Composites Materials and Manufacturing Technologies for Space Applications

NASA Technical Reports Server (NTRS)

Vickers, J. H.; Tate, L. C.; Gaddis, S. W.; Neal, R. E.

2016-01-01

Composite materials offer significant advantages in space applications. Weight reduction is imperative for deep space systems. However, the pathway to deployment of composites alternatives is problematic. Improvements in the materials and processes are needed, and extensive testing is required to validate the performance, qualify the materials and processes, and certify components. Addressing these challenges could lead to the confident adoption of composites in space applications and provide spin-off technical capabilities for the aerospace and other industries. To address the issues associated with composites applications in space systems, NASA sponsored a Technical Interchange Meeting (TIM) entitled, "Composites Materials and Manufacturing Technologies for Space Applications," the proceedings of which are summarized in this Conference Publication. The NASA Space Technology Mission Directorate and the Game Changing Program chartered the meeting. The meeting was hosted by the National Center for Advanced Manufacturing (NCAM)-a public/private partnership between NASA, the State of Louisiana, Louisiana State University, industry, and academia, in association with the American Composites Manufacturers Association. The Louisiana Center for Manufacturing Sciences served as the coordinator for the TIM.

Manufacturing Energy Intensity and Opportunity Analysis for Fiber-Reinforced Polymer Composites and Other Lightweight Materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liddell, Heather; Brueske, Sabine; Carpenter, Alberta

With their high strength-to-weight ratios, fiber-reinforced polymer (FRP) composites are important materials for lightweighting in structural applications; however, manufacturing challenges such as low process throughput and poor quality control can lead to high costs and variable performance, limiting their use in commercial applications. One of the most significant challenges for advanced composite materials is their high manufacturing energy intensity. This study explored the energy intensities of two lightweight FRP composite materials (glass- and carbon-fiber-reinforced polymers), with three lightweight metals (aluminum, magnesium, and titanium) and structural steel (as a reference material) included for comparison. Energy consumption for current typical and state-of-the-artmore » manufacturing processes were estimated for each material, deconstructing manufacturing process energy use by sub-process and manufacturing pathway in order to better understand the most energy intensive steps. Energy saving opportunities were identified and quantified for each production step based on a review of applied R&D technologies currently under development in order to estimate the practical minimum energy intensity. Results demonstrate that while carbon fiber reinforced polymer (CFRP) composites have the highest current manufacturing energy intensity of all materials considered, the large differences between current typical and state-of-the-art energy intensity levels (the 'current opportunity') and between state-of-the-art and practical minimum energy intensity levels (the 'R&D opportunity') suggest that large-scale energy savings are within reach.« less

Key technologies for manufacturing and processing sheet materials: A global perspective

NASA Astrophysics Data System (ADS)

Demeri, Mahmoud Y.

2001-02-01

Modern industrial technologies continue to seek new materials and processes to produce products that meet design and functional requirements. Sheet materials made from ferrous and non-ferrous metals, laminates, composites, and reinforced plastics constitute a large percentage of today’s products, components, and systems. Major manufacturers of sheet products include automotive, aerospace, appliance, and food-packaging industries. The Second Global Symposium on Innovations in Materials Processing & Manufacturing: Sheet Materials is organized to provide a forum for presenting advances in sheet processing and manufacturing by worldwide researchers and engineers from industrial, research, and academic centers. The symposium, sponsored by the TMS Materials Processing & Manufacturing Division (MPMD), was planned for the 2001 TMS Annual Meeting, New Orleans, Louisiana, February 11 15, 2001. This article is a review of key papers submitted for publication in the concurrent volume. The selected papers present significant developments in the rapidly expanding areas of advanced sheet materials, innovative forming methods, industrial applications, primary and secondary processing, composite processing, and numerical modeling of manufacturing processes.

Prediction of composites behavior undergoing an ATP process through data-mining

NASA Astrophysics Data System (ADS)

Martin, Clara Argerich; Collado, Angel Leon; Pinillo, Rubén Ibañez; Barasinski, Anaïs; Abisset-Chavanne, Emmanuelle; Chinesta, Francisco

2018-05-01

The need to characterize composite surfaces for distinct mechanical or physical processes leads to different manners of evaluate the state of the surface. During many manufacturing processes deformation occurs, thus hindering composite classification for fabrication processes. In this work we focus on the challenge of a priori identifying the surfaces' behavior in order to optimize manufacturing. We will propose and validate the curvature of the surface as a reliable parameter and we will develop a tool that allows the prediction of the surface behavior.

Issues in nanocomposite ceramic engineering: focus on processing and properties of alumina-based composites.

PubMed

Palmero, Paola; Kern, Frank; Sommer, Frank; Lombardi, Mariangela; Gadow, Rainer; Montanaro, Laura

2014-12-30

Ceramic nanocomposites, containing at least one phase in the nanometric dimension, have received special interest in recent years. They have, in fact, demonstrated increased performance, reliability and lifetime with respect to monolithic ceramics. However, a successful approach to the production of tailored composite nanostructures requires the development of innovative concepts at each step of manufacturing, from the synthesis of composite nanopowders, to their processing and sintering.This review aims to deepen understanding of some of the critical issues associated with the manufacturing of nanocomposite ceramics, focusing on alumina-based composite systems. Two case studies are presented and briefly discussed. The former illustrates the benefits, in terms of sintered microstructure and related mechanical properties, resulting from the application of an engineering approach to a laboratory-scale protocol for the elaboration of nanocomposites in the system alumina-ZrO2-YAG (yttrium aluminium garnet). The latter illustrates the manufacturing of alumina-based composites for large-scale applications such as cutting tools, carried out by an injection molding process. The need for an engineering approach to be applied in all processing steps is demonstrated also in this second case study, where a tailored manufacturing process is required to obtain the desired results.

High performance poly(etherketoneketone) (PEKK) composite parts fabricated using Big Area Additive Manufacturing (BAAM) processes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kunc, Vlastimil; Kishore, Vidya; Chen, Xun

ORNL collaborated with Arkema Inc. to investigate poly(etherketoneketone) (PEKK) and its composites as potential feedstock material for Big Area Additive Manufacturing (BAAM) system. In this work thermal and rheological properties were investigated and characterized in order to identify suitable processing conditions and material flow behavior for BAAM process.

Simulation and Validation of Injection-Compression Filling Stage of Liquid Moulding with Fast Curing Resins

NASA Astrophysics Data System (ADS)

Martin, Ffion A.; Warrior, Nicholas A.; Simacek, Pavel; Advani, Suresh; Hughes, Adrian; Darlington, Roger; Senan, Eissa

2018-03-01

Very short manufacture cycle times are required if continuous carbon fibre and epoxy composite components are to be economically viable solutions for high volume composite production for the automotive industry. Here, a manufacturing process variant of resin transfer moulding (RTM), targets a reduction of in-mould manufacture time by reducing the time to inject and cure components. The process involves two stages; resin injection followed by compression. A flow simulation methodology using an RTM solver for the process has been developed. This paper compares the simulation prediction to experiments performed using industrial equipment. The issues encountered during the manufacturing are included in the simulation and their sensitivity to the process is explored.

Manufacturing a 9-Meter Thermoplastic Composite Wind Turbine Blade: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

Murray, Robynne; Snowberg, David R; Berry, Derek S

Currently, wind turbine blades are manufactured from a combination of glass and/or carbon fiber composite materials with a thermoset resin such as epoxy, which requires energy-intensive and expensive heating processes to cure. Newly developed in-situ polymerizing thermoplastic resin systems for composite wind turbine blades polymerize at room temperature, eliminating the heating process and significantly reducing the blade manufacturing cycle time and embodied energy, which in turn reduces costs. Thermoplastic materials can also be thermally welded, eliminating the need for adhesive bonds between blade components and increasing the overall strength and reliability of the blades. As well, thermoplastic materials enable end-of-lifemore » blade recycling by reheating and decomposing the materials, which is a limitation of existing blade technology. This paper presents a manufacturing demonstration for a 9-m-long thermoplastic composite wind turbine blade. This blade was constructed in the Composites Manufacturing Education and Technology facility at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) using a vacuum-assisted resin transfer molding process. Johns Manville fiberglass and an Arkema thermoplastic resin called Elium were used. Additional materials included Armacell-recycled polyethylene terephthalate foam from Creative Foam and low-cost carbon- fiber pultruded spar caps (manufactured in collaboration with NREL, Oak Ridge National Laboratory, Huntsman, Strongwell, and Chomarat). This paper highlights the development of the thermoplastic resin formulations, including an additive designed to control the peak exothermic temperatures. Infusion and cure times of less than 3 hours are also demonstrated, highlighting the efficiency and energy savings associated with manufacturing thermoplastic composite blades.« less

Processing Optimization of Deformed Plain Woven Thermoplastic Composites

NASA Astrophysics Data System (ADS)

Smith, John R.; Vaidya, Uday K.

2013-12-01

This research addresses the processing optimization of post-manufactured, plain weave architecture composite panels consisted of four glass layers and thermoplastic polyurethane (TPU) when formed with only localized heating. Often times, during the production of deep drawn composite parts, a fabric preform experiences various defects, including non-isothermal heating and thickness variations. Minimizing these defects is of utmost importance for mass produceability in a practical manufacturing process. The broad objective of this research was to implement a design of experiments approach to minimize through-thickness composite panel variation during manufacturing by varying the heating time, the temperature of heated components and the clamping pressure. It was concluded that the heated tooling with least area contact was most influential, followed by the length of heating time and the amount of clamping pressure.

Feasibility of Carbon Fiber/PEEK Composites for Cryogenic Fuel Tank Applications

NASA Astrophysics Data System (ADS)

Doyle, K.; Doyle, A.; O Bradaigh, C. M.; Jaredson, D.

2012-07-01

This paper investigates the feasibility of CF/PEEK composites for manufacture of cryogenic fuel tanks for Next Generation Space Launchers. The material considered is CF/PEEK tape from Suprem SA and the proposed manufacturing process for the fuel tank is Automated Tape Placement. Material characterization was carried out on test laminates manufactured in an autoclave and also by Automated Tape Placement with in-situ consolidation. The results of the two processes were compared to establish if there is any knock down in properties for the automated tape placement process. A permeability test rig was setup with a helium leak detector and the effect of thermal cycling on the permeability properties of CF/PEEK was measured. A 1/10th scale demonstrator was designed and manufactured consisting of a cylinder manufactured by automated tape placement and an upper dome manufactured by autoclave processing. The assembly was achieved by Amorphous Interlayer Bonding with PEI.

Issues related to processability during the manufacture of thermoplastic composites using on-line consolidation techniques

NASA Astrophysics Data System (ADS)

Ghasemi Nejhad, M. N.

1993-04-01

The on-line consolidation of thermoplastic composites is a relatively new technology that can be used to manufacture composite parts with complex geometries. The localized melting/solidification technique employed in this process can reduce the residual stresses and allow for improved dimensional stability and performance. An additional advantage of this technique is the elimination of the curing steps which are necessary in the processing of thermoset-matrix composites. This article presents the effects of processing parameters on processability in on-line consolidation of thermoplastic composites for tape-laying and filament-winding processes employing anisotropic thermal analyses. The results show that the heater size, preheating conditions, and tow thickness can significantly affect the processing window which, in turn, affects the production rate and the quality of the parts.

Method for manufacturing lightning strike mitigation composites

NASA Technical Reports Server (NTRS)

Vaidyanathan, K. Ranji (Inventor); Campbell, Jeffrey (Inventor)

2012-01-01

A method for manufacturing a composite material utilizes a tooling material having a desired shape. The surface of the tooling material is coated with a composite film that includes a conductive filler material. A composite composition is introduced into contact with the surface of the tooling material to form a desired shape. The composite composition is processed to produce the composite material, and the composite material has a conductive composite surface layer that includes the conductive filler material.

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

NASA Technical Reports Server (NTRS)

Singh, Mrityunjay; Halbig, Michael C.; Grady, Joseph E.

2016-01-01

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

The Development of High Temperature Thermoplastic Composite Materials for Additive Manufactured Autoclave Tooling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kunc, Vlastimil; Duty, Chad E.; Lindahl, John M.

2017-08-01

In this work, ORNL and Techmer investigated and screened different high temperature thermoplastic reinforced materials to fabricate composite molds for autoclave processes using Additive Manufacturing (AM) techniques. This project directly led to the development and commercial release of two printable, high temperature composite materials available through Techmer PM. These new materials are targeted for high temperature tooling made via large scale additive manufacturing.

Additive Manufacturing of Composites and Complex Materials

NASA Astrophysics Data System (ADS)

Spowart, Jonathan E.; Gupta, Nikhil; Lehmhus, Dirk

2018-03-01

Advanced composite materials form an important class of high-performance industrial materials used in weight-sensitive applications such as aerospace structures, automotive structures and sports equipment. In many of these applications, parts are made in small production runs, are highly customized and involve long process development times. Developments in additive manufacturing (AM) methods have helped in overcoming many of these limitations. The special topic of Additive Manufacturing of Composites and Complex Materials captures the state of the art in this area by collecting nine papers that present much novel advancement in this field. The studies under this topic show advancement in the area of AM of carbon fiber and graphene-reinforced composites with high thermal and electrical conductivities, development of new hollow glass particle-filled syntactic foam filaments for printing lightweight structures and integration of sensors or actuators during AM of metallic parts. Some of the studies are focused on process optimization or modification to increase the manufacturing speed or tuning manufacturing techniques to enable AM of new materials.

INTEGRATION OF COST MODELS AND PROCESS SIMULATION TOOLS FOR OPTIMUM COMPOSITE MANUFACTURING PROCESS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pack, Seongchan; Wilson, Daniel; Aitharaju, Venkat

Manufacturing cost of resin transfer molded composite parts is significantly influenced by the cycle time, which is strongly related to the time for both filling and curing of the resin in the mold. The time for filling can be optimized by various injection strategies, and by suitably reducing the length of the resin flow distance during the injection. The curing time can be reduced by the usage of faster curing resins, but it requires a high pressure injection equipment, which is capital intensive. Predictive manufacturing simulation tools that are being developed recently for composite materials are able to provide variousmore » scenarios of processing conditions virtually well in advance of manufacturing the parts. In the present study, we integrate the cost models with process simulation tools to study the influence of various parameters such as injection strategies, injection pressure, compression control to minimize high pressure injection, resin curing rate, and demold time on the manufacturing cost as affected by the annual part volume. A representative automotive component was selected for the study and the results are presented in this paper« less

Producing Hybrid Metal Composites by Combining Additive Manufacturing and Casting

DOE PAGES

Pawlowski, Alex E.; Splitter, Derek A.; Muth, Thomas R.; ...

2017-10-01

Additive manufacturing by itself provides many benefits, but by combining different materials processing techniques like traditional casting with additive manufacturing to create hybrid processes, custom materials can be tailor-made and mass produced for applications with specific performance needs.

ANALYSIS AND EVALUATION OF MYCELIUM REINFORCED NATURAL FIBER BIO-COMPOSITES

USDA-ARS?s Scientific Manuscript database

There is a need for biodegradable alternatives to the inert plastics and expanded foams that are common in both the manufacturing process and device componentry. The material in this study is a bio-composite patented by Ecovative Design LLC. The manufacturer's bio-composite utilizes fungal mycelium ...

40 CFR 63.2232 - What parts of my plant does this subpart cover?

Code of Federal Regulations, 2010 CFR

2010-07-01

... CATEGORIES National Emission Standards for Hazardous Air Pollutants: Plywood and Composite Wood Products What... process units associated with the manufacturing of plywood and composite wood products. The affected... onsite storage and preparation of raw materials used in the manufacture of plywood and/or composite wood...

Ultrasonic NDE Simulation for Composite Manufacturing Defects

NASA Technical Reports Server (NTRS)

Leckey, Cara A. C.; Juarez, Peter D.

2016-01-01

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Haller, William J.; Poinsatte, Philip E.; Halbig, Michael C.; Schnulo, Sydney L.; Singh, Mrityunjay; Weir, Don; Wali, Natalie; Vinup, Michael; Jones, Michael G.;

A cyber physical system approach for composite part: From smart manufacturing to predictive maintenance

NASA Astrophysics Data System (ADS)

Quaranta, Giacomo; Abisset-Chavanne, Emmanuelle; Chinesta, Francisco; Duval, Jean-Louis

2018-05-01

In this work, a Cyber Physical System called Hybrid Twin is proposed for composite parts manufactured from RTM. This allows to introduce in the virtual twin of the parts the defect and the final properties induced by the real manufacturing process and to use on line data collection for predictive maintenance.

Manufacturing Materials and Processes. Grade 11-12. Course #8165 (Semester). Technology Education Course Guide. Industrial Arts/Technology Education.

ERIC Educational Resources Information Center

North Carolina State Dept. of Public Instruction, Raleigh. Div. of Vocational Education.

This guide is intended for use in teaching an introductory course in manufacturing materials and processes. The course centers around four basic materials--metallics, polymers, ceramics, and composites--and seven manufacturing processes--casting, forming, molding, separating, conditioning, assembling, and finishing. Concepts and classifications of…

Consolidation modelling for thermoplastic composites forming simulation

NASA Astrophysics Data System (ADS)

Xiong, H.; Rusanov, A.; Hamila, N.; Boisse, P.

2016-10-01

Pre-impregnated thermoplastic composites are widely used in the aerospace industry for their excellent mechanical properties, Thermoforming thermoplastic prepregs is a fast manufacturing process, the automotive industry has shown increasing interest in this manufacturing processes, in which the reconsolidation is an essential stage. The model of intimate contact is investigated as the consolidation model, compression experiments have been launched to identify the material parameters, several numerical tests show the influents of the temperature and pressure applied during processing. Finally, a new solid-shell prismatic element has been presented for the simulation of consolidation step in the thermoplastic composites forming process.

Manufacturing development of pultruded composite panels

NASA Technical Reports Server (NTRS)

Meade, L. E.

1989-01-01

The weight savings potential, of graphite-epoxy composites for secondary and medium primary aircraft structures, was demonstrated. One of the greatest challenges facing the aircraft industry is to reduce the acquisition costs for composite structures to a level below that of metal structures. The pultrusion process, wherein reinforcing fibers, after being passed through a resin bath are drawn through a die to form and cure the desired cross-section, is an automated low cost manufacturing process for composite structures. The Lockheed Aeronautical Systems Company (LASC) Composites Development Center designed, characterizated materials for, fabricated and tested a stiffened cover concept compatible with the continuous pultrusion process. The procedures used and the results obtained are presented.

MANTECH project book

NASA Astrophysics Data System (ADS)

The effective integration of processes, systems, and procedures used in the production of aerospace systems using computer technology is managed by the Integration Technology Division (MTI). Under its auspices are the Information Management Branch, which is actively involved with information management, information sciences and integration, and the Implementation Branch, whose technology areas include computer integrated manufacturing, engineering design, operations research, and material handling and assembly. The Integration Technology Division combines design, manufacturing, and supportability functions within the same organization. The Processing and Fabrication Division manages programs to improve structural and nonstructural materials processing and fabrication. Within this division, the Metals Branch directs the manufacturing methods program for metals and metal matrix composites processing and fabrication. The Nonmetals Branch directs the manufacturing methods programs, which include all manufacturing processes for producing and utilizing propellants, plastics, resins, fibers, composites, fluid elastomers, ceramics, glasses, and coatings. The objective of the Industrial Base Analysis Division is to act as focal point for the USAF industrial base program for productivity, responsiveness, and preparedness planning.

Present State of the Art of Composite Fabric Forming: Geometrical and Mechanical Approaches

PubMed Central

Cherouat, Abel; Borouchaki, Houman

2009-01-01

Continuous fibre reinforced composites are now firmly established engineering materials for the manufacture of components in the automotive and aerospace industries. In this respect, composite fabrics provide flexibility in the design manufacture. The ability to define the ply shapes and material orientation has allowed engineers to optimize the composite properties of the parts. The formulation of new numerical models for the simulation of the composite forming processes must allow for reduction in the delay in manufacturing and an optimization of costs in an integrated design approach. We propose two approaches to simulate the deformation of woven fabrics: geometrical and mechanical approaches.

Friction Stir Processing of Particle Reinforced Composite Materials

PubMed Central

Gan, Yong X.; Solomon, Daniel; Reinbolt, Michael

2010-01-01

The objective of this article is to provide a review of friction stir processing (FSP) technology and its application for microstructure modification of particle reinforced composite materials. The main focus of FSP was on aluminum based alloys and composites. Recently, many researchers have investigated this technology for treating other alloys and materials including stainless steels, magnesium, titanium, and copper. It is shown that FSP technology is very effective in microstructure modification of reinforced metal matrix composite materials. FSP has also been used in the processing and structure modification of polymeric composite materials. Compared with other manufacturing processes, friction stir processing has the advantage of reducing distortion and defects in materials. The layout of this paper is as follows. The friction stir processing technology will be presented first. Then, the application of this technology in manufacturing and structure modification of particle reinforced composite materials will be introduced. Future application of friction stir processing in energy field, for example, for vanadium alloy and composites will be discussed. Finally, the challenges for improving friction stir processing technology will be mentioned.

No-Oven, No-Autoclave Composite Processing

NASA Technical Reports Server (NTRS)

Rauscher, Michael D.

2015-01-01

Very large composite structures, such as those used in NASA's Space Launch System, push the boundaries imposed by current autoclaves. New technology is needed to maintain composite performance and free manufacturing engineers from the restraints of curing equipment size limitations. Recent efforts on a Phase II project by Cornerstone Research Group, Inc. (CRG), have advanced the technology and manufacturing readiness levels of a unique two-part epoxy resin system. Designed for room-temperature infusion of a dry carbon preform, the system includes a no-heat-added cure that delivers 350 F composite performance in a matter of hours. This no-oven, no-autoclave (NONA) composite processing eliminates part-size constraints imposed by infrastructure and lowers costs by increasing throughput and reducing capital-specific, process-flow bottlenecks. As a result of the Phase II activity, NONA materials and processes were used to make high-temperature composite tooling suitable for further production of carbon-epoxy laminates and honeycomb/ sandwich-structure composites with an aluminum core. The technology platform involves tooling design, resin infusion processing, composite part design, and resin chemistry. The various technology elements are combined to achieve a fully cured part. The individual elements are not unusual, but they are combined in such a way that enables proper management of the heat generated by the epoxy resin during cure. The result is a self-cured carbon/ epoxy composite part that is mechanically and chemically stable at temperatures up to 350 F. As a result of the successful SBIR effort, CRG has launched NONA Composites as a spinoff subsidiary. The company sells resin to end users, fabricates finished goods for customers, and sells composite tooling made with NONA materials and processes to composite manufacturers.

Dry Process for Making Polyimide/ Carbon-and-Boron-Fiber Tape

NASA Technical Reports Server (NTRS)

Belvin, Harry L.; Cano, Roberto J.; Johnston, Norman J.; Marchello, Joseph M.

2003-01-01

A dry process has been invented as an improved means of manufacturing composite prepreg tapes that consist of high-temperature thermoplastic polyimide resin matrices reinforced with carbon and boron fibers. Such tapes are used (especially in the aircraft industry) to fabricate strong, lightweight composite-material structural components. The inclusion of boron fibers results in compression strengths greater than can be achieved by use of carbon fibers alone. The present dry process is intended to enable the manufacture of prepreg tapes (1) that contain little or no solvent; (2) that have the desired dimensions, fiber areal weight, and resin content; and (3) in which all of the fibers are adequately wetted by resin and the boron fibers are fully encapsulated and evenly dispersed. Prepreg tapes must have these properties to be useable in the manufacture of high-quality composites by automated tape placement. The elimination of solvent and the use of automated tape placement would reduce the overall costs of manufacturing.

Modification Of The Manufacturing Process Of A Composite Structure- From System Needs To Elementary Tests

NASA Astrophysics Data System (ADS)

Touzard, Jerome; Veilleraud, Frederic; Collias, Michael

2012-07-01

The SYLDA5 structure (SYstème de Lancement Double Ariane 5 - Ariane 5 dual launch system) is a lightweight carbon composite structure designed and manufactured by Astrium Space Transportation at Les Mureaux premises. In order to improve the manufacturing process of t he SYLDA5, a proposal was made by SYLDA5 technical team to change the manufacturing process of the composite sandwich parts. The SYLDA5 is however one of the main contributors in the dynamic behaviour of the upper part of Ariane 5 launcher and plays an important role in the qualification of the launcher. The present paper describes the overall qualification logic retained, from System requirements to material tests and to global System qualification, in a classical V- type design cycle. It demonstrates the necessity to take into account System needs when modifying a part of it, especially when the System is qualified with actual characteristics of t he parts that may not be defined in product’s initial requirements.

Study on voids of epoxy matrix composites sandwich structure parts

NASA Astrophysics Data System (ADS)

He, Simin; Wen, Youyi; Yu, Wenjun; Liu, Hong; Yue, Cheng; Bao, Jing

2017-03-01

Void is the most common tiny defect of composite materials. Porosity is closely related to composite structure property. The voids forming behaviour in the composites sandwich structural parts with the carbon fiber reinforced epoxy resin skins was researched by adjusting the manufacturing process parameters. The composites laminate with different porosities were prepared with the different process parameter. The ultrasonic non-destructive measurement method for the porosity was developed and verified through microscopic examination. The analysis results show that compaction pressure during the manufacturing process had influence on the porosity in the laminate area. Increasing the compaction pressure and compaction time will reduce the porosity of the laminates. The bond-line between honeycomb core and carbon fiber reinforced epoxy resin skins were also analyzed through microscopic examination. The mechanical properties of sandwich structure composites were studied. The optimization process parameters and porosity ultrasonic measurement method for composites sandwich structure have been applied to the production of the composite parts.

Risks and reliability of manufacturing processes as related to composite materials for spacecraft structures

NASA Technical Reports Server (NTRS)

Bao, Han P.

1995-01-01

Fabricating primary aircraft and spacecraft structures using advanced composite materials entail both benefits and risks. The benefits come from much improved strength-to-weight ratios and stiffness-to-weight ratios, potential for less part count, ability to tailor properties, chemical and solvent resistance, and superior thermal properties. On the other hand, the risks involved include high material costs, lack of processing experience, expensive labor, poor reproducibility, high toxicity for some composites, and a variety of space induced risks. The purpose of this project is to generate a manufacturing database for a selected number of materials with potential for space applications, and to rely on this database to develop quantitative approaches to screen candidate materials and processes for space applications on the basis of their manufacturing risks including costs. So far, the following materials have been included in the database: epoxies, polycyanates, bismalemides, PMR-15, polyphenylene sulfides, polyetherimides, polyetheretherketone, and aluminum lithium. The first four materials are thermoset composites; the next three are thermoplastic composites, and the last one is is a metal. The emphasis of this database is on factors affecting manufacturing such as cost of raw material, handling aspects which include working life and shelf life of resins, process temperature, chemical/solvent resistance, moisture resistance, damage tolerance, toxicity, outgassing, thermal cycling, and void content, nature or type of process, associate tooling, and in-process quality assurance. Based on industry experience and published literature, a relative ranking was established for each of the factors affecting manufacturing as listed above. Potential applications of this database include the determination of a delta cost factor for specific structures with a given process plan and a general methodology to screen materials and processes for incorporation into the current conceptual design optimization of future spacecrafts as being coordinated by the Vehicle Analysis Branch where this research is being conducted.

Study of mould design and forming process on advanced polymer-matrix composite complex structure

NASA Astrophysics Data System (ADS)

Li, S. J.; Zhan, L. H.; Bai, H. M.; Chen, X. P.; Zhou, Y. Q.

2015-07-01

Advanced carbon fibre-reinforced polymer-matrix composites are widely applied to aviation manufacturing field due to their outstanding performance. In this paper, the mould design and forming process of the complex composite structure were discussed in detail using the hat stiffened structure as an example. The key issues of the moulddesign were analyzed, and the corresponding solutions were also presented. The crucial control points of the forming process such as the determination of materials and stacking sequence, the temperature and pressure route of the co-curing process were introduced. In order to guarantee the forming quality of the composite hat stiffened structure, a mathematical model about the aperture of rubber mandrel was introduced. The study presented in this paper may provide some actual references for the design and manufacture of the important complex composite structures.

Automated fiber placement composite manufacturing: The mission at MSFC's Productivity Enhancement Complex

NASA Technical Reports Server (NTRS)

Vickers, John H.; Pelham, Larry I.

1993-01-01

Automated fiber placement is a manufacturing process used for producing complex composite structures. It is a notable leap to the state-of-the-art in technology for automated composite manufacturing. The fiber placement capability was established at the Marshall Space Flight Center's (MSFC) Productivity Enhancement Complex in 1992 in collaboration with Thiokol Corporation to provide materials and processes research and development, and to fabricate components for many of the Center's Programs. The Fiber Placement System (FPX) was developed as a distinct solution to problems inherent to other automated composite manufacturing systems. This equipment provides unique capabilities to build composite parts in complex 3-D shapes with concave and other asymmetrical configurations. Components with complex geometries and localized reinforcements usually require labor intensive efforts resulting in expensive, less reproducible components; the fiber placement system has the features necessary to overcome these conditions. The mechanical systems of the equipment have the motion characteristics of a filament winder and the fiber lay-up attributes of a tape laying machine, with the additional capabilities of differential tow payout speeds, compaction and cut-restart to selectively place the correct number of fibers where the design dictates. This capability will produce a repeatable process resulting in lower cost and improved quality and reliability.

7 CFR 58.145 - Composition and wholesomeness.

Code of Federal Regulations, 2010 CFR

2010-01-01

... contamination or adulteration of the milk or dairy products during manufacturing. All substances and ingredients used in the processing or manufacturing of any dairy product shall be subject to inspection and shall... requirements of the Federal Food, Drug, and Cosmetic Act as to their composition and wholesomeness. ...

Safety concerns in composite manufacturing and machining

NASA Astrophysics Data System (ADS)

Asmatulu, Eylem; Alonayni, Abdullah; Alamir, Mohammed

2018-03-01

Because of the superior properties, composites have been used in many industrial applications, including aerospace, wind turbines, ships, cars, fishing rods, storage tanks, swimming pool panels, and baseball bats. Each application may require different combinations of reinforcements and matrices, which make the manufacturing safety even more challenging while working on these substances. In this study, safety issues in composite manufacturing and machining were investigated in detail, and latest developments were provided for workers. The materials most frequently used in composite manufacturing, such as matrix (polyester, vinylester, phenolic, epoxies, methyl ethyl ketone peroxide, benzoil peroxide, hardeners, and solvents), and reinforcement materials (carbon, glass and Kevlar fibers, honeycomb and foams) can be highly toxic to human body. These materials can also be very toxic to the environment when dumped out uncontrollably, creating major future health and environmental concerns. Throughout the manufacturing process, workers inhale vapors of the liquid matrix, hardeners and solvents / thinners, as well as reinforcement materials (chopped fibers and particles) in airborne. Milling, cutting and machining of the composites can further increase the toxic inhalations of airborne composite particles, resulting in major rashes, irritation, skin disorders, coughing, severe eye and lung injury and other serious illnesses. The major portions of these hazardous materials can be controlled using appropriate personal protective equipment for the chemicals and materials used in composite manufacturing and machining. This study provides best possible safety practices utilized in composite manufacturing facilities for workers, engineers and other participants.

Advanced Manufacturing Technologies

NASA Technical Reports Server (NTRS)

Fikes, John

2016-01-01

Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

Development and demonstration of manufacturing processes for fabricating graphite/LARC 160 polyimide structural elements

NASA Technical Reports Server (NTRS)

Frost, R. K.; Jones, J. S.; Dynes, P. J.; Wykes, D. H.

1981-01-01

The development and demonstration of manufacturing technologies for the structural application of Celion graphite/LARC-160 polyimide composite material is discussed. Process development and fabrication of demonstration components are discussed. Process development included establishing quality assurance of the basic composite material and processing, nondestructive inspection of fabricated components, developing processes for specific structural forms, and qualification of processes through mechanical testing. Demonstration components were fabricated. The demonstration components consisted of flat laminates, skin/stringer panels, honeycomb panels, chopped fiber compression moldings, and a technology demonstrator segment (TDS) representative of the space shuttle aft body flap.

Cost analysis of composite fan blade manufacturing processes

NASA Technical Reports Server (NTRS)

Stelson, T. S.; Barth, C. F.

1980-01-01

The relative manufacturing costs were estimated for large high technology fan blades prepared by advanced composite fabrication methods using seven candidate materials/process systems. These systems were identified as laminated resin matrix composite, filament wound resin matrix composite, superhybrid solid laminate, superhybrid spar/shell, metal matrix composite, metal matrix composite with a spar and shell, and hollow titanium. The costs were calculated utilizing analytical process models and all cost data are presented as normalized relative values where 100 was the cost of a conventionally forged solid titanium fan blade whose geometry corresponded to a size typical of 42 blades per disc. Four costs were calculated for each of the seven candidate systems to relate the variation of cost on blade size. Geometries typical of blade designs at 24, 30, 36 and 42 blades per disc were used. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

An Integrated Computational Materials Engineering Method for Woven Carbon Fiber Composites Preforming Process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Weizhao; Ren, Huaqing; Wang, Zequn

2016-10-19

An integrated computational materials engineering method is proposed in this paper for analyzing the design and preforming process of woven carbon fiber composites. The goal is to reduce the cost and time needed for the mass production of structural composites. It integrates the simulation methods from the micro-scale to the macro-scale to capture the behavior of the composite material in the preforming process. In this way, the time consuming and high cost physical experiments and prototypes in the development of the manufacturing process can be circumvented. This method contains three parts: the micro-scale representative volume element (RVE) simulation to characterizemore » the material; the metamodeling algorithm to generate the constitutive equations; and the macro-scale preforming simulation to predict the behavior of the composite material during forming. The results show the potential of this approach as a guidance to the design of composite materials and its manufacturing process.« less

Structural design of composite rotor blades with consideration of manufacturability, durability, and manufacturing uncertainties

NASA Astrophysics Data System (ADS)

Li, Leihong

A modular structural design methodology for composite blades is developed. This design method can be used to design composite rotor blades with sophisticate geometric cross-sections. This design method hierarchically decomposed the highly-coupled interdisciplinary rotor analysis into global and local levels. In the global level, aeroelastic response analysis and rotor trim are conduced based on multi-body dynamic models. In the local level, variational asymptotic beam sectional analysis methods are used for the equivalent one-dimensional beam properties. Compared with traditional design methodology, the proposed method is more efficient and accurate. Then, the proposed method is used to study three different design problems that have not been investigated before. The first is to add manufacturing constraints into design optimization. The introduction of manufacturing constraints complicates the optimization process. However, the design with manufacturing constraints benefits the manufacturing process and reduces the risk of violating major performance constraints. Next, a new design procedure for structural design against fatigue failure is proposed. This procedure combines the fatigue analysis with the optimization process. The durability or fatigue analysis employs a strength-based model. The design is subject to stiffness, frequency, and durability constraints. Finally, the manufacturing uncertainty impacts on rotor blade aeroelastic behavior are investigated, and a probabilistic design method is proposed to control the impacts of uncertainty on blade structural performance. The uncertainty factors include dimensions, shapes, material properties, and service loads.

Optimization of composite wood structural components : processing and design choices

Treesearch

Theodore L. Laufenberg

1985-01-01

Decreasing size and quality of the world's forest resources are responsible for interest in producing composite wood structural components. Process and design optimization methods are offered in this paper. Processing concepts for wood composite structural products are reviewed to illustrate manufacturing boundaries and areas of high potential. Structural...

Manufacture of composite test specimens for delamination studies

NASA Technical Reports Server (NTRS)

Sumich, M.

1989-01-01

This paper describes the process for manufacturing high-quality test specimens for uses in evaluations of interlaminar tensile strength of laminated composites. The chosen specimen configuration is a curved beam which experiences interlaminar tension in the region of greatest curvature when the beam is subjected to 'opening' forces. The manufacturing process uses a lock-mold tooling approach, the principle of which relies upon the difference in coefficients of thermal expansion between the internal rubber mandrel and the surrounding steel female mold. With this method, compaction pressures above those provided by a typical autoclave can be achieved.

Mechanical, thermal and morphological characterization of polycarbonate/oxidized carbon nanofiber composites produced with a lean 2-step manufacturing process.

PubMed

Lively, Brooks; Kumar, Sandeep; Tian, Liu; Li, Bin; Zhong, Wei-Hong

2011-05-01

In this study we report the advantages of a 2-step method that incorporates an additional process pre-conditioning step for rapid and precise blending of the constituents prior to the commonly used melt compounding method for preparing polycarbonate/oxidized carbon nanofiber composites. This additional step (equivalent to a manufacturing cell) involves the formation of a highly concentrated solid nano-nectar of polycarbonate/carbon nanofiber composite using a solution mixing process followed by melt mixing with pure polycarbonate. This combined method yields excellent dispersion and improved mechanical and thermal properties as compared to the 1-step melt mixing method. The test results indicated that inclusion of carbon nanofibers into composites via the 2-step method resulted in dramatically reduced ( 48% lower) coefficient of thermal expansion compared to that of pure polycarbonate and 30% lower than that from the 1-step processing, at the same loading of 1.0 wt%. Improvements were also found in dynamic mechanical analysis and flexural mechanical properties. The 2-step approach is more precise and leads to better dispersion, higher quality, consistency, and improved performance in critical application areas. It is also consistent with Lean Manufacturing principles in which manufacturing cells are linked together using less of the key resources and creates a smoother production flow. Therefore, this 2-step process can be more attractive for industry.

Temperature and strain registration by fibre-optic strain sensor in the polymer composite materials manufacturing

NASA Astrophysics Data System (ADS)

Matveenko, V. P.; Kosheleva, N. A.; Shardakov, I. N.; Voronkov, A. A.

2018-04-01

The presence of process-induced strains induced by various manufacturing and operational factors is one of the characteristics of polymer composite materials (PCM). Conventional methods of registration and evaluation of process-induced strains can be laborious, time-consuming and demanding in terms of technical applications. The employment of embedded fibre-optic strain sensors (FOSS) offers a real prospect of measuring residual strains. This paper demonstrates the potential for using embedded FOSS for recording technological strains in a PCM plate. The PCM plate is manufactured from prepreg, using the direct compression-moulding method. In this method, the prepared reinforcing package is placed inside a mould, heated, and then exposed to compaction pressure. The examined technology can be used for positioning FOSS between the layers of the composite material. Fibre-optic sensors, interacting with the material of the examined object, make it possible to register the evolution of the strain process during all stages of polymer-composite formation. FOSS data were recorded with interrogator ASTRO X 327. The obtained data were processed using specially developed algorithms.

Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structure

NASA Technical Reports Server (NTRS)

Harris, C. E.

2001-01-01

This viewgraph presentation gives an assessment of the state-of-the-art in the design and manufacturing of large component structures, including details on the use of continuous fiber reinforced polymer matrix composites (CFRP) in commercial and military aircraft and in space launch vehicles. Project risk mitigation plans must include a building-block test approach to structural design development, manufacturing process scale-up development tests, and pre-flight ground tests to verify structural integrity. The potential benefits of composite structures justifies NASA's investment in developing the technology. Advanced composite structures technology is enabling to virtually every Aero-Space Technology Enterprise Goal.

Mechanical properties and production quality of hand-layup and vacuum infusion processed hybrid composite materials for GFRP marine structures

NASA Astrophysics Data System (ADS)

Kim, Sang-Young; Shim, Chun Sik; Sturtevant, Caleb; Kim, Dave (Dae-Wook); Song, Ha Cheol

2014-09-01

Glass Fiber Reinforced Plastic (GFRP) structures are primarily manufactured using hand lay-up or vacuum infusion techniques, which are cost-effective for the construction of marine vessels. This paper aims to investigate the mechanical properties and failure mechanisms of the hybrid GFRP composites, formed by applying the hand lay-up processed exterior and the vacuum infusion processed interior layups, providing benefits for structural performance and ease of manufacturing. The hybrid GFRP composites contain one, two, and three vacuum infusion processed layer sets with consistent sets of hand lay-up processed layers. Mechanical properties assessed in this study include tensile, compressive and in-plane shear properties. Hybrid composites with three sets of vacuum infusion layers showed the highest tensile mechanical properties while those with two sets had the highest mechanical properties in compression. The batch homogeneity, for the GFRP fabrication processes, is evaluated using the experimentally obtained mechanical properties

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kunc, Vlastimil; Lindahl, John M; Dinwiddie, Ralph Barton

The autoclave is a crucial piece of equipment for fabricating Tier 1 polymer composite aerospace structural components with very low void content (i.e. < 5 %). The essential component in this composite manufacturing process is the rigid mold that defines the final shape of the fabricated composite component. The Big Area Additive Manufacturing (BAAM) system located at Oak Ridge National Laboratory s (ORNL) Manufacturing Demonstration Facility (MDF) has been used to manufacture a new generation of in-autoclave tools that can be used to fabricate various aerospace composite parts. Different tools made form Polyphenylene sulfide (PPS) with 50 % by weightmore » carbon fiber and Polyphenylsulfone (PPSU) with 25 % carbon fiber are investigated in this study. The behavior of the printed tools under different temperature ramp rates for the autoclave cycles was observed and analyzed.« less

Fatigue Behavior of a SiC/SiC Composite at 1000 deg C in Air and in Steam

DTIC Science & Technology

2010-12-01

SiC dual-layer interphase. The composite was manufactured by a Polymer Infiltration and Pyrolysis (PIP... Polymer Infiltration and Pyrolysis (PIP) process. A seal coat of SiC and elemental boron was applied to the test specimens after machining. The tensile...manufactured by a Polymer Infiltration and Pyrolysis (PIP) process. A seal coat of SiC and elemental boron was applied to the test specimens

American Society of Composites, 32nd Technical Conference

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aitharaju, Venkat; Yu, Hang; Zhao, Selina

Resin transfer molding (RTM) has become increasingly popular for the manufacturing of composite parts. To enable high volume manufacturing and obtain good quality parts at an acceptable cost to automotive industry, accurate process simulation tools are necessary to optimize the process conditions. Towards that goal, General Motors and the ESI-group are involved in developing a state of the art process simulation tool for composite manufacturing in a project supported by the Department of Energy. This paper describes the modeling of various stages in resin transfer molding such as resin injection, resin curing, and part distortion. An instrumented RTM system locatedmore » at the General Motors Research and Development center was used to perform flat plaque molding experiments. The experimental measurements of fill time, in-mold pressure versus time, cure variation with time, and part deformation were compared with the model predictions and very good correlations were observed.« less

Study of Out-Time on the Processing and Properties of IM7/977-3 Composites

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Sutter, James K.; Scheiman, Daniel A.; Maryanski, Michael; Schlea, Michelle

2010-01-01

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-life limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-life limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The neat resin was evaluated by differential scanning calorimetry, DSC, to characterize cure behavior of the aged material, as well as any change in activation energy. The rise in the modulus of the uncured prepreg was monitored throughout the 60 days by dynamic mechanical analysis, DMA. Composite panels made of the fresh and aged prepreg material were also characterized by DMA. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Out-Life Characteristics of IM7/977-3 Composites

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Sutter, James K.; Hou, Tan-Hung; Scheiman, Daniel A.; Martin, Richard E.; Maryanski, Michael; Schlea, Michelle; Gardner, John M.; Schiferl, Zack R.

2010-01-01

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-time limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-time limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The effects of room temperature aging on the thermal and visco-elastic properties of the materials were investigated. Neat resin was evaluated by differential scanning calorimetry to characterize thermal properties and change in activation energy of cure. Neat resin was also evaluated by rheometry to characterize its processability in composite fabrication. IM7/977-3 prepreg was evaluated by dynamic mechanical analysis to characterize the curing behavior. Prepreg tack was also evaluated over 60 days. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Intelligent Processing Equipment Developments Within the Navy's Manufacturing Technology Centers of Excellence

NASA Technical Reports Server (NTRS)

Nanzetta, Philip

1992-01-01

The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

Axiomatic Design and Fabrication of Composite Structures - Applications in Robots, Machine Tools, and Automobiles

NASA Astrophysics Data System (ADS)

Lee, Dai Gil; Suh, Nam Pyo

2005-11-01

The idea that materials can be designed to satisfy specific performance requirements is relatively new. With high-performance composites, however, the entire process of designing and fabricating a part can be worked out before manufacturing. The purpose of this book is to present an integrated approach to the design and manufacturing of products from advanced composites. It shows how the basic behavior of composites and their constitutive relationships can be used during the design stage, which minimizes the complexity of manufacturing composite parts and reduces the repetitive "design-build-test" cycle. Designing it right the first time is going to determine the competitiveness of a company, the reliability of the part, the robustness of fabrication processes, and ultimately, the cost and development time of composite parts. Most of all, it should expand the use of advanced composite parts in fields that use composites only to a limited extent at this time. To achieve these goals, this book presents the design and fabrication of novel composite parts made for machine tools and other applications like robots and automobiles. This book is suitable as a textbook for graduate courses in the design and fabrication of composites. It will also be of interest to practicing engineers learning about composites and axiomatic design. A CD-ROM is included in every copy of the book, containing Axiomatic CLPT software. This program, developed by the authors, will assist readers in calculating material properties from the microstructure of the composite. This book is part of the Oxford Series on Advanced Manufacturing.

In-situ polymerisation of fully bioresorbable polycaprolactone/phosphate glass fibre composites: In vitro degradation and mechanical properties.

PubMed

Chen, Menghao; Parsons, Andrew J; Felfel, Reda M; Rudd, Christopher D; Irvine, Derek J; Ahmed, Ifty

2016-06-01

Fully bioresorbable composites have been investigated in order to replace metal implant plates used for hard tissue repair. Retention of the composite mechanical properties within a physiological environment has been shown to be significantly affected due to loss of the integrity of the fibre/matrix interface. This study investigated phosphate based glass fibre (PGF) reinforced polycaprolactone (PCL) composites with 20%, 35% and 50% fibre volume fractions (Vf) manufactured via an in-situ polymerisation (ISP) process and a conventional laminate stacking (LS) followed by compression moulding. Reinforcing efficiency between the LS and ISP manufacturing process was compared, and the ISP composites revealed significant improvements in mechanical properties when compared to LS composites. The degradation profiles and mechanical properties were monitored in phosphate buffered saline (PBS) at 37°C for 28 days. ISP composites revealed significantly less media uptake and mass loss (p<0.001) throughout the degradation period. The initial flexural properties of ISP composites were substantially higher (p<0.0001) than those of the LS composites, which showed that the ISP manufacturing process provided a significantly enhanced reinforcement effect than the LS process. During the degradation study, statistically higher flexural property retention profiles were also seen for the ISP composites compared to LS composites. SEM micrographs of fracture surfaces for the LS composites revealed dry fibre bundles and poor fibre dispersion with polymer rich zones, which indicated poor interfacial bonding, distribution and adhesion. In contrast, evenly distributed fibres without dry fibre bundles or polymer rich zones, were clearly observed for the ISP composite samples, which showed that a superior fibre/matrix interface was achieved with highly improved adhesion. Copyright © 2015 Elsevier Ltd. All rights reserved.

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian

2003-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.

Manufacturing and Machining Challenges of Hybrid Aluminium Metal Matix Composites

NASA Astrophysics Data System (ADS)

Baburaja, Kammuluri; Sainadh Teja, S.; Karthik Sri, D.; Kuldeep, J.; Gowtham, V.

2017-08-01

Manufacturing which involves material removal processes or material addition processes or material transformation processes. One or all the processes to obtain the final desired properties for a material with desired shape which meets the required precision and accuracy values for the expected service life of a material in working conditions. Researchers found the utility of aluminium to be the second largest after steel. Aluminium and its metal matrix composite possess wide applications in various applications in aerospace industry, automobile industry, Constructions and even in kitchen utensils. Hybrid Al-MMCconsist of two different materials, and one will be from organic origin along with the base material. In this paper an attempt is made to bring out the importance of utilization of aluminium and the challenges concerned in manufacturing and machining of hybrid aluminium MMC.

Optimizing manufacturing and composition of a TLR4 nanosuspension: physicochemical stability and vaccine adjuvant activity

PubMed Central

2013-01-01

Background Nanosuspensions are an important class of delivery system for vaccine adjuvants and drugs. Previously, we developed a nanosuspension consisting of the synthetic TLR4 ligand glucopyranosyl lipid adjuvant (GLA) and dipalmitoyl phosphatidylcholine (DPPC). This nanosuspension is a clinical vaccine adjuvant known as GLA-AF. We examined the effects of DPPC supplier, buffer composition, and manufacturing process on GLA-AF physicochemical and biological activity characteristics. Results DPPC from different suppliers had minimal influence on physicochemical and biological effects. In general, buffered compositions resulted in less particle size stability compared to unbuffered GLA-AF. Microfluidization resulted in rapid particle size reduction after only a few passes, and 20,000 or 30,000 psi processing pressures were more effective at reducing particle size and recovering the active component than 10,000 psi. Sonicated and microfluidized batches maintained good particle size and chemical stability over 6 months, without significantly altering in vitro or in vivo bioactivity of GLA-AF when combined with a recombinant malaria vaccine antigen. Conclusions Microfluidization, compared to water bath sonication, may be an effective manufacturing process to improve the scalability and reproducibility of GLA-AF as it advances further in the clinical development pathway. Various sources of DPPC are suitable to manufacture GLA-AF, but buffered compositions of GLA-AF do not appear to offer stability advantages over the unbuffered composition. PMID:24359024

Influence of the forming process on the mechanical behavior of a commingled carbon PPS composite part

NASA Astrophysics Data System (ADS)

Patou, J.; De Luycker, E.; Bonnaire, R.; Cutard, T.; Bernhart, G.

2018-05-01

In this research work, the influence of the forming process on commingled thermoplastic composite parts mechanical behavior was investigated. The aim of this work is to evaluate the influence of fabric shearing on the mechanical response of composite laminate. Different sheets with a given shear angle are manufactured. Tensile experimental results are compared with the properties obtained from a simple model based on the laminate plate theory for various off angles. Later, the link with a tetrahedron shape 3D part manufactured by punch deep drawing will be made.

Low cost composite manufacturing utilizing intelligent pultrusion and resin transfer molding (IPRTM)

NASA Astrophysics Data System (ADS)

Bradley, James E.; Wysocki, Tadeusz S., Jr.

1993-02-01

This article describes an innovative method for the economical manufacturing of large, intricately-shaped tubular composite parts. Proprietary intelligent process control techniques are combined with standard pultrusion and RTM methodologies to provide high part throughput, performance, and quality while substantially reducing scrap, rework costs, and labor requirements. On-line process monitoring and control is achieved through a smart tooling interface consisting of modular zone tiles installed on part-specific die assemblies. Real-time archiving of process run parameters provides enhanced SPC and SQC capabilities.

Process and control systems for composites manufacturing

NASA Technical Reports Server (NTRS)

Tsiang, T. H.; Wanamaker, John L.

1992-01-01

A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.

Low-Cost Composite Materials and Structures for Aircraft Applications

NASA Technical Reports Server (NTRS)

Deo, Ravi B.; Starnes, James H., Jr.; Holzwarth, Richard C.

2003-01-01

A survey of current applications of composite materials and structures in military, transport and General Aviation aircraft is presented to assess the maturity of composites technology, and the payoffs realized. The results of the survey show that performance requirements and the potential to reduce life cycle costs for military aircraft and direct operating costs for transport aircraft are the main reasons for the selection of composite materials for current aircraft applications. Initial acquisition costs of composite airframe components are affected by high material costs and complex certification tests which appear to discourage the widespread use of composite materials for aircraft applications. Material suppliers have performed very well to date in developing resin matrix and fiber systems for improved mechanical, durability and damage tolerance performance. The next challenge for material suppliers is to reduce material costs and to develop materials that are suitable for simplified and inexpensive manufacturing processes. The focus of airframe manufacturers should be on the development of structural designs that reduce assembly costs by the use of large-scale integration of airframe components with unitized structures and manufacturing processes that minimize excessive manual labor.

