Influence of Implementation of Composite Materials in Civil Aircraft Industry on reduction of Environmental Pollution and Greenhouse Effect

NASA Astrophysics Data System (ADS)

Beck, A. J.; Hodzic, A.; Soutis, C.; Wilson, C. W.

2011-12-01

Computer-based Life Cycle Analysis (LCA) models were carried out to compare lightweight composites with the traditional aluminium over their useful lifetime. The analysis included raw materials, production, useful life in operation and disposal at the end of the material's useful life. The carbon fibre epoxy resin composite could in some cases reduce the weight of a component by up to 40 % compared to aluminium. As the fuel consumption of an aircraft is strongly influenced by its total weight, the emissions can be significantly reduced by increasing the proportion of composites used in the aircraft structure. Higher emissions, compared to aluminium, produced during composites production meet their 'break even' point after certain number of time units when used in aircraft structures, and continue to save emissions over their long-term operation. The study highlighted the environmental benefits of using lightweight structures in aircraft design, and also showed that utilisation of composites in products without energy saving may lead to increased emissions in the environment.

Next-Generation MKIII Lightweight HUT/Hatch Assembly

NASA Technical Reports Server (NTRS)

McCarthy, Mike; Toscano, Ralph

2013-01-01

The MK III (H-1) carbon-graphite/ epoxy Hard Upper Torso (HUT)/Hatch assembly was designed, fabricated, and tested in the early 1990s. The spacesuit represented an 8.3 psi (˜58 kPa) technology demonstrator model of a zero prebreathe suit. The basic torso shell, brief, and hip areas of the suit were composed of a carbon-graphite/epoxy composite lay-up. In its current configuration, the suit weighs approximately 120 lb (˜54 kg). However, since future planetary suits will be designed to operate at 0.26 bar (˜26 kPa), it was felt that the suit's re-designed weight could be reduced to 79 lb (˜35 kg) with the incorporation of lightweight structural materials. Many robust, lightweight structures based on the technologies of advanced honeycomb materials, revolutionary new composite laminates, metal matrix composites, and recent breakthroughs in fullerene fillers and nanotechnology lend themselves well to applications requiring materials that are both light and strong. The major problem involves the reduction in weight of the HUT/ Hatch assembly for use in lunar and/or planetary applications, while at the same time maintaining a robust structural design. The technical objective is to research, design, and develop manufacturing methods that support fa b rica - tion of a lightweight HUT/Hatch assembly using advanced material and geometric redesign as necessary. Additionally, the lightweight HUT/Hatch assembly will interface directly with current MK III hardware. Using the new operating pressure and current MK III (H-1) interfaces as a starting block, it is planned to maximize HUT/Hatch assembly weight reduction through material selection and geometric redesign. A hard upper torso shell structure with rear-entry closure and corresponding hatch will be fabricated. The lightweight HUT/Hatch assembly will retrofit and interface with existing MK III (H-1) hardware elements, providing NASA with immediate "plug-andplay" capability. NASA crewmembers will have a lightweight, robust, life-support system that will minimize fatigue during extraterrestrial surface sojourns. Its unique feature is the utilization of a new and innovative family of materials used by the aerospace industry, which at the time of this reporting has not been used for the proposed application.

Overview of Lightweight Structures for Rotorcraft Engines and Drivetrains

NASA Technical Reports Server (NTRS)

Roberts, Gary D.

2011-01-01

This is an overview presentation of research being performed in the Advanced Materials Task within the NASA Subsonic Rotary Wing Project. This research is focused on technology areas that address both national goals and project goals for advanced rotorcraft. Specific technology areas discussed are: (1) high temperature materials for advanced turbines in turboshaft engines; (2) polymer matrix composites for lightweight drive system components; (3) lightweight structure approaches for noise and vibration control; and (4) an advanced metal alloy for lighter weight bearings and more reliable mechanical components. An overview of the technology in each area is discussed, and recent accomplishments are presented.

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

Testing and evaluation of a slot and tab construction technique for light-weight wood-fiber-based structural panels under bending

Treesearch

Jinghao Li; John F. Hunt; Shaoqin Gong; Zhiyong Cai

2015-01-01

This paper presented construction and strain distributions for light-weight wood-fiber-based structural panels with tri-grid core made from phenolic impregnated laminated paper composites under bending. A new fastening configuration of slots in the faces and tabs on the core was applied to the face/core interfaces of the sandwich panel in addition to epoxy resin. Both...

Metal matrix composite structural panel construction

NASA Technical Reports Server (NTRS)

Mcwithey, R. R.; Royster, D. M. (Inventor); Bales, T. T.

1983-01-01

Lightweight capped honeycomb stiffeners for use in fabricating metal or metal/matrix exterior structural panels on aerospace type vehicles and the process for fabricating same are disclosed. The stiffener stringers are formed in sheets, cut to the desired width and length and brazed in spaced relationship to a skin with the honeycomb material serving directly as the required lightweight stiffeners and not requiring separate metal encasement for the exposed honeycomb cells.

Reflexive aerostructures: increased vehicle survivability

NASA Astrophysics Data System (ADS)

Margraf, Thomas W.; Hemmelgarn, Christopher D.; Barnell, Thomas J.; Franklin, Mark A.

2007-04-01

Aerospace systems stand to benefit significantly from the advancement of reflexive aerostructure technologies for increased vehicle survivability. Cornerstone Research Group Inc. (CRG) is developing lightweight, healable composite systems for use as primary load-bearing aircraft components. The reflexive system is comprised of piezoelectric structural health monitoring systems, localized thermal activation systems, and lightweight, healable composite structures. The reflexive system is designed to mimic the involuntary human response to damage. Upon impact, the structural health monitoring system will identify the location and magnitude of the damage, sending a signal to a discrete thermal activation control system to resistively heat the shape memory polymer (SMP) matrix composite above activation temperature, resulting in localized shape recovery and healing of the damaged areas. CRG has demonstrated SMP composites that can recover 90 percent of flexural yield stress and modulus after postfailure healing. During the development, CRG has overcome issues of discrete activation, structural health monitoring integration, and healable resin systems. This paper will address the challenges associated with development of a reflexive aerostructure, including integration of structural health monitoring, discrete healing, and healable shape memory resin systems.

Application of an Instrumental and Computational Approach for Improving the Vibration Behavior of Structural Panels Using a Lightweight Multilayer Composite

PubMed Central

Sánchez, Alberto; García, Manuel; Sebastián, Miguel Angel; Camacho, Ana María

2014-01-01

This work presents a hybrid (experimental-computational) application for improving the vibration behavior of structural components using a lightweight multilayer composite. The vibration behavior of a flat steel plate has been improved by the gluing of a lightweight composite formed by a core of polyurethane foam and two paper mats placed on its faces. This composite enables the natural frequencies to be increased and the modal density of the plate to be reduced, moving about the natural frequencies of the plate out of excitation range, thereby improving the vibration behavior of the plate. A specific experimental model for measuring the Operating Deflection Shape (ODS) has been developed, which enables an evaluation of the goodness of the natural frequencies obtained with the computational model simulated by the finite element method (FEM). The model of composite + flat steel plate determined by FEM was used to conduct parametric study, and the most influential factors for 1st, 2nd and 3rd mode were identified using a multifactor analysis of variance (Multifactor-ANOVA). The presented results can be easily particularized for other cases, as it may be used in cycles of continuous improvement as well as in the product development at the material, piece, and complete-system levels. PMID:24618779

Light weight fire resistant graphite composites

NASA Technical Reports Server (NTRS)

Kourtides, D. A.; Parker, J. A.; Hsu, M. T. S.

1986-01-01

Composite structures with a honeycomb core and characterized by lightweight and excellent fire resistance are provided. These sandwich structures employ facesheets made up of bismaleimide-vinyl styrylpyridine copolymers with fiber reinforcement such as carbon fiber reinforcement. In preferred embodiments the facesheets are over layered with a decorative film. The properties of these composites make them attractive materials of construction aircraft and spacecraft.

Manufacturing Precise, Lightweight Paraboloidal Mirrors

NASA Technical Reports Server (NTRS)

Hermann, Frederick Thomas

2006-01-01

A process for fabricating a precise, diffraction- limited, ultra-lightweight, composite- material (matrix/fiber) paraboloidal telescope mirror has been devised. Unlike the traditional process of fabrication of heavier glass-based mirrors, this process involves a minimum of manual steps and subjective judgment. Instead, this process involves objectively controllable, repeatable steps; hence, this process is better suited for mass production. Other processes that have been investigated for fabrication of precise composite-material lightweight mirrors have resulted in print-through of fiber patterns onto reflecting surfaces, and have not provided adequate structural support for maintenance of stable, diffraction-limited surface figures. In contrast, this process does not result in print-through of the fiber pattern onto the reflecting surface and does provide a lightweight, rigid structure capable of maintaining a diffraction-limited surface figure in the face of changing temperature, humidity, and air pressure. The process consists mainly of the following steps: 1. A precise glass mandrel is fabricated by conventional optical grinding and polishing. 2. The mandrel is coated with a release agent and covered with layers of a carbon- fiber composite material. 3. The outer surface of the outer layer of the carbon-fiber composite material is coated with a surfactant chosen to provide for the proper flow of an epoxy resin to be applied subsequently. 4. The mandrel as thus covered is mounted on a temperature-controlled spin table. 5. The table is heated to a suitable temperature and spun at a suitable speed as the epoxy resin is poured onto the coated carbon-fiber composite material. 6. The surface figure of the optic is monitored and adjusted by use of traditional Ronchi, Focault, and interferometric optical measurement techniques while the speed of rotation and the temperature are adjusted to obtain the desired figure. The proper selection of surfactant, speed or rotation, viscosity of the epoxy, and temperature make it possible to obtain the desired diffraction-limited, smooth (1/50th wave) parabolic outer surface, suitable for reflective coating. 7. A reflective coat is applied by use of conventional coating techniques. 8. Once the final figure is set, a lightweight structural foam is applied to the rear of the optic to ensure stability of the figure.

Efficient Design and Analysis of Lightweight Reinforced Core Sandwich and PRSEUS Structures

NASA Technical Reports Server (NTRS)

Bednarcyk, Brett A.; Yarrington, Phillip W.; Lucking, Ryan C.; Collier, Craig S.; Ainsworth, James J.; Toubia, Elias A.

2012-01-01

Design, analysis, and sizing methods for two novel structural panel concepts have been developed and incorporated into the HyperSizer Structural Sizing Software. Reinforced Core Sandwich (RCS) panels consist of a foam core with reinforcing composite webs connecting composite facesheets. Boeing s Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) panels use a pultruded unidirectional composite rod to provide axial stiffness along with integrated transverse frames and stitching. Both of these structural concepts are ovencured and have shown great promise applications in lightweight structures, but have suffered from the lack of efficient sizing capabilities similar to those that exist for honeycomb sandwich, foam sandwich, hat stiffened, and other, more traditional concepts. Now, with accurate design methods for RCS and PRSEUS panels available in HyperSizer, these concepts can be traded and used in designs as is done with the more traditional structural concepts. The methods developed to enable sizing of RCS and PRSEUS are outlined, as are results showing the validity and utility of the methods. Applications include several large NASA heavy lift launch vehicle structures.

Light-weight sandwich panel honeycomb core with hybrid carbon-glass fiber composite skin for electric vehicle application

NASA Astrophysics Data System (ADS)

Cahyono, Sukmaji Indro; Widodo, Angit; Anwar, Miftahul; Diharjo, Kuncoro; Triyono, Teguh; Hapid, A.; Kaleg, S.

2016-03-01

The carbon fiber reinforced plastic (CFRP) composite is relative high cost material in current manufacturing process of electric vehicle body structure. Sandwich panels consisting polypropylene (PP) honeycomb core with hybrid carbon-glass fiber composite skin were investigated. The aim of present paper was evaluate the flexural properties and bending rigidity of various volume fraction carbon-glass fiber composite skins with the honeycomb core. The flexural properties and cost of panels were compared to the reported values of solid hybrid Carbon/Glass FRP used for the frame body structure of electric vehicle. The finite element model of represented sandwich panel was established to characterize the flexural properties of material using homogenization technique. Finally, simplified model was employed to crashworthiness analysis for engine hood of the body electric vehicle structure. The good cost-electiveness of honeycomb core with hybrid carbon-glass fiber skin has the potential to be used as a light-weight alternative material in body electric vehicle fabricated.

The Structure Of The Gaia Deployable Sunshield Assembly

NASA Astrophysics Data System (ADS)

Pereira, Carlos; Urgoiti, Eduardo; Pinto, Inaki

2012-07-01

GAIA is an ESA mission with launch date in 2013. Its main objective is to map the stars. After launch it will unfold a 10.2 m diameter sunshield .The structure of this shield consists of twelve 3.5 meter long composite trusses which act as scaffold to two multilayer insulation blankets. Due to thermal stability constraints the planarity of the shield must be better than 1.0 mm. The trusses are therefore lightweight structures capable of withstanding the launch loads and once deployed, the thermal environment of the spacecraft with a minimum of distortion. This paper details: • The material selection for the composite structure • Validation of the chosen materials and truss layout • The modification of manufacturing process in order to lightweight the structure • The extensive structural and thermal stability testing The sunshield has been delivered to the satellite prime after successful mechanical, thermal and deployment tests.

Optimized adhesives for strong, lightweight, damage-resistant, nanocomposite materials: new insights from natural materials

NASA Astrophysics Data System (ADS)

Hansma, P. K.; Turner, P. J.; Ruoff, R. S.

2007-01-01

From our investigations of natural composite materials such as abalone shell and bone we have learned the following. (1) Nature is frugal with resources: it uses just a few per cent glue, by weight, to glue together composite materials. (2) Nature does not avoid voids. (3) Nature makes optimized glues with sacrificial bonds and hidden length. We discuss how optimized adhesives combined with high specific stiffness/strength structures such as carbon nanotubes or graphene sheets could yield remarkably strong, lightweight, and damage-resistant materials.

Composite Technology for Exploration

NASA Technical Reports Server (NTRS)

Fikes, John

2017-01-01

The CTE (Composite Technology for Exploration) Project will develop and demonstrate critical composites technologies with a focus on joints that utilize NASA expertise and capabilities. The project will advance composite technologies providing lightweight structures to support future NASA exploration missions. The CTE project will demonstrate weight-saving, performance-enhancing bonded joint technology for Space Launch System (SLS)-scale composite hardware.

Engineering report. Part 3: NASA lightweight wheel and brake sub-system. Lightweight brake development. [for application to space shuttle

NASA Technical Reports Server (NTRS)

Bok, L. D.

1973-01-01

The development of light weight wheel and brake systems designed to meet the space shuttle type requirements was investigated. The study includes the use of carbon graphite composite and beryllium as heat sink materials and the compatibility of these heat sink materials with the other structural components of the wheel and brake.

Open-Lattice Composite Design Strengthens Structures

NASA Technical Reports Server (NTRS)

2007-01-01

Advanced composite materials and designs could eventually be applied as the framework for spacecraft or extraterrestrial constructions for long-term space habitation. One such structure in which NASA has made an investment is the IsoTruss grid structure, an extension of a two-dimensional "isogrid" concept originally developed at McDonnell Douglas Astronautics Company, under contract to NASA's Marshall Space Flight Center in the early 1970s. IsoTruss is a lightweight and efficient alternative to monocoque composite structures, and can be produced in a manner that involves fairly simple techniques. The technology was developed with support from NASA to explore space applications, and is garnering global attention because it is extremely lightweight; as much as 12 times stronger than steel; inexpensive to manufacture, transport, and install; low-maintenance; and is fully recyclable. IsoTruss is expected to see application as utility poles and meteorological towers, for the aforementioned reasons and because its design offers superior wind resistance and is less susceptible to breaking and woodpeckers. Other applications, such as reinforcement for concrete structures, stand-alone towers, sign supports, prostheses, irrigation equipment, and sporting goods are being explored

Lightweight composite reflectors for space optics

NASA Astrophysics Data System (ADS)

Williams, Brian E.; McNeal, Shawn R.; Ono, Russell M.

1998-01-01

The primary goal of this work was to advance the state of the art in lightweight, high optical quality reflectors for space- and Earth-based telescopes. This was accomplished through the combination of a precision silicon carbide (SiC) reflector surface and a high specific strength, low-mass SiC structural support. Reducing the mass of components launched into space can lead to substantial cost savings, but an even greater benefit of lightweight reflectors for both space- and Earth-based optics applications is the fact that they require far less complex and less expensive positioning systems. While Ultramet is not the first company to produce SiC by chemical vapor deposition (CVD) for reflector surfaces, it is the first to propose and demonstrate a lightweight, open-cell SiC structural foam that can support a thin layer of the highly desirable polished SiC reflector material. SiC foam provides a substantial structural and mass advantage over conventional honeycomb supports and alternative finned structures. The result is a reflector component that meets or exceeds the optical properties of current high-quality glass, ceramic, and metal reflectors while maintaining a substantially lower areal density.

Flexible Composite-Material Pressure Vessel

NASA Technical Reports Server (NTRS)

Brown, Glen; Haggard, Roy; Harris, Paul A.

2003-01-01

A proposed lightweight pressure vessel would be made of a composite of high-tenacity continuous fibers and a flexible matrix material. The flexibility of this pressure vessel would render it (1) compactly stowable for transport and (2) more able to withstand impacts, relative to lightweight pressure vessels made of rigid composite materials. The vessel would be designed as a structural shell wherein the fibers would be predominantly bias-oriented, the orientations being optimized to make the fibers bear the tensile loads in the structure. Such efficient use of tension-bearing fibers would minimize or eliminate the need for stitching and fill (weft) fibers for strength. The vessel could be fabricated by techniques adapted from filament winding of prior composite-material vessels, perhaps in conjunction with the use of dry film adhesives. In addition to the high-bias main-body substructure described above, the vessel would include a low-bias end substructure to complete coverage and react peak loads. Axial elements would be overlaid to contain damage and to control fiber orientation around side openings. Fiber ring structures would be used as interfaces for connection to ancillary hardware.

Failure analysis of single-bolted joint for lightweight composite laminates and metal plate

NASA Astrophysics Data System (ADS)

Li, Linjie; Qu, Junli; Liu, Xiangdong

2018-01-01

A three-dimensional progressive damage model was developed in ANSYS to predict the damage accumulation of single bolted joint in composite laminates under in-plane tensile loading. First, we describe the formulation and algorithm of this model. Second, we calculate the failure loads of the joint in fibre reinforced epoxy laminated composite plates and compare it with the experiment results, which validates that our model can appropriately simulate the ultimate tensile strength of the joints and the whole process of failure of structure. Finally, this model is applied to study the failure process of the light-weight composite material (USN125). The study also has a great potential to provide a strong basis for bolted joints design in composite Laminates as well as a simple tool for comparing different laminate geometries and bolt arrangements.

High-Temperature Treatments For Polyimide/Graphite Composite

NASA Technical Reports Server (NTRS)

Bowles, Kenneth J.; Lowell, Carl

1992-01-01

Combination of inert-gas heat treatment and coating with material impermeable by oxygen proposed to increase thermo-oxidative and high-temperature structural stabilities of composite materials made of graphite fibers in matrices of PMR-15 polyimide. Proposal directed toward development of lightweight matrix/fiber composites for use in aircraft engines, wherein composites exposed to maximum operating temperatures between 371 and 427 degrees C.

Alkali-silica reactivity of expanded glass granules in structure of lightweight concrete

NASA Astrophysics Data System (ADS)

Bumanis, G.; Bajare, D.; Locs, J.; Korjakins, A.

2013-12-01

Main component in the lightweight concrete, which provides its properties, is aggregate. A lot of investigations on alkali silica reaction (ASR) between cement and lightweight aggregates have been done with their results published in the academic literature. Whereas expanded glass granules, which is relatively new product in the market of building materials, has not been a frequent research object. Therefore lightweight granules made from waste glass and eight types of cement with different chemical and mineralogical composition were examined in this research. Expanded glass granules used in this research is commercially available material produced by Penostek. Lightweight concrete mixtures were prepared by using commercial chemical additives to improve workability of concrete. The aim of the study is to identify effect of cement composition to the ASR reaction which occurs between expanded glass granules and binder. Expanded glass granules mechanical and physical properties were determined. In addition, properties of fresh and hardened concrete were determined. The ASR test was processed according to RILEM AAR-2 testing recommendation. Tests with scanning electron microscope and microstructural investigations were performed for expanded glass granules and hardened concrete specimens before and after exposing them in alkali solution.

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).

Structural materials for NASP

NASA Astrophysics Data System (ADS)

Ronald, Terence M. F.

1991-12-01

Structural materials for the NASP X-30 experimental vehicle are briefly reviewed including titanium alloys, titanium-based metal-matrix composites, carbon-carbon composites, ceramic-matrix composites, and copper-matrix composites. Areas of application of these materials include the airframe where these materials would be used as lightweight skin panels for honeycomb-core, truss-core, or integrally stiffened thin sheet configuration; and the engine, where they would be used in the hot gas path of the ramjet/scramjet, and in the inlet and nozzle areas.

Construction of three-dimensional graphene interfaces into carbon fiber textiles for increasing deposition of nickel nanoparticles: flexible hierarchical magnetic textile composites for strong electromagnetic shielding

NASA Astrophysics Data System (ADS)

Bian, Xing-Ming; Liu, Lin; Li, Hai-Bing; Wang, Chan-Yuan; Xie, Qing; Zhao, Quan-Liang; Bi, Song; Hou, Zhi-Ling

2017-01-01

Since manipulating electromagnetic waves with electromagnetic active materials for environmental and electric engineering is a significant task, here a novel prototype is reported by introducing reduced graphene oxide (RGO) interfaces in carbon fiber (CF) networks for a hierarchical carbon fiber/reduced graphene oxide/nickel (CF-RGO-Ni) composite textile. Upon charaterizations of the microscopic morphologies, electrical and magnetic properties, the presence of three-dimensional RGO interfaces and bifunctional nickel nanoparticles substantially influences the related physical properties in the resulting hierarchical composite textiles. Eletromagnetic interference (EMI) shielding performance suggests that the hierarchical composite textiles hold a strong shielding effectiveness greater than 61 dB, showing greater advantages than conventional polymeric and foamy shielding composites. As a polymer-free lightweight structure, flexible CF-RGO-Ni composites of all electromagnetic active components offer unique understanding of the multi-scale and multiple mechanisms in electromagnetic energy consumption. Such a novel prototype of shielding structures along with convenient technology highlight a strategy to achieve high-performance EMI shielding, coupled with a universal approach for preparing advanced lightweight composites with graphene interfaces.

Construction of three-dimensional graphene interfaces into carbon fiber textiles for increasing deposition of nickel nanoparticles: flexible hierarchical magnetic textile composites for strong electromagnetic shielding.

PubMed

Bian, Xing-Ming; Liu, Lin; Li, Hai-Bing; Wang, Chan-Yuan; Xie, Qing; Zhao, Quan-Liang; Bi, Song; Hou, Zhi-Ling

2017-01-27

Since manipulating electromagnetic waves with electromagnetic active materials for environmental and electric engineering is a significant task, here a novel prototype is reported by introducing reduced graphene oxide (RGO) interfaces in carbon fiber (CF) networks for a hierarchical carbon fiber/reduced graphene oxide/nickel (CF-RGO-Ni) composite textile. Upon charaterizations of the microscopic morphologies, electrical and magnetic properties, the presence of three-dimensional RGO interfaces and bifunctional nickel nanoparticles substantially influences the related physical properties in the resulting hierarchical composite textiles. Eletromagnetic interference (EMI) shielding performance suggests that the hierarchical composite textiles hold a strong shielding effectiveness greater than 61 dB, showing greater advantages than conventional polymeric and foamy shielding composites. As a polymer-free lightweight structure, flexible CF-RGO-Ni composites of all electromagnetic active components offer unique understanding of the multi-scale and multiple mechanisms in electromagnetic energy consumption. Such a novel prototype of shielding structures along with convenient technology highlight a strategy to achieve high-performance EMI shielding, coupled with a universal approach for preparing advanced lightweight composites with graphene interfaces.

The influence of partial replacement of hemp shives by expanded perlite on physical properties of hemp-lime composite

NASA Astrophysics Data System (ADS)

Brzyski, Przemysław; Widomski, Marcin

2017-07-01

The use of waste plants in building materials production is consistent with the principles of sustainable development, including waste management, CO2 balance, biodegradability of the material e.g. after building demolition. The porous structure of plant materials determines their usability as the insulation materials. An example of plant applicable in the construction industry is the industrial hemp. The shives are produced from the wooden core of the hemp stem as lightweight insulating filler in the composite based on lime binder. The discussed hemp-lime composite, due to the presence of lightweight, porous organic aggregates exhibits satisfactory thermal insulation properties and is used as filling and insulation of walls (as well as roofs and floors) in buildings of the wooden frame construction. The irregular shape of shives and their low density causes nonhomogenous compaction of composite and the formation of voids between the randomly arranged shives. In this paper the series of hemp-lime composites were tested. Apart from hemp shives, an additional aggregate - expanded perlite was used as a fine, lightweight, thermal insulating filler. Application of the additional aggregate was aimed to fill the voids between hemp shives and to investigate its influence on the physical properties of composite: apparent density, total porosity, water absorption and thermal conductivity.

Lightweight composites for modular panelized construction

NASA Astrophysics Data System (ADS)

Vaidya, Amol S.

Rapid advances in construction materials technology have enabled civil engineers to achieve impressive gains in the safety, economy, and functionality of structures built to serve the common needs of society. Modular building systems is a fast-growing modern, form of construction gaining recognition for its increased efficiency and ability to apply modern technology to the needs of the market place. In the modular construction technique, a single structural panel can perform a number of functions such as providing thermal insulation, vibration damping, and structural strength. These multifunctional panels can be prefabricated in a manufacturing facility and then transferred to the construction site. A system that uses prefabricated panels for construction is called a "panelized construction system". This study focuses on the development of pre-cast, lightweight, multifunctional sandwich composite panels to be used for panelized construction. Two thermoplastic composite panels are proposed in this study, namely Composite Structural Insulated Panels (CSIPs) for exterior walls, floors and roofs, and Open Core Sandwich composite for multifunctional interior walls of a structure. Special manufacturing techniques are developed for manufacturing these panels. The structural behavior of these panels is analyzed based on various building design codes. Detailed descriptions of the design, cost analysis, manufacturing, finite element modeling and structural testing of these proposed panels are included in this study in the of form five peer-reviewed journal articles. The structural testing of the proposed panels involved in this study included flexural testing, axial compression testing, and low and high velocity impact testing. Based on the current study, the proposed CSIP wall and floor panels were found satisfactory, based on building design codes ASCE-7-05 and ACI-318-05. Joining techniques are proposed in this study for connecting the precast panels on the construction site. Keywords: Modular panelized construction, sandwich composites, composite structural insulated panels (CSIPs).

Integrated Composite Stiffener Structure (ICoSS) Concept for Planetary Entry Vehicles

NASA Technical Reports Server (NTRS)

Kellas, Sotiris

2016-01-01

Results from the design, manufacturing, and testing of a lightweight Integrated Composite Stiffened Structure (ICoSS) concept, intended for multi-mission planetary entry vehicles are presented. Tests from both component and full-scale tests for a typical Earth Entry Vehicle forward shell manufactured using the ICoSS concept are presented and advantages of the concept for the particular application of passive Earth Entry Vehicles over other structural concepts are discussed.

Properties of lightweight cement-based composites containing waste polypropylene

NASA Astrophysics Data System (ADS)

Záleská, Martina; Pavlíková, Milena; Pavlík, Zbyšek

2016-07-01

Improvement of buildings thermal stability represents an increasingly important trend of the construction industry. This work aims to study the possible use of two types of waste polypropylene (PP) for the development of lightweight cement-based composites with enhanced thermal insulation function. Crushed PP waste originating from the PP tubes production is used for the partial replacement of silica sand by 10, 20, 30, 40 and 50 mass%, whereas a reference mixture without plastic waste is studied as well. First, basic physical and thermal properties of granular PP random copolymer (PPR) and glass fiber reinforced PP (PPGF) aggregate are studied. For the developed composite mixtures, basic physical, mechanical, heat transport and storage properties are accessed. The obtained results show that the composites with incorporated PP aggregate exhibit an improved thermal insulation properties and acceptable mechanical resistivity. This new composite materials with enhanced thermal insulation function are found to be promising materials for buildings subsoil or floor structures.

