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All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion elements. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Elements (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By orienting vertically, highly nonlinear and unstable behavior often encountered during horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behavior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

Experimental testing↗

NASA NTRSDate not supplied

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion ele-ments. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Ele-ments (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By ori-enting vertically, highly nonlinear and unstable behavior often encountered dur-ing horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behav-ior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

High-strain composites↗

NASA NTRS1992

Advanced wing design survivability testing and results

Composite wings on current operational aircraft are conservatively designed to account for stress/strain concentrations, and to assure specified damage tolerance. The technology that can lead to improved composite wing structures and associated structural efficiency is to increase design ultimate strain levels beyond their current limit of 3500 to 4000 micro-in/in to 6000 micro-in/in without sacrificing structural integrity, durability, damage tolerance, or survivability. Grumman, under the sponsorship of the Naval Air Development Center (NADC), has developed a high-strain composite wing design for a subsonic aircraft wing using novel and innovative design concepts and manufacturing methods, while maintaining a state-of-the-art fiber/resin system. The current advanced wing design effort addressed a tactical subsonic aircraft wing using previously developed, high-strain wing design concepts in conjunction with newer/emerging fiber and polymer matrix composite (PMC) materials to achieve the same goals, while reducing complexity. Two categories of advanced PMC materials were evaluated: toughened thermosets; and engineered thermoplastics. Advanced PMC materials offer the technological opportunity to take maximum advantage of improved material properties, physical characteristics, and tailorability to increase performance and survivability over current composite structure. Damage tolerance and survivability to various threats, in addition to structural integrity and durability, were key technical issues addressed during this study, and evaluated through test. This paper focuses on the live-fire testing, and the results performed to experimentally evaluate the survivability of the advanced wing design.

Bruno, J.↗

NASA NTRSDate not supplied

Characterization and Modeling of Large Collapsible Tubular Mast Booms

This paper will document the analysis of high-strain composite booms in the joint NASA-German Aerospace Center (DLR) Deployable Composite Booms (DCB) project. The collapsible tubular mast (CTM) booms were manufactured at NASA Langley Research Center, where constituent material coupons were also characterized, and shipped to DLR in Germany for testing of beam properties and the strength of the DLR flight-like root deployer design. With this data, a finite element model of the booms was built, calibrated to one set of experimental measurements, and used to produce a simplified beam model for further engineering studies.The final paper will discuss the process of building this beam model and the treatment of gaps in experimental characterization.

Olive R. Stohlman↗

NASA NTRSDate not supplied

Improved Plate and Beam Models for Thermoviscoelastic Constitutive Modeling of Composites

The effective properties of composites are influenced by the time-dependent behavior of polymer matrices very sensitive to changes in temperature. Improved plate and beam models are required to efficiently design, and simulate composite structures when the long-term performance of large anisotropic composite structures is the matter of interest. In this work, mechanics of structure genome (MSG) is used to con-struct linear thermoviscoelastic plate and beam models that can homogenize three-dimensional heterogeneous materials made of constituents with time- and temperature-dependent behavior. The formulation derives the transient strain energy based on integral formulation for thermorheologically simple materials subject to finite temperature changes with the restriction that the strain is small. The reduced time parameter is introduced to relate the time-temperature dependency of the anisotropic material by means of master curves at reference conditions. The new formulation has been implemented in SwiftCompTM, a general-purpose multiscale constitutive modeling code based on MSG. Experimental data and three-dimensional direct numerical simulations of thin-ply high-strain composites (TP-HSC) using a commercial finite element analysis (FEA) package are conducted to verify the accuracy of SwiftCompTM results. The paper also analyzes the relationship between the shift factor of the polymer matrix and the temperature dependencies of the effective beam properties.

Finite element analysis↗

NASA NTRSDate not supplied

Characterization and Modeling of Large Collapsible Tubular Mast Booms

This paper documents the analysis of high-strain composite booms in the joint NASA-German Aerospace Center (DLR) Deployable Composite Booms (DCB) project. The collapsible tubular mast (CTM) booms were manufactured at NASA Langley Research Center, where constituent material coupons were also characterized, and shipped to DLR in Germany for testing of beam properties and the strength of the DLR flight-like root deployer design. With this data, a finite element model of the booms was built, calibrated to one set of experimental measurements, and used to produce a simplified beam model for further engineering studies. The process of building this beam model and the treatment of gaps in experimental characterization are presented.