Forming of complex-shaped composite tubes using optimized bladder-assisted resin transfer molding

NASA Astrophysics Data System (ADS)

Schillfahrt, Christian; Fauster, Ewald; Schledjewski, Ralf

2018-05-01

This work addresses the manufacturing of tubular composite structures by means of bladder-assisted resin transfer molding using elastomeric bladders. In order to achieve successful processing of such parts, knowledge of the compaction and impregnation behavior of the textile preform is vital. Hence, efficient analytical models that describe the influencing parameters of the preform compaction and filling stage were developed and verified through practical experiments. A process window describing optimal and critical operating conditions during the injection stage was created by evaluating the impact of the relevant process pressures on filling time. Finally, a cascaded injection procedure was investigated that particularly facilitates the manufacturing of long composite tubes.

Microstructures and Grain Refinement of Additive-Manufactured Ti- xW Alloys

NASA Astrophysics Data System (ADS)

Mendoza, Michael Y.; Samimi, Peyman; Brice, David A.; Martin, Brian W.; Rolchigo, Matt R.; LeSar, Richard; Collins, Peter C.

2017-07-01

It is necessary to better understand the composition-processing-microstructure relationships that exist for materials produced by additive manufacturing. To this end, Laser Engineered Net Shaping (LENS™), a type of additive manufacturing, was used to produce a compositionally graded titanium binary model alloy system (Ti- xW specimen (0 ≤ x ≤ 30 wt pct), so that relationships could be made between composition, processing, and the prior beta grain size. Importantly, the thermophysical properties of the Ti- xW, specifically its supercooling parameter ( P) and growth restriction factor ( Q), are such that grain refinement is expected and was observed. The systematic, combinatorial study of this binary system provides an opportunity to assess the mechanisms by which grain refinement occurs in Ti-based alloys in general, and for additive manufacturing in particular. The operating mechanisms that govern the relationship between composition and grain size are interpreted using a model originally developed for aluminum and magnesium alloys and subsequently applied for titanium alloys. The prior beta grain factor observed and the interpretations of their correlations indicate that tungsten is a good grain refiner and such models are valid to explain the grain-refinement process. By extension, other binary elements or higher order alloy systems with similar thermophysical properties should exhibit similar grain refinement.

14 CFR 1260.57 - New technology.

Code of Federal Regulations, 2013 CFR

2013-01-01

... operate, in case of a machine or system; and, in each case, under such conditions as to establish that the... items include, but are not limited to, new processes, machines, manufactures, and compositions of matter, and improvements to, or new applications of, existing processes, machines, manufactures, and...

14 CFR 1260.57 - New technology.

Code of Federal Regulations, 2012 CFR

2012-01-01

... operate, in case of a machine or system; and, in each case, under such conditions as to establish that the... items include, but are not limited to, new processes, machines, manufactures, and compositions of matter, and improvements to, or new applications of, existing processes, machines, manufactures, and...

Dynamic control of moisture during hot pressing of wood composites

Treesearch

Cheng Piao; Todd F. Shupe; Chung Y. Hse

2006-01-01

Hot pressing is an important step in the manufacture of wood composites. In the conventional pressing system, hot press output often acts as a constraint to increased production. Severe drying of the furnish (e.g., particles, flakes, or fibers) required by this process substantially increases the manufacturing cost and creates air-polluting emissions of volatile...

Effect of Polymer Form and its Consolidation on Mechanical Properties and Quality of Glass/PBT Composites

NASA Astrophysics Data System (ADS)

Durai Prabhakaran, R. T.; Pillai, Saju; Charca, Samuel; Oshkovr, Simin Ataollahi; Knudsen, Hans; Andersen, Tom Løgstrup; Bech, Jakob Ilsted; Thomsen, Ole Thybo; Lilholt, Hans

2014-04-01

The aim of this study was to understand the role of the processing in determining the mechanical properties of glass fibre reinforced polybutylene terephthalate composites (Glass/PBT). Unidirectional (UD) composite laminates were manufactured by the vacuum consolidation technique using three different material systems included in this study; Glass/CBT (CBT160 powder based resin), Glass/PBT (prepreg tapes), and Glass/PBT (commingled yarns). The different types of thermoplastic polymer resin systems used for the manufacturing of the composite UD laminate dictate the differences in final mechanical properties which were evaluated by through compression, flexural and short beam transverse bending tests. Microscopy was used to evaluate the quality of the processed laminates, and fractography was used to characterize the observed failure modes. The study provides an improved understanding of the relationships between processing methods, resin characteristics, and mechanical performance of thermoplastic resin composite materials.

Characteristics of diffusion zone in changing glass-metal composite processing conditions

NASA Astrophysics Data System (ADS)

Lyubimova, O. N.; Morkovin, A. V.; Andreev, V. V.

2018-03-01

The influence of manufacturing technology on the characteristics of the glass and steel contact zone in manufacturing new structural material - glass-metal composite is studied theoretically and experimentally. Different types of structures in the contact zone and its dimensions affect the strength characteristics of the composite. Knowledge about changing the width of the glass and steel contact zone after changing such parameters of the technological regime as temperature, holding time and use of solders will allow one to control the structure and characteristics of the glass-metal composite. Experimental measurements of the width of the diffusion zone in the glass-metal composite for different regimes and their statistical processing according to the full factor experiment are presented in this article. The results of analysis of some mechanical characteristics of the diffusion zone are presented: microhardness and modulus of elasticity for samples, prepared according to different processing regimes.

Shape memory alloy wires turn composites into smart structures: II. Manufacturing and properties

NASA Astrophysics Data System (ADS)

Michaud, Veronique J.; Schrooten, Jan; Parlinska, Magdelena; Gotthardt, Rolf; Bidaux, Jacques-Eric

2002-07-01

The manufacturing route and resulting properties of adaptive composites are presented in the second part of this European project report. Manufacturing was performed using a specially designed frame to pre-strain the SMA wires, embed them into Kevlar-epoxy prepregs, and maintain them during the curing process in an autoclave. Composite compounds were then tested for strain response, recovery stress response in a clamped-clamped configuration, as well as vibrational response. Through the understanding of the transformational behavior of constrained SMA wires, interesting and unique functional properties of SMA composites could be measured, explained and modeled. Large recovery stresses and as a consequence, a change in vibrational response in a clamped- clamped condition, or a reversible shape change in a free standing condition, could be generated by the SMA composites in a controllable way. These properties were dependent on composite design aspects and exhibited a reproducible and stable behavior, provided that the properties of the matrix, of the wires and the processing route were carefully optimized. In conclusion, the achievements of this effort in areas such as thermomechanics, transformational and vibrational behavior and durability of SMA based composites provide a first step towards a reliable materials design, and potentially an industrial application.

Damage Threshold Characterization in Structural Composite Materials and Composite Joints

DTIC Science & Technology

2010-02-28

process parameters representative of manufacturing by resin infusion. The approach used in this program has been to develop a test coupon which is... manufactured using vacuum bag resin infusion as summarized in Figure 2. The vacuum bag components are given in Table 1. The aluminum mold was coated... Manufacturer and Designation Fiber Areal Weight, g/m² Total 0° 90° -45° +45° mat stitch Unidir. 0/90 (Fabric D) Vectorply E-LT-5500 1875 1728 114 0

Progress in manufacturing large primary aircraft structures using the stitching/RTM process

NASA Technical Reports Server (NTRS)

Markus, Alan; Thrash, Patrick; Rohwer, Kim

1993-01-01

The Douglas Aircraft/NASA Act contract has been focused over the past three years at developing a materials, manufacturing, and cost base for stitched/Resin Transfer Molded (RTM) composites. The goal of the program is to develop RTM and stitching technology to provide enabling technology for application of these materials in primary aircraft structure with a high degree of confidence. Presented in this paper will be the progress to date in the area of manufacturing and associated cost values of stitched/RTM composites.

Manufacturing Technology Support (MATES II) Task Order 0005: Manufacturing Integration and Technology Evaluation to Enable Technology Transition. Subtask Phase 0 Study Task: Manufacturing Technology (ManTech) and Systems Engineering For Quick Reaction Systems

DTIC Science & Technology

2014-10-01

Porosity from gas entrapment & shrinkage 4 Continuous Fiber Ti Metal Matrix Composites (Aircraft panels and rotor components) [14...process models for casting, forging, and welding , and software capability to integrate various independent models with design, thermal, and structural...Applications, Ph.D. Thesis, Queen’s College, University of Oxford, (2007). 14. S.A. Singerman and J.J. Jackson, Titanium Metal Matrix Composites for

RFI and SCRIMP Model Development and Verification

NASA Technical Reports Server (NTRS)

Loos, Alfred C.; Sayre, Jay

2000-01-01

Vacuum-Assisted Resin Transfer Molding (VARTM) processes are becoming promising technologies in the manufacturing of primary composite structures in the aircraft industry as well as infrastructure. A great deal of work still needs to be done on efforts to reduce the costly trial-and-error methods of VARTM processing that are currently in practice today. A computer simulation model of the VARTM process would provide a cost-effective tool in the manufacturing of composites utilizing this technique. Therefore, the objective of this research was to modify an existing three-dimensional, Resin Film Infusion (RFI)/Resin Transfer Molding (RTM) model to include VARTM simulation capabilities and to verify this model with the fabrication of aircraft structural composites. An additional objective was to use the VARTM model as a process analysis tool, where this tool would enable the user to configure the best process for manufacturing quality composites. Experimental verification of the model was performed by processing several flat composite panels. The parameters verified included flow front patterns and infiltration times. The flow front patterns were determined to be qualitatively accurate, while the simulated infiltration times over predicted experimental times by 8 to 10%. Capillary and gravitational forces were incorporated into the existing RFI/RTM model in order to simulate VARTM processing physics more accurately. The theoretical capillary pressure showed the capability to reduce the simulated infiltration times by as great as 6%. The gravity, on the other hand, was found to be negligible for all cases. Finally, the VARTM model was used as a process analysis tool. This enabled the user to determine such important process constraints as the location and type of injection ports and the permeability and location of the high-permeable media. A process for a three-stiffener composite panel was proposed. This configuration evolved from the variation of the process constraints in the modeling of several different composite panels. The configuration was proposed by considering such factors as: infiltration time, the number of vacuum ports, and possible areas of void entrapment.

A manufacturing database of advanced materials used in spacecraft structures

NASA Technical Reports Server (NTRS)

Bao, Han P.

1994-01-01

Cost savings opportunities over the life cycle of a product are highest in the early exploratory phase when different design alternatives are evaluated not only for their performance characteristics but also their methods of fabrication which really control the ultimate manufacturing costs of the product. In the past, Design-To-Cost methodologies for spacecraft design concentrated on the sizing and weight issues more than anything else at the early so-called 'Vehicle Level' (Ref: DOD/NASA Advanced Composites Design Guide). Given the impact of manufacturing cost, the objective of this study is to identify the principal cost drivers for each materials technology and propose a quantitative approach to incorporating these cost drivers into the family of optimization tools used by the Vehicle Analysis Branch of NASA LaRC to assess various conceptual vehicle designs. The advanced materials being considered include aluminum-lithium alloys, thermoplastic graphite-polyether etherketone composites, graphite-bismaleimide composites, graphite- polyimide composites, and carbon-carbon composites. Two conventional materials are added to the study to serve as baseline materials against which the other materials are compared. These two conventional materials are aircraft aluminum alloys series 2000 and series 7000, and graphite-epoxy composites T-300/934. The following information is available in the database. For each material type, the mechanical, physical, thermal, and environmental properties are first listed. Next the principal manufacturing processes are described. Whenever possible, guidelines for optimum processing conditions for specific applications are provided. Finally, six categories of cost drivers are discussed. They include, design features affecting processing, tooling, materials, fabrication, joining/assembly, and quality assurance issues. It should be emphasized that this database is not an exhaustive database. Its primary use is to make the vehicle designer aware of some of the most important aspects of manufacturing associated with his/her choice of the structural materials. The other objective of this study is to propose a quantitative method to determine a Manufacturing Complexity Factor (MCF) for each material being contemplated. This MCF is derived on the basis of the six cost drivers mentioned above plus a Technology Readiness Factor which is very closely related to the Technology Readiness Level (TRL) as defined in the Access To Space final report. Short of any manufacturing information, our MCF is equivalent to the inverse of TRL. As more manufacturing information is available, our MCF is a better representation (than TRL) of the fabrication processes involved. The most likely application for MCF is in cost modeling for trade studies. On-going work is being pursued to expand the potential applications of MCF.

A manufacturing database of advanced materials used in spacecraft structures

NASA Astrophysics Data System (ADS)

Bao, Han P.

1994-12-01

Cost savings opportunities over the life cycle of a product are highest in the early exploratory phase when different design alternatives are evaluated not only for their performance characteristics but also their methods of fabrication which really control the ultimate manufacturing costs of the product. In the past, Design-To-Cost methodologies for spacecraft design concentrated on the sizing and weight issues more than anything else at the early so-called 'Vehicle Level' (Ref: DOD/NASA Advanced Composites Design Guide). Given the impact of manufacturing cost, the objective of this study is to identify the principal cost drivers for each materials technology and propose a quantitative approach to incorporating these cost drivers into the family of optimization tools used by the Vehicle Analysis Branch of NASA LaRC to assess various conceptual vehicle designs. The advanced materials being considered include aluminum-lithium alloys, thermoplastic graphite-polyether etherketone composites, graphite-bismaleimide composites, graphite- polyimide composites, and carbon-carbon composites. Two conventional materials are added to the study to serve as baseline materials against which the other materials are compared. These two conventional materials are aircraft aluminum alloys series 2000 and series 7000, and graphite-epoxy composites T-300/934. The following information is available in the database. For each material type, the mechanical, physical, thermal, and environmental properties are first listed. Next the principal manufacturing processes are described. Whenever possible, guidelines for optimum processing conditions for specific applications are provided. Finally, six categories of cost drivers are discussed. They include, design features affecting processing, tooling, materials, fabrication, joining/assembly, and quality assurance issues. It should be emphasized that this database is not an exhaustive database. Its primary use is to make the vehicle designer aware of some of the most important aspects of manufacturing associated with his/her choice of the structural materials. The other objective of this study is to propose a quantitative method to determine a Manufacturing Complexity Factor (MCF) for each material being contemplated. This MCF is derived on the basis of the six cost drivers mentioned above plus a Technology Readiness Factor which is very closely related to the Technology Readiness Level (TRL) as defined in the Access To Space final report. Short of any manufacturing information, our MCF is equivalent to the inverse of TRL. As more manufacturing information is available, our MCF is a better representation (than TRL) of the fabrication processes involved.

48 CFR 1852.227-70 - New technology.

Code of Federal Regulations, 2011 CFR

2011-10-01

... method; or to operate, in case of a machine or system; and, in each case, under such conditions as to... contract. Reportable items include, but are not limited to, new processes, machines, manufactures, and compositions of matter, and improvements to, or new applications of, existing processes, machines, manufactures...

14 CFR § 1260.57 - New technology.

Code of Federal Regulations, 2014 CFR

2014-01-01

... operate, in case of a machine or system; and, in each case, under such conditions as to establish that the... items include, but are not limited to, new processes, machines, manufactures, and compositions of matter, and improvements to, or new applications of, existing processes, machines, manufactures, and...

Approaches to Design and Evaluation of Sandwich Composites

NASA Technical Reports Server (NTRS)

Shivakumar, Kunigal; Raju, I. S. (Technical Monitor); Ambur, D. (Technical Monitor)

2001-01-01

This report describes research during the period June 15, 1997 to October 31, 2000. This grant yielded a low cast manufacturing of composite sandwich structures technology and characterization interfacial and subinterfacial cracks in foam core sandwich panels. The manufacturing technology is called the vacuum assisted resin transfer (VARTM). The VARTM is suitable for processing composite materials both at ambient and elevated temperatures and of unlimited component size. This technology has been successfully transferred to a small business fiber preform manufacturing company 3TEX located in Cary, North Carolina. The grant also supported one Ph.D, one M.S and a number of under graduate students, and nine publications and Presentations.

Interaction of microwaves with carbon nanotubes to facilitate modification

NASA Technical Reports Server (NTRS)

Tour, James M. (Inventor); Dyke, Christopher A. (Inventor); Stephenson, Jason J. (Inventor); Yakobson, Boris I. (Inventor)

2011-01-01

The present invention is directed toward methods of crosslinking carbon nanotubes to each other using microwave radiation, articles of manufacture produced by such methods, compositions produced by such methods, and applications for such compositions and articles of manufacture. The present invention is also directed toward methods of radiatively modifying composites and/or blends comprising carbon nanotubes with microwaves, and to the compositions produced by such methods. In some embodiments, the modification comprises a crosslinking process, wherein the carbon nanotubes serve as a conduit for thermally and photolytically crosslinking the host matrix with microwave radiation.

Design and Manufacture of Conical Shell Structures Using Prepreg Laminates

NASA Astrophysics Data System (ADS)

Khakimova, Regina; Burau, Florian; Degenhardt, Richard; Siebert, Mark; Castro, Saullo G. P.

2016-06-01

The design and manufacture of unstiffened composite conical structures is very challenging, as the variation of the fiber orientations, lay-up and the geometry of the ply pieces have a significant influence on the thickness imperfections and ply angle deviations imprinted to the final part. This paper deals with the manufacture of laminated composite cones through the prepeg/autoclave process. The cones are designed to undergo repetitive buckling tests without accumulating permanent damage. The aim is to define a process that allows the control of fiber angle deviations and the removal of thickness imperfections generated from gaps and overlaps between ply pieces. Ultrasonic scan measurements are used to proof the effectiveness of the proposed method.

Process Makes Thermoplastic Prepreg Ribbon

NASA Technical Reports Server (NTRS)

Wilson, Maywood L.; Johnson, Gary S.

1995-01-01

Manufacturing process produces ribbon of composite material (prepreg) consisting of continuous lengthwise fibers impregnated with thermoplastic resin. Ribbon can later be cut into sheets of required sizes and shapes, stacked, then heated under pressure to form composite-material structural components. Process accommodates variety of thermoplastic resins and variety of fibers.

Modelling and simulation of the consolidation behavior during thermoplastic prepreg composites forming process

NASA Astrophysics Data System (ADS)

Xiong, H.; Hamila, N.; Boisse, P.

2017-10-01

Pre-impregnated thermoplastic composites have recently attached increasing interest in the automotive industry for their excellent mechanical properties and their rapid cycle manufacturing process, modelling and numerical simulations of forming processes for composites parts with complex geometry is necessary to predict and optimize manufacturing practices, especially for the consolidation effects. A viscoelastic relaxation model is proposed to characterize the consolidation behavior of thermoplastic prepregs based on compaction tests with a range of temperatures. The intimate contact model is employed to predict the evolution of the consolidation which permits the microstructure prediction of void presented through the prepreg. Within a hyperelastic framework, several simulation tests are launched by combining a new developed solid shell finite element and the consolidation models.

Finite Element Modelling and Analysis of Conventional Pultrusion Processes

NASA Astrophysics Data System (ADS)

Akishin, P.; Barkanov, E.; Bondarchuk, A.

2015-11-01

Pultrusion is one of many composite manufacturing techniques and one of the most efficient methods for producing fiber reinforced polymer composite parts with a constant cross-section. Numerical simulation is helpful for understanding the manufacturing process and developing scientific means for the pultrusion tooling design. Numerical technique based on the finite element method has been developed for the simulation of pultrusion processes. It uses the general purpose finite element software ANSYS Mechanical. It is shown that the developed technique predicts the temperature and cure profiles, which are in good agreement with those published in the open literature.

Microemulsion impregnated catalyst composite and use thereof in a synthesis gas conversion process

DOEpatents

Abrevaya, Hayim; Targos, William M.

1987-01-01

A catalyst composition for synthesis gas conversion comprising a ruthenium metal component deposited on a support carrier wherein the average metal particle size is less than about 100 A. The method of manufacture of the composition via a reverse micelle impregnation technique and the use of the composition in a Fischer-Tropsch conversion process is also disclosed.

Integration of fluidic jet actuators in composite structures

NASA Astrophysics Data System (ADS)

Schueller, Martin; Lipowski, Mathias; Schirmer, Eckart; Walther, Marco; Otto, Thomas; Geßner, Thomas; Kroll, Lothar

2015-04-01

Fluidic Actuated Flow Control (FAFC) has been introduced as a technology that influences the boundary layer by actively blowing air through slots or holes in the aircraft skin or wind turbine rotor blade. Modern wing structures are or will be manufactured using composite materials. In these state of the art systems, AFC actuators are integrated in a hybrid approach. The new idea is to directly integrate the active fluidic elements (such as SJAs and PJAs) and their components in the structure of the airfoil. Consequently, the integration of such fluidic devices must fit the manufacturing process and the material properties of the composite structure. The challenge is to integrate temperature-sensitive active elements and to realize fluidic cavities at the same time. The transducer elements will be provided for the manufacturing steps using roll-to-roll processes. The fluidic parts of the actuators will be manufactured using the MuCell® process that provides on the one hand the defined reproduction of the fluidic structures and, on the other hand, a high light weight index. Based on the first design concept, a demonstrator was developed in order to proof the design approach. The output velocity on the exit was measured using a hot-wire anemometer.

Hydroxyapatite fiber reinforced poly(alpha-hydroxy ester) foams for bone regeneration

NASA Technical Reports Server (NTRS)

Thomson, R. C.; Yaszemski, M. J.; Powers, J. M.; Mikos, A. G.; McIntire, L. V. (Principal Investigator)

1998-01-01

A process has been developed to manufacture biodegradable composite foams of poly(DL-lactic-co-glycolic acid) (PLGA) and hydroxyapatite short fibers for use in bone regeneration. The processing technique allows the manufacture of three-dimensional foam scaffolds and involves the formation of a composite material consisting of a porogen material (either gelatin microspheres or salt particles) and hydroxyapatite short fibers embedded in a PLGA matrix. After the porogen is leached out, an open-cell composite foam remains which has a pore size and morphology defined by the porogen. By changing the weight fraction of the leachable component it was possible to produce composite foams with controlled porosities ranging from 0.47 +/- 0.02 to 0.85 +/- 0.01 (n = 3). Up to a polymer:fiber ratio of 7:6, short hydroxyapatite fibers served to reinforce low-porosity PLGA foams manufactured using gelatin microspheres as a porogen. Foams with a compressive yield strength up to 2.82 +/- 0.63 MPa (n = 3) and a porosity of 0.47 +/- 0.02 (n = 3) were manufactured using a polymer:fiber weight ratio of 7:6. In contrast, high-porosity composite foams (up to 0.81 +/- 0.02, n = 3) suitable for cell seeding were not reinforced by the introduction of increasing quantities of hydroxyapatite short fibers. We were therefore able to manufacture high-porosity foams which may be seeded with cells but which have minimal compressive yield strength, or low porosity foams with enhanced osteoconductivity and compressive yield strength.

Characterization of process air emissions in automotive production plants.

PubMed

D'Arcy, J B; Dasch, J M; Gundrum, A B; Rivera, J L; Johnson, J H; Carlson, D H; Sutherland, J W

2016-01-01

During manufacturing, particles produced from industrial processes become airborne. These airborne emissions represent a challenge from an industrial hygiene and environmental standpoint. A study was undertaken to characterize the particles associated with a variety of manufacturing processes found in the auto industry. Air particulates were collected in five automotive plants covering ten manufacturing processes in the areas of casting, machining, heat treatment and assembly. Collection procedures provided information on air concentration, size distribution, and chemical composition of the airborne particulate matter for each process and insight into the physical and chemical processes that created those particles.

Manufacturing methods of a composite cell case for a Ni-Cd battery

NASA Technical Reports Server (NTRS)

Bauer, J. L.

1979-01-01

Basic manufacturing method refinements for using graphite epoxy material for a nickel cadmium battery cell case were performed to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development, together with material and process control, were integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material, utilizing the internal pressure bag fabrication method, is feasible.

Large-area copper indium diselenide (CIS) process, control and manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gillespie, T.J.; Lanning, B.R.; Marshall, C.H.

1997-12-31

Lockheed Martin Astronautics (LMA) has developed a large-area (30x30cm) sequential CIS manufacturing approach amenable to low-cost photovoltaics (PV) production. A prototype CIS manufacturing system has been designed and built with compositional uniformity (Cu/In ratio) verified within {+-}4 atomic percent over the 30x30cm area. CIS device efficiencies have been measured by the National Renewable Energy Laboratory (NREL) at 7% on a flexible non-sodium-containing substrate and 10% on a soda-lime-silica (SLS) glass substrate. Critical elements of the manufacturing capability include the CIS sequential process selection, uniform large-area material deposition, and in-situ process control. Details of the process and large-area manufacturing approach aremore » discussed and results presented.« less

ANSI/AIAA S-081A, Pressure Vessel Standards Implementation Guidelines

NASA Technical Reports Server (NTRS)

Greene, Nathanael J.

2009-01-01

The stress rupture specification for Composite Overwrapped Pressure Vessels (COPV) is discussed. The composite shell of the COPV shall be designed to meet the design life considering the time it is under sustained load. A Mechcanical Damage Control Plan (MDCP) shall be created and implemented that assures the COPV will not fail due to mechanical damage due to manufacturing, testing, shipping, installation, or flight. Proven processes and procedures for fabrication and repair shall be used to preclude damage or material degradation during material processing, manufacturing operations, and refurbushment.Selected NDI techniques for the liner and/or boss(es) shall be performed before overwrapping with composite. When visual inspection reveals mechanical damage or defects exceeding manufacturing specification levels (and standard repair procedures), the damaged COPV shall be submitted to a material review board (MRB) for disposition. Every COPV shall be subjected to visual and other non-destructive inspection (NDI), per the inspection plan.

Highly oriented carbon fiber–polymer composites via additive manufacturing

DOE PAGES

Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M.; ...

2014-10-16

Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructuremore » and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion and void formation.« less

Development and Validation of a Shear Punch Test Fixture

DTIC Science & Technology

2013-08-01

composites (MMC) manufactured by friction stir processing (FSP) that are being developed as part of a Technology Investment Fund (TIF) project, as the...leading a team of government departments and academics to develop a friction stir processing (FSP) based procedure to create metal matrix composite... friction stir process to fabricate surface metal matrix composites in aluminum alloys for potential application in light armoured vehicles. The

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

NASA Technical Reports Server (NTRS)

Stoner, Mary Cecilia; Hehir, Austin R.; Ivanco, Marie L.; Domack, Marcia S.

2016-01-01

This cost-benefit analysis assesses the benefits of the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. These preliminary, rough order-of-magnitude results report a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Production cost savings of 35 to 58 percent were reported over the composite manufacturing technique used in this study for comparison; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. A case study compared these three alternatives for manufacturing a cylinder of specified geometry, with particular focus placed on production costs and process complexity, with cost analyses performed by the analogy and parametric methods. Furthermore, a scalability study was conducted for three tank diameters to assess the highest potential payoff of the ANNST process for manufacture of large-diameter cryogenic tanks. The analytical hierarchy process (AHP) was subsequently used with a group of selected subject matter experts to assess the value of the various benefits achieved by the ANNST method for potential stakeholders. The AHP study results revealed that decreased final cylinder mass and quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Potential for on-orbit manufacture of large space structures using the pultrusion process

NASA Technical Reports Server (NTRS)

Wilson, Maywood L.; Macconochie, Ian O.; Johnson, Gary S.

1987-01-01

On-orbit manufacture of lightweight, high-strength, advanced-composite structures using the pultrusion process is proposed. This process is adaptable to a zero-gravity environment by using preimpregnated graphite-fiber reinforcement systems. The reinforcement material is preimpregnated with a high-performance thermoplastic resin at a ground station, is coiled on spools for compact storage, and is transported into Earth orbit. A pultrusion machine is installed in the Shuttle cargo bay from which very long lengths of the desired structure is fabricated on-orbit. Potential structural profiles include rods, angles, channels, hat sections, tubes, honeycomb-cored panels, and T, H, and I beams. A potential pultrudable thermoplastic/graphite composite material is presented as a model for determining the effect on Earth-to-orbit package density of an on-orbit manufacture, the package density is increased by 132 percent, and payload volume requirement is decreased by 56.3 percent. The fabrication method has the potential for on-orbit manufacture of structural members for space platforms, large space antennas, and long tethers.

Manufacturing processes for fabricating graphite/PMR 15 polyimide structural elements

NASA Technical Reports Server (NTRS)

Sheppard, C. H.; Hoggatt, J. T.; Symonds, W. A.

1979-01-01

Investigations were conducted to obtain commercially available graphite/PMR-15 polyimide prepreg, develop an autoclave manufacturing process, and demonstrate the process by manufacturing structural elements. Controls were established on polymer, prepreg, composite fabrication, and quality assurance, Successful material quality control and processes were demonstrated by fabricating major structural elements including flat laminates, hat sections, I beam sections, honeycomb sandwich structures, and molded graphite reinforced fittings. Successful fabrication of structural elements and simulated section of the space shuttle aft body flap shows that the graphite/PMR-15 polyimide system and the developed processes are ready for further evaluation in flight test hardware.

An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

NASA Technical Reports Server (NTRS)

Sampson, Paul G.; Sny, Linda C.

1992-01-01

The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

Microemulsion impregnated catalyst composite and use thereof in a synthesis gas conversion process

DOEpatents

Abrevaya, H.; Targos, W.M.

1987-12-22

A catalyst composition is described for synthesis gas conversion comprising a ruthenium metal component deposited on a support carrier wherein the average metal particle size is less than about 100 A. The method of manufacture of the composition via a reverse micelle impregnation technique and the use of the composition in a Fischer-Tropsch conversion process is also disclosed.

Process for the manufacture of 117Sn diethylenetriaminepentaacetic acids

DOEpatents

Srivastava, Suresh C.; Li, Zizhong; Meinken, George

2003-01-01

Novel methods are provided for the manufacture of .sup.117m Sn(Sn.sup.4+) DTPA. The method allows the use of DTPA, a toxic chelating agent, in an approximately 1:1 ratio to .sup.117m Sn(Sn.sup.4+) via either aqueous conditions, or using various organic solvents, such as methylene chloride. A pharmaceutical composition manufactured by the novel method is also provided, as well as methods for treatment of bone tumors and pain associated with bone cancer using the pharmaceutical composition of the invention.

Process simulations for manufacturing of thick composites

NASA Astrophysics Data System (ADS)

Kempner, Evan A.

The availability of manufacturing simulations for composites can significantly reduce the costs associated with process development. Simulations provide a tool for evaluating the effect of processing conditions on the quality of parts produced without requiring numerous experiments. This is especially significant in parts that have troublesome features such as large thickness. The development of simulations for thick walled composites has been approached by examining the mechanics of resin flow and fiber deformation during processing, applying these evaluations to develop simulations, and evaluating the simulation with experimental results. A unified analysis is developed to describe the three-dimensional resin flow and fiber preform deformation during processing regardless of the manufacturing process used. It is shown how the generic governing evaluations in the unified analysis can be applied to autoclave molding, compression molding, pultrusion, filament winding, and resin transfer molding. A comparison is provided with earlier models derived individually for these processes. The evaluations described for autoclave curing were used to produce a one-dimensional cure simulation for autoclave curing of thick composites. The simulation consists of an analysis for heat transfer and resin flow in the composite as well as bleeder plies used to absorb resin removed from the part. Experiments were performed in a hot press to approximate curing in an autoclave. Graphite/epoxy laminates of 3 cm and 5 cm thickness were cured while monitoring temperatures at several points inside the laminate and thickness. The simulation predicted temperatures fairly closely, but difficulties were encountered in correlation of thickness results. This simulation was also used to study the effects of prepreg aging on processing of thick composites. An investigation was also performed on filament winding with prepreg tow. Cylinders were wound of approximately 12 mm thickness with pressure gages at the mandrel-composite interface. Cylinders were hoop wound with tensions ranging from 13-34 N. An analytical model was developed to calculate change in stress due to relaxation during winding. Although compressive circumferential stresses occurred throughout each of the cylinders, the magnitude was fairly low.

Modeling of additive manufacturing processes for metals: Challenges and opportunities

DOE PAGES

Francois, Marianne M.; Sun, Amy; King, Wayne E.; ...

2017-01-09

Here, with the technology being developed to manufacture metallic parts using increasingly advanced additive manufacturing processes, a new era has opened up for designing novel structural materials, from designing shapes and complex geometries to controlling the microstructure (alloy composition and morphology). The material properties used within specific structural components are also designable in order to meet specific performance requirements that are not imaginable with traditional metal forming and machining (subtractive) techniques.

Materials for the General Aviation Industry: Effect of Environment on Mechanical Properties of Glass Fabric/Rubber Toughened Vinyl Ester Laminates

NASA Technical Reports Server (NTRS)

McBride, Timothy M.

1995-01-01

A screening evaluation is being conducted to determine the performance of several glass fabric/vinyl ester composite material systems for use in primary General Aviation aircraft structures. In efforts to revitalize the General Aviation industry, the Integrated Design and Manufacturing Work Package for General Aviation Airframe and Propeller Structures is seeking to develop novel composite materials and low-cost manufacturing methods for lighter, safer and more affordable small aircraft. In support of this Work Package, this study is generating material properties for several glass fabric/rubber toughened vinyl ester composite systems and investigates the effect of environment on property retention. All laminates are made using the Seemann Composites Resin Infusion Molding Process (SCRIMP), a potential manufacturing method for the General Aviation industry.

Additive Manufacturing of Reactive In Situ Zr Based Ultra-High Temperature Ceramic Composites

NASA Astrophysics Data System (ADS)

Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

2016-03-01

Reactive in situ multi-material additive manufacturing of ZrB2-based ultra-high-temperature ceramics in a Zr metal matrix was demonstrated using LENS™. Sound metallurgical bonding was achieved between the Zr metal and Zr-BN composites with Ti6Al4V substrate. Though the feedstock Zr power had α phase, LENS™ processing of the Zr powder and Zr-BN premix powder mixture led to the formation of some β phase of Zr. Microstructure of the Zr-BN composite showed primary grains of zirconium diboride phase in zirconium metal matrix. The presence of ZrB2 ceramic phase was confirmed by X-ray diffraction (XRD) analysis. Hardness of pure Zr was measured as 280 ± 12 HV and, by increasing the BN content in the feedstock, the hardness was found to increase. In Zr-5%BN composite, the hardness was 421 ± 10 HV and the same for Zr-10%BN composite was 562 ± 10 HV. It is envisioned that such multi-materials additive manufacturing will enable products in the future that cannot be manufactured using traditional approaches particularly in the areas of high-temperature metal-ceramic composites with compositional and functional gradation.

Evaluation of Hand Lay-Up and Resin Transfer Molding in Composite Wind Turbine Blade Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

CAIRNS,DOUGLAS S.; SHRAMSTAD,JON D.

2000-06-01

The majority of the wind turbine blade industry currently uses low cost hand lay-up manufacturing techniques to process composite blades. While there are benefits to the hand lay-up process, drawbacks inherent to this process along with advantages of other techniques suggest that better manufacturing alternatives may be available. Resin Transfer Molding (RTM) was identified as a processing alternative and shows promise in addressing the shortcomings of hand lay-up. This report details a comparison of the RTM process to hand lay-up of composite wind turbine blade structures. Several lay-up schedules and critical turbine blade structures were chosen for comparison of theirmore » properties resulting from RTM and hand lay-up processing. The geometries investigated were flat plate, thin and thick flanged T-stiffener, I-beam, and root connection joint. It was found that the manufacturing process played an important role in laminate thickness, fiber volume, and weight for the geometries investigated. RTM was found to reduce thickness and weight and increase fiber volumes for all substructures. RTM resulted in tighter material transition radii and eliminated the need for most secondary bonding operations. These results would significantly reduce the weight of wind turbine blades. Hand lay-up was consistently slower in fabrication times for the structures investigated. A comparison of mechanical properties showed no significant differences after employing fiber volume normalization techniques to account for geometry differences resulting from varying fiber volumes. The current root specimen design does not show significant mechanical property differences according to process and exceeds all static and fatigue requirements.« less

A combinaison of UV curing technology with ATL process

NASA Astrophysics Data System (ADS)

Balbzioui, I.; Hasiaoui, B.; Barbier, G.; L'hostis, G.; Laurent, F.; Ibrahim, A.; Durand, B.

2017-10-01

In order to reduce the time and the cost of manufacturing composite, UV curing technology combined with automated tape placement process (ATL) based on reverse approach by working with a fixed head was studied in this article. First, a brief description of the developed head placement is presented. Mechanical properties are then evaluated by varying process parameters, including compaction force and tape placement speed. Finally, a parametric study is carried out to identify suitable materials and process parameters to manufacture a photo composite material with high mechanical performances. The obtained results show that UV curing is a very good alternative for thermal polymerization because of its fast cure speed due to less dependency on temperature.

Additive technology of soluble mold tooling for embedded devices in composite structures: A study on manufactured tolerances

NASA Astrophysics Data System (ADS)

Roy, Madhuparna

Composite textiles have found widespread use and advantages in various industries and applications. The constant demand for high quality products and services requires companies to minimize their manufacturing costs, and delivery time in order to compete in general and niche marketplaces. Advanced manufacturing methods aim to provide economical methods of mold production. Creation of molding and tooling options for advanced composites encompasses a large portion of the fabrication time, making it a costly process and restraining factor. This research discusses a preliminary investigation into the use of soluble polymer compounds and additive manufacturing to fabricate soluble molds. These molds suffer from dimensional errors due to several factors, which have also been characterized. The basic soluble mold of a composite is 3D printed to meet the desired dimensions and geometry of holistic structures or spliced components. The time taken to dissolve the mold depends on the rate of agitation of the solvent. This process is steered towards enabling the implantation of optoelectronic devices within the composite to provide sensing capability for structural health monitoring. The shape deviation of the 3D printed mold is also studied and compared to its original dimensions to optimize the dimensional quality to produce dimensionally accurate parts. Mechanical tests were performed on compact tension (CT) resin samples prepared from these 3D printed molds and revealed crack propagation towards an embedded intact optical fiber.

Optimization of the Manufacturing Process of Conical Shell Structures Using Prepreg Laminatees

NASA Astrophysics Data System (ADS)

Khakimova, Regina; Zimmermann, Rolf; Burau, Florian; Siebert, Marc; Arbelo, Mariano; Castro, Saullo; Degenhardt, Richard

2014-06-01

The design and manufacture of an unstiffened composite conical structure which is a scaled-down version of the Ariane 5 Midlife Evolution Equipment Bay Structure is presented. For such benchmarking structures the fiber orientation error is critical and then the manufacturing process becomes a big challenge. The paper therefore is focused on the implementation of a tailoring study and on the manufacturing process. The conical structure will be tested to validate a new design approach.This study contributes to the European Union (EU) project DESICOS, whose aim is to develop less conservative design guidelines for imperfection sensitive thin-walled structures.

Monitoring cure properties of out-of-autoclave BMI composites using IFPI sensor

NASA Astrophysics Data System (ADS)

Kaur, Amardeep; Anandan, Sudharshan; Yuan, Lei; Watkins, Steve E.; Chandrashekhara, K.; Xiao, Hai; Phan, Nam

2016-04-01

A non-destructive technique for inspection of a Bismaleimide (BMI) composite is presented using an optical fiber sensor. High performance BMI composites are used for Aerospace application for their mechanical strength. They are also used as an alternative to toughened epoxy resins. A femtosecond-laser-inscribed Intrinsic Fabry-Perot Interferometer (IFPI) sensor is used to perform real time cure monitoring of a BMI composite. The composite is cured using the out-of-autoclave (OOA) process. The IFPI sensor was used for in-situ monitoring; different curing stages are analyzed throughout the curing process. Temperature-induced-strain was measured to analyze the cure properties. The IFPI structure comprises of two reflecting mirrors inscribed on the core of the fiber using a femtosecond-laser manufacturing process. The manufacturing process makes the sensor thermally stable and robust for embedded applications. The sensor can withstand very high temperatures of up to 850 °C. The temperature and strain sensitivities of embedded IFPI sensor were measured to be 1.4 pm/μepsilon and 0.6 pm/μepsilon respectively.

In-situ acoustic signature monitoring in additive manufacturing processes

NASA Astrophysics Data System (ADS)

Koester, Lucas W.; Taheri, Hossein; Bigelow, Timothy A.; Bond, Leonard J.; Faierson, Eric J.

2018-04-01

Additive manufacturing is a rapidly maturing process for the production of complex metallic, ceramic, polymeric, and composite components. The processes used are numerous, and with the complex geometries involved this can make quality control and standardization of the process and inspection difficult. Acoustic emission measurements have been used previously to monitor a number of processes including machining and welding. The authors have identified acoustic signature measurement as a potential means of monitoring metal additive manufacturing processes using process noise characteristics and those discrete acoustic emission events characteristic of defect growth, including cracks and delamination. Results of acoustic monitoring for a metal additive manufacturing process (directed energy deposition) are reported. The work investigated correlations between acoustic emissions and process noise with variations in machine state and deposition parameters, and provided proof of concept data that such correlations do exist.

Piezoelectric Characteristics of Chiral Polymer Composite Films Obtained under Strong Magnetic Field

NASA Astrophysics Data System (ADS)

Nakiri, Takuo; Okuno, Masaki; Maki, Nobuyuki; Kanasaki, Masayoshi; Morimoto, Yu; Okamoto, Satoshi; Ishizuka, Masayuki; Fukuda, Kazuyuki; Takaki, Toshihiko; Tajitsu, Yoshiro

2005-09-01

It is difficult to obtain a drawn chiral polymer/inorganic material composite membrane with shear piezoelectricity by the conventional method because the chiral polymer/inorganic material composite membrane breaks during the drawing process by which shear piezoelectricity is realized. Using a strong magnetic field, we propose to manufacture a drawn composite membrane of poly-l-lactic acid (PLLA), a chiral polymer, and hydroxyapatite (Hap), an inoroganic material (PLLA/Hap composite membrane). The manufacturing method used here is effective for obtaining a drawn PLLA/Hap composite membrane with a large uniform area. Also, the shear piezoelectric constant of the drawn PLLA/Hap composite membrane is about 20 pC/N. This value is large for piezoelectric polymers.

Method for Selective Cleaning of Mold Release from Composite Honeycomb Surfaces

NASA Technical Reports Server (NTRS)

Pugel, Diane

2011-01-01

Honeycomb structures are commonly employed as load- and force-bearing structures as they are structurally strong and lightweight. Manufacturing processes for heat-molded composite honeycomb structures commence with the placement of pre-impregnated composite layups over metal mandrels. To prevent permanent bonding between the composite layup and the metal mandrels, an agent, known as a mold release agent, is used. Mold release agents allow the molded composite material to be removed from mandrels after a heat-forming process. Without a specific removal process, mold release agents may continue to adhere to the surface of the composite material, thereby affecting the bonding of other materials that may come into contact with the composite surface in later stages of processing A constituent common to commercially available household cleaning agents is employed for the removal of mold release agents common to the manufacturing of heat-formed composite materials. The reliability of the solvent has been proven by the longevity and reliability of commercial household cleaners. At the time of this reporting, no one has attempted using constituent for this purpose. The material to be cleaned is immersed in the solution, vertically removed so that the solution is allowed to drain along cell walls and into a solvent bath, and then placed on a compressed airflow table for drying.

Manufacturing methods of a composite cell case for a Ni-Cd battery

NASA Technical Reports Server (NTRS)

Bauer, J. L.; Bogner, R. S.; Lowe, E. P.; Orlowski, E.

1979-01-01

Graphite epoxy material for a nickel cadmium battery cell case has been evaluated and determined to perform in the simulated environment of the battery. The basic manufacturing method requires refinement to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development together with material and process control, have been integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material utilizing internal pressure bag fabrication method is feasible.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing," evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door, were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Manufacturing of Smart Structures Using Fiber Placement Manufacturing Processes

NASA Technical Reports Server (NTRS)

Thomas, Matthew M.; Glowasky, Robert A.; McIlroy, Bruce E.; Story, Todd A.

1996-01-01

Smart structures research and development, with the ultimate aim of rapid commercial and military production of these structures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program. As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smart structure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shape memory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smart material synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.

Study on parameters affecting the mechanical properties of dry fiber bundles during continuous composite manufacturing processes

NASA Astrophysics Data System (ADS)

Maier, A.; Schledjewski, R.

2016-07-01

For continuous manufacturing processes mechanical preloading of the fibers occurs during the delivery of the fibers from the spool creel to the actual manufacturing process step. Moreover preloading of the dry roving bundles might be mandatory, e.g. during winding, to be able to produce high quality components. On the one hand too high tensile loads within dry roving bundles might result in a catastrophic failure and on the other hand the part produced under too low pre-tension might have low quality and mechanical properties. In this work, load conditions influencing mechanical properties of dry glass fiber bundles during continuous composite manufacturing processes were analyzed. Load conditions, i.e. fiber delivery speed, necessary pre-tension and other effects of the delivery system during continuous fiber winding, were chosen in process typical ranges. First, the strain rate dependency under static tensile load conditions was investigated. Furthermore different free gauge lengths up to 1.2 m, interactions between fiber points of contact regarding influence of sizing as well as impregnation were tested and the effect of twisting on the mechanical behavior of dry glass fiber bundles during the fiber delivery was studied.

Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique.

PubMed

Leddy, Michael T; Belter, Joseph T; Gemmell, Kevin D; Dollar, Aaron M

2015-01-01

Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses.

A Hybrid Approach to Composite Damage and Failure Analysis Combining Synergistic Damage Mechanics and Peridynamics

DTIC Science & Technology

2017-12-31

random radial displacement a fiber is given in simulation of the manufacturing process. As seen in the figure, the crack driving force increases...will incorporate voids along with irregular fiber distributions as consequences of composite manufacturing. The crack opening displacement in the as...subjected to IMPa pressure (ANSYS does not allow the, mathematically equivalent, tensile stresses applied at both ends without any displacement constraints

The automotive application of discontinuously reinforced TiB-Ti composites

NASA Astrophysics Data System (ADS)

Saito, Takashi

2004-05-01

In 1998, Toyota Motor Corporation adopted intake valves and exhaust valves made of titanium-based alloys for the engine of its Altezza. Both valves were manufactured via a newly developed cost-effective powder metallurgy process. The exhaust valve is made of a newly developed titanium metal-matrix composite (MMC). The valve has achieved sufficient durability and reliability with a manufacturing cost acceptable for the mass-produced automobile engine components.

Simulation of the infiltration process of a ceramic open-pore body with a metal alloy in semi-solid state to design the manufacturing of interpenetrating phase composites

NASA Astrophysics Data System (ADS)

Schomer, Laura; Liewald, Mathias; Riedmüller, Kim Rouven

2018-05-01

Metal-ceramic Interpenetrating Phase Composites (IPC) belong to a special subcategory of composite materials and reveal enhanced properties compared to conventional composite materials. Currently, IPC are produced by infiltration of a ceramic open-pore body with liquid metal applying high pressure and I or high temperature to avoid residual porosity. However, these IPC are not able to gain their complete potential, because of structural damages and interface reactions occurring during the manufacturing process. Compared to this, the manufacturing of IPC using the semi-solid forming technology offers great perspectives due to relative low processing temperatures and reduced mechanical pressure. In this context, this paper is focusing on numerical investigations conducted by using the FLOW-3D software for gaining a deeper understanding of the infiltration of open-pore bodies with semi-solid materials. For flow simulation analysis, a geometric model and different porous media drag models have been used. They have been adjusted and compared to get a precise description of the infiltration process. Based on these fundamental numerical investigations, this paper also shows numerical investigations that were used for basically designing a semi-solid forming tool. Thereby, the development of the flow front and the pressure during the infiltration represent the basis of the evaluation. The use of an open and closed tool cavity combined with various geometries of the upper die shows different results relating to these evaluation arguments. Furthermore, different overflows were designed and its effects on the pressure at the end of the infiltration process were investigated. Thus, this paper provides a general guideline for a tool design for manufacturing of metal-ceramic IPC using semi-solid forming.

At-line validation of a process analytical technology approach for quality control of melamine-urea-formaldehyde resin in composite wood-panel production using near infrared spectroscopy.

PubMed

Meder, Roger; Stahl, Wolfgang; Warburton, Paul; Woolley, Sam; Earnshaw, Scott; Haselhofer, Klaus; van Langenberg, Ken; Ebdon, Nick; Mulder, Roger

2017-01-01

The reactivity of melamine-urea-formaldehyde resins is of key importance in the manufacture of engineered wood products such as medium density fibreboard (MDF) and other wood composite products. Often the MDF manufacturing plant has little available information on the resin reactivity other than details of the resin specification at the time of batch manufacture, which often occurs off-site at a third-party resin plant. Often too, fresh resin on delivery at the MDF plant is mixed with variable volume of aged resin in storage tanks, thereby rendering any specification of the fresh resin batch obsolete. It is therefore highly desirable to develop a real-time, at-line or on-line, process analytical technology to monitor the quality of the resin prior to MDF panel manufacture. Near infrared (NIR) spectroscopy has been calibrated against standard quality methods and against 13 C nuclear magnetic resonance (NMR) measures of molecular composition in order to provide at-line process analytical technology (PAT), to monitor the resin quality, particularly the formaldehyde content of the resin. At-line determination of formaldehyde content in the resin was made possible using a six-factor calibration with an R 2 (cal) value of 0.973, and R 2 (CV) value of 0.929 and a root-mean-square error of cross-validation of 0.01. This calibration was then used to generate control charts of formaldehyde content at regular four-hourly periods during MDF panel manufacture in a commercial MDF manufacturing plant.

The role of nanocrystalline binder metallic coating into WC after additive manufacturing

NASA Astrophysics Data System (ADS)

Cavaleiro, A. J.; Fernandes, C. M.; Farinha, A. R.; Gestel, C. V.; Jhabvala, J.; Boillat, E.; Senos, A. M. R.; Vieira, M. T.

2018-01-01

Tungsten carbide with microsized particle powders are commonly used embedded in a tough binder metal. The application of these composites is not limited to cutting tools, WC based material has been increasingly used in gaskets and other mechanical parts with complex geometries. Consequently, additive manufacturing processes as Selective Laser Sintering (SLS) might be the solution to overcome some of the manufacturing problems. However, the use of SLS leads to resolve the problems resulting from difference of physical properties between tungsten carbide and the metallic binder, such as laser absorbance and thermal conductivity. In this work, an original approach of powder surface modification was considered to prepare WC-metal composite powders and overcome these constraints, consisting on the sputter-coating of the WC particle surfaces with a nanocrystalline thin film of metallic binder material (stainless steel). The coating improves the thermal behavior and rheology of the WC particles and, at the same time, ensures a binder homogenous distribution. The feasibility of the SLS technology as manufacturing process for WC powder sputter-coated with 13 wt% stainless steel AISI 304L was explored with different laser power and scanning speed parameters. The SLS layers were characterized regarding elemental distribution, phase composition and morphology, and the results are discussed emphasizing the role of the coating on the consolidation process.

Proof test methodology for composites

NASA Technical Reports Server (NTRS)

Wu, Edward M.; Bell, David K.

1992-01-01

The special requirements for proof test of composites are identified based on the underlying failure process of composites. Two proof test methods are developed to eliminate the inevitable weak fiber sites without also causing flaw clustering which weakens the post-proof-test composite. Significant reliability enhancement by these proof test methods has been experimentally demonstrated for composite strength and composite life in tension. This basic proof test methodology is relevant to the certification and acceptance of critical composite structures. It can also be applied to the manufacturing process development to achieve zero-reject for very large composite structures.

International SAMPE Symposium and Exhibition, 35th, Anaheim, CA, Apr. 2-5, 1990, Proceedings. Books 1 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Janicki, G.; Bailey, V.; Schjelderup, H.

The present conference discusses topics in the fields of ultralightweight structures, producibility of thermoplastic composites, innovation in sandwich structures, composite failure processes, toughened materials, metal-matrix composites, advanced materials for future naval systems, thermoplastic polymers, automated composites manufacturers, advanced adhesives, emerging processes for aerospace component fabrication, and modified resin systems. Also discussed are matrix behavior for damage tolerance, composite materials repair, testing for damage tolerance, composite strength analyses, materials workplace health and safety, cost-conscious composites, bismaleimide systems, and issues facing advanced composite materials suppliers.

The effect of mesostructure heterogeneity on cracks initiation and the displacement distribution in NCF composites

NASA Astrophysics Data System (ADS)

Zrida, H.; Giannadis, K.; Varna, J.; Ayadi, Z.

