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At least 19 records

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Optimal toolpath design of additive manufactured composite cylindrical structures

Structural design optimization for additive manufacturing is primarily focused on planar layer-by-layer processes and design of composite cylindrical structures does not often accommodate manufacturing constraints. In this study, we propose to optimize the toolpath trajectory of additively manufactured composite cylinders comprised of multiple thin cylindrical annuli. Additionally, our printing process is based on direct ink writing in which short carbon fibers in a thermoset resin are extruded through a moving nozzle to build up a structure. Since the fibers are primarily aligned in the flow direction of the extrudate, the printing trajectory influences the material properties of the composite structure. To accommodate this, we define the toolpaths as contours of parameterized level-set functions. This parameterization allows us to optimize the material properties and impose manufacturing constraints such as no-overlap, no-sag, minimum radius of curvature, and continuity of the toolpaths. Several examples illustrate the optimization procedure.

42 ENGINEERING↗

NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗

NASA NTRSDate not supplied

RESIDUAL DEFORMATION ANALYSIS IN COMPOSITE SHELL STRUCTURES MANUFACTURED USING AUTOMATED FIBER PLACEMENT

The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.

Composites↗

NASA NTRSDate not supplied

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.

thermoplastic composites↗

NASA NTRS2022

In-Situ Consolidation Automated Fiber Placement of Thermoplastic Composites for High-Rate Aircraft Manufacturing

laser heating↗

NASA NTRS1991

Cost-efficient manufacturing of composite structures

The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed.

Freeman, W. Tom↗

NASA NTRS1994

Innovative design of composite structures: Design, manufacturing, and testing of plates utilizing curvilinear fiber trajectories

As a means of improving structural design, the concept of fabricating flat plates containing holes by incorporating curvilinear fiber trajectories to transmit loads around the hole is studied. In the present discussion this concept is viewed from a structural level, where access holes, windows, doors, and other openings are of significant size. This is opposed to holes sized for mechanical fasteners. Instead of cutting the important load-bearing fibers at the hole edge, as a conventional straightline design does, the curvilinear design preserves the load-bearing fibers by orienting them in smooth trajectories around the holes, their loading not ending abruptly at the hole edge. Though the concept of curvilinear fiber trajectories has been studied before, attempts to manufacture and test such plates have been limited. This report describes a cooperative effort between Cincinnati Milacron Inc., NASA Langley Research Center, and Virginia Polytechnic Institute and State University to design, manufacture, and test plates using the curvilinear fiber trajectory concept. The paper discusses details of the plate design, details of the manufacturing, and a summary of results from testing the plates with inplane compressive buckling loads and tensile loads. Comparisons between the curvilinear and conventional straightline fiber designs based on measurements and observation are made. Failure modes, failure loads, strains, deflections, and other key responses are compared.

Hyer, M. W.↗

NASA NTRS2018

Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and Their Effect on Porosity

Porosity can have significant impact on the mechanical performance of composite structures. The primary sources of voids during the cure of composites include air entrapped during lay-up, bag or tool leaks, and the off gassing of volatiles. Capturing the physics of void evolution during composite processing is a challenge due to the number of sources and changing phenomena that give rise to voids as the resin cures. Local changes in resin pressure due to geometric features or cure shrinkage have been experimentally linked to a higher likelihood of void formation. In this work, a preliminary model was developed to predict local resin pressure which can be used to identify regions more susceptible to porosity. Experiments were conducted to validate the model accuracy. Ultimately, this model can be used as a tool to minimize the likelihood of porosity by optimizing the material selection, part design, layup, and cure process.

Bedayat, Houman↗

NASA NTRS2019

A Numerical and Experimental Approach for Modeling Porosity Due to Entrapped Air and Volatiles Off-Gassing During Manufacturing of Composite Structures

High performance composite structures have strict requirements regarding acceptable levels of porosity. The impact can be significant on mechanical performance and mitigating the growth of voids can be a challenge given the complexity of the problem. The evolution of porosity can be summarized as a balance between sources and sinks which determine void growth or shrinkage. The primary sources of void growth include bag leaks, entrapped air in the system, off-gassing of volatiles, and cure shrinkage. Mechanisms which mitigate porosity include removal of air from the system and maintaining sufficient resin pressure during the process to keep volatiles in solution. In this paper, an approach for modeling the evolution of voids due to entrapped air and volatiles is presented. It has been shown in previous experimental studies that decreases in local resin pressure are linked to a higher likelihood of porosity formation. Results of the study are compared to experiments in which the local resin pressure was measured and micrographs of the panels were taken to characterize the porosity.

