Sandwich panel construction Patent
Sandwich panel structure for removing heat from shield between hot and cold areas
Anderson, R. A.↗
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Metal matrix composite structural panel construction
Lightweight capped honeycomb stiffeners for use in fabricating metal or metal/matrix exterior structural panels on aerospace type vehicles and the process for fabricating same are disclosed. The stiffener stringers are formed in sheets, cut to the desired width and length and brazed in spaced relationship to a skin with the honeycomb material serving directly as the required lightweight stiffeners and not requiring separate metal encasement for the exposed honeycomb cells.
Mcwithey, R. R.↗
Relative structural efficiencies of flat balsa-core sandwich and stiffened-panel construction
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Hubka, Ralph E↗
Buckling analysis and test correlation of high temperature structural panels
This paper focuses on the design, analysis, and test of a high temperature structural panel, constructed of Ti-6-4, subjected to a variety of thermal and mechanical load conditions. A follow-on panel, constructed of TMC, is also discussed in less detail. The design constraints and test set-up are discussed, as well as the test methods that were used: the grid shadow moire method and a single gage force stiffness method. The agreement between the test data and analysis for this test program provides confidence in the methods that are currently being used to design structures for hypersonic vehicles. The agreement also suggests that postbuckled strength may potentially be used to reduce the vehicle weight.
Teare, Wendy P.↗
Strong, Lighweight Curved Panels
Sandwich construction gives panels structural efficiency. Large panels with compound curvatures are formed from a honeycomb core faced with sheets of graphite/epoxy cloth and tape. Developed for pod on Space Shuttle, construction readily adapted to curved skin panels on cars, trucks, and airplanes.
Molho, R.↗
A Simple Panel System to Overcome Interface Challenges for Retrofits: Preprint
Retrofitting buildings is usually an expensive and labor-intensive process. Weatherization measures can improve comfort and energy affordability to some extent, but deep energy retrofits are needed to optimize performance and comfort, and to achieve significant energy cost savings. Barriers to deep energy retrofits include a limited supply of skilled labor, different building types, planning complexity, split incentives, and a long or non-existent ROI horizon. The "Simple Panel System" (SPS) workflow developed and demonstrated in this effort streamlines deep energy retrofits by applying advanced site capture, machine learning, and mixed reality to panelized construction. The result is a one-stop, product-independent solution for rapidly scalable retrofits with the potential to reduce construction time and project costs by 50%. Soft costs are reduced by more than 66%, total costs by more than 50%, and field construction time by more than 50% - not to mention the reduction in construction waste, improvement in working conditions, and the ability to scale without an influx of skilled labor. This paper presents the SPS and the preliminary results and findings from the pilot project.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Broadband Transmission Loss Due to Reverberant Excitation
The noise transmission characteristics of candidate curved aircraft sidewall panel constructions is examined analytically using finite element models of the selected panel geometries. The models are validated by experimental modal analyses and transmission loss testing. The structural and acoustic response of the models are then examined when subjected to random or reverberant excitation, the simulation of which is also discussed. For a candidate curved honeycomb panel, the effect of add-on trim panel treatments is examined. Specifically, two different mounting configurations are discussed and their effect on the transmission loss of the panel is presented. This study finds that the add-on acoustical treatments do improve on the primary structures transmission loss characteristics, however, much more research is necessary to draw any valid conclusions about the optimal configuration for the maximum noise transmission loss. This paper describes several directions for the extension of this work.
Barisciano, Lawrence P. Jr.↗
Modular Composite Damage Detection System (MCDDS)
The 2020 CIF funded Modular Composite Damage Detection System (MCDDS) aims to advance the technology of damage detection in composites in the areas of thin, flexible damage detection panel construction, encapsulation techniques in composite matrixes, innovative integration and interfacing techniques with flexible embedded sensory panels, repair methods of composite materials, and improved packaging of the MCDDS. Custom thin, flexible polyimide printed circuit boards (PCBs) were designed and procured for fabrication of test specimens. A custom interface PCB was designed and fabricated to monitor the newly developed damage detection test specimens. Test specimens were fabricated using the novel flexible circuitry that were either fully or partially encapsulated. The fully encapsulated specimens were used to demonstrate embedded damage detection concepts and the partially encapsulated specimens were used to demonstrate surface-mounted (laminate) damage detection concepts. The new composite damage detection test specimens were tested and evaluated to determine if the novel damage detection sensory panels could withstand low-cycle threshold fatigue loading per a modified version of American Society for Testing and Materials (ASTM) D 7264 for up to 50 cycles without void formation. The data for multiple sensory panels indicates that the newly fabricated sensory panels are robust and do indeed withstand three-point bend flexural loading for more than 50 cycles. Additionally, testing was performed to determine if damage could be detected in damage detection test specimens subjected to failure using a 3-point bend test per a modified version of ASTM D 7264. Again, multiple sensory panels (both fully and partially encapsulated) showed the ability to detect damage to specimens subjected to failure per a modified version of ASTM D 7264. Additionally, a novel concept for tracking and monitoring of cracking (and potentially delamination) in composites was designed and developed that utilizes painted-on conductors.
