SEARCH · Search NASA

Results for “composite overwrap”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

All sources NASA NTRS DOE OSTI

NASA NTRS2012

Voluntary Consensus Organization Standards for Nondestructive Evaluation of Thin-Walled Metallic Liners and Composite Overwraps in Composite Overwrapped Pressure Vessels

NASA fracture control requirements outlined in NASA-STD-5009 and NASA-STD-5014 are predicated on the availability and use of sensitive nondestructive evaluation (NDE) methods that can detect and monitor defects, thereby providing data that can be used to predict failure or reduce the risk of failure in fracture critical components. However, in the case of composite materials and components, including composite overwrapped pressure vessels (COPVs), the effect of defects is poorly understood, the NDE methods used to evaluate locate and size defects are typically at lower technical readiness level than analogous NDE methods used for metals, and demonstration studies to verify the probability of detection (POD) are generally lacking or unavailable. These factors together make failure prediction of fracture critical composite materials and components based on size, quantity, or orientation of defects nearly impossible. Also, when inspecting metal liners in as-manufactured COPVs, sensitivity is lost and only the inner surface of the liner is accessible. Also, NDE of COPVs as applied during manufacturing varies significantly from manufacturer to manufacturer and has not yet been standardized. Although requirements exist to perform NDE immediately after manufacturing to establish initial integrity of the parts, procedural detail for NDE of composites is still nonexistent or under development. For example, in practice, only a visual inspection of COPVs is performed during manufacturing and service, leaving in question whether defects of concern, for example, bridging, overwrap winding anomalies, impact damage below visible threshold, out-of-family strain growth, and liner buckling have been adequately detected and monitored. To address these shortcomings, in 2005 the NASA Nondestructive Evaluation Working Group (NNWG) began funding work to develop and adopt standards for nondestructive evaluation of aerospace composites in collaboration with the American Society for Testing and Materials (ASTM) Committee E07 on Nondestructive Testing. Similarly, in 2006 the NASA Engineering and Safety Center (NESC) recommended that nondestructive evaluation methods that can predict composite failure in COPVs should be developed and verified, and integrated into the damage control plan for these vessels

Waller, Jess↗

NASA NTRS2006

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.

Sutter, James K.↗

NASA NTRS2007

Interrelationship of Nondestructive Evaluation Methodologies Applied to Testing of Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are commonly used in spacecraft for containment of pressurized gases and fluids, incorporating strength and weight savings. The energy stored is capable of extensive spacecraft damage and personal injury in the event of sudden failure. These apparently simple structures, composed of a metallic media impermeable liner and fiber/resin composite overwrap are really complex structures with numerous material and structural phenomena interacting during pressurized use which requires multiple, interrelated monitoring methodologies to monitor and understand subtle changes critical to safe use. Testing of COPVs at NASA Johnson Space Center White Sands T est Facility (WSTF) has employed multiple in-situ, real-time nondestructive evaluation (NDE) methodologies as well as pre- and post-test comparative techniques to monitor changes in material and structural parameters during advanced pressurized testing. The use of NDE methodologies and their relationship to monitoring changes is discussed based on testing of real-world spacecraft COPVs. Lessons learned are used to present recommendations for use in testing, as well as a discussion of potential applications to vessel health monitoring in future applications.

Leifeste, Mark R.↗

NASA NTRS2011

Continued Development of Meandering Winding Magnetometer (MWM (Register Trademark)) Eddy Current Sensors for the Health Monitoring, Modeling and Damage Detection of Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are used in essentially all NASA spacecraft, launch. vehicles and payloads to contain high-pressure fluids for propulsion, life support systems and science experiments. Failure of any COPV either in flight or during ground processing would result in catastrophic damage to the spacecraft or payload, and could lead to loss of life. Therefore, NASA continues to investigate new methods to non-destructively inspect (NDE) COPVs for structural anomalies and to provide a means for in-situ structural health monitoring (SHM) during operational service. Partnering with JENTEK Sensors, engineers at NASA, Kennedy Space Center have successfully conducted a proof-of-concept study to develop Meandering Winding Magnetometer (MWM) eddy current sensors designed to make direct measurements of the stresses of the internal layers of a carbon fiber composite wrapped COPV. During this study three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed good correlation with actual surface strain gage measurements. MWM-Array technology for scanning COPVs can reliably be used to image and detect mechanical damage. To validate this conclusion, several COPVs were scanned to obtain a baseline, and then each COPV was impacted at varying energy levels and then rescanned. The baseline subtracted images were used to demonstrate damage detection. These scans were performed with two different MWM-Arrays. with different geometries for near-surface and deeper penetration imaging at multiple frequencies and in multiple orientations of the linear MWM drive. This presentation will include a review of micromechanical models that relate measured sensor responses to composite material constituent properties, validated by the proof of concept study, as the basis for SHM and NDE data analysis as well as potential improvements including design changes to miniaturize and make the sensors durable in the vacuum of space

