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At least 19 records

STITCHED COMPOSITES WITH THREE-DIMENSIONAL STITCH PATHS

Stitched composites have been shown to exhibit damage tolerance and to reduce weight compared to traditional layered composites through unitization of the structure by elimination of fasteners. Stitching capabilities have been incorporated into the Integrated Structural Assembly of Advanced Composites (ISAAC) system at NASA Langley Research Center with the introduction of two stitching heads. Stitching path control was initially implemented as straight lines in space, as was done for previous stitching development. However, more complex stitched structures such as a wind tunnel blade or around cutouts within a fuselage or wing skin, require that the stitching paths be implemented as three-dimensional (3D) stitching paths in space. Unfortunately, control programming output by an existing preprocessor program cannot stitch these curved paths due to problems that arise in stitch formation and the introduction of side forces on the needles using the conventional programming approach whereby the head is simultaneously controlled through translations and rotations. This lack of capability is most significant for the single-sided stitching head, where two needles are in the preform at the same time for the majority of the stitching process. A means to program 3D stitching paths in space was developed whereby the translation and rotation of each stitch were decoupled, thereby eliminating the problems associated with current control programming approach. Using this newly developed stitching path definition and control programming, complex stitching paths have successfully been stitched at the ISAAC facility. The ability to stitch general 3D stitching paths in space enables the use of stitching on more complex parts.

carbon-epoxy↗

Stitched Composites with Three-Dimensional Stitch Paths

Stitched composites have been shown to exhibit damage tolerance and to reduce weight compared to traditional layered composites through unitization of the structure by elimination of fasteners. Stitching capabilities have been incorporated into the Integrated Structural Assembly of Advanced Composites (ISAAC) system at NASA Langley Research Center with the introduction of two stitching heads. Stitching path control was initially implemented as straight lines in space, as was done for previous stitching development. However, more complex stitched structures such as a wind tunnel blade or around cutouts within a fuselage or wing skin, require that the stitching paths be implemented as three-dimensional (3D) stitching paths in space. Unfortunately, control programming output by an existing preprocessor program cannot stitch these curved paths due to problems that arise in stitch formation and the introduction of side forces on the needles using the conventional programming approach whereby the head is simultaneously controlled through translations and rotations. This lack of capability is most significant for the single-sided stitching head, where two needles are in the preform at the same time for the majority of the stitching process. A means to program 3D stitching paths in space was developed whereby the translation and rotation of each stitch were decoupled, thereby eliminating the problems associated with current control programming approach. Using this newly developed stitching path definition and control programming, complex stitching paths have successfully been stitched at the ISAAC facility. The ability to stitch general 3D stitching paths in space enables the use of stitching on more complex parts.

carbon-epoxy↗

Improvements to Stitching Controls for Manufacturing Advanced Stitched Composites

Stitched composites have been extensively studied and have been shown to have benefits over unstitched composites for stiffened structures, including improved damage tolerance, reduced weight, and fewer fasteners. These benefits make stitched composites attractive from a performance perspective, however, the nature of stitching the preforms prior to infusion includes additional manufacturing steps and equipment compared to conventional resin infusion. Stitching of composite material structures at NASA Langley Research Center (LaRC) is performed at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility using control algorithms developed by the lead author. Two deficiencies have been identified in the current control algorithms, and mitigations for these deficiencies were developed within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) project and are presented herein. First, decoupling stitch translation and rotation takes more time for stitching since two robot operation control steps are executed for each stitch. Therefore, a method was developed to determine when to decouple the translation and rotation for stitching, which reduces stitch time by decoupling the operation control steps only when necessary to execute the stitch properly. Second, a correction to the sideslip stitching approach that eliminates a significant portion of the pre- and post-stitching activities was developed. The developed method adjusts the sideslip stitch angle based on the rotations of previous stitches to ensure that the width of the stitching seam remains constant along its length. Constant seam width eliminates observed overlap of the insertion and catcher thread portions for highly curved paths, which maintains the desired uniformity of through-the-thickness architecture along the seam and eliminates the local degradation of properties where the insertion needle is too close to, or crosses, the catcher needle portion of the seam.