Silicon Carbide Technologies for Lightweighted Aerospace Mirrors

NASA Astrophysics Data System (ADS)

Matson, L.; Chen, M.; Deblonk, B.; Palusinski, I.

The use of monolithic glass and beryllium to produce lightweighted aerospace mirror systems has reached its limits due to the long lead times, high processing costs, environmental effects and launch load/weight requirements. New material solutions and manufacturing processes are required to meet DoD's directed energy weapons, reconnaissance/surveillance, and secured communications needs. Over the past several years the Air Force, MDA, and NASA has focused their efforts on the fabrication, lightweighting, and scale-up of numerous silicon carbide (SiC) based materials. It is anticipated that SiC can be utilized for most applications from cryogenic to high temperatures. This talk will focus on describing the SOA for these (near term) SiC technology solutions for making mirror structural substrates, figuring and finishing technologies being investigated to reduce cost time and cost, and non-destructive evaluation methods being investigated to help eliminate risk. Mirror structural substrates made out of advanced engineered materials (far term solutions) such as composites, foams, and microsphere arrays for ultra lightweighting will also be briefly discussed.

Structural considerations in design of lightweight glass-fiber composite pressure vessels

NASA Technical Reports Server (NTRS)

Faddoul, J. R.

1973-01-01

The development of structurally efficient, metal-lined, glass-fiber composite pressure vessels. Both the current state-of-the-art and current problems are discussed along with fracture mechanics considerations for the metal liner. The design concepts used for metal-lined, glass-fiber, composite pressure vessels are described and the structural characteristics of the composite designs are compared with each other and with homogeneous metal pressure vessels. Specific design techniques and available design data are identified. Results of a current program to evaluate flaw growth and fracture characteristics of the metal liners are reviewed and the impact of these results on composite pressure vessel designs is discussed.

Metal- and Polymer-Matrix Composites: Functional Lightweight Materials for High-Performance Structures

NASA Astrophysics Data System (ADS)

Gupta, Nikhil; Paramsothy, Muralidharan

2014-06-01

The special topic "Metal- and Polymer-Matrix Composites" is intended to capture the state of the art in the research and practice of functional composites. The current set of articles related to metal-matrix composites includes reviews on functionalities such as self-healing, self-lubricating, and self-cleaning capabilities; research results on a variety of aluminum-matrix composites; and investigations on advanced composites manufacturing methods. In addition, the processing and properties of carbon nanotube-reinforced polymer-matrix composites and adhesive bonding of laminated composites are discussed. The literature on functional metal-matrix composites is relatively scarce compared to functional polymer-matrix composites. The demand for lightweight composites in the transportation sector is fueling the rapid development in this field, which is captured in the current set of articles. The possibility of simultaneously tailoring several desired properties is attractive but very challenging, and it requires significant advancements in the science and technology of composite materials. The progress captured in the current set of articles shows promise for developing materials that seem capable of moving this field from laboratory-scale prototypes to actual industrial applications.

Research and technology, 1983

NASA Technical Reports Server (NTRS)

1983-01-01

Highlights of major accomplishments and applications made during the past year illustrate the broad range of research and technology activities at the Langley Research Center. Advances are reported in the following areas: systems engineering and operation; aeronautics; electronics; space applications; aircraft and spacecraft structures; composite structures; laminar flow control; subsonic transport aircraft; and supersonic fighter concepts. Technology utilization efforts described cover a hyperthermia monitor, a lightweight composite wheelchair; and a vehicle ride quality meter.

Flight Testing of a Low Cost De-Orbiting Device for Small Satellites

NASA Technical Reports Server (NTRS)

Turse, Dana; Keller, Phil; Taylor, Robert; Reavis, Mark; Tupper, Mike; Koehler, Chris

2014-01-01

Use of small and very small spacecraft is rapidly becoming more common. Methods to intentionally deorbit these spacecraft at the end of useful satellite life are required. A family of mass efficient Roll-Out De- Orbiting devices (RODEO"TM") was developed by Composite Technology Development, Inc. (CTD). RODEO"TM" consists of lightweight film attached to a simple, ultra-lightweight, roll-out composite boom structure. This system is rolled to stow within a lightweight launch canister, allowing easy integration to the small satellite bus. The device is released at the end of useful lifetime and the RODEO"TM" composite boom unrolls the drag sail in a matter of seconds. This dramatically increases the deployed surface area, resulting in the higher aerodynamic drag that significantly reduces the time until reentry. A RODEO"TM" flight demonstration was recently conducted as part of the Colorado Space Grant Consortium's (COSGC) RocketSat-8 program, a program to provide students hands-on experience in developing experiments for space flight. The experiment was ultimately a success and RODEO (trademark) is now ready for future CubeSat missions.

Characterization of Polyimide Foams for Ultra-Lightweight Space Structures

NASA Technical Reports Server (NTRS)

Meador, Michael (Technical Monitor); Hillman, Keithan; Veazie, David R.

2003-01-01

Ultra-lightweight materials have played a significant role in nearly every area of human activity ranging from magnetic tapes and artificial organs to atmospheric balloons and space inflatables. The application range of ultra-lightweight materials in past decades has expanded dramatically due to their unsurpassed efficiency in terms of low weight and high compliance properties. A new generation of ultra-lightweight materials involving advanced polymeric materials, such as TEEK (TM) polyimide foams, is beginning to emerge to produce novel performance from ultra-lightweight systems for space applications. As a result, they require that special conditions be fulfilled to ensure adequate structural performance, shape retention, and thermal stability. It is therefore important and essential to develop methodologies for predicting the complex properties of ultra-lightweight foams. To support NASA programs such as the Reusable Launch Vehicle (RLV), Clark Atlanta University, along with SORDAL, Inc., has initiated projects for commercial process development of polyimide foams for the proposed cryogenic tank integrated structure (see figure 1). Fabrication and characterization of high temperature, advanced aerospace-grade polyimide foams and filled foam sandwich composites for specified lifetimes in NASA space applications, as well as quantifying the lifetime of components, are immensely attractive goals. In order to improve the development, durability, safety, and life cycle performance of ultra-lightweight polymeric foams, test methods for the properties are constant concerns in terms of timeliness, reliability, and cost. A major challenge is to identify the mechanisms of failures (i.e., core failure, interfacial debonding, and crack development) that are reflected in the measured properties. The long-term goal of the this research is to develop the tools and capabilities necessary to successfully engineer ultra-lightweight polymeric foams. The desire is to reduce density at the material and structural levels, while at the same time maintaining or increasing mechanical and other properties.

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.

Composite armored vehicle advanced technology demonstator

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

Ostberg, D.T.; Dunfee, R.S.; Thomas, G.E.

1996-12-31

Composite structures are a key technology needed to develop future lightweight combat vehicles that are both deployable and survivable. The Composite Armored Vehicle Advanced Technology Demonstrator Program that started in fiscal year 1994 will continue through 1998 to verily that composite structures are a viable solution for ground combat vehicles. Testing thus far includes material characterization, structural component tests and full scale quarter section tests. Material and manufacturing considerations, tests, results and changes, and the status of the program will be described. The structural component tests have been completed successfully, and quarter section testing is in progress. Upon completion ofmore » the critical design review, the vehicle demonstrator will be Fabricated and undergo government testing.« less

Optimization of SMA layers in composite structures to enhance damping

NASA Astrophysics Data System (ADS)

Haghdoust, P.; Cinquemani, S.; Lecis, N.; Bassani, P.

2016-04-01

The performance of lightweight structures can be severely affected by vibration. New design concepts leading to lightweight, slender structural components can increase the vulnerability of the components to failure due to excessive vibration. The intelligent approach to address the problem would be the use of materials which are more capable in dissipating the energy due to their high value of loss factor. Among the different materials available to achieve damping, much attention has been attached to the use of shape memory alloys (SMAs) because of their unique microstructure, leading to good damping capacity. This work describes the design and optimization of a hybrid layered composite structure for the passive suppression of flexural vibrations in slender and light structures. Embedding the SMA layers in composite structure allows to combine different properties: the lightness of the base composite (e.g. fiber glass), the mechanical strength of the insert of metallic material and the relevant damping properties of SMA, in the martensitic phase. In particular, we put our attention on embedding the CuZnAl in the form of thin sheet in a layered composite made by glass fiber reinforced epoxy. By appropriately positioning of the SMA sheets so that they are subjected to the maximum curvature, the damping of the hybrid system can be considerably enhanced. Accordingly analytical method for evaluating the energy dissipation of the thin sheets with different shapes and patterns is developed and is followed by a shape optimization based on genetic algorithm. Eventually different configurations of the hybrid beam structure with different patterns of SMA layer are proposed and compared in the term of damping capacity.

Microstructural Developments and Tensile Properties of Lean Fe-Mn-Al-C Lightweight Steels

NASA Astrophysics Data System (ADS)

Sohn, S. S.; Lee, S.; Lee, B.-J.; Kwak, J.-H.

2014-09-01

Concepts of Fe-Al-Mn-C-based lightweight steels are fairly simple, but primary metallurgical issues are complicated. In this study, recent studies on lean-composition lightweight steels were reviewed, summarized, and emphasized by their microstructural development and mechanical properties. The lightweight steels containing a low-density element of Al were designed by thermodynamic calculation and were manufactured by conventional industrial processes. Their microstructures consisted of various secondary phases as κ-carbide, martensite, and austenite in the ferrite matrix according to manufacturing and annealing procedures. The solidification microstructure containing segregations of C, Mn, and Al produced a banded structure during the hot rolling. The (ferrite + austenite) duplex microstructure was formed after the annealing, and the austenite was retained at room temperature. It was because the thermal stability of austenite nucleated from fine κ-carbide was quite high due to fine grain size of austenite. Because these lightweight steels have outstanding properties of strength and ductility as well as reduced density, they give a promise for automotive applications requiring excellent properties.

System concept for a moderate cost Large Deployable Reflector (LDR)

NASA Technical Reports Server (NTRS)

Swanson, P. N.; Breckinridge, J. B.; Diner, A.; Freeland, R. E.; Irace, W. R.; Mcelroy, P. M.; Meinel, A. B.; Tolivar, A. F.

1986-01-01

A study was carried out at JPL during the first quarter of 1985 to develop a system concept for NASA's LDR. Major features of the concept are a four-mirror, two-stage optical system; a lightweight structural composite segmented primary reflector; and a deployable truss backup structure with integral thermal shield. The two-stage optics uses active figure control at the quaternary reflector located at the primary reflector exit pupil, allowing the large primary to be passive. The lightweight composite reflector panels limit the short-wavelength operation to approximately 30 microns but reduce the total primary reflector weight by a factor of 3 to 4 over competing technologies. On-orbit thermal analysis indicates a primary reflector equilibrium temperature of less than 200 K with a maximum gradient of about 5 C across the 20-m aperture. Weight and volume estimates are consistent with a single Shuttle launch, and are based on Space Station assembly and checkout.

Future Nanotube Commercialization Opportunities at the NASA Marshall Space Flight Center and the US Army Aviation and Missile Command

NASA Technical Reports Server (NTRS)

Watson, Michael; Shah, Sandeep; Kaul, Raj; Zhu, Shen; Vandiver, Terry; Zimmerman, Joe E. (Technical Monitor)

2001-01-01

Nanotube technology has broad applicability to programs at both the NASA Marshall Space Flight Center (MSFC) and the US Army Aviation and Missile Command (AMCOM). MSFC has interest in applications of nanotubes as sensors and high strength lightweight materials for propulsion system components, avionic systems, and scientific instruments. MSFC is currently pursuing internal programs to develop nanotube temperature sensors, heat pipes, and metal matrix composites. In support of these application areas MSFC is interested in growth of long nanotubes, growth of nanotubes in the microgravity environment, and nanotubes fabricated from high temperature materials such as Boron Nitride or Silicon Carbide. AMCOM is similarly interested in nanotube applications which take advantage of the nanotube thermal conductance properties, high strength, and lightweight. Applications of interest to AMCOM include rocket motor casing structures, rocket nozzles, and lightweight structure and aeronautic skins.

Stiff, Thermally Stable and Highly Anisotropic Wood-Derived Carbon Composite Monoliths for Electromagnetic Interference Shielding.

PubMed

Yuan, Ye; Sun, Xianxian; Yang, Minglong; Xu, Fan; Lin, Zaishan; Zhao, Xu; Ding, Yujie; Li, Jianjun; Yin, Weilong; Peng, Qingyu; He, Xiaodong; Li, Yibin

2017-06-28

Electromagnetic interference (EMI) shielding materials for electronic devices in aviation and aerospace not only need lightweight and high shielding effectiveness, but also should withstand harsh environments. Traditional EMI shielding materials often show heavy weight, poor thermal stability, short lifetime, poor tolerance to chemicals, and are hard-to-manufacture. Searching for high-efficiency EMI shielding materials overcoming the above weaknesses is still a great challenge. Herein, inspired by the unique structure of natural wood, lightweight and highly anisotropic wood-derived carbon composite EMI shielding materials have been prepared which possess not only high EMI shielding performance and mechanical stable characteristics, but also possess thermally stable properties, outperforming those metals, conductive polymers, and their composites. The newly developed low-cost materials are promising for specific applications in aerospace electronic devices, especially regarding extreme temperatures.

Morphology and microstructure of composite materials

NASA Technical Reports Server (NTRS)

Tiwari, S. N.; Srinivansan, K.

1991-01-01

Lightweight continuous carbon fiber based polymeric composites are currently enjoying increasing acceptance as structural materials capable of replacing metals and alloys in load bearing applications. As with most new materials, these composites are undergoing trials with several competing processing techniques aimed at cost effectively producing void free consolidations with good mechanical properties. As metallic materials have been in use for several centuries, a considerable database exists on their morphology - microstructure; and the interrelationships between structure and properties have been well documented. Numerous studies on composites have established the crucial relationship between microstructure - morphology and properties. The various microstructural and morphological features of composite materials, particularly those accompanying different processing routes, are documented.

Design Analysis and Thermo-Mechanical Fatigue of a Polyimide Composite for Combustion Chamber Support

NASA Technical Reports Server (NTRS)

Thesken, J. C.; Melis, M.; Shin, E.; Sutter, J.; Burke, Chris

2004-01-01

Polyimide composites are being evaluated for use in lightweight support structures designed to preserve the ideal flow geometry within thin shell combustion chambers of future space launch propulsion systems. Principles of lightweight design and innovative manufacturing techniques have yielded a sandwich structure with an outer face sheet of carbon fiber polyimide matrix composite. While the continuous carbon fiber enables laminated skin of high specific stiffness; the polyimide matrix materials ensure that the rigidity and durability is maintained at operation temperatures of 316 C. Significant weight savings over all metal support structures are expected. The protypical structure is the result of ongoing collaboration, between Boeing and NASA-GRC seeking to introduce polyimide composites to the harsh environmental and loads familiar to space launch propulsion systems. Design trade analyses were carried out using relevant closed form solutions, approximations for sandwich beams/panels and finite element analysis. Analyses confirm the significant thermal stresses exist when combining materials whose coefficients of thermal expansion (CTEs) differ by a factor of about 10 for materials such as a polymer composite and metallic structures. The ramifications on design and manufacturing alternatives are reviewed and discussed. Due to stringent durability and safety requirements, serious consideration is being given to the synergistic effects of temperature and mechanical loads. The candidate structure operates at 316 C, about 80% of the glass transition temperature T(sub g). Earlier thermomechanical fatigue (TMF) investigations of chopped fiber polyimide composites made this near to T(sub g), showed that cyclic temperature and stress promoted excessive creep damage and strain accumulation. Here it is important to verify that such response is limited in continuous fiber laminates.

Mechanical properties of geopolymer lightweight brick with styrofoam pellet

NASA Astrophysics Data System (ADS)

Abdullah, Mohd Mustafa Al Bakri; Tahir, Muhammad Faheem Mohd; Kadir, Aeslina Abdul; Hussin, Kamarudin; Samson, W. Saiful Iskandar W.

2017-09-01

The utilization of fly ash in brick as partial replacement of cement is gaining immense importance today, mainly on account of the improvement in the long-term durability of brick combined with ecological benefits. In this research, the lightweight brick was produced by using fly ash (class F) as a main material to replace Ordinary Portland Cement (OPC) in the composition of brick. Class F Fly Ash was mixed with an alkaline activator solution (a mixture of sodium silicate and NaOH), and styrofoam pellet was added to the geopolymer mixture to produce lightweight brick. The brick was prepared in two methods that is wet method and dry method due to different brick composition which is dry method for composition with sand and wet method for composition without sand. The bricks were cured in room temperature at 7 aging days. After 7 days, the compressive strength, water absorption, and density of the brick were investigated, where the optimum ratio for the best bricks has been determined from the lightweight density and has compressive strength more than minimum standard requirement. The best bricks are further produce for curing at 60°C in oven at 28 aging days. Those bricks also were characterized using optical microscope to measure the distribution of styrofoam in brick structure. From the result obtained, the brick that cured at 60°C in oven at 28 aging days has high strength compare to brick that cured in room temperature and at 7 day cured. The water absorption is decreasing as the curing temperature and aging days increased whereas density is increasing.

Program Evaluation - Automotive Lightweighting Materials Program Research and Development Projects Assessment of Benefits - Case Studies No. 2

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

Das, S.

This report is the second of a series of studies to evaluate research and development (R&D) projects funded by the Automotive Lightweighting Materials (ALM) Program of the Office of Advanced Automotive Technologies (OAAT) of the U.S. Department of Energy (DOE). The objectives of the program evaluation are to assess short-run outputs and long-run outcomes that may be attributable to the ALM R&D projects. The ALM program focuses on the development and validation of advanced technologies that significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. Funded projects range from fundamentalmore » materials science research to applied research in production environments. Collaborators on these projects include national laboratories, universities, and private sector firms, such as leading automobile manufacturers and their suppliers. Three ALM R&D projects were chosen for this evaluation: Design and Product Optimization for Cast Light Metals, Durability of Lightweight Composite Structures, and Rapid Tooling for Functional Prototyping of Metal Mold Processes. These projects were chosen because they have already been completed. The first project resulted in development of a comprehensive cast light metal property database, an automotive application design guide, computerized predictive models, process monitoring sensors, and quality assurance methods. The second project, the durability of lightweight composite structures, produced durability-based design criteria documents, predictive models for creep deformation, and minimum test requirements and suggested test methods for establishing durability properties and characteristics of random glass-fiber composites for automotive structural composites. The durability project supported Focal Project II, a validation activity that demonstrates ALM program goals and reduces the lead time for bringing new technology into the marketplace. Focal projects concentrate on specific classes of materials and nonproprietary components and are done jointly by DOE and the Automotive Composites Consortium of U.S. Council for Automotive Research (USCAR). The third project developed a rapid tooling process that reduces tooling time, originally some 48-52 weeks, to less than 12 weeks by means of rapid generation of die-casting die inserts and development of generic holding blocks, suitable for use with large casting applications. This project was conducted by the United States Automotive Materials Partnership, another USCAR consortium.« less

Preliminary Assessment of Potential Habitat Composites' Durability when Exposed to a Long-Term Radiation Environment and Micrometeoroid Impacts

NASA Technical Reports Server (NTRS)

Rojdev, Kristina; Graves, Russell; Golden, John; Atwell, William; O'Rouke, Mary Jane; Hill, Charles; Alred, John

2011-01-01

NASA's exploration goals include extending human presence beyond low earth orbit (LEO). As a result, habitation for crew is a critical requirement for meeting this goal. However, habitats are very large structures that contain a multitude of subsystems to sustain human life over long-durations in space, and one of the key challenges has been keeping weight to a minimum in order to reduce costs. Thus, light-weight and multifunctional structural materials are of great interest for habitation. NASA has started studying polymeric composite materials as potential lightweight and multifunctional structural materials for use in long-duration spaceflight. However, little is known about the survivability of these materials when exposed to the space environment outside of LEO for long durations. Thus, a study has been undertaken to investigate the durability of composite materials when exposed to long-duration radiation. Furthermore, as an addition to the primary study, a secondary preliminary investigation has been started on the micrometeoroid and orbital debris (MMOD) susceptibility of these materials after radiation exposure. The combined effects of radiation and MMOD impacts are the focus of this paper.

Lightweight Thermal Protection System for Atmospheric Entry

NASA Technical Reports Server (NTRS)

Stewart, David; Leiser, Daniel

2007-01-01

TUFROC (Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite) has been developed as a new thermal protection system (TPS) material for wing leading edge and nose cap applications. The composite withstands temperatures up to 1,970 K, and consists of a toughened, high-temperature surface cap and a low-thermal-conductivity base, and is applicable to both sharp and blunt leading edge vehicles. This extends the possible application of fibrous insulation to the wing leading edge and/or nose cap on a hypersonic vehicle. The lightweight system comprises a treated carbonaceous cap composed of ROCCI (Refractory Oxidation-resistant Ceramic Carbon Insulation), which provides dimensional stability to the outer mold line, while the fibrous base material provides maximum thermal insulation for the vehicle structure.

Structural and thermal testing of lightweight reflector panels

NASA Technical Reports Server (NTRS)

Mcgregor, J.; Helms, R.; Hill, T.

1992-01-01

The paper describes the test facility developed for testing large lightweight reflective panels with very accurate and stable surfaces, such as the mirror panels of composite construction developed for the NASA's Precision Segmented Reflector (PSR). Special attention is given to the panel construction and the special problems posed by the characteristics of these panels; the design of the Optical/Thermal Vacuum test facility for structural and thermal testing, developed at the U.S. AFPL; and the testing procedure. The results of the PSR panel test program to date are presented. The test data showed that the analytical approaches used for the panel design and for the prediction of the on-orbit panel behavior were adequate.

Bioinspired Hydroxyapatite/Poly(methyl methacrylate) Composite with a Nacre-Mimetic Architecture by a Bidirectional Freezing Method.

PubMed

Bai, Hao; Walsh, Flynn; Gludovatz, Bernd; Delattre, Benjamin; Huang, Caili; Chen, Yuan; Tomsia, Antoni P; Ritchie, Robert O

2016-01-06

Using a bidirectional freezing technique, combined with uniaxial pressing and in situ polymerization, "nacre-mimetic" hydroxyapatite/poly(methyl methacrylate) (PMMA) composites are developed by processing large-scale aligned lamellar ceramic scaffolds. Structural and mechanical characterization shows "brick-and-mortar" structures, akin to nacre, with interesting combinations of strength, stiffness, and work of fracture, which provide a pathway to making strong and tough lightweight materials. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Structural Design and Analysis of a Light-Weight Laminated Composite Heat Sink for Spaceflight PWBs

NASA Technical Reports Server (NTRS)

Fan, Mark S.; Niemeyer, W. Lee

1997-01-01

In order to reduce the overall weight in spaceborne electronic systems, a conventional metallic heat sink typically used for double-sided printed wiring boards was suggested to be replaced by light-weight and high-strength laminated composite materials. Through technology validation assurance (TVA) approach, it has been successfully demonstrated that using laminated composite heat sink can not only reduce the weight of the heat sink by nearly 50%, but also significantly lower the internal thermally-induced stresses that are largely responsible for potential delamination under cyclic temperature variations. With composite heat sink, both thermal and dynamic performance of the double-sided printed wiring board (PWB) exceeds that of its counterpart with metallic heat sink. Also included in this work is the original contribution to the understanding of creep behavior of the worst-case leadless chip carrier (LCC) surface mount solder joint. This was identified as the interconnection most susceptible to thermal fatigue damage in the PWB assembly.

Lightning strike protection of composites

NASA Astrophysics Data System (ADS)

Gagné, Martin; Therriault, Daniel

2014-01-01

Aircraft structures are being redesigned to use fiber-reinforced composites mainly due to their high specific stiffness and strength. One of the main drawbacks from changing from electrically conductive metals to insulating or semi-conducting composites is the higher vulnerability of the aircraft to lightning strike damage. The current protection approach consists of bonding a metal mesh to the surface of the composite structure, but this weight increase negatively impact the fuel efficiency. This review paper presents an overview of the lightning strike problematic, the regulations, the lightning damage to composite, the current protection solutions and other material or technology alternatives. Advanced materials such as polymer-based nanocomposites and carbon nanotube buckypapers are promising candidates for lightweight lightning strike protection technology.

2016 Summer Series - Kenneth Cheung: Building Blocks for Aerospace Structures

NASA Image and Video Library

2016-06-16

Strong, ultra-lightweight materials are expected to play a key role in the design of future aircraft and space vehicles. Lower structural mass leads to improved performance, maneuverability, efficiency, range and payload capacity. Dr. Kenneth Cheung is developing cellular composite building blocks, or digital materials, to create transformable aerostructures. In his presentation, Dr. Cheung will discuss the implications of the digital materials and morphing structures.

Nanocrystalline Aluminum Truss Cores for Lightweight Sandwich Structures

NASA Astrophysics Data System (ADS)

Schaedler, Tobias A.; Chan, Lisa J.; Clough, Eric C.; Stilke, Morgan A.; Hundley, Jacob M.; Masur, Lawrence J.

2017-12-01

Substitution of conventional honeycomb composite sandwich structures with lighter alternatives has the potential to reduce the mass of future vehicles. Here we demonstrate nanocrystalline aluminum-manganese truss cores that achieve 2-4 times higher strength than aluminum alloy 5056 honeycombs of the same density. The scalable fabrication approach starts with additive manufacturing of polymer templates, followed by electrodeposition of nanocrystalline Al-Mn alloy, removal of the polymer, and facesheet integration. This facilitates curved and net-shaped sandwich structures, as well as co-curing of the facesheets, which eliminates the need for extra adhesive. The nanocrystalline Al-Mn alloy thin-film material exhibits high strength and ductility and can be converted into a three-dimensional hollow truss structure with this approach. Ultra-lightweight sandwich structures are of interest for a range of applications in aerospace, such as fairings, wings, and flaps, as well as for the automotive and sports industries.

Lightweight, fire-retardant, crashworthy aircraft seat cushioning

NASA Technical Reports Server (NTRS)

Haslim, Leonard A.; Mcdonough, Paul T.

1991-01-01

A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.

Facesheet Delamination of Composite Sandwich Materials at Cryogenic Temperatures

NASA Technical Reports Server (NTRS)

Gates, Thomas S.; Odegard, Gregory M.; Herring, Helen M.

2003-01-01

The next generation of space transportation vehicles will require advances in lightweight structural materials and related design concepts to meet the increased demands on performance. One potential source for significant structural weight reduction is the replacement of traditional metallic cryogenic fuel tanks with new designs for polymeric matrix composite tanks. These new tank designs may take the form of thin-walled sandwich constructed with lightweight core and composite facesheets. Life-time durability requirements imply the materials must safely carry pressure loads, external structural loads, resist leakage and operate over an extremely wide temperature range. Aside from catastrophic events like tank wall penetration, one of the most likely scenarios for failure of a tank wall of sandwich construction is the permeation of cryogenic fluid into the sandwich core and the subsequent delamination of the sandwich facesheet due to the build-up of excessive internal pressure. The research presented in this paper was undertaken to help understand this specific problem of core to facesheet delamination in cryogenic environments and relate this data to basic mechanical properties. The experimental results presented herein provide data on the strain energy release rate (toughness) of the interface between the facesheet and the core of a composite sandwich subjected to simulated internal pressure. A unique test apparatus and associated test methods are described and the results are presented to highlight the effects of cryogenic temperature on the measured material properties.