Russell, Richard↗

NASA NTRS2007

Stress Rupture Life Reliability Measures for Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are often used for storing pressurant gases onboard spacecraft. Kevlar (DuPont), glass, carbon and other more recent fibers have all been used as overwraps. Due to the fact that overwraps are subjected to sustained loads for an extended period during a mission, stress rupture failure is a major concern. It is therefore important to ascertain the reliability of these vessels by analysis, since the testing of each flight design cannot be completed on a practical time scale. The present paper examines specifically a Weibull statistics based stress rupture model and considers the various uncertainties associated with the model parameters. The paper also examines several reliability estimate measures that would be of use for the purpose of recertification and for qualifying flight worthiness of these vessels. Specifically, deterministic values for a point estimate, mean estimate and 90/95 percent confidence estimates of the reliability are all examined for a typical flight quality vessel under constant stress. The mean and the 90/95 percent confidence estimates are computed using Monte-Carlo simulation techniques by assuming distribution statistics of model parameters based also on simulation and on the available data, especially the sample sizes represented in the data. The data for the stress rupture model are obtained from the Lawrence Livermore National Laboratories (LLNL) stress rupture testing program, carried out for the past 35 years. Deterministic as well as probabilistic sensitivities are examined.

Murthy, Pappu L. N.↗

NASA NTRS2009

Designing of a Fleet-Leader Program for Carbon Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are often used for storing pressurant gases on board spacecraft when mass saving is a prime requirement. Substantial weight savings can be achieved compared to all metallic pressure vessels. For example, on the space shuttle, replacement of all metallic pressure vessels with Kevlar COPVs resulted in a weight savings of about 30 percent. Mass critical space applications such as the Ares and Orion vehicles are currently being planned to use as many COPVs as possible in place of all-metallic pressure vessels to minimize the overall mass of the vehicle. Due to the fact that overwraps are subjected to sustained loads during long periods of a mission, stress rupture failure is a major concern. It is, therefore, important to ascertain the reliability of these vessels by analysis, since it is practically impossible to show by experimental testing the reliability of flight quality vessels. Also, it is a common practice to set aside flight quality vessels as "fleet leaders" in a test program where these vessels are subjected to slightly accelerated operating conditions so that they lead the actual flight vessels both in time and load. The intention of fleet leaders is to provide advanced warning if there is a serious design flaw in the vessels so that a major disaster in the flight vessels can be averted with advance warning. On the other hand, the accelerating conditions must be not so severe as to be prone to false alarms. The primary focus of the present paper is to provide an analytical basis for designing a viable fleet leader program for carbon COPVs. The analysis is based on a stress rupture behavior model incorporating Weibull statistics and power-law sensitivity of life to fiber stress level.

Murthy, Pappu L.N.↗

NASA NTRS2007

Reliability Considerations for Composite Overwrapped Pressure Vessels on Spacecraft

Composite Overwrapped Pressure Vessels (COPVs) are used to store gases under high pressure onboard spacecraft. These are used for a variety of purposes such as propelling liquid fuel etc, Kevlar, glass, Carbon and other more recent fibers have all been in use to overwrap the vessels. COPVs usually have a thin metallic liner with the primary purpose of containing the gases and prevent any leakage. The liner is overwrapped with filament wound composite such as Kevlar, Carbon or Glass fiber. Although the liner is required to perform in the leak before break mode making the failure a relatively benign mode, the overwrap can fail catastrophically under sustained load due to stress rupture. It is this failure mode that is of major concern as the stored energy of such vessels is often great enough ta cause loss of crew and vehicle. The present paper addresses some of the reliability concerns associated specifically with Kevlar Composite Overwrapped Pressure Vessels. The primary focus of the paper is on how reliability of COPV's are established for the purpose of deciding in general their flight worthiness and continued use. Analytical models based on existing design data will be presented showing how to achieve the required reliability metric to the end of a specific period of performance. Uncertainties in the design parameters and how they affect reliability and confidence intervals will be addressed as well. Some trade studies showing how reliability changes with time during a program period will be presented.