stitching↗

STITCHES: creating new scenarios of climate model output by stitching together pieces of existing simulations

Abstract. Climate model output emulation has long been attempted to support impact research, mainly to fill in gaps in the scenario space. Given the computational cost of running coupled earth system models (ESMs), which are usually the domain of supercomputers and require on the order of days to weeks to complete a century-long simulation, only a handful of different scenarios are usually chosen to externally force ESM simulations. An effective emulator, able to run on standard computers in times of the order of minutes rather than days could therefore be used to derive climate information under scenarios that were not run by ESMs. Lately, the necessity of accounting for internal variability has also made the availability of initial-condition ensembles, under a specific scenario, important, further increasing the computational demand. At least so far, emulators have been limited to simplified ESM-like output, either seasonal, annual, or decadal averages of basic quantities, like temperature and precipitation, often emulated independently of one another. With this work, we propose a more comprehensive solution to ESM output emulation. Our emulator, STITCHES, uses existing archives of earth system models' (ESMs) scenario experiments to construct ESM-like output under new scenarios or enrich existing initial-condition ensembles, which is what other emulators also aim to do. Importantly, however, STITCHES' output has the same characteristics of the ESM output it sets out to emulate: multivariate, spatially resolved, and high frequency, representing both the forced component and the internal variability around it. STITCHES extends the idea of time sampling – according to which climate outcomes are stratified by the global warming level at which they manifest themselves, irrespective of the scenario and time at which they occur – to the construction of a continuous history of ESM-like output over the whole 21st century, consistent with a 21st-century trajectory of global surface air temperature (GSAT) derived from the scenario that has been chosen as the target of the emulation. STITCHES does so by first splitting the target GSAT trajectory into decade-long windows, then matching each window in turn to a decade-long window within an existing model simulation from the available scenario runs according to its proximity to the target in absolute size of the temperature anomaly and its rate of change. A look-up table is therefore created of a sequence of existing experiment–time-window combinations that, when stitched together, create a GSAT trajectory “similar” to the target. Importantly, we can then stitch together much more than GSAT from these windows, i.e., any output that the ESM has saved for these existing experiment–time-window combinations, at any frequency and spatial scale available in its archive. We show that the stitching does not introduce artifacts in the great majority of cases (we look at temperature and precipitation at monthly frequency and on the native grid of the ESM and at an index of ENSO activity, the Southern Oscillation Index). This is true even if the criteria for the identification of the decades to be stitched together are chosen to work for a smoothed time series of annual GSAT, a result we expect given the larger amount of noise affecting most other variables at finer spatial scales and higher frequencies, which therefore are more “forgiving” of the stitching. We successfully test the method's performance over many ESMs and scenarios. Only a few exceptions surface, but these less-than-optimal outcomes are always associated with a scarcity of the archived simulations from which we can gather the decade-long windows that form the building blocks of the emulated time series. In the great majority of cases, STITCHES' performance is satisfactory according to metrics that reward consistency in trends, interannual and inter-ensemble variance, and autocorrelation structure of the time series stitched together. The method therefore can be used to create ESM-like output according to new scenarios, on the basis of a trajectory of GSAT produced according to that scenario, which could be easily obtained by a simple climate model. It can also be used to increase the size of existing initial-condition ensembles. There are aspects of our emulator that will immediately disqualify it for specific applications, like when climate information is needed whose characteristics result from accumulated quantities over windows of times longer than those used as pieces by STITCHES, droughts longer than a decade for example. But for many applications, we argue that a stitched product can satisfy the climate information needs of impact researchers. STITCHES cannot emulate ESM output from scenarios that result in GSAT trajectories outside of the envelope available in the archive, nor can it emulate trajectories with shapes different from existing ones (overshoots with negative derivative, for example). Therefore, the size and characteristics of the available archives of ESM output are the principal limitations for STITCHES' deployment. Thus, we argue for the possibility of designing scenario experiments within, for example, the next phase of the Coupled Model Intercomparison Project according to new principles, relieved of the need to produce a number of similar trajectories that vary only in radiative forcing strength but more strategically covering the space of temperature anomalies and rates of change.