2012-02-01

Non Crimp Fabrics (NCF) are promising new generation composite materials. They are now being used in some sections of composite industry, for example in wind turbine blades and boat hulls. The aerospace industry also shows an increasing interest in this material, thanks to the low cost of its manufacturing process. NCFs are special types of textile composites, made of layers of parallel fiber bundles oriented in different directions and separated by resin. Due to the manufacturing process the fiber bundles are not perfectly straight. They show a certain degree of waviness which decreases the stiffness and the strength of the material. The heterogeneous mesostructure affects the mechanical properties of the material and the failure mechanisms. This was studied using both numerical and experimental methods. In our experimental approach, a carbon fiber/epoxy resin laminate with uniform fiber distribution was manufactured by voluntarily introducing waviness to simulate the NCF composites. The displacement map was studied against the thickness of a sample loaded in tension, using ESPI (Electronic Speckle Pattern Interferometry). This can give us a primary idea of the micro damage initiation and the cracks' shapes.

A Complex Shaped Reinforced Thermoplastic Composite Part Made of Commingled Yarns With Integrated Sensor

NASA Astrophysics Data System (ADS)

Risicato, Jean-Vincent; Kelly, Fern; Soulat, Damien; Legrand, Xavier; Trümper, Wolfgang; Cochrane, Cedric; Koncar, Vladan

2015-02-01

This paper focuses on the design and one shot manufacturing process of complex shaped composite parts based on the overbraiding of commingled yarns. The commingled yarns contain thermoplastic fibres used as the matrix and glass fibres as the reinforcement material. This technology reduces the flow path length for the melted thermoplastic and aims to improve the impregnation of materials with high viscosity. The tensile strength behaviour of the material was firstly investigated in order to evaluate the influence of the manufacturing parameters on flat structured braids that have been consolidated on a heating press. A good compatibility between the required geometry and the braiding process was observed. Additionally, piezo-resistive sensor yarns, based on glass yarns coated with PEDOT: PSS, have been successfully integrated within the composite structure. The sensor yarns have been inserted into the braided fabric, before consolidation. The inserted sensors provide the ability to monitor the structural health of the composite part in a real time. The design and manufacture of the complete complex shaped part has then been successfully achieved.

Aerogel composites and method of manufacture

DOEpatents

Cao, Wanqing; Hunt, Arlon Jason

1999-01-01

Disclosed herewith is a process of forming an aerogel composite which comprises introducing a gaseous material into a formed aerogel monolith or powder, and causing decomposition of said gaseous material in said aerogel in amounts sufficient to cause deposition of the decomposition products of the gas on the surfaces of the pores of the said aerogel. Also disclosed are the composites made by the process.

New possibilities using additive manufacturing with materials that are difficult to process and with complex structures

NASA Astrophysics Data System (ADS)

Olsson, Anders; Hellsing, Maja S.; Rennie, Adrian R.

2017-05-01

Additive manufacturing (or 3D printing) opens the possibility of creating new designs and manufacturing objects with new materials rapidly and economically. Particularly for use with polymers and polymer composites, simple printers can make high quality products, and these can be produced easily in offices, schools and in workshops and laboratories. This technology has opened a route for many to test ideas or to make custom devices. It is possible to easily manufacture complex geometries that would be difficult or even impossible to create with traditional methods. Naturally this technology has attracted attention in many fields that include the production of medical devices and prostheses, mechanical engineering as well as basic sciences. Materials that are highly problematic to machine can be used. We illustrate process developments with an account of the production of printer parts to cope with polymer fillers that are hard and abrasive; new nozzles with ruby inserts designed for such materials are durable and can be used to print boron carbide composites. As with other materials, complex parts can be printed using boron carbide composites with fine structures, such as screw threads and labels to identify materials. General ideas about design for this new era of manufacturing customised parts are presented.

Orodispersible films: Product transfer from lab-scale to continuous manufacturing.

PubMed

Thabet, Yasmin; Breitkreutz, Joerg

2018-01-15

Orodispersible films have been described as new beneficial dosage forms for special patient populations. Due to various production settings, different requirements on film formulations are required for non- continuous and continuous manufacturing. In this study, a continuous coating machine was qualified in regards of the process conditions for film compositions and their effects on the formed films. To investigate differences between both manufacturing processes, various film formulations of hydrochlorothiazide and hydroxypropylcellulose (HPC) or hydroxypropylmethycellulose (HPMC) as film formers were produced and the resulting films were characterized. The qualification of the continuously operating coating machine reveals no uniform heat distribution during drying. Coating solutions for continuous manufacturing should provide at least a dynamic viscosity of 1 Pa*s (wet film thickness of 500 μm, velocity of 15.9 cm/min). HPC films contain higher residuals of ethanol or acetone in bench-scale than in continuous production mode. Continuous production lead to lower drug content of the films. All continuously produced films disintegrate within less than 30 s. There are observed significant effects of the production process on the film characteristics. When transferring film manufacturing from lab-scale to continuous mode, film compositions, processing conditions and suitable characterization methods have to be carefully selected and adopted. Copyright © 2017 Elsevier B.V. All rights reserved.

Development of a stitched/RFI composite transport wing

NASA Technical Reports Server (NTRS)

Kropp, Yury

1995-01-01

Development of a composite wing primary structure for commercial transport aircraft is being undertaken at McDonnell Douglas under NASA contract. The focus of the program is to design and manufacture a low cost composite wing which can effectively compete with conventional metal wing structures in terms of cost, weight, and ability to withstand damage. These goals are being accomplished by utilizing the stitched/RFI manufacturing process during which the dry fiber preforms consisting of several stacks of warp-knit material are stitched together, impregnated with resin and cured. The stitched/RFI wing skin panels have exceptional damage tolerance and fatigue characteristics, are easily repairable, and can carry higher gross stress than their metal counterparts. This paper gives an overview of the program, describes the key features of the composite wing design and addresses major issues on analysis and manufacturing.

Design and Manufacturing of Composite Tower Structure for Wind Turbine Equipment

NASA Astrophysics Data System (ADS)

Park, Hyunbum

2018-02-01

This study proposes the composite tower design process for large wind turbine equipment. In this work, structural design of tower and analysis using finite element method was performed. After structural design, prototype blade manufacturing and test was performed. The used material is a glass fiber and epoxy resin composite. And also, sand was used in the middle part. The optimized structural design and analysis was performed. The parameter for optimized structural design is weight reduction and safety of structure. Finally, structure of tower will be confirmed by structural test.

Computer-aided design of polymers and composites

NASA Technical Reports Server (NTRS)

Kaelble, D. H.

1985-01-01

This book on computer-aided design of polymers and composites introduces and discusses the subject from the viewpoint of atomic and molecular models. Thus, the origins of stiffness, strength, extensibility, and fracture toughness in composite materials can be analyzed directly in terms of chemical composition and molecular structure. Aspects of polymer composite reliability are considered along with characterization techniques for composite reliability, relations between atomic and molecular properties, computer aided design and manufacture, polymer CAD/CAM models, and composite CAD/CAM models. Attention is given to multiphase structural adhesives, fibrous composite reliability, metal joint reliability, polymer physical states and transitions, chemical quality assurance, processability testing, cure monitoring and management, nondestructive evaluation (NDE), surface NDE, elementary properties, ionic-covalent bonding, molecular analysis, acid-base interactions, the manufacturing science, and peel mechanics.

Reinforced Plastic Composites Production: National Emission Standards for Hazardous Air Pollutants

EPA Pesticide Factsheets

National emissions standards for hazardous air pollutants for reinforced plastic composites production facilities. Regulates production and ancillary processes used to manufacture products with thermoset resins and gel coats.

Simulation Based Low-Cost Composite Process Development at the US Air Force Research Laboratory

NASA Technical Reports Server (NTRS)

Rice, Brian P.; Lee, C. William; Curliss, David B.

2003-01-01

Low-cost composite research in the US Air Force Research Laboratory, Materials and Manufacturing Directorate, Organic Matrix Composites Branch has focused on the theme of affordable performance. Practically, this means that we use a very broad view when considering the affordability of composites. Factors such as material costs, labor costs, recurring and nonrecurring manufacturing costs are balanced against performance to arrive at the relative affordability vs. performance measure of merit. The research efforts discussed here are two projects focused on affordable processing of composites. The first topic is the use of a neural network scheme to model cure reaction kinetics, then utilize the kinetics coupled with simple heat transport models to predict, in real-time, future exotherms and control them. The neural network scheme is demonstrated to be very robust and a much more efficient method that mechanistic cure modeling approach. This enables very practical low-cost processing of thick composite parts. The second project is liquid composite molding (LCM) process simulation. LCM processing of large 3D integrated composite parts has been demonstrated to be a very cost effective way to produce large integrated aerospace components specific examples of LCM processes are resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), and other similar approaches. LCM process simulation is a critical part of developing an LCM process approach. Flow simulation enables the development of the most robust approach to introducing resin into complex preforms. Furthermore, LCM simulation can be used in conjunction with flow front sensors to control the LCM process in real-time to account for preform or resin variability.

Novel folding device for manufacturing aerospace composite structures

NASA Astrophysics Data System (ADS)

Tewfic, Tarik; Sarhadi, M.

2000-10-01

A new manufacturing methodology, termed shape-inclusive lay-up has been applied that allows the generation of three-dimensional preforms for the resin transfer molding (RTM) process. A flexible novel folding device for forming dry fabrics including non-crimp fabric (NCF) preform is designed and integrated with a Material Delivery System (MDS) into a robotic cell for manufacturing dry fiber composite aerospace components. The paper describes detailed design, implementation and operational performance of a prototype device. The proposed folding device has been implemented and tested by manufacturing a range of reinforcement structure preforms (C,T,J and I reinforcement preforms), normally used in aerostructure applications. A key advantage of the proposed device is its flexibility. The system is capable of manufacturing a wide range of components of various sizes without the need for reconfiguration.

Lightweight bio-composites based on hemp fibres produced by conventional and unconventional processes

NASA Astrophysics Data System (ADS)

Boccarusso, L.; Durante, M.; Formisano, A.; Langella, A.; Minutolo, F. Memola Capece

2017-10-01

Considering that nowadays the interest in the use of bio-composite materials is increasing more and more, this work is focused on the manufacturing of lightweight components based on hemp fibres for future applications, for example as a core for sandwich structures. Three different no-complex processes were used: a conventional hand lay-up, an unconventional infusion process and a hand lay-up process followed by injection moulding. They were used to produce bio-composite structures using an epoxy resin and/or a polyurethane foam as matrix. Depending on the process used for the manufacturing, laminates with different values of density were obtained. A detailed study in terms of both static and dynamic properties was carried out and the different mechanical behaviour for each sample typology was highlighted. The results showed that the process in which both the epoxy resin and the polyurethane foam were used as matrix allowed to obtain laminates with lower density and higher specific mechanical properties.

In-situ cure monitoring of isocyanate adhesives using microdielectric analysis

Treesearch

Micahel P. Wolcott; Timothy G. Rials

1995-01-01

Recent advances in microelectronics have produced small electrodes that can be used for remote dielectric measurements. These miniature sensors are small enough to be embedded in a composite panel during manufacture with little disturbance to the manufacturing process. Small particleboard panels (5 by 4.5 by 0.25 in.) were manufactured with 6 percent polymeric...

In-situ cure monitoring of isocyanate adhesives using microdielectric analysis

Treesearch

Michael P. Wolcott; Timothy G. Rials

1995-01-01

Recent advances in microelectronics have produced small electrodes that can be used for remote dielectric measurements. These miniature sensors are small enought to be embedded in a composite panel during manufacture with little disturbance to the manufacturing process. Small particleboard panels (5 by 4.5 by 0.25 in) were manufactured with 6 percent polymeric...

Wood-based composite materials : panel products, glued-laminated timber, structural composite lumber, and wood-nonwood composite materials

Treesearch

Nicole M. Stark; Zhiyong Cai; Charles Carll

2010-01-01

This chapter gives an overview of the general types and composition of wood-based composite products and the materials and processes used to manufacture them. It describes conventional wood-based composite panels and structural composite materials intended for general construction, interior use, or both. This chapter also describes wood–nonwood composites. Mechanical...

Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

NASA Technical Reports Server (NTRS)

Grimsley, Brian W.; Sutter, James K.; Dixon, Genevieve D.; Smeltzer, Satn S.

2013-01-01

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates.

Manufacturing of Nanocomposite Carbon Fibers and Composite Cylinders

NASA Technical Reports Server (NTRS)

Tan, Seng; Zhou, Jian-guo

2013-01-01

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.

Composition and Manufacturing Effects on Electrical Conductivity of Li/FeS 2 Thermal Battery Cathodes

DOE PAGES

Reinholz, Emilee L.; Roberts, Scott A.; Apblett, Christopher A.; ...

2016-06-11

The electrical conductivity is key to the performance of thermal battery cathodes. In this work we present the effects of manufacturing and processing conditions on the electrical conductivity of Li/FeS2 thermal battery cathodes. Finite element simulations were used to compute the conductivity of three-dimensional microcomputed tomography cathode microstructures and compare results to experimental impedance spectroscopy measurements. A regression analysis reveals a predictive relationship between composition, processing conditions, and electrical conductivity; a trend which is largely erased after thermally-induced deformation. Moreover, the trend applies to both experimental and simulation results, although is not as apparent in simulations. This research is amore » step toward a more fundamental understanding of the effects of processing and composition on thermal battery component microstructure, properties, and performance.« less

On the realization of the bulk modulus bounds for two-phase viscoelastic composites

NASA Astrophysics Data System (ADS)

Andreasen, Casper Schousboe; Andreassen, Erik; Jensen, Jakob Søndergaard; Sigmund, Ole

2014-02-01

Materials with good vibration damping properties and high stiffness are of great industrial interest. In this paper the bounds for viscoelastic composites are investigated and material microstructures that realize the upper bound are obtained by topology optimization. These viscoelastic composites can be realized by additive manufacturing technologies followed by an infiltration process. Viscoelastic composites consisting of a relatively stiff elastic phase, e.g. steel, and a relatively lossy viscoelastic phase, e.g. silicone rubber, have non-connected stiff regions when optimized for maximum damping. In order to ensure manufacturability of such composites the connectivity of the matrix is ensured by imposing a conductivity constraint and the influence on the bounds is discussed.

Control of microstructure in soldered, brazed, welded, plated, cast or vapor deposited manufactured components

DOEpatents

Ripley, Edward B.; Hallman, Russell L.

2015-11-10

Disclosed are methods and systems for controlling of the microstructures of a soldered, brazed, welded, plated, cast, or vapor deposited manufactured component. The systems typically use relatively weak magnetic fields of either constant or varying flux to affect material properties within a manufactured component, typically without modifying the alloy, or changing the chemical composition of materials or altering the time, temperature, or transformation parameters of a manufacturing process. Such systems and processes may be used with components consisting of only materials that are conventionally characterized as be uninfluenced by magnetic forces.

A critical review of nanotechnologies for composite aerospace structures

NASA Astrophysics Data System (ADS)

Kostopoulos, Vassilis; Masouras, Athanasios; Baltopoulos, Athanasios; Vavouliotis, Antonios; Sotiriadis, George; Pambaguian, Laurent

2017-03-01

The past decade extensive efforts have been invested in understanding the nano-scale and revealing the capabilities offered by nanotechnology products to structural materials. Integration of nano-particles into fiber composites concludes to multi-scale reinforced composites and has opened a new wide range of multi-functional materials in industry. In this direction, a variety of carbon based nano-fillers has been proposed and employed, individually or in combination in hybrid forms, to approach the desired performance. Nevertheless, a major issue faced lately more seriously due to the interest of industry is on how to incorporate these nano-species into the final composite structure through existing manufacturing processes and infrastructure. This interest originates from several industrial applications needs that request the development of new multi-functional materials which combine enhanced mechanical, electrical and thermal properties. In this work, an attempt is performed to review the most representative processes and related performances reported in literature and the experience obtained on nano-enabling technologies of fiber composite materials. This review focuses on the two main composite manufacturing technologies used by the aerospace industry; Prepreg/Autoclave and Resin Transfer technologies. It addresses several approaches for nano-enabling of composites for these two routes and reports latest achieved results focusing on performance of nano-enabled fiber reinforced composites extracted from literature. Finally, this review work identifies the gap between available nano-technology integration routes and the established industrial composite manufacturing techniques and the challenges to increase the Technology Readiness Level to reach the demands for aerospace industry applications.

Magnetically assisted slip casting of bioinspired heterogeneous composites

NASA Astrophysics Data System (ADS)

Le Ferrand, Hortense; Bouville, Florian; Niebel, Tobias P.; Studart, André R.

2015-11-01

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

Outgassing of Out-of-Autoclave Composite Primary Structures for Small Satellites

NASA Astrophysics Data System (ADS)

Komus, Alastair

Out-of-autoclave vacuum-bagged-only (VBO) processing is capable of producing lower cost composite primary structures for small satellites than autoclave processing. However, the outgassing performance of VBO structures in a vacuum environment has not been examined. Panels were manufactured from CYCOM 5320-1 and TC275-1 carbon fiber/epoxy prepreg using VBO processing. The humidity level, pre-cure dwell time, and cure cycle parameters were varied during manufacturing. The degree of cure and glass transition temperature were shown to increase with increasing oven temperature. Processing humidity levels and the length of pre-cure dwell times had no discernable effect on the total mass loss (TML) and collected volatile condensable material (CVCM) that were outgassed under vacuum. Instead the TML was controlled by moisture saturation after manufacturing. Fourier transform infrared spectroscopy showed that epoxy oligomers were the primary CVCM. The study showed the VBO laminates had outgassing values that were comparable to the autoclave-cured laminates.

Thermochemical pretreatment of underutilized woody biomass for manufacturing wood composites

NASA Astrophysics Data System (ADS)

Pelaez Samaniego, Manuel Raul

Prescribed fires, one method for reducing hazardous fuel loads from forest lands in the US, are limited by geographical, environmental, and social impacts. Mechanical operations are an alternative type of fuel treatment but these processes are constrained by the difficulty of economically harvesting and/or using large amounts of low-value woody biomass. Adoption and integration of new technologies into existing wood composite facilities offer better utilization of this material. A pretreatment that enables integration of technologies in a typical composite facility will aid with diversification of product portfolio (e.g. wood composites, fuel pellets, liquid fuels, chemicals). Hot water extraction (HWE) is an option for wood pretreatment. This work provides a fundamental understanding of the physicochemical changes to wood resulting from HWE, and how these changes impact processing and performance of composites. Specific objectives were to: 1) review literature on studies related to the manufacture of composites produced with thermally pretreated wood, 2) manufacture wood plastic composites (WPC) and particleboard using HWE wood and evaluate the impacts of pretreatment on product properties, 3) develop an understanding of the effect of HWE on lignin properties, specifically lignin at the cells surface level after migration from cell walls and middle lamella, 4) discern the influence of lignin on the fiber surface on processing WPCs, and, 5) investigate the effect of changing the pretreatment environment (inert gas instead of water) on lignin behavior. Results show that HWE enhances the resistance of both WPCs and particleboard to water with positive or no effect on mechanical properties. Reduction of hemicelluloses and lignin property changes are suggested as the main reasons for enhancing interaction between wood fiber and resins during composite processing. Lignin on the surface of particles after HWE interacts with thermoplastics during WPCs compounding, thus improving bond quality between the constituents and maintaining the mechanical properties of the composites. The amount and properties of lignin on the fiber surfaces depends on the pretreatment conditions. Thus, it seems possible to control the pretreatment process to increase or decrease the amount of lignin on particles surfaces, which is of great interest for managing downstream processes within biorefinery concepts.

Quality control developments for graphite/PMR15 polyimide composites materials

NASA Technical Reports Server (NTRS)

Sheppard, C. H.; Hoggatt, J. T.

1979-01-01

The problem of lot-to-lot and within-lot variability of graphite/PMR-15 prepreg was investigated. The PMR-15 chemical characterization data were evaluated along with the processing conditions controlling the manufacture of PMR-15 resin and monomers. Manufacturing procedures were selected to yield a consistently reproducible graphite prepreg that could be processed into acceptable structural elements.

On-Site Additive Manufacturing by Selective Laser Melting of Composite Objects

NASA Astrophysics Data System (ADS)

Fateri, M.; Khosravi, M.

2012-06-01

This paper proposes a method for cost reduction of future space missions by manufacturing parts on foreign planets. The suitability of Selective Laser Melting process for on-site production of metallic, ceramic and glass products on mars is examined.

Mycelium reinforced agricultural fiber bio-composites: Summary of research

USDA-ARS?s Scientific Manuscript database

Industry and the public sector have a growing interest in utilizing natural fibers, such as agricultural substrates, in the manufacture of components and products currently manufactured from fossil fuels. A patented process, developed by Ecovative Design, LLC (Ecovative), for growing fungal species ...

Additive Manufacturing in Production: A Study Case Applying Technical Requirements

NASA Astrophysics Data System (ADS)

Ituarte, Iñigo Flores; Coatanea, Eric; Salmi, Mika; Tuomi, Jukka; Partanen, Jouni

Additive manufacturing (AM) is expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters. The variability of these parameters affects the manufacturing drastically and therefore standardized processes and harmonized methodologies need to be developed to characterize the technology for end use applications and enable the technology for manufacturing. This research proposes a composite methodology integrating Taguchi Design of Experiments, multi-objective optimization and statistical process control, to optimize the manufacturing process and fulfil multiple requirements imposed to an arbitrary geometry. The proposed methodology aims to characterize AM technology depending upon manufacturing process variables as well as to perform a comparative assessment of three AM technologies (Selective Laser Sintering, Laser Stereolithography and Polyjet). Results indicate that only one machine, laser-based Stereolithography, was feasible to fulfil simultaneously macro and micro level geometrical requirements but mechanical properties were not at required level. Future research will study a single AM system at the time to characterize AM machine technical capabilities and stimulate pre-normative initiatives of the technology for end use applications.

Bio-composites from mycelium reinforced agricultural substrates

USDA-ARS?s Scientific Manuscript database

There is a need for biodegradable alternatives to the inert plastics and expanded foams currently used in in manufacturing processes and device components. The material focused on in this report is a bio-composite patented by Ecovative Design, LLC. The bio-composite utilizes the fungus mycelium to i...

Carbon Fiber Reinforced Ceramic Composites for Propulsion Applications

NASA Technical Reports Server (NTRS)

Shivakumar, Kunigal; Argade, Shyam

2003-01-01

This report presents a critical review of the processing techniques for fabricating continuous fiber-reinforced CMCs for possible applications at elevated temperatures. Some of the issues affecting durability of the composite materials such as fiber coatings and cracking of the matrix because of shrinkage in PIP-process are also examined. An assessment of the potential inexpensive processes is also provided. Finally three potential routes of manufacturing C/SiC composites using a technology that NC A&T developed for carbon/carbon composites are outlined. Challenges that will be encountered are also listed.

Glass sealing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brow, R.K.; Kovacic, L.; Chambers, R.S.

1996-04-01

Hernetic glass sealing technologies developed for weapons component applications can be utilized for the design and manufacture of fuel cells. Design and processing of of a seal are optimized through an integrated approach based on glass composition research, finite element analysis, and sealing process definition. Glass sealing procedures are selected to accommodate the limits imposed by glass composition and predicted calculations.

The Economics of Big Area Addtiive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Post, Brian; Lloyd, Peter D; Lindahl, John

Case studies on the economics of Additive Manufacturing (AM) suggest that processing time is the dominant cost in manufacturing. Most additive processes have similar performance metrics: small part sizes, low production rates and expensive feedstocks. Big Area Additive Manufacturing is based on transitioning polymer extrusion technology from a wire to a pellet feedstock. Utilizing pellets significantly increases deposition speed and lowers material cost by utilizing low cost injection molding feedstock. The use of carbon fiber reinforced polymers eliminates the need for a heated chamber, significantly reducing machine power requirements and size constraints. We hypothesize that the increase in productivity coupledmore » with decrease in feedstock and energy costs will enable AM to become more competitive with conventional manufacturing processes for many applications. As a test case, we compare the cost of using traditional fused deposition modeling (FDM) with BAAM for additively manufacturing composite tooling.« less

Local Structure Fixation in the Composite Manufacturing Chain

NASA Astrophysics Data System (ADS)

Girdauskaite, Lina; Krzywinski, Sybille; Rödel, Hartmut; Wildasin-Werner, Andrea; Böhme, Ralf; Jansen, Irene

2010-12-01

Compared to metal materials, textile reinforced composites show interesting features, but also higher production costs because of low automation rate in the manufacturing chain at this time. Their applicability is also limited due to quality problems, which restrict the production of complex shaped dry textile preforms. New technologies, design concepts, and cost-effective manufacturing methods are needed in order to establish further fields of application. This paper deals with possible ways to improve the textile deformation process by locally applying a fixative to the structure parallel to the cut. This hinders unwanted deformation in the textile stock during the subsequent stacking and formation steps. It is found that suitable thermoplastic binders, applied in the appropriate manner do not restrict formation of the textile and have no negative influence on the mechanical properties of the composite.

Cost Models for MMC Manufacturing Processes

NASA Technical Reports Server (NTRS)

Elzey, Dana M.; Wadley, Haydn N. G.

1996-01-01

Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

Structural Optimisation Of Payload Fairings

NASA Astrophysics Data System (ADS)

Santschi, Y.; Eaton, N.; Verheyden, S.; Michaud, V.

2012-07-01

RUAG Space are developing materials and processing technologies for manufacture of the Next Generation Launcher (NGL) payload fairing, together with the Laboratory of Polymer and Composite Technology at the EPFL, in a project running under the ESA Future Launchers Preparatory Program (FLPP). In this paper the general aims and scope of the project are described, details of the results obtained shall be presented at a later stage. RUAG Space design, develop and manufacture fairings for the European launch vehicles Ariane 5 and VEGA using well proven composite materials and production methods which provide adequate cost/performance ratio for these applications. However, the NGL shall make full use of innovations in materials and process technologies to achieve a gain in performance at a much reduced overall manufacturing cost. NGL is scheduled to become operational in 2025, with actual development beginning in 2014. In this current project the basic technology is being developed and validated, in readiness for application in the NGL. For this new application, an entirely new approach to the fairing manufacture is evaluated.

Unitized Stiffened Composite Textile Panels: Manufacturing, Characterization, Experiments, and Analysis

NASA Astrophysics Data System (ADS)

Kosztowny, Cyrus Joseph Robert

Use of carbon fiber textiles in complex manufacturing methods creates new implementations of structural components by increasing performance, lowering manufacturing costs, and making composites overall more attractive across industry. Advantages of textile composites include high area output, ease of handling during the manufacturing process, lower production costs per material used resulting from automation, and provide post-manufacturing assembly mainstreaming because significantly more complex geometries such as stiffened shell structures can be manufactured with fewer pieces. One significant challenge with using stiffened composite structures is stiffener separation under compression. Axial compression loading conditions have frequently observed catastrophic structural failure due to stiffeners separating from the shell skin. Characterizing stiffener separation behavior is often costly computationally and experimentally. The objectives of this research are to demonstrate unitized stiffened textile composite panels can be manufactured to produce quality test specimens, that existing characterization techniques applied to state-of-the-art high-performance composites provide valuable information in modeling such structures, that the unitized structure concept successfully removes stiffener separation as a primary structural failure mode, and that modeling textile material failure modes are sufficient to accurately capture postbuckling and final failure responses of the stiffened structures. The stiffened panels in this study have taken the integrally stiffened concept to an extent such that the stiffeners and skin are manufactured at the same time, as one single piece, and from the same composite textile layers. Stiffener separation is shown to be removed as a primary structural failure mode for unitized stiffened composite textile panels loaded under axial compression well into the postbuckling regime. Instead of stiffener separation, a material damaging and failure model effectively captures local post-peak material response via incorporating a mesoscale model using a multiscaling framework with a smeared crack element-based failure model in the macroscale stiffened panel. Material damage behavior is characterized by simple experimental tests and incorporated into the post-peak stiffness degradation law in the smeared crack implementation. Computational modeling results are in overall excellent agreement compared to the experimental responses.

Fusion processing of itraconazole solid dispersions by kinetisol dispersing: a comparative study to hot melt extrusion.

PubMed

DiNunzio, James C; Brough, Chris; Miller, Dave A; Williams, Robert O; McGinity, James W

2010-03-01

KinetiSol Dispersing (KSD) is a novel high energy manufacturing process investigated here for the production of pharmaceutical solid dispersions. Solid dispersions of itraconazole (ITZ) and hypromellose were produced by KSD and compared to identical formulations produced by hot melt extrusion (HME). Materials were characterized for solid state properties by modulated differential scanning calorimetry and X-ray diffraction. Dissolution behavior was studied under supersaturated conditions. Oral bioavailability was determined using a Sprague-Dawley rat model. Results showed that KSD was able to produce amorphous solid dispersions in under 15 s while production by HME required over 300 s. Dispersions produced by KSD exhibited single phase solid state behavior indicated by a single glass transition temperature (T(g)) whereas compositions produced by HME exhibited two T(g)s. Increased dissolution rates for compositions manufactured by KSD were also observed compared to HME processed material. Near complete supersaturation was observed for solid dispersions produced by either manufacturing processes. Oral bioavailability from both processes showed enhanced AUC compared to crystalline ITZ. Based on the results presented from this study, KSD was shown to be a viable manufacturing process for the production of pharmaceutical solid dispersions, providing benefits over conventional techniques including: enhanced mixing for improved homogeneity and reduced processing times. 2009 Wiley-Liss, Inc. and the American Pharmacists Association

Polymeric compositions and their method of manufacture. [forming filled polymer systems using cryogenics

NASA Technical Reports Server (NTRS)

Moser, B. G.; Landel, R. F. (Inventor)

1972-01-01

Filled polymer compositions are made by dissolving the polymer binder in a suitable sublimable solvent, mixing the filler material with the polymer and its solvent, freezing the resultant mixture, and subliming the frozen solvent from the mixture from which it is then removed. The remaining composition is suitable for conventional processing such as compression molding or extruding. A particular feature of the method of manufacture is pouring the mixed solution slowly in a continuous stream into a cryogenic bath wherein frozen particles of the mixture result. The frozen individual particles are then subjected to the sublimation.

Key issues in application of composites to transport aircraft

NASA Technical Reports Server (NTRS)

Stone, M.

1978-01-01

The application of composite materials to transport aircraft was identified and reviewed including the major contributing disciplines of design, manufacturing, and processing. Factors considered include: crashworthiness considerations (structural integrity, postcrash fires, and structural fusing), electrical/avionics subsystems integration, lightning, and P-static protection design; manufacturing development, evaluation, selection, and refining of tooling and curing procedures; and major joint design considerations. Development of the DC-10 rudder, DC-10 vertical stabilizer, and the DC-9 wing study project was reviewed. The Federal Aviation Administration interface and the effect on component design of compliance with Federal Aviation Regulation 25 Composite Guidelines are discussed.

Vacuum infusion manufacturing and experimental characterization of Kevlar/epoxy composites

NASA Astrophysics Data System (ADS)

Ricciardi, M. R.; Giordano, M.; Langella, A.; Nele, L.; Antonucci, V.

2014-05-01

Epoxy/Kevlar composites have been manufactured by conventional Vacuum Infusion process and the Pulse Infusion technique. Pulse Infusion allows to control the pressure of the vacuum bag on the dry fiber reinforcement by using a proper designed pressure distributor that induces a pulsed transverse action and promotes the through thickness resin flow. The realized composite panel have been mechanically characterized by performing tensile and short beam shear tests according with the ASTM D3039 and ASTM D2344/D 2344M standard respectively in order to investigate the effect of Pulse Infusion on the tensile strength and ILSS.

Vacuum infusion manufacturing and experimental characterization of Kevlar/epoxy composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ricciardi, M. R.; Giordano, M.; Antonucci, V.

2014-05-15

Epoxy/Kevlar composites have been manufactured by conventional Vacuum Infusion process and the Pulse Infusion technique. Pulse Infusion allows to control the pressure of the vacuum bag on the dry fiber reinforcement by using a proper designed pressure distributor that induces a pulsed transverse action and promotes the through thickness resin flow. The realized composite panel have been mechanically characterized by performing tensile and short beam shear tests according with the ASTM D3039 and ASTM D2344/D 2344M standard respectively in order to investigate the effect of Pulse Infusion on the tensile strength and ILSS.

Nitroaliphatic difluoroformals and process of manufacture

DOEpatents

Peters, H.M.; Simon, R.L. Jr.

1975-12-16

Some new nitroaliphatic difluoroformal compounds are described. The compounds are intended for use in formulating PBX compositions and as energetic plasticizers or fluidic dispersant materials for plastic explosive compositions. Methods of preparation and several examples are given. (PMA)

Center for Composites Manufacturing : fabrication guide

DOT National Transportation Integrated Search

2003-06-01

The objective of this report is to describe thermoplastic composite materials and processes and to demonstrate fabrication methods for molding these materials into transit bus flooring components or other large components for use in buses and other m...

Advances in Composites Technology

NASA Technical Reports Server (NTRS)

Tenney, D. R.; Dexter, H. B.

1985-01-01

A significant level of research is currently focused on the development of tough resins and high strain fibers in an effort to gain improved damage tolerance. Moderate success has been achieved with the development of new resins such as PEEK and additional improvements look promising with new thermoplastic resins. Development of innovative material forms such as 2-D and 3-D woven fabrics and braided structural subelements is also expected to improve damage tolerance and durability of composite hardware. The new thrust in composites is to develop low cost manufacturing and design concepts to lower the cost of composite hardware. Processes being examined include automated material placement, filament winding, pultrusion, and thermoforming. The factory of the future will likely incorporate extensive automation in all aspects of manufacturing composite components.

Nanotechnologies for Composite Structures- From Nanocomposites to Multifunctional Nano-Enabled Fibre Reinforced Composites for Spacecrafts

NASA Astrophysics Data System (ADS)

Kostopoulos, Vassilis; Vavouliotis, Antonios; Baltopoulos, Athanasios; Sotiririadis, George; Masouras, Athanasios; Pambaguian, Laurent

2014-06-01

The past decade, extensive efforts have been invested in understanding the nano-scale and revealing the capabilities offered by nanotechnology products to structural materials. Nevertheless, a major issue faced lately more seriously due to the interest of industry is on how to incorporate these nano-species into the final composite structure through existing manufacturing processes and infrastructure. In this work, we present the experience obtained from the latest nanotechnology research activities supported by ESA. The paper focuses on prepreg composite manufacturing technology and addresses:- Approaches for nano-enabling of composites- Up-scaling strategies towards final structures- Latest results on performance of nano-enabledfiber reinforced compositesSeveral approaches for the utilization of nanotechnology products in structural composite structures have been proposed and are reviewed, in short along with respective achieved results. A variety of nano-fillers has been proposed and employed, individually or in combination in hybrid forms, to approach the desired performance. A major part of the work deals with the up-scaling routes of these technologies to reach final products and industrial scales and processes while meeting end-user performance.

The simulation method of chemical composition of vermicular graphite iron on the basis of genetic algorithm

NASA Astrophysics Data System (ADS)

Yusupov, L. R.; Klochkova, K. V.; Simonova, L. A.

2017-09-01

The paper presents a methodology of modeling the chemical composition of the composite material via genetic algorithm for optimization of the manufacturing process of products. The paper presents algorithms of methods based on intelligent system of vermicular graphite iron design

Industry technology assessment of graphite-polymide composite materials. [conferences

NASA Technical Reports Server (NTRS)

1975-01-01

An assessment of the current state of the art and the future prospects for graphite polyimide composite material technology is presented. Presentations and discussions given at a minisymposium of major issues on the present and future use, availability, processing, manufacturing, and testing of graphite polyimide composite materials are summarized.

Collector surface for a microwave tube comprising a carbon-bonded carbon-fiber composite

DOEpatents

Lauf, Robert J.; McMillan, April D.; Johnson, Arvid C.; Moorhead, Arthur J.

1998-01-01

In a microwave tube, an improved collector surface coating comprises a porous carbon composite material, preferably a carbon-bonded carbon fiber composite having a bulk density less than about 2 g/cc. Installation of the coating is readily adaptable as part of the tube manufacturing process.

Portable Device Slices Thermoplastic Prepregs

NASA Technical Reports Server (NTRS)

Taylor, Beverly A.; Boston, Morton W.; Wilson, Maywood L.

1993-01-01

Prepreg slitter designed to slit various widths rapidly by use of slicing bar holding several blades, each capable of slicing strip of preset width in single pass. Produces material evenly sliced and does not contain jagged edges. Used for various applications in such batch processes involving composite materials as press molding and autoclaving, and in such continuous processes as pultrusion. Useful to all manufacturers of thermoplastic composites, and in slicing B-staged thermoset composites.

The Papers Printing Quality Complex Assessment Algorithm Development Taking into Account the Composition and Production Technological Features

NASA Astrophysics Data System (ADS)

Babakhanova, Kh A.; Varepo, L. G.; Nagornova, I. V.; Babluyk, E. B.; Kondratov, A. P.

2018-04-01

Paper is one of the printing system key components causing the high-quality printed products output. Providing the printing companies with the specified printing properties paper, while simultaneously increasing the paper products range and volume by means of the forecasting methods application and evaluation during the production process, is certainly a relevant problem. The paper presents the printing quality control algorithm taking into consideration the paper printing properties quality assessment depending on the manufacture technological features and composition variation. The information system including raw material and paper properties data and making possible pulp and paper enterprises to select paper composition optimal formulation is proposed taking into account the printing process procedure peculiarities of the paper manufacturing with specified printing properties.

Advanced Manufacturing Systems in Food Processing and Packaging Industry

NASA Astrophysics Data System (ADS)

Shafie Sani, Mohd; Aziz, Faieza Abdul

2013-06-01

In this paper, several advanced manufacturing systems in food processing and packaging industry are reviewed, including: biodegradable smart packaging and Nano composites, advanced automation control system consists of fieldbus technology, distributed control system and food safety inspection features. The main purpose of current technology in food processing and packaging industry is discussed due to major concern on efficiency of the plant process, productivity, quality, as well as safety. These application were chosen because they are robust, flexible, reconfigurable, preserve the quality of the food, and efficient.

Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds

DOE Office of Scientific and Technical Information (OSTI.GOV)

Post, Brian K.; Chesser, Phillip C.; Lind, Randall F.

The goal of this project was to explore the feasibility of using Big Area Additive Manufacturing (BAAM) to directly manufacture a boat mold without the need for coatings. All prior tooling projects with BAAM required the use to thick coatings to overcome the surface finish limitations of the BAAM process. While the BAAM process significantly lowers the cost of building the mold, the high cost element rapidly became the coatings (cost of the material, labor on coating, and finishing). As an example, the time and cost to manufacture the molds for the Wind Turbine project with TPI Composites Inc. andmore » the molds for the submarine project with Carderock Naval Warfare Systems was a fraction of the time and cost of the coatings. For this project, a catamaran boat hull mold was designed, manufactured, and assembled with an additional 0.15” thickness of material on all mold surfaces. After printing, the mold was immediately machined and assembled. Alliance MG, LLC (AMG), the industry partner of this project, experimented with mold release agents on the carbon-fiber reinforced acrylonitrile butadiene styrene (CF ABS) to verify that the material can be directly used as a mold (rather than needing a coating). In addition, for large molds (such as the wind turbine mold with TPI Composites Inc.), the mold only provided the target surface. A steel subframe had to be manufactured to provide structural integrity. If successful, this will significantly reduce the time and cost necessary for manufacturing large resin infusion molds using the BAAM process.« less

Archaeometallurgical characterization of the earliest European metal helmets

PubMed Central

Mödlinger, Marianne; Piccardo, Paolo; Kasztovszky, Zsolt; Kovács, Imre; Szőkefalvi-Nagy, Zoltán; Káli, György; Szilágyi, Veronika

2013-01-01

Archaeometric analyses on conical and decorated cap helmets from the Bronze Age are presented. The helmets are dated to the 14–12th century BC according to associated finds in hoards. Alloy composition, material structure and manufacturing processes are determined and shed light on the earliest development of weaponry production in Central and Eastern Europe. Analyses were carried out using light and dark field microscopy, SEM–EDXS, PIXE, TOF-ND and PGAA. The results allowed reconstructing the manufacturing process, the differences between the cap of the helmets and their knobs (i.e. alloy composition) and the joining technique of the two parts. PMID:26523114

Viscous and thermal modelling of thermoplastic composites forming process

NASA Astrophysics Data System (ADS)

Guzman, Eduardo; Liang, Biao; Hamila, Nahiene; Boisse, Philippe

2016-10-01

Thermoforming thermoplastic prepregs is a fast manufacturing process. It is suitable for automotive composite parts manufacturing. The simulation of thermoplastic prepreg forming is achieved by alternate thermal and mechanical analyses. The thermal properties are obtained from a mesoscopic analysis and a homogenization procedure. The forming simulation is based on a viscous-hyperelastic approach. The thermal simulations define the coefficients of the mechanical model that depend on the temperature. The forming simulations modify the boundary conditions and the internal geometry of the thermal analyses. The comparison of the simulation with an experimental thermoforming of a part representative of automotive applications shows the efficiency of the approach.

Carbon Nanotube Chopped Fiber for Enhanced Properties in Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Menchhofer, Paul A.; Johnson, Joseph E.; Lindahl, John M.

2016-06-06

Nanocomp Technologies, Inc. is working with Oak Ridge National Laboratory to develop carbon nanotube (CNT) composite materials and evaluate their use in additive manufacturing (3D printing). The first phase demonstrated feasibility and improvements for carbon nanotube (CNT)- acrylonitrile butadiene styrene (ABS) composite filaments use in additive manufacturing, with potential future work centering on further improvements. By focusing the initial phase on standard processing methods (developed mainly for the incorporation of carbon fibers in ABS) and characterization techniques, a basis of knowledge for the incorporation of CNTs in ABS was learned. The ability to understand the various processing variables is criticalmore » to the successful development of these composites. From the degradation effects on ABS (caused by excessive temperatures), to the length of time the ABS is in the melt state, to the order of addition of constituents, and also to the many possible mixing approaches, a workable flow sequence that addresses each processing step is critical to the final material properties. Although this initial phase could not deal with each of these variables in-depth, a future study is recommended that will build on the lessons learned for this effort.« less

Investigation into the use of microwave sensors to monitor particulate manufacturing processes

NASA Astrophysics Data System (ADS)

Austin, John Samuel, III

Knowledge of a material's properties in-line during manufacture is of critical importance to many industries, including the pharmaceutical industry, and can be used for either process or quality control. Different microwave sensor configurations were tested to determine both the moisture content and the bulk density in pharmaceutical powders during processing on-line. Although these parameters can significantly affect a material's flowability, compressibility, and cohesivity, in the presence of blends, the picture is incomplete. Due to the ease with which particulate blends tend to segregate, blend uniformity and chemical composition are two critical parameters in nearly all solids manufacturing industries. The prevailing wisdom has been that microwave sensors are not capable of or sensitive enough to measure the relative concentrations of components in a blend. Consequently, it is common to turn to near infrared sensing to determine material composition on-line. In this study, a novel microwave sensor was designed and utilized to determine, separately, the concentrations of different components in a blend of pharmaceutical powders. This custom microwave sensor was shown to have comparable accuracy to the state-of-the-art for both chemical composition and moisture content determination.

Feasibility study of custom manufacturing methods of ionic polymer-metal composite sensors

NASA Astrophysics Data System (ADS)

Nelson, Shelby E.

The ability to create an ion exchange membrane with any shape or thickness through custom manufacturing techniques is highly desirable in ionic polymer-metal composite (IPMC) research. This is caused by the poor selection and limited availability of certain thicknesses of commercial ion exchange membranes. The objective of this study is to determine the feasibility of manufacturing custom ion exchange membranes for IPMC sensors. The manufacturing methods used in this study are extrusion, injection molding, and hot pressing. A commercial membrane from Golden Energy Fuel Cells (GEFC) is used as a comparison. After the membranes are fabricated, certain properties of the membranes are tested throughout each processing stage to determine if they are suitable to be developed into IPMCs. The three processing stages are pre-activation, activation (hydrated and dehydrated), and IPMC. It was observed that the stiffness of the membranes increased from pre-activation to activation and decreased from activation to IPMC. A more flexible membrane in an IPMC allows for larger cation displacement within the membrane. The extruded and injection molded membranes showed the most potential with having the lowest stiffness of all the samples; however, they were not able to be made into IPMCs due to repeated membrane failures in the primary plating process. Gas accumulated between the layers that formed in the membranes due to the extrusion and injection molding cooling process during manufacturing. The hot pressed membrane was the only custom manufactured membrane to be fully processed into an IPMC. The hot pressed and GEFC IPMC sensors were operated at 1 Hz, 5 Hz, and 10 Hz frequencies with the GEFC IPMC producing the strongest output voltage signal. While the extruded and injection molded membranes showed potential to become IPMCs with their high water uptake percentage, high ion exchange capacity, and low stiffness, more development is needed within the manufacturing process to make a uniform sample that does not fail during chemical processing.

One-step manufacturing of innovative flat-knitted 3D net-shape preforms for composite applications

NASA Astrophysics Data System (ADS)

Bollengier, Quentin; Wieczorek, Florian; Hellmann, Sven; Trümper, Wolfgang; Cherif, Chokri

2017-10-01

Mostly due to the cost-intensive manually performed processing operations, the production of complex-shaped fibre reinforced plastic composites (FRPC) is currently very expensive and therefore either restricted to sectors with high added value or for small batch applications (e.g. in the aerospace or automotive industry). Previous works suggest that the successful integration of conventional textile manufacturing processes in the FRPC-process chain is the key to a cost-efficient manufacturing of complex three-dimensional (3D) FRPC-components with stress-oriented fibre arrangement. Therefore, this work focuses on the development of the multilayer weft knitting technology for the one-step manufacturing of complex 3D net-shaped preforms for high performance FRPC applications. In order to highlight the advantages of net-shaped multilayer weft knitted fabrics for the production of complex FRPC parts, seamless preforms such as 3D skin-stringer structures and tubular fabrics with load oriented fibre arrangement are realised. In this paper, the development of the textile bindings and performed technical modifications on flat knitting machines are presented. The results show that the multilayer weft knitting technology meets perfectly the requirements for a fully automated and reproducible manufacturing of complex 3D textile preforms with stress-oriented fibre arrangement.

Current manufacturing processes of drug-eluting sutures.

PubMed

Champeau, Mathilde; Thomassin, Jean-Michel; Tassaing, Thierry; Jérôme, Christine

2017-11-01

Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Two general approaches can be followed: (i) the ones that add the API into the material during the manufacturing process of the suture and (ii) the ones that load the API to an already manufactured suture. Areas covered: This review provides an overview of the current manufacturing processes for drug-eluting suture production and discusses their benefits and drawbacks depending on the type of drugs. The mechanical properties and the drug delivery profile of drug-eluting sutures are highlighted since these implants must fulfill both criteria. Expert opinion: For limited drug contents, melt extrusion and electrospinning are the emerging processes since the drug is added during the suture manufacture process. Advantageously, the drug release profile can be tuned by controlling the processing parameters specific to each process and the composition of the drug-containing polymer. If high drug content is targeted, the coating or grafting of a drug layer on a pre-manufactured suture allows for preservation of the tensile strength requirements of the suture.

Production of fiberglass/metal composite material suitable for building habitat and manufacturing facilities

NASA Technical Reports Server (NTRS)

1987-01-01

The production of a fiberglass/metal composite material suitable for building habitats and manufacturing facilities was the project for Clemson. The concept and development of the knowledge necessary to produce glass fibers originated in the spring semester. During the summer, while at Johnson Space Center, fiberglass from a rock composition similar to ones found at the Apollo 16 site on the moon was successfully produced. The project this year was a continuation of last year's studies. We addressed the following problems which emerged as the work progressed: (1) Methods for coating the fibers with a metal were explored. We manufactured composites in two stages: Glass fibers without any coating on them; and fibers coated with metals as they were made. This proved to be a difficult process. Future activities include using a chemical vapor deposition process on fibers which have been made. (2) A glass furnace was developed which relies primarily on solar energy for melting the glass. The temperature of the melted glass is maintained by electrical means. The design is for 250 kg of glass per day. An electrical engineering student developed a scheme for controlling the melting and manufacturing process from the earth. This was done to minimize the human risk. Graphite refractories are relied on to contain the melt. (3) The glass composition chosen for the project is a relatively pure anorthite which is available in the highland regions of the lunar surface. A major problems with this material is that it melts at a comparatively high temperature. This problem will be solved by using graphite refractory materials for the furnace. The advantage of this glass composition is that it is very stable and does not tend to crystallize. (4) We have also refined the experimental furnace and fiber making machinery which we will be using at Johnson Space Center this summer. We believe that we will be able to draw and coat glass fibers in a vacuum for use in composites. We intend to make and test the mechanical properties of these composites.

Lessons learned for composite structures

NASA Technical Reports Server (NTRS)

Whitehead, R. S.

1991-01-01

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Materials Testing and Cost Modeling for Composite Parts Through Additive Manufacturing

DTIC Science & Technology

2016-04-30

FDM include plastic jet printing (PJP), fused filament modeling ( FFM ), and fused filament fabrication (FFF). FFF was coined by the RepRap project to...additive manufacturing processes? • Fused deposition modeling (FDM) trademarked by Stratasys • Fused filament modeling ( FFM ) and fused filament

Relationship between mozzarella yield and milk composition, processing factors, and recovery of whey constituents.

PubMed

Sales, D C; Rangel, A H N; Urbano, S A; Freitas, Alfredo R; Tonhati, Humberto; Novaes, L P; Pereira, M I B; Borba, L H F

2017-06-01

Our aim was to identify the relationship between mozzarella cheese yield and buffalo milk composition, processing factors, and recovery of whey constituents. A production of 30 batches of mozzarella cheese at a dairy industry in northeast Brazil (Rio Grande do Norte) was monitored between March and November 2015. Mozzarella yield and 32 other variables were observed for each batch, and divided into 3 groups: milk composition variables (12); variables involved in the cheesemaking process (14); and variables for recovery of whey constituents (6). Data were analyzed using descriptive statistics, Pearson correlation, and principal component analysis. Most of the correlations between milk composition variables and between the variables of the manufacturing processes were not significant. Significant correlations were mostly observed between variables for recovery of whey constituents. Yield only showed significant correlation with time elapsed between curd cuttings and age of the starter culture, and it showed greater association with age of the starter culture, time elapsed between curd cuttings, and during stretching, as well as with milk pH and density. Thus, processing factors and milk characteristics are closely related to dairy efficiency in mozzarella manufacturing. Copyright © 2017 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian; Munafo, Paul M. (Technical Monitor)

2002-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.

Composite chronicles: A study of the lessons learned in the development, production, and service of composite structures

NASA Technical Reports Server (NTRS)

Vosteen, Louis F.; Hadcock, Richard N.

1994-01-01

A study of past composite aircraft structures programs was conducted to determine the lessons learned during the programs. The study focused on finding major underlying principles and practices that experience showed have significant effects on the development process and should be recognized and understood by those responsible for using of composites. Published information on programs was reviewed and interviews were conducted with personnel associated with current and past major development programs. In all, interviews were conducted with about 56 people representing 32 organizations. Most of the people interviewed have been involved in the engineering and manufacturing development of composites for the past 20 to 25 years. Although composites technology has made great advances over the past 30 years, the effective application of composites to aircraft is still a complex problem that requires experienced personnel with special knowledge. All disciplines involved in the development process must work together in real time to minimize risk and assure total product quality and performance at acceptable costs. The most successful programs have made effective use of integrated, collocated, concurrent engineering teams, and most often used well-planned, systematic development efforts wherein the design and manufacturing processes are validated in a step-by-step or 'building block' approach. Such approaches reduce program risk and are cost effective.

Laser additive manufacturing bulk graphene-copper nanocomposites.

PubMed

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J

2017-11-03

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Laser additive manufacturing bulk graphene-copper nanocomposites

NASA Astrophysics Data System (ADS)

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J.

2017-11-01

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Influence of the intramedullary nail preparation method on nail's mechanical properties and degradation rate.

