue light profilometer is used for fast 2D height profiling. After scans are collected, they are process by ML algorithms, displayed to an operator through the UI, and stored in a database. The overall goal of the inspection system is to add an additional tool for AFP manufacturing. Traditional AFP inspection is done manually adding to manufacturing time and being subject to inspector errors or fatigue. For large parts, the inspection process can be cumbersome. The proposed inspection system has the capability of accelerating this process while still keeping a human inspector integrated and in control. This allows for the rapid capability of the automated inspection software and the robustness of a human checking for defects that the system either missed or misclassified.

Sacco, Christopher↗
DOE OSTI2025

Characterizing the AFP Spin Flipper for the Nab Experiment

The Nab experiment at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory (ORNL) aims to yield a precise measurement of the electron-neutrino correlation parameter, a , to $\frac{Δa}{a}$ = 1 × 10 −3 from the beta-decay of the free neutron. To achieve Nab’s precision goal, polarization of the neutron beam must be near-zero. A polarizer/analyzer combination, neutron monitors, and an Adiabatic Fast Passage (AFP) spin flipper will be used to determine a beam polarization effectively less than 2 × 10 −5 . Here, I will discuss the initial characterization efforts of the Nab spin flipper as well as plans for further testing.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS2019

An Experimental Investigation concerning the Effects of AFP Defects on Progressive Failure of Tensile Coupons

This paper discusses characterization approaches for the evaluation of potential defects that may occur during the automated fiber placement (AFP) process. Two nondestructive evaluation techniques were utilized simultaneously, acoustic emission (AE) and digital image correlation (DIC), to investigate correlations between mechanical properties and damage propagation during tension tests. The layup configuration is designed with the defect running across the width, and the stacking sequence with seven layers is produced: [−45/0/45/̅9̅̅0̅]s. A total of 3 panels were manufactured: one containing a gap defect in the middle layer, another one with an overlap defect, and a pristine panel for baseline comparison. Each panel accommodates six coupons having dimensions of 20” x 2”. The results indicate that defects caused during the manufacturing process affect damage initiation and growth.

Anay, Rafal↗
NASA NTRS2019

Plasma Surface Functionalization of AFP Manufactured Composites for Improved Adhesive Bond Performance

Application of carbon fiber reinforced polymer (CFRP) as a high-performance structural material has widespread application in the present aerospace industry. However, as-processed composite materials require a comprehensive surface treatment prior to bonding to remove contaminants and impart surface functionality and topography to overcome their poor adhesion properties. Atmospheric pressure plasma jet treatment (APPJT) has been increasingly garnering attention as an alternate method for surface preparation of CFRP. This method has been reported to achieve success in imparting favorable polar functional groups into the composite surfaces enhancing wettability and surface energy of the bonded surfaces. In some cases, APPJT has been demonstrated to remove contaminants or, in the case of silicones, convert them to silica. In this study, an atmospheric pressure plasma jet (APPJ) system was used for surface activation of a composite laid-up by an automated fiber placement (AFP) machine. Surface modifications prior to and after treatment were characterized using water contact angle (WCA) measurements, X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), and atomic force microscopy (AFM). Double cantilever beam (DCB) tests were performed to quantify the bonding performance of the composites. The results show a marked enhancement of the mode I interlaminar fracture toughness with the application of APPJT.

Sarikaya, Ibrahim↗
NASA NTRS1993

The AFP-675 Far Ultraviolet Cameras experiment - Observations of the far-UV space environment

The NRL's Far UV Cameras experiment flew aboard the Shuttle Orbiter on STS-39, in 1991: obtaining 105-200 nm measurements of the upper atmosphere, astronomical targets, and the Shuttle environment. Attention is presently given to observations of O2 density vs altitude in the nighttime atmosphere, the nocturnal ionosphere, Space Shuttle FUV glow, and photometry for both the stars and diffuse sources of 12 star fields at high and low galactic latitudes. The first FUV observations of the extended region of reflection nebulosity in Scorpius are included.

Carruthers, George R.↗
DOE OSTI2024

On the engulfment of antifreeze proteins by ice

Antifreeze proteins (AFPs) are remarkable biomolecules that suppress ice formation at trace concentrations. To inhibit ice growth, AFPs must not only bind to ice crystals, but also resist engulfment by ice. The highest supercooling, ΔT*, for which AFPs are able to resist engulfment is widely believed to scale as the inverse of the separation, L, between bound AFPs, whereas its dependence on the molecular characteristics of the AFP remains poorly understood. By using specialized molecular simulations and interfacial thermodynamics, here, we show that in contrast with conventional wisdom, ΔT* scales as L –2 and not as L –1 . We further show that ΔT* is proportional to AFP size and that diverse naturally occurring AFPs are optimal at resisting engulfment by ice. By facilitating the development of AFP structure–function relationships, we hope that our findings will pave the way for the rational design of AFPs.