Lightweight Radiator System for a Spacecraft

NASA Technical Reports Server (NTRS)

Copeland, Robert J.; Mason, Georgia; Weislogel, Mark M.

2005-01-01

Three documents describe various aspects of a proposed lightweight, deployable radiator system for dissipating excess heat from the life-support system of a habitable spacecraft. The first document focuses on a radiator tube that would include a thin metal liner surrounded and supported by a thicker carbon-fiber-reinforced composite tubular structure that, in turn, would be formed as part of a unitary composite radiator-fin structure consisting mostly of a sheet of reticulated vitreous carbon laminated between carbon-fiber-reinforced face sheets. The thermal and mechanical properties, including the anisotropies, of the component materials are taken into account in the design. The second document describes thermo-structural bumpers, in the form of exterior multiple-ply carbon-fiber sheets enclosing hollows on opposite sides of a radiator fin, which would protect the radiator tube against impinging micrometeors and orbital debris. The third document describes a radiator system that would include multiple panels containing the aforementioned components, among others. The system would also include mechanisms for deploying the panels from compact stowage. Deployment would not involve breaking and remaking of fluid connections to the radiator panels.

Materials and structures

NASA Astrophysics Data System (ADS)

Saito, Theodore T.; Langenbeck, Sharon L.; Al-Jamily, Ghanim; Arnold, Joe; Barbee, Troy; Coulter, Dan; Dolgin, Ben; Fichter, Buck; George, Patricia; Gorenstein, Paul

1992-08-01

Materials and structures technology covers a wide range of technical areas. Some of the most pertinent issues for the Astrotech 21 missions include dimensionally stable structural materials, advanced composites, dielectric coatings, optical metallic coatings for low scattered light applications, low scattered light surfaces, deployable and inflatable structures (including optical), support structures in 0-g and 1-g environments, cryogenic optics, optical blacks, contamination hardened surfaces, radiation hardened glasses and crystals, mono-metallic telescopes and instruments, and materials characterization. Some specific examples include low coefficients of thermal expansion (CTE) structures (0.01 ppm/K), lightweight thermally stable mirror materials, thermally stable optical assemblies, high reliability/accuracy (1 micron) deployable structures, and characterization of nanometer level behavior of materials/structures for interferometry concepts. Large filled-aperture concepts will require materials with CTE's of 10(exp 9) at 80 K, anti-contamination coatings, deployable and erectable structures, composite materials with CTE's less than 0.01 ppm/K and thermal hysteresis, 0.001 ppm/K. Gravitational detection systems such as LAGOS will require rigid/deployable structures, dimensionally stable components, lightweight materials with low conductivity, and high stability optics. The Materials and Structures panel addressed these issues and the relevance of the Astrotech 21 mission requirements by dividing materials and structures technology into five categories. These categories, the necessary development, and applicable mission/program development phasing are summarized. For each of these areas, technology assessments were made and development plans were defined.

Nondestructive Evaluation of Advanced Materials with X-ray Phase Mapping

NASA Technical Reports Server (NTRS)

Hu, Zhengwei

2005-01-01

X-ray radiation has been widely used for imaging applications since Rontgen first discovered X-rays over a century ago. Its large penetration depth makes it ideal for the nondestructive visualization of the internal structure and/or defects of materials unobtainable otherwise. Currently used nondestructive evaluation (NDE) tools, X-ray radiography and tomography, are absorption-based, and work well in heavy-element materials where density or composition variations due to internal structure or defects are high enough to produce appreciable absorption contrast. However, in many cases where materials are light-weight and/or composites that have similar mass absorption coefficients, the conventional absorption-based X-ray methods for NDE become less useful. Indeed, the light-weight and ultra-high-strength requirements for the most advanced materials used or developed for current flight mission and future space exploration pose a great challenge to the standard NDE tools in that the absorption contrast arising from the internal structure of these materials is often too weak to be resolved. In this presentation, a solution to the problem, the use of phase information of X-rays for phase contrast X-ray imaging, will be discussed, along with a comparison between the absorption-based and phase-contrast imaging methods. Latest results on phase contrast X-ray imaging of lightweight Space Shuttle foam in 2D and 3D will be presented, demonstrating new opportunities to solve the challenging issues encountered in advanced materials development and processing.

Characterization of Carbon Nanotube Reinforced Nickel

NASA Technical Reports Server (NTRS)

Gill, Hansel; Hudson, Steve; Bhat, Biliyar; Munafo, Paul M. (Technical Monitor)

2002-01-01

Carbon nanotubes are cylindrical molecules composed of carbon atoms in a regular hexagonal arrangement. If nanotubes can be uniformly dispersed in a supporting matrix to form structural materials, the resulting structures could be significantly lighter and stronger than current aerospace materials. Work is currently being done to develop an electrolyte-based self-assembly process that produces a Carbon Nanotube/Nickel composite material with high specific strength. This process is expected to produce a lightweight metal matrix composite material, which maintains it's thermal and electrical conductivities, and is potentially suitable for applications such as advanced structures, space based optics, and cryogenic tanks.

Evaluation of a Gamma Titanium Aluminide for Hypersonic Structural Applications

NASA Technical Reports Server (NTRS)

Johnson, W. Steven; Weeks, Carrell E.

2005-01-01

Titanium matrix composites (TMCs) have been extensively evaluated for their potential to replace conventional superalloys in high temperature structural applications, with significant weight-savings while maintaining comparable mechanical properties. New gamma titanium aluminide alloys and an appropriate fiber could offer an improved TMC for use in intermediate temperature applications (400-800 C). The purpose of this investigation is the evaluation of a gamma titanium aluminide alloy with nominal composition Ti-46.5Al-4(Cr,Nb,Ta,B)at.% as a structural material in future aerospace transportation systems, where very light-weight structures are necessary to meet the goals of advanced aerospace programs.

MADCAT Aircraft Wings Optimize Their Shape For Efficient Flight

NASA Image and Video Library

2016-11-09

The Mission Adaptive Digital Composites Aerostructures Technology (MADCAT) project is designing an aircraft wing that can change its shape to adapt to changing flight conditions. Constructed of lightweight lattice structures made of carbon fiber materials, the goal is to reduce drag, leading to more efficient airplanes.

Concepts for the development of light-weight composite structures for rotor burst containment

NASA Technical Reports Server (NTRS)

Holmes, A. G.

1977-01-01

A set of hypotheses is established as to what variables might control the design of a weight-efficient protective device. A particular experiment for evaluating the hypotheses and materials was designed. The design and methods for the analysis of results are described.

Carbon Nanotube Coatings as Used in Strain Sensors for Composite Tanks

NASA Technical Reports Server (NTRS)

Trigwell, Steve; Snyder, Sarah; Hatfield, Walt; Dervishi, Enkeleda; Biris, Alexandru S.

2011-01-01

The next generation of cryogenic fuel tanks, crew habitats and other components for future spacecraft will focus on the usc of lightweight carbon fiber composite materials. A critical issue in the design and optimization of such tanks and structures will bc in structural health monitoring, however, current strain sensors have limitations. In this study, a novel carbon nanotube thin film was applied to carbon fiber composites for structural monitoring. Applying a load using a 3-point bend test to simulate bowing of a tank wall, induced significant increases in the film's electrical resistance at small deflections. Upon release of the load, the resistance returned to its approximate start value and was reproducible over multiple tests. The results show that a carbon nanotube thin film has great potential for the health monitoring of composite structures.

MSFC Combustion Devices in 2001

NASA Technical Reports Server (NTRS)

Dexter, Carol; Turner, James (Technical Monitor)

2001-01-01

The objectives of the project detailed in this viewgraph presentation were to reduce thrust assembly weights to create lighter engines and to increase the cycle life and/or operating temperatures. Information is given on material options (metal matrix composites and polymer matrix composites), ceramic matrix composites subscale liners, lightweight linear chambers, lightweight injector development, liquid/liquid preburner tasks, and vortex chamber tasks.

Silicon Carbide Monofilament Reinforced Titanium Composites For Space Structures: A New Material Option

NASA Astrophysics Data System (ADS)

Kyle-Henney, Stephen; Flitcroft, Stephen; Shatwell, Robert; Gibbon, David; Voss, Gary; Harkness, Patrick

2012-07-01

Silicon carbide fibre reinforced titanium composite material has been in development since the 1980s initially for high temperature structures on hypersonic vehicles (HOTOL, NASP). Since then development has focused on military and civil aircraft. Development in the European Union has reached a level of maturity where it is again being considered for space applications. Current activities include pressure vessels and studies for launch vehicles and satellite applications. The paper provides background to the technology key performance characteristics current application work and future activities. The renewed interest in hypersonic vehicles has also picked up on the potential for lightweight metallic composites.

Bonded repair of composite aircraft structures: A review of scientific challenges and opportunities

NASA Astrophysics Data System (ADS)

Katnam, K. B.; Da Silva, L. F. M.; Young, T. M.

2013-08-01

Advanced composite materials have gained popularity in high-performance structural designs such as aerospace applications that require lightweight components with superior mechanical properties in order to perform in demanding service conditions as well as provide energy efficiency. However, one of the major challenges that the aerospace industry faces with advanced composites - because of their inherent complex damage behaviour - is structural repair. Composite materials are primarily damaged by mechanical loads and/or environmental conditions. If material damage is not extensive, structural repair is the only feasible solution as replacing the entire component is not cost-effective in many cases. Bonded composite repairs (e.g. scarf patches) are generally preferred as they provide enhanced stress transfer mechanisms, joint efficiencies and aerodynamic performance. With an increased usage of advanced composites in primary and secondary aerospace structural components, it is thus essential to have robust, reliable and repeatable structural bonded repair procedures to restore damaged composite components. But structural bonded repairs, especially with primary structures, pose several scientific challenges with the current existing repair technologies. In this regard, the area of structural bonded repair of composites is broadly reviewed - starting from damage assessment to automation - to identify current scientific challenges and future opportunities.

Investigation of transfer length, development length, flexural strength, and prestress losses in lightweight prestressed concrete girders.

DOT National Transportation Integrated Search

2003-01-01

Encouraged by the performance of high performance normal weight composite girders, the Virginia Department of Transportation has sought to exploit the use of high performance lightweight composite concrete (HPLWC) girders to achieve economies brought...

Porous CNTs/Co Composite Derived from Zeolitic Imidazolate Framework: A Lightweight, Ultrathin, and Highly Efficient Electromagnetic Wave Absorber.

PubMed

Yin, Yichao; Liu, Xiaofang; Wei, Xiaojun; Yu, Ronghai; Shui, Jianglan

2016-12-21

Porous carbon nanotubes/cobalt nanoparticles (CNTs/Co) composite with dodecahedron morphology was synthesized by in situ pyrolysis of the Co-based zeolitic imidazolate framework in a reducing atmosphere. The morphology and microstructure of the composite can be well tuned by controlling the pyrolysis conditions. At lower pyrolysis temperature, the CNTs/Co composite is composed of well-dispersed Co nanoparticles and short CNT clusters with low graphitic degree. The increase of pyrolysis temperature/time promotes the growth and graphitization of CNTs and leads to the aggregation of Co nanoparticles. The optimized CNTs/Co composite exhibits strong dielectric and magnetic losses as well as a good impedance matching property. Interestingly, the CNTs/Co composite displays extremely strong electromagnetic wave absorption with a maximum reflection loss of -60.4 dB. More importantly, the matching thickness of the absorber is as thin as 1.81 mm, and the filler loading of composite in the matrix is only 20 wt %. The highly efficient absorption is closely related to the well-designed structure and the synergistic effect between CNTs and Co nanoparticles. The excellent absorbing performance together with lightweight and ultrathin thickness endows the CNTs/Co composite with the potential for application in the electromagnetic wave absorbing field.

High temperature structural sandwich panels

NASA Astrophysics Data System (ADS)

Papakonstantinou, Christos G.

High strength composites are being used for making lightweight structural panels that are being employed in aerospace, naval and automotive structures. Recently, there is renewed interest in use of these panels. The major problem of most commercial available sandwich panels is the fire resistance. A recently developed inorganic matrix is investigated for use in cases where fire and high temperature resistance are necessary. The focus of this dissertation is the development of a fireproof composite structural system. Sandwich panels made with polysialate matrices have an excellent potential for use in applications where exposure to high temperatures or fire is a concern. Commercial available sandwich panels will soften and lose nearly all of their compressive strength temperatures lower than 400°C. This dissertation consists of the state of the art, the experimental investigation and the analytical modeling. The state of the art covers the performance of existing high temperature composites, sandwich panels and reinforced concrete beams strengthened with Fiber Reinforced Polymers (FRP). The experimental part consists of four major components: (i) Development of a fireproof syntactic foam with maximum specific strength, (ii) Development of a lightweight syntactic foam based on polystyrene spheres, (iii) Development of the composite system for the skins. The variables are the skin thickness, modulus of elasticity of skin and high temperature resistance, and (iv) Experimental evaluation of the flexural behavior of sandwich panels. Analytical modeling consists of a model for the flexural behavior of lightweight sandwich panels, and a model for deflection calculations of reinforced concrete beams strengthened with FRP subjected to fatigue loading. The experimental and analytical results show that sandwich panels made with polysialate matrices and ceramic spheres do not lose their load bearing capability during severe fire exposure, where temperatures reach several hundred degrees Centigrade. Hence the material has excellent potential for various types of applications. The analytical predictions from both models provide reasonably accurate results. Glass, AR-glass, carbon and Nicalon tows and carbon fabrics could be successfully used as skin reinforcements increasing the flexural stiffness and strength of the core. No occurrence of fiber delamination was observed.

Orthotic devices using lightweight composite materials

NASA Technical Reports Server (NTRS)

Harrison, E., Jr.

1983-01-01

Potential applications of high strength, lightweight composite technology in the orthotic field were studied. Several devices were designed and fabricated using graphite-epoxy composite technology. Devices included shoe plates, assistive walker devices, and a Simes prosthesis reinforcement. Several other projects having medical application were investigated and evaluations were made of the potential for use of composite technology. A seat assembly was fabricated using sandwich construction techniques for the Total Wheelchair Project.

Structures, Design and Test: Materials

NASA Technical Reports Server (NTRS)

2004-01-01

NASA Marshall has developed a technology that combines a film/adhesive laydown module with fiber placement technology to enable the processing of composite prepreg tow/tape and films, foils, or adhesives on the same placement machine. The deve!opment of this technology grew out of NASA's need for lightweight, permeation-resistant cryogenic propellant tanks.

Lightweight NiFe2O4 with controllable 3D network structure and enhanced microwave absorbing properties

NASA Astrophysics Data System (ADS)

Wang, Fen; Wang, Xing; Zhu, Jianfeng; Yang, Haibo; Kong, Xingang; Liu, Xiao

2016-11-01

3D network structure NiFe2O4 was successfully synthesized by a templated salt precipitation method using PMMA colloid crystal as templates. The morphology, phase composition and microwave absorbing properties of as-prepared samples were characterized by scanning electron microscopy (SEM), X-ray diffraction (XRD), vector network analyzer (VNA), and so on. The results revealed that the 3D network structure was configurated with smooth spherical walls composed of NiFe2O4 nanocrystals and their pore diameters being in the range of 80-250 nm. The microwave absorption properties of the 3D network structure NiFe2O4 were crucially determined by the special structure. The synergy of intrinsic magnetic loss of magnetic NiFe2O4 and the interfacial polarization enhanced by 3D network structure and the interaction of multiple mechanisms endowed the sample with the feature of strong absorption, broad bandwidth and lightweight. There is more than one valley in the reflection loss curves and the maximum reflection loss is 27.5 dB with a bandwidth of 4 GHz. Moreover, the 3D network structure NiFe2O4 show a greater reflection loss with the same thickness comparing to the ordinary NiFe2O4 nanoparticles, which could achieve the feature of lightweight of the microwave absorbing materials.

Lightweight NiFe2O4 with controllable 3D network structure and enhanced microwave absorbing properties

PubMed Central

Wang, Fen; Wang, Xing; Zhu, Jianfeng; Yang, Haibo; Kong, Xingang; Liu, Xiao

2016-01-01

3D network structure NiFe2O4 was successfully synthesized by a templated salt precipitation method using PMMA colloid crystal as templates. The morphology, phase composition and microwave absorbing properties of as-prepared samples were characterized by scanning electron microscopy (SEM), X-ray diffraction (XRD), vector network analyzer (VNA), and so on. The results revealed that the 3D network structure was configurated with smooth spherical walls composed of NiFe2O4 nanocrystals and their pore diameters being in the range of 80–250 nm. The microwave absorption properties of the 3D network structure NiFe2O4 were crucially determined by the special structure. The synergy of intrinsic magnetic loss of magnetic NiFe2O4 and the interfacial polarization enhanced by 3D network structure and the interaction of multiple mechanisms endowed the sample with the feature of strong absorption, broad bandwidth and lightweight. There is more than one valley in the reflection loss curves and the maximum reflection loss is 27.5 dB with a bandwidth of 4 GHz. Moreover, the 3D network structure NiFe2O4 show a greater reflection loss with the same thickness comparing to the ordinary NiFe2O4 nanoparticles, which could achieve the feature of lightweight of the microwave absorbing materials. PMID:27897209

Up-cycling waste glass to minimal water adsorption/absorption lightweight aggregate by rapid low temperature sintering: optimization by dual process-mixture response surface methodology.

PubMed

Velis, Costas A; Franco-Salinas, Claudia; O'Sullivan, Catherine; Najorka, Jens; Boccaccini, Aldo R; Cheeseman, Christopher R

2014-07-01

Mixed color waste glass extracted from municipal solid waste is either not recycled, in which case it is an environmental and financial liability, or it is used in relatively low value applications such as normal weight aggregate. Here, we report on converting it into a novel glass-ceramic lightweight aggregate (LWA), potentially suitable for high added value applications in structural concrete (upcycling). The artificial LWA particles were formed by rapidly sintering (<10 min) waste glass powder with clay mixes using sodium silicate as binder and borate salt as flux. Composition and processing were optimized using response surface methodology (RSM) modeling, and specifically (i) a combined process-mixture dual RSM, and (ii) multiobjective optimization functions. The optimization considered raw materials and energy costs. Mineralogical and physical transformations occur during sintering and a cellular vesicular glass-ceramic composite microstructure is formed, with strong correlations existing between bloating/shrinkage during sintering, density and water adsorption/absorption. The diametrical expansion could be effectively modeled via the RSM and controlled to meet a wide range of specifications; here we optimized for LWA structural concrete. The optimally designed LWA is sintered in comparatively low temperatures (825-835 °C), thus potentially saving costs and lowering emissions; it had exceptionally low water adsorption/absorption (6.1-7.2% w/wd; optimization target: 1.5-7.5% w/wd); while remaining substantially lightweight (density: 1.24-1.28 g.cm(-3); target: 0.9-1.3 g.cm(-3)). This is a considerable advancement for designing effective environmentally friendly lightweight concrete constructions, and boosting resource efficiency of waste glass flows.

Lightweight, Rack-Mountable Composite Cold Plate/Shelves

NASA Technical Reports Server (NTRS)

Hurlbert, Kathryn M.; Ruemmele, Warren; Nguyen, Hai D.; Andish, Kambiz; McCalley, Sean

2004-01-01

Rack-mountable composite-material structural components that would serve as both shelves and cold plates for removing heat from electronic or other equipment mounted on the shelves have been proposed as lightweight alternatives to all-metal cold plate/shelves now in use. A proposed cold plate/shelf would include a highly thermally conductive face sheet containing oriented graphite fibers bonded to an aluminum honeycomb core, plus an extruded stainless-steel substructure containing optimized flow passages for a cooling fluid, and an inlet and outlet that could be connected to standard manifold sections. To maximize heat-transfer efficiency, the extruded stainless-steel substructure would be connected directly to the face sheet. On the basis of a tentative design, the proposed composite cold plate/shelf would weigh about 38 percent less than does an all-aluminum cold plate in use or planned for use in some spacecraft and possibly aircraft. Although weight is a primary consideration, the tentative design offers the additional benefit of reduction of thickness to half that of the all-aluminum version.

Overview of SBIR Phase II Work on Hollow Graphite Fibers

NASA Technical Reports Server (NTRS)

Stallcup, Michael; Brantley, Lott W. (Technical Monitor)

2001-01-01

Ultra-Lightweight materials are enabling for producing space based optical components and support structures. Heretofore, innovative designs using existing materials has been the approach to produce lighter-weight optical systems. Graphite fiber reinforced composites, because of their light weight, have been a material of frequent choice to produce space based optical components. Hollow graphite fibers would be lighter than standard solid graphite fibers and, thus, would save weight in optical components. The Phase I SBIR program demonstrated it is possible to produce hollow carbon fibers that have strengths up to 4.2 GPa which are equivalent to commercial fibers, and composites made from the hollow fibers had substantially equivalent composite strengths as commercial fiber composites at a 46% weight savings. The Phase II SBIR program will optimize processing and properties of the hollow carbon fiber and scale-up processing to produce sufficient fiber for fabricating a large ultra-lightweight mirror for delivery to NASA. Information presented here includes an overview of the strength of some preliminary hollow fibers, photographs of those fibers, and a short discussion of future plans.

Multifunctional Structural-energy Storage Nanocomposites for Ultra Lightweight Micro Autonomous Vehicles

DTIC Science & Technology

2013-02-01

supplement the main power supply. Here we report on the use of flexible carbon nanotube (CNT)-based composites for multifunctional structural energy storage...TERMS Micro vehicle, Supercapacitor, Carbon Nanotubes , CNTs, Energy Storage, Multifunctional Materials 16. SECURITY CLASSIFICATION OF: 17...consists of a current collector, a porous electrode layer ( carbon nanotubes [CNTs], in this case) infiltrated with an electrolyte (i.e., a liquid

Lightweight sheet molding compound (SMC) composites containing cellulose nanocrystals

Treesearch

Amir Asadi; Mark Miller; Arjun V. Singh; Robert J. Moon; Kyriaki Kalaitzidou

2017-01-01

A scalable technique was introduced to produce high volume lightweight composites using sheet molding compound (SMC) manufacturing method by replacing 10 wt% glass fibers (GF) with a small amount of cellulose nanocrystals (CNC). The incorporation of 1 and 1.5 wt% CNC by dispersing in the epoxy matrix of short GF/epoxy SMC composites with 25 wt% GF content (25GF/CNC-...

Lightweight armor system and process for producing the same

DOEpatents

Chu, Henry S.; Bruck, H. Alan; Strempek, Gary C.; Varacalle, Jr., Dominic J.

2004-01-20

A lightweight armor system may comprise a substrate having a graded metal matrix composite layer formed thereon by thermal spray deposition. The graded metal matrix composite layer comprises an increasing volume fraction of ceramic particles imbedded in a decreasing volume fraction of a metal matrix as a function of a thickness of the graded metal matrix composite layer. A ceramic impact layer is affixed to the graded metal matrix composite layer.

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

Chandrasekaran, S.; Liebig, W. V.; Mecklenberg, M.

Aerographite (AG) is a mechanically robust, lightweight synthetic cellular material, which consists of a 3D interconnected network of tubular carbon [1]. The presence of open channels in AG aids to infiltrate them with polymer matrices, thereby yielding an electrical conducting and lightweight composite. Aerographite produced with densities in the range of 7–15 mg/cm 3 was infiltrated with a low viscous epoxy resin by means of vacuum infiltration technique. Detailed morphological and structural investigations on synthesized AG and AG/epoxy composite were performed by scanning electron microscopic techniques. Our present study investigates the fracture and failure of AG/epoxy composites and its energymore » absorption capacity under compression. The composites displayed an extended plateau region when uni-axially compressed, which led to an increase in energy absorption of ~133% per unit volume for 1.5 wt% of AG, when compared to pure epoxy. Preliminary results on fracture toughness showed an enhancement of ~19% in K IC for AG/epoxy composites with 0.45 wt% of AG. Furthermore, our observations of fractured surfaces under scanning electron microscope gives evidence of pull-out of arms of AG tetrapod, interface and inter-graphite failure as the dominating mechanism for the toughness improvement in these composites. These observations were consistent with the results obtained from photoelasticity experiments on a thin film AG/epoxy model composite.« less

Analytical design model for a piezo-composite unimorph actuator and its verification using lightweight piezo-composite curved actuators

NASA Astrophysics Data System (ADS)

Yoon, K. J.; Park, K. H.; Lee, S. K.; Goo, N. S.; Park, H. C.

2004-06-01

This paper describes an analytical design model for a layered piezo-composite unimorph actuator and its numerical and experimental verification using a LIPCA (lightweight piezo-composite curved actuator) that is lighter than other conventional piezo-composite type actuators. The LIPCA is composed of top fiber composite layers with high modulus and low CTE (coefficient of thermal expansion), a middle PZT ceramic wafer, and base layers with low modulus and high CTE. The advantages of the LIPCA design are to replace the heavy metal layer of THUNDER by lightweight fiber-reinforced plastic layers without compromising the generation of high force and large displacement and to have design flexibility by selecting the fiber direction and the number of prepreg layers. In addition to the lightweight advantage and design flexibility, the proposed device can be manufactured without adhesive layers when we use a resin prepreg system. A piezo-actuation model for a laminate with piezo-electric material layers and fiber composite layers is proposed to predict the curvature and residual stress of the LIPCA. To predict the actuation displacement of the LIPCA with curvature, a finite element analysis method using the proposed piezo-actuation model is introduced. The predicted deformations are in good agreement with the experimental ones.

The Development of a Conical Composite Energy Absorber for Use in the Attenuation of Crash/Impact Loads

NASA Technical Reports Server (NTRS)

Littell, Justin D.

2014-01-01

A design for a novel light-weight conical shaped energy absorbing (EA) composite subfloor structure is proposed. This composite EA is fabricated using repeated alternating patterns of a conical geometry to form long beam structures which can be implemented as aircraft subfloor keel beams or frame sections. The geometrical features of this conical design, along with the hybrid composite materials used in the manufacturing process give a strength tailored to achieve a constant 25-40 g sustained crush load, small peak crush loads and long stroke limits. This report will discuss the geometrical design and fabrication methods, along with results from static and dynamic crush testing of 12-in. long subcomponents.

The Development of Lightweight Electronics Enclosures for Space Applications

NASA Technical Reports Server (NTRS)

Fenske, Matthew T.; Barth, Jane L.; Didion, Jeffrey R.; Mule, Peter

1999-01-01

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Multifunctional smart composites with integrated carbon nanotube yarn and sheet

NASA Astrophysics Data System (ADS)

Chauhan, Devika; Hou, Guangfeng; Ng, Vianessa; Chaudhary, Sumeet; Paine, Michael; Moinuddin, Khwaja; Rabiee, Massoud; Cahay, Marc; Lalley, Nicholas; Shanov, Vesselin; Mast, David; Liu, Yijun; Yin, Zhangzhang; Song, Yi; Schulz, Mark

2017-04-01

Multifunctional smart composites (MSCs) are materials that combine the good electrical and thermal conductivity, high tensile and shear strength, good impact toughness, and high stiffness properties of metals; the light weight and corrosion resistance properties of composites; and the sensing or actuation properties of smart materials. The basic concept for MSCs was first conceived by Daniel Inman and others about 25 years ago. Current laminated carbon and glass fiber polymeric composite materials have high tensile strength and are light in weight, but they still lack good electrical and thermal conductivity, and they are sensitive to delamination. Carbon nanotube yarn and sheets are lightweight, electrically and thermally conductive materials that can be integrated into laminated composite materials to form MSCs. This paper describes the manufacturing of high quality carbon nanotube yarn and sheet used to form MSCs, and integrating the nanotube yarn and sheet into composites at low volume fractions. Various up and coming technical applications of MSCs are discussed including composite toughening for impact and delamination resistance; structural health monitoring; and structural power conduction. The global carbon nanotube overall market size is estimated to grow from 2 Billion in 2015 to 5 Billion by 2020 at a CAGR of 20%. Nanotube yarn and sheet products are predicted to be used in aircraft, wind machines, automobiles, electric machines, textiles, acoustic attenuators, light absorption, electrical wire, sporting equipment, tires, athletic apparel, thermoelectric devices, biomedical devices, lightweight transformers, and electromagnets. In the future, due to the high maximum current density of nanotube conductors, nanotube electromagnetic devices may also become competitive with traditional smart materials in terms of power density.