Hickmott, Curtis↗

NASA NTRSDate not supplied

Process Development and Testing for Lunar Habitats

Non-metallic solutions for Lunar bases are appealing due to their light weight and ability to block many forms of radiation. Composite materials made from different combinations of these non-metallic materials enable effective mating of dissimilar materials for strong structures such as pressurized habitats. Inserting and manufacturing composite structural materials on the Moon presents several challenges, however: the oxygen levels inside pressurized habitats will be relatively high, radiation that is blocked causes damage and the lack of atmosphere results in a high-magnitude negative pressure environment. In the past two years, the Materials and Processes Lab (EM01) invested in two internal research and development (IRAD) proposals for testing and procurement of composite materials. One proposal endeavors to determine flammability and radiation damage of various composite materials with a focus on carbon fiber and ultra-high molecular weight polyethylene (UHWMPE). The other proposal enables procurement of chopped fiber spray equipment materials which will be used to develop a novel technique for chopped UHMWPE fiber layup, similar to the chopped fiberglass layups used for making large structures such a boat hulls and hot tubs.

Composite↗

NASA NTRS2001

An Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structures for Aerospace Vehicles

An assessment of the State-of-the-Art in the design and manufacturing of large composite structures has been conducted. The focus of the assessment is large structural components in commercial and military aircraft. Applications of composites are reviewed for commercial transport aircraft, general aviation aircraft, rotorcraft, and military aircraft.

Harris, Charles E.↗

NASA NTRS1978

Transition from glass to graphite in manufacture of composite aircraft structure

The transition from fiberglass reinforced plastic composites to graphite reinforced plastic composites is described. Structural fiberglass design and manufacturing background are summarized. How this experience provides a technology base for moving into graphite composite secondary structure and then to composite primary structure is considered. The technical requirements that must be fulfilled in the transition from glass to graphite composite structure are also included.

Buffum, H. E.↗

NASA NTRS2007

Millimeter Wave Holographical Inspection of Honeycomb Composites

Multi-layered composite structures manufactured with honeycomb, foam or balsa wood cores are finding increasing utility in a variety of aerospace, transportation, and infrastructure applications. Due to the low conductivity and inhomogeneity associated with these composites standard nondestructive testing (NDT) methods are not always capable of inspecting their interior for various defects caused during the manufacturing process or as a result of in-service loading. On the contrary, microwave and millimeter wave NDT methods are well-suited for inspecting these structures since signals at these frequencies readily penetrate through these structures and reflect from different interior boundaries revealing the presence of a wide range of defects such as disbond, delamination, moisture and oil intrusion, impact damage, etc. Millimeter wave frequency spectrum spans 30 GHz - 300 GHz with corresponding wavelengths of 10 - 1 mm. Due to the inherent short wavelengths at these frequencies, one can produce high spatial resolution images of these composites either using real-antenna focused or synthetic-aperture focused methods. In addition, incorporation of swept-frequency in the latter method (i.e., holography) results in high-resolution three-dimensional images. This paper presents the basic steps behind producing such images at millimeter wave frequencies and the results of two honeycomb composite panels are demonstrated at Q-band (33-50 GHz). In addition, these results are compared to previous results using X-ray computed tomography.

Case, J. T.↗

NASA NTRS2001

An Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structures for Aerospace Vehicles

The results of an assessment of the state-of-the-art in the design and manufacturing of large composite structures are described. The focus of the assessment is on the use of polymeric matrix composite materials for large airframe structural components. such as those in commercial and military aircraft and space transportation vehicles. Applications of composite materials for large commercial transport aircraft, general aviation aircraft, rotorcraft, military aircraft. and unmanned rocket launch vehicles are reviewed. The results of the assessment of the state-of-the-art include a summary of lessons learned, examples of current practice, and an assessment of advanced technologies under development. The results of the assessment conclude with an evaluation of the future technology challenges associated with applications of composite materials to the primary structures of commercial transport aircraft and advanced space transportation vehicles.