PubMed

Morawska-Chochół, Anna; Chłopek, Jan; Szaraniec, Barbara; Domalik-Pyzik, Patrycja; Balacha, Ewa; Boguń, Maciej; Kucharski, Rafael

2015-06-01

When it comes to the treatment of long bone fractures, scientists are still investigating new materials for intramedullary nails and different manufacturing methods. Some of the most promising materials used in the field are resorbable polymers and their composites, especially since there is a wide range of potential manufacturing and processing methods. The aim of this work was to select the best manufacturing method and technological parameters to obtain multiphase, and multifunctional, biodegradable intramedullary nails. All composites were based on a poly(l-lactide) matrix. Either magnesium alloy wires or carbon and alginate fibres were introduced in order to reinforce the nails. The polylactide matrix was also modified with tricalcium phosphate and gentamicin sulfate. The composite nails were manufactured using three different methods: forming from solution, injection moulding and hot pressing. The effect of each method of manufacturing on mechanical properties and degradation rate of the nails was evaluated. The study showed that injection moulding provides higher uniformity and homogeneity of the particle-modified polylactide matrix, whereas hot pressing favours applying higher volume fractions of fibres and their better impregnation with the polymer matrix. Thus, it was concluded that the fabrication method should be individually selected dependently on the nail's desired phase composition. Copyright © 2015 Elsevier B.V. All rights reserved.

IMPLICATIONS OF VOCATIONAL EDUCATION FOR PLANT SITE LOCATION.

ERIC Educational Resources Information Center

DEAN, ERNEST H.

THE PURPOSE OF THIS PROJECT WAS TO DETERMINE THE SIGNIFICANCE OF VOCATIONAL-TECHNICAL EDUCATION IN THE MANUFACTURING INDUSTRY PLANT SITE SELECTION PROCESS. FROM A COMPOSITE LISTING OF 619 MANUFACTURING COMPANIES WHICH HAD LOCATED IN COLORADO, NEW MEXICO, ARIZONA, NEVADA, IDAHO, UTAH, AND WYOMING SINCE JANUARY 1960, 116 INTERVIEWS AND 90 COMPLETED…

Application of a design-build-team approach to low cost and weight composite fuselage structure

NASA Technical Reports Server (NTRS)

Ilcewicz, L. B.; Walker, T. H.; Willden, K. S.; Swanson, G. D.; Truslove, G.; Metschan, S. L.; Pfahl, C. L.

1991-01-01

Relationships between manufacturing costs and design details must be understood to promote the application of advanced composite technologies to transport fuselage structures. A team approach, integrating the disciplines responsible for aircraft structural design and manufacturing, was developed to perform cost and weight trade studies for a twenty-foot diameter aft fuselage section. Baseline composite design and manufacturing concepts were selected for large quadrant panels in crown, side, and keel areas of the fuselage section. The associated technical issues were also identified. Detailed evaluation of crown panels indicated the potential for large weight savings and costs competitive with aluminum technology in the 1995 timeframe. Different processes and material forms were selected for the various elements that comprise the fuselage structure. Additional cost and weight savings potential was estimated for future advancements.

Collector surface for a microwave tube comprising a carbon-bonded carbon-fiber composite

DOEpatents

Lauf, R.J.; McMillan, A.D.; Johnson, A.C.; Moorhead, A.J.

1998-07-28

In a microwave tube, an improved collector surface coating comprises a porous carbon composite material, preferably a carbon-bonded carbon fiber composite having a bulk density less than about 2 g/cc. Installation of the coating is readily adaptable as part of the tube manufacturing process. 4 figs.

Rapid production of hollow SS316 profiles by extrusion based additive manufacturing

NASA Astrophysics Data System (ADS)

Rane, Kedarnath; Cataldo, Salvatore; Parenti, Paolo; Sbaglia, Luca; Mussi, Valerio; Annoni, Massimiliano; Giberti, Hermes; Strano, Matteo

2018-05-01

Complex shaped stainless steel tubes are often required for special purpose biomedical equipment. Nevertheless, traditional manufacturing technologies, such as extrusion, lack the ability to compete in a market of customized complex components because of associated expenses towards tooling and extrusion presses. To rapid manufacture few of such components with low cost and high precision, a new Extrusion based Additive Manufacturing (EAM) process, is proposed in this paper, and as an example, short stainless steel 316L complex shaped and sectioned tubes were prepared by EAM. Several sample parts were produced using this process; the dimensional stability, surface roughness and chemical composition of sintered samples were investigated to prove process competence. The results indicate that feedstock with a 316L particle content of 92.5 wt. % can be prepared with a sigma blade mixing, whose rheological behavior is fit for EAM. The green samples have sufficient strength to handle them for subsequent treatments. The sintered samples considerably shrunk to designed dimensions and have a homogeneous microstructure to impart mechanical strength. Whereas, maintaining comparable dimensional accuracy and chemical composition which are required for biomedical equipment still need iterations, a kinematic correction and modification in debinding cycle was proposed.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Reents, W.D. Jr.

Particles present in the environment have significant affects in many areas from personal health due to atmospheric particles to various industrial processes that can be ruined due to particulate contamination such as semiconductor device manufacture and manufacture of sterile health products. The ability to detect deleterious contamination requires appropriate instrumentation to detect these particles. To prevent such contamination, the particle source must be identified by determining the composition of the offending particles. In a controlled environment, particle contamination often occurs in transients. In order to identify unknown particles, a technique must obtain compositional and size information regardless of particle identity,more » and perform this analysis in real-time so as to separate {open_quotes}background{close_quotes} particles from those produced in the transient event. Since processes are sensitive to certain particle size regimes and possibly, compositions, the instrumentation must be designed with these needs in mind. The authors have developed an instrument, the Ultra-Sensitive Particle Analysis System (USPAS) for situations where ultrafine particles, down to 0.002 micron, are of concern, such as the semiconductor manufacturing industry and the ambient environment.« less

Precision replenishable grinding tool and manufacturing process

DOEpatents

Makowiecki, D.M.; Kerns, J.A.; Blaedel, K.L.; Colella, N.J.; Davis, P.J.; Juntz, R.S.

1998-06-09

A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool are disclosed. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools. 11 figs.

Precision replenishable grinding tool and manufacturing process

DOEpatents

Makowiecki, Daniel M.; Kerns, John A.; Blaedel, Kenneth L.; Colella, Nicholas J.; Davis, Pete J.; Juntz, Robert S.

1998-01-01

A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools.

Study on the influence of design parameters on the damping property of glass fiber reinforced epoxy composite

NASA Astrophysics Data System (ADS)

Bhattacharjee, A.; Nanda, B. K.

2018-04-01

Fiber reinforced composites are widely used in industrial applications due to their high strength, light weight and ease in manufacturing. In applications such as automotive, aerospace and structural parts, the components are subjected to unwanted vibrations which reduce their service life, accuracy as well as increases noise. Therefore, it is essential to avoid the detrimental effects of vibrations by enhancing their damping characteristics. The current research deals with estimating the damping properties of Glass fiber reinforced epoxy (GFRE) composites. Processing of the GFRE composites is carried out using hand-lay technique. Various design parameters such as number of glass fiber layers, orientation of fibers and weight ratio are varied while manufacturing GFRE composites. The effects of variation of these design parameters on damping property of GFRE composites are studied extensively.

Society for the advancement of material and process engineering. 41st International SAMPE symposium and exhibition, Volume 41, Books 1 and 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

NONE

This document contains reports which were presented at the 41st International Society For The Advancement of Material and Process Engineering Symposium and Exhibition. Topics include: structural integrity of aging aircraft; composite materials development; affordable composites and processes; corrosion characterization of aging aircraft; adhesive advances; composite design; dual use materials and processing; repair of aircraft structures; adhesive inspection; materials systems for infrastructure; fire safety; composite impact/energy absorption; advanced materials for space; seismic retrofit; high temperature resins; preform technology; thermoplastics; alternative energy and transportation; manufacturing; and durability. Individual reports have been processed separately for the United States Department of Energy databases.

Water-Based Coating Simplifies Circuit Board Manufacturing

NASA Technical Reports Server (NTRS)

2008-01-01

The Structures and Materials Division at Glenn Research Center is devoted to developing advanced, high-temperature materials and processes for future aerospace propulsion and power generation systems. The Polymers Branch falls under this division, and it is involved in the development of high-performance materials, including polymers for high-temperature polymer matrix composites; nanocomposites for both high- and low-temperature applications; durable aerogels; purification and functionalization of carbon nanotubes and their use in composites; computational modeling of materials and biological systems and processes; and developing polymer-derived molecular sensors. Essentially, this branch creates high-performance materials to reduce the weight and boost performance of components for space missions and aircraft engine components. Under the leadership of chemical engineer, Dr. Michael Meador, the Polymers Branch boasts world-class laboratories, composite manufacturing facilities, testing stations, and some of the best scientists in the field.

Process for manufacturing an auto-collimating scintillator and product produced thereby

DOEpatents

Goodman, C.A.; Lyon, A.F.; Perez-Mendez, V.

1995-06-27

There is described a process for the vapor deposition of a scintillator phosphor composition with concomitant shadowing wherein the substrate to be processed is rotated through an arc relative to a vapor source of the scintillator phosphor composition whereby shadowing introduces voided gaps or interstices between columns as a result of the preferential components receiving more coating flux, particularly in the presence of oblique flux. 8 figs.

Process for manufacturing an auto-collimating scintillator and product produced thereby

DOEpatents

Goodman, Claude A.; Lyon, Alan F.; Perez-Mendez, Victor

1995-01-01

There is described a process for the vapor deposition of a scintillator phosphor composition with concomitant shadowing wherein the substrate to be processed is rotated through an arc relative to a vapor source of the scintillator phosphor composition whereby shadowing introduces voided gaps or interstices between columns as a result of the preferential components receiving more coating flux, particularly in the presence of oblique flux.

Advanced composites structural concepts and materials technologies for primary aircraft structures: Design/manufacturing concept assessment

NASA Technical Reports Server (NTRS)

Chu, Robert L.; Bayha, Tom D.; Davis, HU; Ingram, J. ED; Shukla, Jay G.

1992-01-01

Composite Wing and Fuselage Structural Design/Manufacturing Concepts have been developed and evaluated. Trade studies were performed to determine how well the concepts satisfy the program goals of 25 percent cost savings, 40 percent weight savings with aircraft resizing, and 50 percent part count reduction as compared to the aluminum Lockheed L-1011 baseline. The concepts developed using emerging technologies such as large scale resin transfer molding (RTM), automatic tow placed (ATP), braiding, out-of-autoclave and automated manufacturing processes for both thermoset and thermoplastic materials were evaluated for possible application in the design concepts. Trade studies were used to determine which concepts carry into the detailed design development subtask.

Advantages of utilizing DMD based rapid manufacturing systems in mass customization applications

NASA Astrophysics Data System (ADS)

El-Siblani, A.

2010-02-01

The Use of DMD based Rapid Manufacturing Systems has proven to be very advantageous in the production of highly accurate plastic based components for use in mass customization market such as hearing aids, and dental markets. The voxelization process currently afforded with the DLP technology eliminates any layering effect associated with all existing additive Rapid Manufacturing technologies. The smooth accurate surfaces produced in an additive process utilizing DLP technology, through the voxelization approach, allow for the production of custom finished products. The implementation of DLP technology in rapid prototyping and rapid manufacturing systems allow for the usage of highly viscous photopolymer based liquid and paste composites for rapid manufacturing that could not be used in any other additive process prior to implementation of DLP technology in RP and RM systems. It also allowed for the greater throughput in production without sacrificing quality and accuracy.

Surface Coating of Oxide Powders: A New Synthesis Method to Process Biomedical Grade Nano-Composites

PubMed Central

Palmero, Paola; Montanaro, Laura; Reveron, Helen; Chevalier, Jérôme

2014-01-01

Composite and nanocomposite ceramics have achieved special interest in recent years when used for biomedical applications. They have demonstrated, in some cases, increased performance, reliability, and stability in vivo, with respect to pure monolithic ceramics. Current research aims at developing new compositions and architectures to further increase their properties. However, the ability to tailor the microstructure requires the careful control of all steps of manufacturing, from the synthesis of composite nanopowders, to their processing and sintering. This review aims at deepening understanding of the critical issues associated with the manufacturing of nanocomposite ceramics, focusing on the key role of the synthesis methods to develop homogeneous and tailored microstructures. In this frame, the authors have developed an innovative method, named “surface-coating process”, in which matrix oxide powders are coated with inorganic precursors of the second phase. The method is illustrated into two case studies; the former, on Zirconia Toughened Alumina (ZTA) materials for orthopedic applications, and the latter, on Zirconia-based composites for dental implants, discussing the advances and the potential of the method, which can become a valuable alternative to the current synthesis process already used at a clinical and industrial scale. PMID:28788117

Integrating Materials, Manufacturing, Design and Validation for Sustainability in Future Transport Systems

NASA Astrophysics Data System (ADS)

Price, M. A.; Murphy, A.; Butterfield, J.; McCool, R.; Fleck, R.

2011-05-01

The predictive methods currently used for material specification, component design and the development of manufacturing processes, need to evolve beyond the current `metal centric' state of the art, if advanced composites are to realise their potential in delivering sustainable transport solutions. There are however, significant technical challenges associated with this process. Deteriorating environmental, political, economic and social conditions across the globe have resulted in unprecedented pressures to improve the operational efficiency of the manufacturing sector generally and to change perceptions regarding the environmental credentials of transport systems in particular. There is a need to apply new technologies and develop new capabilities to ensure commercial sustainability in the face of twenty first century economic and climatic conditions as well as transport market demands. A major technology gap exists between design, analysis and manufacturing processes in both the OEMs, and the smaller companies that make up the SME based supply chain. As regulatory requirements align with environmental needs, manufacturers are increasingly responsible for the broader lifecycle aspects of vehicle performance. These include not only manufacture and supply but disposal and re-use or re-cycling. In order to make advances in the reduction of emissions coupled with improved economic efficiency through the provision of advanced lightweight vehicles, four key challenges are identified as follows: Material systems, Manufacturing systems, Integrated design methods using digital manufacturing tools and Validation systems. This paper presents a project which has been designed to address these four key issues, using at its core, a digital framework for the creation and management of key parameters related to the lifecycle performance of thermoplastic composite parts and structures. It aims to provide capability for the proposition, definition, evaluation and demonstration of advanced lightweight structures for new generation vehicles in the context of whole life performance parameters.

Synchronized manufacture of composites knowledge study (SMACKS)

NASA Astrophysics Data System (ADS)

Strickland, B.; Oliver, M.

1990-06-01

The need for a competitive manufacturing knowledge base for the composites industry, encompasses a change from a 'functionally' organized factory to a product-based organization, and has led to major reductions in inventories, manufacturing costs and cycle times. The net effect was that products became more price- and delivery-competitive. It is believed that composite manufacturers have an equal need to improve their competitive edge, particularly as the demand for composite products grows and more manufacturers enter the marketplace. 'SMACKS' has begun to establish these needs and market trends, with a view to establishing the advantages offered to composite manufacturers by synchronized manufacturing methods.

CHARACTERIZATION OF MANUFACTURING PROCESSES AND EMISSIONS AND POLLUTION PREVENTION OPTIONS FOR THE COMPOSITE WOOD INDUSTRY

EPA Science Inventory

The report summarizes information gathered on emissions from the composite wood industry (also called the Plywood and particleboard industry) and potential pollution prevention options. Information was gathered during a literature search that included trade association publicatio...

Laminated composite of magnetic alloy powder and ceramic powder and process for making same

DOEpatents

Moorhead, Arthur J.; Kim, Hyoun-Ee

1999-01-01

A laminated composite structure of alternating metal powder layers, and layers formed of an inorganic bonding media powder, and a method for manufacturing same are discosed. The method includes the steps of assembling in a cavity alternating layers of a metal powder and an inorganic bonding media of a ceramic, glass, and glass-ceramic. Heat, with or without pressure, is applied to the alternating layers until the particles of the metal powder are sintered together and bonded into the laminated composite structure by the layers of sintered inorganic bonding media to form a strong composite structure. The method finds particular application in the manufacture of high performance magnets wherein the metal powder is a magnetic alloy powder.

Laminated composite of magnetic alloy powder and ceramic powder and process for making same

DOEpatents

Moorhead, A.J.; Kim, H.

1999-08-10

A laminated composite structure of alternating metal powder layers, and layers formed of an inorganic bonding media powder, and a method for manufacturing same are disclosed. The method includes the steps of assembling in a cavity alternating layers of a metal powder and an inorganic bonding media of a ceramic, glass, and glass-ceramic. Heat, with or without pressure, is applied to the alternating layers until the particles of the metal powder are sintered together and bonded into the laminated composite structure by the layers of sintered inorganic bonding media to form a strong composite structure. The method finds particular application in the manufacture of high performance magnets wherein the metal powder is a magnetic alloy powder. 9 figs.

A preliminary 'test case' manufacturing sequence for 50 cents/watt solar photovoltaic modules in 1986

NASA Technical Reports Server (NTRS)

Bickler, D. B.

1979-01-01

The paper describes a 'test case' manufacturing process sequence for solar photovoltaic modules which will cost 50 cents/watt in 1986. The process, which starts with the purification of silicon grown into 75-mm-wide thin ribbons, is discussed, and the plant layout is depicted; each department is sized to produce 250 MW of modules/per year. The cost of this process sequence is compared to present technology at various companies showing considerable spread for each process; data are tabulated in a composite state-of-the-art cell processing cost summary for these processes.

The Composites Institute`s FirstSource directory

DOE Office of Scientific and Technical Information (OSTI.GOV)

NONE

1998-12-31

This book is the gateway to the composites industry, containing pertinent phone numbers along with a glossary of terms. The glossary is a complete listing of current composites terminology and their definitions, from Ablative Plastic to Young`s Modulus. Contents include: (1) corporate index; (2) manufacturing processes; (3) materials suppliers; (4) markets--parts/products/components; (5) tooling; (6) processing equipment and supplies; (7) distributors/agents; (8) consulting, testing and other services; (9) geographical listing; and (10) glossary.

Applications for carbon fibre recovered from composites

NASA Astrophysics Data System (ADS)

Pickering; Liu, Z.; Turner, TA; Wong, KH

2016-07-01

Commercial operations to recover carbon fibre from waste composites are now developing and as more recovered fibre becomes available new applications for recovered fibre are required. Opportunities to use recovered carbon fibre as a structural reinforcement are considered involving the use of wet lay processes to produce nonwoven mats. Mats with random in-plane fibre orientation can readily be produced using existing commercial processes. However, the fibre volume fraction, and hence the mechanical properties that can be achieved, result in composites with limited mechanical properties. Fibre volume fractions of 40% can be achieved with high moulding pressures of over 100 bar, however, moulding at these pressures results in substantial fibre breakage which reduces the mean fibre length and the properties of the composite manufactured. Nonwoven mats made from aligned, short carbon fibres can achieve higher fibre volume fractions with lower fibre breakage even at high moulding pressure. A process for aligning short fibres is described and a composite of over 60% fibre volume fraction has been manufactured at a pressures up to 100 bar with low fibre breakage. Further developments of the alignment process have been undertaken and a composite of 46% fibre volume fraction has been produced moulded at a pressure of 7 bar in an autoclave, exhibiting good mechanical properties that compete with higher grade materials. This demonstrates the potential for high value applications for recovered carbon fibre by fibre alignment.

Viscoelastic processing and characterization of high-performance polymeric composite systems

NASA Astrophysics Data System (ADS)

Buehler, Frederic Ulysse

2000-10-01

Fiber reinforced composites, a combination of reinforcing fiber and resin matrix, offer many advantages over traditional materials, and have therefore found wide application in the aerospace and sporting goods industry. Among the advantages that composite materials offer, the most often cited are weight saving, high modulus, high strength-to-weight ratio, corrosion resistance, and fatigue resistance. As much as their attributes are desirable, composites are difficult to process due to their heterogeneous, anisotropic, and viscoelastic nature. It is therefore not surprising that the interrelationship between structure, property, and process is not fully understood. Consequently, the major purpose of this research work was to investigate this interrelationship, and ways to scale it to utilization. First, four prepreg materials, which performed differently in the manufacturing of composite parts, but were supposedly identical, were characterized. The property variations that were found among these prepregs in terms of tack and frictional resistance assessed the need for improved understanding of the prepregging process. Therefore, the influence of the processing parameters on final prepreg quality were investigated, and led to the definition of more adequate process descriptors. Additionally, one of the characterization techniques used in this work, temperature modulated differential scanning calorimetry, was examined in depth with the development of a mathematical model. This model, which enabled the exploration of the relationship between user parameters, sample thermophysical properties, and final results, was then compared to literature data. Collectively, this work explored and identified the key connectors between process, structure, and property as they relate to the manufacturing, design, and performance of composite materials.

Large Composite Structures Processing Technologies for Reusable Launch Vehicles

NASA Technical Reports Server (NTRS)

Clinton, R. G., Jr.; Vickers, J. H.; McMahon, W. M.; Hulcher, A. B.; Johnston, N. J.; Cano, R. J.; Belvin, H. L.; McIver, K.; Franklin, W.; Sidwell, D.

2001-01-01

Significant efforts have been devoted to establishing the technology foundation to enable the progression to large scale composite structures fabrication. We are not capable today of fabricating many of the composite structures envisioned for the second generation reusable launch vehicle (RLV). Conventional 'aerospace' manufacturing and processing methodologies (fiber placement, autoclave, tooling) will require substantial investment and lead time to scale-up. Out-of-autoclave process techniques will require aggressive efforts to mature the selected technologies and to scale up. Focused composite processing technology development and demonstration programs utilizing the building block approach are required to enable envisioned second generation RLV large composite structures applications. Government/industry partnerships have demonstrated success in this area and represent best combination of skills and capabilities to achieve this goal.

Control of formaldehyde and TVOC emission from wood-based flooring composites at various manufacturing processes by surface finishing.

PubMed

Kim, Sumin

2010-04-15

This paper assesses the reproducibility of testing formaldehyde and TVOC emission behavior from wood flooring composites bonded by urea-formaldehyde resin at various manufacturing steps for surface finishing materials. The surface adhesion step of laminate flooring for this research was divided into two steps; HDF only and HDF with LPMs. In the case of engineered flooring, the manufacturing steps were divided into three steps; plywood only, fancy veneer bonded on plywood and UV coated on fancy veneer with plywood. Formaldehyde and VOCs emission decreased at the process of final surface finishing materials; LPMs were applied on the surface of HDF for laminate flooring. Although emissions increased when fancy veneer was bonded onto plywood in the case of engineered flooring, emission was dramatically reduced up to similar level with plywood only when final surface finishing; UV-curable coating was applied on fancy veneer. This study suggests that formaldehyde and VOCs emission from floorings can be controlled at manufacturing steps for surface finishing. 2009 Elsevier B.V. All rights reserved.

Establishing the relationship between manufacturing and component performance in stretch formed thermoplastic composites

NASA Technical Reports Server (NTRS)

Santare, Michael H.; Pipes, R. Byron; Beaussart, A. J.; Coffin, D. W.; Otoole, B. J.; Shuler, S. F.

1993-01-01

Flexible manufacturing methods are needed to reduce the cost of using advanced composites in structural applications. One method that allows for this is the stretch forming of long discontinuous fiber materials with thermoplastic matrices. In order to exploit this flexibility in an economical way, a thorough understanding of the relationship between manufacturing and component performance must be developed. This paper reviews some of the recent work geared toward establishing this understanding. Micromechanics models have been developed to predict the formability of the material during processing. The latest improvement of these models includes the viscoelastic nature of the matrix and comparison with experimental data. A finite element scheme is described which can be used to model the forming process. This model uses equivalent anisotropic viscosities from the micromechanics models and predicts the microstructure in the formed part. In addition, structural models have been built to account for the material property gradients that can result from the manufacturing procedures. Recent developments in this area include the analysis of stress concentrations and a failure model each accounting for the heterogeneous material fields.

An Innovative Manufacturing of CCC Ion Thruster Grids by North Carolina A&T's RTM Carbon/Carbon Process

NASA Technical Reports Server (NTRS)

Haag, Thomas W. (Technical Monitor); Shivakumar, Kunigal N.

2003-01-01

Electric ion thrusters are the preferred engines for deep space missions, because of very high specific impulse. The ion engine consists of screen and accelerator grids containing thousands of concentric very small holes. The xenon gas accelerates between the two grids, thus developing the impulse force. The dominant life-limiting mechanism in the state-of-the-art molybdenum thrusters is the xenon ion sputter erosion of the accelerator grid. Carbon/carbon composites (CCC) have shown to be have less than 1/7 the erosion rates than the molybdenum, thus for interplanetary missions CCC engines are inevitable. Early effort to develop CCC composite thrusters had a limited success because of limitations of the drilling technology and the damage caused by drilling. The proposed is an in-situ manufacturing of holes while the CCC is made. Special low CTE molds will be used along with the NC A&T s patented resin transfer molding (RTM) technology to manufacture the CCC grids. First, a manufacture process for 10-cm diameter thruster grids will be developed and verified. Quality of holes, density, CTE, tension, flexure, transverse fatigue and sputter yield properties will be measured. After establishing the acceptable quality and properties, the process will be scaled to manufacture 30-cm diameter grids. The properties of the two grid sizes are compared with each other.

Materials and Process Activities for NASA's Composite Crew Module

NASA Technical Reports Server (NTRS)

Polis, Daniel L.

2012-01-01

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center (NESC) to design, build, and test a full-scale Composite Crew Module (CCM). The overall goal of the CCM project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project s baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. The materials and process activities were prioritized based on a rapid prototype approach. This approach focused developmental activities on design details with greater risk and uncertainty, such as out-of-autoclave joining, over some of the more traditional lamina and laminate building block levels. While process development and associated building block testing were performed, several anomalies were still observed at the full-scale level due to interactions between process robustness and manufacturing scale-up. This paper describes the process anomalies that were encountered during the CCM development and the subsequent root cause investigations that led to the final design solutions. These investigations highlight the importance of full-scale developmental work early in the schedule of a complex composite design/build project.

Effect of processing method on surface and weathering characteristics of wood-flour/HDPE composites

Treesearch

Nicole M. Stark; Laurent M. Matuana; Craig M. Clemons

2004-01-01

Wood-plastic lumber is promoted as a low maintenance high-durability product. When exposed to accelerated weathering, however, wood-plastic composites may experience a color change and/or loss in mechanical properties. Different methods of manufacturing wood-plastic composites lead to different surface characteristics, which can influence weathering, In this study, 50...

Effect of processing method on accelerated weathering of wood-flour/HDPE composites

Treesearch

Nicole M. Stark; Laurent M. Matuana; Craig M. Clemons

2003-01-01

Wood-plastic lumber is promoted as a low maintenance high-durability product. When exposed to accelerated weathering, however, wood-plastic composites may experience a color change and/or loss in mechanical properties. Different methods of manufacturing wood-plastic composites lead to different surface characteristics, which can influence weathering, In this study, 50...

Metal spar/superhybrid shell composite fan blades. [for application to turbofan engins

NASA Technical Reports Server (NTRS)

Salemme, C. T.; Murphy, G. C.

1979-01-01

The use of superhybrid materials in the manufacture and testing of large fan blades is analyzed. The FOD resistance of large metal spar/superhybrid fan blades is investigated. The technical effort reported was comprised of: (1) preliminary blade design; (2) detailed analysis of two selected superhybrid blade designs; (3) manufacture of two process evaluation blades and destructive evaluation; and (4) manufacture and whirligig testing of six prototype superhybrid blades.

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Lort, Richard D., III; Zimmerman, Thomas J.; Sutter, James K.; Pelham, Larry I.; McCorkle, Linda S.; Scheiman, Daniel A.

2012-01-01

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kg/sq m (3.1 lb/cu ft (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Lort, Richard D., III; Zimmerman, Thomas J.; Sutter, James K.; Pelham, Larry I.; McCorkle, Linda S.; Scheiman, Daniel A.

2012-01-01

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Optimization of process parameters in drilling of fibre hybrid composite using Taguchi and grey relational analysis

NASA Astrophysics Data System (ADS)

Vijaya Ramnath, B.; Sharavanan, S.; Jeykrishnan, J.

2017-03-01

Nowadays quality plays a vital role in all the products. Hence, the development in manufacturing process focuses on the fabrication of composite with high dimensional accuracy and also incurring low manufacturing cost. In this work, an investigation on machining parameters has been performed on jute-flax hybrid composite. Here, the two important responses characteristics like surface roughness and material removal rate are optimized by employing 3 machining input parameters. The input variables considered are drill bit diameter, spindle speed and feed rate. Machining is done on CNC vertical drilling machine at different levels of drilling parameters. Taguchi’s L16 orthogonal array is used for optimizing individual tool parameters. Analysis Of Variance is used to find the significance of individual parameters. The simultaneous optimization of the process parameters is done by grey relational analysis. The results of this investigation shows that, spindle speed and drill bit diameter have most effect on material removal rate and surface roughness followed by feed rate.

Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing

PubMed Central

Hofmann, Douglas C.; Roberts, Scott; Otis, Richard; Kolodziejska, Joanna; Dillon, R. Peter; Suh, Jong-ook; Shapiro, Andrew A.; Liu, Zi-Kui; Borgonia, John-Paul

2014-01-01

Interest in additive manufacturing (AM) has dramatically expanded in the last several years, owing to the paradigm shift that the process provides over conventional manufacturing. Although the vast majority of recent work in AM has focused on three-dimensional printing in polymers, AM techniques for fabricating metal alloys have been available for more than a decade. Here, laser deposition (LD) is used to fabricate multifunctional metal alloys that have a strategically graded composition to alter their mechanical and physical properties. Using the technique in combination with rotational deposition enables fabrication of compositional gradients radially from the center of a sample. A roadmap for developing gradient alloys is presented that uses multi-component phase diagrams as maps for composition selection so as to avoid unwanted phases. Practical applications for the new technology are demonstrated in low-coefficient of thermal expansion radially graded metal inserts for carbon-fiber spacecraft panels. PMID:24942329

Advanced Manufacturing at the Marshall Space Flight Center and Application to Ares I and Ares V Launch Vehicles

NASA Technical Reports Server (NTRS)

Carruth, Ralph

2008-01-01

There are various aspects of advanced manufacturing technology development at the field centers of the National Aeronautics and Space Administration (NASA). The Marshall Space Flight Center (MSFC) has been given the assignment to lead the National Center for Advanced Manufacturing (NCAM) at MSFC and pursue advanced development and coordination with other federal agencies for NASA. There are significant activities at the Marshall Center as well as at the Michoud Assembly Facility (MAF) in New Orleans which we operate in conjunction with the University of New Orleans. New manufacturing processes in metals processing, component development, welding operations, composite manufacturing and thermal protection system material and process development will be utilized in the manufacturing of the United States two new launch vehicles, the Ares I and the Ares V. An overview of NCAM will be presented as well as some of the development activities and manufacturing that are ongoing in Ares Upper Stage development. Some of the tools and equipment produced by Italian owned companies and their application in this work will be mentioned.

Composite Cure Process Modeling and Simulations using COMPRO(Registered Trademark) and Validation of Residual Strains using Fiber Optics Sensors

NASA Technical Reports Server (NTRS)

Sreekantamurthy, Thammaiah; Hudson, Tyler B.; Hou, Tan-Hung; Grimsley, Brian W.

2016-01-01

Composite cure process induced residual strains and warping deformations in composite components present significant challenges in the manufacturing of advanced composite structure. As a part of the Manufacturing Process and Simulation initiative of the NASA Advanced Composite Project (ACP), research is being conducted on the composite cure process by developing an understanding of the fundamental mechanisms by which the process induced factors influence the residual responses. In this regard, analytical studies have been conducted on the cure process modeling of composite structural parts with varied physical, thermal, and resin flow process characteristics. The cure process simulation results were analyzed to interpret the cure response predictions based on the underlying physics incorporated into the modeling tool. In the cure-kinetic analysis, the model predictions on the degree of cure, resin viscosity and modulus were interpreted with reference to the temperature distribution in the composite panel part and tool setup during autoclave or hot-press curing cycles. In the fiber-bed compaction simulation, the pore pressure and resin flow velocity in the porous media models, and the compaction strain responses under applied pressure were studied to interpret the fiber volume fraction distribution predictions. In the structural simulation, the effect of temperature on the resin and ply modulus, and thermal coefficient changes during curing on predicted mechanical strains and chemical cure shrinkage strains were studied to understand the residual strains and stress response predictions. In addition to computational analysis, experimental studies were conducted to measure strains during the curing of laminated panels by means of optical fiber Bragg grating sensors (FBGs) embedded in the resin impregnated panels. The residual strain measurements from laboratory tests were then compared with the analytical model predictions. The paper describes the cure process procedures and residual strain predications, and discusses pertinent experimental results from the validation studies.

Dry Process for Manufacturing Hybridized Boron Fiber/Carbon Fiber Thermoplastic Composite Materials from a Solution Coated Precursor

NASA Technical Reports Server (NTRS)

Belvin, Harry L. (Inventor); Cano, Roberto J. (Inventor)

2003-01-01

An apparatus for producing a hybrid boron reinforced polymer matrix composite from precursor tape and a linear array of boron fibers. The boron fibers are applied onto the precursor tapes and the precursor tape processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the precursor tape with the boron fibers becomes a hybrid boron reinforced polymer matrix composite. A driving mechanism is used to pulled the precursor tape through the method and a take-up spool is used to collect the formed hybrid boron reinforced polymer matrix composite.

Composites Manufacturing Education and Technology Facility Expedites Manufacturing Innovation

DOE Office of Scientific and Technical Information (OSTI.GOV)

The Composites Manufacturing Education and Technology facility (CoMET) at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) paves the way for innovative wind turbine components and accelerated manufacturing. Available for use by industry partners and university researchers, the 10,000-square-foot facility expands NREL's composite manufacturing research capabilities by enabling researchers to design, prototype, and test composite wind turbine blades and other components -- and then manufacture them onsite. Designed to work in conjunction with NREL's design, analysis, and structural testing capabilities, the CoMET facility expedites manufacturing innovation.

The Institute for Advanced Composites Manufacturing Innovation | Wind |

Science.gov Websites

NREL The Institute for Advanced Composites Manufacturing Innovation The Institute for Advanced Composites Manufacturing Innovation Building on its 30-year history of collaboration with major wind turbine of the Institute for Advanced Composites Manufacturing Innovation (IACMI). Photo of a crowd of people

Magnet Assisted Composite Manufacturing: A Flexible New Technique for Achieving High Consolidation Pressure in Vacuum Bag/Lay-Up Processes.

PubMed

Pishvar, Maya; Amirkhosravi, Mehrad; Altan, M Cengiz

2018-05-17

This work demonstrates a protocol to improve the quality of composite laminates fabricated by wet lay-up vacuum bag processes using the recently developed magnet assisted composite manufacturing (MACM) technique. In this technique, permanent magnets are utilized to apply a sufficiently high consolidation pressure during the curing stage. To enhance the intensity of the magnetic field, and thus, to increase the magnetic compaction pressure, the magnets are placed on a magnetic top plate. First, the entire procedure of preparing the composite lay-up on a magnetic bottom steel plate using the conventional wet lay-up vacuum bag process is described. Second, placement of a set of Neodymium-Iron-Boron permanent magnets, arranged in alternating polarity, on the vacuum bag is illustrated. Next, the experimental procedures to measure the magnetic compaction pressure and volume fractions of the composite constituents are presented. Finally, methods used to characterize microstructure and mechanical properties of composite laminates are discussed in detail. The results prove the effectiveness of the MACM method in improving the quality of wet lay-up vacuum bag laminates. This method does not require large capital investment for tooling or equipment and can also be used to consolidate geometrically complex composite parts by placing the magnets on a matching top mold positioned on the vacuum bag.

The Effect of Tow Shearing on Reinforcement Positional Fidelity in the Manufacture of a Continuous Fiber Reinforced Thermoplastic Matrix Composite via Pultrusion-Like Processing of Commingled Feedstock

NASA Astrophysics Data System (ADS)

Warlick, Kent M.

While the addition of short fiber to 3D printed articles has increased structural performance, ultimate gains will only be realized through the introduction of continuous reinforcement placed along pre-planned load paths. Most additive manufacturing research focusing on the addition of continuous reinforcement has revolved around utilization of a prefrabricated composite filament or a fiber and matrix mixed within a hot end prior to deposition on a printing surface such that conventional extrusion based FDM can be applied. Although stronger 3D printed parts can be made in this manner, high quality homogenous composites are not possible due to fiber dominated regions, matrix dominated regions, and voids present between adjacent filaments. Conventional composite manufacturing processes are much better at creating homogeneous composites; however, the layer by layer approach in which they are made is inhibiting the alignment of reinforcement with loads. Automated Fiber Placement techniques utilize in plane bending deformation of the tow to facilitate tow steering. Due to buckling fibers on the inner radius of curves, manufacturers recommend a minimum curvature for path placement with this technique. A method called continuous tow shearing has shown promise to enable the placement of tows in complex patterns without tow buckling, spreading, and separation inherent in conventional forms of automated reinforcement positioning. The current work employs fused deposition modeling hardware and the continuous tow shearing technique to manufacture high quality fiber reinforced composites with high positional fidelity, varying continuous reinforcement orientations within a layer, and plastic elements incorporated enabling the ultimate gains in structural performance possible. A mechanical system combining concepts of additive manufacturing with fiber placement via filament winding was developed. Paths with and without tension inherent in filament winding were analyzed through microscopy in order to examine best and worst case scenarios. High quality fiber reinforced composite materials, in terms of low void content, high fiber volume fractions and homogeneity in microstructure, were manufactured in both of these scenarios. In order to improve fidelity and quality in fiber path transition regions, a forced air cooling manifold was designed, printed, and implemented into the current system. To better understand the composite performance that results from varying pertinent manufacturing parameters, the effect of feed rate, hot end temperature, forced air cooling, and deposition surface (polypropylene and previously deposited glass polypropylene commingled tow) on interply performance, microstructure, and positional fidelity were analyzed. Interply performance, in terms of average maximum load and average peel strength, was quantified through a t-peel test of the bonding quality between two surfaces. With use of forced air cooling, minor decreases in average peel strength were present due to a reduction in tow deposition temperature which was found to be the variable most indicative of performance. Average maximum load was comparable between the forced air cooled and non-air cooled samples. Microstructure was evaluated through characterization of composite area, void content, and flash percentage. Low void contents mostly between five to seven percent were attained. Further reduction of this void content to two percent is possible through higher processing temperatures; however, reduced composite area, low average peel strength performance, and the presence of smoke during manufacturing implied thermal degradation of the polypropylene matrix occurred in these samples with higher processing temperatures. Positional fidelity was measured through calculations of shear angle, shift width, and error of a predefined path. While positional fidelity variation was low with a polypropylene deposition surface, forced air cooling is necessary to achieve fidelity on top of an already deposited tow surface as evident by the fifty-six percent reduction in error tolerance profile achieved. Lastly, proof of concept articles with unique fiber paths and neat plastic elements incorporated were produced to demonstrate fiber placement along pre-planned load paths and the ability to achieve greater structural efficiency through the use of less material. The results show that high positional fidelity and high quality composites can be produced through the use of the tow shearing technique implemented in the developed mechanical system. The implementation of forced air cooling was critical in achieving fidelity and quality in transition regions. Alignment of continuous reinforcement with pre-planned load paths was demonstrated in the proof of concept article with varying fiber orientations within a layer. Combining fused deposition modeling of plastic with the placement of continuous reinforcement enabled a honeycomb composite to be produced with higher specific properties than traditional composites. Thus, the current system demonstrated a greater capability of achieving ultimate gains in structural performance than previously possible.

Toughening and healing of composites by CNTs reinforced copolymer nylon micro-particles

NASA Astrophysics Data System (ADS)

Kostopoulos, V.; Kotrotsos, A.; Tsokanas, P.; Tsantzalis, S.

2018-02-01

In this work, nylon micro-particles, both undoped and doped with multiwall carbon nanotubes played the role of the self-healing agent into carbon fibre/epoxy composites (CFRPs). These micro-particles were blended with epoxy matrix and the resulting mixture was used for the composites fabrication. Three types of composites were manufactured; the reference CFRP and the modified CFRPs with undoped and doped nylon micro-particles. After manufacturing, these composites were tested under mode I and II fracture loading conditions and it was shown that the interlaminar fracture toughness characteristics of both nylon modified composites were significantly increased. After first fracture, healing process was activated for the tested nylon modified samples and revealed high fracture toughness characteristics recovery. Morphology examinations supported the results and elucidated the involved toughening and failure mechanisms. Finally, the in-plane mechanical and thermo-mechanical properties of all the composites were characterized for identifying possible knock-down effects due to the nylon modification of composites.

Development of Specialized Advanced Materials Curriculum.

ERIC Educational Resources Information Center

Malmgren, Thomas; And Others

This course is intended to give students a comprehensive experience in current and future manufacturing materials and processes. It familiarizes students with: (1) base of composite materials; (2) composites--a very light, strong material used in spacecraft and stealth aircraft; (3) laminates; (4) advanced materials--especially aluminum alloys;…

A New Fiber Preform with Nanocarbon Binder for Manufacturing Carbon Fiber Reinforced Composite by Liquid Molding Process.

PubMed

Seong, Dong Gi; Ha, Jong Rok; Lee, Jea Uk; Lee, Wonoh; Kim, Byung Sun

2015-11-01

Carbon fiber reinforced composite has been a good candidate of lightweight structural component in the automotive industry. As fast production speed is essential to apply the composite materials for the mass production area such as automotive components, the high speed liquid composite molding processes have been developed. Fast resin injection through the fiber preform by high pressure is required to improve the production speed, but it often results in undesirable deformations of the fiber preform which causes defectives in size and properties of the final composite products. In order to prevent the undesirable deformation and improve the stability of preform shape, polymer type binder materials are used. More stable fiber preform can be obtained by increasing the amount of binder material, but it disturbs the resin impregnation through the fiber preform. In this study, carbon nanomaterials such as graphene oxide were embedded on the surface of carbon fiber by electrophoretic deposition method in order to improve the shape stability of fiber preform and interfacial bonding between polymer and the reinforcing fiber. Effects of the modified reinforcing fiber were investigated in two respects. One is to increase the binding energy between fiber tows, and the other is to increase the interfacial bonding between polymer matrix and fiber surface. The effects were analyzed by measuring the binding force of fiber preform and interlaminar shear strength of the composite. This study also investigated the high speed liquid molding process of the composite materials composed of polymer matrix and the carbon fiber preforms embedded by carbon nanomaterials. Process parameter such as permeability of fiber preform was measured to investigate the effect of nanoscale surface modification on the macroscale processing condition for composite manufacturing.

Design and Evaluation of Glass/epoxy Composite Blade and Composite Tower Applied to Wind Turbine

NASA Astrophysics Data System (ADS)

Park, Hyunbum

2018-02-01

In the study, the analysis and manufacturing of small class wind turbine blade was performed. In the structural design, firstly the loading conditions are defined through the load case analysis. The proposed structural configuration of blade has a sandwich type composite structure with the E-glass/Epoxy face sheets and the Urethane foam core for lightness, structural stability, low manufacturing cost and easy manufacturing process. And also, this work proposes a design procedure and results of tower for the small scale wind turbine systems. Structural analysis of blade including load cases, stress, deformation, buckling, vibration and fatigue life was performed using the finite element method, the load spectrum analysis and the Miner rule. Moreover, investigation on structural safety of tower was verified through structural analysis by FEM. The manufacturing of blade and tower was performed based on structural design. In order to investigate the designed structure, the structural tests were conducted and its results were compared with the calculated results. It is confirmed that the final proposed blade and tower meet the design requirements.

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carpenter, John S.; Beese, Allison M.; Bourell, David L.

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2015-06-26

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Resin-composite blocks for dental CAD/CAM applications.

PubMed

Ruse, N D; Sadoun, M J

2014-12-01

Advances in digital impression technology and manufacturing processes have led to a dramatic paradigm shift in dentistry and to the widespread use of computer-aided design/computer-aided manufacturing (CAD/CAM) in the fabrication of indirect dental restorations. Research and development in materials suitable for CAD/CAM applications are currently the most active field in dental materials. Two classes of materials are used in the production of CAD/CAM restorations: glass-ceramics/ceramics and resin composites. While glass-ceramics/ceramics have overall superior mechanical and esthetic properties, resin-composite materials may offer significant advantages related to their machinability and intra-oral reparability. This review summarizes recent developments in resin-composite materials for CAD/CAM applications, focusing on both commercial and experimental materials. © International & American Associations for Dental Research.

Standardization of Good Manufacturing Practice-compliant production of bone marrow-derived human mesenchymal stromal cells for immunotherapeutic applications.

PubMed

Wuchter, Patrick; Bieback, Karen; Schrezenmeier, Hubert; Bornhäuser, Martin; Müller, Lutz P; Bönig, Halvard; Wagner, Wolfgang; Meisel, Roland; Pavel, Petra; Tonn, Torsten; Lang, Peter; Müller, Ingo; Renner, Matthias; Malcherek, Georg; Saffrich, Rainer; Buss, Eike C; Horn, Patrick; Rojewski, Markus; Schmitt, Anita; Ho, Anthony D; Sanzenbacher, Ralf; Schmitt, Michael

2015-02-01

Human mesenchymal stem or stromal cells (MSCs) represent a potential resource not only for regenerative medicine but also for immunomodulatory cell therapies. The application of different MSC culture protocols has significantly hampered the comparability of experimental and clinical data from different laboratories and has posed a major obstacle for multicenter clinical trials. Manufacturing of cell products for clinical application in the European Community must be conducted in compliance with Good Manufacturing Practice and requires a manufacturing license. In Germany, the Paul-Ehrlich-Institut as the Federal Authority for Vaccines and Biomedicines is critically involved in the approval process. This report summarizes a consensus meeting between researchers, clinicians and regulatory experts on standard quality requirements for MSC production. The strategy for quality control testing depends on the product's cell composition, the manufacturing process and the indication and target patient population. Important quality criteria in this sense are, among others, the immunophenotype of the cells, composition of the culture medium and the risk for malignant transformation, as well as aging and the immunosuppressive potential of the manufactured MSCs. This position paper intends to provide relevant information to interested parties regarding these criteria to foster the development of scientifically valid and harmonized quality standards and to support approval of MSC-based investigational medicinal products. Copyright © 2015 International Society for Cellular Therapy. Published by Elsevier Inc. All rights reserved.

Continuous manufacturing of extended release tablets via powder mixing and direct compression.

PubMed

Ervasti, Tuomas; Simonaho, Simo-Pekka; Ketolainen, Jarkko; Forsberg, Peter; Fransson, Magnus; Wikström, Håkan; Folestad, Staffan; Lakio, Satu; Tajarobi, Pirjo; Abrahmsén-Alami, Susanna

2015-11-10

The aim of the current work was to explore continuous dry powder mixing and direct compression for manufacturing of extended release (ER) matrix tablets. The study was span out with a challenging formulation design comprising ibuprofen compositions with varying particle size and a relatively low amount of the matrix former hydroxypropyl methylcellulose (HPMC). Standard grade HPMC (CR) was compared to a recently developed direct compressible grade (DC2). The work demonstrate that ER tablets with desired quality attributes could be manufactured via integrated continuous mixing and direct compression. The most robust tablet quality (weight, assay, tensile strength) was obtained using high mixer speed and large particle size ibuprofen and HPMC DC2 due to good powder flow. At low mixer speed it was more difficult to achieve high quality low dose tablets. Notably, with HPMC DC2 the processing conditions had a significant effect on drug release. Longer processing time and/or faster mixer speed was needed to achieve robust release with compositions containing DC2 compared with those containing CR. This work confirms the importance of balancing process parameters and material properties to find consistent product quality. Also, adaptive control is proven a pivotal means for control of continuous manufacturing systems. Copyright © 2015 Elsevier B.V. All rights reserved.

Electrohydrodynamic Printing and Manufacturing

NASA Technical Reports Server (NTRS)

Aksay, Ilhan A. (Inventor); Poon, Hak Fei (Inventor); Korkut, Sibel (Inventor); Saville, Dudley A. (Inventor); Chen, Chuan-hua (Inventor)

2014-01-01

An stable electrohydrodynamic filament is obtained by causing a straight electrohydrodynamic filament formed from a liquid to emerge from a Taylor cone, the filament having a diameter of from 10 nm to 100.mu.m. Such filaments are useful in electrohydrodynamic printing and manufacturing techniques and their application in liquid drop/particle and fiber production, colloidal deployment and assembly, and composite materials processing.

Properties of Organic Matrix Short Fiber Composites

DTIC Science & Technology

1982-02-01

reinforced SMC composites ( Owens Corning Fiberglas System) ............... ........................ ... 37 4 Schematic of process used to manufacture XMC...71 Vi F, viii. TLST OF TABLES TABLEPAE 1 Material formulations and densitius of SMC materials (PPG-PPG Industries, OFC- Owens Corning Fiberglas) (refs...Composite Materials, 14 (April 1980) , 142-154. 16 ,. Table 1. Material formulations and densities of SMC materials. (PPG-PPG Industries, OFC- Owens

2D net shape weaving for cost effective manufacture of textile reinforced composites

NASA Astrophysics Data System (ADS)

Vo, D. M. P.; Kern, M.; Hoffmann, G.; Cherif, C.

2017-10-01

Despite significant weight and performance advantages over metal parts, the today’s demand for fibre-reinforced polymer composites (FRPC) has been limited mainly by their large manufacturing cost. The combination of dry textile preforms and low-cost consolidation processes such as resin transfer molding (RTM) has been appointed as a promising approach to low-cost FRPC manufacture. At the current state of the art, tooling and impregnation technology is well understood whereas preform fabrication technology has not been developed effectively. This paper presents an advanced 2D net shape weaving technology developed with the aim to establish a more cost effective system for the manufacture of dry textile preforms for FRPC. 2D net shape weaving is developed based on open reed weave (ORW) technology and enables the manufacture of 2D contoured woven fabrics with firm edge, so that oversize cutting and hand trimming after molding are no longer required. The introduction of 2D net shape woven fabrics helps to reduce material waste, cycle time and preform manufacturing cost significantly. Furthermore, higher grade of automation in preform fabrication can be achieved.

Nanofibre distribution in composites manufactured with epoxy reinforced with nanofibrillated cellulose: model prediction and verification

NASA Astrophysics Data System (ADS)

Aitomäki, Yvonne; Westin, Mikael; Korpimäki, Jani; Oksman, Kristiina

2016-07-01

In this study a model based on simple scattering is developed and used to predict the distribution of nanofibrillated cellulose in composites manufactured by resin transfer moulding (RTM) where the resin contains nanofibres. The model is a Monte Carlo based simulation where nanofibres are randomly chosen from probability density functions for length, diameter and orientation. Their movements are then tracked as they advance through a random arrangement of fibres in defined fibre bundles. The results of the model show that the fabric filters the nanofibres within the first 20 µm unless clear inter-bundle channels are available. The volume fraction of the fabric fibres, flow velocity and size of nanofibre influence this to some extent. To verify the model, an epoxy with 0.5 wt.% Kraft Birch nanofibres was made through a solvent exchange route and stained with a colouring agent. This was infused into a glass fibre fabric using an RTM process. The experimental results confirmed the filtering of the nanofibres by the fibre bundles and their penetration in the fabric via the inter-bundle channels. Hence, the model is a useful tool for visualising the distribution of the nanofibres in composites in this manufacturing process.

Scaffolds with a standardized macro-architecture fabricated from several calcium phosphate ceramics using an indirect rapid prototyping technique

PubMed Central

Wilson, C. E.; van Blitterswijk, C. A.; Verbout, A. J.; de Bruijn, J. D.

2010-01-01

Calcium phosphate ceramics, commonly applied as bone graft substitutes, are a natural choice of scaffolding material for bone tissue engineering. Evidence shows that the chemical composition, macroporosity and microporosity of these ceramics influences their behavior as bone graft substitutes and bone tissue engineering scaffolds but little has been done to optimize these parameters. One method of optimization is to place focus on a particular parameter by normalizing the influence, as much as possible, of confounding parameters. This is difficult to accomplish with traditional fabrication techniques. In this study we describe a design based rapid prototyping method of manufacturing scaffolds with virtually identical macroporous architectures from different calcium phosphate ceramic compositions. Beta-tricalcium phosphate, hydroxyapatite (at two sintering temperatures) and biphasic calcium phosphate scaffolds were manufactured. The macro- and micro-architectures of the scaffolds were characterized as well as the influence of the manufacturing method on the chemistries of the calcium phosphate compositions. The structural characteristics of the resulting scaffolds were remarkably similar. The manufacturing process had little influence on the composition of the materials except for the consistent but small addition of, or increase in, a beta-tricalcium phosphate phase. Among other applications, scaffolds produced by the method described provide a means of examining the influence of different calcium phosphate compositions while confidently excluding the influence of the macroporous structure of the scaffolds. PMID:21069558

Evaluation of mycelium reinforced agricultural fiber biocomposites for diverse applications

USDA-ARS?s Scientific Manuscript database

There is a genuine need for new biodegradable alternatives to the inert plastics and expanded foams that are common in both manufacturing processes and device componentry. The material emphasized in this report is a bio-composite patented by Ecovative Design, LLC. The bio-composite utilizes fungus m...