Structural Assessment of Tungsten-Epoxy Bonding in Spacecraft Composite Enclosures with Enhanced Radiation Protection

NASA Astrophysics Data System (ADS)

Kanerva, M.; Koerselman, J. R.; Revitzer, H.; Johansson, L.-S.; Sarlin, E.; Rautiainen, A.; Brander, T.; Saarela, O.

2014-06-01

Spacecraft include sensitive electronics that must be protected against radiation from the space environment. Hybrid laminates consisting of tungsten layers and carbon- fibre-reinforced epoxy composite are a potential solution for lightweight, efficient, and protective enclosure material. Here, we analysed six different surface treatments for tungsten foils in terms of the resulting surface tension components, composition, and bonding strength with epoxy. A hydrofluoric-nitric-sulfuric-acid method and a diamond-like carbon-based DIARC® coating were found the most potential surface treatments for tungsten foils in this study.

Structural aspects of cold-formed steel section designed as U-shape composite beam

NASA Astrophysics Data System (ADS)

Saggaff, Anis; Tahir, Mahmood Md.; Azimi, Mohammadamin; Alhajri, T. M.

2017-11-01

Composite beam construction usually associated with old-style Hot-Rolled Steel Section (HRSS) has proven to act much better in compare with Cold-Formed Steel Section (CFSS) sections due to thicker section. Due, it's getting popular to replace HRSS with CFSS in some aspects as a composite beam. The advantages such as lightweight, cost effective and easy to install have contributed to the apply CFSS as a preferred construction material for composite beam. There is a few technical data available regarding the application of the usage of CFSS as a composite system, despite the potentials use for residential and light-weight industrial constructions. This paper presents an experimental tests results which have been conducted using CFSS as composite beam. Composite action of CFSS arranged as double beam with Self-Compacting Concrete (SCC) slab are integrated together with bolted shear connectors were used. A full-scale test comprised of 3 proposed composite beam specimens with bolted shear connector spaced at 300 mm interval of grade 8.8 was using single nut with washer on flange of CFS, cast to the slab and loaded until failed. The test show that the bolted shear connector yielded better capacity of ultimate strength and ultimate moment for the proposed composite beam. It can be concluded that, bolted shear connectors of 16 mm in diameter performed better than the other diameter size of bolted shear connectors.

Development of integrated damage detection system for international America's Cup class yacht structures using a fiber optic distributed sensor

NASA Astrophysics Data System (ADS)

Akiyoshi, Shimada; Naruse, Hiroshi; Uzawa, Kyoshi; Murayama, Hideaki; Kageyama, Kazuro

2000-06-01

We constructed a new health monitoring system to detect damage using a fiber optic distributed sensor, namely a Brillouin optical time domain reflectometer (BOTDR), and installed it in International America's Cup Class (IACC) yachts, the Japanese entry in America's Cup 2000. IACC yachts are designed to be as fast as possible, so it is essential that they are lightweight and encounter minimum water resistance. Advanced composite sandwich structures, made with carbon fiber reinforced plastic (CFRP) skins and a honeycomb core, are used to achieve the lightweight structure. Yacht structure designs push the strength of the materials to their limit and so it is important to detect highly stressed or damaged regions that might cause a catastrophic fracture. The BOTDR measures changes in the Brillouin frequency shift caused by distributed strain along one optical fiber. We undertook two experiments: a pulling test and a four point bending test on a composite beam. The former showed that no slippage occurred between the optical fiber glass and its coating. The latter confirmed that a debonding between the skin and the core of 300 mm length could be found with the BOTDR. Next we examined the effectiveness with which this system can assess the structural integrity of IACC yachts. The results show that our system has the potential for use as a damage detection system for smart structures.

Metal-Matrix Composite Parts With Metal Inserts

NASA Technical Reports Server (NTRS)

Majkowski, T.; Kashalikar, U.

1995-01-01

Developmental fabrication process produces metal-matrix composite (MMC) parts with integral metal inserts. With inserts, MMC parts readily joined to similar parts by use of brazing, welding, or mechanical fasteners. Process conceived to make strong, lightweight components of structures erected in outer space. Also useful on Earth, in such automotive parts as rocker arms, cylinder liners, and pistons. Potential industrial applications include parts subjected to high stresses at high temperatures, as in power-generation, mining, and oil-drilling equipment.

Concepts for the development of light-weight composite structures for rotor burst containment

NASA Technical Reports Server (NTRS)

Holms, A. G.

1977-01-01

Based on published results on rotor burst containment with single materials, and on body armor using composite materials, a set of hypotheses is established as to what variables might control the design of a weight-efficient protective device. Based on modern concepts for the design and analysis of small optimum seeking experiments, a particular experiment for evaluating the hypotheses and materials was designed. The design and methods for the analysis of results are described.

Influence of reinforcement type on the mechanical behavior and fire response of hybrid composites and sandwich structures

NASA Astrophysics Data System (ADS)

Giancaspro, James William

Lightweight composites and structural sandwich panels are commonly used in marine and aerospace applications. Using carbon, glass, and a host of other high strength fiber types, a broad range of laminate composites and sandwich panels can be developed. Hybrid composites can be constructed by laminating multiple layers of varying fiber types while sandwich panels are manufactured by laminating rigid fiber facings onto a lightweight core. However, the lack of fire resistance of the polymers used for the fabrication remains a very important problem. The research presented in this dissertation deals with an inorganic matrix (Geopolymer) that can be used to manufacture laminate composites and sandwich panels that are resistant up to 1000°C. This dissertation deals with the influence of fiber type on the mechanical behavior and the fire response of hybrid composites and sandwich structures manufactured using this resin. The results are categorized into the following distinct studies. (i) High strength carbon fibers were combined with low cost E-glass fibers to obtain hybrid laminate composites that are both economical and strong. The E-glass fabrics were used as a core while the carbon fibers were placed on the tension face and on both tension and compression faces. (ii) Structural sandwich beams were developed by laminating various types of reinforcement onto the tension and compression faces of balsa wood cores. The flexural behavior of the beams was then analyzed and compared to beams reinforced with organic composite. The effect of core density was evaluated using oak beams reinforced with inorganic composite. (iii) To measure the fire response, balsa wood sandwich panels were manufactured using a thin layer of a fire-resistant paste to serve for fire protection. Seventeen sandwich panels were fabricated and tested to measure the heat release rates and smoke-generating characteristics. The results indicate that Geopolymer can be effectively used to fabricate both high strength composite plates and sandwich panels. A 2 mm thick coating of fireproofing on balsa wood is sufficient to satisfy FAA fire requirements.

The Study on Development of Light-Weight Foamed Mortar for Tunnel Backfill

NASA Astrophysics Data System (ADS)

Ma, Sang-Joon; Kang, Eun-Gu; Kim, Dong-Min

This study was intended to develop the Light-Weight Foamed Mortar which is used for NATM Composite lining backfill. In the wake of the study, the mixing method which satisfies the requirements for compressive strength, permeability coefficient, fluidity, specific gravity and settlement was developed and moreover field applicability was verified through the model test. Thus the mixing of Light-Weight Foamed Mortar developed in this study is expected to be applicable to NATM Composite lining, thereby making commitment to improving the stability and drainage performance of lining.

Finite element simulation of a novel composite light-weight microporous cladding panel

NASA Astrophysics Data System (ADS)

Tian, Lida; Wang, Dongyan

2018-04-01

A novel composite light-weight microporous cladding panel with matched connection detailing is developed. Numerical simulation on the experiment is conducted by ABAQUS. The accuracy and rationality of the finite element model is verified by comparison between the simulation and the experiment results. It is also indicated that the novel composite cladding panel is of desirable bearing capacity, stiffness and deformability under out-of-plane load.

Density-tunable lightweight polymer composites with dual-functional ability of efficient EMI shielding and heat dissipation.

PubMed

Lee, Seung Hwan; Yu, Seunggun; Shahzad, Faisal; Kim, Woo Nyon; Park, Cheolmin; Hong, Soon Man; Koo, Chong Min

2017-09-21

Lightweight dual-functional materials with high EMI shielding performance and thermal conductivity are of great importance in modern cutting-edge applications, such as mobile electronics, automotive, aerospace, and military. Unfortunately, a clear material solution has not emerged yet. Herein, we demonstrate a simple and effective way to fabricate lightweight metal-based polymer composites with dual-functional ability of excellent EMI shielding effectiveness and thermal conductivity using expandable polymer bead-templated Cu hollow beads. The low-density Cu hollow beads (ρ ∼ 0.44 g cm -3 ) were fabricated through electroless plating of Cu on the expanded polymer beads with ultralow density (ρ ∼ 0.02 g cm -3 ). The resulting composites that formed a continuous 3D Cu network with a very small Cu content (∼9.8 vol%) exhibited excellent EMI shielding (110.7 dB at 7 GHz) and thermal conductivity (7.0 W m -1 K -1 ) with isotropic features. Moreover, the densities of the composites are tunable from 1.28 to 0.59 g cm -3 in accordance with the purpose of their applications. To the best of our knowledge, the resulting composites are the best lightweight dual-functional materials with exceptionally high EMI SE and thermal conductivity performance among synthetic polymer composites.

Feasibility Study on Manufacturing Lightweight Aggregates from Water Purification Sludge

NASA Astrophysics Data System (ADS)

Peng, Ching-Fang; Chen, How-Ji

2018-02-01

This study mainly discussed the feasibility of manufacturing lightweight aggregates from water purification sludge in Taiwan. They were analysed for the physical and chemical composition before the sintering test for lightweight aggregates in a laboratory. Then the physical and mechanical properties of the synthesized aggregates were assessed. The result showed that the chemical composition of sludge in the water purification plants was within the appropriate range for manufacturing lightweight aggregate as proposed in the literature. The sintering test demonstrated that the particle density of aggregates from the ten types of water purification sludge were mostly less than 1.8 g/cm3. In addition, the dry unit weight, the organic impurity, the ignition loss, and other characteristics of synthesized aggregates met the requirement of CNS standards, while its water absorption and crushing strength also fulfilled the general commercial specifications. Therefore, reclamation of water purification sludge for production of lightweight aggregate is indeed feasible.

High-Temperature, Lightweight, Self-Healing Ceramic Composites for Aircraft Engine Applications

NASA Technical Reports Server (NTRS)

Raj, Sai V.; Bhatt, Ramkrishna

2013-01-01

The use of reliable, high-temperature, lightweight materials in the manufacture of aircraft engines is expected to result in lower fossil and biofuel consumption, thereby leading to cost savings and lower carbon emissions due to air travel. Although nickel-based superalloy blades and vanes have been successfully used in aircraft engines for several decades, there has been an increased effort to develop high-temperature, lightweight, creep-resistant substitute materials under various NASA programs over the last two decades. As a result, there has been a great deal of interest in developing SiC/SiC ceramic matrix composites (CMCs) due to their higher damage tolerance compared to monolithic ceramics. Current-generation SiC/SiC ceramic matrix composites rely almost entirely on the SiC fibers to carry the load, owing to the premature cracking of the matrix during loading. Thus, the high-temperature usefulness of these CMCs falls well below their theoretical capabilities. The objective of this work is to develop a new class of high-temperature, lightweight, self-healing, SiC fiber-reinforced, engineered matrix ceramic composites.

Fracture, failure and compression behaviour of a 3D interconnected carbon aerogel (Aerographite) epoxy composite

DOE PAGES

Chandrasekaran, S.; Liebig, W. V.; Mecklenberg, M.; ...

2015-11-04

Aerographite (AG) is a mechanically robust, lightweight synthetic cellular material, which consists of a 3D interconnected network of tubular carbon [1]. The presence of open channels in AG aids to infiltrate them with polymer matrices, thereby yielding an electrical conducting and lightweight composite. Aerographite produced with densities in the range of 7–15 mg/cm 3 was infiltrated with a low viscous epoxy resin by means of vacuum infiltration technique. Detailed morphological and structural investigations on synthesized AG and AG/epoxy composite were performed by scanning electron microscopic techniques. Our present study investigates the fracture and failure of AG/epoxy composites and its energymore » absorption capacity under compression. The composites displayed an extended plateau region when uni-axially compressed, which led to an increase in energy absorption of ~133% per unit volume for 1.5 wt% of AG, when compared to pure epoxy. Preliminary results on fracture toughness showed an enhancement of ~19% in K IC for AG/epoxy composites with 0.45 wt% of AG. Furthermore, our observations of fractured surfaces under scanning electron microscope gives evidence of pull-out of arms of AG tetrapod, interface and inter-graphite failure as the dominating mechanism for the toughness improvement in these composites. These observations were consistent with the results obtained from photoelasticity experiments on a thin film AG/epoxy model composite.« less

Developments in Nano-Satellite Structural Subsystem Design at NASA-GSFC

NASA Technical Reports Server (NTRS)

Rossoni, Peter; Panetta, Peter V.

1999-01-01

The NASA-GSFC Nano-satellite Technology Development Program will enable flying constellations of tens to hundreds of nano-satellites for future NASA Space and Earth Science missions. Advanced technology components must be developed to make these future spacecraft compact, lightweight, low-power, low-cost, and survivable to a radiation environment over a two-year mission lifetime. This paper describes the efforts underway to develop lightweight, low cost, and multi-functional structures, serviceable designs, and robust mechanisms. As designs shrink, the integration of various subsystems becomes a vital necessity. This paper also addresses structurally integrated electrical power, attitude control, and thermal systems. These innovations bring associated fabrication, integration, and test challenges. Candidate structural materials and processes are examined and the merits of each are discussed. Design and fabrication processes include flat stock composite construction, cast aluminum-beryllium alloy, and an injection molded fiber-reinforced plastic. A viable constellation deployment scenario is described as well as a Phase-A Nano-satellite Pathfinder study.

Porosimetric, Thermal and Strength Tests of Aerated and Nonaerated Concretes

NASA Astrophysics Data System (ADS)

Strzałkowski, Jarosław; Garbalińska, Halina

2017-10-01

The paper presents the results of porosimetry tests of lightweight concretes, obtained with three research methods. Impact of different porosity structures on the basic thermal and strength properties was also evaluated. Tests were performed, using the pressure gauge method on fresh concrete mixes, as well as using the mercury porosimetry test and optic RapidAir method on specimens prepared from mature composites. The study was conducted on lightweight concretes, based on expanded clay aggregate and fly ash aggregate, in two variants: with non-aerated and aerated cement matrix. In addition, two reference concretes, based on normal aggregate, were prepared, also in two variants of matrix aeration. Changes in thermal conductivity λ and volumetric specific heat cv throughout the first three months of curing of the concretes were examined. Additionally, tests for compressive strength on cubic samples were performed during the first three months of curing. It was found that the pressure gauge method, performed on a fresh mix, gave lowered values of porosity, compared to the other methods. The mercury porosity tests showed high sensitivity in evaluation of pores smaller than 30μm. Unfortunately, this technique is not suitable for analysing pores greater than 300μm. On the other hand, the optical method proves good in evaluation of large pores, greater than 300μm. The paper also presents results of correlation of individual methods of porosity testing. A consolidated graph of the pore structure, derived from both mercury and optical methods, was presented, too. For the all of six tested concretes, differential graphs of porosity, prepared with both methods, show a very broad convergence. The thermal test results indicate usefulness of aeration of the cement matrix of the composites based on lightweight aggregates for the further reduction of the thermal conductivity coefficient λ of the materials. The lowest values of the λ coefficient were obtained for the aerated concretes based of fly ash aggregate. A diminishing influence of aeration on the volumetric heat capacity cv is clearly seen. Simultaneous aeration of the matrix and use of lightweight aggregates brought about also a significant decrease in the average compressive strength fcm of the tested composites.

Process combinations for the manufacturing of metal-plastic hybrid parts

NASA Astrophysics Data System (ADS)

Drossel, W.-G.; Lies, C.; Albert, A.; Haase, R.; Müller, R.; Scholz, P.

2016-03-01

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of “using the right material at the right place” is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

A method to optimize the shield compact and lightweight combining the structure with components together by genetic algorithm and MCNP code.

PubMed

Cai, Yao; Hu, Huasi; Pan, Ziheng; Hu, Guang; Zhang, Tao

2018-05-17

To optimize the shield for neutrons and gamma rays compact and lightweight, a method combining the structure and components together was established employing genetic algorithms and MCNP code. As a typical case, the fission energy spectrum of 235 U which mixed neutrons and gamma rays was adopted in this study. Six types of materials were presented and optimized by the method. Spherical geometry was adopted in the optimization after checking the geometry effect. Simulations have made to verify the reliability of the optimization method and the efficiency of the optimized materials. To compare the materials visually and conveniently, the volume and weight needed to build a shield are employed. The results showed that, the composite multilayer material has the best performance. Copyright © 2018 Elsevier Ltd. All rights reserved.

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.

EFFECTS OF TEMPERATURE AND ENVIRONMENT ON MECHANICAL PROPERTIES OF TWO CHOPPED-FIBER AUTOMOTIVE STRUCTURAL COMPOSITES

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

Ruggles-Wrenn, M.B.

2003-10-06

The Durability of Lightweight Composite Structures Project was established at Oak Ridge National Laboratory (ORNL) by the U.S. Department of Energy to provide the experimentally-based, durability-driven design guidelines necessary to assure long-term structural integrity of automotive composite components. The initial focus of the ORNL Durability Project was on composite materials consisting of polyurethane reinforced with E-glass. Current focus of the project is on composite materials reinforced with carbon fibers. The primary purpose of this report is to provide the individual specimen test date. Basic mechanical property testing and results for two chopped-fiber composite materials, one reinforced with glass- and themore » other with carbon fiber are provided. Both materials use the same polyurethane matrix. Preforms for both materials were produced using the P4 process. Behavioral trends, effects of temperature and environment, and corresponding design knockdown factors are established for both materials. Effects of prior short-time loads and of prior thermal cycling are discussed.« less

Damage prognosis of adhesively-bonded joints in laminated composite structural components of unmanned aerial vehicles

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

Farrar, Charles R; Gobbato, Maurizio; Conte, Joel

2009-01-01

The extensive use of lightweight advanced composite materials in unmanned aerial vehicles (UAVs) drastically increases the sensitivity to both fatigue- and impact-induced damage of their critical structural components (e.g., wings and tail stabilizers) during service life. The spar-to-skin adhesive joints are considered one of the most fatigue sensitive subcomponents of a lightweight UAV composite wing with damage progressively evolving from the wing root. This paper presents a comprehensive probabilistic methodology for predicting the remaining service life of adhesively-bonded joints in laminated composite structural components of UAVs. Non-destructive evaluation techniques and Bayesian inference are used to (i) assess the current statemore » of damage of the system and, (ii) update the probability distribution of the damage extent at various locations. A probabilistic model for future loads and a mechanics-based damage model are then used to stochastically propagate damage through the joint. Combined local (e.g., exceedance of a critical damage size) and global (e.g.. flutter instability) failure criteria are finally used to compute the probability of component failure at future times. The applicability and the partial validation of the proposed methodology are then briefly discussed by analyzing the debonding propagation, along a pre-defined adhesive interface, in a simply supported laminated composite beam with solid rectangular cross section, subjected to a concentrated load applied at mid-span. A specially developed Eliler-Bernoulli beam finite element with interlaminar slip along the damageable interface is used in combination with a cohesive zone model to study the fatigue-induced degradation in the adhesive material. The preliminary numerical results presented are promising for the future validation of the methodology.« less

Designing bioinspired composite reinforcement architectures via 3D magnetic printing

NASA Astrophysics Data System (ADS)

Martin, Joshua J.; Fiore, Brad E.; Erb, Randall M.

2015-10-01

Discontinuous fibre composites represent a class of materials that are strong, lightweight and have remarkable fracture toughness. These advantages partially explain the abundance and variety of discontinuous fibre composites that have evolved in the natural world. Many natural structures out-perform the conventional synthetic counterparts due, in part, to the more elaborate reinforcement architectures that occur in natural composites. Here we present an additive manufacturing approach that combines real-time colloidal assembly with existing additive manufacturing technologies to create highly programmable discontinuous fibre composites. This technology, termed as `3D magnetic printing', has enabled us to recreate complex bioinspired reinforcement architectures that deliver enhanced material performance compared with monolithic structures. Further, we demonstrate that we can now design and evolve elaborate reinforcement architectures that are not found in nature, demonstrating a high level of possible customization in discontinuous fibre composites with arbitrary geometries.

Designing bioinspired composite reinforcement architectures via 3D magnetic printing.

PubMed

Martin, Joshua J; Fiore, Brad E; Erb, Randall M

2015-10-23

Discontinuous fibre composites represent a class of materials that are strong, lightweight and have remarkable fracture toughness. These advantages partially explain the abundance and variety of discontinuous fibre composites that have evolved in the natural world. Many natural structures out-perform the conventional synthetic counterparts due, in part, to the more elaborate reinforcement architectures that occur in natural composites. Here we present an additive manufacturing approach that combines real-time colloidal assembly with existing additive manufacturing technologies to create highly programmable discontinuous fibre composites. This technology, termed as '3D magnetic printing', has enabled us to recreate complex bioinspired reinforcement architectures that deliver enhanced material performance compared with monolithic structures. Further, we demonstrate that we can now design and evolve elaborate reinforcement architectures that are not found in nature, demonstrating a high level of possible customization in discontinuous fibre composites with arbitrary geometries.

Shape-morphing composites with designed micro-architectures

NASA Astrophysics Data System (ADS)

Rodriguez, Jennifer N.; Zhu, Cheng; Duoss, Eric B.; Wilson, Thomas S.; Spadaccini, Christopher M.; Lewicki, James P.

2016-06-01

Shape memory polymers (SMPs) are attractive materials due to their unique mechanical properties, including high deformation capacity and shape recovery. SMPs are easier to process, lightweight, and inexpensive compared to their metallic counterparts, shape memory alloys. However, SMPs are limited to relatively small form factors due to their low recovery stresses. Lightweight, micro-architected composite SMPs may overcome these size limitations and offer the ability to combine functional properties (e.g., electrical conductivity) with shape memory behavior. Fabrication of 3D SMP thermoset structures via traditional manufacturing methods is challenging, especially for designs that are composed of multiple materials within porous microarchitectures designed for specific shape change strategies, e.g. sequential shape recovery. We report thermoset SMP composite inks containing some materials from renewable resources that can be 3D printed into complex, multi-material architectures that exhibit programmable shape changes with temperature and time. Through addition of fiber-based fillers, we demonstrate printing of electrically conductive SMPs where multiple shape states may induce functional changes in a device and that shape changes can be actuated via heating of printed composites. The ability of SMPs to recover their original shapes will be advantageous for a broad range of applications, including medical, aerospace, and robotic devices.

Lightweight Thermoformed Structural Components and Optics

NASA Technical Reports Server (NTRS)

Zeiders, Glenn W.; Bradford, Larry J.

2004-01-01

A technique that involves the use of thermoformed plastics has been developed to enable the design and fabrication of ultra-lightweight structural components and mirrors for use in outer space. The technique could also be used to produce items for special terrestrial uses in which minimization of weight is a primary design consideration. Although the inherent strengths of thermoplastics are clearly inferior to those of metals and composite materials, thermoplastics offer a distinct advantage in that they can be shaped, at elevated temperatures, to replicate surfaces (e.g., prescribed mirror surfaces) precisely. Furthermore, multiple elements can be bonded into structures of homogeneous design that display minimal thermal deformation aside from simple expansion. The design aspect of the present technique is based on the principle that the deflection of a plate that has internal structure depends far more on the overall thickness than on the internal details; thus, a very stiff, light structure can be made from thin plastic that is heatformed to produce a sufficiently high moment of inertia. General examples of such structures include I beams and eggcrates.

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.

Fundamental Study on the Development of Structural Lightweight Concrete by Using Normal Coarse Aggregate and Foaming Agent

PubMed Central

Lee, Han-Seung; Ismail, Mohamed A.; Woo, Young-Je; Min, Tae-Beom; Choi, Hyun-Kook

2014-01-01

Structural lightweight concrete (SLWC) has superior properties that allow the optimization of super tall structure systems for the process of design. Because of the limited supply of lightweight aggregates in Korea, the development of structural lightweight concrete without lightweight aggregates is needed. The physical and mechanical properties of specimens that were cast using normal coarse aggregates and different mixing ratios of foaming agent to evaluate the possibility of creating structural lightweight concrete were investigated. The results show that the density of SLWC decreases as the dosage of foaming agent increases up to a dosage of 0.6%, as observed by SEM. It was also observed that the foaming agent induced well separated pores, and that the size of the pores ranged from 50 to 100 μm. Based on the porosity of concrete specimens with foaming agent, compressive strength values of structural lightweight foam concrete (SLWFC) were obtained. It was also found that the estimated values from proposed equations for compressive strength and modulus of elasticity of SLWFC, and values obtained by actual measurements were in good agreement. Thus, this study confirms that new structural lightweight concrete using normal coarse aggregates and foaming agent can be developed successfully. PMID:28788691

Transient Thermal Response of Lightweight Cementitious Composites Made with Polyurethane Foam Waste

NASA Astrophysics Data System (ADS)

Kismi, M.; Poullain, P.; Mounanga, P.

2012-07-01

The development of low-cost lightweight aggregate (LWA) mortars and concretes presents many advantages, especially in terms of lightness and thermal insulation performances of structures. Low-cost LWA mainly comes from the recovery of vegetal or plastic wastes. This article focuses on the characterization of the thermal conductivity of innovative lightweight cementitious composites made with fine particles of rigid polyurethane (PU) foam waste. Five mortars were prepared with various mass substitution rates of cement with PU-foam particles. Their thermal conductivity was measured with two transient methods: the heating-film method and the hot-disk method. The incorporation of PU-foam particles causes a reduction of up to 18 % of the mortar density, accompanied by a significant improvement of the thermal insulating performance. The effect of segregation on the thermal properties of LWA mortars due to the differences of density among the cementitious matrix, sand, and LWA has also been quantified. The application of the hot-disk method reveals a gradient of thermal conductivity along the thickness of the specimens, which could be explained by a non-uniform repartition of fine PU-foam particles and mineral aggregates within the mortars. The results show a spatial variation of the thermal conductivity of the LWA mortars, ranging from 9 % to 19 %. However, this variation remains close to or even lower than that observed on a normal weight aggregate mortar. Finally, a self-consistent approach is proposed to estimate the thermal conductivity of PU-foam cement-based composites.

Additive manufacturing of biologically-inspired materials.

PubMed

Studart, André R

2016-01-21

Additive manufacturing (AM) technologies offer an attractive pathway towards the fabrication of functional materials featuring complex heterogeneous architectures inspired by biological systems. In this paper, recent research on the use of AM approaches to program the local chemical composition, structure and properties of biologically-inspired materials is reviewed. A variety of structural motifs found in biological composites have been successfully emulated in synthetic systems using inkjet-based, direct-writing, stereolithography and slip casting technologies. The replication in synthetic systems of design principles underlying such structural motifs has enabled the fabrication of lightweight cellular materials, strong and tough composites, soft robots and autonomously shaping structures with unprecedented properties and functionalities. Pushing the current limits of AM technologies in future research should bring us closer to the manufacturing capabilities of living organisms, opening the way for the digital fabrication of advanced materials with superior performance, lower environmental impact and new functionalities.

Development of technology for the fabrication of reliable laminar flow control panels on subsonic transports

NASA Technical Reports Server (NTRS)

1976-01-01

The feasibility of using porous composite materials (Kevlar, Doweave, and Leno Weave) as lightweight, efficient laminar flow control (LFC) surface materials is compared to the metallic 319L stainless Dynapore surfaces and electron beam drilled composite surfaces. Areas investigated include: (1) selection of the LFC-suitable surface materials, structural materials, and fabrication techniques for the LFC aircraft skins; (2) aerodynamic static air flow test results in terms of pressure drop through the LFC panel and the corresponding effective porosity; (3) structural design definition and analyses of the panels, and (4) contamination effects on static drop and effective porosity. Conclusions are presented and discussed.