Science & Technology - Other Topics↗
DOE OSTI2026

Engineering Antifreeze Proteins to Optimally Resist Engulfment by Ice

Antifreeze proteins (AFPs) facilitate the survival of organisms in cold climates by inhibiting the growth and/or recrystallization of ice. To function, AFPs must first bind to ice crystals; bound AFPs must then resist engulfment by using their nonbinding side (NBS) to pin the ice–water interface. Here, we seek to understand how the molecular characteristics of an NBS, such as its ice-phobicity or shape, influence its ability to resist engulfment. By characterizing the free energy barriers that impede the engulfment of model AFPs, we find that the critical supercooling ΔT*, above which an AFP is engulfed, is dictated by an optimal pinning site on the NBS. We further find that the optimal pinning site is determined by an interplay between the contact line perimeter P and a pinning efficiency η, with ΔT* ∝ ηP at the optimal pinning site. For a hemispherical AFP, which displays progressively inward tapering, we find that η increases during engulfment, whereas P decreases; conversely, an NBS with outward tapering can achieve high P, but it suffers from low η. Because the product of η and P determines ΔT*, the inverse correlation between them limits ΔT. To circumvent such limiting behavior, we propose an NBS shape with an outward bulge; by initially tapering outward, a bulged NBS permits higher P, and by subsequently tapering inward, it promotes high η as well. Importantly, we find that ΔT* is enhanced by more than a factor of 2 with an outward bulge of only 1 nm. We also find that the more ice-phobic an NBS is, the more efficiently it pins the ice–water interface, resulting in a higher ΔT. Furthermore, our findings shed light on how the NBS molecular characteristics influence ΔT* and suggest strategies for engineering the NBS to optimally resist engulfment by ice.

Antifreeze↗
DOE OSTI2023

Accumulation of Antifreeze Proteins on Ice Is Determined by Adsorption

Antifreeze proteins (AFPs) enable the survival of organisms in freezing environments by binding to ice crystals and suppressing their growth. The rate at which AFPs accumulate on ice is determined by an interplay between their diffusion from the aqueous solution and their adsorption to the ice crystal. To interrogate the relative importance of these two processes, we combined fluorescence experiments with reaction–diffusion modeling. We found that as AFPs accumulate on ice, their concentration in the aqueous solution does not develop a gradient but remains equal to its bulk concentration throughout our experiments. Furthermore, these findings led us to conclude that AFP accumulation on ice crystals, which are smaller than 100 μm in radius, is not limited by the diffusion of AFPs, but by the kinetics of AFP adsorption.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2019

Automated Fiber Placement Manufactured Composites for Science Applications

Science instruments with large collecting areas that maintain dimensional stability, such as James Webb Space Telescope and Wide Field Space Telescope, help achieve next generation science advancements. Composite materials often used for science applications include high modulus fibers in cyanate ester matrices to result in dimensionally stable structures with low contamination. Hand lay-up fabrication is the most common approach for science instrument structures. Automated Fiber Placement (AFP) using intermediate modulus fibers is commonplace in aircraft production reducing manufacturing time and increasing quality and consistency. AFP manufacturing for future large science instruments can similarly reduce costs and increase reliability. However, high modulus fibers are more prone to damage than intermediate modulus fibers. This study investigates the manufacturing viability of M55J/RS3C (Tencate) slit tape material using AFP processing. Tencate provides slit tape materials. NASA Langley Research Center (LaRC) manufactured hand layup and AFP lay-up laminates under room temperature for initial trials, Marshall Space Flight Center (MSFC) manufactured AFP laminates under room temperature and elevated temperature conditions to evaluate processing affects. Goddard Space Flight Center (GSFC) tests and evaluates tension and Coefficient of Thermal Expansion (CTE) properties by hand lay-up and AFP slit tape automated manufacturing for large science applications. These results show processing material warm reduces process induced fiber fracture; leading to stiffness and CTE properties consistent with hand lay-up, while observing a slight degradation in tensile strength.

Segal, Kenneth N.↗
NASA NTRS2019

Design and Analysis of a Tool for Automated Fiber Placement of Composite Wind Tunnel Blades

For decades, composite wind tunnel blades have been constructed using labor-intensive hand layup processes. Automated Fiber Placement (AFP) is a relatively new technology that has not seen widespread use in manufacturing composite wind tunnel blades. AFP offers the potential for reduced manufacturing time, reduced cost, and improved consistency compared to traditional hand layup procedures. These manufacturing qualities are becoming increasingly important as existing wind tunnel blades are replaced due to impact damage or wear and tear from decades of use. Researchers at the NASA Langley Research Center are currently using the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to investigate the feasibility of AFP for manufacturing composite wind tunnel blades. ISAAC uses manufacturing tools as surfaces on which to place fiber tows. A manufacturing tool was developed for using AFP to build a wind tunnel blade shape. This paper presents the structural design and analysis of this tool, for use with AFP, constructed from high temperature thermoplastics. The tool fabricated by this design process was successfully used for AFP and oven cure of two representative airfoil shaped composite structures.

Brian Mason↗
NASA NTRS2016

Advances in In-Situ Inspection of Automated Fiber Placement Systems

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems present is the uniformity of the deposited prepreg tape layers, which are prone to laps, gaps, overlaps and twists. The current detection modus operandi involves halting fabrication and performing a time consuming visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The idea was proposed to use the preheated base layer as a through transmission heat source and to inspect the newly added tape layer using a thermographic camera. As a preliminary study of this concept a laboratory proof of concept device was designed and constructed to simulate the through transmission heat source. Using the proof of concept device, we inspected an AFP-built uncured composite specimen with artificial manufacturing defects. This paper will discuss the results of this preliminary study and the implications involved with deploying a full-scale AFP inspection system.

Juarez, Peter D.↗