composite materials↗

NASA NTRSDate not supplied

Using DIC for Long Slender Structures

High-strain composite deployable structures have been developed for systems such as solar arrays, camera masts or solar sailing propulsion elements. Composite booms in such applications are often flattened and then rolled into a small footprint for low-packaged volume and are then deployed in space. There is a need to obtain deformation for long, slender composite booms on earth through gravity offloading by suspending them vertically and applying distal end (tip) loads. Three-dimensional digital image correlation (3D-DIC), along with other measurement techniques, were used to obtain strain and displacement along the length of a 7.5 m subscale composite Triangular, Rollable, and Collapsible (TRAC) boom in preparation for full scale testing of a 30 m boom. However, incorporating 3D-DIC as a primary measurement tool on long, slender, high-aspect-ratio boom structures presents significant challenges. Challenges include small correlated area due to high aspect ratio, limited standoff distance due to size of test area, coordinate system alignment of multiple camera systems along the length of the boom, nodal mesh extraction for adequate test/analysis correlation, as well as measurement comparison between DIC and other instrumentation used such as fiber optic strain sensing (FOSS) and laser displacement tracking. The contents of the proposed paper will focus on techniques and methods for overcoming the previously mentioned challenges associated with applying 3D-DIC to long, slender boom structures. Results from subscale test along with lessons learned will be discussed.

Deployable Boom↗

NASA NTRS2019

Micromechanical Modeling of High-Strain Thin-Ply Composites

This paper presents a micromechanical analysis for the elastic and viscoelastic behavior of high-strain thin-ply composites. The modeling approach is based on unit cell homogenization. The geometry of the internal weave architecture and ply configuration is characterized via micrographic analysis and explicitly modeled in the unit cell. The composites are modeled as Kirchhoff plates and the homogenization analysis computes the effective relaxation ABD matrix represented by Prony series using the elastic and viscoelastic properties of the constituent fiber and matrix. The formulation of the micromechanical model and numerical implementation d. Composite laminates with 3-ply and 4-ply configurations are studied.

Hamillage, Milinda Yapa↗

NASA NTRSDate not supplied

Gravity Offloading and Analysis of Long Imperfection-Sensitive Elements (GOALIE)

Use of large-scale deployable structures (e.g., iROSA) can enable space exploration and science missions (e.g., ACS3, Solar Cruiser). Numerical models predicting behavior of deployable structures in microgravity are difficult to validate because ground testing of long, slender, and flexible booms is challenging due to the influence of Earth’s gravity. The GOALIE team is collecting data for model validation through experimental testing to increase confidence in numerical models. Redwire, Inc. provided a subscale (7 m) and a full-scale (30 m) Triangular, Rollable, and Collapsible (TRAC) boom to use for test development. Other boom designs may be tested in the future.

Composites↗

NASA NTRS1982

Environmental and High-Strain Rate effects on composites for engine applications

The Lewis Research Center is conducting a series of programs intended to investigate and develop the application of composite materials to structural components for turbojet engines. A significant part of that effort is directed to establishing resistance, defect growth, and strain rate characteristics of composite materials over the wide range of environmental and load conditions found in commercial turbojet engine operations. Both analytical and experimental efforts are involved.

Chamis, C. C.↗

NASA NTRSDate not supplied

Analysis of Triangular Rollable and Collapsible (TRAC) Composite Booms under the Effects of Gravity and Twist

Finite element analysis is used to investigate Triangular Rollable and Collapsible (TRAC) composite booms. The TRAC booms are subjected to a suite of loading conditions, including in-plane bending, out-of-plane bending, and axial compression. Simulations containing as-designed boom geometry are performed, as are simulations with geometric deviations associated with the as-built conditions of a sample TRAC boom. Namely, a cross-sectional twist along the length of the boom is incorporated into the analysis to study the effect of the twist on the deformation characteristics of the boom. Twisting in the sample boom was observed after short-term storage in a rolled configuration and may be attributed to differential creep deformation between the inner and outer flanges of the TRAC boom. Simulations are conducted with and without the effects of gravity to understand the significance of gravity on testing conditions. Booms of three lengths are evaluated: 3 meters, 7.5 meters and 30 meters. The mechanical responses of the TRAC booms are discussed with reference to the effects of gravity, boom length and cross-sectional twisting. Gravity is found to have a more significant effect on boom mechanical response as boom length is increased. Cross-sectional twisting is found to have a more significant effect on boom mechanical response in the shorter booms.

High-strain composites↗

NASA NTRSDate not supplied

Analysis of Triangular Rollable and Collapsible Composite Booms Under the Effects of Gravity and Twist

High-strain composites↗

NASA NTRS1988

Properties of two composite materials made of toughened epoxy resin and high-strain graphite fiber

Results are presented from an experimental evaluation of IM7/8551-7 and IM6/18081, two new toughened epoxy resin, high strain graphite fiber composite materials. Data include ply-level strengths and moduli, notched tension and compression strengths and compression-after-impact assessments. The measured properties are compared with those of other graphite-epoxy materials.