Modelling the development of defects during composite reinforcements and prepreg forming

PubMed Central

Hamila, N.; Madeo, A.

2016-01-01

Defects in composite materials are created during manufacture to a large extent. To avoid them as much as possible, it is important that process simulations model the onset and the development of these defects. It is then possible to determine the manufacturing conditions that lead to the absence or to the controlled presence of such defects. Three types of defects that may appear during textile composite reinforcement or prepreg forming are analysed and modelled in this paper. Wrinkling is one of the most common flaws that occur during textile composite reinforcement forming processes. The influence of the different rigidities of the textile reinforcement is studied. The concept of ‘locking angle’ is questioned. A second type of unusual behaviour of fibrous composite reinforcements that can be seen as a flaw during their forming process is the onset of peculiar ‘transition zones’ that are directly related to the bending stiffness of the fibres. The ‘transition zones’ are due to the bending stiffness of fibres. The standard continuum mechanics of Cauchy is not sufficient to model these defects. A second gradient approach is presented that allows one to account for such unusual behaviours and to master their onset and development during forming process simulations. Finally, the large slippages that may occur during a preform forming are discussed and simulated with meso finite-element models used for macroscopic forming. This article is part of the themed issue ‘Multiscale modelling of the structural integrity of composite materials’. PMID:27242300

Modelling the development of defects during composite reinforcements and prepreg forming.

PubMed

Boisse, P; Hamila, N; Madeo, A

2016-07-13

Defects in composite materials are created during manufacture to a large extent. To avoid them as much as possible, it is important that process simulations model the onset and the development of these defects. It is then possible to determine the manufacturing conditions that lead to the absence or to the controlled presence of such defects. Three types of defects that may appear during textile composite reinforcement or prepreg forming are analysed and modelled in this paper. Wrinkling is one of the most common flaws that occur during textile composite reinforcement forming processes. The influence of the different rigidities of the textile reinforcement is studied. The concept of 'locking angle' is questioned. A second type of unusual behaviour of fibrous composite reinforcements that can be seen as a flaw during their forming process is the onset of peculiar 'transition zones' that are directly related to the bending stiffness of the fibres. The 'transition zones' are due to the bending stiffness of fibres. The standard continuum mechanics of Cauchy is not sufficient to model these defects. A second gradient approach is presented that allows one to account for such unusual behaviours and to master their onset and development during forming process simulations. Finally, the large slippages that may occur during a preform forming are discussed and simulated with meso finite-element models used for macroscopic forming. This article is part of the themed issue 'Multiscale modelling of the structural integrity of composite materials'. © 2016 The Author(s).

Multilayer composites and manufacture of same

DOEpatents

Holesinger, Terry G.; Jia, Quanxi

2006-02-07

The present invention is directed towards a process of depositing multilayer thin films, disk-shaped targets for deposition of multilayer thin films by a pulsed laser or pulsed electron beam deposition process, where the disk-shaped targets include at least two segments with differing compositions, and a multilayer thin film structure having alternating layers of a first composition and a second composition, a pair of the alternating layers defining a bi-layer wherein the thin film structure includes at least 20 bi-layers per micron of thin film such that an individual bi-layer has a thickness of less than about 100 nanometers.

Process and assembly plans for low cost commercial fuselage structure

NASA Technical Reports Server (NTRS)

Willden, Kurtis; Metschan, Stephen; Starkey, Val

1991-01-01

Cost and weight reduction for a composite structure is a result of selecting design concepts that can be built using efficient low cost manufacturing and assembly processes. Since design and manufacturing are inherently cost dependent, concurrent engineering in the form of a Design-Build Team (DBT) is essential for low cost designs. Detailed cost analysis from DBT designs and hardware verification must be performed to identify the cost drivers and relationships between design and manufacturing processes. Results from the global evaluation are used to quantitatively rank design, identify cost centers for higher ranking design concepts, define and prioritize a list of technical/economic issues and barriers, and identify parameters that control concept response. These results are then used for final design optimization.

Structural evaluation of curved stiffened composite panels fabricated using a THERM-Xsm process

NASA Technical Reports Server (NTRS)

Kassapoglou, Christos; Dinicola, Albert J.; Chou, Jack C.; Deaton, Jerry W.

1991-01-01

The use of composites in aircraft structures is often limited by material and manufacturing costs which, for some designs and applications, are prohibitively high. To increase the frequency of application of composites in primary airframe components alternative manufacturing processes are sought that reduce cost and/or enhance structural efficiency. One alternative process involves the use of THERM-Xsm as the pressure transfer medium during autoclave curing. THERM-Xsm, a silicon-based flow able polymer which behaves like a liquid under autoclave presssure, transmits quasi-hydrostatic pressure to all contacting surfaces of the part to be cured. Once the autoclave pressure is relieved, THERM-Xsm reverts back to the powdery solid state and can be reused many times. The THERM-Xsm process to be evaluated is depicted and consists of (1) enclosing the tool and part to be cured by a set of frames that create a box, (2) pouring THERM-Xsm powder onto the part and filling the box, and (3) placing a vacuum bag over the box assembly. In this program, a separating non-porous film (Teflon) was placed between the part to be cured and THERM-Xsm powder to avoid any contamination. The use of THERM-Xsm has two significant advantages over conventional manufacturing procedures. First, it eliminates complicated hard tooling since it guarantees uniform pressure transfer and thus, good compaction at complex structural details (such as frame-stiffener intersections and corners). Second, it greatly simplifies vacuum bagging, since once the part to be cured is covered by THERM-Xsm powder, the vacuum bag need only conform to a relatively flat shape reducing significantly the number of pleats required. A program is on-going at Sikorsky Aircraft to evaluate the structural performance of complex composite fuselage structures made with this THERM-Xsm process and to quantify the impact of THERM-Xsm on manufacturing labor hours and cost. The program involves fuselage panel optimization analysis, a building block test program where structural details representative of the full-scale article are analyzed and tested, and static and fatigue test/analysis of the full-scale test articles. The main results of this program are reported.

Effect of HNT on the Microstructure, Thermal and Mechanical Properties of Al/FACS-HNT Composites Produced by GPI

NASA Astrophysics Data System (ADS)

Siewiorek, A.; Malczyk, P.; Sobczak, N.; Sobczak, J. J.; Czulak, A.; Kozera, R.; Gude, M.; Boczkowska, A.; Homa, M.

2016-08-01

To develop an optimised manufacturing method of fly ash-reinforced metal matrix composites, the preliminary tests were performed on the cenospheres selected from fly ash (FACS) with halloysite nanotubes (HNTs) addition. The preform made out of FACS with and without the addition of HNT (with 5 and 10 wt.%) has been infiltrated by the pure aluminium (Al) via adapted gas pressure infiltration process. This paper reveals the influence of HNT addition on the microstructure (analysis was done by computed tomography and scanning electron microscopy combined with energy-dispersive x-ray spectroscopy), thermal properties (thermal expansion coefficient, thermal conductivity and specific heat) and the mechanical properties (hardness and compression test) of manufactured composites. The analysis of structure-property relationships for Al/FACS-HNT composites produced shows that the addition of 5 wt.% of HNT to FACS preform contributes to receiving of the best mechanical and structural properties of investigated composites.

Manufacturing of composite titanium-titanium nitride coatings by reactive very low pressure plasma spraying (R-VLPPS)

NASA Astrophysics Data System (ADS)

Vautherin, B.; Planche, M.-P.; Quet, A.; Bianchi, L.; Montavon, G.

2014-11-01

Very Low Pressure Plasma Spraying (VLPPS) is an emerging spray process nowadays intensively studied by many research centers in the World. To date, studies are mostly focused on the manufacturing of ceramic or metallic coatings. None refers to composite coatings manufacturing by reactive plasma spraying under very low pressure (i.e., ~150 Pa). This paper aims at presenting the carried-out developments and some results concerning the manufacturing of composite coatings by reactive spraying. Titanium was selected as metallic material in order to deposit titanium-nitride titanium coatings (Ti-TiN). Nitrogen was used as plasma gas and was injected along an Ar-H2-N2 plasma jet via a secondary injector in order to reach the nitrogen content on the substrate surface. Thus, different kind of reactive mechanisms were highlighted. Resulting coatings were characterized by Scanning Electron Microscopy (SEM) observations. Porous microstructures are clearly identified and the deposits exhibit condensed vapours and molten particles. Glow Discharge Optical Emission Spectroscopy (GDOES) analysis evidenced nitrogen inside the deposits and X-Ray Diffraction (XRD) analysis confirmed the formation of titanium nitride phases, such as TiN and Ti2N, depending upon the location of the nitrogen injection. Microhardness values as high as 800 VHN were measured on manufactured samples (to be compared to 220 VHN for pure titanium VLPPS-manufactured coatings).

Fabrication Of Carbon-Boron Reinforced Dry Polymer Matrix Composite Tape

NASA Technical Reports Server (NTRS)

Belvin, Harry L.; Cano, Roberto J.; Treasure, Monte; Shahood, Thomas W.

1999-01-01

Future generation aerospace vehicles will require specialized hybrid material forms for component structure fabrication. For this reason, high temperature composite prepregs in both dry and wet forms are being developed at NASA Langley Research Center (LaRC). In an attempt to improve compressive properties of carbon fiber reinforced composites, a hybrid carbon-boron tape was developed and used to fabricate composite laminates which were subsequently cut into flexural and compression specimens and tested. The hybrid material, given the designation HYCARB, was fabricated by modifying a previously developed process for the manufacture of dry polymer matrix composite (PMC) tape at LaRC. In this work, boron fibers were processed with IM7/LaRC(TradeMark)IAX poly(amide acid) solution-coated prepreg to form a dry hybrid tape for Automated Tow Placement (ATP). Boron fibers were encapsulated between two (2) layers of reduced volatile, low fiber areal weight poly(amide acid) solution-coated prepreg. The hybrid prepreg was then fully imidized and consolidated into a dry tape suitable for ATP. The fabrication of a hybrid boron material form for tow placement aids in the reduction of the overall manufacturing cost of boron reinforced composites, while realizing the improved compression strengths. Composite specimens were press-molded from the hybrid material and exhibited excellent mechanical properties.

Materials processing in zero gravity. [space manufacturing

NASA Technical Reports Server (NTRS)

Wuenscher, H. F.

1973-01-01

Manufacturing processes which are expected to show drastic changes in a space environment due to the absence of earth gravity are classified according to (1) buoyancy and thermal convection sensitive processes and (2) processes where molecular forces like cohesion and adhesion remain as the relatively strongest and hence controlling factors. Some specific process demonstration experiments carried out during the Apollo 14 mission and in the Skylab program are described. These include chemical separation by electrophoresis, the M551 metals melting experiment, the M552 exothermic brazing experiment, the M553 sphere forming experiment, the M554 composite casting experiment, and the M555 gallium arsenide crystal growth experiment.

Method and apparatus for manufacturing gas tags

DOEpatents

Gross, K.C.; Laug, M.T.

1996-12-17

For use in the manufacture of gas tags employed in a gas tagging failure detection system for a nuclear reactor, a plurality of commercial feed gases each having a respective noble gas isotopic composition are blended under computer control to provide various tag gas mixtures having selected isotopic ratios which are optimized for specified defined conditions such as cost. Using a new approach employing a discrete variable structure rather than the known continuous-variable optimization problem, the computer controlled gas tag manufacturing process employs an analytical formalism from condensed matter physics known as stochastic relaxation, which is a special case of simulated annealing, for input feed gas selection. For a tag blending process involving M tag isotopes with N distinct feed gas mixtures commercially available from an enriched gas supplier, the manufacturing process calculates the cost difference between multiple combinations and specifies gas mixtures which approach the optimum defined conditions. The manufacturing process is then used to control tag blending apparatus incorporating tag gas canisters connected by stainless-steel tubing with computer controlled valves, with the canisters automatically filled with metered quantities of the required feed gases. 4 figs.

Method and apparatus for manufacturing gas tags

DOEpatents

Gross, Kenny C.; Laug, Matthew T.

1996-01-01

For use in the manufacture of gas tags employed in a gas tagging failure detection system for a nuclear reactor, a plurality of commercial feed gases each having a respective noble gas isotopic composition are blended under computer control to provide various tag gas mixtures having selected isotopic ratios which are optimized for specified defined conditions such as cost. Using a new approach employing a discrete variable structure rather than the known continuous-variable optimization problem, the computer controlled gas tag manufacturing process employs an analytical formalism from condensed matter physics known as stochastic relaxation, which is a special case of simulated annealing, for input feed gas selection. For a tag blending process involving M tag isotopes with N distinct feed gas mixtures commercially available from an enriched gas supplier, the manufacturing process calculates the cost difference between multiple combinations and specifies gas mixtures which approach the optimum defined conditions. The manufacturing process is then used to control tag blending apparatus incorporating tag gas canisters connected by stainless-steel tubing with computer controlled valves, with the canisters automatically filled with metered quantities of the required feed gases.

Trapped rubber processing for advanced composites

NASA Technical Reports Server (NTRS)

Marra, P. J.

1976-01-01

Trapped rubber processing is a molding technique for composites in which precast silicone rubber is placed within a closed cavity where it thermally expands against the composite's surface supported by the vessel walls. The method has been applied by the Douglas Aircraft Company, under contract to NASA-Langley, to the design and fabrication of 10 DC-10 graphite/epoxy upper aft rudder assemblies. A three-bay development tool form mold die has been designed and manufactured, and tooling parameters have been established. Fabrication procedures include graphite layup, assembly of details in the tool, and a cure cycle. The technique has made it possible for the cocured fabrication of complex primary box structures otherwise impracticable via standard composite material processes.

14 CFR § 1240.102 - Definitions.

Code of Federal Regulations, 2014 CFR

2014-01-01

... experimental or beta phase of development, that performs in accordance with its specifications, and includes... mathematical, engineering or scientific concept, idea, design, process, or product. (h) Innovator means any..., method, process, machine, manufacture, design, or composition of matter, or any new and useful...

48 CFR 1827.301 - Definitions.

Code of Federal Regulations, 2010 CFR

2010-10-01

... date of the contract. Reportable items include, but are not limited to, new processes, machines, manufactures, and compositions of matter, and improvements to, or new applications of, existing processes... used in this subpart, means any invention, discovery, improvement, or innovation of the contractor...

From Artisanal to CAD-CAM Blocks: State of the Art of Indirect Composites.

PubMed

Mainjot, A K; Dupont, N M; Oudkerk, J C; Dewael, T Y; Sadoun, M J

2016-05-01

Indirect composites have been undergoing an impressive evolution over the last few years. Specifically, recent developments in computer-aided design-computer-aided manufacturing (CAD-CAM) blocks have been associated with new polymerization modes, innovative microstructures, and different compositions. All these recent breakthroughs have introduced important gaps among the properties of the different materials. This critical state-of-the-art review analyzes the strengths and weaknesses of the different varieties of CAD-CAM composite materials, especially as compared with direct and artisanal indirect composites. Indeed, new polymerization modes used for CAD-CAM blocks-especially high temperature (HT) and, most of all, high temperature-high pressure (HT-HP)-are shown to significantly increase the degree of conversion in comparison with light-cured composites. Industrial processes also allow for the augmentation of the filler content and for the realization of more homogeneous structures with fewer flaws. In addition, due to their increased degree of conversion and their different monomer composition, some CAD-CAM blocks are more advantageous in terms of toxicity and monomer release. Finally, materials with a polymer-infiltrated ceramic network (PICN) microstructure exhibit higher flexural strength and a more favorable elasticity modulus than materials with a dispersed filler microstructure. Consequently, some high-performance composite CAD-CAM blocks-particularly experimental PICNs-can now rival glass-ceramics, such as lithium-disilicate glass-ceramics, for use as bonded partial restorations and crowns on natural teeth and implants. Being able to be manufactured in very low thicknesses, they offer the possibility of developing innovative minimally invasive treatment strategies, such as "no prep" treatment of worn dentition. Current issues are related to the study of bonding and wear properties of the different varieties of CAD-CAM composites. There is also a crucial need to conduct clinical studies. Last, manufacturers should provide more complete information regarding their product polymerization process, microstructure, and composition, which significantly influence CAD-CAM material properties. © International & American Associations for Dental Research 2016.

Additive Manufacturing of Fuel Injectors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sadek Tadros, Dr. Alber Alphonse; Ritter, Dr. George W.; Drews, Charles Donald

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventionalmore » manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project were: • Powder metal input stock: Powder characterization, dimensional accuracy, metallurgical characterization, and mechanical properties evaluation. • Process parameters: Laser parameter effects, post-printing heat-treatment development, mechanical properties evaluation, and post-finishing technique. • Material design curves: Room and elevated temperature tensiles, low cycle fatigue, and creep rupture properties curves generated. • AM specifications: Key metal powder characteristics, laser parameters, and heat-treatment controls identified.« less

Design concepts for a composite door frame system for general automotive applications

NASA Technical Reports Server (NTRS)

Tauber, J. A.

1976-01-01

Conceptual design, manufacturing process, and costs are explored to determine the feasibility of replacing present steel parts in automotive door structures with various composite materials. The problems of conforming to present anti-intrusion specifications with advanced materials are examined and discussed. Modest weight reductions, at competitive costs, were identified for the utilization of specific composite materials in automotive door structures.

40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

Code of Federal Regulations, 2012 CFR

2012-07-01

... shape or design during manufacture, (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use, and (iii) which has either no change of chemical composition... particles are not considered articles regardless of shape or design. (3) The terms byproduct, EPA...

40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

Code of Federal Regulations, 2011 CFR

2011-07-01

... shape or design during manufacture, (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use, and (iii) which has either no change of chemical composition... particles are not considered articles regardless of shape or design. (3) The terms byproduct, EPA...

40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

Code of Federal Regulations, 2013 CFR

2013-07-01

... shape or design during manufacture, (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use, and (iii) which has either no change of chemical composition... particles are not considered articles regardless of shape or design. (3) The terms byproduct, EPA...

40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

Code of Federal Regulations, 2014 CFR

2014-07-01

... shape or design during manufacture, (ii) which has end use function(s) dependent in whole or in part upon its shape or design during end use, and (iii) which has either no change of chemical composition... particles are not considered articles regardless of shape or design. (3) The terms byproduct, EPA...

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

5th Conference on Aerospace Materials, Processes, and Environmental Technology

NASA Technical Reports Server (NTRS)

Cook, M. B. (Editor); Stanley, D. Cross (Editor)

2003-01-01

Records are presented from the 5th Conference on Aerospace Materials, Processes, and Environmental Technology. Topics included pollution prevention, inspection methods, advanced materials, aerospace materials and technical standards,materials testing and evaluation, advanced manufacturing,development in metallic processes, synthesis of nanomaterials, composite cryotank processing, environmentally friendly cleaning, and poster sessions.

FRP MODEL - VERSION 1.0 FOR ESTIMATING STYRENE EMISSIONS FROM FIBER-REINFORCED PLASTICS FABRICATION PROCESSES

EPA Science Inventory

This software estimates styrene emissions from the manufacture of fiber-reinforced plastics/composite (FRP/C) products. In using the model, the user first chooses the appropriate process: gel coating, resin sprayup, hand layup, etc. Choosing a process will cause the 'baseline' in...

A Novel Multiscale Design of Interfaces for Polymeric Composites and Bonded Joints using Additive Manufacturing

DTIC Science & Technology

2016-09-13

AFRL-AFOSR-VA-TR-2016-0317 A Novel Multiscale Design of Interfaces for Polymeric Composites and Bonded Joints using Additive Manufacturing Pavana...Composites and Bonded Joints using Additive Manufacturing AWARD NO.: FA9550-15-1-0216 AGENCY NAME: The Air Force Office of Scientific Research (AFOSR), Ar...20 3 Additive Manufacturing for Bonded Composite Joints 21 3.1 Introduction

Graphite nanoplatelet enabled embeddable fiber sensor for in situ curing monitoring and structural health monitoring of polymeric composites.

PubMed

Luo, Sida; Liu, Tao

2014-06-25

A graphite nanoplatelet (GNP) thin film enabled 1D fiber sensor (GNP-FibSen) was fabricated by a continuous roll-to-roll spray coating process, characterized by scanning electron microscopy and Raman spectroscopy and evaluated by coupled electrical-mechanical tensile testing. The neat GNP-FibSen sensor shows very high gauge sensitivity with a gauge factor of ∼17. By embedding the sensor in fiberglass prepreg laminate parts, the dual functionalities of the GNP-FibSen sensor were demonstrated. In the manufacturing process, the resistance change of the embedded sensor provides valuable local resin curing information. After the manufacturing process, the same sensor is able to map the strain/stress states and detect the failure of the host composite. The superior durability of the embedded GNP-FibSen sensor has been demonstrated through 10,000 cycles of coupled electromechanical tests.

VARTM Process Modeling of Aerospace Composite Structures

NASA Technical Reports Server (NTRS)

Song, Xiao-Lan; Grimsley, Brian W.; Hubert, Pascal; Cano, Roberto J.; Loos, Alfred C.

2003-01-01

A three-dimensional model was developed to simulate the VARTM composite manufacturing process. The model considers the two important mechanisms that occur during the process: resin flow, and compaction and relaxation of the preform. The model was used to simulate infiltration of a carbon preform with an epoxy resin by the VARTM process. The model predicted flow patterns and preform thickness changes agreed qualitatively with the measured values. However, the predicted total infiltration times were much longer than measured most likely due to the inaccurate preform permeability values used in the simulation.

Method of manufacturing aerogel composites

DOEpatents

Cao, W.; Hunt, A.J.

1999-03-09

Disclosed herewith is a process of forming an aerogel composite which comprises introducing a gaseous material into a formed aerogel monolith or powder, and causing decomposition of said gaseous material in said aerogel in amounts sufficient to cause deposition of the decomposition products of the gas on the surfaces of the pores of the said aerogel.

Method of manufacturing aerogel composites

DOEpatents

Cao, Wanqing; Hunt, Arlon Jason

1999-01-01

Disclosed herewith is a process of forming an aerogel composite which comprises introducing a gaseous material into a formed aerogel monolith or powder, and causing decomposition of said gaseous material in said aerogel in amounts sufficient to cause deposition of the decomposition products of the gas on the surfaces of the pores of the said aerogel.

Silkworms transformed with chimeric silkworm/spider silk genes spin composite silk fibers with improved mechanical properties

USDA-ARS?s Scientific Manuscript database

The development of a spider silk manufacturing process is of great interest. piggyBac vectors were used to create transgenic silkworms encoding chimeric silkworm/spider silk proteins. The silk fibers produced by these animals were composite materials that included chimeric silkworm/spider silk prote...

Tribology of Polymer Matrix Composites (PMCs) Fabricated by Additive Manufacturing (AM)

NASA Technical Reports Server (NTRS)

Gupta, S.; Dunnigan, R.; Salem, A.; Kuentz, L.; Halbig, M. C.; Singh, M.

2016-01-01

The integral process of depositing thin layers of material, one after another, until the designed component is created is collectively referred to as Additive Manufacturing (AM). Fused deposition process (FDP) is a type of AM where feedstock is extruded into filaments which then are deposited by 3D printing, and the solidification occurs during cooling of the melt. Currently, complex structures are being fabricated by commercial and open source desktop 3D printers. Recently, metal powder containing composite filaments based on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) have emerged, which could be utilized for multifunctional applications. For further deployment in the field, especially for aerospace and ground-based applications, it is critical to understand the tribological behavior of 3D printed materials. In this presentation, we will report the tribological behavior of different polymer matrix composites fabricated by fused deposition process. These results will be compared with the base polymer systems. During this study, the tribological behavior of all the samples will be evaluated with tab-on-disc method and compared for different metallic powder reinforcements.

21 CFR 3.7 - Request for designation.

Code of Federal Regulations, 2013 CFR

2013-04-01

... biological composition; (vi) Status and brief reports of the results of developmental work, including animal testing; (vii) Description of the manufacturing processes, including the sources of all components; (viii...

21 CFR 3.7 - Request for designation.

Code of Federal Regulations, 2011 CFR

2011-04-01

... biological composition; (vi) Status and brief reports of the results of developmental work, including animal testing; (vii) Description of the manufacturing processes, including the sources of all components; (viii...

21 CFR 3.7 - Request for designation.

Code of Federal Regulations, 2010 CFR

2010-04-01

... biological composition; (vi) Status and brief reports of the results of developmental work, including animal testing; (vii) Description of the manufacturing processes, including the sources of all components; (viii...

21 CFR 3.7 - Request for designation.

Code of Federal Regulations, 2014 CFR

2014-04-01

... biological composition; (vi) Status and brief reports of the results of developmental work, including animal testing; (vii) Description of the manufacturing processes, including the sources of all components; (viii...

21 CFR 3.7 - Request for designation.

Code of Federal Regulations, 2012 CFR

2012-04-01

... biological composition; (vi) Status and brief reports of the results of developmental work, including animal testing; (vii) Description of the manufacturing processes, including the sources of all components; (viii...

Influence of Cellulosic Fibres on the Physical Properties of Fibre Cement Composites

NASA Astrophysics Data System (ADS)

Hospodarova, V.; Stevulova, N.; Vaclavik, V.; Dvorsky, T.

2017-10-01

Nowadays, there are new approaches directing to processing of non-conventional fibre-cement composites for application in the housing construction. Vegetable cellulosic fibres coming from natural resources used as reinforcement in cost-effective and environmental friendly building products are in the spotlight. The applying of natural fibres in cement based composites is narrowly linked to the ecological building sector, where a choice of materials is based on components including recyclable, renewable raw materials and low-resource manufacture techniques. In this paper, two types of cellulosic fibres coming from wood pulp and recycled waste paper with 0.2%; 0.3% and 0.5% of fibre addition into cement mixtures were used. Differences in the physical characteristics (flowability, density, coefficient of thermal conductivity and water absorbability) of 28 days hardened fibre-cement composites are investigated. Addition of cellulosic fibres to cement mixture caused worsening the workability of fresh mixture as well as absorbability of hardened composites due to hydrophilic nature of biomaterial, whereas density and thermal conductivity of manufactured cement based fibre plaster are enhanced. The physical properties of cement plasters based on cellulosic fibres depend on structural, physical characteristics of cellulosic fibres, their nature and processing.

Defense Small Business Innovation Research Program (SBIR). Volume 3. Air Force Abstracts of Phase 1 Awards 1991

DTIC Science & Technology

1991-01-01

The development of low-cost fabrication processes for high-performance composites is of paramount importance in the economical use of composites in...This proposal offers to evaluate the feasibility of marrying multiscale image processing techniques to multisensor image data. The product would be a...biotechnology to the production of 4-hydroxybenzocyclobutene will allow bulk manufacture of this polymer precursor by more economical means than is

Process simulation for advanced composites production

DOE Office of Scientific and Technical Information (OSTI.GOV)

Allendorf, M.D.; Ferko, S.M.; Griffiths, S.

1997-04-01

The objective of this project is to improve the efficiency and lower the cost of chemical vapor deposition (CVD) processes used to manufacture advanced ceramics by providing the physical and chemical understanding necessary to optimize and control these processes. Project deliverables include: numerical process models; databases of thermodynamic and kinetic information related to the deposition process; and process sensors and software algorithms that can be used for process control. Target manufacturing techniques include CVD fiber coating technologies (used to deposit interfacial coatings on continuous fiber ceramic preforms), chemical vapor infiltration, thin-film deposition processes used in the glass industry, and coatingmore » techniques used to deposit wear-, abrasion-, and corrosion-resistant coatings for use in the pulp and paper, metals processing, and aluminum industries.« less

Metal organic chemical vapor deposition of 111-v compounds on silicon

DOEpatents

Vernon, Stanley M.

1986-01-01

Expitaxial composite comprising thin films of a Group III-V compound semiconductor such as gallium arsenide (GaAs) or gallium aluminum arsenide (GaAlAs) on single crystal silicon substrates are disclosed. Also disclosed is a process for manufacturing, by chemical deposition from the vapor phase, epitaxial composites as above described, and to semiconductor devices based on such epitaxial composites. The composites have particular utility for use in making light sensitive solid state solar cells.

Measurement and analysis of flow in 3D preforms for aerospace composites

NASA Astrophysics Data System (ADS)

Stewart, Andrew Lawrence

Composite materials have become viable alternatives to traditional engineering materials for many different product categories. Liquid transfer moulding (LTM) processes, specifically resin transfer moulding (RTM), is a cost-effective manufacturing technique for creating high performance composite parts. These parts can be tailor-made to their specific application by optimizing the properties of the textile preform. Preforms which require little or no further assembly work and are close to the shape of the final part are critical to obtaining high quality parts while simultaneously reducing labour and costs associated with other composite manufacturing techniques. One type of fabric which is well suited for near-net- shape preforms is stitched non-crimp fabrics. These fabrics offer very high in-plane strength and stiffness while also having increased resistance to delamination. Manufacturing parts from these dry preforms typically involves long-scale fluid flow through both open channels and porous fibre bundles. This thesis documents and analyzes the flow of fluid through preforms manufactured from non-crimp fabrics featuring through-thickness stitches. The objective of this research is to determine the effect of this type of stitch on the RTM injection process. All of the tests used preforms with fibre volume fractions representative of primary and secondary structural parts. A series of trials was conducted using different fibre materials, flow rates, fibre volumes fractions, and degrees of fibre consolidation. All of the trials were conducted for cases similar to RTM. Consolidation of the fibres showed improvements to both the thoroughness of the filling and to the fibre volume fraction. Experimentally determined permeability data was shown to trend well with simple models and precision of the permeability data was comparable to values presented by other authors who studied fabrics which did not feature the through-thickness stitches.

Verification and Validation of Residual Stresses in Bi-Material Composite Rings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nelson, Stacy Michelle; Hanson, Alexander Anthony; Briggs, Timothy

Process-induced residual stresses commonly occur in composite structures composed of dissimilar materials. These residual stresses form due to differences in the composite materials’ coefficients of thermal expansion and the shrinkage upon cure exhibited by polymer matrix materials. Depending upon the specific geometric details of the composite structure and the materials’ curing parameters, it is possible that these residual stresses could result in interlaminar delamination or fracture within the composite. Therefore, the consideration of potential residual stresses is important when designing composite parts and their manufacturing processes. However, the experimental determination of residual stresses in prototype parts can be time andmore » cost prohibitive. As an alternative to physical measurement, it is possible for computational tools to be used to quantify potential residual stresses in composite prototype parts. Therefore, the objectives of the presented work are to demonstrate a simplistic method for simulating residual stresses in composite parts, as well as the potential value of sensitivity and uncertainty quantification techniques during analyses for which material property parameters are unknown. Specifically, a simplified residual stress modeling approach, which accounts for coefficient of thermal expansion mismatch and polymer shrinkage, is implemented within the Sandia National Laboratories’ developed SIERRA/SolidMechanics code. Concurrent with the model development, two simple, bi-material structures composed of a carbon fiber/epoxy composite and aluminum, a flat plate and a cylinder, are fabricated and the residual stresses are quantified through the measurement of deformation. Then, in the process of validating the developed modeling approach with the experimental residual stress data, manufacturing process simulations of the two simple structures are developed and undergo a formal verification and validation process, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.« less

Fused filament 3D printing of ionic polymer-metal composites for soft robotics

NASA Astrophysics Data System (ADS)

Carrico, James D.; Leang, Kam K.

2017-04-01

Additive manufacturing techniques are used to create three-dimensional structures with complex shapes and features from polymer and/or metal materials. For example, fused filament three-dimensional (3D) printing utilizes non-electroactive polymers, such as acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA), to build structures and components in a layer-by-layer fashion for a wide variety of applications. Presented here is a summary of recent work on a fused filament 3D-printing technique to create 3D ionic polymer-metal composite (IPMC) structures for applications in soft robotics. The 3D printing technique overcomes some of the limitations of existing manufacturing processes for creating IPMCs, such as limited shapes and sizes and time-consuming manufacturing steps. In the process described, first a precursor material (non-acid Nafion precursor resin) is extruded into a thermoplastic filament for 3D printing. Then, a custom-designed 3D printer is described that utilizes the precursor filament to manufacture custom-shaped structures. Finally, the 3D-printed samples are functionalized by hydrolyzing them in an aqueous solution of potassium hydroxide and dimethyl sulfoxide, followed by application of platinum electrodes. Presented are example 3D-printed single and multi-degree-of-freedom IPMC actuators and characterization results, as well as example soft-robotic devices to demonstrate the potential of this process.

Continuous fiber-reinforced titanium aluminide composites

NASA Technical Reports Server (NTRS)

Mackay, R. A.; Brindley, P. K.; Froes, F. H.

1991-01-01

An account is given of the fabrication techniques, microstructural characteristics, and mechanical behavior of a lightweight, high service temperature SiC-reinforced alpha-2 Ti-14Al-21Nb intermetallic-matrix composite. Fabrication techniques under investigation to improve the low-temperature ductility and environmental resistance of this material system, while reducing manufacturing costs to competitive levels, encompass powder-cloth processing, foil-fiber-foil processing, and thermal-spray processing. Attention is given to composite microstructure problems associated with fiber distribution and fiber-matrix interfaces, as well as with mismatches of thermal-expansion coefficient; major improvements are noted to be required in tensile properties, thermal cycling effects, mechanical damage, creep, and environmental effects.

Development of Manufacturable Process to Deposit Metal Matrix Composites on Inverted Metamorphic Multijunction Solar Cells

DTIC Science & Technology

2015-01-14

substrates using a titanium adhesion layer, and (3) characterized hardness and electrical conductivity of plated silver before and after rapid thermal...layer composite films. We observed that the silver erosion during carboxylated carbon nanotube deposition leads to significant porosity within the...composite films. We plan to explore amine-terminated carbon nanotubes in the near future to eliminate the porosity and study how different

Thermal Protection System Application to Composite Cryotank Technology Demonstrator

NASA Technical Reports Server (NTRS)

Protz, Alison; Nettles, Mindy

2015-01-01

The EM41 Thermal Protection System (TPS) team contributed to the success of the Composite Cryotank Technology Demonstrator (CCTD) manufacturing by developing and implementing a low-cost solution to apply cryoinsulation foam on the exterior surface of the tank in the NASA Marshall Space Flight Center (MSFC) TPS Development Facility, Bldg. 4765. The TPS team used techniques developed for the smallscale composite cryotank to apply Stepanfoam S-180 polyurethane foam to the 5.5-meter CCTD using a manual spray process. Manual spray foam technicians utilized lifts and scaffolding to access the barrel and dome sections of the large-scale tank in the horizontal orientation. During manufacturing, the tank was then oriented vertically, allowing access to the final barrel section for manual spray foam application. The CCTD was the largest application of manual spray foam performed to date with the S-180 polyurethane foam and required the TPS team to employ best practices for process controls on the development article.

A Comparison of the Properties of Carbon Fiber Epoxy Composites Produced by Non-autoclave with Vacuum Bag Only Prepreg and Autoclave Process

NASA Astrophysics Data System (ADS)

Park, Sang Yoon; Choi, Chi Hoon; Choi, Won Jong; Hwang, Seong Soon

2018-05-01

The non-autoclave curing technique with vacuum bag only (VBO) prepreg has been conceived as a cost-effective manufacturing method for producing high-quality composite part. This study demonstrated the feasibility of improving composite part's performances and established the effective mitigation strategies for manufacturing induced defects, such as internal voids and surface porosity. The experimental results highlighted the fact that voids and surface porosity were clearly dependent on the resin viscosity state at an intermediate dwell stage of the curing process. Thereafter, the enhancement of resin flow could lead to achieving high quality parts with minimal void content (1.3%) and high fiber fraction (53 vol.%). The mechanical testing showed comparable in-plane shear and compressive strength to conventional autoclave. The microscopic observations also supported the evidence of improved interfacial bonding in terms of excellent fiber wet-out and minimal void content for the optimized cure cycle condition.

Low-Cost Nanocellulose-Reinforced High-Temperature Polymer Composites for Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ozcan, Soydan; Tekinalp, Halil L.; Love, Lonnie J.

2016-07-13

ORNL worked with American Process Inc. to demonstrate the potential use of bio-based BioPlus ® lignin-coated cellulose nanofibrils (L-CNF) as a reinforcing agent in the development of polymer feedstock suitable for additive manufacturing. L-CNF-reinforced polylactic acid (PLA) testing coupons were prepared and up to 69% increase in tensile strength and 133% increase in elastic modulus were demonstrated.

14 CFR 1240.102 - Definitions.

Code of Federal Regulations, 2010 CFR

2010-01-01

... Contributions Board. (d) Commercial quality refers to computer software that is not in an experimental or beta..., engineering or scientific concept, idea, design, process, or product, reported as new technology on NASA Form...) Invention includes any act, method, process, machine, manufacture, design, or composition of matter, or any...

14 CFR 1240.102 - Definitions.

Code of Federal Regulations, 2012 CFR

2012-01-01

... Contributions Board. (d) Commercial quality refers to computer software that is not in an experimental or beta..., engineering or scientific concept, idea, design, process, or product, reported as new technology on NASA Form...) Invention includes any act, method, process, machine, manufacture, design, or composition of matter, or any...

Acquisition of equipment for composite manufacturing laboratory.

DOT National Transportation Integrated Search

2009-12-01

An interdisciplinary team of faculty was formed to upgrade the Composite Manufacturing and Testing Facilities at Missouri S&T. The Metering Unit is useful to manufacture composite pultruded parts using two part polyurethane resin system. Prior to the...

Microstructure and High Temperature Oxidation Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Powder Injection Molding Process

NASA Astrophysics Data System (ADS)

Joo, Yeun-Ah; Kim, Young-Kyun; Yoon, Tae-Sik; Lee, Kee-Ahn

2018-03-01

This study investigated the microstructure and high temperature oxidation property of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding process. Observations of initial microstructure showed a unique structure where α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performed at 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84 and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented parabolic curves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identified Cr2O3 and SiO2 at 900 and 1000 °C. In addition to Cr2O3 and SiO2, CrBO3 and FeCr2O4 formed due to phase decomposition of boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidation mechanism of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding, and the possibility of its application as a high temperature component material was also discussed.

Sustainability of fiber reinforced laminate and honeycomb composites in manufacturing industries

NASA Astrophysics Data System (ADS)

Asmatulu, Eylem; Alonayni, Abdullah; Alamir, Mohammed; Rahman, Muhammad M.

2018-03-01

Fiber reinforced polymer (FRP) composites provide a lot of benefits, including strength-to-weight ratio / light weight, superior mechanical properties, low maintenance, prolonged service life, as well as corrosion, fatigue and creep resistance. However, sustainability of the FRP composites have not been studied in detail in terms of long term productions in various industries, such as aerospace, wind energy, automotive and defense. Carbon fibers are relatively expensive because of the energy intensive production systems, and lack of easy production options, which forces many companies to recycle and reuse the FRP composites in the same or different manufacturing industries. This study mainly deals with two important issues, including the disposal of composite wastes generated during the manufacturing of composite parts, and the disposal of the products at the end of their useful life. It is believed that the carbon fibers in the used composites will have still high mechanical strengths to use in different composite manufacturing after its end of life. The major manufacturing costs come from the labor and raw materials, so using the recycled carbon fibers will make sustainable composite productions in other industries. This paper presents the current status and outlook of the FRP composite recycling and re-manufacturing techniques in the same or different industries. A future vision of the FRP composites will be investigated with sustainability point of views. This study will also mention about the sustainability issues in laminate and honeycomb composites, new product design and developments and potential applications in different manufacturing industries.

Preparation and evaluation of Apollo 14 composite experiments

NASA Technical Reports Server (NTRS)

Steurer, W. H.; Kaye, S.

1971-01-01

An account is given of the work aimed at flight experiments on Apollo 14, in relation to space manufacturing processes. Evaluation of suitable materials, definition of in-flight processing procedures, preparation of preprocessed materials and delivery, and evaluation of the space-processed samples after return from the Apollo 14 flight are presented.

On-line consolidation of thermoplastic composites

NASA Astrophysics Data System (ADS)

Shih, Po-Jen

An on-line consolidation system, which includes a computer-controlled filament winding machine and a consolidation head assembly, has been designed and constructed to fabricate composite parts from thermoplastic towpregs. A statistical approach was used to determine the significant processing parameters and their effect on the mechanical and physical properties of composite cylinders fabricated by on-line consolidation. A central composite experimental design was used to select the processing conditions for manufacturing the composite cylinders. The thickness, density, void content, degree of crystallinity and interlaminar shear strength (ILSS) were measured for each composite cylinder. Micrographs showed that complete intimate contact and uniform fiber-matrix distribution were achieved. The degree of crystallinity of the cylinders was found to be in the range of 25-30%. Under optimum processing conditions, an ILSS of 58 MPa and a void content of <1% were achieved for APC-2 (PEEK/Carbon fiber) composite cylinders. An in-situ measurement system which uses a slip ring assembly and a computer data acquisition system was developed to obtain temperature data during winding. Composite cylinders were manufactured with eight K-type thermocouples installed in various locations inside the cylinder. The temperature distribution inside the composite cylinder during winding was measured for different processing conditions. ABAQUS finite element models of the different processes that occur during on-line consolidation were constructed. The first model was used to determine the convective heat transfer coefficient for the hot-air heat source. A convective heat transfer coefficient of 260 w/msp{2°}K was obtained by matching the calculated temperature history to the in-situ measurement data. To predict temperature distribution during winding an ABAQUS winding simulation model was developed. The winding speed was modeled by incrementally moving the convective boundary conditions around the outer surface of the composite cylinder. A towpreg heating model was constructed to predict the temperature distribution on the cross section of the incoming towpreg. For the process-induced thermal stresses analysis, a thermoelastic finite element model was constructed. Using the temperature history obtained from thermal analysis as the initial conditions, the thermal stresses during winding and cooling were investigated.

THE DURABILITY OF LARGE-SCALE ADDITIVE MANUFACTURING COMPOSITE MOLDS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Post, Brian K; Love, Lonnie J; Duty, Chad

2016-01-01

Oak Ridge National Laboratory s Big Area Additive Manufacturing (BAAM) technology permits the rapid production of thermoplastic composite molds using a carbon fiber filled Acrylonitrile-Butadiene-Styrene (ABS) thermoplastic. Demonstration tools (i.e. 0.965 m X 0.559 m X 0.152 m) for composite part fabrication have been printed, coated, and finished with a traditional tooling gel. We present validation results demonstrating the stability of thermoplastic printed molds for room temperature Vacuum Assisted Resin Transfer Molding (VARTM) processes. Arkema s Elium thermoplastic resin was investigated with a variety of reinforcement materials. Experimental results include dimensional characterization of the tool surface using laser scanning techniquemore » following demolding of 10 parts. Thermoplastic composite molds offer rapid production compared to traditionally built thermoset molds in that near-net deposition allows direct digital production of the net geometry at production rate of 45 kg/hr.« less

Extrudable polymer-polymer composites based on ultra-high molecular weight polyethylene

NASA Astrophysics Data System (ADS)

Panin, S. V.; Kornienko, L. A.; Alexenko, V. O.; Buslovich, D. G.; Dontsov, Yu. V.

2017-12-01

Mechanical and tribotechnical characteristics of polymer-polymeric composites of UHMWPE are studied with the aim of developing extrudable, wear-resistant, self-lubricant polymer mixtures for Additive Manufacturing (AM). The motivation of the study is their further application as feedstocks for 3D printing. Blends of UHMWPE with graft- and block copolymers of low-density polyethylene (HDPE-g-VTMS, HDPE-g-SMA, HDPE-b-EVA), polypropylene (PP), block copolymers of polypropylene and polyamide with linear low density polyethylene (PP-b-LLDPE, PA-b-LLDPE), as well as cross-linked polyethylene (PEX-b), are examined. The choice of compatible polymer components for an ultra- high molecular weight matrix for increasing processability (extrudability) is motivated by the search for commercially available and efficient additives aimed at developing wear-resistant extrudable polymer composites for additive manufacturing. The extrudability, mechanical properties and wear resistance of UHMWPE-based polymer-polymeric composites under sliding friction with different velocities and loads are studied.

Effect of Sizings on the Durability of High Temperature Polymer Composites

NASA Technical Reports Server (NTRS)

Allred, Ronald E.; Shin, E. Eugene; Inghram, Linda; McCorkle, Linda; Papadopoulos, Demetrios; Wheeler, Donald; Sutter, James K.

2003-01-01

To increase performance and durability of high-temperature composite for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizing commercially supplied on most carbon fiber are not compatible with polyimides. In this study, the chemistry of sizing on two high modulus carbon fiber (M40J and M60J, Tiray) was characterized. A continuous desizling system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the butter bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Design of intelligent composites with life-cycle health management capabilities

NASA Astrophysics Data System (ADS)

Rosania, Colleen L.; Larrosa, Cecilia C.; Chang, Fu-Kuo

2015-03-01

Use of carbon fiber reinforced polymers (CFRPs) presents challenges because of their complex manufacturing processes and different damage mechanics in relation to legacy metal materials. New monitoring methods for manufacturing, quality verification, damage estimation, and prognosis are needed to use CFRPs safely and efficiently. This work evaluates the development of intelligent composite materials using integrated piezoelectric sensors to monitor the material during cure and throughout service life. These sensors are used to propagate ultrasonic waves through the structure for health monitoring. During manufacturing, data is collected at different stages during the cure cycle, detecting the changing material properties during cure and verifying quality and degree of cure. The same sensors can then be used with previously developed techniques to perform damage detection, such as impact detection and matrix crack density estimation. Real-time damage estimation can be combined with prognostic models to predict future propagation of damage in the material. In this work experimental results will be presented from composite coupons with embedded piezoelectric sensors. Cure monitoring and damage detection results derived from analysis of the ultrasonic sensor signal will be shown. Sensitive signal parameters to the different stimuli in both the time and frequency domains will be explored for this analysis. From these results, use of the same sensor networks from manufacturing throughout the life of the composite material will demonstrate the full life-cycle monitoring capability of these intelligent materials.

Aspects regarding manufacturing technologies of composite materials for brake pad application

NASA Astrophysics Data System (ADS)

Craciun, A. L.; Hepuţ, T.; Pinca-Bretotean, C.

2018-01-01

Current needs in road safety, requires the development of new technical solutions for automotive braking system. Their safe operation is subject to following factors: concept design, materials used and electronic control. Among the factors previously listed, choice of materials and manufacturing processes are difficult stage but very important for achieving technical performance and getting a relatively small cost of constituting parts of brake system. The choice is based on the promotion of organic composite material, popular in areas where the weight of materials plays an important role. The brake system is composed of many different parts including brake pads, a master cylinder, wheel cylinders and a hydraulic control system. The brake pads are an important component in the braking system of automotive. These are of different types, suitable for different types of automotive and engines. Brake pads are designed for friction stability, durability, minimization of noise and vibration. The typology of the brake pads depends on the material which they are made. The aim of this paper is to presents the manufacturing technologies for ten recipes of composite material used in brake pads applications. In this work will be done: choosing the constituents of the recipes, investigation of their basic characteristics, setting the proportions of components, obtaining the composite materials in laboratory, establishing the parameters of manufacturing technology and technological analysis.

Thermoplastic polymides and composites therefrom

NASA Technical Reports Server (NTRS)

Harris, Frank W. (Inventor)

1994-01-01

A new class polyimide and polyimide precursors based on diaryl oxyalkylene diamines, such as 1,3-bis[4-aminophenoxy]-2,2-dimethyl propane, a process for their preparation and their use as the continuous phase for the manufacture of composites and composite laminates reinforced by reinforcing agents such as carbon fibers, Kevlar.TM., and other similar high strength reinforcing agents. The polyimides and molecular composites obtained from the diamines according to the invention show thermoplastic properties, excellent flex fatigue and fracture resistance, and excellent thermal and oxidative stability.

Polymer infiltration studies

NASA Technical Reports Server (NTRS)

Marchello, Joseph M.

1992-01-01

The preparation is reported of carbon fiber composites using advanced polymer resins. Current and ongoing research activities include: powder towpreg process; weaving, braiding and stitching dry powder prepreg; advanced tow placement; and customized ATP towpreg. The goal of these studies is to produce advanced composite materials for automated part fabrication using textile and robotics technology in the manufacture of subsonic and supersonic aircraft.

Changes in the Composition of Raw Tea Leaves from the Korean Yabukida Plant during High-temperature Processing to Pan-Fried Kamairi-cha Green Tea

USDA-ARS?s Scientific Manuscript database

To develop a better understanding of compositional changes occurring during the production of commercial teas, we determined by high-performance liquid chromatography (HPLC) changes in ingredient levels during each of several manufacturing steps used to produce Kamairi-cha, a premium green tea. We ...

Evaluating the warping of laminated particleboard panels

Treesearch

Zhiyong Cai

2004-01-01

Laminated wood composites have been used widely in the secondary manufacturing processes in the wood panel industries. Warping, which is defined as the out-of-plane deformation of an initially flat panel, is a longstanding problem associated with the use of laminated wood composites. The mechanism of warping is still not fully understood. A new two- dimensional warping...

Field and Laboratory Decay Evaluations of wood-plastic Composites

Treesearch

Rebecca E. Ibach; Marek Gnatowski; Grace Sun

2013-01-01

Experimental wood–plastic composites (WPCs) were made so that they matched the manufacturing process, dimensions, and water absorption of some commercial decking boards. WPC samples from selected formulations were divided into two identical groups. The first group was exposed in exterior conditions in Vancouver, British Columbia, and Hilo, Hawaii, at sun and shadow...

Evolution of Non-metallic Inclusions and Precipitates in Oriented Silicon Steel

NASA Astrophysics Data System (ADS)

Luo, Yan; Yang, Wen; Ren, Qiang; Hu, Zhiyuan; Li, Ming; Zhang, Lifeng

2018-06-01

The evolution of inclusions in oriented silicon steel during the manufacturing process was carried out by chemical composition analysis, non-aqueous electrolytic corrosion, and thermodynamic calculation. The morphology, composition, and size of inclusions were analyzed introducing field emission scanning electron microscope. The oxides were mainly formed during the secondary refining, and the nitrides, sulfides, and compounds were formed during the solidification and cooling of steel in the processes of continuous casting and hot rolling.

Advanced materials for aircraft engine applications.

PubMed

Backman, D G; Williams, J C

1992-02-28

A review of advances for aircraft engine structural materials and processes is presented. Improved materials, such as superalloys, and the processes for making turbine disks and blades have had a major impact on the capability of modern gas turbine engines. New structural materials, notably composites and intermetallic materials, are emerging that will eventually further enhance engine performance, reduce engine weight, and thereby enable new aircraft systems. In the future, successful aerospace manufacturers will combine product design and materials excellence with improved manufacturing methods to increase production efficiency, enhance product quality, and decrease the engine development cycle time.

Textile technology development

NASA Technical Reports Server (NTRS)

Shah, Bharat M.

1995-01-01

The objectives of this report were to evaluate and select resin systems for Resin Transfer Molding (RTM) and Powder Towpreg Material, to develop and evaluate advanced textile processes by comparing 2-D and 3-D braiding for fuselage frame applications and develop window belt and side panel structural design concepts, to evaluate textile material properties, and to develop low cost manufacturing and tooling processes for the automated manufacturing of fuselage primary structures. This research was in support of the NASA and Langley Research Center (LaRc) Advanced Composite Structural Concepts and Materials Technologies for Primary Aircraft Structures program.