Murthy, Pappu L. N.↗

NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗

NASA NTRS2015

Structural CNT Composites Part II: Assessment of CNT Yarns as Reinforcement for Composite Overwrapped Pressure Vessels

Carbon nanotubes (CNTs) are one-dimensional nanomaterials with outstanding electrical and thermal conductivities and mechanical properties. This combination of properties offers routes to enable lightweight structural aerospace components. Recent advances in the manufacturing of CNTs have made bulk forms such as yarns, tapes and sheets available in commercial quantities to permit the evaluation of these materials for aerospace use, where the superior tensile properties of CNT composites can be exploited in tension dominated applications such as composite overwrapped pressure vessels (COPVs). To investigate their utility in this application, aluminum rings were overwrapped with thermoset/CNT yarn composite and their mechanical properties measured. CNT composite overwrap characteristics such as processing method, CNT/resin ratio, and applied tension during CNT yarn winding were varied to determine their effects on the mechanical performance of the CNT composite overwrapped Al rings (CCOARs). Mechanical properties of the CCOARs were measured under static and cyclic loads at room, elevated, and cryogenic temperatures to evaluate their mechanical performance relative to bare Al rings. At room temperature, the breaking load of CCOARs with a 10.8% additional weight due to the CNT yarn/thermoset overwrap increased by over 200% compared to the bare Al ring. The quality of the wound CNT composites was also investigated using x-ray computed tomography.

Kim, Jae-Woo↗

NASA NTRS1992

Composite overwrapped nickel-hydrogen pressure vessels

The presentation is made in viewgraph format, the first of which states the purpose, which is to stimulate interest in composite overwrapped pressure vessel technology as applied to nickel hydrogen battery pressure vessels. The next viewgraph presents the history of nickel hydrogen pressure vessels over the last 15 years including materials, operating conditions, and market expansion to internationals. Basic materials properties are itemized such as thermal conductivity, corrosion resistance, and strength to weight ratio. The monolithic and composite overwrapped construction approaches are compared. A detailed description is presented of the advantages of composite overwrapped pressure vessels showing weight savings, manufacturing schedule reductions, and improved fatigue life. A discussion is also presented of B-1 application, the wide range of usable materials, and a sketch of a possible optimized design.

Reagan, John↗

NASA NTRS2007

Nondestructive Methods and Special Test Instrumentation Supporting NASA Composite Overwrapped Pressure Vessel Assessments

Many aging composite overwrapped pressure vessels (COPVs), being used by the National Aeronautics and Space Administration (NASA) are currently under evaluation to better quantify their reliability and clarify their likelihood of failure due to stress rupture and age-dependent issues. As a result, some test and analysis programs have been successfully accomplished and other related programs are still in progress at the NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) and other NASA centers, with assistance from the commercial sector. To support this effort, a group of Nondestructive Evaluation (NDE) experts was assembled to provide NDE competence for pretest evaluation of test articles and for application of NDE technology to real-time testing. Techniques were required to provide assurance that the test article had adequate structural integrity and manufacturing consistency to be considered acceptable for testing and these techniques were successfully applied. Destructive testing is also being accomplished to better understand the physical and chemical property changes associated with progression toward "stress rupture" (SR) failure, and it is being associated with NDE response, so it can potentially be used to help with life prediction. Destructive work also includes the evaluation of residual stresses during dissection of the overwrap, laboratory evaluation of specimens extracted from the overwrap to evaluate physical property changes, and quantitative microscopy to inform the theoretical micromechanics.