Harris, Charles E.↗

NASA NTRS1982

Opportunities for composites in commercial transport structures

Manufacturers are developing composite versions of structural components on existing aircraft. Development involves testing of various material options before selecting one and then extensive testing to develop an adequate data base of material strength and stiffness properties. Design options are narrowed through analysis and a varied spectrum of development tests on small and large subcomponents. In parallel with this, a suitable production process including economical ply preparation and cure at high temperature and pressure is evolved, tools are designed and fabricated, and full scale components are then manufactured for ground qualification tests, flight tests, and airline service. The various tests include many that are required by the FAA for flight certification, which must precede airline service. Inspection and repair methods to insure adequate maintenance in service are also developed.

Herman L. Bohon↗

DOE OSTI2023

Modeling the interfacial failure and resulting mechanical properties of z-pinned additively manufactured composites

The mechanical properties of Fused Filament Fabrication (FFF) parts are limited in the build direction, albeit advantages such as design flexibility and in-house customization. Here, in this paper, a novel z-pinning approach that enhances mechanical properties in the build direction by depositing material across multiple layers within the part was investigated through numerical simulations and validated experimentally. A finite element model for z-pinned composite structures was developed by assigning fiber-orientation dependent material properties obtained using a micromechanics approach to beads and pins. The bead-to-bead and pin-to-pin adhesions within the z-pinned structures were modeled using a cohesive traction separation law. The properties of cohesive elements for carbon fiber-reinforced polylactic acid (CF-PLA) z-pinned composites were calibrated using tensile experiments. The elastic modulus and tensile strength of CF-PLA z-pinned composites in the build direction were predicted with the developed numerical model. The numerical investigation on various geometrical parameters revealed that the largest pin volume increases the stiffness and tensile strength by 40% and thus, has the greatest influence on the mechanical properties of the z-pinned composites. The effect of z-pin geometrical parameters on the mechanical properties was summarized to aid in the design of z-pinned additively manufactured composite structures.

36 MATERIALS SCIENCE↗

NASA NTRS1995

A kinematically driven anisotropic viscoelastic constitutive model applied to tires

Aircraft tires are composite structures manufactured with viscoelastic materials such as carbon black filled rubber and nylon cords. When loaded they experience large deflections and moderately large strains. Detailed structural models of tires require the use of either nonlinear shell or nonlinear three dimensional solid finite elements. Computational predictions of the dynamic response of tires must consider the composite viscoelastic material behavior in a realistic fashion. We describe a modification to a nonlinear anisotropic shell finite element so it can be used to model viscoelastic stresses during general deformations. The model is developed by introducing internal variables of the type used to model elastic strain energy. The internal variables are strains, curvatures, and transverse shear angles which are in a one-to-one correspondence with the generalized coordinates used to model the elastic strain energy for nonlinear response. A difference-relaxation equation is used to relate changes in the observable strain field to changes in the internal strain field. The internal stress state is introduced into the equilibrium equations by converting it to nodal loads associated with the element's displacement degrees of freedom. In this form the tangent matrix in the Newton-Raphson solution algorithm is not modified from its form for the nonlinear statics problem. Only the gradient vector is modified and the modification is not computationally costly. The existing finite element model for the Space Shuttle nose gear tire is used to provide examples of the algorithm. In the first example, the tire's rim is displaced at a constant rate up to a fixed value. In the second example, the tire's rim is enforced to follow a saw tooth load and unload curve to generate hysteresis loops.

Johnson, Arthur R.↗

NASA NTRS2013

Manufacturing of Nanocomposite Carbon Fibers and Composite Cylinders

Pitch-based nanocomposite carbon fibers were prepared with various percentages of carbon nanofibers (CNFs), and the fibers were used for manufacturing composite structures. Experimental results show that these nanocomposite carbon fibers exhibit improved structural and electrical conductivity properties as compared to unreinforced carbon fibers. Composite panels fabricated from these nanocomposite carbon fibers and an epoxy system also show the same properties transformed from the fibers. Single-fiber testing per ASTM C1557 standard indicates that the nanocomposite carbon fiber has a tensile modulus of 110% higher, and a tensile strength 17.7% times higher, than the conventional carbon fiber manufactured from pitch. Also, the electrical resistance of the carbon fiber carbonized at 900 C was reduced from 4.8 to 2.2 ohm/cm. The manufacturing of the nanocomposite carbon fiber was based on an extrusion, non-solvent process. The precursor fibers were then carbonized and graphitized. The resultant fibers are continuous.

Tan, Seng↗