Multi-Scale CNT-Based Reinforcing Polymer Matrix Composites for Lightweight Structures

NASA Technical Reports Server (NTRS)

Eberly, Daniel; Ou, Runqing; Karcz, Adam; Skandan, Ganesh; Mather, Patrick; Rodriguez, Erika

2013-01-01

Reinforcing critical areas in carbon polymer matrix composites (PMCs), also known as fiber reinforced composites (FRCs), is advantageous for structural durability. Since carbon nanotubes (CNTs) have extremely high tensile strength, they can be used as a functional additive to enhance the mechanical properties of FRCs. However, CNTs are not readily dispersible in the polymer matrix, which leads to lower than theoretically predicted improvement in mechanical, thermal, and electrical properties of CNT composites. The inability to align CNTs in a polymer matrix is also a known issue. The feasibility of incorporating aligned CNTs into an FRC was demonstrated using a novel, yet commercially viable nanofiber approach, termed NRMs (nanofiber-reinforcing mats). The NRM concept of reinforcement allows for a convenient and safe means of incorporating CNTs into FRC structural components specifically where they are needed during the fabrication process. NRMs, fabricated through a novel and scalable process, were incorporated into FRC test panels using layup and vacuum bagging techniques, where alternating layers of the NRM and carbon prepreg were used to form the reinforced FRC structure. Control FRC test panel coupons were also fabricated in the same manner, but comprised of only carbon prepreg. The FRC coupons were machined to size and tested for flexural, tensile, and compression properties. This effort demonstrated that FRC structures can be fabricated using the NRM concept, with an increased average load at break during flexural testing versus that of the control. The NASA applications for the developed technologies are for lightweight structures for in-space and launch vehicles. In addition, the developed technologies would find use in NASA aerospace applications such as rockets, aircraft, aircraft/spacecraft propulsion systems, and supporting facilities. The reinforcing aspect of the technology will allow for more efficient joining of fiber composite parts, thus offering additional weight savings. More robust structures capable of withstanding micrometeoroid and space debris impacts will be possible with the enhanced mechanical properties imparted by the aligned CNTs incorporated into the fiber composite structure, as well as the potential for improved electrical and thermal properties. The materials fabrication approach developed in the present effort is a platform for customer applications where additional reinforcement is required or would be beneficial, especially in FRC structures and component parts. Depending upon the specific customer application, the NRM could be tailored to the specific matrix resin and desired property enhancement.

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.

Process Integration and Optimization of ICME Carbon Fiber Composites for Vehicle Lightweighting: A Preliminary Development

DOE PAGES

Xu, Hongyi; Li, Yang; Zeng, Danielle

2017-01-02

Process integration and optimization is the key enabler of the Integrated Computational Materials Engineering (ICME) of carbon fiber composites. In this paper, automated workflows are developed for two types of composites: Sheet Molding Compounds (SMC) short fiber composites, and multi-layer unidirectional (UD) composites. For SMC, the proposed workflow integrates material processing simulation, microstructure representation volume element (RVE) models, material property prediction and structure preformation simulation to enable multiscale, multidisciplinary analysis and design. Processing parameters, microstructure parameters and vehicle subframe geometry parameters are defined as the design variables; the stiffness and weight of the structure are defined as the responses. Formore » multi-layer UD structure, this work focuses on the discussion of different design representation methods and their impacts on the optimization performance. Challenges in ICME process integration and optimization are also summarized and highlighted. Two case studies are conducted to demonstrate the integrated process and its application in optimization.« less

Flammability of self-extinguishing kenaf/ABS nanoclays composite for aircraft secondary structure

NASA Astrophysics Data System (ADS)

Karunakaran, S.; Majid, D. L.; Mohd Tawil, M. L.

2016-10-01

This study investigates the flammability properties of kenaf fiber reinforced acrylonitrile butadiene styrene (ABS) with nanoclays composites. Natural fiber is one of the potential materials to be used with thermoplastic as a composite due to its attractive properties such as lightweight and strong. In this paper, flammability properties of this material are evaluated through Underwriters Laboratory 94 Horizontal Burning (UL94 HB), which has been conducted for both controlled and uncontrolled conditions, smoke density and limiting oxygen index tests (LOI). These flammability tests are in compliance with the Federal Aviation Regulation (FAR) requirement. The results from UL94 HB and smoke density tests show that the presence of nanoclays with effective composition of kenaf fiber reinforced ABS has enhanced the burning characteristics of the material by hindering propagation of flame spread over the surface of the material through char formation. Consequently, this decreases the burning rate and produces low amount of smoke during burning. On contrary, through LOI test, this material requires less oxygen to burn when exposed to fire, which hinders the enhancement of burning characteristics. This is due to burning mechanism exhibited by nanoclays that catalyzes barrier formation and flame propagation rate over the surface of the biocomposite material. Overall, these experimental results suggest that this biocomposite material is capable of self-extinguishing and possesses effective fire extinction. The observed novel synergism from the result obtained is promising to be implemented in secondary structures of aircraft with significant benefits such as cost-effective, lightweight and biodegradable self-extinguishing biocomposite.

Analysis of stress-strain, fracture and ductility behavior of aluminum matrix composites containing discontinuous silicon carbide reinforcement

NASA Technical Reports Server (NTRS)

Mcdanels, D. L.

1984-01-01

Mechanical properties and stress-strain behavior for several types of commercially fabricated aluminum matrix composites, containing up to 40 vol % discontinuous SiC whisker, nodule, or particulate reinforcement were evaluated. It was found that the elastic modulus of the composites was isotropic, to be independent of type of reinforcement, and to be controlled solely by the volume percentage of SiC reinforcement present. The yield/tensile strengths and ductility were controlled primarily by the matrix alloy and temper condition. Ductility decreased with increasing reinforcement content, however, the fracture strains observed were higher than those reported in the literature for this type of composite. This increase in fracture strain is attributed to cleaner matrix powder and increased mechanical working during fabrication. Conventional aluminum and titanium structural alloys were compared and have shown that the properties of these low cost, lightweight composites have good potential for application to aerospace structures.

Composite Payload Fairing Structural Architecture Assessment and Selection

NASA Technical Reports Server (NTRS)

Krivanek, Thomas M.; Yount, Bryan C.

2012-01-01

This paper provides a summary of the structural architecture assessments conducted and a recommendation for an affordable high performance composite structural concept to use on the next generation heavy-lift launch vehicle, the Space Launch System (SLS). The Structural Concepts Element of the Advanced Composites Technology (ACT) project and its follow on the Lightweight Spacecraft Structures and Materials (LSSM) project was tasked with evaluating a number of composite construction technologies for specific Ares V components: the Payload Shroud, the Interstage, and the Core Stage Intertank. Team studies strived to address the structural challenges, risks and needs for each of these vehicle components. Leveraging off of this work, the subsequent Composites for Exploration (CoEx) effort is focused on providing a composite structural concept to support the Payload Fairing for SLS. This paper documents the evaluation and down selection of composite construction technologies and evolution to the SLS Payload Fairing. Development of the evaluation criteria (also referred to as Figures of Merit or FOMs), their relative importance, and association to vehicle requirements are presented. A summary of the evaluation results, and a recommendation of the composite concept to baseline in the Composites for Exploration (CoEx) project is presented. The recommendation for the SLS Fairing is a Honeycomb Sandwich architecture based primarily on affordability and performance with two promising alternatives, Hat stiffened and Fiber Reinforced Foam (FRF) identified for eventual program block upgrade.

Lightweight carbon nanotube-based structural-energy storage devices for micro unmanned systems

NASA Astrophysics Data System (ADS)

Rivera, Monica; Cole, Daniel P.; Hahm, Myung Gwan; Reddy, Arava L. M.; Vajtai, Robert; Ajayan, Pulickel M.; Karna, Shashi P.; Bundy, Mark L.

2012-06-01

There is a strong need for small, lightweight energy storage devices that can satisfy the ever increasing power and energy demands of micro unmanned systems. Currently, most commercial and developmental micro unmanned systems utilize commercial-off-the-shelf (COTS) lithium polymer batteries for their energy storage needs. While COTS lithium polymer batteries are the industry norm, the weight of these batteries can account for up to 60% of the overall system mass and the capacity of these batteries can limit mission durations to the order of only a few minutes. One method to increase vehicle endurance without adding mass or sacrificing payload capabilities is to incorporate multiple system functions into a single material or structure. For example, the body or chassis of a micro vehicle could be replaced with a multifunctional material that would serve as both the vehicle structure and the on-board energy storage device. In this paper we present recent progress towards the development of carbon nanotube (CNT)-based structural-energy storage devices for micro unmanned systems. Randomly oriented and vertically aligned CNT-polymer composite electrodes with varying degrees of flexibility are used as the primary building blocks for lightweight structural-supercapacitors. For the purpose of this study, the mechanical properties of the CNT-based electrodes and the charge-discharge behavior of the supercapacitor devices are examined. Because incorporating multifunctionality into a single component often degrades the properties or performance of individual structures, the performance and property tradeoffs of the CNT-based structural-energy storage devices will also be discussed.

Southern Regional Center for Lightweight Innovative Design

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

Wang, Paul T.

The Southern Regional Center for Lightweight Innovative Design (SRCLID) has developed an experimentally validated cradle-to-grave modeling and simulation effort to optimize automotive components in order to decrease weight and cost, yet increase performance and safety in crash scenarios. In summary, the three major objectives of this project are accomplished: To develop experimentally validated cradle-to-grave modeling and simulation tools to optimize automotive and truck components for lightweighting materials (aluminum, steel, and Mg alloys and polymer-based composites) with consideration of uncertainty to decrease weight and cost, yet increase the performance and safety in impact scenarios; To develop multiscale computational models that quantifymore » microstructure-property relations by evaluating various length scales, from the atomic through component levels, for each step of the manufacturing process for vehicles; and To develop an integrated K-12 educational program to educate students on lightweighting designs and impact scenarios. In this final report, we divided the content into two parts: the first part contains the development of building blocks for the project, including materials and process models, process-structure-property (PSP) relationship, and experimental validation capabilities; the second part presents the demonstration task for Mg front-end work associated with USAMP projects.« less

Stiff, light, strong and ductile: nano-structured High Modulus Steel.

PubMed

Springer, H; Baron, C; Szczepaniak, A; Uhlenwinkel, V; Raabe, D

2017-06-05

Structural material development for lightweight applications aims at improving the key parameters strength, stiffness and ductility at low density, but these properties are typically mutually exclusive. Here we present how we overcome this trade-off with a new class of nano-structured steel - TiB 2 composites synthesised in-situ via bulk metallurgical spray-forming. Owing to the nano-sized dispersion of the TiB 2 particles of extreme stiffness and low density - obtained by the in-situ formation with rapid solidification kinetics - the new material has the mechanical performance of advanced high strength steels, and a 25% higher stiffness/density ratio than any of the currently used high strength steels, aluminium, magnesium and titanium alloys. This renders this High Modulus Steel the first density-reduced, high stiffness, high strength and yet ductile material which can be produced on an industrial scale. Also ideally suited for 3D printing technology, this material addresses all key requirements for high performance and cost effective lightweight design.

On a high-potential variable flexural stiffness device

NASA Astrophysics Data System (ADS)

Henke, Markus; Gerlach, Gerald

2013-05-01

There are great efforts in developing effective composite structures for lightweight constructions for nearly every field of engineering. This concerns for example aeronautics and spacecrafts, but also automotive industry and energy harvesting applications. Modern concepts of lightweight components try to make use of structures with properties which can be adjusted in a controllable was. However, classic composite materials can only slightly adapt to varying environmental conditions because most materials, like carbon or glass-fiber composites show properties which are time-constant and not changeable. This contribution describes the development, the potential and the limitations of novel smart, self-controlling structures which can change their mechanical properties - e.g. their flexural stiffness - by more then one order of magnitude. These structures use a multi-layer approach with a 10-layer stack of 0.75 mm thick polycarbonate. The set-up is analytically described and its mechanical behavior is predicted by finite element analysis done with ABAQUS. The layers are braided together by an array of shape memory alloy (SMA) wires, which can be activated independently. Depending on the temperature applied by the electrical current flowing through the wires and the corresponding contraction the wires can tightly clamp the layers so that they cannot slide against each other due to friction forces. In this case the multilayer acts as rigid beam with high stiffness. If the friction-induced shear stress is smaller than a certain threshold, then the layers can slide over each other and the multilayer becomes compliant under bending load. The friction forces between the layers and, hence, the stiffness of the beam is controlled by the electrical current through the wires. The more separate parts of SMA wires the structure has the larger is the number of steps of stiffness changes of the flexural beam.

Thermal Applications for Advanced Metallic Materials (Preprint)

DTIC Science & Technology

2007-01-01

Mondolfo, L.E., Aluminum Alloys-Structure and Properties . 1976: Butterworths. 21. Tritt, T.M. and M.A. Subramanian, Thermoelectric Materials...for Potential Thermoelectric Applications. MRS Bulletin, 2006. 31(March): p. 206-210. 32. Rao, A.M., X. Ji, and T.M. Tritt, Properties of...conductivity metallic composites; lightweight metallic phase-change materials for managing thermal transients; high-efficiency thermoelectric materials for

Thermal stability of lightweight graphite glass sandwich reflectors for far infrared astronomy

NASA Technical Reports Server (NTRS)

Bluege, J. H.; Mayor, R. A.; Hoffman, W. F.

1986-01-01

Graphite fiber-reinforced glass matrix composites are being developed for a variety of structural applications requiring excellent thermomechanical stability. These materials are ideally suited for lightweight, high strength, thermally stable infrared mirrors because of their low density, low thermal expansion, high strength and stiffness, and their ability to be machined, replicated and figured using standard polishing techniques. These properties are particularly promising for applications such as a 3-meter balloon-borne far-infrared and submillimeter telescope mirror which must be both very lightweight and able to retain its figure accuracy when cycled between room temperature and its operating temperature of -50 C. This paper presents the results of a set of low temperature optical tests conducted to determine the figure stability of a 30-cm diameter, frit-bonded graphite/glass mirror in the +20 to -60 C temperature range using a 10.6 micron laser interferometer. The results indicate that the residual change in figure was less than 0.3 microns, rms.

Graphene in the Sky and Beyond

NASA Technical Reports Server (NTRS)

Siochi, Emilie J.

2014-01-01

With the premium placed on strong, lightweight structures, carbon materials have a long history of use in aerospace applications. Graphitized carbon and carbon/carbon composites are used in thermal protection systems and heat shields, carbon fiber composites in aircraft, and more recently, carbon nanotubes have been used on spacecraft. As the newest member of this family of materials, graphene also has a number of interesting properties that intersect with unique aerospace requirements. Despite its many attractive properties, graphene-based structures and systems, like any other material used in aerospace, must clear a number of hurdles before it will be accepted for use in flight structures. Carbon fiber, for example, underwent a development period of several decades between initial discovery and large-scale application in commercial aircraft.

Fabrication of High Strength Lightweight Metals for Armor and Structural Applications: Large Scale Equal Channel Angular Extrusion Processing of Aluminum 5083 Alloy

DTIC Science & Technology

2017-06-01

ARL-TR-8047 ● JUNE 2017 US Army Research Laboratory Fabrication of High -Strength Lightweight Metals for Armor and Structural...to the originator. ARL-TR-8047 ● JUNE 2017 US Army Research Laboratory Fabrication of High -Strength Lightweight Metals for...Fabrication of High -Strength Lightweight Metals for Armor and Structural Applications: Large-Scale Equal Channel Angular Extrusion Processing of

Fiber-optically sensorized composite wing

NASA Astrophysics Data System (ADS)

Costa, Joannes M.; Black, Richard J.; Moslehi, Behzad; Oblea, Levy; Patel, Rona; Sotoudeh, Vahid; Abouzeida, Essam; Quinones, Vladimir; Gowayed, Yasser; Soobramaney, Paul; Flowers, George

2014-04-01

Electromagnetic interference (EMI) immune and light-weight, fiber-optic sensor based Structural Health Monitoring (SHM) will find increasing application in aerospace structures ranging from aircraft wings to jet engine vanes. Intelligent Fiber Optic Systems Corporation (IFOS) has been developing multi-functional fiber Bragg grating (FBG) sensor systems including parallel processing FBG interrogators combined with advanced signal processing for SHM, structural state sensing and load monitoring applications. This paper reports work with Auburn University on embedding and testing FBG sensor arrays in a quarter scale model of a T38 composite wing. The wing was designed and manufactured using fabric reinforced polymer matrix composites. FBG sensors were embedded under the top layer of the composite. Their positions were chosen based on strain maps determined by finite element analysis. Static and dynamic testing confirmed expected response from the FBGs. The demonstrated technology has the potential to be further developed into an autonomous onboard system to perform load monitoring, SHM and Non-Destructive Evaluation (NDE) of composite aerospace structures (wings and rotorcraft blades). This platform technology could also be applied to flight testing of morphing and aero-elastic control surfaces.

Durability of polymer matrix composites for automotive structural applications: A state-of-the-art review

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

Corum, J.M.; Simpson, W.A. Jr.; Sun, C.T.

1995-07-01

A key unanswered question that must be addressed before polymeric composites will be widely used in automotive structural components is their known durability. Major durability issues are the effects that cyclic loadings, creep, automotive fluid environments, and low-energy impacts have on dimensional stability, strength, and stiffness throughout the required life of a composite component. This report reviews the current state of understanding in each of these areas. It also discusses the limited information that exists on one of the prime candidate materials for automotive structural applications--an isocyanurate reinforced with a continuous strand, swirl mat. Because of the key role thatmore » nondestructive evaluations must play in understanding damage development and progression, a chapter is included on ultrasonic techniques. A final chapter then gives conclusions and recommendations for research needed to resolve the various durability issues. These recommendations will help provide a sound basis for program planning for the Durability of Lightweight Composite Structures Project sponsored by the US Department of Energy in cooperation with the Automotive Composites Consortium of Chrysler, Ford, and General Motors.« less

Solidification of Magnesium (AM50A) / vol%. SiCp composite

NASA Astrophysics Data System (ADS)

Zhang, X.; Hu, H.

2012-01-01

Magnesium matrix composite is one of the advanced lightweight materials with high potential to be used in automotive and aircraft industries due to its low density and high specific mechanical properties. The magnesium composites can be fabricated by adding the reinforcements of fibers or/and particles. In the previous literature, extensive studies have been performed on the development of matrix grain structure of aluminum-based metal matrix composites. However, there is limited information available on the development of grain structure during the solidification of particulate-reinforced magnesium. In this work, a 5 vol.% SiCp particulate-reinforced magnesium (AM50A) matrix composite (AM50A/SiCp) was prepared by stir casting. The solidification behavior of the cast AM50A/SiCp composite was investigated by computer-based thermal analysis. Optical and scanning electron microscopies (SEM) were employed to examine the occurrence of nucleation and grain refinement involved. The results indicate that the addition of SiCp particulates leads to a finer grain structure in the composite compared with the matrix alloy. The refinement of grain structure should be attributed to both the heterogeneous nucleation and the restricted primary crystal growth.

Combustion synthesis of low exothermic component rich composites

DOEpatents

Halverson, Danny C.; Lum, Beverly Y.; Munir, Zuhair A.

1991-01-01

A self-sustaining combustion synthesis process for producing hard, tough, lightweight, low exothermic potential product (LEPP)/high exothermic potential product (HEPP) composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the LEPP and HEPP reactants. For lightweight products the composition must be relatively rich in the LEPP component. LEPP rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

Next Generation Space Telescope Ultra-Lightweight Mirror Program

NASA Technical Reports Server (NTRS)

Bilbro, James W.

1998-01-01

The Next Generation Space Telescope is currently envisioned as a eight meter diameter cryogenic deployable telescope that will operate at the earth sun libration point L2. A number of different designs are being examined within NASA and under industry studies by Ball Aerospace, Lockheed-Martin and TRW. Although these designs differ in many respects, they all require significant advancements in the state-of-the-art with respect to large diameter, ultra-lightweight, mirrors. The purpose of this paper is to provide insight into the current status of the mirror development program NGST is a tremendously ambitious undertaking that sets the mark for new NASA missions. In order to achieve the weight, cost and performance requirements of NGST, the primary mirror must be made lighter, cheaper and better than anything that has ever been done. In order to accomplish this an aggressive technology program has been put in place. The scope of the program was determined by examining historically what has been accomplished; assessing recent technological advances in fabrication and testing; and evaluating the effect of these advances relative to enabling the manufacture of lightweight mirrors that meet NGST requirements. As it is currently envisioned, the primary mirror for NGST is on the order of eight meters in diameter, it is to be diffraction limited at a wave length of 2 microns and has an overall weight requirement of 15 kilograms per square meter. Two large scale demonstration projects are under way along with a number of smaller scale demonstrations on a variety of mirror materials and concepts. The University of Arizona (UA) mirror concept is based around a 2mm thick Borosilicate glass face sheet mounted to a composite backplane structure via actuators for mirror figure correction. The Composite Optics Inc.(COI) concept consists of a 3.2mm thick Zerodur face sheet bonded to a composite support structure which in turn is mounted to a composite backplane structure via actuators for mirror phasing. These mirrors are due to be performance tested in ambient conditions in the fall of '98, and cryogenically tested in the spring of '99. The smaller scale efforts include the following: Beryllium is being investigated at Ball Aerospace, Electroform nickel is being investigated in-house at MSFC, Chemical Vapor Deposition (CVD) Silicon Carbide (SiC) is being investigated at Morton International Silicon mirrors are being investigated at Schafer, Carbon Fiber Reinforced Silicon Carbide (CSIC) is being investigated at IABG. SiC at SSG, Composite mirrors at COI, pyrolyzed graphite mirrors at Ultramet, reaction bonded SiC mirrors at Xinetics, along with techniques for lightweighting using waterjets at Waterjet Technology Inc. are all being investigated under the Small Business innovative Research Program SBIR program. A procurement for a third large scale demonstration (nominally 1.5m in diameter) is being planned for release this fall.

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Noebe, Ronald D.; Revilock, Duane M.

2003-01-01

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

KSC-08pd2088

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center mate the Hubble vertical platform to the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2098

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2097

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2089

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center secure the Hubble vertical platform to the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2096

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center installs a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2094

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center install the pallet support struts on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2087

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center move the Hubble vertical platform toward the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, to which it will be mated. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2085

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, elevated at left, is ready to be mated to the Hubble vertical platform, at right. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2086

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. – In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, workers from NASA's Goddard Space Flight Center move the Hubble vertical platform toward the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope, to which it will be mated. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

KSC-08pd2095

NASA Image and Video Library

2008-07-21

CAPE CANAVERAL, Fla. -- In the high bay of the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a worker from NASA's Goddard Space Flight Center documents the installation of a pallet support strut on the Super Lightweight Interchangeable Carrier for the Hubble Space Telescope. The Super Lightweight Interchangeable Carrier, or SLIC, is one of four carriers supporting hardware for space shuttle Atlantis' STS-125 mission to service the telescope. SLIC is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The Orbital Replacement Unit Carrier, or ORUC, and the Flight Support System, or FSS, have also arrived at Kennedy. The Multi-Use Lightweight Equipment carrier will be delivered in early August. The carriers will be prepared for the integration of telescope science instruments, both internal and external replacement components, as well as the flight support equipment to be used by the astronauts during the Hubble servicing mission, targeted for launch Oct. 8. Photo credit: NASA/Jack Pfaller

Grips for Lightweight Tensile Specimens

NASA Technical Reports Server (NTRS)

Witte, William G., Jr.; Gibson, Walter D.

1987-01-01

Set of grips developed for tensile testing of lightweight composite materials. Double-wedge design substantially increases gripping force and reduces slippage. Specimen held by grips made of hardened wedges. Assembly screwed into load cell in tensile-testing machine.

Composite piston

NASA Technical Reports Server (NTRS)

Taylor, Allan H. (Inventor)

1988-01-01

A composite piston structure is disclosed which provides a simple and reliable means for joining a carbon-carbon or ceramic piston cap with a metallic piston body. Attachment is achieved by means of a special geometry which compensates for differences in thermal expansion without complicated mechanical fastening devices. The shape employs a flange created by opposed frustoconical shapes with coincident vertices intersecting on the radial centerline of the piston in order to retain the piston cap. The use of carbon-carbon for the piston cap material allows a close fit between the piston and a cylinder wall, eliminating the need for piston rings. The elimination of extra mechanical parts of previous composite pistons provides a lightweight composite piston capable of extended high temperature operation.

Research requirements to reduce empty weight of helicopters by use of advanced materials

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

Hoffstedt, D.J.

1976-12-01

Utilization of the new, lightweight, high-strength, aerospace structural-composite (filament/matrix) materials, when specifically designed into a new aircraft, promises reductions in structural empty weight of 12% at recurring costs competetive with metals. A program of basic and applied research and demonstration is identified with the objective of advancing the state of the art to the point where civil helicopters are confidently designed, produced, certified, and marketed by 1985. A structural empty-weight reduction of 12% was shown to significantly reduce energy consumption in modern high-performance helicopters.

Lightweight Material Patches Allow for Quick Repairs

NASA Technical Reports Server (NTRS)

2010-01-01

Cornerstone Research Group Inc., of Dayton, Ohio, has been the recipient of 16 Small Business Innovation Research (SBIR) contracts with NASA with a variety of different focuses, including projects like creating inflatable structures for radio frequency antennas and, most recently, healable polymer matrix composites for future space vehicles. One of its earlier SBIR contracts, with Kennedy Space Center, led to the development of a new type of structural patch for a variety of consumer uses: Rubbn Repair, for automotive uses; and Rec Repair for the outdoors and adventure market. Both are flexible, heat-activated structural patches.

Boron-carbide-aluminum and boron-carbide-reactive metal cermets

DOEpatents

Halverson, Danny C.; Pyzik, Aleksander J.; Aksay, Ilhan A.

1986-01-01

Hard, tough, lightweight boron-carbide-reactive metal composites, particularly boron-carbide-aluminum composites, are produced. These composites have compositions with a plurality of phases. A method is provided, including the steps of wetting and reacting the starting materials, by which the microstructures in the resulting composites can be controllably selected. Starting compositions, reaction temperatures, reaction times, and reaction atmospheres are parameters for controlling the process and resulting compositions. The ceramic phases are homogeneously distributed in the metal phases and adhesive forces at ceramic-metal interfaces are maximized. An initial consolidation step is used to achieve fully dense composites. Microstructures of boron-carbide-aluminum cermets have been produced with modulus of rupture exceeding 110 ksi and fracture toughness exceeding 12 ksi.sqroot.in. These composites and methods can be used to form a variety of structural elements.

An Investigation on the Use of a Laser Ablation Treatment on Metallic Surfaces and the Influence of Temperature on Fracture Toughness of Hybrid Co-Cured Metal-PMC Interfaces

NASA Technical Reports Server (NTRS)

Connell, John; Palmieri, Frank; Truong, Hieu; Ochoa, Ozden; Lagoudas, Dimitris

2015-01-01

Hybrid composite laminates that contain alternating layers of titanium alloys and carbon fabric reinforced polyimide matrix composites (PMC) are excellent candidates for light-weight, high-temperature structural materials for high-speed aerospace vehicles. The delamination resistance of the hybrid titanium-PMC interface is of crucial consideration for structural integrity during service. Here, we report the first investigations on the use of laser ablation in combination with sol-gel treatment technique on Ti/NiTi foil surfaces in co-cured hybrid polyimide matrix composite laminates. Mode-I and mode-II fracture toughness of the hybrid Ti/NiTi-PMC interface as a function of temperature were determined via experimental testing and finite element analysis.