The Anatomy of AP1000 Mono-Block Low Pressure Rotor Forging

NASA Astrophysics Data System (ADS)

Jin, Jia-yu; Rui, Shou-tai; Wang, Qun

AP1000 mono-block low pressure (LP) rotor forgings for nuclear power station have maximum ingot weight, maximum diameter and the highest technical requirements. It confronts many technical problems during manufacturing process such as composition segregation and control of inclusion in the large ingot, core compaction during forging, control of grain size and mechanical performance. The rotor forging were anatomized to evaluate the manufacturing level of CFHI. This article introduces the anatomical results of this forging. The contents include chemical composition, mechanical properties, inclusions and grain size and other aspects from the full-length and full cross-section of this forging. The fluctuation of mechanical properties, uniformity of microstructure and purity of chemical composition were emphasized. The results show that the overall performance of this rotor forging is particularly satisfying.

Marshall Space Flight Center Materials and Processes Laboratory

NASA Technical Reports Server (NTRS)

Tramel, Terri L.

2012-01-01

Marshall?s Materials and Processes Laboratory has been a core capability for NASA for over fifty years. MSFC has a proven heritage and recognized expertise in materials and manufacturing that are essential to enable and sustain space exploration. Marshall provides a "systems-wise" capability for applied research, flight hardware development, and sustaining engineering. Our history of leadership and achievements in materials, manufacturing, and flight experiments includes Apollo, Skylab, Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, Chandra, and the International Space Station. MSFC?s National Center for Advanced Manufacturing, NCAM, facilitates major M&P advanced manufacturing partnership activities with academia, industry and other local, state and federal government agencies. The Materials and Processes Laborato ry has principal competencies in metals, composites, ceramics, additive manufacturing, materials and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide products ranging from materials research in space to fully integrated solutions for large complex systems challenges. Marshall?s materials research, development and manufacturing capabilities assure that NASA and National missions have access to cutting-edge, cost-effective engineering design and production options that are frugal in using design margins and are verified as safe and reliable. These are all critical factors in both future mission success and affordability.

Mechanical, physical and tribological characterization of nano-cellulose fibers reinforced bio-epoxy composites: An attempt to fabricate and scale the 'Green' composite.

PubMed

Barari, Bamdad; Omrani, Emad; Dorri Moghadam, Afsaneh; Menezes, Pradeep L; Pillai, Krishna M; Rohatgi, Pradeep K

2016-08-20

The development of bio-based composites is essential in order to protect the environment while enhancing energy efficiencies. In the present investigation, the plant-derived cellulose nano-fibers (CNFs)/bio-based epoxy composites were manufactured using the Liquid Composite Molding (LCM) process. More specifically, the CNFs with and without chemical modification were utilized in the composites. The curing kinetics of the prepared composites was studied using both the isothermal and dynamic Differential Scanning Calorimetry (DSC) methods. The microstructure as well as the mechanical and tribological properties were investigated on the cured composites in order to understand the structure-property correlations of the composites. The results indicated that the manufactured composites showed improved mechanical and tribological properties when compared to the pure epoxy samples. Furthermore, the chemically modified CNFs reinforced composites outperformed the untreated composites. The surface modification of the fibers improved the curing of the resin by reducing the activation energy, and led to an improvement in the mechanical properties. The CNFs/bio-based epoxy composites form uniform tribo-layer during sliding which minimizes the direct contact between surfaces, thus reducing both the friction and wear of the composites. Copyright © 2016 Elsevier Ltd. All rights reserved.

Investigation into the influence of laser energy input on selective laser melted thin-walled parts by response surface method

NASA Astrophysics Data System (ADS)

Liu, Yang; Zhang, Jian; Pang, Zhicong; Wu, Weihui

2018-04-01

Selective laser melting (SLM) provides a feasible way for manufacturing of complex thin-walled parts directly, however, the energy input during SLM process, namely derived from the laser power, scanning speed, layer thickness and scanning space, etc. has great influence on the thin wall's qualities. The aim of this work is to relate the thin wall's parameters (responses), namely track width, surface roughness and hardness to the process parameters considered in this research (laser power, scanning speed and layer thickness) and to find out the optimal manufacturing conditions. Design of experiment (DoE) was used by implementing composite central design to achieve better manufacturing qualities. Mathematical models derived from the statistical analysis were used to establish the relationships between the process parameters and the responses. Also, the effects of process parameters on each response were determined. Then, a numerical optimization was performed to find out the optimal process set at which the quality features are at their desired values. Based on this study, the relationship between process parameters and SLMed thin-walled structure was revealed and thus, the corresponding optimal process parameters can be used to manufactured thin-walled parts with high quality.

Safety Evaluation Report: Development of Improved Composite Pressure Vessels for Hydrogen Storage, Lincoln Composites, Lincoln, NE, May 25, 2010

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fort, III, William C.; Kallman, Richard A.; Maes, Miguel

2010-12-22

Lincoln Composites operates a facility for designing, testing, and manufacturing composite pressure vessels. Lincoln Composites also has a U.S. Department of Energy (DOE)-funded project to develop composite tanks for high-pressure hydrogen storage. The initial stage of this project involves testing the permeation of high-pressure hydrogen through polymer liners. The company recently moved and is constructing a dedicated research/testing laboratory at their new location. In the meantime, permeation tests are being performed in a corner of a large manufacturing facility. The safety review team visited the Lincoln Composites site on May 25, 2010. The project team presented an overview of themore » company and project and took the safety review team on a tour of the facility. The safety review team saw the entire process of winding a carbon fiber/resin tank on a liner, installing the boss and valves, and curing and painting the tank. The review team also saw the new laboratory that is being built for the DOE project and the temporary arrangement for the hydrogen permeation tests.« less

Vision Systems Illuminate Industrial Processes

NASA Technical Reports Server (NTRS)

2013-01-01

When NASA designs a spacecraft to undertake a new mission, innovation does not stop after the design phase. In many cases, these spacecraft are firsts of their kind, requiring not only remarkable imagination and expertise in their conception but new technologies and methods for their manufacture. In the realm of manufacturing, NASA has from necessity worked on the cutting-edge, seeking new techniques and materials for creating unprecedented structures, as well as capabilities for reducing the cost and increasing the efficiency of existing manufacturing technologies. From friction stir welding enhancements (Spinoff 2009) to thermoset composites (Spinoff 2011), NASA s innovations in manufacturing have often transferred to the public in ways that enable the expansion of the Nation s industrial productivity. NASA has long pursued ways of improving upon and ensuring quality results from manufacturing processes ranging from arc welding to thermal coating applications. But many of these processes generate blinding light (hence the need for special eyewear during welding) that obscures the process while it is happening, making it difficult to monitor and evaluate. In the 1980s, NASA partnered with a company to develop technology to address this issue. Today, that collaboration has spawned multiple commercial products that not only support effective manufacturing for private industry but also may support NASA in the use of an exciting, rapidly growing field of manufacturing ideal for long-duration space missions.

Additive manufacturing of RF absorbers

NASA Astrophysics Data System (ADS)

Mills, Matthew S.

The ability of additive manufacturing techniques to fabricate integrated electromagnetic absorbers tuned for specific radio frequency bands within structural composites allows for unique combinations of mechanical and electromagnetic properties. These composites and films can be used for RF shielding of sensitive electromagnetic components through in-plane and out-of-plane RF absorption. Structural composites are a common building block of many commercial platforms. These platforms may be placed in situations in which there is a need for embedded RF absorbing properties along with structural properties. Instead of adding radar absorbing treatments to the external surface of existing structures, which adds increased size, weight and cost; it could prove to be advantageous to integrate the microwave absorbing properties directly into the composite during the fabrication process. In this thesis, a method based on additive manufacturing techniques of composites structures with prescribed electromagnetic loss, within the frequency range 1 to 26GHz, is presented. This method utilizes screen printing and nScrypt micro dispensing to pattern a carbon based ink onto low loss substrates. The materials chosen for this study will be presented, and the fabrication technique that these materials went through to create RF absorbing structures will be described. The calibration methods used, the modeling of the RF structures, and the applications in which this technology can be utilized will also be presented.

Dense high temperature ceramic oxide superconductors

DOEpatents

Landingham, Richard L.

1993-01-01

Dense superconducting ceramic oxide articles of manufacture and methods for producing these articles are described. Generally these articles are produced by first processing these superconducting oxides by ceramic processing techniques to optimize materials properties, followed by reestablishing the superconducting state in a desired portion of the ceramic oxide composite.

Dense high temperature ceramic oxide superconductors

DOEpatents

Landingham, R.L.

1993-10-12

Dense superconducting ceramic oxide articles of manufacture and methods for producing these articles are described. Generally these articles are produced by first processing these superconducting oxides by ceramic processing techniques to optimize materials properties, followed by reestablishing the superconducting state in a desired portion of the ceramic oxide composite.

Optimisation des proprietes physiques d'un composite carbone epoxy fabrique par le procede RFI

NASA Astrophysics Data System (ADS)

Koanda, Mahamat Mamadou Lamine

The RFI (Resin Film Infusion) process is a composite materials manufacturing process. Especially known for the small investment it requires, RFI processes are more and more widely used in the aeronautical industry. However a number of aspects of this process are still not well controlled. The quality of the final part depends on which process is used. In the case of RFI, controlling physical characteristics such as thickness, fiber volume fraction or void content remains a major challenge. This dissertation deals with the optimization of the physical properties of a carbon composite manufactured with RFI processes. The ASTMD3171 and ASTMD792 standards were used to measure the void content and fiber volume fraction. First, we introduced different layup sequences in the RFI process and evaluate their impact on the physical properties of the final product. The experiments show the primary mode A, with the resin film at the bottom, resulting in much better quality with controlled fiber volume fraction and void content. Mode B (film in the symmetrical plane) yields results identical to mode A except more irregular thicknesses. Mode C (symmetrical film in the laminate) produces locally unacceptable void contents. Mode D (resin film on the top of the laminate) yields much better results than mode A with the exception of the more irregular thicknesses. Making gaps and overlaps with the resin film has negative effects beyond 2.54cm (one inch) and should be avoided. Several C-scan observations of the manufactured samples showed a large accumulation of porosity in the resin rich areas, as well as surface defects. Ultimately we analyzed the cure cycle in light of the thermodynamic porosity models. It is evident that the diffusion phenomenon is essential in this process. Therefore a better conditioning of the resin film made by Cytec is required. An optimal design with a cycle stop and pressure lag yields the optimal cure cycle for the RFI process.

Development and manufacture of reactive-transfer-printed CIGS photovoltaic modules

NASA Astrophysics Data System (ADS)

Eldada, Louay; Sang, Baosheng; Lu, Dingyuan; Stanbery, Billy J.

2010-09-01

In recent years, thin-film photovoltaic (PV) companies started realizing their low manufacturing cost potential, and grabbing an increasingly larger market share from multicrystalline silicon companies. Copper Indium Gallium Selenide (CIGS) is the most promising thin-film PV material, having demonstrated the highest energy conversion efficiency in both cells and modules. However, most CIGS manufacturers still face the challenge of delivering a reliable and rapid manufacturing process that can scale effectively and deliver on the promise of this material system. HelioVolt has developed a reactive transfer process for CIGS absorber formation that has the benefits of good compositional control, high-quality CIGS grains, and a fast reaction. The reactive transfer process is a two stage CIGS fabrication method. Precursor films are deposited onto substrates and reusable print plates in the first stage, while in the second stage, the CIGS layer is formed by rapid heating with Se confinement. High quality CIGS films with large grains were produced on a full-scale manufacturing line, and resulted in high-efficiency large-form-factor modules. With 14% cell efficiency and 12% module efficiency, HelioVolt started to commercialize the process on its first production line with 20 MW nameplate capacity.

3D Representative Volume Element Reconstruction of Fiber Composites via Orientation Tensor and Substructure Features

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Yi; Chen, Wei; Xu, Hongyi

To provide a seamless integration of manufacturing processing simulation and fiber microstructure modeling, two new stochastic 3D microstructure reconstruction methods are proposed for two types of random fiber composites: random short fiber composites, and Sheet Molding Compounds (SMC) chopped fiber composites. A Random Sequential Adsorption (RSA) algorithm is first developed to embed statistical orientation information into 3D RVE reconstruction of random short fiber composites. For the SMC composites, an optimized Voronoi diagram based approach is developed for capturing the substructure features of SMC chopped fiber composites. The proposed methods are distinguished from other reconstruction works by providing a way ofmore » integrating statistical information (fiber orientation tensor) obtained from material processing simulation, as well as capturing the multiscale substructures of the SMC composites.« less

Insensitive explosive composition of halogenated copolymer and triaminotrinitrobenzene

DOEpatents

Benziger, Theodore M.

1976-01-01

A highly insensitive and heat resistant plastic-bonded explosive containing 90 wt % triaminotrinitrobenzene and 10 wt % of a fully saturated copolymer of chlorotrifluoroethylene and vinylidene fluoride is readily manufactured by the slurry process.

Particulate Titanium Matrix Composites Tested-Show Promise for Space Propulsion Applications

NASA Technical Reports Server (NTRS)

Thesken, John C.; Lerch, Bradley A.; Arnold, Steven M.

2003-01-01

New manufacturing technologies can now produce uniformly distributed particle strengthened titanium matrix composites (TMCs) at lower cost than many types of continuous-fiber composites. The innovative process results in near-final-shape components having a material stiffness up to 26-percent greater than that of components made with conventional titanium materials. This benefit is achieved with no significant increase in the weight of the component. The improved mechanical performance and low-cost manufacturing capability motivated a review of particulate-reinforced metal composite technology as a way to lower the cost and weight of space-access propulsion systems. Focusing on the elevated-temperature properties of titanium alloy Ti-6Al-4V as the matrix material, researchers at the NASA Glenn Research Center conducted experiments to verify the improved performance of the alloy containing 10 wt% of ceramic titanium carbide (TiC) particles. The appropriate blend of metal and ceramic powder underwent a series of cold and hot isostatic pressing procedures to yield bar stock. A set of round dogbone specimens was manufactured from a small sample of the bars. The TMC material proved to have good machinability at this particle concentration as there was no difficulty in producing high-quality specimens.

Development of lightweight THUNDER with fiber composite layers

NASA Astrophysics Data System (ADS)

Yoon, Kwang J.; Shin, Sukjoon; Kim, Jusik; Park, Hoon C.; Kwak, Moon K.

2000-06-01

This paper is concerned with design, manufacturing and performance test of lightweight THUNDER using a top fiber composite layer with near-zero CTE, a PZT ceramic wafer and a bottom glass/epoxy layer with high CTE. The main point of this design is to replace the heavy metal layers of THUNDER by the lightweight fiber reinforced plastic layers without losing capabilities to generate high force and displacement. It is possible to save weight up to about 30 percent if we replace the metallic backing materials by the light fiber composite layer. We can also have design flexibility by selecting the fiber direction and the size of prepreg layers. In addition to the lightweight advantage and design flexibility, the proposed device can be manufactured without adhesive layers when we use epoxy resin prepreg system. Glass/epoxy prepregs, a ceramic wafer with electrode surfaces, and a graphite/epoxy prepreg were simply stacked and cured at an elevated temperature by following autoclave bagging process. It was found that the manufactured composite laminate device had a sufficient curvature after detaching form a flat mold. From experimental actuation tests, it was observed that the developed actuator could generate larger actuation displacement than THUNDER.

Effect of fabrication process on physical and mechanical properties of tungsten carbide - cobalt composite: A review

NASA Astrophysics Data System (ADS)

Mahaidin, Ahmad Aswad; Jaafar, Talib Ria; Selamat, Mohd Asri; Budin, Salina; Sulaiman, Zaim Syazwan; Hamid, Mohamad Hasnan Abdul

2017-12-01

WC-Co, which is also known as cemented carbide, is widely used in metal cutting industry and wear related application due to their excellent mechanical properties. Manufacturing industries are focusing on improving productivity and reducing operational cost with machining operation is considered as one of the factors. Thus, machining conditions are becoming more severe and required better cutting tool bit with improved mechanical properties to withstand high temperature operation. Numerous studies have been made over the generation for further improvement of cemented carbide properties to meet the constant increase in demand. However, the results of these studies vary due to different process parameters and manufacturing technology. This paper summarizes the studies to improve the properties of WC-Co composite using different consolidation (powder size, mixing method, formulation, etc) and sintering parameters (temperature, time, atmosphere, etc).

Rice straw-wood particle composite for sound absorbing wooden construction materials.

PubMed

Yang, Han-Seung; Kim, Dae-Jun; Kim, Hyun-Joong

2003-01-01

In this study, rice straw-wood particle composite boards were manufactured as insulation boards using the method used in the wood-based panel industry. The raw material, rice straw, was chosen because of its availability. The manufacturing parameters were: a specific gravity of 0.4, 0.6, and 0.8, and a rice straw content (10/90, 20/80, and 30/70 weight of rice straw/wood particle) of 10, 20, and 30 wt.%. A commercial urea-formaldehyde adhesive was used as the composite binder, to achieve 140-290 psi of bending modulus of rupture (MOR) with 0.4 specific gravity, 700-900 psi of bending MOR with 0.6 specific gravity, and 1400-2900 psi of bending MOR with a 0.8 specific gravity. All of the composite boards were superior to insulation board in strength. Width and length of the rice straw particle did not affect the bending MOR. The composite boards made from a random cutting of rice straw and wood particles were the best and recommended for manufacturing processes. Sound absorption coefficients of the 0.4 and 0.6 specific gravity boards were higher than the other wood-based materials. The recommended properties of the rice straw-wood particle composite boards are described, to absorb noises, preserve the temperature of indoor living spaces, and to be able to partially or completely substitute for wood particleboard and insulation board in wooden constructions.

Processable polyimide adhesive and matrix composite resin

NASA Technical Reports Server (NTRS)

Pratt, J. Richard (Inventor); St.clair, Terry L. (Inventor); Progar, Donald J. (Inventor)

1990-01-01

A high temperature polyimide composition prepared by reacting 4,4'-isophthaloyldiphthalic anhydride with metaphenylenediamine is employed to prepare matrix resins, adhesives, films, coatings, moldings, and laminates, especially those showing enhanced flow with retention of mechanical and adhesive properties. It can be used in the aerospace industry, for example, in joining metals to metals or metals to composite structures. One area of application is in the manufacture of lighter and stronger aircraft and spacecraft structures.

Polymer-based composites for aerospace: An overview of IMAST results

NASA Astrophysics Data System (ADS)

Milella, Eva; Cammarano, Aniello

2016-05-01

This paper gives an overview of technological results, achieved by IMAST, the Technological Cluster on Engineering of Polymeric Composite Materials and Structures, in the completed Research Projects in the aerospace field. In this sector, the Cluster developed different solutions: lightweight multifunctional fiber-reinforced polymer composites for aeronautic structures, advanced manufacturing processes (for the optimization of energy consumption and waste reduction) and multifunctional components (e.g., thermal, electrical, acoustic and fire resistance).

Causes and remedies for porosity in composite manufacturing

NASA Astrophysics Data System (ADS)

Fernlund, G.; Wells, J.; Fahrang, L.; Kay, J.; Poursartip, A.

2016-07-01

Porosity is a challenge in virtually all composite processes but in particular in low pressure processes such as out of autoclave processing of prepregs, where the maximum pressure is one atmosphere. This paper discusses the physics behind important transport phenomena that control porosity and how we can use our understanding of the underlying science to develop strategies to achieve low porosity for these materials and processes in an industrial setting. A three step approach is outlined that addresses and discusses: gas evacuation of trapped air, volatiles and off-gassing, and resin infiltration of evacuated void space.

Grain Structure Control of Additively Manufactured Metallic Materials

PubMed Central

Faierson, Eric J.

2017-01-01

Grain structure control is challenging for metal additive manufacturing (AM). Grain structure optimization requires the control of grain morphology with grain size refinement, which can improve the mechanical properties of additive manufactured components. This work summarizes methods to promote fine equiaxed grains in both the additive manufacturing process and subsequent heat treatment. Influences of temperature gradient, solidification velocity and alloy composition on grain morphology are discussed. Equiaxed solidification is greatly promoted by introducing a high density of heterogeneous nucleation sites via powder rate control in the direct energy deposition (DED) technique or powder surface treatment for powder-bed techniques. Grain growth/coarsening during post-processing heat treatment can be restricted by presence of nano-scale oxide particles formed in-situ during AM. Grain refinement of martensitic steels can also be achieved by cyclic austenitizing in post-processing heat treatment. Evidently, new alloy powder design is another sustainable method enhancing the capability of AM for high-performance components with desirable microstructures.

Numerical and Experimental Characterization of a Composite Secondary Bonded Adhesive Lap Joint Using the Ultrasonics method

NASA Astrophysics Data System (ADS)

Kumar, M. R.; Ghosh, A.; Karuppannan, D.

2018-05-01

The construction of aircraft using advanced composites have become very popular during the past two decades, in which many innovative manufacturing processes, such as cocuring, cobonding, and secondary bonding processes, have been adopted. The secondary bonding process has become less popular than the other two ones because of nonavailability of process database and certification issues. In this article, an attempt is made to classify the quality of bonding using nondestructive ultrasonic inspection methods. Specimens were prepared and tested using the nondestructive ultrasonic Through Transmission (TT), Pulse Echo (PE), and air coupled guided wave techniques. It is concluded that the ultrasonic pulse echo technique is the best one for inspecting composite secondary bonded adhesive joints.

Characterization of Ti and Co based biomaterials processed via laser based additive manufacturing

NASA Astrophysics Data System (ADS)

Sahasrabudhe, Himanshu

Titanium and Cobalt based metallic materials are currently the most ideal materials for load-bearing metallic bio medical applications. However, the long term tribological degradation of these materials still remains a problem that needs a solution. To improve the tribological performance of these two metallic systems, three different research approaches were adapted, stemming out four different research projects. First, the simplicity of laser gas nitriding was utilized with a modern LENS(TM) technology to form an in situ nitride rich later in titanium substrate material. This nitride rich composite coating improved the hardness by as much as fifteen times and reduced the wear rate by more than a magnitude. The leaching of metallic ions during wear was also reduced by four times. In the second research project, a mixture of titanium and silicon were processed on a titanium substrate in a nitrogen rich environment. The results of this reactive, in situ additive manufacturing process were Ti-Si-Nitride coatings that were harder than the titanium substrate by more than twenty times. These coatings also reduced the wear rate by more than two magnitudes. In the third research approach, composites of CoCrMo alloy and Calcium phosphate (CaP) bio ceramic were processed using LENS(TM) based additive manufacturing. These composites were effective in reducing the wear in the CoCrMo alloy by more than three times as well as reduce the leaching of cobalt and chromium ions during wear. The novel composite materials were found to develop a tribofilm during wear. In the final project, a combination of hard nitride coating and addition of CaP bioceramic was investigated by processing a mixture of Ti6Al4V alloy and CaP in a nitrogen rich environment using the LENS(TM) technology. The resultant Ti64-CaP-Nitride coatings significantly reduced the wear damage on the substrate. There was also a drastic reduction in the metal ions leached during wear. The results indicate that the three tested approaches for reducing the wear damage in Ti and Co based were successful. These approaches and the associated research investigations could pave the way for future work in alleviating wear and corrosion related damage, especially via the additive manufacturing route.

Carbon Fiber Reinforced Ceramic Composites for Propulsion Applications

NASA Technical Reports Server (NTRS)

Freedman, Marc (Technical Monitor); Shivakumar, Kunigal N.

2003-01-01

Fiber reinforced ceramic composites are materials of choice for gas turbine engines because of their high thermal efficiency, thrust/weight ratio, and operating temperatures. However, the successful introduction of ceramic composites to hot structures is limited because of excessive cost of manufacturing, reproducibility, nonuniformity, and reliability. Intense research is going on around the world to address some of these issues. The proposed effort is to develop a comprehensive status report of the technology on processing, testing, failure mechanics, and environmental durability of carbon fiber reinforced ceramic composites through extensive literature study, vendor and end-user survey, visits to facilities doing this type of work, and interviews. Then develop a cooperative research plan between NASA GRC and NCA&T (Center for Composite Materials Research) for processing, testing, environmental protection, and evaluation of fiber reinforced ceramic composites.

Preparation of nonwoven and green composites from collagen fibrous networks

USDA-ARS?s Scientific Manuscript database

The disposal of solid wastes, such as trimmings and splits generated in various manufacturing processes in a tannery is a serious challenge to the hides and leather industries. Most of these wastes are transported out of processing plants for landfills, not only incurring the expense of transportat...

On the monitoring and implications of growing damages caused by manufacturing defects in composite structures

NASA Astrophysics Data System (ADS)

Schagerl, M.; Viechtbauer, C.; Hörrmann, S.

2015-07-01

Damage tolerance is a classical safety concept for the design of aircraft structures. Basically, this approach considers possible damages in the structure, predicts the damage growth under applied loading conditions and predicts the following decrease of the structural strength. As a fundamental result the damage tolerance approach yields the maximum inspection interval, which is the time a damage grows from a detectable to a critical level. The above formulation of the damage tolerance safety concept targets on metallic structures where the damage is typically a simple fatigue crack. Fiber-reinforced polymers show a much more complex damage behavior, such as delaminationsin laminated composites. Moreover, progressive damage in composites is often initiated by manufacturing defects. The complex manufacturing processes for composite structures almost certainly yield parts with defects, e.g. pores in the matrix or undulations of fibers. From such defects growing damages may start after a certain time of operation. The demand to simplify or even avoid the inspection of composite structures has therefore led to a comeback of the traditional safe-life safety concept. The aim of the so-called safe-life flaw tolerance concept is a structure that is capable of carrying the static loads during operation, despite significant damages and after a representative fatigue load spectrum. A structure with this property does not need to be inspected, respectively monitored at all during its service life. However, its load carrying capability is thereby not fully utilized. This article presents the possible refinement of the state-of-the-art safe-life flaw tolerance concept for composite structures towards a damage tolerance approach considering also the influence of manufacturing defects on damage initiation and growth. Based on fundamental physical relations and experimental observations the challenges when developing damage growth and residual strength curves are discussed.

Bisphenol A Release: Survey of the Composition of Dental Composite Resins

PubMed Central

Dursun, Elisabeth; Fron-Chabouis, Hélène; Attal, Jean-Pierre; Raskin, Anne

2016-01-01

Background: Bisphenol A (BPA) is an endocrine disruptor with potential toxicity. Composite resins may not contain pure BPA, but its derivatives are widely used. Several studies found doses of BPA or its derivatives in saliva or urine of patients after composite resin placement. Objective: The aims of this study were to establish an exhaustive list of composite resins marketed in Europe and their composition, and to assess the extent of BPA derivatives used. Methods: A research on manufacturers' websites was performed to reference all composite resins marketed in Europe, then their composition was determined from both material safety data sheets and a standardized questionnaire sent to manufacturers. Manufacturers had to indicate whether their product contained the monomers listed, add other monomers if necessary, or indicate “not disclosed”. Results: 160 composite resins were identified from 31 manufacturers and 23 manufacturers (74.2%) responded to the survey. From the survey and websites, the composition of 130 composite resins (81.2%) was: 112 (86.2%) based on BPA derivatives, 97 (74.7%) on bis-GMA, 17 (13.1%) without monomer derived from BPA (UDMA, sometimes with TEGDMA) and 6 (4.6%) with UDMA (only); 1 (0.8%) did not contain a BPA derivative or UDMA or TEGDMA. Pure BPA was never reported. Conclusion: This work has established a list of 18 composite resins that contain no BPA derivative. Manufacturers should be required to report the exact composition of their products as it often remains unclear or incomplete. PMID:27708726

Bisphenol A Release: Survey of the Composition of Dental Composite Resins.

PubMed

Dursun, Elisabeth; Fron-Chabouis, Hélène; Attal, Jean-Pierre; Raskin, Anne

2016-01-01

Bisphenol A (BPA) is an endocrine disruptor with potential toxicity. Composite resins may not contain pure BPA, but its derivatives are widely used. Several studies found doses of BPA or its derivatives in saliva or urine of patients after composite resin placement. The aims of this study were to establish an exhaustive list of composite resins marketed in Europe and their composition, and to assess the extent of BPA derivatives used. A research on manufacturers' websites was performed to reference all composite resins marketed in Europe, then their composition was determined from both material safety data sheets and a standardized questionnaire sent to manufacturers. Manufacturers had to indicate whether their product contained the monomers listed, add other monomers if necessary, or indicate "not disclosed". 160 composite resins were identified from 31 manufacturers and 23 manufacturers (74.2%) responded to the survey. From the survey and websites, the composition of 130 composite resins (81.2%) was: 112 (86.2%) based on BPA derivatives, 97 (74.7%) on bis-GMA, 17 (13.1%) without monomer derived from BPA (UDMA, sometimes with TEGDMA) and 6 (4.6%) with UDMA (only); 1 (0.8%) did not contain a BPA derivative or UDMA or TEGDMA. Pure BPA was never reported. This work has established a list of 18 composite resins that contain no BPA derivative. Manufacturers should be required to report the exact composition of their products as it often remains unclear or incomplete.

Hypersonic Composites Resist Extreme Heat and Stress

NASA Technical Reports Server (NTRS)

2007-01-01

Through research contracts with NASA, Materials and Electrochemical Research Corporation (MER), of Tucson, Arizona, contributed a number of technologies to record-breaking hypersonic flights. Through this research, MER developed a coating that successfully passed testing to simulate Mach 10 conditions, as well as provide several additional carbon-carbon (C-C) composite components for the flights. MER created all of the leading edges for the X-43A test vehicles at Dryden-considered the most critical parts of this experimental craft. In addition to being very heat resistant, the coating had to be very lightweight and thin, as the aircraft was designed to very precise specifications and could not afford to have a bulky coating. MER patented its carbon-carbon (C-C) composite process and then formed a spinoff company, Frontier Materials Corporation (FMC), also based in Tucson. FMC is using the patent in conjunction with low-cost PAN (polyacrylonitrile)-based fibers to introduce these materials to the commercial markets. The C-C composites are very lightweight and exceptionally strong and stiff, even at very high temperatures. The composites have been used in industrial heating applications, the automotive and aerospace industries, as well as in glass manufacturing and on semiconductors. Applications also include transfer components for glass manufacturing and structural members for carrier support in semiconductor processing.

Field-structured material media and methods for synthesis thereof

DOEpatents

Martin, James E.; Hughes, Robert C.; Anderson, Robert A.

2001-09-18

The present application is directed to a new class of composite materials, called field-structured composite (FSC) materials, which comprise a oriented aggregate structure made of magnetic particles suspended in a nonmagnetic medium, and to a new class of processes for their manufacture. FSC materials have much potential for application, including use in chemical, optical, environmental, and mechanical sensors.

Glue-free assembly of glass fiber reinforced thermoplastics using laser light

NASA Astrophysics Data System (ADS)

Binetruy, C.; Clement, S.; Deleglise, M.; Franz, C.; Knapp, W.; Oumarou, M.; Renard, J.; Roesner, A.

2011-05-01

The use of laser light for bonding of continuous fiber reinforced thermoplastic composites (CFTPC) offers new possibilities to overcome the constraints of conventional joining technologies. Laser bonding is environmentally friendly as no chemical additive or glue is necessary. Accuracy and flexibility of the laser process as well as the quality of the weld seams provide benefits which are already used in many industrial applications. Laser transmission welding has already been introduced in manufacturing of short fiber thermoplastic composites. The laser replaces hot air in tapelaying systems for pre-preg carbon fiber placement. The paper provides an overview concerning the technical basics of the joining process and outline some material inherent characteristics to be considered when using continuous glass fiber reinforced composites The technical feasibility and the mechanical characterization of laser bonded CFTPC are demonstrated. The influence of the different layer configurations on the laser interaction with the material is investigated and the dependency on the mechanical strength of the weld seem is analyzed. The results show that the laser provides an alternative joining technique and offers new perspectives to assemble structural components emerging in automotive or aeronautical manufacturing. It overcomes the environmental and technical difficulties related to existing gluing processes.

Building Block Approach' for Structural Analysis of Thermoplastic Composite Components for Automotive Applications

NASA Astrophysics Data System (ADS)

Carello, M.; Amirth, N.; Airale, A. G.; Monti, M.; Romeo, A.

2017-12-01

Advanced thermoplastic prepreg composite materials stand out with regard to their ability to allow complex designs with high specific strength and stiffness. This makes them an excellent choice for lightweight automotive components to reduce mass and increase fuel efficiency, while maintaining the functionality of traditional thermosetting prepreg (and mechanical characteristics) and with a production cycle time and recyclability suited to mass production manufacturing. Currently, the aerospace and automotive sectors struggle to carry out accurate Finite Elements (FE) component analyses and in some cases are unable to validate the obtained results. In this study, structural Finite Elements Analysis (FEA) has been done on a thermoplastic fiber reinforced component designed and manufactured through an integrated injection molding process, which consists in thermoforming the prepreg laminate and overmolding the other parts. This process is usually referred to as hybrid molding, and has the provision to reinforce the zones subjected to additional stresses with thermoformed themoplastic prepreg as required and overmolded with a shortfiber thermoplastic resin in single process. This paper aims to establish an accurate predictive model on a rational basis and an innovative methodology for the structural analysis of thermoplastic composite components by comparison with the experimental tests results.

A Review on Functionally Gradient Materials (FGMs) and Their Applications

NASA Astrophysics Data System (ADS)

Bhavar, Valmik; Kattire, Prakash; Thakare, Sandeep; patil, Sachin; Singh, RKP, Dr.

2017-09-01

Functionally gradient materials (FGM) are innovative materials in which final properties varies gradually with dimensions. It is the recent development in traditional composite materials which retains their strengths and eliminates their weaknesses. It can be formed by varying chemical composition, microstructure or design attributes from one end to other as per requirement. This feature allows FGM to have best material properties in required quantities only where it is needed. Though there are several methods available for manufacturing FGMs, additive based metal deposition (by laser, electron beam, plasma etc.) technologies are reaping particular interest owing to their recent developments. This paper presents evolution, current status and challenges of functionally gradient materials (FGMs). Various manufacturing processes of different types of FGMs are also presented. In addition, applications of FGMs in various fields including aerospace, defence, mining, power and tools manufacturing sectors are discussed in detail.

Composite intersection reinforcement

NASA Technical Reports Server (NTRS)

Misciagna, David T. (Inventor); Fuhrer, Jessica J. (Inventor); Funk, Robert S. (Inventor); Tolotta, William S. (Inventor)

2010-01-01

An assembly and method for manufacturing a composite reinforcement for unitizing a structure are provided. According to one embodiment, the assembly includes a base having a plurality of pins extending outwardly therefrom to define a structure about which a composite fiber is wound to define a composite reinforcement preform. The assembly also includes a plurality of mandrels positioned adjacent to the base and at least a portion of the composite reinforcement preform, and a cap that is positioned over at least a portion of the plurality of mandrels. The cap is configured to engage each of the mandrels to support the mandrels and the composite reinforcement preform during a curing process to form the composite reinforcement.

Composite Intersection Reinforcement

NASA Technical Reports Server (NTRS)

Misciagna, David T. (Inventor); Fuhrer, Jessica J. (Inventor); Funk, Robert S. (Inventor); Tolotta, William S. (Inventor)

2013-01-01

An assembly and method for manufacturing a composite reinforcement for unitizing a structure are provided. According to one embodiment, the assembly includes a base having a plurality of pins extending outwardly therefrom to define a structure about which a composite fiber is wound to define a composite reinforcement preform. The assembly also includes a plurality of mandrels positioned adjacent to the base and at least a portion of the composite reinforcement preform, and a cap that is positioned over at least a portion of the plurality of mandrels. The cap is configured to engage each of the mandrels to support the mandrels and the composite reinforcement preform during a curing process to form the composite reinforcement.

Applications research in ultrasonic testing of carbon fiber composite based on an optical fiber F-p sensor

NASA Astrophysics Data System (ADS)

Shan, Ning

2016-10-01

Carbon fiber composite is widely applied to the field of aerospace engineering because of its excellent performance. But it will be able to form more defects in the process of manufacturing inevitably on account of unique manufacturing process. Meanwhile it has sophisticated structure and services in the bad environment long time. The existence of defects will be able to cause the sharp decline in component's performance when the defect accumulates to a certain degree. So the reliability and safety test demand of carbon fiber composite is higher and higher. Ultrasonic testing technology is the important means used for characteristics of component inspection of composite materials. Ultrasonic information detection uses acoustic transducer generally. It need coupling agent and is higher demand for the surface of sample. It has narrow frequency band and low test precision. The extrinsic type optical fiber F-P interference cavity structure is designed to this problem. Its optical interference model is studied. The initial length of F-P cavity is designed. The realtime online detection system of carbon fiber composite is established based on optical fiber F-P Ultrasound sensing technology. Finally, the testing experiment study is conducted. The results show that the system can realize real-time online detection of carbon fiber composite's defect effectively. It operates simply and realizes easily. It has low cost and is easy to practical engineering.

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2010 CFR

2010-07-01

... CATEGORIES National Emissions Standards for Hazardous Air Pollutants: Reinforced Plastic Composites... the reinforced plastic composites you manufacture are used in manufacturing your boats, you are not... applicability criteria in § 63.5785, and produce reinforced plastic composites that are not used in fiberglass...

Critical Needs for Robust and Reliable Database for Design and Manufacturing of Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Singh, M.

1999-01-01

Ceramic matrix composite (CMC) components are being designed, fabricated, and tested for a number of high temperature, high performance applications in aerospace and ground based systems. The critical need for and the role of reliable and robust databases for the design and manufacturing of ceramic matrix composites are presented. A number of issues related to engineering design, manufacturing technologies, joining, and attachment technologies, are also discussed. Examples of various ongoing activities in the area of composite databases. designing to codes and standards, and design for manufacturing are given.

Effect of seasonal variation on the composition and properties of raw milk destined for processing in the UK.

PubMed

Chen, Biye; Lewis, Michael J; Grandison, Alistair S

2014-09-01

The composition and physical properties of raw milk from a commercial herd were studied over a 1 year period in order to understand how best to utilise milk for processing throughout the year. Protein and fat levels demonstrated seasonal trends, while minerals and many physical properties displayed considerable variations, which were apparently unrelated to season. However, rennet clotting time, ethanol stability and foaming ability were subject to seasonal variation. Many significant interrelationships in physico-chemical properties were found. It is clear that the milk supply may be more suited to the manufacture of different products at different times of the year or even on a day to day basis. Subsequent studies will report on variation in production and quality of products manufactured from the same milk samples described in the current study and will thus highlight potential advantages of seasonal processing of raw milk. Copyright © 2014 Elsevier Ltd. All rights reserved.

Variations in Physicochemical Properties of a Traditional Mercury-Based Nanopowder Formulation: Need for Standard Manufacturing Practices

PubMed Central

Kamath, S. U.; Pemiah, B.; Rajan, K. S.; Krishnaswamy, S.; Sethuraman, S.; Krishnan, U. M.

2014-01-01

Rasasindura is a mercury-based nanopowder synthesized using natural products through mechanothermal processing. It has been used in the Ayurvedic system of medicine since time immemorial for various therapeutic purposes such as rejuvenation, treatment of syphilis and in genital disorders. Rasasindura is said to be composed of mercury, sulphur and organic moieties derived from the decoction of plant extracts used during its synthesis. There is little scientific understanding of the preparation process so far. Though metallic mercury is incorporated deliberately for therapeutic purposes, it certainly raises toxicity concerns. The lack of gold standards in manufacturing of such drugs leads to a variation in the chemical composition of the final product. The objective of the present study was to assess the physicochemical properties of Rasasindura samples of different batches purchased from different manufacturers and assess the extent of deviation and gauge its impact on human health. Modern characterization techniques were employed to analyze particle size and morphology, surface area, zeta potential, elemental composition, crystallinity, thermal stability and degradation. Average particle size of the samples observed through scanning electron microscope ranged from 5-100 nm. Mercury content was found to be between 84 and 89% from elemental analysis. Despite batch-to-batch and manufacturer-to-manufacturer variations in the physicochemical properties, all the samples contained mercury in the form of HgS. These differences in the physicochemical properties may ultimately impact its biological outcome. PMID:25593382

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.

2015-01-01

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

40 CFR 158.2120 - Microbial pesticides product analysis data requirements table.

Code of Federal Regulations, 2011 CFR

2011-07-01

... Product Chemistry and Composition 885.1100 Product Identity R MP EP -- 885.1200 Manufacturing process R... Certification of limits R MP EP -- Physical and Chemical Characteristics 830.6302 Color R TGAI TGAI -- 830.6303...

40 CFR 158.2120 - Microbial pesticides product analysis data requirements table.

Code of Federal Regulations, 2012 CFR

2012-07-01

... Product Chemistry and Composition 885.1100 Product Identity R MP EP -- 885.1200 Manufacturing process R... Certification of limits R MP EP -- Physical and Chemical Characteristics 830.6302 Color R TGAI TGAI -- 830.6303...

Modeling the VARTM Composite Manufacturing Process

NASA Technical Reports Server (NTRS)

Song, Xiao-Lan; Loos, Alfred C.; Grimsley, Brian W.; Cano, Roberto J.; Hubert, Pascal

2004-01-01

A comprehensive simulation model of the Vacuum Assisted Resin Transfer Modeling (VARTM) composite manufacturing process has been developed. For isothermal resin infiltration, the model incorporates submodels which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly effect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly.

A neural network controller for automated composite manufacturing

NASA Technical Reports Server (NTRS)

Lichtenwalner, Peter F.

1994-01-01

At McDonnell Douglas Aerospace (MDA), an artificial neural network based control system has been developed and implemented to control laser heating for the fiber placement composite manufacturing process. This neurocontroller learns an approximate inverse model of the process on-line to provide performance that improves with experience and exceeds that of conventional feedback control techniques. When untrained, the control system behaves as a proportional plus integral (PI) controller. However after learning from experience, the neural network feedforward control module provides control signals that greatly improve temperature tracking performance. Faster convergence to new temperature set points and reduced temperature deviation due to changing feed rate have been demonstrated on the machine. A Cerebellar Model Articulation Controller (CMAC) network is used for inverse modeling because of its rapid learning performance. This control system is implemented in an IBM compatible 386 PC with an A/D board interface to the machine.

Hand dismantling and shredding of Japanese automobiles to determine material contents and metal recoveries. Report of investigations/1984

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sterner, J.W.; Steele, D.K.; Shirts, M.B.

The Bureau of Mines conducted studies on four makes of Japanese automobiles, three 1981 and one 1982 model years, received from three manufacturers to determine if their materials composition would present problems to the current technology used to process junk automobiles for metal recovery. One of each make of automobile was hand-dismantled to determine the materials composition. In addition, two nearly identical automobiles of each make were shredded at a commercial operation where all metal products and rejects were collected for analysis to determine metal and nonmetal distribution. The average weight of the four automobiles to be dismantled, less batteries,more » tools, and fluids, was 1,938.3 lb. There were no materials used in the manufacture of the late model Japanese automobiles that should present handling or processing problems to the steelmaking or secondary metal recyclers.« less

High temperature superconducting composite conductor and method for manufacturing the same

DOEpatents

Holesinger, Terry G.; Bingert, John F.

2002-01-01

A high temperature superconducting composite conductor is provided including a high temperature superconducting material surrounded by a noble metal layer, the high temperature superconducting composite conductor characterized as having a fill factor of greater than about 40. Additionally, the conductor can be further characterized as containing multiple cores of high temperature superconducting material surrounded by a noble metal layer, said multiple cores characterized as having substantially uniform geometry in the cross-sectional dimensions. Processes of forming such a high temperature superconducting composite conductor are also provided.

Energetic Materials - Technology, Manufacturing and Processing, 27th International Annual Conference of ICT June 25 - June 28, 1996 Karisruhe, Federal Republic of Germany.

DTIC Science & Technology

1997-02-01

PROPELLANTS WITH VARYING COMPOSITION L.F. Dimaranan, I. Lee, F.E. Hudson III V12 A COMBUSTION MODEL FOR AN/HTPB-IPDI COMPOSITE SOLID PROPELLANTS P... COMPOSITE PROPELLANTS WITH A LOW PRESSURE EXPONENT SUITABLE FOR NOZZLELESS BOOSTER MOTORS G.J. van Zyl V21 PROPERTIES OF AN AND PSAN/GAP-PROPELLANTS K...APPLICATION B.N. Kondrikov SENSITIVITY TO PROJECTILE IMPACT OF PRE-HEATED EXPLOSIVE COMPOSITIONS H.Cherin, D. Lemoine, L. Gautier VULNERABILITY TESTING OF

Wear study of Al-SiC metal matrix composites processed through microwave energy

NASA Astrophysics Data System (ADS)

Honnaiah, C.; Srinath, M. S.; Prasad, S. L. Ajit

2018-04-01

Particulate reinforced metal matrix composites are finding wider acceptance in many industrial applications due to their isotropic properties and ease of manufacture. Uniform distribution of reinforcement particulates and good bonding between matrix and reinforcement phases are essential features in order to obtain metal matrix composites with improved properties. Conventional powder metallurgy technique can successfully overcome the limitation of stir casting techniques, but it is time consuming and not cost effective. Use of microwave technology for processing particulate reinforced metal matrix composites through powder metallurgy technique is being increasingly explored in recent times because of its cost effectiveness and speed of processing. The present work is an attempt to process Al-SiC metal matrix composites using microwaves irradiated at 2.45 GHz frequency and 900 W power for 10 minutes. Further, dry sliding wear studies were conducted at different loads at constant velocity of 2 m/s for various sliding distances using pin-on-disc equipment. Analysis of the obtained results show that the microwave processed Al-SiC composite material shows around 34 % of resistance to wear than the aluminium alloy.

Influence of thermal residual stress on behaviour of metal matrix composites reinforced with particles

NASA Astrophysics Data System (ADS)

Guzmán, R. E.; Hernández Arroyo, E.

2016-02-01

The properties of a metallic matrix composites materials (MMC's) reinforced with particles can be affected by different events occurring within the material in a manufacturing process. The existence of residual stresses resulting from the manufacturing process of these materials (MMC's) can markedly differentiate the curves obtained in tensile tests obtained from compression tests. One of the themes developed in this work is the influence of residual stresses on the mechanical behaviour of these materials. The objective of this research work presented is numerically estimate the thermal residual stresses using a unit cell model for the Mg ZC71 alloy reinforced with SiC particles with volume fraction of 12% (hot-forging technology). The MMC's microstructure is represented as a three dimensional prismatic cube-shaped with a cylindrical reinforcing particle located in the centre of the prism. These cell models are widely used in predicting stress/strain behaviour of MMC's materials, in this analysis the uniaxial stress/strain response of the composite can be obtained through the calculation using the commercial finite-element code.

48 CFR 952.227-13 - Patent rights-acquisition by the Government.

Code of Federal Regulations, 2011 CFR

2011-10-01

... a process or method; or to operate, in the case of a machine or system; and, in each case, under... procedures. (2) If the Contracting Officer learns of an unreported Contractor invention which the Contracting... upon the practice of any specific process, method, machine, manufacture, or composition of matter...

48 CFR 952.227-13 - Patent rights-acquisition by the Government.

Code of Federal Regulations, 2010 CFR

2010-10-01

... a process or method; or to operate, in the case of a machine or system; and, in each case, under... procedures. (2) If the Contracting Officer learns of an unreported Contractor invention which the Contracting... upon the practice of any specific process, method, machine, manufacture, or composition of matter...

40 CFR 63.2292 - What definitions apply to this subpart?

Code of Federal Regulations, 2013 CFR

2013-07-01

..., board coolers, and other process units associated with the manufacturing of plywood and composite wood... are not part of the dryer heated zones. Dry forming means the process of making a mat of resinated..., medium density fiberboard, or hardboard. Dry rotary dryer means a rotary dryer that dries wood particles...

40 CFR 63.2292 - What definitions apply to this subpart?

Code of Federal Regulations, 2012 CFR

2012-07-01

..., board coolers, and other process units associated with the manufacturing of plywood and composite wood... are not part of the dryer heated zones. Dry forming means the process of making a mat of resinated..., medium density fiberboard, or hardboard. Dry rotary dryer means a rotary dryer that dries wood particles...

48 CFR 952.227-13 - Patent rights-acquisition by the Government.

Code of Federal Regulations, 2014 CFR

2014-10-01

... a process or method; or to operate, in the case of a machine or system; and, in each case, under... procedures. (2) If the Contracting Officer learns of an unreported Contractor invention which the Contracting... upon the practice of any specific process, method, machine, manufacture, or composition of matter...

48 CFR 952.227-13 - Patent rights-acquisition by the Government.

Code of Federal Regulations, 2013 CFR

2013-10-01

... a process or method; or to operate, in the case of a machine or system; and, in each case, under... procedures. (2) If the Contracting Officer learns of an unreported Contractor invention which the Contracting... upon the practice of any specific process, method, machine, manufacture, or composition of matter...

48 CFR 952.227-13 - Patent rights-acquisition by the Government.

Code of Federal Regulations, 2012 CFR

2012-10-01

... a process or method; or to operate, in the case of a machine or system; and, in each case, under... procedures. (2) If the Contracting Officer learns of an unreported Contractor invention which the Contracting... upon the practice of any specific process, method, machine, manufacture, or composition of matter...

Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision

NASA Astrophysics Data System (ADS)

Xiong, Jun; Zhang, Guangjun

2013-11-01

Additive manufacturing based on gas metal arc welding is an advanced technique for depositing fully dense components with low cost. Despite this fact, techniques to achieve accurate control and automation of the process have not yet been perfectly developed. The online measurement of the deposited bead geometry is a key problem for reliable control. In this work a passive vision-sensing system, comprising two cameras and composite filtering techniques, was proposed for real-time detection of the bead height and width through deposition of thin walls. The nozzle to the top surface distance was monitored for eliminating accumulated height errors during the multi-layer deposition process. Various image processing algorithms were applied and discussed for extracting feature parameters. A calibration procedure was presented for the monitoring system. Validation experiments confirmed the effectiveness of the online measurement system for bead geometry in layered additive manufacturing.

Optimal cure cycle design of a resin-fiber composite laminate

NASA Technical Reports Server (NTRS)

Hou, Jean W.; Hou, Tan H.; Sheen, Jeen S.

1987-01-01

Fibers reinforced composites are used in many applications. The composite parts and structures are often manufactured by curing the prepreg or unmolded material. The magnitudes and durations of the cure temperature and the cure pressure applied during the cure process have significant consequences on the performance of the finished product. The goal of this study is to exploit the potential of applying the optimization technique to the cure cycle design. The press molding process of a polyester is used as an example. Various optimization formulations for the cure cycle design are investigated. Recommendations are given for further research in computerizing the cure cycle design.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jabbari, M.; Hattel, J. H.; Jambhekar, V. A.

Evaporation of water from a ceramic layer is a key phenomenon in the drying process for the manufacturing of tape cast ceramics. This process contains mass, momentum and energy exchange between the porous medium and the free–flow region. In order to analyze such interaction processes, a Representative Elementary Volume (REV)–scale model concept is presented for coupling non–isothermal multi–phase compositional porous–media flow and single–phase compositional laminar free–flow. The preliminary results show the typical expected evaporation behaviour from a porous medium initially saturated with water, and its transport to the free–flow region according to the existent results from the literature.

New electron beam facility for R&D and production at acsion industries

NASA Astrophysics Data System (ADS)

Lopata, V. J.; Barnard, J. W.; Saunders, C. B.; Stepanik, T. M.

2003-08-01

Since its incorporation in 1998, Acsion Industries Inc. has been working with clients to develop industrial uses of electron processing for improving products and manufacturing processes. Acsion has promoted this technology for sterilizing medical devices and pharmaceuticals, for treating wood pulp in the viscose/rayon process, for reducing pathogens in food and animal feed, and for curing advanced composites for the aerospace industry. As a result of significant developments in its composite curing programs, Acsion has recently made major modifications to its facility to increase its production and R&D capabilities. These modifications are described in this paper.

Strength Analysis and Process Simulation of Subway Contact Rail Support Bracket of Composite Materials

NASA Astrophysics Data System (ADS)

Fedulov, Boris N.; Safonov, Alexander A.; Sergeichev, Ivan V.; Ushakov, Andrey E.; Klenin, Yuri G.; Makarenko, Irina V.

2016-10-01

An application of composites for construction of subway brackets is a very effective approach to extend their lifetime. However, this approach involves the necessity to prevent process-induced distortions of the bracket due to thermal deformation and chemical shrinkage. At present study, a process simulation has been carried out to support the design of the production tooling. The simulation was based on the application of viscoelastic model for the resin. Simulation results were verified by comparison with results of manufacturing experiments. To optimize the bracket structure the strength analysis was carried out as well.