54 ENVIRONMENTAL SCIENCES↗

Delamination and Stitched Failure in Stitched Composite Joints

The effect of stitches on the failure of a single lap joint configuration was determined in a combined experimental and finite element study. The experimental program was conducted to determine debond growth under static monotonic loading. The stitches were shown to delay the initiation of the debond and provide load transfer beyond the load necessary to completely debond the stitched lap joint. The experimentally determined debond length vs. applied load was used as an input parameter in the finite element analysis of both configurations. The strain energy release rates at the debond from were calculated using plate finite elements. Nonlinear fastener elements were used to model the stitches and multipoint constraints were used to model the contact problem. Models of the unstitched configuration showed significant values of modes I and II across the width of the joint and showed that mode III is zero at the centerline but increases near the free edge. Models of the stitched configuration showed that the stitches were effective in reducing mode I to zero, but had less of an effect on modes II and III.

Glaessgen, E. H.↗

Modeling the Influence of Stitching on Delamination Growth in Stitched Warp-Knit Composite Lap Joints

The effect of stitches on the failure of a single lap joint configuration was determined in a combined experimental and analytical study. The experimental study was conducted to determine debond growth under static monotonic loading. The stitches were shown to delay the initiation of the debond and provide load transfer beyond the load necessary to completely debond the stitched lap joint. The strain energy release rates at the debond front were calculated using a finite element-based technique. Models of the unstitched configuration showed significant values of modes I and II across the width of the joint and showed that mode III is zero at the centerline but increases near the free edge. Models of the stitched configuration showed that the stitches effectively reduced mode I to zero, but had less of an effect on modes II and III.

Glaessgen, E. H.↗

Advanced stitching head for making stitches in a textile article having variable thickness

A stitching head for a computer numerically controlled stitching machine includes a thread tensioning mechanism for automatically adjusting thread tension according to the thickness of the material being stitched. The stitching head also includes a mechanism for automatically adjusting thread path geometry according to the thickness of the material being stitched.

Thrash, Patrick J.↗

A Study of How Stitch Placement Affects the Open Hole Tension Strength of Stitched Textile Composite Materials

This paper investigates the relationship between open hole tensile strength and distance between a hole and a stitch in a textile composite material. Tension tests were completed on various specimens with widths of 1 in., 2 in., 3 in. and a constant width to hole diameter ratio of 4. The composites tested were warp knits with AS4 fibers and 3501-6 resin. Test results show a small percent change of net strength with stitch location. However, due to the large scatter in data, the small 6% change in net strength is considered negligible.

Pierucci, Kathleen A.↗

Parametric studies of stitching effectiveness for preventing substructure disbond

A methodology is desired that will allow a designer to select appropriate amounts of through-thickness reinforcement needed to meet design requirements. The goal is to use a relatively simple analysis to minimize the amount of testing that needs to be performed, and to make test results from simple configurations applicable to more general structures. Using this methodology one should be able to optimize the selection of stitching materials, the weight of the yarn, and the stitching density. The analysis approach is to treat substructure disbond as a crack propagation problem. In this approach, the stitches have little influence until a delamination begins to grow. Once the delamination reaches, or extends beyond a stitch, the stitch serves to reduce the strain-energy-release-rate (G) at the crack tip for a given applied load. The reduced G can then be compared to the unstitched materials toughness to predict the load required to further extend the crack. The current model treats the stitch as a simple spring which responds to displacements in the vertical (through-thickness) direction. In concept, this approach is similar to that proposed by other authors. Test results indicate that the model should be refined to include the shearing stiffness of the stitch. The strain-energy-release-rate calculations are performed using a code which uses interconnected higher-order plates to model built-up composite cross-sections. When plates are stacked vertically, the interfacial tractions between the plates can be computed. The plate differential equations are solved in closed-form. The code, called SUBLAM, was developed as part of this section in one dimension. Because of this limitation, rows of stitches are treated as a two-dimensional sheet. The spring stiffness of a row of stitches can be estimated from the stitch material, weight, and density. As a practical and conservative approach, we can assume that the stitch is bonded until a crack passes the stitch location. After the crack passes, it is fully bonded. A series of tests were performed to exercise this methodology and incorporated an attached flange such that the sudden change in thickness initiated a delamination. The analysis was used to estimate the materials' critical G from that of the unstitched specimens. With this data, a prediction was made for the load required to delaminate the stitched specimens. Using the methodology, design charts have been created for simplified geometries. These charts give stitch force, along with G(sub 1) and G(sub 2) as as function of the stitch spring stiffness. Using the charts, it should be possible to determine the stitch spring stiffness and strength required to reduce the G to a desired level. From these parameters, the actual stitching material, weight, and density can be computed.