Saulsberry, Regor↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗

NASA NTRS2012

Summary of Activities for Health Monitoring of Composite Overwrapped Pressure Vessels

This new start project (FY12-14) will design and demonstrate the ability of nondestructive evaluation sensors for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. Results will be correlated with other nondestructive evaluation technologies such as Acoustic Emission. The project will build upon a proof of concept study performed at KSC which demonstrated the ability of Magnetic Stress Gages to measure stresses at internal overwraps and upon current acoustic emission research being performed at WSTF; The gages will be produced utilizing Maundering Winding Magnetometer and/or Maundering Winding Magnetometer-array eddy current technology. The proof-of-concept study demonstrated a correlation between the sensor response and pressure or strain. The study also demonstrated the ability of Maundering Winding Magnetometer technology to monitor the stresses in a Composite Overwrapped Pressure Vessel at different orientations and depths. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs.

Russell, Rick↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

Filament winding a polymer/carbon fiber composite overwrap onto an additively manufactured copper combustion chamber will allow it to act as a light-weight structural jacket, significantly reducing weight for high pressure thrust chamber assemblies and reducing overall cost and fabrication schedules. Chamber assemblies for 2k lb. and 7k lb. of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. The recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

composite overwrap↗

NASA NTRS2015

The Effect of Localized Damage on the Electrical Conductivity of Bare Carbon Fiber Tow and its Use as a Non-Destructive Evaluation Tool for Composite Overwrapped Pressure Vessels

Composite materials are beneficial because of their high specific strength and low weight. Safety, Destructive testing and destructive testing, Non-Destructive Testing (NDT) and Non-Destructive Evaluation (NDE). Problem: Neither NDT nor NDE can provide sufficient data to determine life expectancy or quantify the damage state of a composite material.

Wentzel, Daniel↗

NASA NTRS2013

Summary of Activities for Health Monitoring of Composite Overwrapped Pressure Vessels

This three-year project (FY12-14) will design and demonstrate the ability of new Magnetic Stress Gages for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. The sensors are being tested at White Sands Testing Facility (WSTF) where the results will be correlated with a known nondestructive technique acoustic emission. The gages will be produced utilizing Meandering Winding Magnetometer (MWM) and/or MWM array eddy current technology. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs. The first full-scale pressurization test was performed at WSTF in June 2012. The goals of this test were to determine adaptations of the magnetic stress gauge instrumentation that would be necessary to allow multiple sensors to monitor the vessel's condition simultaneously and to determine how the sensor response changes with sensor selection and orientation. The second full scale pressurization test was performed at WSTF in August 2012. The goals of this test were to monitor the vessel's condition with multiple sensors simultaneously, to determine the viability of the multiplexing units (MUX) for the application, and to determine if the sensor responses in different orientations are repeatable. For both sets of tests the vessel was pressured up to 6,000 psi to simulate maximum operating pressure. Acoustic events were observed during the first pressurization cycle. This suggested that the extended storage period prior to use of this bottle led to a relaxation of the residual stresses imparted during auto-frettage. The pressurization tests successfully demonstrated the use of multiplexers with multiple MWM arrays to monitor a vessel. It was discovered that depending upon the sensor orientation, the frequencies, and the sense element, the MWM arrays can provide a variety of complementary information about the composite overwrapped pressure vessel load conditions. For example, low frequency measurements can be used to monitor the overwrap thickness and changes associated with pressure level. High frequency data is dominated by the properties of the overwrap, including the fiber orientations and lay-up of the layers.

Russell, Rick↗

NASA NTRS2010

Composite Overwrapped Pressure Vessels (COPV) Materials Aging Issues

This slide presentation reviews some of the issues concerning the aging of the materials in a Composite Overwrapped Pressure Vessels (COPV). The basic composition of the COPV is a Boss, a composite overwrap, and a metallic liner. The lifetime of a COPV is affected by the age of the overwrap, the cyclic fatigue of the metallic liner, and stress rupture life, a sudden and catastrophic failure of the overwrap while holding at a stress level below the ultimate strength for an extended time. There is information about the coupon tests that were performed, and a test on a flight COPV.

Source record↗

NASA NTRS2011

Composite Overwrapped Pressure Vessels, A Primer

Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels.

McLaughlan, Pat B.↗