Superalloy Lattice Block Structures

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.; Nathal, M. V.; Hebsur, M. G.; Kraus, D. L.

2003-01-01

In their simplest form, lattice block panels are produced by direct casting and result in lightweight, fully triangulated truss-like configurations which provide strength and stiffness [2]. The earliest realizations of lattice block were made from A1 and steels, primarily under funding from the US Navy [3]. This work also showed that the mechanical efficiency (eg., specific stiffness) of lattice block structures approached that of honeycomb structures [2]. The lattice architectures are also less anisotropic, and the investment casting route should provide a large advantage in cost and temperature capability over honeycombs which are limited to alloys that can be processed into foils. Based on this early work, a program was initiated to determine the feasibility of extending the high temperature superalloy lattice block [3]. The objective of this effort was to provide an alternative to intermetallics and composites in achieving a lightweight high temperature structure without sacrificing the damage tolerance and moderate cost inherent in superalloys. To establish the feasibility of the superalloy lattice block concept, work was performed in conjunction with JAMCORP, Inc. Billerica, MA, to produce a number of lattice block panels from both IN71 8 and Mar-M247.

Ceramic-ceramic shell tile thermal protection system and method thereof

NASA Technical Reports Server (NTRS)

Riccitiello, Salvatore R. (Inventor); Smith, Marnell (Inventor); Goldstein, Howard E. (Inventor); Zimmerman, Norman B. (Inventor)

1986-01-01

A ceramic reusable, externally applied composite thermal protection system (TPS) is proposed. The system functions by utilizing a ceramic/ceramic upper shell structure which effectively separates its primary functions as a thermal insulator and as a load carrier to transmit loads to the cold structure. The composite tile system also prevents impact damage to the atmospheric entry vehicle thermal protection system. The composite tile comprises a structurally strong upper ceramic/ceramic shell manufactured from ceramic fibers and ceramic matrix meeting the thermal and structural requirements of a tile used on a re-entry aerospace vehicle. In addition, a lightweight high temperature ceramic lower temperature base tile is used. The upper shell and lower tile are attached by means effective to withstand the extreme temperatures (3000 to 3200F) and stress conditions. The composite tile may include one or more layers of variable density rigid or flexible thermal insulation. The assembly of the overall tile is facilitated by two or more locking mechanisms on opposing sides of the overall tile assembly. The assembly may occur subsequent to the installation of the lower shell tile on the spacecraft structural skin.

Flexible and weaveable capacitor wire based on a carbon nanocomposite fiber.

PubMed

Ren, Jing; Bai, Wenyu; Guan, Guozhen; Zhang, Ye; Peng, Huisheng

2013-11-06

A flexible and weaveable electric double-layer capacitor wire is developed by twisting two aligned carbon nanotube/ordered mesoporous carbon composite fibers with remarkable mechanical and electronic properties as electrodes. This capacitor wire exhibits high specific capacitance and long life stability. Compared with the conventional planar structure, the capacitor wire is also lightweight and can be integrated into various textile structures that are particularly promising for portable and wearable electronic devices. © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Microstructure and orientation effects on properties of discontinuous silicon carbide/aluminum composites

NASA Technical Reports Server (NTRS)

Mcdanels, D. L.; Hoffman, C. A.

1984-01-01

Composite panels containing up to 40 vol % discontinuous silicon carbide SiC whisker, nodule, or particulate reinforcement in several aluminum matrices are commercially fabricated and the mechanical properties and microstructual characteristics are evaluated. The yield and tensile strengths and the ductility are controlled primarily by the matrix alloy, the temper condition, and the reinforcement content. Particulate and nodule reinforcements are as effective as whisker reinforcement. Increased ductility is attributed to purer, more uniform starting materials and to more mechanical working during fabrication. Comparing mechanical properties with those of other aluminum alloys shows that these low cost, lightweight composites demonstrate very good potential for application to aerospace structures.

Development of Lightweight Material Composites to Insulate Cryogenic Tanks for 30-Day Storage in Outer Space

NASA Technical Reports Server (NTRS)

Krause, D. R.

1972-01-01

A conceptual design was developed for an MLI system which will meet the design constraints of an ILRV used for 7- to 30-day missions. The ten tasks are briefly described: (1) material survey and procurement, material property tests, and selection of composites to be considered; (2) definition of environmental parameters and tooling requirements, and thermal and structural design verification test definition; (3) definition of tanks and associated hardware to be used, and definition of MLI concepts to be considered; (4) thermal analyses, including purge, evacuation, and reentry repressurization analyses; (5) structural analyses (6) thermal degradation tests of composite and structural tests of fastener; (7) selection of MLI materials and system; (8) definition of a conceptual MLI system design; (9) evaluation of nondestructive inspection techniques and definition of procedures for repair of damaged areas; and (10) preparation of preliminary specifications.

Shape-morphing composites with designed micro-architectures

DOE PAGES

Rodriguez, Jennifer N.; Zhu, Cheng; Duoss, Eric B.; ...

2016-06-15

Shape memory polymers (SMPs) are attractive materials due to their unique mechanical properties, including high deformation capacity and shape recovery. SMPs are easier to process, lightweight, and inexpensive compared to their metallic counterparts, shape memory alloys. However, SMPs are limited to relatively small form factors due to their low recovery stresses. Lightweight, micro-architected composite SMPs may overcome these size limitations and offer the ability to combine functional properties (e.g., electrical conductivity) with shape memory behavior. Fabrication of 3D SMP thermoset structures via traditional manufacturing methods is challenging, especially for designs that are composed of multiple materials within porous microarchitectures designedmore » for specific shape change strategies, e.g. sequential shape recovery. We report thermoset SMP composite inks containing some materials from renewable resources that can be 3D printed into complex, multi-material architectures that exhibit programmable shape changes with temperature and time. Through addition of fiber-based fillers, we demonstrate printing of electrically conductive SMPs where multiple shape states may induce functional changes in a device and that shape changes can be actuated via heating of printed composites. As a result, the ability of SMPs to recover their original shapes will be advantageous for a broad range of applications, including medical, aerospace, and robotic devices.« less

Compact, Lightweight, Ceramic Matrix Composite (CMC) Based Acoustic Liners for Reducing Subsonic Jet Aircraft Engine Noise

NASA Technical Reports Server (NTRS)

Kiser, J. Douglas; Grady, Joseph E.; Miller, Christopher J.; Hultgren, Lennart S.; Jones, Michael G.

2016-01-01

Recent developments have reduced fan and jet noise contributions to overall subsonic aircraft jet-engine noise. Now, aircraft designers are turning their attention toward reducing engine core noise. The NASA Glenn Research Center and NASA Langley Research Center have teamed to investigate the development of a compact, lightweight acoustic liner based on oxide/oxide ceramic matrix composite (CMC) materials. The NASA team has built upon an existing oxide/oxide CMC sandwich structure concept that provides monotonal noise reduction. Oxide/oxide composites have good high temperature strength and oxidation resistance, which could allow them to perform as core liners at temperatures up to 1000C (1832F), and even higher depending on the selection of the composite constituents. NASA has initiated the evaluation of CMC-based liners that use cells of different lengths (variable-depth channels) or effective lengths to achieve broadband noise reduction. Reducing the overall liner thickness is also a major goal, to minimize the volume occupied by the liner. As a first step toward demonstrating the feasibility of our concepts, an oxide/oxide CMC acoustic testing article with different channel lengths was tested. Our approach, summary of test results, current status, and goals for the future are reported.

Polymer/Carbon Nanotube Networks for Smart, Self-Repairing and Light-Weighted Nanocomposites

DTIC Science & Technology

2012-11-05

was develop smart, strong, and light-weight polymer/carbon nanotube (CNT) composites which will sense tribologically induced damages and self-heal by...light-weight polymer/carbon nanotube (CNT) composites which will sense tribologically induced damages and self-heal by inhibiting such degradation...one of support references for EPSRC instrument grant application for Micro Materials NanoTest Vantage Testing Suite with NTX4Controller. The grant

Experimental Study on Composite Light-weight Microporous Concrete Cladding Panels

NASA Astrophysics Data System (ADS)

Lida, Tian; Dongyan, Wang; Kang, Liu

2018-03-01

A new type of composite light-weight microporous concrete cladding panel was developed, with the compound function of retaining and heat preservation. Two specimens of the new cladding panel and connection detailing were made for out-of-plane bending experiment. The results indicate that the new cladding panel and its connection detailing are of sufficient stiffness, bearing capacity and deformability under wind load and out-of-plane seismic action.

Upgrading the Center for Lightweighting Automotive Materials and Processing - a GATE Center of Excellence at the University of Michigan-Dearborn

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

Mallick, P. K.

2012-08-30

The Center for Lightweighting Materials and Processing (CLAMP) was established in September 1998 with a grant from the Department of Energy’s Graduate Automotive Technology Education (GATE) program. The center received the second round of GATE grant in 2005 under the title “Upgrading the Center for Lightweighting Automotive Materials and Processing”. Using the two grants, the Center has successfully created 10 graduate level courses on lightweight automotive materials, integrated them into master’s and PhD programs in Automotive Systems Engineering, and offered them regularly to the graduate students in the program. In addition, the Center has created a web-based lightweight automotive materialsmore » database, conducted research on lightweight automotive materials and organized seminars/symposia on lightweight automotive materials for both academia and industry. The faculty involved with the Center has conducted research on a variety of topics related to design, testing, characterization and processing of lightweight materials for automotive applications and have received numerous research grants from automotive companies and government agencies to support their research. The materials considered included advanced steels, light alloys (aluminum, magnesium and titanium) and fiber reinforced polymer composites. In some of these research projects, CLAMP faculty have collaborated with industry partners and students have used the research facilities at industry locations. The specific objectives of the project during the current funding period (2005 – 2012) were as follows: (1) develop new graduate courses and incorporate them in the automotive systems engineering curriculum (2) improve and update two existing courses on automotive materials and processing (3) upgrade the laboratory facilities used by graduate students to conduct research (4) expand the Lightweight Automotive Materials Database to include additional materials, design case studies and make it more accessible to outside users (5) provide support to graduate students for conducting research on lightweight automotive materials and structures (6) provide industry/university interaction through a graduate certificate program on automotive materials and technology idea exchange through focused seminars and symposia on automotive materials.« less

Graphite Composite Panel Polishing Fixture

NASA Technical Reports Server (NTRS)

Hagopian, John; Strojny, Carl; Budinoff, Jason

2011-01-01

The use of high-strength, lightweight composites for the fixture is the novel feature of this innovation. The main advantage is the light weight and high stiffness-to-mass ratio relative to aluminum. Meter-class optics require support during the grinding/polishing process with large tools. The use of aluminum as a polishing fixture is standard, with pitch providing a compliant layer to allow support without deformation. Unfortunately, with meter-scale optics, a meter-scale fixture weighs over 120 lb (.55 kg) and may distort the optics being fabricated by loading the mirror and/or tool used in fabrication. The use of composite structures that are lightweight yet stiff allows standard techniques to be used while providing for a decrease in fixture weight by almost 70 percent. Mounts classically used to support large mirrors during fabrication are especially heavy and difficult to handle. The mount must be especially stiff to avoid deformation during the optical fabrication process, where a very large and heavy lap often can distort the mount and optic being fabricated. If the optic is placed on top of the lapping tool, the weight of the optic and the fixture can distort the lap. Fixtures to support the mirror during fabrication are often very large plates of aluminum, often 2 in. (.5 cm) or more in thickness and weight upwards of 150 lb (68 kg). With the addition of a backing material such as pitch and the mirror itself, the assembly can often weigh over 250 lb (.113 kg) for a meter-class optic. This innovation is the use of a lightweight graphite panel with an aluminum honeycomb core for use as the polishing fixture. These materials have been used in the aerospace industry as structural members due to their light weight and high stiffness. The grinding polishing fixture consists of the graphite composite panel, fittings, and fixtures to allow interface to the polishing machine, and introduction of pitch buttons to support the optic under fabrication. In its operation, the grinding polishing fixture acts as a reaction structure to the polishing tool. It must be stiff enough to avoid imparting a distorted shape to the optic under fabrication and light enough to avoid self-deflection. The fixture must also withstand significant tangential loads from the polishing machine during operations.

Mechanical analysis of CFRP-steel hybrid composites considering the interfacial adhesion

NASA Astrophysics Data System (ADS)

Jang, Jinhyeok; Sung, Minchang; Han, Sungjin; Shim, Wonbo; Yu, Woong-Ryeol

2017-10-01

Recently, hybrid composites of carbon fiber reinforced plastics (CFRP) and steel have attracted great attention from automotive engineers due to their high potential for lightweight and multi-materials structures. Interestingly, such hybrid composites have demonstrated increased breaking strain, i.e., the breaking strain of CFRP in the hybrid was larger than that of single CFRP. As such the mechanical properties of hybrid composites could not be calculated using the rule of mixture. In addition, such increase is strongly dependent on the adhesion between CFRP and steel. In this study, a numerical analysis model was built to investigate the mechanism behind increased breaking strain of CFRP in the hybrid structure. Using cohesive zone model, the adhesion between CFRP and steel was effectively considered. The numerical results showed that the simulated mechanical behavior of the hybrid composites did not change as much as observed in experimental as the interfacial adhesion varied. We will investigate this discrepancy in detail and will report new analysis method suitable for CFRP and steel hybrid composites.

Experimental Observations for Determining the Maximum Torque Values to Apply to Composite Components Mechanically Joined With Fasteners (MSFC Center Director's Discretionary Fund Final Report, Proj. 03-13}

NASA Technical Reports Server (NTRS)

Thomas, F. P.

2006-01-01

Aerospace structures utilize innovative, lightweight composite materials for exploration activities. These structural components, due to various reasons including size limitations, manufacturing facilities, contractual obligations, or particular design requirements, will have to be joined. The common methodologies for joining composite components are the adhesively bonded and mechanically fastened joints and, in certain instances, both methods are simultaneously incorporated into the design. Guidelines and recommendations exist for engineers to develop design criteria and analyze and test composites. However, there are no guidelines or recommendations based on analysis or test data to specify a torque or torque range to apply to metallic mechanical fasteners used to join composite components. Utilizing the torque tension machine at NASA s Marshall Space Flight Center, an initial series of tests were conducted to determine the maximum torque that could be applied to a composite specimen. Acoustic emissions were used to nondestructively assess the specimens during the tests and thermographic imaging after the tests.

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.

Combustion synthesis of boride and other composites

DOEpatents

Halverson, Danny C.; Lum, Beverly Y.; Munir, Zuhair A.

1989-01-01

A self-sustaining combustion synthesis process for producing hard, tough, lightweight B.sub.4 C/TiB.sub.2 composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the B.sub.4 C and TiB.sub.2 reactants. For lightweight products the composition must be relatively rich in the B.sub.4 C component. B.sub.4 C-rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

Lightweight design of automobile frame based on magnesium alloy

NASA Astrophysics Data System (ADS)

Lyu, R.; Jiang, X.; Minoru, O.; Ju, D. Y.

2018-06-01

The structural performance and lightweighting of car base frame design is a challenging task due to all the performance targets that must be satisfied. In this paper, three kinds of materials (iron, aluminum and magnesium alloy) replacement along with section design optimization strategy is proposed to develop a lightweight car frame structure to satisfy the tensile and safety while reducing weight. Two kinds of cross-sections are considered as the design variables. Using Ansys static structure, the design optimization problem is solved, comparing the results of each step, structure of the base flame is optimized for lightweight.

Lightweight Metal/Polymer/Metal Sandwich Composites for Automotive Applications

NASA Astrophysics Data System (ADS)

Ferrari, Federico

Sandwich composites are becoming increasingly popular in the automotive sector as they are lightweight and facilitate noise attenuation. However, given that sandwich composites are relatively new in the sector, there are questions as to whether they can effectively replace monolithic metals and damping patches without compromising mechanical performance. Quiet Aluminum RTM, a sandwich composite produced by Material Sciences Corporation (MSC), employs as skins two aluminum alloys that are common in automotive manufacturing: 5754-O and 6061-T4. The current study examines and compares the mechanical properties of Quiet AluminumRTM with the main Fiat Chrysler Automobiles (FCA) requirements for laminates with non-structural loads. The adhesion mechanism between the layers of the sandwich composites received was examined through: T-Peel test, roughness measurements and metallographic cross sectioning technique. The current study then employed tensile tests with different treatments applied to the sandwich materials, a Self-Piercing Riveting (SPR) joining evaluation, and hardness tests on the core section of the aluminum skins. The samples, which presented rolling mill-finish surface roughness Ra range of 0.46-0.56 micro m, met the FCA adhesion requirements with adhesive failure mode even after the paint bake-cycle simulation (20 min at 185 °C) and the hardening treatment applied on the sandwich with AA6061-T4 skin (1 h at 200 °C). The tensile properties, computed simulating stamping process (2% pre-applied strain), the paint-bake cycle and the hardening treatment were comparable to the monolithic ones. Finally, SPR technique, evaluated through lap shear test and macro-graphic measurements, successfully joined Quiet AluminumRTM samples (1.06 mm thickness) with structural High Strength Low Alloy steel (HSLA,1.8 mm thickness and 340 MPa minimum yield strength).

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.

Characterizing the Conductivity and Enhancing the Piezoresistivity of Carbon Nanotube-Polymeric Thin Films

PubMed Central

Zhao, Yingjun; Schagerl, Martin; Viechtbauer, Christoph

2017-01-01

The concept of lightweight design is widely employed for designing and constructing aerospace structures that can sustain extreme loads while also being fuel-efficient. Popular lightweight materials such as aluminum alloy and fiber-reinforced polymers (FRPs) possess outstanding mechanical properties, but their structural integrity requires constant assessment to ensure structural safety. Next-generation structural health monitoring systems for aerospace structures should be lightweight and integrated with the structure itself. In this study, a multi-walled carbon nanotube (MWCNT)-based polymer paint was developed to detect distributed damage in lightweight structures. The thin film’s electromechanical properties were characterized via cyclic loading tests. Moreover, the thin film’s bulk conductivity was characterized by finite element modeling. PMID:28773084

Detection of Micro-Leaks Through Complex Geometries Under Mechanical Load and at Cryogenic Temperature

NASA Technical Reports Server (NTRS)

Rivers, H. Kevin; Sikora, J. G.; Sankaran, S. N.

2001-01-01

Polymer Matrix Composite (PMC) hydrogen tanks have been proposed as an enabling technology for reducing the weight of Single-Stage-to-Orbit reusable launch vehicles where structural mass has a large impact on vehicle performance. A key development issue of these lightweight structures is the leakage of hydrogen through the composite material. The rate of hydrogen leakage can be a function of the material used, method of 6 fabrication used to manufacture the tank, mechanical load the tank must react, internal damage-state of the material, and the temperatures at which the tank must operate. A method for measuring leakage through a geometrically complex structure at cryogenic temperature and under mechanical load was developed, calibrated and used to measure hydrogen leakage through complex X-33 liquid-hydrogen tank structure sections.

Bioinspired Design: Magnetic Freeze Casting

NASA Astrophysics Data System (ADS)

Porter, Michael Martin

Nature is the ultimate experimental scientist, having billions of years of evolution to design, test, and adapt a variety of multifunctional systems for a plethora of diverse applications. Next-generation materials that draw inspiration from the structure-property-function relationships of natural biological materials have led to many high-performance structural materials with hybrid, hierarchical architectures that fit form to function. In this dissertation, a novel materials processing method, magnetic freeze casting, is introduced to develop porous scaffolds and hybrid composites with micro-architectures that emulate bone, abalone nacre, and other hard biological materials. This method uses ice as a template to form ceramic-based materials with continuously, interconnected microstructures and magnetic fields to control the alignment of these structures in multiple directions. The resulting materials have anisotropic properties with enhanced mechanical performance that have potential applications as bone implants or lightweight structural composites, among others.

Materials Refining for Structural Elements From Lunar Resources

NASA Astrophysics Data System (ADS)

Landis, Geoffrey A.

1998-01-01

Use of in situ resources for construction on the Moon will require manufacturing structural materials out of lunar resources. Many materials that are currently used for aerospace and construction require materials that have low availability on the Moon. For example, graphite fiber, SiC fiber, and artificial fiber composites (such as Kevlar, Spectra, etc.) are used as advanced lightweight structural materials on Earth, but the low availability of C on the Moon makes these poor choices. Likewise the polymers used as the matrix for these composites, epoxy or polyester, also suffer from the low availability of C. Bulk paving and construction materials such as cement or concrete suffer from the low availability of water on the Moon, while asphalt, a common paving material on Earth, suffers from the low availability of C.

Mechanical Properties of T650-35/AFR-PE-4 at Elevated Temperatures for Lightweight Aeroshell Designs

NASA Technical Reports Server (NTRS)

Whitley, Karen S.; Collins, TImothy J.

2006-01-01

Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.

Study on the Mechanical Properties of Bionic Coupling Layered B4C/5083Al Composite Materials

PubMed Central

Zhao, Qian; Liang, Yunhong; Liu, Qingping; Zhang, Zhihui; Yu, Zhenglei; Ren, Luquan

2018-01-01

Based on microstructure characteristics of Meretrix lusoria shell and Rapana venosa shell, bionic coupling layered B4C/5083Al composites with different layered structures and hard/soft combination models were fabricated via hot pressed sintering. The simplified bionic coupling models with hard and soft layers were similar to layered structure and hardness tendency of shells, guiding the bionic design and fabrication. B4C/5083Al composites with various B4C contents and pure 5083Al were treated as hard and soft layers, respectively. Hot pressed sintering maintained the designed bionic structure and enhanced high bonding strength between ceramics and matrix. Compared with B4C/5083Al composites, bionic layered composites exhibited high mechanical properties including flexural strength, fracture toughness, compressive strength and impact toughness. The hard layers absorbed applied loads in the form of intergranular fracture. Besides connection role, soft layers restrained slabbing phenomenon and reset extension direction of cracks among layers. The coupling functions of bionic composites proved the feasibility and practicability of bionic fabrication, providing a new method for improvement of ceramic/Al composite with properties of being lightweight and high mechanical strength. PMID:29701707

Development of lightweight graphite/polyimide sandwich panels.

NASA Technical Reports Server (NTRS)

Poesch, J. G.

1972-01-01

Lightweight graphite/polyimide composite honeycomb core and sandwich panels were fabricated and tested. Honeycomb cores of 1/4-in. and 3/8-in. cell sizes of hexagonal configuration were produced from thin plus or minus 45 deg cross plied sheets of prepreg producing core weights between 1.8 and 3.6 lb/cu ft. Thin gauge prepreg using Hercules graphite tow and Monsanto Skybond 710 polyimide resin were manufactured to produce cured ply thicknesses of 0.001 to 0.002 in. Graphite core properties measured at temperatures from -150 to 600 F are reported. Core properties which are superior to available materials were obtained. Sandwich panels weighing less than 0.5 lb/sq ft were designed and fabricated which meet the support structure loads for the shuttle orbiter thermal protection system.

NASA Glenn Research Center UEET (Ultra-Efficient Engine Technology) Program: Agenda and Abstracts

NASA Technical Reports Server (NTRS)

Manthey, Lri

2001-01-01

Topics discussed include: UEET Overview; Technology Benefits; Emissions Overview; P&W Low Emissions Combustor Development; GE Low Emissions Combustor Development; Rolls-Royce Low Emissions Combustor Development; Honeywell Low Emissions Combustor Development; NASA Multipoint LDI Development; Stanford Activities In Concepts for Advanced Gas Turbine Combustors; Large Eddy Simulation (LES) of Gas Turbine Combustion; NASA National Combustion Code Simulations; Materials Overview; Thermal Barrier Coatings for Airfoil Applications; Disk Alloy Development; Turbine Blade Alloy; Ceramic Matrix Composite (CMC) Materials Development; Ceramic Matrix Composite (CMC) Materials Characterization; Environmental Barrier Coatings (EBC) for Ceramic Matrix Composite (CMC) Materials; Ceramic Matrix Composite Vane Rig Testing and Design; Ultra-High Temperature Ceramic (UHTC) Development; Lightweight Structures; NPARC Alliance; Technology Transfer and Commercialization; and Turbomachinery Overview; etc.

The Cutting Edge of High-Temperature Composites

NASA Technical Reports Server (NTRS)

2006-01-01

NASA s Ultra-Efficient Engine Technology (UEET) program was formed in 1999 at Glenn Research Center to manage an important national propulsion program for the Space Agency. The UEET program s focus is on developing innovative technologies to enable intelligent, environmentally friendly, and clean-burning turbine engines capable of reducing harmful emissions while maintaining high performance and increasing reliability. Seven technology projects exist under the program, with each project working towards specific goals to provide new technology for propulsion. One of these projects, Materials and Structures for High Performance, is concentrating on developing and demonstrating advanced high-temperature materials to enable high-performance, high-efficiency, and environmentally compatible propulsion systems. Materials include ceramic matrix composite (CMC) combustor liners and turbine vanes, disk alloys, turbine airfoil material systems, high-temperature polymer matrix composites, and lightweight materials for static engine structures.

Advanced Ceramic Materials for Future Aerospace Applications

NASA Technical Reports Server (NTRS)

Misra, Ajay

2015-01-01

With growing trend toward higher temperature capabilities, lightweight, and multifunctionality, significant advances in ceramic matrix composites (CMCs) will be required for future aerospace applications. The presentation will provide an overview of material requirements for future aerospace missions, and the role of ceramics and CMCs in meeting those requirements. Aerospace applications will include gas turbine engines, aircraft structure, hypersonic and access to space vehicles, space power and propulsion, and space communication.

Towards intelligent microstructural design of Nanocomposite Materials. Lightweight, high strength structural/armor materials for service in extreme environments

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

Mara, Nathan Allan; Bronkhorst, Curt Allan; Beyerlein, Irene Jane

2015-12-21

The intent of this research effort is to prove the hypothesis that: Through the employment of controlled processing parameters which are based upon integrated advanced material characterization and multi-physics material modeling, bulk nanolayered composites can be designed to contain high densities of preferred interfaces that can serve as supersinks for the defects responsible for premature damage and failure.

Evaluation of lightweight material concepts for aircraft turbine engine rotor failure protection

DOT National Transportation Integrated Search

1997-07-01

Results of the evaluation of lightweight materials for aircraft turbine engine rotor failure protection are presented in this report. The program consisted of two phases. Phase 1 was an evaluation of a group of composite materials which could possibl...

Influence of the vacuum resin process, on the ballistic behaviour of lightweight armouring solutions

NASA Astrophysics Data System (ADS)

Lefebvre, M.; Boussu, F.; Coutellier, D.; Vallee, D.

2012-08-01

The armour of vehicles against conventional threats is mainly composed with steel or aluminium panels. Efficient heavy solutions exist, but the involved industries require new lightweight structures. Moreover, unconventional threats as IEDs (Improvised Explosive Devices) may cause severe damages on these structural and protective panel solutions. Thus, combination of aluminium or steel plates with textile composite structures used as a backing, leads to the mass reduction and better performance under delamination behaviour against these new threats. This paper is a part of a study dealing with the impact behaviour of three warp interlocks weaving structures under Fragment Simulating Projectile (FSP) impact. During this research, several parameters has being studied as the influence of the yarns insertions [1-4], the degradation of the yarns during the weaving process [5-7], and the influence of the resin rate on the ballistic behaviour. The resin rate inside composite materials is dependant on the final application. In ballistic protection, we need to control the resin rate in order to have a deformable structure in order to absorb the maximum of energy. However, with the warp interlocks weaving structure, the yarns insertions induce empty spaces between the yarns where the resin takes place without being evacuated. The resin rate inside the warp interlocks structures is in the most of cases less than 50%, which lead to have brittle and hard material during the impact. Contrary to interlocks structures, the existing protection based on prepreg structure have a high fibres ratio around 88% of weight. That leads to have the best ballistic properties during the impact and good deformability of the structure. The aim of this paper is to evaluate the influence of the resin rate on the ballistic results of the composites materials. For that, we have chosen two kinds of warp interlocks fabrics which were infused with epoxy resin following two processes. The first is a classical vacuum resin infusion; the second used a press in order to reach a resin ratio near to the existing protection. The existing protection is a prepreg structure with a fibre content of 88%. It has been revealed that a resin rate less than 35% inside the warp interlocks composite material leads to have equivalent ballistics performances than existing protection.