Flanagan, Gerry↗

Improved Method for Increased-Rate Stitched Composites Manufacturing

Stitched composites, as defined herein, are created by stitching a dry preform, infusing the preform with resin and curing the resin. Stitched composites have been shown to have benefits over unstitched composites for stiffened structures, including improved damage tolerance, reduced weight, and fewer fasteners. However, conventional stitched composite structure production is very time and manual-labor intensive, and therefore is not conducive for high-rate production of commercial aircraft main structure. The National Aeronautics and Space Administration (NASA) Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project has the objective to increase the manufacturing rate for future composite aircraft. Stitched resin infused (SRI) composites are one of the technologies being considered under the HiCAM Project, but to be viable, production rates must be increased (i.e., production time reduced). Previous work has shown that it is possible to reduce the time required to stitch a dry composite preform, such as a skin with integral stiffeners, but the stitching process is a small portion of the total time required to produce a stitched preform. To significantly reduce overall stitched preform production time, a study was undertaken to examine a new stitching method that would yield time reduction in the pre- and post-stitching activities that include all portions of a stitched preform production with the exception of the actual stitching process. The new method resulted in significant reduction in production time, from 27% to 40%, while at the same time reducing the costs associated with fabricating a stitched preform by eliminating stations within the production line, simplifying tooling, reducing labor, and reducing consumables.

Stitching↗

Improved Method for Increased-Rate Stitched Composites Manufacturing

Stitched composites, as defined herein, are created by stitching a dry preform, infusing the preform with resin and curing the resin. Stitched composites have been shown to have benefits over unstitched composites for stiffened structures, including improved damage tolerance, reduced weight, and fewer fasteners. However, conventional stitched composite structure production is very time and manual-labor intensive, and therefore is not conducive for high-rate production of commercial aircraft main structure. The National Aeronautics and Space Administration (NASA) Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project has the objective to increase the manufacturing rate for future composite aircraft. Stitched resin infused (SRI) composites are one of the technologies being considered under the HiCAM Project, but to be viable, production rates must be increased (i.e., production time reduced). Previous work has shown that it is possible to reduce the time required to stitch a dry composite preform, such as a skin with integral stiffeners, but the stitching process is a small portion of the total time required to produce a stitched preform. To significantly reduce overall stitched preform production time, a study was undertaken to examine a new stitching method that would yield time reduction in the pre- and post-stitching activities that include all portions of a stitched preform production with the exception of the actual stitching process. The new method resulted in significant reduction in production time, from 27% to 40%, while at the same time reducing the costs associated with fabricating a stitched preform by eliminating stations within the production line, simplifying tooling, reducing labor, and reducing consumables.

Stitching↗

A bi-channel aided stitching of atomic force microscopy images

Microscopy is an essential tool in scientific research, enabling the visualization of structures at micro- and nanoscale resolutions. However, the field of microscopy often encounters limitations in field-of-view (FOV), restricting the amount of sample that can be imaged in a single capture. To overcome this limitation, image stitching techniques have been developed to seamlessly merge multiple overlapping images into a single, high-resolution composite. The images collected from microscope need to be optimally stitched before accurate physical information can be extracted from post analysis. However, the existing stitching tools either struggle to stitch images together when the microscopy images are feature sparse or cannot address all the transformations of images when performing image stitching. To address these issues, we propose a bi-channel aided feature-based image stitching method and demonstrate its use on Atomic Force Microscopy (AFM) generated Pantoea sp. YR343 biofilm and PTO thin film sample images as experimental data. The topographical channel image of AFM data captures the morphological details of the sample, and a stitched topographical image is desired for researchers. We utilize the amplitude and phase channels of AFM data to maximize the matching features and to estimate the position of the original topographical images and show that the proposed bi-channel aided stitching method outperforms the traditional direct stitching approach in AFM topographical image stitching task. Here, we demonstrated the application on AFM, but similar approaches could be employed of optical microscopy with brightfield and fluorescence channels. We believe this proposed workflow can serve as a valuable augmentation strategy for microscopy image stitching tasks and will benefit the experimentalist to avoid erroneous analysis and discovery due to incorrect stitching.