Composite scaffolds for osteochondral repair obtained by combination of additive manufacturing, leaching processes and hMSC-CM functionalization.

PubMed

Díaz Lantada, Andrés; Alarcón Iniesta, Hernán; García-Ruíz, Josefa Predestinación

2016-02-01

Articular repair is a relevant and challenging area for the emerging fields of tissue engineering and biofabrication. The need of significant gradients of properties, for the promotion of osteochondral repair, has led to the development of several families of composite biomaterials and scaffolds, using different effective approaches, although a perfect solution has not yet been found. In this study we present the design, modeling, rapid manufacturing and in vitro testing of a composite scaffold aimed at osteochondral repair. The presented composite scaffold stands out for having a functional gradient of density and stiffness in the bony phase, obtained in titanium by means of computer-aided design combined with additive manufacture using selective laser sintering. The chondral phase is obtained by sugar leaching, using a PDMS matrix and sugar as porogen, and is joined to the bony phase during the polymerization of PDMS, therefore avoiding the use of supporting adhesives or additional intermediate layers. The mechanical performance of the construct is biomimetic and the stiffness values of the bony and chondral phases can be tuned to the desired applications, by means of controlled modifications of different parameters. A human mesenchymal stem cell (h-MSC) conditioned medium (CM) is used for improving scaffold response. Cell culture results provide relevant information regarding the viability of the composite scaffolds used. Copyright © 2015 Elsevier B.V. All rights reserved.

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

NASA Astrophysics Data System (ADS)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

A study on the compatibility between one-bottle dentin adhesives and composite resins using micro-shear bond strength.

PubMed

Song, Minju; Shin, Yooseok; Park, Jeong-Won; Roh, Byoung-Duck

2015-02-01

This study was performed to determine whether the combined use of one-bottle self-etch adhesives and composite resins from same manufacturers have better bond strengths than combinations of adhesive and resins from different manufacturers. 25 experimental micro-shear bond test groups were made from combinations of five dentin adhesives and five composite resins with extracted human molars stored in saline for 24 hr. Testing was performed using the wire-loop method and a universal testing machine. Bond strength data was statistically analyzed using two way analysis of variance (ANOVA) and Tukey's post hoc test. Two way ANOVA revealed significant differences for the factors of dentin adhesives and composite resins, and significant interaction effect (p < 0.001). All combinations with Xeno V (Dentsply De Trey) and Clearfil S(3) Bond (Kuraray Dental) adhesives showed no significant differences in micro-shear bond strength, but other adhesives showed significant differences depending on the composite resin (p < 0.05). Contrary to the other adhesives, Xeno V and BondForce (Tokuyama Dental) had higher bond strengths with the same manufacturer's composite resin than other manufacturer's composite resin. Not all combinations of adhesive and composite resin by same manufacturers failed to show significantly higher bond strengths than mixed manufacturer combinations.

Consolidation & Factors Influencing Sintering Process in Polymer Powder Based Additive Manufacturing

NASA Astrophysics Data System (ADS)

Sagar, M. B.; Elangovan, K.

2017-08-01

Additive Manufacturing (AM) is two decade old technology; where parts are build layer manufacturing method directly from a CAD template. Over the years, AM techniques changes the future way of part fabrication with enhanced intricacy and custom-made features are aimed. Commercially polymers, metals, ceramic and metal-polymer composites are in practice where polymers enhanced the expectations in AM and are considered as a kind of next industrial revolution. Growing trend in polymer application motivated to study their feasibility and properties. Laser sintering, Heat sintering and Inhibition sintering are the most successful AM techniques for polymers but having least application. The presentation gives up selective sintering of powder polymers and listed commercially available polymer materials. Important significant factors for effective processing and analytical approaches to access them are discussed.

Additive Manufacturing of Hierarchical Multi-Phase High-Entropy Alloys for Nuclear Component

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Nan

In recent years, high entropy alloys (HEAs), composed of four or more metallic elements mixed in equal or near equal atomic percent, have attracted significant attention due to their excellent mechanical properties and good corrosion resistance. They show significant promise as candidates for high temperature fission and fusion structural applications. However, the conventional synthesis methods are unlikely to present an industrially suitable route for the production and use of HEAs. Recognizing rapidly evolving additive manufacturing (AM) techniques, the goal of this proposal is to optimize the AM process to fabricate HEAs with predesigned chemical compositions and phase morphologies for nuclearmore » components. For this project, two HEAs FeCrNiMn and FeCrNiMnAl have been successfully synthesized. Correlated mechanical response has been systematically characterized under a variety of laser processing and ion irradiations. Both high entropy alloys are found to present comparable swelling and extraordinary irradiation tolerance (limited voids and stabilized phase structure under high irradiation dose). In addition, the microstructure and radiation-induced hardening can be tailored by laser processing under additive manufacturing. And we have assembled at LANL a unique database of HEAs containing a total of 674 compositions with Phase Stability information. Based on this, the machine learning and Artificial Intelligence capability now are established to predict the microstructure of casted HEAs by given chemical compositions. This unique integration will lead to an optimal AM recipe for fabricating radiation tolerant HEAs. The development of both modeling models and experimental capability will also benefit other programs at LANL.« less

Inkjet Assisted Creation of Self-Healing Layers Between Composite Plies

DTIC Science & Technology

2013-07-29

technology into a prepreg manufacturing process. The approach consisted of depositing novel thermoplastic low-viscosity microdroplets with chemically and...mechanically comparable properties to epoxy matrix in aerospace grade composites onto fiber-reinforced epoxy prepregs before curing using an ink-jet... prepreg Cycom977-2. Double cantilever beam (DCB) and short beam shear (SBS) tests were used to evaluate the self-healing efficiency. It was shown

Structural Foaming at the Nano-, Micro-, and Macro-Scales of Continuous Carbon Fiber Reinforced Polymer Matrix Composites

DTIC Science & Technology

2012-10-29

up to 40%. Approach: Our approach was to work with conventional composite systems manufactured through the traditional prepreg and autoclave...structural porosity at MNM scales could be introduced into the matrix, the carbon fiber reinforcement, and during prepreg lamination processing, without...areas, including fibers. Furthermore, investigate prepreg thickness and resin content effects on the thermomechanical performance of laminated

The Effects of Fiber Orientation and Volume Fraction of Fiber on Mechanical Properties of Additively Manufactured Composite Material

NASA Astrophysics Data System (ADS)

Kuchipudi, Suresh Chandra

Additive manufacturing (AM) also known as 3D printing has tremendous advancements in recent days with a vast number of applications in industrial, automotive, architecture, consumer projects, fashion, toys, food, art, etc. Composite materials are widely used in structures with weight as a critical factor especially in aerospace industry. Recently, additive manufacturing technology, a rapidly growing innovative technology, has gained lot of importance in making composite materials. The properties of composite materials depend upon the properties of constituent's matrix and fiber. There is lot of research on effect of fiber orientation on mechanical properties of composite materials made using conventional manufacturing methods. It will be interesting and relevant to study the relationship between the fiber orientation and fiber volume with mechanical properties of additively manufactured composite materials. This thesis work presents experimental investigation of mechanical behavior like tensile strength and fatigue life with variation in fiber orientation and fiber volume fraction of 3D printed composite materials. The aim is to study the best combination of volume fraction of fiber and fiber orientation that has better fatigue strength for additive manufactured composite materials. Using this study, we can decide the type of orientation and volume percent for desired properties. This study also finds the range of fatigue limits of 3d printed composite materials.

Effect of natural weathering conditions on the dynamic behavior of woven aramid composites

NASA Astrophysics Data System (ADS)

Kaya, A. I.; Kısa, M.; Özen, M.

2018-02-01

In this study, aging of woven aramid/epoxy composites under different natural conditions were studied. Composite beams were manufactured by Vacuum Assisted Resin Infusion Method (VARIM). Composites were cut into specimen according to ASTM D3039 and vibration tests. Elastic moduli of reference composites were found according to ASTM D3039 standard. Validation of methodology was performed numerically in Ansys software before aging process. An algorithm, which is predicated on FFT (Fast Fourier Transforms), was composed in Matlab to process output of vibration analysis data so as to identify natural frequencies of beams. Composites were aged for 12 months and various natural weathering aging conditions effects on woven aramid composite beams were surveyed through vibration analysis with 3 months interval. Five specimens of woven aramid beams were considered for dynamic tests and effect of aging on first three natural frequencies were determined.

International collaborative project to compare and monitor the nutritional composition of processed foods.

PubMed

Dunford, Elizabeth; Webster, Jacqui; Metzler, Adriana Blanco; Czernichow, Sebastien; Ni Mhurchu, Cliona; Wolmarans, Petro; Snowdon, Wendy; L'Abbe, Mary; Li, Nicole; Maulik, Pallab K; Barquera, Simon; Schoj, Verónica; Allemandi, Lorena; Samman, Norma; de Menezes, Elizabete Wenzel; Hassell, Trevor; Ortiz, Johana; Salazar de Ariza, Julieta; Rahman, A Rashid; de Núñez, Leticia; Garcia, Maria Reyes; van Rossum, Caroline; Westenbrink, Susanne; Thiam, Lim Meng; MacGregor, Graham; Neal, Bruce

2012-12-01

Chronic diseases are the leading cause of premature death and disability in the world with overnutrition a primary cause of diet-related ill health. Excess energy intake, saturated fat, sugar, and salt derived from processed foods are a major cause of disease burden. Our objective is to compare the nutritional composition of processed foods between countries, between food companies, and over time. Surveys of processed foods will be done in each participating country using a standardized methodology. Information on the nutrient composition for each product will be sought either through direct chemical analysis, from the product label, or from the manufacturer. Foods will be categorized into 14 groups and 45 categories for the primary analyses which will compare mean levels of nutrients at baseline and over time. Initial commitments to collaboration have been obtained from 21 countries. This collaborative approach to the collation and sharing of data will enable objective and transparent tracking of processed food composition around the world. The information collected will support government and food industry efforts to improve the nutrient composition of processed foods around the world.

Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

NASA Astrophysics Data System (ADS)

Famodimu, Omotoyosi H.; Stanford, Mark; Oduoza, Chike F.; Zhang, Lijuan

2018-06-01

Laser melting of aluminium alloy—AlSi10Mg has increasingly been used to create specialised products in various industrial applications, however, research on utilising laser melting of aluminium matrix composites in replacing specialised parts have been slow on the uptake. This has been attributed to the complexity of the laser melting process, metal/ceramic feedstock for the process and the reaction of the feedstock material to the laser. Thus, an understanding of the process, material microstructure and mechanical properties is important for its adoption as a manufacturing route of aluminium metal matrix composites. The effects of several parameters of the laser melting process on the mechanical blended composite were thus investigated in this research. This included single track formations of the matrix alloy and the composite alloyed with 5% and 10% respectively for their reaction to laser melting and the fabrication of density blocks to investigate the relative density and porosity over different scan speeds. The results from these experiments were utilised in determining a process window in fabricating near-fully dense parts.

40 CFR 158.2171 - Experimental use permit microbial pesticides product analysis data requirements table.

Code of Federal Regulations, 2014 CFR

2014-07-01

... notes Product Chemistry and Composition 885.1100 Product identity R MP EP 885.1200 Manufacturing process....1500 Certification of limits R MP EP Physical and Chemical Characteristics 830.6302 Color R TGAI TGAI...

40 CFR 158.2171 - Experimental use permit microbial pesticides product analysis data requirements table.

Code of Federal Regulations, 2013 CFR

2013-07-01

... notes Product Chemistry and Composition 885.1100 Product identity R MP EP 885.1200 Manufacturing process....1500 Certification of limits R MP EP Physical and Chemical Characteristics 830.6302 Color R TGAI TGAI...

Properties of CF/PA6 friction spun hybrid yarns for textile reinforced thermoplastic composites

NASA Astrophysics Data System (ADS)

Hasan, MMB; Nitsche, S.; Abdkader, A.; Cherif, Ch

2017-10-01

Due to their excellent strength, rigidity and damping properties as well as low weight, carbon fibre reinforced composites (CFRC) are widely being used for load bearing structures. On the other hand, with an increased demand und usage of CFRCs, effective methods to re-use waste carbon fibre (CF) materials, which are recoverable either from the process scraps or from the end-of-life components are attracting increased attention. In this paper, hybrid yarns consisting of staple CF and polyamide 6 (PA 6) are manufactured on a DREF-3000 friction spinning machine with various machine parameters such as spinning drum speed and suction air pressure. The relationship between different textile physical properties of the hybrid yarns, such as tensile strength and elongation with different spinning parameters and CF content of hybrid yarn is investigated. Furthermore, the tensile properties of uni-directional (UD) composites manufactured from the developed hybrid yarn shows 80% of the UD composite strength made from CF filament yarn.

Technological assessment of local manufacturers for wind turbine blade manufacturing in Pakistan

NASA Astrophysics Data System (ADS)

Mahmood, Khurram; Haroon, General

2012-11-01

Composite materials manufacturing industry is one of the world's hi-tech industry. Manufacturing of wind turbine blades is one of the specialized fields requiring high degree of precision and composite manufacturing techniques. This paper identifies the industries specializing in the composite manufacturing and is able to manufacture wind turbines blades in Pakistan. In the second phase, their technology readiness level is determined, based on some factors and then a readiness level are assigned to them. The assigned technology readiness level will depict the absorptive capacity of each manufacturing unit and its capability to take on such projects. The individual readiness level of manufacturing unit will then be used to establish combined technology readiness level of Pakistan particularly for wind turbine blades manufacturing. The composite manufacturing industry provides many spin offs and a diverse range of products can be manufactured using this facility. This research will be helpful to categorize the strong points and flaws of local industry for the gap analysis. It can also be used as a prerequisite study before the evaluation of technologies and specialties to improve the industry of the country for the most favorable results. This will form a basic data base which can be used for the decision making related to transfer of technology, training of local skilled workers and general up-gradation of the local manufacturing units.

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Halbig, Michael Charles; Singh, Mrityunjay

2015-01-01

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

[Interchangeability of biological drugs: considerations about the approval of biogeneric formulations in Chile].

PubMed

Saavedra S, Iván; Quiñones S, Luis

2006-12-01

Once drug patents expire, the health authorities can approve the registry of similar products. They must request to the manufacturer, the bibliographic background of the original product and the analytical results that certify drug quality. An inspection of the premises of the manufacturer is also required. The main goal of this approval is to decrease cost, considering that the original product is usually more expensive. This is a current situation due to the imminent expiration of the patents of many biopharmaceutical products. Therefore, in Chile, the Public Health (ISP) and the Ministry of Health should consider that for this kind of products, until now, there are no interchangeable generic drugs, and that the similar drugs that are offered have a different chemical composition, since they have been manufactured through different processes. In the case of biological drugs (e.g. erythropoietir, somatotropin, heparin) the quality and homogeneity depend from the manufacture process. Its complete composition can not be absolutely elucidated; therefore small impurities or conformational variants can elicit an altered immune response or unexpected adverse reactions. This indicates that the approval of a biogeneric drug requires in addition to pharmacokinetic studies, preclinical and clinical analytical studies such as physicochemical assays, biological and immunological test. This issues have been established by WHO and have been incorporated for the main drug registry entities all over the world (FDA, EMEA, ANVISA) to approve biogeneric products.

Modeling and control of flow during impregnation of heterogeneous porous media, with application to composite mold-filling processes

NASA Astrophysics Data System (ADS)

Bickerton, Simon

Liquid Composite Molding (LCM) encompasses a growing list of composite material manufacturing techniques. These processes have provided the promise for complex fiber reinforced plastics parts, manufactured from a single molding step. In recent years a significant research effort has been invested in development of process simulations, providing tools that have advanced current LCM technology and broadened the range of applications. The requirement for manufacture of larger, more complex parts has motivated investigation of active control of LCM processes. Due to the unlimited variety of part geometries that can be produced, finite element based process simulations will be used to some extent in design of actively controlled processes. Ongoing efforts are being made to improve material parameter specification for process simulations, increasing their value as design tools. Several phenomena occurring during mold filling have been addressed through flow visualization experimentation and analysis of manufactured composite parts. The influence of well defined air channels within a mold cavity is investigated, incorporating their effects within existing filling simulations. Three different flow configurations have been addressed, testing the application of 'equivalent permeabilities', effectively approximating air channels as representative porous media. LCM parts having doubly curved regions require preform fabrics to undergo significant, and varying deformation throughout a mold cavity. Existing methods for predicting preform deformation, and the resulting permeability distribution have been applied to a conical mold geometry. Comparisons between experiment and simulation are promising, while the geometry studied has required large deformation over much of the part, shearing the preform fabric beyond the scope of the models applied. An investigational study was performed to determine the magnitude of effect, if any, on mold filling caused by corners within LCM mold cavities. The molds applied in this study have required careful consideration of cavity thickness variations. Any effects on mold filling due to corner radii have been overshadowed by those due to preform compression. While numerical tools are available to study actively controlled mold filling in a virtual environment, some development is required for the physical equipment to implement this in practice. A versatile, multiple line fluid injection system is developed here. The equipment and control algorithms employed have provided servo control of flow rate, or injection pressure, and have been tested under very challenging conditions. The single injection line developed is expanded to a multiple line system, and shows great potential for application to actual resin systems. A case study is presented, demonstrating design and implementation of a simple actively controlled injection scheme. The experimental facility developed provides an excellent testbed for application of actively controlled mold filling concepts, an area that is providing great promise for the advancement of LCM processes.

Design and manufacture of a lightweight piezo-composite curved actuator

NASA Astrophysics Data System (ADS)

Yoon, K. Joon; Shin, Seokjun; Park, Hoon C.; Goo, Nam Seo

2002-02-01

In this paper we are concerned with the design, manufacture and performance test of a lightweight piezo-composite curved actuator (called LIPCA) using a top carbon fiber composite layer with near-zero coefficient of thermal expansion (CTE), a middle PZT ceramic wafer, and a bottom glass/epoxy layer with a high CTE. The main point of the design for LIPCA is to replace the heavy metal layers of THUNDERTM by lightweight fiber reinforced plastic layers without losing the capabilities for generating high force and large displacement. It is possible to save up to about 40% of the weight if we replace the metallic backing material by the light fiber composite layer. We can also have design flexibility by selecting the fiber direction and the size of prepreg layers. In addition to the lightweight advantage and design flexibility, the proposed device can be manufactured without adhesive layers when we use an epoxy resin prepreg system. Glass/epoxy prepregs, a ceramic wafer with electrode surfaces, and a carbon prepreg were simply stacked and cured at an elevated temperature (177 °C) after following an autoclave bagging process. We found that the manufactured composite laminate device had a sufficient curvature after being detached from a flat mould. An analysis method using the classical lamination theory is presented to predict the curvature of LIPCA after curing at an elevated temperature. The predicted curvatures are in quite good agreement with the experimental values. In order to investigate the merits of LIPCA, performance tests of both LIPCA and THUNDERTM have been conducted under the same boundary conditions. From the experimental actuation tests, it was observed that the developed actuator could generate larger actuation displacement than THUNDERTM.

Cost-Benefit Analysis for the Advanced Near Net Shape Technology (ANNST) Method for Fabricating Stiffened Cylinders

NASA Technical Reports Server (NTRS)

Ivanco, Marie L.; Domack, Marcia S.; Stoner, Mary Cecilia; Hehir, Austin R.

2016-01-01

Low Technology Readiness Levels (TRLs) and high levels of uncertainty make it challenging to develop cost estimates of new technologies in the R&D phase. It is however essential for NASA to understand the costs and benefits associated with novel concepts, in order to prioritize research investments and evaluate the potential for technology transfer and commercialization. This paper proposes a framework to perform a cost-benefit analysis of a technology in the R&D phase. This framework was developed and used to assess the Advanced Near Net Shape Technology (ANNST) manufacturing process for fabricating integrally stiffened cylinders. The ANNST method was compared with the conventional multi-piece metallic construction and composite processes for fabricating integrally stiffened cylinders. Following the definition of a case study for a cryogenic tank cylinder of specified geometry, data was gathered through interviews with Subject Matter Experts (SMEs), with particular focus placed on production costs and process complexity. This data served as the basis to produce process flowcharts and timelines, mass estimates, and rough order-of-magnitude cost and schedule estimates. The scalability of the results was subsequently investigated to understand the variability of the results based on tank size. Lastly, once costs and benefits were identified, the Analytic Hierarchy Process (AHP) was used to assess the relative value of these achieved benefits for potential stakeholders. These preliminary, rough order-of-magnitude results predict a 46 to 58 percent reduction in production costs and a 7-percent reduction in weight over the conventional metallic manufacturing technique used in this study for comparison. Compared to the composite manufacturing technique, these results predict cost savings of 35 to 58 percent; however, the ANNST concept was heavier. In this study, the predicted return on investment of equipment required for the ANNST method was ten cryogenic tank barrels when compared with conventional metallic manufacturing. The AHP study results revealed that decreased final cylinder mass and improved quality assurance were the most valued benefits of cylinder manufacturing methods, therefore emphasizing the relevance of the benefits achieved with the ANNST process for future projects.

Media milling process optimization for manufacture of drug nanoparticles using design of experiments (DOE).

PubMed

Nekkanti, Vijaykumar; Marwah, Ashwani; Pillai, Raviraj

2015-01-01

Design of experiments (DOE), a component of Quality by Design (QbD), is systematic and simultaneous evaluation of process variables to develop a product with predetermined quality attributes. This article presents a case study to understand the effects of process variables in a bead milling process used for manufacture of drug nanoparticles. Experiments were designed and results were computed according to a 3-factor, 3-level face-centered central composite design (CCD). The factors investigated were motor speed, pump speed and bead volume. Responses analyzed for evaluating these effects and interactions were milling time, particle size and process yield. Process validation batches were executed using the optimum process conditions obtained from software Design-Expert® to evaluate both the repeatability and reproducibility of bead milling technique. Milling time was optimized to <5 h to obtain the desired particle size (d90 < 400 nm). The desirability function used to optimize the response variables and observed responses were in agreement with experimental values. These results demonstrated the reliability of selected model for manufacture of drug nanoparticles with predictable quality attributes. The optimization of bead milling process variables by applying DOE resulted in considerable decrease in milling time to achieve the desired particle size. The study indicates the applicability of DOE approach to optimize critical process parameters in the manufacture of drug nanoparticles.

The effect of manufacturing conditions on discontinuity population and fatigue fracture behavior in carbon/epoxy composites

NASA Astrophysics Data System (ADS)

Hakim, Issa; Laquai, Rene; Walter, David; Mueller, Bernd; Graja, Paul; Meyendorf, Norbert; Donaldson, Steven

2017-02-01

Carbon fiber composites have been increasingly used in aerospace, military, sports, automotive and other fields due to their excellent properties, including high specific strength, high specific modulus, corrosion resistance, fatigue resistance, and low thermal expansion coefficient. Interlaminar fracture is a serious failure mode leading to a loss in composite stiffness and strength. Discontinuities formed during manufacturing process degrade the fatigue life and interlaminar fracture resistance of the composite. In his study, three approaches were implemented and their results were correlated to quantify discontinuities effecting static and fatigue interlaminar fracture behavior of carbon fiber composites. Samples were fabricated by hand layup vacuum bagging manufacturing process under three different vacuum levels, indicated High (-686 mmHg), Moderate (-330 mmHg) and Poor (0 mmHg). Discontinuity content was quantified through-thickness by destructive and nondestructive techniques. Eight different NDE methods were conducted including imaging NDE methods: X-Ray laminography, ultrasonic, high frequency eddy current, pulse thermography, pulse phase thermography and lock-in-thermography, and averaging NDE techniques: X-Ray refraction and thermal conductivity measurements. Samples were subsequently destructively serial sectioned through-thickness into several layers. Both static and fatigue interlaminar fracture behavior under Mode I were conducted. The results of several imaging NDE methods revealed the trend in percentages of discontinuity. However, the results of averaging NDE methods showed a clear correlation since they gave specific values of discontinuity through-thickness. Serial sectioning exposed the composite's internal structure and provided a very clear idea about the type, shape, size, distribution and location of most discontinuities included. The results of mechanical testing showed that discontinuities lead to a decrease in Mode I static interlaminar fracture toughness and a decrease in Mode I cyclic strain energy release rates fatigue life. Finally, all approaches were correlated: the resulted NDE percentages and parameters were correlated with the features revealed by the destructive test of serial sectioning and static and fatigue values in order to quantify discontinuities such as delamination and voids.

Tooling Foam for Structural Composite Applications

NASA Technical Reports Server (NTRS)

DeLay, Tom; Smith, Brett H.; Ely, Kevin; MacArthur, Doug

1998-01-01

Tooling technology applications for composite structures fabrication have been expanded at MSFC's Productivity Enhancement Complex (PEC). Engineers from NASA/MSFC and Lockheed Martin Corporation have developed a tooling foam for use in composite materials processing and manufacturing that exhibits superior thermal and mechanical properties in comparison with other tooling foam materials. This tooling foam is also compatible with most preimpregnated composite resins such as epoxy, bismaleimide, phenolic and their associated cure cycles. MARCORE tooling foam has excellent processability for applications requiring either integral or removable tooling. It can also be tailored to meet the requirements for composite processing of parts with unlimited cross sectional area. A shelf life of at least six months is easily maintained when components are stored between 50F - 70F. The MARCORE tooling foam system is a two component urethane-modified polyisocyanurate, high density rigid foam with zero ozone depletion potential. This readily machineable, lightweight tooling foam is ideal for composite structures fabrication and is dimensionally stable at temperatures up to 350F and pressures of 100 psi.

Applied Integrated Design in Composite UAV Development

NASA Astrophysics Data System (ADS)

Vasić, Zoran; Maksimović, Stevan; Georgijević, Dragutin

2018-04-01

This paper presents a modern approach to integrated development of Unmanned Aerial Vehicle made of laminated composite materials from conceptual design, through detail design, strength and stiffness analyses, definition and management of design and production data, detailed tests results and other activities related to development of laminated composite structures with main of its particularities in comparison to metal structures. Special attention in this work is focused to management processes of product data during life cycle of an UAV and experimental tests of its composite wing. Experience shows that the automation management processes of product data during life cycle, as well as processes of manufacturing, are inevitable if a company wants to get cheaper and quality composite aircraft structures. One of the most effective ways of successful management of product data today is Product Life cycle Management (PLM). In terms of the PLM, a spectrum of special measures and provisions has to be implemented when defining fiber-reinforced composite material structures in comparison to designing with metals which is elaborated in the paper.

Characterization and manufacture of braided composites for large commercial aircraft structures

NASA Technical Reports Server (NTRS)

Fedro, Mark J.; Willden, Kurtis

1992-01-01

Braided composite materials has been recognized as a potential cost effective material form for fuselage structural elements. Consequently, there is a strong need for more knowledge in the design, manufacture, test, and analysis of textile structural composites. Advance braided composite technology is advanced towards applications to a large commercial transport fuselage. The mechanics are summarized of materials and manufacturing demonstration results which were obtained in order to acquire an understanding of how braided composites can be applied to a commercial fuselage. Textile composites consisting of 2-D, 2-D triaxial, and 3-D braid patterns with thermoplastic and two resin transfer molding resin systems were studied. The structural performance of braided composites was evaluated through an extensive mechanical test program. Analytical methods were also developed and applied to predict the following: internal fiber architecture; stiffness; fiber stresses; failure mechanisms; notch effects; and the history of failure of the braided composite specimens. The applicability of braided composites to a commercial transport fuselage was further assessed through a manufacturing demonstration.

The Microwave Assisted Composite Manufacturing and Repair (MACMAR) Project

NASA Technical Reports Server (NTRS)

Falker, John; Terrier, Douglas; Clayton, Ronald G.; Worthy, Erica; Sosa, Edward

2015-01-01

The inherent microwave property of carbon nanotubes (CNTs) generates the thermal energy required to induce reversible polymerization of the matrix in these self-healing composites. Microwaves will be used to demonstrate advanced composite manufacturing and repair using self-healing composites.

Composite structural materials. [fiber reinforced composites for aircraft structures

NASA Technical Reports Server (NTRS)

Ansell, G. S.; Loewy, R. G.; Wiberly, S. E.

1981-01-01

Physical properties of fiber reinforced composites; structural concepts and analysis; manufacturing; reliability; and life prediction are subjects of research conducted to determine the long term integrity of composite aircraft structures under conditions pertinent to service use. Progress is reported in (1) characterizing homogeneity in composite materials; (2) developing methods for analyzing composite materials; (3) studying fatigue in composite materials; (4) determining the temperature and moisture effects on the mechanical properties of laminates; (5) numerically analyzing moisture effects; (6) numerically analyzing the micromechanics of composite fracture; (7) constructing the 727 elevator attachment rib; (8) developing the L-1011 engine drag strut (CAPCOMP 2 program); (9) analyzing mechanical joints in composites; (10) developing computer software; and (11) processing science and technology, with emphasis on the sailplane project.

Electron Beam-Cure Polymer Matrix Composites: Processing and Properties

NASA Technical Reports Server (NTRS)

Wrenn, G.; Frame, B.; Jensen, B.; Nettles, A.

2001-01-01

Researchers from NASA and Oak Ridge National Laboratory are evaluating a series of electron beam curable composites for application in reusable launch vehicle airframe and propulsion systems. Objectives are to develop electron beam curable composites that are useful at cryogenic to elevated temperatures (-217 C to 200 C), validate key mechanical properties of these composites, and demonstrate cost-saving fabrication methods at the subcomponent level. Electron beam curing of polymer matrix composites is an enabling capability for production of aerospace structures in a non-autoclave process. Payoffs of this technology will be fabrication of composite structures at room temperature, reduced tooling cost and cure time, and improvements in component durability. This presentation covers the results of material property evaluations for electron beam-cured composites made with either unidirectional tape or woven fabric architectures. Resin systems have been evaluated for performance in ambient, cryogenic, and elevated temperature conditions. Results for electron beam composites and similar composites cured in conventional processes are reviewed for comparison. Fabrication demonstrations were also performed for electron beam-cured composite airframe and propulsion piping subcomponents. These parts have been built to validate manufacturing methods with electron beam composite materials, to evaluate electron beam curing processing parameters, and to demonstrate lightweight, low-cost tooling options.

Development and study of the displaced foam dispersion methodology for the manufacture of multiscale/hybrid composites

NASA Astrophysics Data System (ADS)

McCrary-Dennis, Micah C. L.

Incorporating nanostructured functional constituents within polymers has become extensive in processes and products for manufacturing composites. The conception of carbon nanotubes (CNTs) and their heralded attributes yielding property enhancements to the carrier system is leading many industries and research endeavors. Displaced Foam Dispersion (DFD) methodology is a novel and effective approach to facilitating the incorporation of CNTs within fiber reinforced polymer composites (FRPC). The methodology consists of six separate solubility phases that lead to the manufacture of CNT-FRPCs (also termed hybrid/multiscale composites). This study was primarily initiated to characterize the interaction parameters of nanomaterials (multiwall carbon nanotubes), polymers (polystyrene), and solvents (dimethyl formamide (DMF) and acetone) in the current paradigm of the DFD materials manufacture. Secondly, we sought to illustrate the theoretical potential for the methodology to be used in conjunction with other nanomaterial-polymer-solvent systems. Herein, the theory of Hansen's solubility parameters (HSP) is employed to explain the DFD constituents manufacturing combination parameters and aid in the explanation of the experimental results. The results illustrate quantitative values for the relative energy differences between each polymer-solvent system. Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) were used to characterize the multiwalled carbon nanotubes (MWCNTs) in each of the solubility stages and culminates with an indication of good dispersion potential in the final multiscale composite. Additionally, acetone absorption, evaporation mass loss and retention are reported for the sorbed plasticized PS-CNT (CNTaffy) nanocomposites that has successfully achieved up through approximately 60 weight percent loading. The findings indicate that as CNT loading percentage increases the acetone absorbency also increases, but the materials retention of acetone over time decreases. This directly influences the manufacturability of the porous polymer nanocomposite (P-PNC) in the DFD methodology. Localized interlaminar CNT enrichment was achieved through 60 wt. % loading within the P-PNC and verified under two-electrode electrical conductivity testing of the final multiscale composite. The electrical properties of low weight percent (approximately 0.15 - 2.5 wt. %) nanomaterials show a decreasing trend in the materials' resistivity that indicates the ability to become increasingly conductive with increasing CNT loadings. Finally, the mechanical properties will show evidence of toughness, increased strain to failure, and the potential for greater energy absorption.

Monolayer boron-aluminum compacted sheet material

NASA Technical Reports Server (NTRS)

Sumner, E. V.

1973-01-01

The manufacturing techniques, basic materials used, and equipment required to produce monolayer boron-aluminum composites are described. Tentative materials and process specifications are included. Improvements in bonding and filament spacing obtained through use of brazing powder in the fugitive binder are discussed.

Film Delivery Module For Fiber Placement Fabrication of Hybridized Composite Structures

NASA Technical Reports Server (NTRS)

Hulcher, Anthony Bruce; Young, Greg

2005-01-01

A new fabrication technology has been developed at the NASA Marshall Space Flight Center that will allow for the fabrication of hybridized composite structures using fiber placement processing. This technology was originally developed in response to a need to address the issue of hydrogen permeation and microcracking in cryogenic propellant tanks. Numerous thin polymeric and metallized films were investigated under low temperatures conditions for use as barrier films in a composite tank. Manufacturing studies conducted at that time did not address the processing issues related to fabrication of a hybridized tank wall. A film processing head was developed that will allow for the processing of thin polymeric and metallized films, metallic foils, and adhesives using fiber placement processing machinery. The film head is designed to enable the simultaneous processing of film materials and composite tape/tow during the composite part layup process and is also capable of processing the film during an independent operation. Several initial demonstrations were conducted to assess the performance of the film module device. Such assessments included film strip lay-up accuracy, capability to fabricate panels having internal film liners, and fabrication of laminates with embedded film layers.

A review on the advances in 3D printing and additive manufacturing of ceramics and ceramic matrix composites for optical applications

NASA Astrophysics Data System (ADS)

Goodman, William A.

2017-09-01

This paper provides a review of advances in 3D printing and additive manufacturing of ceramic and ceramic matrix composites for optical applications. Dr. Goodman has been pioneering additive manufacturing of ceramic matrix composites since 2008. He is the inventor of HoneySiC material, a zero-CTE additively manufactured carbon fiber reinforced silicon carbide ceramic matrix composite, briefly mentioned here. More recently Dr. Goodman has turned his attention to the direct printing of ceramics for optical applications via various techniques including slurry and laser sintering of silicon carbide and other ceramic materials.

Development and kinetic analysis of cobalt gradient formation in WC-Co composites

NASA Astrophysics Data System (ADS)

Guo, Jun

2011-12-01

Functionally graded cemented tungsten carbide (FG WC-Co) is one of the main research directions in the field of WC-Co over decades. Although it has long been recognized that FG WC-Co could outperform conventional homogeneous WC-Co owing to its potentially superior combinations of mechanical properties, until recently there has been a lack of effective and economical methods to make such materials. The lack of the technology has prevented the manufacturing and industrial applications of FG WC-Co from becoming a reality. This dissertation is a comprehensive study of an innovative atmosphere heat treatment process for producing FG WC-Co with a surface cobalt compositional gradient. The process exploited a triple phase field in W-C-Co phase diagram among three phases (solid WC, solid Co, and liquid Co) and the dependence of the migration of liquid Co on temperature and carbon content. WC-Co with a graded surface cobalt composition can be achieved by controlling the diffusion of carbon transported from atmosphere during sintering or during postsintering heat treatment. The feasibility of the process was validated by the successful preparations of FG WC-Co via both carburization and decarburization process following conventional liquid phase sintering. A study of the carburization process was undertaken to further understand and quantitatively modeled this process. The effects of key processing parameters (including heat treating temperature, atmosphere, and time) and key materials variables (involving Co content, WC grain size, and addition of grain growth inhibitors) on the formation of Co gradients were examined. Moreover, a carbon-diffusion controlled kinetic model was developed for simulating the formation of the gradient during the process. The parameters involved in this model were determined by thermodynamic calculations and regression-fit of simulation results with experimental data. In summary, this research first demonstrated the principle of the approach. Second, a model was developed to predict the gradients produced by the carbon-controlled atmosphere heat treatment process, which is useful for manufacturing WC-Co with designed gradients. FG WC-Co materials produced using this method are expected to exhibit superior performance in many applications and to have a profound impact on the manufacturing industries that use tungsten carbide tools.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Sang-Woo; Seong, Dong Gi; Yi, Jin-Woo

In order to manufacture carbon fiber-reinforced polyamide-6 (PA-6) composite, we optimized the reactive processing system. The in-situ anionic ring-opening polymerization of ε-caprolactam was utilized with proper catalyst and initiator for PA-6 matrix. The mechanical properties such as tensile strength, inter-laminar shear strength and compressive strength of the produced carbon fiber-reinforced PA-6 composite were measured, which were compared with the corresponding scanning electron microscope (SEM) images to investigate the polymer properties as well as the interfacial interaction between fiber and polymer matrix. Furthermore, kinetics of in-situ anionic ring-opening polymerization of ε-caprolactam will be discussed in the viewpoint of increasing manufacturing speedmore » and interfacial bonding between PA-6 matrix and carbon fiber during polymerization.« less

Method for manufacturing whisker preforms and composites

DOEpatents

Lessing, Paul A.

1995-01-01

A process for manufacturing Si.sub.3 N.sub.4 /SiAlON whiskers by mixing silicon carbide powder with aluminum nitride powder, adding impurities such as calcium oxide or potassium chloride to control whisker characteristics, forming the mixture in a boron nitrogen mold of desired shaped and hot isostatically pressing the formed mixture in a nitrogen environment to produce whiskers comprised substantially of SiAlON at the nucleating end of the whisker and Si.sub.3 N.sub.4 at the other end of the whisker. In one embodiment, reinforced composites are formed by impregnating the Si.sub.3 N.sub.4 /SiAlON whisker preform with a matrix material such as resin binders, liquid metals, intermetallics or ceramic materials.

Method for manufacturing whisker preforms and composites

DOEpatents

Lessing, P.A.

1995-11-07

A process is disclosed for manufacturing Si{sub 3}N{sub 4}/SiAlON whiskers by mixing silicon carbide powder with aluminum nitride powder, adding impurities such as calcium oxide or potassium chloride to control whisker characteristics, forming the mixture in a boron nitrogen mold of desired shaped and hot isostatically pressing the formed mixture in a nitrogen environment to produce whiskers comprised substantially of SiAlON at the nucleating end of the whisker and Si{sub 3}N{sub 4} at the other end of the whisker. In one embodiment, reinforced composites are formed by impregnating the Si{sub 3}N{sub 4}/SiAlON whisker preform with a matrix material such as resin binders, liquid metals, intermetallics or ceramic materials.

MANTECH Project Book, 1992

DTIC Science & Technology

1992-01-01

RUGATE FILTER PROCESS AND PRODUCTION ................ 111 MANUFACTURING SCIENCE FOR TITANIUM ALUMINIDE COMPOSITE ENGINE STRU CTURES...rejection and mission filters , anti-reflection coatings, and dichroic layers which can have demanding optical requirements. Rugate m coatings can be used to...SCIENCE RUGATE FILTER PROCESS AND PRODUCTION CONTRACT NUMBER: F33615-86-C-5059STATEMENT OF NEED Achieving the optical performance specifications for

Processing bulk natural wood into a high-performance structural material

Treesearch

Jianwei Song; Chaoji Chen; Shuze Zhu; Mingwei Zhu; Jiaqi Dai; Upamanyu Ray; Yiju Li; Yudi Kuang; Yongfeng Li; Nelson Quispe; Yonggang Yao; Amy Gong; Ulrich H. Leiste; Hugh A. Bruck; J. Y. Zhu; Azhar Vellore; Heng Li; Marilyn L. Minus; Zheng Jia; Ashlie Martini; Teng Li; Liangbing Hu

2018-01-01

Synthetic structural materials with exceptional mechanical performance suffer from either large weight and adverse environmental impact (for example, steels and alloys) or complex manufacturing processes and thus high cost (for example, polymer-based and biomimetic composites)1–8. Natural wood is a low-cost and abundant material and has been used...

Innovative forming and fabrication technologies : new opportunities.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Davis, B.; Hryn, J.; Energy Systems

2008-01-31

The advent of light metal alloys and advanced materials (polymer, composites, etc.) have brought the possibility of achieving important energy reductions into the full life cycle of these materials, especially in transportation applications. 1 These materials have gained acceptance in the aerospace industry but use of light metal alloys needs to gain wider acceptance in other commercial transportation areas. Among the main reasons for the relatively low use of these materials are the lack of manufacturability, insufficient mechanical properties, and increased material costs due to processing inefficiencies. Considering the enormous potential energy savings associated with the use of light metalmore » alloys and advanced materials in transportation, there is a need to identify R&D opportunities in the fields of materials fabrication and forming aimed at developing materials with high specific mechanical properties combined with energy efficient processes and good manufacturability. This report presents a literature review of the most recent developments in the areas of fabrication and metal forming focusing principally on aluminum alloys. In the first section of the document, the different sheet manufacturing technologies including direct chill (DC) casting and rolling, spray forming, spray rolling, thin slab, and strip casting are reviewed. The second section of the document presents recent research on advanced forming processes. The various forming processes reviewed are: superplastic forming, electromagnetic forming, age forming, warm forming, hydroforming, and incremental forming. Optimization of conventional forming processes is also discussed. Potentially interesting light metal alloys for high structural efficiency including aluminum-scandium, aluminum-lithium, magnesium, titanium, and amorphous metal alloys are also reviewed. This section concludes with a discussion on alloy development for manufacturability. The third section of the document reviews the latest developments in fiber-reinforced composite materials. Emerging curing processes are presented along with a discussion on the possible developments in biocomposite materials. The fourth section presents recent developments in the fabrication of bulk nanomaterials and nanoparticles reinforced materials. Advanced joining technologies are presented in the fifth section. Future research is proposed in the last section.« less

Logistics for the implementation of lead-free solders on electronic assemblies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vianco, P.T.; Artaki, I.

1993-12-31

The prospects of legislative and regulatory action aimed at taxing, restricting or banning lead-bearing materials from manufactured products has prompted the electronics community to examine the implementation of lead-free solders to replace currently used lead-containing alloys in the manufacture of electronic devices and assemblies. The logistics for changing the well established ``tin-lead solder technology`` require not only the selection of new compositions but also the qualification of different surface finishes and manufacturing processes. The meniscometer/wetting balance technique was used to evaluate the wettability of several candidate lead-free solders as well as to establish windows on processing parameters so as tomore » facilitate prototype manufacturing. Electroplated and electroless 100Sn coatings, as well as organic preservatives, were also examined as potential alternative finishes for device leads and terminations as well as circuit board conductor surfaces to replace traditional tin-lead layers. Sandia National Laboratories and AT&T have implemented a program to qualify the manufacturing feasibility of surface mount prototype circuit boards using several commercial lead-free solders by infrared reflow technology.« less

Composite and Nanocomposite Metal Foams

PubMed Central

Duarte, Isabel; Ferreira, José M. F.

2016-01-01

Open-cell and closed-cell metal foams have been reinforced with different kinds of micro- and nano-sized reinforcements to enhance their mechanical properties of the metallic matrix. The idea behind this is that the reinforcement will strengthen the matrix of the cell edges and cell walls and provide high strength and stiffness. This manuscript provides an updated overview of the different manufacturing processes of composite and nanocomposite metal foams. PMID:28787880

Mechanical and thermal properties of biocomposites from nonwoven industrial Fique fiber mats with Epoxy Resin and Linear Low Density Polyethylene

NASA Astrophysics Data System (ADS)

Hidalgo-Salazar, Miguel A.; Correa, Juan P.

2018-03-01

In this work Linear Low Density Polyethylene-nonwoven industrial Fique fiber mat (LLDPE-Fique) and Epoxy Resin-nonwoven industrial Fique fiber mat (EP-Fique) biocomposites were prepared using thermocompression and resin film infusion processes. Neat polymeric matrices and its biocomposites were tested following ASTM standards in order to evaluate tensile and flexural mechanical properties. Also, thermal behavior of these materials has been studied by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Tensile and flexural test revealed that nonwoven Fique reinforced composites exhibited higher modulus and strength but lower deformation capability as compared with LLDPE and EP neat matrices. TG thermograms showed that nonwoven Fique fibers incorporation has an effect on the thermal stability of the composites. On the other hand, Fique fibers did not change the crystallization and melting processes of the LLDPE matrix but restricts the motion of EP macromolecules chains thus increases the Tg of the EP-Fique composite. Finally, this work opens the possibility of considering non-woven Fique fibers as a reinforcement material with a high potential for the manufacture of biocomposites for automotive applications. In addition to the processing test specimens, it was also possible to manufacture a part of LLDPE-Fique, and one part of EP-Fique.

Systems and methods for the synthesis of high thermoelectric performance doped-SnTe materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ren, Zhifeng; Zhang, Qian; Chen, Gang

A thermoelectric composition comprising tin (Sn), tellurium (Te) and at least one dopant that comprises a peak dimensionless figure of merit (ZT) of 1.1 and a Seebeck coefficient of at least 50 .mu.V/K and a method of manufacturing the thermoelectric composition. A plurality of components are disposed in a ball-milling vessel, wherein the plurality of components comprise tin (Sn), tellurium (Te), and at least one dopant such as indium (In). The components are subsequently mechanically and thermally processed, for example, by hot-pressing. In response to the mechanical-thermally processing, a thermoelectric composition is formed, wherein the thermoelectric composition comprises a dimensionlessmore » figure of merit (ZT) of the thermoelectric composition is at least 0.8, and wherein a Seebeck coefficient of the thermoelectric composition is at least 50 .mu.V/K at any temperature.« less

Biomimetic Structural Materials: Inspiration from Design and Assembly.

PubMed

Yaraghi, Nicholas A; Kisailus, David

2018-04-20

Nature assembles weak organic and inorganic constituents into sophisticated hierarchical structures, forming structural composites that demonstrate impressive combinations of strength and toughness. Two such composites are the nacre structure forming the inner layer of many mollusk shells, whose brick-and-mortar architecture has been the gold standard for biomimetic composites, and the cuticle forming the arthropod exoskeleton, whose helicoidal fiber-reinforced architecture has only recently attracted interest for structural biomimetics. In this review, we detail recent biomimetic efforts for the fabrication of strong and tough composite materials possessing the brick-and-mortar and helicoidal architectures. Techniques discussed for the fabrication of nacre- and cuticle-mimetic structures include freeze casting, layer-by-layer deposition, spray deposition, magnetically assisted slip casting, fiber-reinforced composite processing, additive manufacturing, and cholesteric self-assembly. Advantages and limitations to these processes are discussed, as well as the future outlook on the biomimetic landscape for structural composite materials.

Biomimetic Structural Materials: Inspiration from Design and Assembly

NASA Astrophysics Data System (ADS)

Yaraghi, Nicholas A.; Kisailus, David

2018-04-01

Nature assembles weak organic and inorganic constituents into sophisticated hierarchical structures, forming structural composites that demonstrate impressive combinations of strength and toughness. Two such composites are the nacre structure forming the inner layer of many mollusk shells, whose brick-and-mortar architecture has been the gold standard for biomimetic composites, and the cuticle forming the arthropod exoskeleton, whose helicoidal fiber-reinforced architecture has only recently attracted interest for structural biomimetics. In this review, we detail recent biomimetic efforts for the fabrication of strong and tough composite materials possessing the brick-and-mortar and helicoidal architectures. Techniques discussed for the fabrication of nacre- and cuticle-mimetic structures include freeze casting, layer-by-layer deposition, spray deposition, magnetically assisted slip casting, fiber-reinforced composite processing, additive manufacturing, and cholesteric self-assembly. Advantages and limitations to these processes are discussed, as well as the future outlook on the biomimetic landscape for structural composite materials.

Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors

NASA Technical Reports Server (NTRS)

Vudler, Vladimir

2012-01-01

High-precision mirrors for space applications are traditionally manufactured from one piece of material, such as lightweight glass sandwich or beryllium. The purpose of this project was to develop and test the feasibility of a manufacturing process capable of producing mirrors out of welded segments of AlBeMet(Registered Trademark) (AM162H). AlBeMet(Registered Trademark) is a HIP'd (hot isostatic pressed) material containing approximately 62% beryllium and 38% aluminum. As a result, AlBeMet shares many of the benefits of both of those materials for use in high performance mirrors, while minimizing many of their weaknesses.

Nondestructive evaluation of nuclear-grade graphite

NASA Astrophysics Data System (ADS)

Kunerth, D. C.; McJunkin, T. R.

2012-05-01

The material of choice for the core of the high-temperature gas-cooled reactors being developed by the U.S. Department of Energy's Next Generation Nuclear Plant Program is graphite. Graphite is a composite material whose properties are highly dependent on the base material and manufacturing methods. In addition to the material variations intrinsic to the manufacturing process, graphite will also undergo changes in material properties resulting from radiation damage and possible oxidation within the reactor. Idaho National Laboratory is presently evaluating the viability of conventional nondestructive evaluation techniques to characterize the material variations inherent to manufacturing and in-service degradation. Approaches of interest include x-ray radiography, eddy currents, and ultrasonics.

Composite Design and Engineering

NASA Astrophysics Data System (ADS)

van der Woude, J. H. A.; Lawton, E. L.

Fiberglass is a versatile and cost-effective reinforcement for composites. Many processes, resins, and forms of fiberglass facilitate this versatility. The design, engineering, manufacture, and properties of fiberglass-reinforced composite products from diverse thermoset and thermoplastic resins are described. The attributes of fiberglass-reinforced composites include its mechanical and chemical properties, lightweight, corrosion resistance, longevity, low total system cost, and Class A surface properties. Specific examples illustrate the importance of the form of the fiberglass reinforcement and of the interfacial bond between the glass fibers and the matrix resin in optimizing composite properties. In addition, recent advances are described with regard to the fabrication of fiberglass-reinforced wind turbine blades.

Composite Characterization Using Laser Doppler Vibrometry and Multi-Frequency Wavenumber Analysis

NASA Technical Reports Server (NTRS)

Juarez, Peter; Leckey, Cara

2015-01-01

NASA has recognized the need for better characterization of composite materials to support advances in aeronautics and the next generation of space exploration vehicles. An area of related research is the evaluation of impact induced delaminations. Presented is a non-contact method of measuring the ply depth of impact delamination damage in a composite through use of a Scanning Laser Doppler Vibrometer (SLDV), multi-frequency wavenumber analysis, and a wavenumber-ply correlation algorithm. A single acquisition of a chirp excited lamb wavefield in an impacted composite is post-processed into a numerous single frequency excitation wavefields through a deconvolution process. A spatially windowed wavenumber analysis then extracts local wavenumbers from the wavefield, which are then correlated to theoretical dispersion curves for ply depth determination. SLDV based methods to characterize as-manufactured composite variation using wavefield analysis will also be discussed.

Three-dimensional printing fiber reinforced hydrogel composites.

PubMed

Bakarich, Shannon E; Gorkin, Robert; in het Panhuis, Marc; Spinks, Geoffrey M

2014-09-24

An additive manufacturing process that combines digital modeling and 3D printing was used to prepare fiber reinforced hydrogels in a single-step process. The composite materials were fabricated by selectively pattering a combination of alginate/acrylamide gel precursor solution and an epoxy based UV-curable adhesive (Emax 904 Gel-SC) with an extrusion printer. UV irradiation was used to cure the two inks into a single composite material. Spatial control of fiber distribution within the digital models allowed for the fabrication of a series of materials with a spectrum of swelling behavior and mechanical properties with physical characteristics ranging from soft and wet to hard and dry. A comparison with the "rule of mixtures" was used to show that the swollen composite materials adhere to standard composite theory. A prototype meniscus cartilage was prepared to illustrate the potential application in bioengineering.

Pulse Power Capability Of High Energy Density Capacitors Based on a New Dielectric Material

NASA Technical Reports Server (NTRS)

Winsor, Paul; Scholz, Tim; Hudis, Martin; Slenes, Kirk M.