Research requirements to reduce empty weight of helicopters by use of advanced materials

NASA Technical Reports Server (NTRS)

Hoffstedt, D. J.

1976-01-01

Utilization of the new, lightweight, high-strength, aerospace structural-composite (filament/matrix) materials, when specifically designed into a new aircraft, promises reductions in structural empty weight of 12 percent at recurring costs competive with metals. A program of basic and applied research and demonstration is identified with the objective of advancing the state of the art to the point where civil helicopters are confidently designed, produced, certified, and marketed by 1985. A structural empty-weight reduction of 12 percent was shown to significantly reduce energy consumption in modern high-performance helicopters.

Lightweight, Fire-Resistant Graphite Composites

NASA Technical Reports Server (NTRS)

Kourtides, D. A.; Parker, J. A.; MING-TA-HSU

1986-01-01

Aircraft safety improved with interior paneling made of new laminate with good thermophysical properties. Featuring lightweight graphite composite, laminate more heat-and flame-resistant and produces much less smoke in fire than commonly used epoxy-resin-containing laminates. New laminate prepared without epoxy resin. Graphite unidirectional cloth preimpregnated with blend of vinyl polystyrylpyridine and bismaleimide (VPSP-BMI). Either of two types of VPSP-BMI blend used, depending on method of preparation of chemicals and technique used to fabricate panel.

Lightweight graphene nanoplatelet/boron carbide composite with high EMI shielding effectiveness

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

Tan, Yongqiang; Luo, Heng; Zhang, Haibin, E-mail: hbzhang@caep.cn, E-mail: pengshuming@caep.cn

2016-03-15

Lightweight graphene nanoplatelet (GNP)/boron carbide (B{sub 4}C) composites were prepared and the effect of GNPs loading on the electromagnetic interference (EMI) shielding effectiveness (SE) has been evaluated in the X-band frequency range. Results have shown that the EMI SE of GNP/B{sub 4}C composite increases with increasing the GNPs loading. An EMI SE as high as 37 ∼ 39 dB has been achieved in composite with 5 vol% GNPs. The high EMI SE is mainly attributed to the high electrical conductivity, high dielectric loss as well as multiple reflections by aligned GNPs inside the composite. The GNP/B{sub 4}C composite is demonstratedmore » to be promising candidate of high-temperature microwave EMI shielding material.« less

Combustion synthesis of boride and other composites

DOEpatents

Halverson, D.C.; Lum, B.Y.; Munir, Z.A.

1988-07-28

A self-sustaining combustion synthesis process for producing hard, tough, lightweight B/sub 4/C/TiB/sub 2/ composites is described. It is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the B/sub 4/C and TiB/sub 2/ reactants. For lightweight products the composition must be relatively rich in the B/sub 4/C component. B/sub 4/C-rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component. 9 figs., 4 tabs.

Ceramic honeycomb structures and the method thereof

NASA Technical Reports Server (NTRS)

Riccitiello, Salvatore R. (Inventor); Cagliostro, Domenick E. (Inventor)

1987-01-01

The subject invention pertains to a method of producing an improved composite-composite honeycomb structure for aircraft or aerospace use. Specifically, the subject invention relates to a method for the production of a lightweight ceramic-ceramic composite honeycomb structure, which method comprises: (1) pyrolyzing a loosely woven fabric/binder having a honeycomb shape and having a high char yield and geometric integrity after pyrolysis at between about 700 and 1,100 C; (2) substantially evenly depositing at least one layer of ceramic material on the pyrolyzed fabric/binder of step (1); (3) recovering the coated ceramic honeycomb structure; (4) removing the pyrolyzed fabric/binder of the structure of step (3) by slow pyrolysis at between 700 and 1000 C in between about a 2 to 5% by volume oxygen atmosphere for between about 0.5 and 5 hr.; and (5) substantially evenly depositing on and within the rigid hollow honeycomb structure at least one additional layer of the same or a different ceramic material by chemical vapor deposition and chemical vapor infiltration. The honeycomb shaped ceramic articles have enhanced physical properties and are useful in aircraft and aerospace uses.

An Integrated Approach Linking Process to Structural Modeling With Microstructural Characterization for Injections-Molded Long-Fiber Thermoplastics

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

Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Smith, Mark T.

2008-09-01

The objective of our work is to enable the optimum design of lightweight automotive structural components using injection-molded long fiber thermoplastics (LFTs). To this end, an integrated approach that links process modeling to structural analysis with experimental microstructural characterization and validation is developed. First, process models for LFTs are developed and implemented into processing codes (e.g. ORIENT, Moldflow) to predict the microstructure of the as-formed composite (i.e. fiber length and orientation distributions). In parallel, characterization and testing methods are developed to obtain necessary microstructural data to validate process modeling predictions. Second, the predicted LFT composite microstructure is imported into amore » structural finite element analysis by ABAQUS to determine the response of the as-formed composite to given boundary conditions. At this stage, constitutive models accounting for the composite microstructure are developed to predict various types of behaviors (i.e. thermoelastic, viscoelastic, elastic-plastic, damage, fatigue, and impact) of LFTs. Experimental methods are also developed to determine material parameters and to validate constitutive models. Such a process-linked-structural modeling approach allows an LFT composite structure to be designed with confidence through numerical simulations. Some recent results of our collaborative research will be illustrated to show the usefulness and applications of this integrated approach.« less

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

NASA Technical Reports Server (NTRS)

Gamwell, W. R.; McGill, P. B.

2006-01-01

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Synthesis and microwave absorption property of graphene oxide/carbon nanotubes modified with cauliflower-like Fe3O4 nanospheres

NASA Astrophysics Data System (ADS)

Yan, Shaojiu; Wang, Lina; Wang, Tihong; Zhang, Liqiang; Li, Yongfeng; Dai, Shenglong

2016-03-01

We report a simple procedure to fabricate graphene oxide/carbon nanotube hybrids coated with cauliflower-like Fe3O4 sphere. Characterizations have been carried out to investigate the morphology, crystalline structure of the composites by scanning electron microscopy, transmission electron microscopy and X-ray diffraction. Fe3O4 particles have the morphologies of multi-lacuna; moreover, some spheres are hollow. As a kind of potential microwave absorption material, the composites are lightweight and exhibit excellent microwave absorbing ability in the range of 2-16 GHz.

Production Principles and Technological Development of Novel Woven Spacer Preforms and Integrated Stiffener Structures

NASA Astrophysics Data System (ADS)

Torun, Ahmet R.; Mountasir, Adil; Hoffmann, Gerald; Cherif, Chokri

2013-06-01

3D textile preforms offer a high potential to increase mechanical properties of composites and/or decrease manufacturing costs. Within the scope of this study, production principles were developed for complex spacer preforms and integrated stiffeners. These principles were applied through technological further development of the well-known face-to-face and terry weaving techniques. Various woven preforms were produced with Glass fibre/Polypropylene (GF/PP) Commingled yarns, however, the technology is suitable for any type of reinforcement yarns. U-shaped woven spacer preform was consolidated into a sandwich composite component for lightweight applications.

Large-area, lightweight and thick biomimetic composites with superior material properties via fast, economic, and green pathways.

PubMed

Walther, Andreas; Bjurhager, Ingela; Malho, Jani-Markus; Pere, Jaakko; Ruokolainen, Janne; Berglund, Lars A; Ikkala, Olli

2010-08-11

Although remarkable success has been achieved to mimic the mechanically excellent structure of nacre in laboratory-scale models, it remains difficult to foresee mainstream applications due to time-consuming sequential depositions or energy-intensive processes. Here, we introduce a surprisingly simple and rapid methodology for large-area, lightweight, and thick nacre-mimetic films and laminates with superior material properties. Nanoclay sheets with soft polymer coatings are used as ideal building blocks with intrinsic hard/soft character. They are forced to rapidly self-assemble into aligned nacre-mimetic films via paper-making, doctor-blading or simple painting, giving rise to strong and thick films with tensile modulus of 45 GPa and strength of 250 MPa, that is, partly exceeding nacre. The concepts are environmentally friendly, energy-efficient, and economic and are ready for scale-up via continuous roll-to-roll processes. Excellent gas barrier properties, optical translucency, and extraordinary shape-persistent fire-resistance are demonstrated. We foresee advanced large-scale biomimetic materials, relevant for lightweight sustainable construction and energy-efficient transportation.

Lightweight Ceramics for Aeroacoustic Applications

NASA Technical Reports Server (NTRS)

Kwan, H. W.; Spamer, G. T.; Yu, J.; Yasukawa, B.

1997-01-01

The use of a HTP (High Temperature Performance) ceramic foam for aeroacoustic applications is investigated. HTP ceramic foam is a composition of silica and alumina fibers developed by LMMS. This foam is a lightweight high-temperature fibrous bulk material with small pore size, ultra high porosity, and good strength. It can be used as a broadband noise absorber at both room and high temperature (up to 1800 F). The investigation included an acoustic assessment as well as material development, and environmental and structural evaluations. The results show that the HTP ceramic foam provides good broadband noise absorbing capability and adequate strength when incorporating the HTP ceramic foam system into a honeycomb sandwich structure. On the other hand, the material is sensitive to Skydrol and requires further improvements. Good progress has been made in the impedance model development. A relationship between HTP foam density, flow resistance, and tortuosity will be established in the near future. Additional effort is needed to investigate the coupling effects between face sheet and HTP foam material.

Overall Water Splitting with Room-Temperature Synthesized NiFe Oxyfluoride Nanoporous Films

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

Liang, Kun; Guo, Limin; Marcus, Kyle

Freestanding and lightweight thin-films were rationally designed to serve as robust electrodes for renewable energy applications. A facile and scalable nanomanufacturing process was developed to fabricate these transformative thin-film electrodes (iron group mixed oxides) that exhibit a nanoporous structure and controllable composition. More specifically, electrodeposition and anodic treatments were employed to produce freestanding and lightweight metal oxides nanoporous layers (NPL). These NPL can be directly used as flexible and additive-free electrodes for renewable energy generation (water splitting) and storage (supercapacitor) applications without requiring binders and current collector and other additives. Significantly enhanced electrochemical performance was achieved due to the uniquemore » merits of the NPL: i) highly porous structure considerably increases the electrode/electrolyte interface, which facilitate electrochemical reactions; ii) NPL substantially increase the number of active sites that are favorable in electrochemical reactions; iii) residual metal network within the NPL forms a conductive framework, drastically improving electrode strength, flexibility and conductivity.« less

Strength and failure analysis of composite-to-composite adhesive bonds with different surface treatments

NASA Astrophysics Data System (ADS)

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

2018-03-01

Adhesives are widely utilized materials in aviation, automotive, energy, defense, and marine industries. Adhesive joints are gradually supplanting mechanical fasteners because they are lightweight structures, thus making the assembly lighter and easier. They also act as a sealant to prevent a structural joint from galvanic corrosion and leakages. Adhesive bonds provide high joint strength because of the fact that the load is distributed uniformly on the joint surface, while in mechanical joints, the load is concentrated at one point, thus leading to stress at that point and in turn causing joint failures. This research concentrated on the analysis of bond strength and failure loads in adhesive joint of composite-to-composite surfaces. Different durations of plasma along with the detergent cleaning were conducted on the composite surfaces prior to the adhesive applications and curing processes. The joint strength of the composites increased about 34% when the surface was plasma treated for 12 minutes. It is concluded that the combination of different surface preparations, rather than only one type of surface treatment, provides an ideal joint quality for the composites.

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

NASA Technical Reports Server (NTRS)

Shin, E. Eugene; Johnston, J. Chris; Haas, Daniel

2011-01-01

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Multifunctional fiber reinforced polymer composites using carbon and boron nitride nanotubes

NASA Astrophysics Data System (ADS)

Ashrafi, Behnam; Jakubinek, Michael B.; Martinez-Rubi, Yadienka; Rahmat, Meysam; Djokic, Drazen; Laqua, Kurtis; Park, Daesun; Kim, Keun-Su; Simard, Benoit; Yousefpour, Ali

2017-12-01

Recent progress in nanotechnology has made several nano-based materials available with the potential to address limitations of conventional fiber reinforced polymer composites, particularly in reference to multifunctional structures. Carbon nanotubes (CNTs) are the most prevalent case and offer amazing properties at the individual nanotube level. There are already a few high-profile examples of the use of CNTs in space structures to provide added electrical conductivity for static dissipation and electromagnetic shielding. Boron nitride nanotubes (BNNTs), which are structurally analogous to CNTs, also present a range of attractive properties. Like the more widely explored CNTs, individual BNNTs display remarkable mechanical properties and high thermal conductivity but with contrasting functional attributes including substantially higher thermal stability, high electrical insulation, polarizability, high neutron absorption and transparency to visible light. This presents the potential of employing either or both BNNTs and CNTs to achieve a range of lightweight, functional composites for space structures. Here we present the case for application of BNNTs, in addition to CNTs, in space structures and describe recent advances in BNNT production at the National Research Council Canada (NRC) that have, for the first time, provided sufficiently large quantities to enable commercialization of high-quality BNNTs and accelerate development of chemistry, composites and applications based on BNNTs. Early demonstrations showing the fabrication and limited structural testing of polymer matrix composites, including glass fiber-reinforced composite panels containing BNNTs will be discussed.

Unitized Regenerative Fuel Cell System Gas Storage-Radiator Development

NASA Technical Reports Server (NTRS)

Burke, Kenneth A.; Jakupta, Ian

2005-01-01

High-energy-density regenerative fuel cell systems that are used for energy storage require novel approaches to integrating components in order to preserve mass and volume. A lightweight unitized regenerative fuel cell (URFC) energy storage system concept is being developed at the NASA Glenn Research Center. This URFC system minimizes mass by using the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The waste heat generated by the URFC stack during charging and discharging is transferred from the cell stack to the surface of each tank by loop heat pipes, which are coiled around each tank and covered with a thin layer of thermally conductive carbon composite. The thin layer of carbon composite acts as a fin structure that spreads the heat away from the heat pipe and across the entire tank surface. Two different-sized commercial-grade composite tanks were constructed with integral heat pipes and tested in a thermal vacuum chamber to examine the feasibility of using the storage tanks as system radiators. The storage tank-radiators were subjected to different steady-state heat loads and varying heat load profiles. The surface emissivity and specific heat capacity of each tank were calculated. In the future, the results will be incorporated into a model that simulates the performance of similar radiators using lightweight, spacerated carbon composite tanks.

Effect of Multiwalled Carbon Nanotubes on the Mechanical Properties of Carbon Fiber-Reinforced Polyamide-6/Polypropylene Composites for Lightweight Automotive Parts.

PubMed

Nguyen-Tran, Huu-Duc; Hoang, Van-Tho; Do, Van-Ta; Chun, Doo-Man; Yum, Young-Jin

2018-03-15

The development of lightweight automotive parts is an important issue for improving the efficiency of vehicles. Polymer composites have been widely applied to reduce weight and improve mechanical properties by mixing polymers with carbon fibers, glass fibers, and carbon nanotubes. Polypropylene (PP) has been added to carbon fiber-reinforced nylon-6 (CF/PA6) composite to achieve further weight reduction and water resistance. However, the mechanical properties were reduced by the addition of PP. In this research, multiwalled carbon nanotubes (CNTs) were added to compensate for the reduced mechanical properties experienced when adding PP. Tensile testing and bending tests were carried out to evaluate the mechanical properties. A small amount of CNTs improved the mechanical properties of carbon fiber-reinforced PA6/PP composites. For example, the density of CF/PA6 was reduced from 1.214 to 1.131 g/cm³ (6.8%) by adding 30 wt % PP, and the tensile strength of 30 wt % PP composite was improved from 168 to 173 MPa (3.0%) by adding 0.5 wt % CNTs with small increase of density (1.135 g/cm³). The developed composite will be widely used for lightweight automotive parts with improved mechanical properties.

Effect of Multiwalled Carbon Nanotubes on the Mechanical Properties of Carbon Fiber-Reinforced Polyamide-6/Polypropylene Composites for Lightweight Automotive Parts

PubMed Central

Nguyen-Tran, Huu-Duc; Do, Van-Ta; Yum, Young-Jin

2018-01-01

The development of lightweight automotive parts is an important issue for improving the efficiency of vehicles. Polymer composites have been widely applied to reduce weight and improve mechanical properties by mixing polymers with carbon fibers, glass fibers, and carbon nanotubes. Polypropylene (PP) has been added to carbon fiber-reinforced nylon-6 (CF/PA6) composite to achieve further weight reduction and water resistance. However, the mechanical properties were reduced by the addition of PP. In this research, multiwalled carbon nanotubes (CNTs) were added to compensate for the reduced mechanical properties experienced when adding PP. Tensile testing and bending tests were carried out to evaluate the mechanical properties. A small amount of CNTs improved the mechanical properties of carbon fiber-reinforced PA6/PP composites. For example, the density of CF/PA6 was reduced from 1.214 to 1.131 g/cm3 (6.8%) by adding 30 wt % PP, and the tensile strength of 30 wt % PP composite was improved from 168 to 173 MPa (3.0%) by adding 0.5 wt % CNTs with small increase of density (1.135 g/cm3). The developed composite will be widely used for lightweight automotive parts with improved mechanical properties. PMID:29543754

Development of a composite geodetic structure for space construction, phase 1A

NASA Technical Reports Server (NTRS)

1980-01-01

The development of a geodetic beam and beam builder for on orbit construction of large truss type space structures is discussed. The geodetic beam is a lightweight, open lattice structure composed of an equilateral gridwork of crisscrossing rods. The beam provides a high degree of stiffness and minimizes structural distortion, due to temperature gradients, through the incorporation of a new graphite and glass reinforced thermoplastic composite material with a low coefficient of thermal expansion. A low power consuming, high production rate, beam builder automatically fabricates the geodetic beams in space using rods preprocessed on Earth. Three areas of the development are focused upon; (1) geodetic beam designs for local attachment of equipment or beam to beam joining in a parallel or crossing configurations, (2) evaluation of long life pultruded rods capable of service temperatures higher than possible with the HMS/P1700 rod material, and (3) evalaution of high temperature joint encapsulant materials.

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

NASA Technical Reports Server (NTRS)

Scully, John R.; Shiflet, Gary J.; Stoner, Glenn E.; Wert, John A.

1996-01-01

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. Three research areas are being actively investigated, including: (1) Mechanical and environmental degradation mechanisms in advanced light metals, (2) Aerospace materials science, and (3) Mechanics of materials for light aerospace structures.

High-resolution deployable telescope for satellite applications

NASA Astrophysics Data System (ADS)

Pica, Giulia; Ciofaniello, Luca; Mattei, Stefania; Santovito, Maria Rosaria; Gardi, Roberto

2004-02-01

CO.RI.S.T.A. is involved in a research project funded by ASI (Italian Space Agency), named MITAR, to realise a very compact, lightweight deployable telescope in visible wavelength range to get earth images from microsatellite. The satellite considered for the study is SMART, an Italian academic multi-mission microsatellite operating on circular sun-synchronous orbits. The telescope has a Cassegrain configuration with a parabolic primary mirror and an hyperbolic secondary mirror. This configuration guaranties the best aberrations corrections and the best compactness. The primary and the secondary mirror are 40 cm and 10 cm in diameter respectively, while their relative distance is 52cm. Mirrors will be realised with innovative composite material to obtain lightweight optical elements. Thanks to its limited size and light weight, the system can be easily deployed. The deployable structure will keep the secondary mirror close to the primary one during launch phases. Once in orbit, a system of lenticular tape springs and dumpers will extend the structure. The structure will be enclosed in multilayer blankets that will shield the sensor from light and will thermally stabilize the structure, preventing excessive thermal deformation. The images will be detected by a very high resolution CCD camera installed onboard the satellite.

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST). Research on Materials for the High Speed Civil Transport

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Starke, Edgar A., Jr.; Kelly, Robert G.; Scully, John R.; Stoner, Glenn E.; Wert, John A.

1997-01-01

Since 1986, the NASA-Langley Research Center has sponsored the NASA-UVa Light Alloy and Structures Technology (LA2ST) Program at the University of Virginia (UVa). The fundamental objective of the LA2ST program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures. The LA2ST program has aimed to product relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. The scope of the LA2ST Program is broad. Research areas include: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals and Composites, (2) Aerospace Materials Science, (3) Mechanics of materials for Aerospace Structures, and (4) Thermal Gradient Structures. A substantial series of semi-annual progress reports issued since 1987 documents the technical objectives, experimental or analytical procedures, and detailed results of graduate student research in these topical areas.

Effect of Different Concentration of Sodium Hydroxide [NaOH] on Kenaf Sandwich Structures

NASA Astrophysics Data System (ADS)

Aziz, M.; Halim, Z.; Othman, M.

2018-01-01

Sandwich panels are structures that made of three layers, low-density core inserted in between thin skin layers. This structures allow the achievement of excellent mechanical performance with low weight, thus this characteristic fulfil requirement to be use in aircraft application. In recent time, sandwich structures have been studied due to it has multifunction properties and lightweight. The aim of this study is to fabricate a composite sandwich structures with biodegradable material for face sheet [skin] where the fibre being treat with different concentration of sodium hydroxide [NaOH] with 10 and 20 hours of soaking time. Kenaf fibre [treated] reinforced epoxy will be used as skins and Nomex honeycomb is chosen to perform as core for this sandwich composite structure. The mechanical properties that are evaluated such as flexural strength and impact energy of kenaf fibre-reinforced epoxy sandwich structures. For flexural test, the optimum flexural strength is 13.4 MPa and impact strength is 18.3 J.

Literature Review of Shear Performance of Light-weight Steel Framing Wall Panels

NASA Astrophysics Data System (ADS)

Zhang, Zhuangnan; Liu, Shen; Liu, Hong

2018-03-01

In this paper, a comprehensive review of light-weight steel framing wall panels was carried out. The structure and force characteristics of light-weight steel framing wall panels were introduced. The testing and theoretical research results on the shear behaviour of light-weight steel framing wall panels were summarized in the domestic and foreign. And combined with the existing standards in China, the author's views and ideas are put forward to the problems in the research field of this kind of structural system.

Aerogel Hybrid Composite Materials: Designs and Testing for Multifunctional Applications

NASA Technical Reports Server (NTRS)

Williams, Martha K.; Fesmire, James E.

2016-01-01

This webinar will introduce the broad spectrum of aerogel composites and their diverse performance properties such as reduced heat transfer to energy storage, and expands specifically on the aerogel/fiber laminate systems and testing methodologies. The multi-functional laminate composite system, AeroFiber, and its construction is designed by varying the type of fiber (e.g. polyester, carbon, Kevlar®, Spectra® or Innegral(TradeMark) and combinations thereof), the aerogel panel type and thickness, and overall layup configuration. The combination and design of materials may be customized and tailored to achieve a range of desired properties in the resulting laminate system. Multi-functional properties include structural strength, impact resistance, reduction in heat transfer, increased fire resistance, mechanical energy absorption, and acoustic energy dampening. Applications include aerospace, aircraft, automotive, boating, building and construction, lightweight portable structures, liquefied natural gas, cryogenics, transportation and energy, sporting equipment, and military protective gear industries.

Lightweight, Thermally Insulating Structural Panels

NASA Technical Reports Server (NTRS)

Eisen, Howard J.; Hickey, Gregory; Wen, Liang-Chi; Layman, William E.; Rainen, Richard A.; Birur, Gajanana C.

1996-01-01

Lightweight, thermally insulating panels that also serve as structural members developed. Honeycomb-core panel filled with low-thermal-conductivity, opacified silica aerogel preventing convection and minimizes internal radiation. Copper coating on face sheets reduces radiation. Overall thermal conductivities of panels smaller than state-of-art commercial non-structurally-supporting foam and fibrous insulations. On Earth, panels suitable for use in low-air-pressure environments in which lightweight, compact, structurally supporting insulation needed; for example, aboard high-altitude aircraft or in partially evacuated panels in refrigerators.

Analysis of stress-strain, fracture, and ductility behavior of aluminum maxtrix composites containing discontinuous silicon carbide reinforcement

NASA Technical Reports Server (NTRS)

Mcdanels, D. L.

1985-01-01

Mechanical properties and stress-strain behavior were evaluated for several types of commercially fabricated aluminum matrix composites, containing up to 40 vol pct discontinuous SiC whisker, nodule, or particulate reinforcement. The elastic modulus of the composites was found to be isotropic, to be independent of type of reinforcement, and to be controlled solely by the volume percentage of SiC reinforcement present. The yield/tensile strengths and ductility were controlled primarily by the matrix alloy and temper condition. Type and orientation of reinforcement had some effect on the strengths of composites, but only for those in which the whisker reinforcement was highly oriented. Ductility decreased with increasing reinforcement content; however, the fracture strains observed were higher than those reported in the literature for this type of composite. This increase in fracture strain was probably attributable to cleaner matrix powder, better mixing, and increased mechanical working during fabrication. Comparison of properties with conventional aluminum and titanium structural alloys showed that the properties of the low-cost, lightweight composites demonstrated very good potential for application to aerospace structures.

Experimental Behavior of Fatigued Single Stiffener PRSEUS Specimens

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2009-01-01

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structure. In this concept a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. By adding unidirectional carbon rods to the top of stiffeners, the panel becomes more structurally efficient. This combination produces a more damage tolerant design. This document describes the results of experimentation on PRSEUS specimens loaded in unidirectional compression in fatigue and to failure.

CARBON FIBER COMPOSITES IN HIGH VOLUME

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

Warren, Charles David; Das, Sujit; Jeon, Dr. Saeil

2014-01-01

Vehicle lightweighting represents one of several design approaches that automotive and heavy truck manufacturers are currently evaluating to improve fuel economy, lower emissions, and improve freight efficiency (tons-miles per gallon of fuel). With changes in fuel efficiency and environmental regulations in the area of transportation, the next decade will likely see considerable vehicle lightweighting throughout the ground transportation industry. Greater use of carbon fiber composites and light metals is a key component of that strategy. This paper examines the competition between candidate materials for lightweighting of heavy vehicles and passenger cars. A 53-component, 25 % mass reduction, body-in-white cost analysismore » is presented for each material class, highlighting the potential cost penalty for each kilogram of mass reduction and then comparing the various material options. Lastly, as the cost of carbon fiber is a major component of the elevated cost of carbon fiber composites, a brief look at the factors that influence that cost is presented.« less

Surface characterization of carbon fiber polymer composites and aluminum alloys after laser interference structuring

DOE PAGES

Sabau, Adrian S.; Greer, Clayton M.; Chen, Jian; ...

2016-05-03

Here, the increasing use of Carbon Fiber-reinforced Polymer matrix Composites (CFPC) and aluminum alloys as lightweight materials in the automotive and aerospace industries demands enhanced surface preparation and control of surface morphology prior to joining. In this study, surfaces of both composite and aluminum were prepared for joining using an Nd:YAG laser in a two-beam interference setup, enabling the (a) structuring of the AL 5182 surface, (b) removal of the resin layer on top of carbon fibers, and (c) structuring of the carbon fibers. CFPC specimens of T700S carbon fiber, Prepreg - T8 3 epoxy, 5 ply thick, 0/90o plaquesmore » were used. The effect of laser fluence, scanning speed, and number of shots-per-spot was investigated on the removal rate of the resin without an excessive damage of the fibers. Optical micrographs, 3D imaging, and scanning electron microscope (SEM) imaging were used to study the effect of the laser processing on surface morphology.« less

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.