Atomic force microscopy↗

Stiffener Jumping for Unitized Stitched Composite Preform Manufacturing

A single-sided stitching head is used to assemble unitized three-dimensional preforms using the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) robotic manufacturing system. Typically, assembly of a preform includes a “skin” that is stiffened by stiffener elements stitched to the skin. The single-sided stitching head has two needles that pass through the preform from the same side to form the stitch, typically from the smooth outer surface so the needles penetrate through the preform towards the stiffener side. The single-sided head cannot stitch across stiffening elements (e.g., stringer, frame, integral cap, etc.) because the needles would penetrate into the stiffener web, which would not allow the stitch form because the thread movement would be impeded. As a result, stitching seams cannot cross stiffening elements, and therefore are very short and must remain in the skin/flange connections within the space between the stiffening element webs. Each short segment requires a stop and cut process that takes a significant amount of time. A stiffener jumping stitching method was developed that eliminates the need to cut and restart seams when encountering a stiffener, thus providing a long, continuous seam with a significant reduction in stitching time by eliminating cutting operations and associated excess thread end trimming. This stiffener jumping process places what could be considered a very long stitch that bridges the stiffener to connect the end of one segment of the seam with the beginning of the next segment of the seam to provide a longer continuous seam. As a result, all intermediate thread cuts that would be done at the end of each individual segment of the seam are eliminated, with only a single cut at the end of the seam. The process and programming requirements for carrying out the stiffener jumping stitching approach are presented in this paper. Using the presented stiffener jumping approach to produce the long continuous seams, the stitching time for a representative commercial transport unitized stiffened wing cover panel can possibly be reduced by at least 25 percent.

stitched↗

Open hole and post-impact compression fatigue of stitched and unstitched carbon/epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, M. A.↗

Open hole and postimpact compressive fatigue of stitched and unstitched carbon-epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, Marc A.↗

Effects of stitching on fracture toughness of uniweave textile graphite/epoxy laminates

The effects of through-the-thickness stitching on impact damage resistance, impact damage tolerance, and Mode 1 and Mode 2 fracture toughness of textile graphite/epoxy laminates were studied experimentally. Graphite/epoxy laminates were fabricated from AS4 graphite uniweave textiles and 3501-6 epoxy using Resin Transfer Molding. The cloths were stitched with Kevlar(tm) and glass yarns before resin infusion. Delamination was implanted during processing to simulate impact damage. Sublaminate buckling tests were performed in a novel fixture to measure Compression After Impact (CAI) strength of stitched laminates. The results show that CAI strength can be improved up to 400% by through-the-thickness stitching. Double Cantilever Beam tests were performed to study the effect of stitching on Mode 1 fracture toughness G(sub 1c). It was found that G(sub 1c) increased 30 times for a low stitching density of 16 stitches/sq in. Mode 2 fracture toughness was measured by testing the stitched beams in End Notch Flexure tests. Unlike in the unstitiched beams, crack propagation in the stitched beams was steady. The current formulas for ENF tests were not found suitable for determining G(sub 2C) for stitched beams. Hence two new methods were developed - one based on crack area measured from ultrasonic C-scanning and the other based on equivalent crack area measured from the residual stiffness of the specimen. The G(sub 2c) was found to be at least 5-15 times higher for the stitched laminates. The mechanisms by which stitching increases the CAI strength and fracture toughness are discussed.

Sankar, Bhavani V.↗