Christopher Forney↗
Lightweight sidewalls for aircraft interior noise control
A theoretical and experimental study was performed to devise lightweight sidewalls for turboprop aircraft. Seven concepts for new sidewalls were analyzed and tested for noise reduction using flat panels of 1.2 m x 1.8 m (4 ft x 6 ft), some of which were aircraft-type constructions and some of which were simpler, easier-to-construct panels to test the functioning of an acoustic principle. Aircraft-application sidewalls were then conceived for each of the seven concepts, and were subjectively evaluated for their ability to meet aircraft nonacoustic design requirements. As a result of the above, the following sidewall concepts were recommended for further investigation: a sidewall in which the interior cavity is vented to ceiling and underfloor areas; sidewalls with wall-mounted resonators, one having a conventional trim panel and one a limp one; and a sidewall with a stiff outer wall and a limp trim panel. These sidewalls appear to promise lower weights than conventional sidewalls adjusted to meet similar acoustic requirements, and further development may prove them to be practical.
May, D. N.↗
Design, fabrication and test of liquid metal heat-pipe sandwich panels
Integral heat-pipe sandwich panels, which synergistically combine the thermal efficiency of heat pipes and the structural efficiency of honeycomb sandwich panel construction, were fabricated and tested. The designs utilize two different wickable honeycomb cores, facesheets with screen mesh sintered to the internal surfaces, and potassium or sodium as the working fluid. Panels were tested by radiant heating, and the results indicate successful heat pipe operation at temperatures of approximately 922 K (1200 F). These panels, in addition to solving potential thermal stress problems in an Airframe-Integrated Scramjet Engine, have potential applications as cold plates for electronic component cooling, as radiators for space platforms, and as low distortion, large area structures.
Basiulis, A.↗
Design, fabrication and test of liquid metal heat-pipe sandwich panels
Integral heat-pipe sandwich panels, which synergistically combine the thermal efficiency of heat pipes and the structural efficiency of honeycomb sandwich panel construction, were fabricated and tested. The designs utilize two different wickable honeycomb cores, facesheets with screen mesh sintered to the internal surfaces, and potassium or sodium as the working fluid. Panels were tested by radiant heating, and the results indicate successful heat pipe operation at temperatures of approximately 922K (1200F). These panels, in addition to solving potential thermal stress problems in an Airframe-Integrated Scramjet Engine, have potential applications as cold plates for electronic component cooling, as radiators for space platforms, and as low distortion, large area structures.
Basiulis, A.↗
Structural efficiencies of five compression panels with curved elements
Structural-efficiency analyses are used to determine the minimum-mass proportions of some panel configurations loaded in uniaxial compression. Five panel constructions, four of which incorporate circular-arc elements and the other a beaded-web corrugation, are shown to have improved structural efficiencies over conventional configurations. In addition to the structural-efficiency equations, which give the mass equivalent flat-plate thickness of the panel necessary to carry a given load, related design equations for calculating the cross-sectional dimensions of these minimum-mass panels are presented. The upper and lower limits of loading, where the design constraints of minimum gage or material yield strength become the dominant design conditions, are established and the corresponding design equations which are applicable outside these limits are also presented.