Dow, Marvin B.↗

DOE OSTI2026

Design, characterization and shape recovery behavior of 3D/4D printed shape memory polymers (SMPs)

Shape memory polymers (SMPs) represent a paradigm shift in material science, uniquely capable of undergoing reversible shape transformations triggered by external stimuli, positioning them as pivotal in developing next-generation biomedical devices, aerospace components, and adaptive structures. Extensive research has been done on SMPs with a major focus on high-temperature programming methods, which can limit energy efficiency and applicability with temperature-sensitive materials. Additionally, while various SMP blends have demonstrated great potential, limited work has been done on the suitability for 3D printing these materials, particularly under high-strain and ambient temperature programming conditions. In this study, a three-component optimized SMP composition was evaluated by 3D printing via the Material Extrusion (MEX) technique and investigating its ambient temperature-programming behavior at high strains. The SMP formulation studied was a tailored blend of thermoplastic polyurethane (TPU), polycaprolactone (PCL), and an octadecane diol-based copolymer (OBC) that exhibits robust shape memory behavior, high strain tolerance, and efficient force generation. Rigorous thermal, mechanical, and shape recovery analyses, along with optimized printing parameters and consistent shape recovery rates of up to 90%, were achieved under dynamic mechanical analysis (DMA), even under ambient programming conditions. This work demonstrates the SMP composition’s potential for adaptive, self-deployable systems with 4D printing characteristics ideal for bio-inspired structures and artificial muscle fibers.

Sudan, Kavish [University of Louisville, KY]↗

NASA NTRS2005

Structural Benchmark Tests of Composite Combustion Chamber Support Completed

A series of mechanical load tests was completed on several novel design concepts for extremely lightweight combustion chamber support structures at the NASA Glenn Research Center (http://www.nasa.gov/glenn/). The tests included compliance evaluation, preliminary proof loadings, high-strain cyclic testing, and finally residual strength testing of each design (see the photograph on the left). Loads were applied with single rollers (see the photograph on the right) or pressure plates (not shown) located midspan on each side to minimize the influence of contact stresses on corner deformation measurements. Where rollers alone were used, a more severe structural loading was produced than the corresponding equal-force pressure loading: the maximum transverse shear force existed over the entire length of each side, and the corner bending moments were greater than for a distributed (pressure) loading. Failure modes initiating at the corner only provided a qualitative indication of the performance limitations since the stress state was not identical to internal pressure. Configurations were tested at both room and elevated temperatures. Experimental results were used to evaluate analytical prediction tools and finite-element methodologies for future work, and they were essential to provide insight into the deformation at the corners. The tests also were used to assess fabrication and bonding details for the complicated structures. They will be used to further optimize the design of the support structures for weight performance and the efficacy of corner reinforcement.

Krause, David L.↗

NASA NTRS1990

Interface effects in interlaminar fracture of thermoplastic composites

Mode I interlaminar fracture toughness was determined on a series of unidirectional poly(phenylene oxide)/carbon fiber composites using the double cantilever beam test. Initial toughness for growth of a delamination from an insert depends on fiber type, and ranges from 190 to 440 J/sq m, with intermediate modulus fibers tending to give lower values than high-strain fibers. Low toughness values are attributed to poor fiber-matrix adhesion. As a delamination progress down the beam, fiber bridging increases the apparent toughness by up to a factor of 7, depending on the fiber.

Hinkley, J. A.↗

NASA NTRS1990

Survivability characteristics of composite compression structure

Test and evaluation was performed to determine the compression residual capability of graphite reinforced composite panels following perforation by high-velocity fragments representative of combat threats. Assessments were made of the size of the ballistic damage, the effect of applied compression load at impact, damage growth during cyclic loading and residual static strength. Several fiber/matrix systems were investigated including high-strain fibers, tough epoxies, and APC-2 thermoplastic. Additionally, several laminate configurations were evaluated including hard and soft laminates and the incorporation of buffer strips and stitching for improved damage resistance of tolerance. Both panels (12 x 20-inches) and full scale box-beam components were tested to assure scalability of results. The evaluation generally showed small differences in the responses of the material systems tested. The soft laminate configurations with concentrated reinforcement exhibited the highest residual strength. Ballistic damage did not grow or increase in severity as a result of cyclic loading, and the effects of applied load at impact were not significant under the conditions tested.

Avery, John G.↗