1999-01-01

A new dielectric composite consisting of a polymer coated onto a high-density metallized Kraft has been developed for application in high energy density pulse power capacitors. The polymer coating is custom formulated for high dielectric constant and strength with minimum dielectric losses. The composite can be wound and processed using conventional wound film capacitor manufacturing equipment. This new system has the potential to achieve 2 to 3 J/cu cm whole capacitor energy density at voltage levels above 3.0 kV, and can maintain its mechanical properties to temperatures above 150 C. The technical and manufacturing development of the composite material and fabrication into capacitors are summarized in this paper. Energy discharge testing, including capacitance and charge-discharge efficiency at normal and elevated temperatures, as well as DC life testing were performed on capacitors manufactured using this material. TPL (Albuquerque, NM) has developed the material and Aerovox (New Bedford, MA) has used the material to build and test actual capacitors. The results of the testing will focus on pulse power applications specifically those found in electro-magnetic armor and guns, high power microwave sources and defibrillators.

Development of a thermally-assisted piercing (TAP) process for introducing holes into thermoplastic composites

NASA Astrophysics Data System (ADS)

Brown, Nicholas W. A.

Composite parts can be manufactured to near-net shape with minimum wastage of material; however, there is almost always a need for further machining. The most common post-manufacture machining operations for composite materials are to create holes for assembly. This thesis presents and discusses a thermally-assisted piercing process that can be used as a technique for introducing holes into thermoplastic composites. The thermally-assisted piercing process heats up, and locally melts, thermoplastic composites to allow material to be displaced around a hole, rather than cutting them out from the structure. This investigation was concerned with how the variation of piercing process parameters (such as the size of the heated area, the temperature of the laminate prior to piercing and the geometry of the piercing spike) changed the material microstructure within carbon fibre/Polyetheretherketone (PEEK) laminates. The variation of process parameters was found to significantly affect the formation of resin rich regions, voids and the fibre volume fraction in the material surrounding the hole. Mechanical testing (using open-hole tension, open-hole compression, plain-pin bearing and bolted bearing tests) showed that the microstructural features created during piercing were having significant influence over the resulting mechanical performance of specimens. By optimising the process parameters strength improvements of up to 11% and 21% were found for pierced specimens when compared with drilled specimens for open-hole tension and compression loading, respectively. For plain-pin and bolted bearing tests, maximum strengths of 77% and 85%, respectively, were achieved when compared with drilled holes. Improvements in first failure force (by 10%) and the stress at 4% hole elongation (by 18%), however, were measured for the bolted bearing tests when compared to drilled specimens. The overall performance of pierced specimens in an industrially relevant application ultimately depends on the properties required for that specific scenario. The results within this thesis show that the piercing technique could be used as a direct replacement to drilling depending on this application.

Plasma Processing Systems for the Manufacture of Refractory Metals and their Alloys for Military Needs

DTIC Science & Technology

1978-10-09

melting point is around 4000*K. An exceedingly interesting feature of these solidification composites is the formation of fibrous MC type carbide ...the matrix could be refractory metal binary alloys with copper or uranium and the eutectic phase could be carbide of tungsten, * molybdenum, tantalum or...42 Accs -n or - *DTTI Tf Avn ! -7ll ’ i CrDi t , l’’*i,;. LIST OF FIGURES FIG. 1 Flow Diagram of Cemented Carbide Manufacture

Investigation of Composite Structures

NASA Technical Reports Server (NTRS)

Hyer, Michael W.

2000-01-01

This final report consists of a compilation of four separate written documents, three dealing with the response and failure of elliptical composite cylinders to an internal pressure load, and the fourth dealing with the influence of manufacturing imperfections in curved composite panels. The three focused on elliptical cylinders consist of the following: 1 - A paper entitled "Progressive Failure Analysis of Internally Pressurized Elliptical Composite Cylinders," 2 - A paper entitled "Influence of Geometric Nonlinearities on the Response and Failure of Internally Pressurized Elliptical Composite Cylinders," and 3 - A report entitled "Response and Failure of Internally Pressurized Elliptical Composite Cyclinders." The document which deals with the influence of manufacturing imperfections is a paper entitled "Manufacturing Distortions of Curved Composite Panels."

Material, process, and product design of thermoplastic composite materials

NASA Astrophysics Data System (ADS)

Dai, Heming

Thermoplastic composites made of polypropylene (PP) and E-glass fibers were investigated experimentally as well as theoretically for two new classes of product designs. The first application was for reinforcement of wood. Commingled PP/glass yarn was consolidated and bonded on wood panel using a tie layer. The processing parameters, including temperature, pressure, heating time, cooling time, bonding strength, and bending strength were tested experimentally and evaluated analytically. The thermoplastic adhesive interface was investigated with environmental scanning electron microscopy. The wood/composite structural design was optimized and evaluated using a Graphic Method. In the second application, we evaluated use of thermoplastic composites for explosion containment in an arrester. PP/glass yarn was fabricated in a sleeve form and wrapped around the arrester. After consolidation, the flexible composite sleeve forms a solid composite shell. The composite shell acts as a protection layer in a surge test to contain the fragments of the arrester. The manufacturing process for forming the composite shell was designed. Woven, knitted, and braided textile composite shells made of commingled PP/glass yarn were tested and evaluated. Mechanical performance of the woven, knitted, and braided composite shells was examined analytically. The theoretical predictions were used to verify the experimental results.

Development of the technology for the fabrication of reliable laminar from control panels

NASA Technical Reports Server (NTRS)

Meade, L. E.; Kays, A. O.; Ferrill, R. S.; Young, H. R.

1977-01-01

Materials were assessed and fabrication techniques were developed for use in the manufacture of wing surface materials compatible with the application of both aluminum alloys and nonmetallic composites. The concepts investigated included perforations and slots in the metallic test panels and microporosity and perforations in the composite test panels. Perforations were produced in the metallic test panels by the electron beam process and slots were developed by controlled gaps between the metal sheets. Microporosity was produced in the composite test panels by the resin bleed process, and perforations were produced by the fugitive fiber technique. Each of these concepts was fabricated into test panels, and air flow tests were conducted on the panels.

Temperature distribution of thick thermoset composites

NASA Astrophysics Data System (ADS)

Guo, Zhan-Sheng; Du, Shanyi; Zhang, Boming

2004-05-01

The development of temperature distribution of thick polymeric matrix laminates during an autoclave vacuum bag process was measured and compared with numerically calculated results. The finite element formulation of the transient heat transfer problem was carried out for polymeric matrix composite materials from the heat transfer differential equations including internal heat generation produced by exothermic chemical reactions. Software based on the general finite element software package was developed for numerical simulation of the entire composite process. From the experimental and numerical results, it was found that the measured temperature profiles were in good agreement with the numerical ones, and conventional cure cycles recommended by prepreg manufacturers for thin laminates should be modified to prevent temperature overshoot.

Analysis of pultrusion processing for long fiber reinforced thermoplastic composite system

NASA Technical Reports Server (NTRS)

Tso, W.; Hou, T. H.; Tiwari, S. N.

1993-01-01

Pultrusion is one of the composite processing technology, commonly recognized as a simple and cost-effective means for the manufacturing of fiber-reinforced, resin matrix composite parts with different regular geometries. Previously, because the majority of the pultruded composite parts were made of thermosetting resin matrix, emphasis of the analysis on the process has been on the conservation of energy from various sources, such as heat conduction and the curing kinetics of the resin system. Analysis on the flow aspect of the process was almost absent in the literature for thermosetting process. With the increasing uses of thermoplastic materials, it is desirable to obtain the detailed velocity and pressure profiles inside the pultrusion die. Using a modified Darcy's law for flow through porous media, closed form analytical solutions for the velocity and pressure distributions inside the pultrusion die are obtained for the first time. This enables us to estimate the magnitude of viscous dissipation and it's effects on the pultruded parts. Pulling forces refined in the pultrusion processing are also analyzed. The analytical model derived in this study can be used to advance our knowledge and control of the pultrusion process for fiber reinforced thermoplastic composite parts.

Multi-Response Parameter Interval Sensitivity and Optimization for the Composite Tape Winding Process.

PubMed

Deng, Bo; Shi, Yaoyao; Yu, Tao; Kang, Chao; Zhao, Pan

2018-01-31

The composite tape winding process, which utilizes a tape winding machine and prepreg tapes, provides a promising way to improve the quality of composite products. Nevertheless, the process parameters of composite tape winding have crucial effects on the tensile strength and void content, which are closely related to the performances of the winding products. In this article, two different object values of winding products, including mechanical performance (tensile strength) and a physical property (void content), were respectively calculated. Thereafter, the paper presents an integrated methodology by combining multi-parameter relative sensitivity analysis and single-parameter sensitivity analysis to obtain the optimal intervals of the composite tape winding process. First, the global multi-parameter sensitivity analysis method was applied to investigate the sensitivity of each parameter in the tape winding processing. Then, the local single-parameter sensitivity analysis method was employed to calculate the sensitivity of a single parameter within the corresponding range. Finally, the stability and instability ranges of each parameter were distinguished. Meanwhile, the authors optimized the process parameter ranges and provided comprehensive optimized intervals of the winding parameters. The verification test validated that the optimized intervals of the process parameters were reliable and stable for winding products manufacturing.

Multi-Response Parameter Interval Sensitivity and Optimization for the Composite Tape Winding Process

PubMed Central

Yu, Tao; Kang, Chao; Zhao, Pan

2018-01-01

The composite tape winding process, which utilizes a tape winding machine and prepreg tapes, provides a promising way to improve the quality of composite products. Nevertheless, the process parameters of composite tape winding have crucial effects on the tensile strength and void content, which are closely related to the performances of the winding products. In this article, two different object values of winding products, including mechanical performance (tensile strength) and a physical property (void content), were respectively calculated. Thereafter, the paper presents an integrated methodology by combining multi-parameter relative sensitivity analysis and single-parameter sensitivity analysis to obtain the optimal intervals of the composite tape winding process. First, the global multi-parameter sensitivity analysis method was applied to investigate the sensitivity of each parameter in the tape winding processing. Then, the local single-parameter sensitivity analysis method was employed to calculate the sensitivity of a single parameter within the corresponding range. Finally, the stability and instability ranges of each parameter were distinguished. Meanwhile, the authors optimized the process parameter ranges and provided comprehensive optimized intervals of the winding parameters. The verification test validated that the optimized intervals of the process parameters were reliable and stable for winding products manufacturing. PMID:29385048

Metal Matrix Composite Material by Direct Metal Deposition

NASA Astrophysics Data System (ADS)

Novichenko, D.; Marants, A.; Thivillon, L.; Bertrand, P. H.; Smurov, I.

Direct Metal Deposition (DMD) is a laser cladding process for producing a protective coating on the surface of a metallic part or manufacturing layer-by-layer parts in a single-step process. The objective of this work is to demonstrate the possibility to create carbide-reinforced metal matrix composite objects. Powders of steel 16NCD13 with different volume contents of titanium carbide are tested. On the base of statistical analysis, a laser cladding processing map is constructed. Relationships between the different content of titanium carbide in a powder mixture and the material microstructure are found. Mechanism of formation of various precipitated titanium carbides is investigated.

Development of hybrid lifecycle cost estimating tool (HLCET) for manufacturing influenced design tradeoff

NASA Astrophysics Data System (ADS)

Sirirojvisuth, Apinut

In complex aerospace system design, making an effective design decision requires multidisciplinary knowledge from both product and process perspectives. Integrating manufacturing considerations into the design process is most valuable during the early design stages since designers have more freedom to integrate new ideas when changes are relatively inexpensive in terms of time and effort. Several metrics related to manufacturability are cost, time, and manufacturing readiness level (MRL). Yet, there is a lack of structured methodology that quantifies how changes in the design decisions impact these metrics. As a result, a new set of integrated cost analysis tools are proposed in this study to quantify the impacts. Equally important is the capability to integrate this new cost tool into the existing design methodologies without sacrificing agility and flexibility required during the early design phases. To demonstrate the applicability of this concept, a ModelCenter environment is used to develop software architecture that represents Integrated Product and Process Development (IPPD) methodology used in several aerospace systems designs. The environment seamlessly integrates product and process analysis tools and makes effective transition from one design phase to the other while retaining knowledge gained a priori. Then, an advanced cost estimating tool called Hybrid Lifecycle Cost Estimating Tool (HLCET), a hybrid combination of weight-, process-, and activity-based estimating techniques, is integrated with the design framework. A new weight-based lifecycle cost model is created based on Tailored Cost Model (TCM) equations [3]. This lifecycle cost tool estimates the program cost based on vehicle component weights and programmatic assumptions. Additional high fidelity cost tools like process-based and activity-based cost analysis methods can be used to modify the baseline TCM result as more knowledge is accumulated over design iterations. Therefore, with this concept, the additional manufacturing knowledge can be used to identify a more accurate lifecycle cost and facilitate higher fidelity tradeoffs during conceptual and preliminary design. Advanced Composite Cost Estimating Model (ACCEM) is employed as a process-based cost component to replace the original TCM result of the composite part production cost. The reason for the replacement is that TCM estimates production costs from part weights as a result of subtractive manufacturing of metallic origin such as casting, forging, and machining processes. A complexity factor can sometimes be adjusted to reflect different types of metal and machine settings. The TCM assumption, however, gives erroneous results when applied to additive processes like those of composite manufacturing. Another innovative aspect of this research is the introduction of a work measurement technique called Maynard Operation Sequence Technique (MOST) to be used, similarly to Activity-Based Costing (ABC) approach, to estimate manufacturing time of a part by virtue of breaking down the operations occurred during its production. ABC allows a realistic determination of cost incurred in each activity, as opposed to using a traditional method of time estimation by analogy or using response surface equations from historical process data. The MOST concept provides a tailored study of an individual process typically required for a new, innovative design. Nevertheless, the MOST idea has some challenges, one of which is its requirement to build a new process from ground up. The process development requires a Subject Matter Expertise (SME) in manufacturing method of the particular design. The SME must have also a comprehensive understanding of the MOST system so that the correct parameters are chosen. In practice, these knowledge requirements may demand people from outside of the design discipline and a priori training of MOST. To relieve the constraint, this study includes an entirely new sub-system architecture that comprises 1) a knowledge-based system to provide the required knowledge during the process selection; and 2) a new user-interface to guide the parameter selection when building the process using MOST. Also included in this study is the demonstration of how the HLCET and its constituents can be integrated with a Georgia Tech' Integrated Product and Process Development (IPPD) methodology. The applicability of this work will be shown through a complex aerospace design example to gain insights into how manufacturing knowledge helps make better design decisions during the early stages. The setup process is explained with an example of its utility demonstrated in a hypothetical fighter aircraft wing redesign. The evaluation of the system effectiveness against existing methodologies is illustrated to conclude the thesis.

Cost model relationships between textile manufacturing processes and design details for transport fuselage elements

NASA Technical Reports Server (NTRS)

Metschan, Stephen L.; Wilden, Kurtis S.; Sharpless, Garrett C.; Andelman, Rich M.

1993-01-01

Textile manufacturing processes offer potential cost and weight advantages over traditional composite materials and processes for transport fuselage elements. In the current study, design cost modeling relationships between textile processes and element design details were developed. Such relationships are expected to help future aircraft designers to make timely decisions on the effect of design details and overall configurations on textile fabrication costs. The fundamental advantage of a design cost model is to insure that the element design is cost effective for the intended process. Trade studies on the effects of processing parameters also help to optimize the manufacturing steps for a particular structural element. Two methods of analyzing design detail/process cost relationships developed for the design cost model were pursued in the current study. The first makes use of existing databases and alternative cost modeling methods (e.g. detailed estimating). The second compares design cost model predictions with data collected during the fabrication of seven foot circumferential frames for ATCAS crown test panels. The process used in this case involves 2D dry braiding and resin transfer molding of curved 'J' cross section frame members having design details characteristic of the baseline ATCAS crown design.

Detection of CFRP Composite Manufacturing Defects Using a Guided Wave Approach

NASA Technical Reports Server (NTRS)

Hudson, Tyler B.; Hou, Tan-Hung; Grimsley, Brian W.; Yuan, Fuh-Gwo

2015-01-01

NASA Langley Research Center is investigating a guided-wave based defect detection technique for as-fabricated carbon fiber reinforced polymer (CFRP) composites. This technique will be extended to perform in-process cure monitoring, defect detection and size determination, and ultimately a closed-loop process control to maximize composite part quality and consistency. The overall objective of this work is to determine the capability and limitations of the proposed defect detection technique, as well as the number and types of sensors needed to identify the size, type, and location of the predominant types of manufacturing defects associated with laminate layup and cure. This includes, porosity, gaps, overlaps, through-the-thickness fiber waviness, and in-plane fiber waviness. The present study focuses on detection of the porosity formed from variations in the matrix curing process, and on local overlaps intentionally introduced during layup of the prepreg. By terminating the cycle prematurely, three 24-ply unidirectional composite panels were manufactured such that each subsequent panel had a higher final degree of cure, and lower level of porosity. It was demonstrated that the group velocity, normal to the fiber direction, of a guided wave mode increased by 5.52 percent from the first panel to the second panel and 1.26 percent from the second panel to the third panel. Therefore, group velocity was utilized as a metric for degree of cure and porosity measurements. A fully non-contact guided wave hybrid system composed of an air-coupled transducer and a laser Doppler vibrometer (LDV) was used for the detection and size determination of an overlap By transforming the plate response from the time-space domain to the frequency-wavenumber domain, the total wavefield was then separated into the incident and backscatter waves. The overlap region was accurately imaged by using a zero-lag cross-correlation (ZLCC) imaging condition, implying the incident and backscattered waves are in phase over the overlap boundaries.

Recent developments in turbomachinery component materials and manufacturing challenges for aero engine applications

NASA Astrophysics Data System (ADS)

Srinivas, G.; Raghunandana, K.; Satish Shenoy, B.

2018-02-01

In the recent years the development of turbomachinery materials performance enhancement plays a vital role especially in aircraft air breathing engines like turbojet engine, turboprop engine, turboshaft engine and turbofan engines. Especially the transonic flow engines required highly sophisticated materials where it can sustain the entire thrust which can create by the engine. The main objective of this paper is to give an overview of the present cost-effective and technological capabilities process for turbomachinery component materials. Especially the main focus is given to study the Electro physical, Photonic additive removal process and Electro chemical process for turbomachinery parts manufacture. The aeronautical propulsion based technologies are reviewed thoroughly where in surface reliability, geometrical precession, and material removal and highly strengthened composite material deposition rates usually difficult to cut dedicated steels, Titanium and Nickel based alloys. In this paper the past aeronautical and propulsion mechanical based manufacturing technologies, current sophisticated technologies and also future challenging material processing techniques are covered. The paper also focuses on the brief description of turbomachinery components of shaping process and coating in aeromechanical applications.

Design of novel materials for additive manufacturing - Isotropic microstructure and high defect tolerance.

PubMed

Günther, J; Brenne, F; Droste, M; Wendler, M; Volkova, O; Biermann, H; Niendorf, T

2018-01-22

Electron Beam Melting (EBM) is a powder-bed additive manufacturing technology enabling the production of complex metallic parts with generally good mechanical properties. However, the performance of powder-bed based additively manufactured materials is governed by multiple factors that are difficult to control. Alloys that solidify in cubic crystal structures are usually affected by strong anisotropy due to the formation of columnar grains of preferred orientation. Moreover, processing induced defects and porosity detrimentally influence static and cyclic mechanical properties. The current study presents results on processing of a metastable austenitic CrMnNi steel by EBM. Due to multiple phase transformations induced by intrinsic heat-treatment in the layer-wise EBM process the material develops a fine-grained microstructure almost without a preferred crystallographic grain orientation. The deformation-induced phase transformation yields high damage tolerance and, thus, excellent mechanical properties less sensitive to process-induced inhomogeneities. Various scan strategies were applied to evaluate the width of an appropriate process window in terms of microstructure evolution, porosity and change of chemical composition.

Technical assessment for quality control of resins

NASA Technical Reports Server (NTRS)

Gosnell, R. B.

1977-01-01

Survey visits to companies involved in the manufacture and use of graphite-epoxy prepregs were conducted to assess the factors which may contribute to variability in the mechanical properties of graphite-epoxy composites. In particular, the purpose was to assess the contributions of the epoxy resins to variability. Companies represented three segments of the composites industry - aircraft manufacturers, prepreg manufacturers, and epoxy resin manufacturers. Several important sources of performance variability were identified from among the complete spectrum of potential sources which ranged from raw materials to composite test data interpretation.

Advanced Infusion Techniques with 3-D Printed Tooling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nuttall, David; Elliott, Amy; Post, Brian K.

The manufacturing of tooling for large, contoured surfaces for fiber-layup applications requires significant effort to understand the geometry and then to subtractively manufacture the tool. Traditional methods for the auto industry use clay that is hand sculpted. In the marine pleasure craft industry, the exterior of the model is formed from a foam lay-up that is either hand cut or machined to create smooth lines. Engineers and researchers at Oak Ridge National Laboratory s Manufacturing Demonstration Facility (ORNL MDF) collaborated with Magnum Venus Products (MVP) in the development of a process for reproducing legacy whitewater adventure craft via digital scanningmore » and large scale 3-D printed layup molds. The process entailed 3D scanning a legacy canoe form, converting that form to a CAD model, additively manufacturing (3-D Print) the mold tool, and subtractively finishing the mold s transfer surfaces. Future work will include applying a gelcoat to the mold transfer surface and infusing using vacuum assisted resin transfer molding, or VARTM principles, to create a watertight vessel. The outlined steps were performed on a specific canoe geometry found by MVP s principal participant. The intent of utilizing this geometry is to develop an energy efficient and marketable process for replicating complex shapes, specifically focusing on this particular watercraft, and provide a finished product for demonstration to the composites industry. The culminating part produced through this agreement has been slated for public presentation and potential demonstration at the 2016 CAMX (Composites and Advanced Materials eXpo) exposition in Anaheim, CA. Phase I of this collaborative research and development agreement (MDF-15-68) was conducted under CRADA NFE-15-05575 and was initiated on May 7, 2015, with an introduction to the MVP product line, and concluded in March of 2016 with the printing of and processing of a canoe mold. The project partner Magnum Venous Products (MVP) is a small business. Phase II as discussed herein is under consideration by MVP as of this writing. Overall, it is anticipated that developing this process for manufacturing tooling for complex contoured surfaces has applicability to naval and other watercraft as well as bathrooms and large trucks.« less

Data-driven multi-scale multi-physics models to derive process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Lian, Yanping; Yu, Cheng; Liu, Zeliang; Yan, Jinhui; Wolff, Sarah; Wu, Hao; Ndip-Agbor, Ebot; Mozaffar, Mojtaba; Ehmann, Kornel; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-05-01

Additive manufacturing (AM) possesses appealing potential for manipulating material compositions, structures and properties in end-use products with arbitrary shapes without the need for specialized tooling. Since the physical process is difficult to experimentally measure, numerical modeling is a powerful tool to understand the underlying physical mechanisms. This paper presents our latest work in this regard based on comprehensive material modeling of process-structure-property relationships for AM materials. The numerous influencing factors that emerge from the AM process motivate the need for novel rapid design and optimization approaches. For this, we propose data-mining as an effective solution. Such methods—used in the process-structure, structure-properties and the design phase that connects them—would allow for a design loop for AM processing and materials. We hope this article will provide a road map to enable AM fundamental understanding for the monitoring and advanced diagnostics of AM processing.

Data-driven multi-scale multi-physics models to derive process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Lian, Yanping; Yu, Cheng; Liu, Zeliang; Yan, Jinhui; Wolff, Sarah; Wu, Hao; Ndip-Agbor, Ebot; Mozaffar, Mojtaba; Ehmann, Kornel; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-01-01

Additive manufacturing (AM) possesses appealing potential for manipulating material compositions, structures and properties in end-use products with arbitrary shapes without the need for specialized tooling. Since the physical process is difficult to experimentally measure, numerical modeling is a powerful tool to understand the underlying physical mechanisms. This paper presents our latest work in this regard based on comprehensive material modeling of process-structure-property relationships for AM materials. The numerous influencing factors that emerge from the AM process motivate the need for novel rapid design and optimization approaches. For this, we propose data-mining as an effective solution. Such methods—used in the process-structure, structure-properties and the design phase that connects them—would allow for a design loop for AM processing and materials. We hope this article will provide a road map to enable AM fundamental understanding for the monitoring and advanced diagnostics of AM processing.

Polyimide Composites from 'Salt-Like' Solution Precursors

NASA Technical Reports Server (NTRS)

Cano, Roberto J.; Hou, Tan H.; Weiser, Erik S.; SaintClair, Terry L.

2001-01-01

Four NASA Langley-developed polyimide matrix resins, LaRC(TM)-IA, LaRC(TM)-IAX, LaRC(TM)-8515 and LaRC(TM)-PETI-5, were produced via a 'saltlike' process developed by Unitika Ltd. The salt-like solutions (65% solids in NMP) were prepregged onto Hexcel IM7 carbon fiber using the NASA LaRC multipurpose tape machine. Process parameters were determined and composite panels fabricated. The temperature dependent volatile depletion rates, the thermal crystallization behavior and the resin rheology were characterized. Composite molding cycles were developed which consistently yielded well consolidated, void-free laminated parts. Composite mechanical properties such as the short beam shear strength; the longitudinal and transverse flexural strength and flexural modulus; the longitudinal compression strength and modulus; and the open hole compression strength and compression after impact strength were measured at room temperature and elevated temperatures. The processing characteristics and the composite mechanical properties of the four intermediate modulus carbon fiber/polyimide matrix composites were compared to existing data on the same polyimide resin systems and IM7 carbon fiber manufactured via poly(amide acid) solutions (30-35% solids in NMP). This work studies the effects of varying the synthetic route on the processing and mechanical properties of the polyimide composites.

Carbon dioxide capture from a cement manufacturing process

DOEpatents

Blount, Gerald C [North Augusta, SC; Falta, Ronald W [Seneca, SC; Siddall, Alvin A [Aiken, SC

2011-07-12

A process of manufacturing cement clinker is provided in which a clean supply of CO.sub.2 gas may be captured. The process also involves using an open loop conversion of CaO/MgO from a calciner to capture CO.sub.2 from combustion flue gases thereby forming CaCO.sub.3/CaMg(CO.sub.3).sub.2. The CaCO.sub.3/CaMg(CO.sub.3).sub.2 is then returned to the calciner where CO.sub.2 gas is evolved. The evolved CO.sub.2 gas, along with other evolved CO.sub.2 gases from the calciner are removed from the calciner. The reactants (CaO/MgO) are feed to a high temperature calciner for control of the clinker production composition.

Colloidal-based additive manufacturing of bio-inspired composites

NASA Astrophysics Data System (ADS)

Studart, Andre R.

Composite materials in nature exhibit heterogeneous architectures that are tuned to fulfill the functional demands of the surrounding environment. Examples range from the cellulose-based organic structure of plants to highly mineralized collagen-based skeletal parts like bone and teeth. Because they are often utilized to combine opposing properties such as strength and low-density or stiffness and wear resistance, the heterogeneous architecture of natural materials can potentially address several of the technical limitations of artificial homogeneous composites. However, current man-made manufacturing technologies do not allow for the level of composition and fiber orientation control found in natural heterogeneous systems. In this talk, I will present two additive manufacturing technologies recently developed in our group to build composites with exquisite architectures only rivaled by structures made by living organisms in nature. Since the proposed techniques utilize colloidal suspensions as feedstock, understanding the physics underlying the stability, assembly and rheology of the printing inks is key to predict and control the architecture of manufactured parts. Our results will show that additive manufacturing routes offer a new exciting pathway for the fabrication of biologically-inspired composite materials with unprecedented architectures and functionalities.

Bamboo–Polylactic Acid (PLA) Composite Material for Structural Applications

PubMed Central

Pozo Morales, Angel; Güemes, Alfredo; Fernandez-Lopez, Antonio; Carcelen Valero, Veronica; De La Rosa Llano, Sonia

2017-01-01

Developing an eco-friendly industry based on green materials, sustainable technologies, and optimum processes with low environmental impact is a general societal goal, but this remains a considerable challenge to achieve. Despite the large number of research on green structural composites, limited investigation into the most appropriate manufacturing methodology to develop a structural material at industrial level has taken place. Laboratory panels have been manufactured with different natural fibers but the methodologies and values obtained could not be extrapolated at industrial level. Bamboo industry panels have increased in the secondary structural sector such as building application, flooring and sport device, because it is one of the cheapest raw materials. At industrial level, the panels are manufactured with only the inner and intermediate region of the bamboo culm. However, it has been found that the mechanical properties of the external shells of bamboo culm are much better than the average cross-sectional properties. Thin strips of bamboo (1.5 mm thick and 1500 mm long) were machined and arranged with the desired lay-up and shape to obtain laminates with specific properties better than those of conventional E-Glass/Epoxy laminates in terms of both strength and stiffness. The strips of bamboo were bonded together by a natural thermoplastic polylactic acid (PLA) matrix to meet biodegradability requirements. The innovative mechanical extraction process developed in this study can extract natural strip reinforcements with high performance, low cost, and high rate, with no negative environmental impact, as no chemical treatments are used. The process can be performed at the industrial level. Furthermore, in order to validate the structural applications of the composite, the mechanical properties were analyzed under ageing conditions. This material could satisfy the requirements for adequate mechanical properties and life cycle costs at industrial sectors such as energy or automotive. PMID:29120398

Bamboo-Polylactic Acid (PLA) Composite Material for Structural Applications.

PubMed

Pozo Morales, Angel; Güemes, Alfredo; Fernandez-Lopez, Antonio; Carcelen Valero, Veronica; De La Rosa Llano, Sonia

2017-11-09

Developing an eco-friendly industry based on green materials, sustainable technologies, and optimum processes with low environmental impact is a general societal goal, but this remains a considerable challenge to achieve. Despite the large number of research on green structural composites, limited investigation into the most appropriate manufacturing methodology to develop a structural material at industrial level has taken place. Laboratory panels have been manufactured with different natural fibers but the methodologies and values obtained could not be extrapolated at industrial level. Bamboo industry panels have increased in the secondary structural sector such as building application, flooring and sport device, because it is one of the cheapest raw materials. At industrial level, the panels are manufactured with only the inner and intermediate region of the bamboo culm. However, it has been found that the mechanical properties of the external shells of bamboo culm are much better than the average cross-sectional properties. Thin strips of bamboo (1.5 mm thick and 1500 mm long) were machined and arranged with the desired lay-up and shape to obtain laminates with specific properties better than those of conventional E-Glass/Epoxy laminates in terms of both strength and stiffness. The strips of bamboo were bonded together by a natural thermoplastic polylactic acid (PLA) matrix to meet biodegradability requirements. The innovative mechanical extraction process developed in this study can extract natural strip reinforcements with high performance, low cost, and high rate, with no negative environmental impact, as no chemical treatments are used. The process can be performed at the industrial level. Furthermore, in order to validate the structural applications of the composite, the mechanical properties were analyzed under ageing conditions. This material could satisfy the requirements for adequate mechanical properties and life cycle costs at industrial sectors such as energy or automotive.

Testing of self-repairing composite airplane components by use of CAI and the release of the repair chemicals from carefully inserted small tubes

NASA Astrophysics Data System (ADS)

Dry, Carolyn

2007-04-01

The research on self repair of airplane components, under an SBIR phase II with Wright Patterson Air Force Base, has investigated the attributes and best end use applications for such a technology. These attributes include issues related to manufacturability, cost, potential benefits such as weight reduction, and cost reduction. The goal of our research has been to develop self-repairing composites with unique strength for air vehicles. Our revolutionary approach involves the autonomous release of repair chemicals from within the composite matrix itself. The repair agents are contained in hollow, structural fibers that are embedded within the matrix. Under stress, the composite senses external environmental factors and reacts by releasing the repair agents from within the hollow vessels. This autonomous response occurs wherever and whenever cracking, debonding or other matrix damage transpires. Superior performance over the life of the composite is achieved through this self-repairing mechanism. The advantages to the military would be safely executed missions, fewer repairs and eventually lighter vehicles. In particular the research has addressed the issues by correlating the impact of the various factors, such as 1) delivery vessel placement, shape/size and effect on composite strength, chemicals released and their effect on the matrix, release trigger and efficacy and any impact on matrix properties 2) impact of composite processing methods that involve heat and pressure on the repair vessels. Our self repairing system can be processed at temperatures of 300-350F, repairs in less than 30 seconds and does not damage the composite by repair fiber insertion or chemical release. Scaling up and manufacture of components has revealed that anticipating potential problems allowed us to avoid those associated with processing temperatures and pressures. The presentation will focus on compression after impact testing and the placement of repair fibers/tubes into prepreg laminates.

Formation of alcohol conversion catalysts

DOEpatents

Wachs, Israel E.; Cai, Yeping

2001-01-01

The method of the present invention involves a composition containing an intimate mixture of (a) metal oxide support particles and (b) a catalytically active metal oxide from Groups VA, VIA, or VIIA, its method of manufacture, and its method of use for converting alcohols to aldehydes. During the conversion process, catalytically active metal oxide from the discrete catalytic metal oxide particles migrates to the oxide support particles and forms a monolayer of catalytically active metal oxide on the oxide support particle to form a catalyst composition having a higher specific activity than the admixed particle composition.

Composite Cryotank Technologies and Demonstration

NASA Technical Reports Server (NTRS)

Vickers, John

2015-01-01

NASA is exploring advanced composite materials and processes to reduce the overall cost and weight of liquid hydrogen (LH2) cryotanks while maintaining the reliability of existing metallic designs. The fundamental goal of the composite cryotank project was to provide new and innovative technologies that enable human space exploration to destinations beyond low-Earth orbit such as the Moon, near-Earth asteroids, and Mars. In September 2011, NASA awarded Boeing the contract to design, manufacture, and test two lightweight composite cryogenic propellant tanks. The all-composite tanks shown iare fabricated with an automated fiber placement machine using a prepreg system of IM7 carbon fiber/CYCOM 5320-1 epoxy resin. This is a resin system developed for out-of-autoclave applications. Switching from metallic to composite construction holds the potential to dramatically increase the performance capabilities of future space systems through a dramatic reduction in weight. Composite Cryotank Technologies and Demonstration testing was an agency-wide effort with NASA Marshall Space Flight Center (MSFC) leading project management, manufacturing, and test; Glenn Research Center leading the materials; and Langley Research Center leading the structures effort for this project. Significant contributions from NASA loads/stress personnel contributed to the understanding of thermal/mechanical strain response while undergoing testing at cryogenic temperatures. The project finalized in September 2014.

Characterization of waviness in wind turbine blades using air coupled ultrasonics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chakrapani, Sunil Kishore; Dayal, Vinay; Hsu, David K.

2011-06-23

Waviness in glass fiber reinforced composite is of great interest in composite research, since it results in the loss of stiffness. Several NDE techniques have been used previously to detect waviness. This work is concerned with waves normal to the plies in a composite. Air-coupled ultrasonics was used to detect waviness in thick composites used in the manufacturing of wind turbine blades. Composite samples with different wave aspect ratios were studied. Different wavy samples were characterized, and a three step process was developed to make sure the technique is field implementable. This gives us a better understanding of the effectmore » of waviness in thick composites, and how it affects the life and performance of the composite.« less

Mechanical properties and material characterization of polysialate structural composites

NASA Astrophysics Data System (ADS)

Foden, Andrew James

One of the major concerns in using Fiber Reinforced Composites in applications that are subjected to fire is their resistance to high temperature. Some of the fabrics used in FRC, such as carbon, are fire resistant. However, almost all the resins used cannot withstand temperatures higher than 200°C. This dissertation deals with the development and use of a potassium aluminosilicate (GEOPOLYMER) resin that is inorganic and can sustain more than 1000°C. The results presented include the mechanical properties of the unreinforced polysialate matrix in tension, flexure, and compression as well as the strain capacities and surface energy. The mechanical properties of the matrix reinforced with several different fabrics were obtained in flexure, tension, compression and shear. The strength and stiffness of the composite was evaluated for each loading condition. Tests were conducted on unexposed samples as well as samples exposed to temperatures from 200 to 1000°C. Fatigue properties were determined using flexural loading. A study of the effect of several processing variables on the properties of the composite was undertaken to determine the optimum procedure for manufacturing composite plates. The processing variables studied were the curing temperature and pressure, and the post cure drying time required to remove any residual water. The optimum manufacturing conditions were determined using the void content, density, fiber volume fraction, and flexural strength. Analytical models are presented based on both micro and macro mechanical analysis of the composite. Classic laminate theory is used to evaluate the state of the composite as it is being loaded to determine the failure mechanisms. Several failure criteria theories are considered. The analysis is then used to explain the mechanical behavior of the composite that was observed during the experimental study.

Incorporation of composite defects from ultrasonic NDE into CAD and FE models

NASA Astrophysics Data System (ADS)

Bingol, Onur Rauf; Schiefelbein, Bryan; Grandin, Robert J.; Holland, Stephen D.; Krishnamurthy, Adarsh

2017-02-01

Fiber-reinforced composites are widely used in aerospace industry due to their combined properties of high strength and low weight. However, owing to their complex structure, it is difficult to assess the impact of manufacturing defects and service damage on their residual life. While, ultrasonic testing (UT) is the preferred NDE method to identify the presence of defects in composites, there are no reasonable ways to model the damage and evaluate the structural integrity of composites. We have developed an automated framework to incorporate flaws and known composite damage automatically into a finite element analysis (FEA) model of composites, ultimately aiding in accessing the residual life of composites and make informed decisions regarding repairs. The framework can be used to generate a layer-by-layer 3D structural CAD model of the composite laminates replicating their manufacturing process. Outlines of structural defects, such as delaminations, are automatically detected from UT of the laminate and are incorporated into the CAD model between the appropriate layers. In addition, the framework allows for direct structural analysis of the resulting 3D CAD models with defects by automatically applying the appropriate boundary conditions. In this paper, we show a working proof-of-concept for the composite model builder with capabilities of incorporating delaminations between laminate layers and automatically preparing the CAD model for structural analysis using a FEA software.

Atomic Step Formation on Sapphire Surface in Ultra-precision Manufacturing

PubMed Central

Wang, Rongrong; Guo, Dan; Xie, Guoxin; Pan, Guoshun

2016-01-01

Surfaces with controlled atomic step structures as substrates are highly relevant to desirable performances of materials grown on them, such as light emitting diode (LED) epitaxial layers, nanotubes and nanoribbons. However, very limited attention has been paid to the step formation in manufacturing process. In the present work, investigations have been conducted into this step formation mechanism on the sapphire c (0001) surface by using both experiments and simulations. The step evolutions at different stages in the polishing process were investigated with atomic force microscopy (AFM) and high resolution transmission electron microscopy (HRTEM). The simulation of idealized steps was constructed theoretically on the basis of experimental results. It was found that (1) the subtle atomic structures (e.g., steps with different sawteeth, as well as steps with straight and zigzag edges), (2) the periodicity and (3) the degree of order of the steps were all dependent on surface composition and miscut direction (step edge direction). A comparison between experimental results and idealized step models of different surface compositions has been made. It has been found that the structure on the polished surface was in accordance with some surface compositions (the model of single-atom steps: Al steps or O steps). PMID:27444267

Atomic Step Formation on Sapphire Surface in Ultra-precision Manufacturing

NASA Astrophysics Data System (ADS)

Wang, Rongrong; Guo, Dan; Xie, Guoxin; Pan, Guoshun

2016-07-01

Surfaces with controlled atomic step structures as substrates are highly relevant to desirable performances of materials grown on them, such as light emitting diode (LED) epitaxial layers, nanotubes and nanoribbons. However, very limited attention has been paid to the step formation in manufacturing process. In the present work, investigations have been conducted into this step formation mechanism on the sapphire c (0001) surface by using both experiments and simulations. The step evolutions at different stages in the polishing process were investigated with atomic force microscopy (AFM) and high resolution transmission electron microscopy (HRTEM). The simulation of idealized steps was constructed theoretically on the basis of experimental results. It was found that (1) the subtle atomic structures (e.g., steps with different sawteeth, as well as steps with straight and zigzag edges), (2) the periodicity and (3) the degree of order of the steps were all dependent on surface composition and miscut direction (step edge direction). A comparison between experimental results and idealized step models of different surface compositions has been made. It has been found that the structure on the polished surface was in accordance with some surface compositions (the model of single-atom steps: Al steps or O steps).

FINAL REPORT: Transformational electrode drying process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Claus Daniel, C.; Wixom, M.

2013-12-19

This report includes major findings and outlook from the transformational electrode drying project performance period from January 6, 2012 to August 1, 2012. Electrode drying before cell assembly is an operational bottleneck in battery manufacturing due to long drying times and batch processing. Water taken up during shipment and other manufacturing steps needs to be removed before final battery assembly. Conventional vacuum ovens are limited in drying speed due to a temperature threshold needed to avoid damaging polymer components in the composite electrode. Roll to roll operation and alternative treatments can increase the water desorption and removal rate without overheatingmore » and damaging other components in the composite electrode, thus considerably reducing drying time and energy use. The objective of this project was the development of an electrode drying procedure, and the demonstration of processes with no decrease in battery performance. The benchmark for all drying data was an 80°C vacuum furnace treatment with a residence time of 18 – 22 hours. This report demonstrates an alternative roll to roll drying process with a 500-fold improvement in drying time down to 2 minutes and consumption of only 30% of the energy compared to vacuum furnace treatment.« less

Modeling of process-induced residual stresses and resin flow behavior in resin transfer molded composites with woven fiber mats

NASA Astrophysics Data System (ADS)

Golestanian, Hossein

This research focuses on modeling Resin Transfer Molding process for manufacture of composite parts with woven fiber mats. Models are developed to determine cure dependent stiffness matrices for composites manufactured with two types of woven fiber mats. Five-harness carbon and eight-harness fiberglass mats with EPON 826 resin composites are considered. The models presented here take into account important material/process parameters with emphasis on; (1) The effects of cure-dependent resin mechanical properties, (2) Fiber undulation due to the weave of the fiber fill and warp bundles, and (3) Resin interaction with the fiber bundles at a microscopic scale. Cure-dependent mechanical properties were then used in numerical models to determine residual stresses and deformation in the composite parts. The complete cure cycle was modeled in these analyses. Also the cool down stage after the composite cure was analyzed. The effect of 5% resin shrinkage on residual stresses and deformations was also investigated. In the second part of the study, Finite Element models were developed to simulate mold filling in RTM processes. Resin flow in the fiber mats was modeled as flow through porous media. Physical models were also developed to investigate resin flow behavior into molds of rectangular and irregular shapes. Silicone fluids of 50 and 100 centistoke viscosities as well as EPON 826 epoxy resin were used in the mold filling experiments. The reinforcements consisted of several layers of woven fiberglass and carbon fiber mats. The effects of injection pressure, fluid viscosity, type of reinforcement, and mold geometry on mold filling times were investigated. Fiber mat permeabilities were determined experimentally for both types of reinforcements. Comparison of experimental and numerical resin front positions indicated the importance of edge effects in resin flow behavior in small cavities. The resin front positions agreed well for the rectangular mold geometry.

Spring-back of Thick Uni-Directional Carbon Fibre Reinforced Composite Laminate for Aircraft Structure Application

NASA Astrophysics Data System (ADS)

Zakaria, M.; Aminanda, Y.; Rashidi, S. A.; Mat Sah, M. A.

2018-04-01

The springback phenomena of CFRP after curing process through autoclave manufacturing method results on the out of tolerance for its utilisation in aerospace industry. This paper relates to the measurements of springback for Uni-directional flat laminate as a first steps to the springback study for the real aircraft composite laminate structures. A flat laminate with dimension of 300 mm x 300 mm, 400 mm x 400 mm and 500mm x 500 mm with different number of ply; 20, 24 and 28 are manufactured. The choice of dimension and number of lay-up corresponds to the dimension and lay-up of rib structure. After process, the springbacks are measured using 3D scanner (optical-based three-dimensional) with an accuracy of 42 micrometers to obtain an accurate measurement. The analysis of the effect of dimension and number of ply to the magnitude of springback are presented within the range of specimen studied in this work.

Sol-Gel Manufactured Energetic Materials

DOEpatents

Simpson, Randall L.; Lee, Ronald S.; Tillotson, Thomas M.; Hrubesh, Lawrence W.; Swansiger, Rosalind W.; Fox, Glenn A.

2005-05-17

Sol-gel chemistry is used for the preparation of energetic materials (explosives, propellants and pyrotechnics) with improved homogeneity, and/or which can be cast to near-net shape, and/or made into precision molding powders. The sol-gel method is a synthetic chemical process where reactive monomers are mixed into a solution, polymerization occurs leading to a highly cross-linked three dimensional solid network resulting in a gel. The energetic materials can be incorporated during the formation of the solution or during the gel stage of the process. The composition, pore, and primary particle sizes, gel time, surface areas, and density may be tailored and controlled by the solution chemistry. The gel is then dried using supercritical extraction to produce a highly porous low density aerogel or by controlled slow evaporation to produce a xerogel. Applying stress during the extraction phase can result in high density materials. Thus, the sol-gel method can be used for precision detonator explosive manufacturing as well as producing precision explosives, propellants, and pyrotechnics, along with high power composite energetic materials.

Sol-gel manufactured energetic materials

DOEpatents

Simpson, Randall L.; Lee, Ronald S.; Tillotson, Thomas M.; Hrubesh, Lawrence W.; Swansiger, Rosalind W.; Fox, Glenn A.

2003-12-23

Sol-gel chemistry is used for the preparation of energetic materials (explosives, propellants and pyrotechnics) with improved homogeneity, and/or which can be cast to near-net shape, and/or made into precision molding powders. The sol-gel method is a synthetic chemical process where reactive monomers are mixed into a solution, polymerization occurs leading to a highly cross-linked three dimensional solid network resulting in a gel. The energetic materials can be incorporated during the formation of the solution or during the gel stage of the process. The composition, pore, and primary particle sizes, gel time, surface areas, and density may be tailored and controlled by the solution chemistry. The gel is then dried using supercritical extraction to produce a highly porous low density aerogel or by controlled slow evaporation to produce a xerogel. Applying stress during the extraction phase can result in high density materials. Thus, the sol-gel method can be used for precision detonator explosive manufacturing as well as producing precision explosives, propellants, and pyrotechnics, along with high power composite energetic materials.

Comprehensive Lipidome-Wide Profiling Reveals Dynamic Changes of Tea Lipids during Manufacturing Process of Black Tea.

PubMed

Li, Jia; Hua, Jinjie; Zhou, Qinghua; Dong, Chunwang; Wang, Jinjin; Deng, Yuliang; Yuan, Haibo; Jiang, Yongwen

2017-11-22

As important biomolecules in Camellia sinensis L., lipids undergo substantial changes during black tea manufacture, which is considered to contribute to tea sensory quality. However, limited by analytical capacity, detailed lipid composition and its dynamic changes during black tea manufacture remain unclear. Herein, we performed tea lipidome profiling using high resolution liquid chromatography coupled to mass spectrometry (LC-MS), which allows simultaneous and robust analysis of 192 individual lipid species in black tea, covering 17 (sub)classes. Furthermore, dynamic changes of tea lipids during black tea manufacture were investigated. Significant alterations of lipid pattern were revealed, involved with chlorophyll degradation, metabolic pathways of glycoglycerolipids, and other extraplastidial membrane lipids. To our knowledge, this report presented most comprehensive coverage of lipid species in black tea. This study provides a global and in-depth metabolic map of tea lipidome during black tea manufacture.

Manufacturing DTaP-based combination vaccines: industrial challenges around essential public health tools.

PubMed

Vidor, Emmanuel; Soubeyrand, Benoit

2016-12-01

The manufacture of DTP-backboned combination vaccines is complex, and vaccine quality is evaluated by both batch composition and conformance of manufacturing history. Since their first availability, both the manufacturing regulations for DTP combination vaccines and their demand have evolved significantly. This has resulted in a constant need to modify manufacturing and quality control processes. Areas covered: Regulations that govern the manufacture of complex vaccines can be inconsistent between countries and need to be aligned with the regulatory requirements that apply in all countries of distribution. Changes in product mix and quantities can lead to uncertainty in vaccine supply maintenance. These problems are discussed in the context of the importance of these products as essential public health tools. Expert commentary: Increasing demand for complex vaccines globally has led to problems in supply due to intrinsically complex manufacturing and regulatory procedures. Vaccine manufacturers are fully engaged in the resolution of these challenges, but currently changes in demand need ideally to be anticipated approximately 3 years in advance due to long production cycle times.

Machining of Fibre Reinforced Plastic Composite Materials.

PubMed

Caggiano, Alessandra

2018-03-18

Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented.

Machining of Fibre Reinforced Plastic Composite Materials

PubMed Central

2018-01-01

Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented. PMID:29562635

Numerical simulation of multi-layered textile composite reinforcement forming

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, P.; Hamila, N.; Boisse, P.

2011-05-04

One important perspective in aeronautics is to produce large, thick or/and complex structural composite parts. The forming stage presents an important role during the whole manufacturing process, especially for LCM processes (Liquid Composites Moulding) or CFRTP (Continuous Fibre Reinforcements and Thermoplastic resin). Numerical simulations corresponding to multi-layered composite forming allow the prediction for a successful process to produce the thick parts, and importantly, the positions of the fibres after forming to be known. This paper details a set of simulation examples carried out by using a semi-discrete shell finite element made up of unit woven cells. The internal virtual workmore » is applied on all woven cells of the element taking into account tensions, in-plane shear and bending effects. As one key problem, the contact behaviours of tool/ply and ply/ply are described in the numerical model. The simulation results not only improve our understanding of the multi-layered composite forming process but also point out the importance of the fibre orientation and inter-ply friction during formability.« less

Manufacturing development of DC-10 advanced rudder

NASA Technical Reports Server (NTRS)

Cominsky, A.

1979-01-01

The design, manufacture, and ground test activities during development of production methods for an advanced composite rudder for the DC-10 transport aircraft are described. The advanced composite aft rudder is satisfactory for airline service and a cost saving in a full production manufacturing mode is anticipated.

Manufacturing and actuation characterization of ionic polymer metal composites with silver as electrodes

NASA Astrophysics Data System (ADS)

Pandita, Surya D.; Lim, Hyoung Tae; Yoo, Youngtai; Park, Hoon Cheol

2006-03-01

Manufacturing and characterization of ionic polymer metal composites (IPMCs) with silver as electrodes have been investigated. Tollen's reagent that contains ion Ag(NH 3) II + was used as a raw material for silver deposition on the surfaces of the polymer membrane Nafion"R". Two types of inner solvents, namely common water based electrolyte solution (LiOH 1N) and ionic liquid were used and investigated. Compared to IPMCs with platinum electrodes, silver-plated IPMCs with water electrolyte showed higher conductivity. The actuation response of silver-plated IPMCs with the water based electrolyte was faster than that of platinum IPMCs. However, the silver electrode was too brittle and severely damaged during the solvent exchange process from water to ionic liquid, resulted in high resistance and hence very low actuation behavior.

75 FR 9638 - Safety Advisory Notice: Use of Composite Cargo Tanks Manufactured Under DOT Special Permits

Federal Register 2010, 2011, 2012, 2013, 2014

2010-03-03

.... PHMSA-2010-0046; Notice No. 10-1] Safety Advisory Notice: Use of Composite Cargo Tanks Manufactured... use composite cargo tank motor vehicles authorized under DOT special permits of the requirement to... for composite cargo tanks, such as fiber reinforced plastic (FRP) or glass fiber reinforced plastic...

Composition, apparatus, and process, for sorption of gaseous compounds of group II-VII elements

DOEpatents

Tom, Glenn M.; McManus, James V.; Luxon, Bruce A.

1991-08-06

Scavenger compositions are disclosed, which have utility for effecting the sorptive removal of hazardous gases containing Group II-VII elements of the Periodic Table, such as are widely encountered in the manufacture of semiconducting materials and semiconductor devices. Gas sorption processes including the contacting of Group II-VII gaseous compounds with such scavenger compositions are likewise disclosed, together with critical space velocity contacting conditions pertaining thereto. Further described are gas contacting apparatus, including mesh structures which may be deployed in gas contacting vessels containing such scavenger compositions, to prevent solids from being introduced to or discharged from the contacting vessel in the gas stream undergoing treatment. A reticulate heat transfer structure also is disclosed, for dampening localized exothermic reaction fronts when gas mixtures comprising Group II-VII constituents are contacted with the scavenger compositions in bulk sorption contacting vessels according to the invention.