Giles, G. L.↗
Tow-Steered Panels With Holes Subjected to Compression or Shear Loads
Tailoring composite laminates to vary the fiber orientations within a fiber layer of a laminate to address non-uniform stress states and provide structural advantages such as the alteration of principal load paths has potential application to future low-cost, light-weight structures for commercial transport aircraft. Evaluation of this approach requires the determination of the effectiveness of stiffness tailoring through the use of curvilinear fiber paths in flat panels including the reduction of stress concentrations around the holes and the increase in load carrying capability. Panels were designed through the use of an optimization code using a genetic algorithm and fabricated using a tow-steering approach. Manufacturing limitations, such as the radius of curvature of tows the machine could support, avoidance of wrinkling of fibers and minimization of gaps between fibers were considered in the design process. Variable stiffness tow-steered panels constructed with curvilinear fiber paths were fabricated so that the design methodology could be verified through experimentation. Finite element analysis where each element s stacking sequence was accurately defined is used to verify the behavior predicted based on the design code. Experiments on variable stiffness flat panels with central circular holes were conducted with the panels loaded in axial compression or shear. Tape and tow-steered panels are used to demonstrate the buckling, post-buckling and failure behavior of elastically tailored panels. The experimental results presented establish the buckling performance improvements attainable by elastic tailoring of composite laminates.
Jegley, Dawn C.↗
Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges
A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design combines the compact, lightness and simplicity characteristics of advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm and operations under development by a related parallel project. The seven-panel hexagonal sub-reflector is divided into hexagonal panels of that efficiently stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics. A secondary mechanism ultimately closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for actuation, the actuation mechanisms, and the lightweight sandwich construction panels. A finite element analysis parametric study assessed how design features of the hinge affect its stowage and deployment dynamics. The component fabrication and testing plans for the two-panel assembly breadboard model are outlined.
deployable reflectors↗
Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges
A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design combines the compact, lightness and simplicity characteristics of advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm and operations under development by a related parallel project. The seven-panel hexagonal sub-reflector is divided into hexagonal panels of that efficiently stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics. A secondary mechanism ultimately closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for actuation, the actuation mechanisms, and the lightweight sandwich construction panels. A finite element analysis parametric study assessed how design features of the hinge affect its stowage and deployment dynamics. The component fabrication and testing plans for the two-panel assembly breadboard model are outlined.
deployable reflectors↗
Satellite Validation: A Project to Create a Data-Logging System to Monitor Lake Tahoe
Flying aboard the satellite Terra, the Advanced Spaceborne Thermal Emission and Reflection Radiometer (ASTER) is an imaging instrument used to acquire detailed maps of Earth's surface temperature, elevation, emissivity, and reflectance. An automated site consisting of four buoys was established 6 years ago at Lake Tahoe for the validation of ASTERS thermal infrared data. Using Campbell CR23X Dataloggers, a replacement system to be deployed on a buoy was designed and constructed for the measurement of the lake's temperature profile, surrounding air temperature, humidity, wind direction and speed, net radiation, and surface skin temperature. Each Campbell Datalogger has been programmed to control, power, and monitor 14 different temperature sensors, a JPL-built radiometer, and an RM Young 32500 meteorological station. The logger communicates with the radiometer and meteorological station through a Campbell SDM-SIO4 RS232 serial interface, sending polling commands, and receiving filtered data back from the sensors. This data is then cataloged and sent back across a cellular modem network every hour to JPL. Each instrument is wired via a panel constructed with 18 individual plugs that allow for simple installation and expansion. Data sent back from the system are analyzed at JPL, where they are used to calibrate ASTER data.
Roy, Rudy A.↗
Advanced radiographic imaging techniques.
Examination of the nature and operational constraints of conventional X-radiographic and neutron imaging methods, providing a foundation for a discussion of advanced radiographic imaging systems. Two types of solid-state image amplifiers designed to image X rays are described. Operational theory, panel construction, and performance characteristics are discussed. A closed-circuit television system for imaging neutrons is then described and the system design, operational theory, and performance characteristics are outlined. Emphasis is placed on a description of the advantages of these imaging systems over conventional methods.
Beal, J. B.↗
Deployable radiators for waste heat dissipation from Shuttle payloads
Thermal control of Shuttle instruments will require the use of a pumped fluid space radiator system to reject large quantities of waste heat. Many payloads, however, will have insufficient vehicle surface area available for radiators to reject this waste heat and will, therefore, require the use of deployed panels. It is desirable to utilize modularized, deployable radiator systems which have a high degree of configuration and component commonality to minimize the design, development, and fabrication costs. Prototypes of two radiator systems which meet these criteria are currently under development for Shuttle payload utilization: a 'rigid' radiator system which utilizes aluminum honeycomb panels of the Shuttle Orbiter configuration that are deployed by an Apollo Telescope Mount type scissors mechanism; and two 'flexible' radiator systems which use panels constructed from flexible metal/dielectric composite materials that are deployed by 'unrolling' or 'extending' in orbit. Detailed descriptions of these deployable radiator systems, along with design and performance features, are presented.
Cox, R. L.↗