Lightweight Composite Materials for Heavy Duty Vehicles

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

Pruez, Jacky; Shoukry, Samir; Williams, Gergis

The main objective of this project is to develop, analyze and validate data, methodologies and tools that support widespread applications of automotive lightweighting technologies. Two underlying principles are guiding the research efforts towards this objective: • Seamless integration between the lightweight materials selected for certain vehicle systems, cost-effective methods for their design and manufacturing, and practical means to enhance their durability while reducing their Life-Cycle-Costs (LCC). • Smooth migration of the experience and findings accumulated so far at WVU in the areas of designing with lightweight materials, innovative joining concepts and durability predictions, from applications to the area of weightmore » savings for heavy vehicle systems and hydrogen storage tanks, to lightweighting applications of selected systems or assemblies in light–duty vehicles.« less

Production and characterization of a composite insulation material from waste polyethylene teraphtalates

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

Kurtulmus, Erhan; Karaboyacı, Mustafa; Yigitarslan, Sibel

2013-12-16

The pollution of polyethylene teraphtalate (PET) is in huge amounts due to the most widely usage as a packaging material in several industries. Regional pumice has several desirable characteristics such as porous structure, low-cost and light-weight. Considering the requirements approved by the Ministry of Public Works on isolation, composite insulation material consisting of PET and pumice was studied. Sheets of composites differing both in particle size of pumice and composition of polymer were produced by hot-molding technique. Characterization of new composite material was achieved by measuring its weight, density, flammability, endurance against both to common acids and bases, and tomore » a force applied, heat insulation and water adsorption capacity. The results of the study showed that produced composite material is an alternative building material due to its desirable characteristics; low weight, capability of low heat conduction.« less

NASA Tech Briefs, July 2004

NASA Technical Reports Server (NTRS)

2004-01-01

Topics: Optoelectronic Sensor System for Guidance in Docking; Hybrid Piezoelectric/Fiber-Optic Sensor Sheets; Multisensor Arrays for Greater Reliability and Accuracy; Integrated-Optic Oxygen Sensors; Ka-Band Autonomous Formation Flying Sensor; CMOS VLSI Active-Pixel Sensor for Tracking; Lightweight, Self-Deploying Foam Antenna Structures; Electrically Small Microstrip Quarter-Wave Monopole Antennas; A 2-to-28-MHz Phase-Locked Loop; Portable Electromyograph; Open-Source Software for Modeling of Nanoelectronic Devices; Software for Generating Strip Maps from SAR Data; Calibration Software for use with Jurassicprok; Software for Probabilistic Risk Reduction; Software Processes SAR Motion-Measurement Data; Improved Method of Purifying Carbon Nanotubes; Patterned Growth of Carbon Nanotubes or Nanofibers; Lightweight, Rack-Mountable Composite Cold Plate/Shelves; SiC-Based Miniature High-Temperature Cantilever Anemometer; Inlet Housing for a Partial-Admission Turbine; Lightweight Thermoformed Structural Components and Optics; Growing High-Quality InAs Quantum Dots for Infrared Lasers; Selected Papers on Protoplanetary Disks; Module for Oxygenating Water without Generating Bubbles; Coastal Research Imaging Spectrometer; Rapid Switching and Modulation by use of Coupled VCSELs; Laser-Induced-Fluorescence Photogrammetry and Videogrammetry; Laboratory Apparatus Generates Dual-Species Cold Atomic Beam; Laser Ablation of Materials for Propulsion of Spacecraft; Small Active Radiation Monitor; Hybrid Image-Plane/Stereo Manipulation; Partitioning a Gridded Rectangle into Smaller Rectangles; Digital Radar-Signal Processors Implemented in FPGAs; Part 1 of a Computational Study of a Drop-Laden Mixing Layer; and Some Improvements in Signal-Conditioning Circuits.

Fiber Bragg Grating Sensors toward Structural Health Monitoring in Composite Materials: Challenges and Solutions

PubMed Central

Kinet, Damien; Mégret, Patrice; Goossen, Keith W.; Qiu, Liang; Heider, Dirk; Caucheteur, Christophe

2014-01-01

Nowadays, smart composite materials embed miniaturized sensors for structural health monitoring (SHM) in order to mitigate the risk of failure due to an overload or to unwanted inhomogeneity resulting from the fabrication process. Optical fiber sensors, and more particularly fiber Bragg grating (FBG) sensors, outperform traditional sensor technologies, as they are lightweight, small in size and offer convenient multiplexing capabilities with remote operation. They have thus been extensively associated to composite materials to study their behavior for further SHM purposes. This paper reviews the main challenges arising from the use of FBGs in composite materials. The focus will be made on issues related to temperature-strain discrimination, demodulation of the amplitude spectrum during and after the curing process as well as connection between the embedded optical fibers and the surroundings. The main strategies developed in each of these three topics will be summarized and compared, demonstrating the large progress that has been made in this field in the past few years. PMID:24763215

Lightweight Mg-based composites with thermodynamically stable interfaces by in-situ combustion synthesis

NASA Astrophysics Data System (ADS)

Jo, Ilguk

Lightweight Mg-based composites have been produced by in-situ combustion synthesis of the Al-Ti-C reaction system. The characteristics of the in-situ composites were investigated in terms of phase evolution and interfacial stability using various analysis techniques. The structural analysis results showed that full conversion of the Al-Ti-C reactants into spherical TiC reinforcements with sizes around 1mum was achieved by the combustion reaction. In-situ formed TiC had less oxygen and higher Al contents at the interface than ex-situ formed TiC; these clean interfaces with an Al layer on the reinforcements were shown to yield interfacial stability. For these reasons, the in-situ composites exhibited higher theoretical densities and also good mechanical properties compared with ex-situ produced composites. The interfacial characteristics of molten Mg with the Al-Ti-C reactants and the commercial TiC+Al substrates were evaluated using an infiltration technique under an argon atmosphere. Infiltration length increased with time at temperature, yielding activation energies (Ea) for each system. The value of Ea for the Al-Ti-C system (307.31kJ/mol) is lower than that for the other system (350.84kJ/mol); the high Ea value indicates that the infiltration is not a simple viscosity-controlled phenomenon but involves a chemical reaction. Formation of the Al3Ti phase was observed from the crystal structural analysis of the infiltrated area; thus, existence of reaction promoting the wetting of Mg. The phase evolution, reaction mechanism and kinetics of the Al-Ti-C reaction were studied using DSC and HT-XRD. It was confirmed that, along with the melting of Al, there was formation of Al3Ti by reaction between Al and Ti. A detailed structural analysis indicates that, the reaction mechanism involves melting of Al followed by formation and growth of Al 3Ti, which then contacts the graphite powder and initiates the combustion reaction. The effect of important process parameters, such as the Al content and the reactant sizes, on the microstructure of the resulting in-situ composites is discussed. Feasibility and castability of the composites were investigated by high pressure die casting the composite preforms into automotive parts and durability tests were conducted on the cast parts.

Optimization of thermal conductivity lightweight brick type AAC (Autoclaved Aerated Concrete) effect of Si & Ca composition by using Artificial Neural Network (ANN)

NASA Astrophysics Data System (ADS)

Zulkifli; Wiryawan, G. P.

2018-03-01

Lightweight brick is the most important component of building construction, therefore it is necessary to have lightweight thermal, mechanical and aqustic thermal properties that meet the standard, in this paper which is discussed is the domain of light brick thermal conductivity properties. The advantage of lightweight brick has a low density (500-650 kg/m3), more economical, can reduce the load 30-40% compared to conventional brick (clay brick). In this research, Artificial Neural Network (ANN) is used to predict the thermal conductivity of lightweight brick type Autoclaved Aerated Concrete (AAC). Based on the training and evaluation that have been done on 10 model of ANN with number of hidden node 1 to 10, obtained that ANN with 3 hidden node have the best performance. It is known from the mean value of MSE (Mean Square Error) validation for three training times of 0.003269. This ANN was further used to predict the thermal conductivity of four light brick samples. The predicted results for each of the AAC1, AAC2, AAC3 and AAC4 light brick samples were 0.243 W/m.K, respectively; 0.29 W/m.K; 0.32 W/m.K; and 0.32 W/m.K. Furthermore, ANN is used to determine the effect of silicon composition (Si), Calcium (Ca), to light brick thermal conductivity. ANN simulation results show that the thermal conductivity increases with increasing Si composition. Si content is allowed maximum of 26.57%, while the Ca content in the range 20.32% - 30.35%.

Application of lightweight materials in structure concept design of large-scale solar energy unmanned aerial vehicle

NASA Astrophysics Data System (ADS)

Zhang, Wei; Lv, Shengli; Guan, XiQi

2017-09-01

Carbon fiber composites and film materials can be effectively used in light aircraft structures, especially for solar unmanned aerial vehicles. The use of light materials can reduce the weight of the aircraft, but also can effectively improve the aircraft's strength and stiffness. The structure of the large aspect ratio solar energy UAV was analyzed in detail, taking Solar-impulse solar aircraft as an example. The solar energy UAV has a wing aspect ratio greater than 20, and the detailed digital model of the wing structure including beam, ribs and skin was built, also the Finite Element Method was applied to analyze the static and dynamic performance of the structure. The upper skin of the wing is covered with silicon solar cells, while the lower skin is light and transparent film. The single beam truss form of carbon fiber lightweight material is used in the wing structure. The wing beam is a box beam with rectangular cross sections. The box beam connected the front parts and after parts of the ribs together. The fuselage of the aircraft was built by space truss structure. According to the static and dynamic analysis with Finite Element method, it was found that the aircraft has a small wingtip deflection relative to the wingspan in the level flight state. The first natural frequency of the wing structure is pretty low, which is closed to the gust load.

Mapping the coupled role of structure and materials in mechanics of platelet-matrix composites

NASA Astrophysics Data System (ADS)

Farzanian, Shafee; Shahsavari, Rouzbeh

2018-03-01

Despite significant progresses on understanding and mimicking the delicate nano/microstructure of biomaterials such as nacre, decoding the indistinguishable merger of materials and structures in controlling the tradeoff in mechanical properties has been long an engineering pursuit. Herein, we focus on an archetype platelet-matrix composite and perform ∼400 nonlinear finite element simulations to decode the complex interplay between various structural features and material characteristics in conferring the balance of mechanical properties. We study various combinatorial models expressed by four key dimensionless parameters, i.e. characteristic platelet length, matrix plasticity, platelet dissimilarity, and overlap offset, whose effects are all condensed in a new unifying parameter, defined as the multiplication of strength, toughness, and stiffness over composite volume. This parameter, which maximizes at a critical characteristic length, controls the transition from intrinsic toughening (matrix plasticity driven without crack growths) to extrinsic toughening phenomena involving progressive crack propagations. This finding, combined with various abstract volumetric and radar plots, will not only shed light on decoupling the complex role of structure and materials on mechanical performance and their trends, but provides important guidelines for designing lightweight staggered platelet-matrix composites while ensuring the best (balance) of their mechanical properties.

Open-Section Composite Structural Elements

NASA Technical Reports Server (NTRS)

Loftin, T. A.; Smith, C. A.; Raheb, S. J.; Nowitzky, A. M.

1991-01-01

Report describes investigation of manufacture and mechanical properties of graphite-fiber/aluminum-matrix open-section structural elements; e.g., channels and angle bars. Conducted with view toward using such elements to build lightweight, thermally stable truss structures in outer space. Other applications transport to, and assembly at, remote or otherwise uninviting locations. Advantages include shapes permitting high packing density during shipment, convenient paths for routing tubes, hoses, and cables; accessibility of both inner and outer surfaces for repair; and ease of attachment of additional hardware. Easier and require less equipment to fabricate, and more amenable to automated fabrication and assembly at remote site. Disadvantages, not as resistant to some kinds of deformation under load.

A novel biomimetic approach to the design of high-performance ceramic–metal composites

PubMed Central

Launey, Maximilien E.; Munch, Etienne; Alsem, Daan Hein; Saiz, Eduardo; Tomsia, Antoni P.; Ritchie, Robert O.

2010-01-01

The prospect of extending natural biological design to develop new synthetic ceramic–metal composite materials is examined. Using ice-templating of ceramic suspensions and subsequent metal infiltration, we demonstrate that the concept of ordered hierarchical design can be applied to create fine-scale laminated ceramic–metal (bulk) composites that are inexpensive, lightweight and display exceptional damage-tolerance properties. Specifically, Al2O3/Al–Si laminates with ceramic contents up to approximately 40 vol% and with lamellae thicknesses down to 10 µm were processed and characterized. These structures achieve an excellent fracture toughness of 40 MPa√m at a tensile strength of approximately 300 MPa. Salient toughening mechanisms are described together with further toughening strategies. PMID:19828498

Analysis and trade-off studies of large lightweight mirror structures. [large space telescope

NASA Technical Reports Server (NTRS)

Soosaar, K.; Grin, R.; Ayer, F.

1975-01-01

A candidate mirror, hexagonally lightweighted, is analyzed under various loadings using as complete a procedure as possible. Successive simplifications are introduced and compared to an original analysis. A model which is a reasonable compromise between accuracy and cost is found and is used for making trade-off studies of the various structural parameters of the lightweighted mirror.

An Overview of Materials Structures for Extreme Environments Efforts for 2015 SBIR Phases I and II

NASA Technical Reports Server (NTRS)

Nguyen, Hung D.; Steele, Gynelle C.

2017-01-01

Technological innovation is the overall focus of NASA's Small Business Innovation Research (SBIR) program. The program invests in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for Agency projects. This report highlights innovative SBIR 2015 Phase I and II projects that specifically address areas in Materials and Structures for Extreme Environments, one of six core competencies at NASA Glenn Research Center. Each article describes an innovation, defines its technical objective, and highlights NASA applications as well as commercial and industrial applications. Ten technologies are featured: metamaterials-inspired aerospace structures, metallic joining to advanced ceramic composites, multifunctional polyolefin matrix composite structures, integrated reacting fluid dynamics and predictive materials degradation models for propulsion system conditions, lightweight inflatable structural airlock (LISA), copolymer materials for fused deposition modeling 3-D printing of nonstandard plastics, Type II strained layer superlattice materials development for space-based focal plane array applications, hydrogenous polymer-regolith composites for radiation-shielding materials, a ceramic matrix composite environmental barrier coating durability model, and advanced composite truss printing for large solar array structures. This report serves as an opportunity for NASA engineers, researchers, program managers, and other personnel to learn about innovations in this technology area as well as possibilities for collaboration with innovative small businesses that could benefit NASA programs and projects.

Joining of polymer-metal lightweight structures using self-piercing riveting (SPR) technique: Numerical approach and simulation results

NASA Astrophysics Data System (ADS)

Amro, Elias; Kouadri-Henni, Afia

2018-05-01

Restrictions in pollutant emissions dictated at the European Commission level in the past few years have urged mass production car manufacturers to engage rapidly several strategies in order to reduce significantly the energy consumption of their vehicles. One of the most relevant taken action is light-weighting of body in white (BIW) structures, concretely visible with the increased introduction of polymer-based composite materials reinforced by carbon/glass fibers. However, the design and manufacturing of such "hybrid" structures is limiting the use of conventional assembly techniques like resistance spot welding (RSW) which are not transferable as they are for polymer-metal joining. This research aims at developing a joining technique that would eventually enable the assembly of a sheet molding compound (SMC) polyester thermoset-made component on a structure composed of several high strength steel grades. The state of the art of polymer-metal joining techniques highlighted the few ones potentially able to respond to the industrial challenge, which are: structural bonding, self-piercing riveting (SPR), direct laser joining and friction spot welding (FSpW). In this study, the promising SPR technique is investigated. Modelling of SPR process in the case of polymer-metal joining was performed through the building of a 2D axisymmetric FE model using the commercial code Abaqus CAE 6.10-1. Details of the numerical approach are presented with a particular attention to the composite sheet for which Mori-Tanaka's homogenization method is used in order to estimate overall mechanical properties. Large deformations induced by the riveting process are enabled with the use of a mixed finite element formulation ALE (arbitrary Lagrangian-Eulerian). FE model predictions are compared with experimental data followed by a discussion.

The development of composite materials for spacecraft precision reflector panels

NASA Technical Reports Server (NTRS)

Tompkins, Stephen S.; Bowles, David E.; Funk, Joan G.; Towell, Timothy W.; Lavoie, J. A.

1990-01-01

One of the critical technology needs for large precision reflectors required for future astrophysics and optical communications is in the area of structural materials. Therefore, a major area of the Precision Segmented Reflector Program at NASA is to develop lightweight composite reflector panels with durable, space environmentally stable materials which maintain both surface figure and required surface accuracy necessary for space telescope applications. Results from the materials research and development program at NASA Langley Research Center are discussed. Advanced materials that meet the reflector panel requirements are identified. Thermal, mechanical and durability properties of candidate materials after exposure to simulated space environments are compared to the baseline material.

Concepts for the development of light-weight composite structures for rotor burst containment

NASA Technical Reports Server (NTRS)

Holms, A. G.

1977-01-01

Published results on rotor burst containment with single materials, and on body armor using composite materials were used to establish a set of hypotheses about what variables might control the design of a weight-efficient protective device. Based on modern concepts for the design and analysis of small optimum seeking experiments, a particular experiment for evaluating the hypotheses and materials was designed. The design and methods for the analysis of results are described. The consequence of such hypotheses is that the device should consist of as many as four concentric rings, each to consist of a material uniquely chosen for its position in the penetration sequence.

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.

High-Capacity Communications from Martian Distances Part 2: Spacecraft Antennas and Power Systems

NASA Technical Reports Server (NTRS)

Hodges, Richard E.; Kodis, Mary Anne; Epp, Larry W.; Orr, Richard; Schuchman, Leonard; Collins, Michael; Sands, O. Scott; Vyas, Hemali; Williams, W. Dan

2006-01-01

This paper summarizes recent advances in antenna and power systems technology to enable a high data rate Ka-band Mars-to-Earth telecommunications system. Promising antenna technologies are lightweight, deployable space qualified structures at least 12-m in diameter (potentially up to 25-m). These technologies include deployable mesh reflectors, inflatable reflectarray and folded thermosetting composite. Advances in 1kW-class RF power amplifiers include both TWTA and SSPA technologies.

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

Nelson, Stacy; English, Shawn; Briggs, Timothy

Fiber-reinforced composite materials offer light-weight solutions to many structural challenges. In the development of high-performance composite structures, a thorough understanding is required of the composite materials themselves as well as methods for the analysis and failure prediction of the relevant composite structures. However, the mechanical properties required for the complete constitutive definition of a composite material can be difficult to determine through experimentation. Therefore, efficient methods are necessary that can be used to determine which properties are relevant to the analysis of a specific structure and to establish a structure's response to a material parameter that can only be definedmore » through estimation. The objectives of this paper deal with demonstrating the potential value of sensitivity and uncertainty quantification techniques during the failure analysis of loaded composite structures; and the proposed methods are applied to the simulation of the four-point flexural characterization of a carbon fiber composite material. Utilizing a recently implemented, phenomenological orthotropic material model that is capable of predicting progressive composite damage and failure, a sensitivity analysis is completed to establish which material parameters are truly relevant to a simulation's outcome. Then, a parameter study is completed to determine the effect of the relevant material properties' expected variations on the simulated four-point flexural behavior as well as to determine the value of an unknown material property. This process demonstrates the ability to formulate accurate predictions in the absence of a rigorous material characterization effort. Finally, the presented results indicate that a sensitivity analysis and parameter study can be used to streamline the material definition process as the described flexural characterization was used for model validation.« less

Relationship between critical mechanical properties and age for structural lightweight concrete.

DOT National Transportation Integrated Search

1964-02-25

The necessity to use structural lightweight concrete has created : a need for investigations into its critical mechanical properties that : affect the design and performance of structures. The primary critical : properties were found to be direct ten...

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.

Experimental investigation of fiberglass sandwich composite bending behaviour after severe aging condition

NASA Astrophysics Data System (ADS)

Gambaro, Carla; Lertora, Enrico; Mandolfino, Chiara

2016-10-01

Fiber Reinforced Polymer (FRP) sandwich panels are increasing their application as structural and non-structural components in all kinds of construction. By varying the material and thickness of core and face sheets, it is possible to obtain sandwich structures with different properties and performance. In particular, their advantages as lightweight and high mechanical properties make them extremely suitable for the transport industry. One of the most critical aspects regarding composite materials for engineering application is their performance after hygrothermal aging. The panels used in this study are composed of low density core, made by thermosetting resin foam with microspheres and glass fibers rolled until obtaining the required thickness, and two face sheets of the same material but realized in high density. In this study, the authors focused on the bending behaviour of this kind of sandwich panel, as received and after severe aging cycles.

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.

Behavior of Frame-Stiffened Composite Panels with Damage

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2013-01-01

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structures. In this concept, a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. Stitching and the use of thin skins with rod-stiffeners to move loading away from the morevulnerable outer surface produces a structurally efficient, damage tolerant design. This study focuses on the behavior of PRSEUS panels loaded in the frame direction and subjected to severe damage in the form of a severed central frame in a three-frame panel. Experimental results for a pristine two-frame panel and analytical predictions for pristine two-frame and three-frame panels as well as damaged three-frame panels are described.

NASA advanced design program: Analysis, design, and construction of a solar powered aircraft. B.S. Thesis

NASA Technical Reports Server (NTRS)

Chan, Agnes; Conley, Kristin; Javorski, Christian T.; Cheung, Kwok-Hung; Crivelli, Paul M.; Torrey, Nancy P.; Traver, Michael L.

1992-01-01

Increase in energy demands coupled with rapid depletion of natural energy resources have deemed solar energy as the most logical alternative source of power. The major objective of this project was to build a solar powered remotely controlled aircraft to demonstrate the feasibility of solar energy as an effective, alternate source of power. The final design was optimized for minimum weight and maximum strength of the structure. These design constraints necessitated a carbon fiber composite structure. Surya is a lightweight, durable aircraft capable of achieving level flight powered entirely by solar cells.

Development of Lightweight CubeSat with Multi-Functional Structural Battery Systems

NASA Technical Reports Server (NTRS)

Karkkainen, Ryan L.; Hunter, Roger C.; Baker, Christopher

2017-01-01

This collaborative multi-disciplinary effort aims to develop a lightweight, 1-unit (1U) CubeSat (10x10x10 cm) which utilizes improved and fully integrated structural battery materials for mission life extension, larger payload capability, and significantly reduced mass.The electrolytic carbon fiber material serves the multifunctional capacitive energy system as both a lightweight, load bearing structure and an electrochemical battery system. This implementation will improve traditional multifunctional energy storage concepts with a highly effective energy storage capability.

Acoustic Modeling of Lightweight Structures: A Literature Review

NASA Astrophysics Data System (ADS)

Yang, Shasha; Shen, Cheng

2017-10-01

This paper gives an overview of acoustic modeling for three kinds of typical lightweight structures including double-leaf plate system, stiffened single (or double) plate and porous material. Classical models are citied to provide frame work of theoretical modeling for acoustic property of lightweight structures; important research advances derived by our research group and other authors are introduced to describe the current state of art for acoustic research. Finally, remaining problems and future research directions are concluded and prospected briefly

Hybrid Composites for LH2 Fuel Tank Structure

NASA Technical Reports Server (NTRS)

Grimsley, Brian W.; Cano, Roberto J.; Johnston, Norman J.; Loos, Alfred C.; McMahon, William M.

2001-01-01

The application of lightweight carbon fiber reinforced plastics (CFRP) as structure for cryogenic fuel tanks is critical to the success of the next generation of Reusable Launch Vehicles (RLV). The recent failure of the X-33 composite fuel tank occurred in part due to microcracking of the polymer matrix, which allowed cryogen to permeate through the inner skin to the honeycomb core. As part of an approach to solve these problems, NASA Langley Research Center (LaRC) and Marshall Space Flight Center (MSFC) are working to develop and investigate polymer films that will act as a barrier to the permeation of LH2 through the composite laminate. In this study two commercially available films and eleven novel LaRC films were tested in an existing cryogenics laboratory at MSFC to determine the permeance of argon at room temperature. Several of these films were introduced as a layer in the composite to form an interleaved, or hybrid, composite to determine the effects on permeability. In addition, the effects of the interleaved layer thickness, number, and location on the mechanical properties of the composite laminate were investigated. In this initial screening process, several of the films were found to exhibit lower permeability to argon than the composite panels tested.

Designing optimized ultra-lightweighted mirror structures made of Cesic for space and ground based applications

NASA Astrophysics Data System (ADS)

Hofbauer, Peter; Krödel, Matthias R.

2010-07-01

Today's space applications increasingly utilize lightweighted construction concepts, motivated by the demands of manufacturing and functionality, and by economics. Particularly for space optics, mirror stability and stiffness need to be maximized, while mass needs to be minimized. Therefore, mirror materials must possess, besides high material strength and manufacturing versatility, high thermal conductivity combined with low heat capacity and long-term stability against varying thermal loads. Additionally, optical surfaces need to be compatible with reflective coating materials. In order to achieve these requirements, the interplay between material properties and mirror design on one hand, and budgetary constraints on the other must be considered. In this paper, we address these issues by presenting an FEM design study of open and closed-back mirror structures with extremely thin reinforcing ribs, with the goal of obtaining optimal physical and optical characteristics. Furthermore, we show that ECM's carbon-fiber reinforced SiC composite, Cesic®, and its newly developed, HB-Cesic® , with their low CTE, low density, and high stiffness, are not only excellent mirror materials, but allow the rapid manufacturing of complex monolithic optical structures at reasonable cost.

Lightweight thermally efficient composite feedlines, preliminary design and evaluation. [for the space tug propulsion system

NASA Technical Reports Server (NTRS)

Spond, D. E.; Holzworth, R. E.; Hall, C. A.

1974-01-01

Six liquid hydrogen feedline design concepts were developed for the cryogenic space tug. The feedlines include composite and all-metal vacuum jacketed and non-vacuum jacketed concepts, and incorporate the latest technology developments in the areas of thermally efficient vacuum jacket end closures and standoffs, radiation shields in the vacuum annulus, thermal coatings, and lightweight dissimilar metal flanged joints. The feedline design concepts were evaluated on the basis of thermal performance, weight, cost, reliability, and reusability. It is shown that composite tubing provides improved thermal performance and reduced weight for each design concept considered. Approximately 12 kg (26 lb.) can be saved by the use of composite tubing for the LH2 feedline and the other propulsion lines in the space tug.

Surface Modification of Carbon Fiber Polymer Composites after Laser Structuring

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Chen, Jian; Jones, Jonaaron F.; Hackett, Alexandra; Jellison, Gerald D.; Daniel, Claus; Warren, David; Rehkopf, Jackie D.

The increasing use of Carbon Fiber-reinforced Polymer matrix Composites (CFPC) as a lightweight material in automotive and aerospace industries requires the control of surface morphology. In this study, the composites surface was prepared by ablating the resin on the top fiber layer of the composite using an Nd:YAG laser. The CFPC specimens with T700S carbon fiber and Prepreg — T83 resin (epoxy) were supplied by Plasan Carbon Composites, Inc. as 4 ply thick, 0/90° plaques. The effect of laser fluence, scanning speed, and wavelength was investigated on the removal rate of the resin without an excessive damage of the fibers. In addition, resin ablation due to the power variation created by a laser interference technique is presented. Optical property measurements, optical micrographs, 3D imaging, and high-resolution optical profiler images were used to study the effect of the laser processing on surface morphology.

Finite element analysis of composite beam-to-column connection with cold-formed steel section

NASA Astrophysics Data System (ADS)

Firdaus, Muhammad; Saggaff, Anis; Tahir, Mahmood Md

2017-11-01

Cold-formed steel (CFS) sections are well known due to its lightweight and high structural performance which is very popular for building construction. Conventionally, they are used as purlins and side rails in the building envelopes of the industrial buildings. Recent research development on cold-formed steel has shown that the usage is expanded to the use in composite construction. This paper presents the modelling of the proposed composite connection of beam-to-column connection where cold-formed steel of lipped steel section is positioned back-to-back to perform as beam. Reinforcement bars is used to perform the composite action anchoring to the column and part of it is embedded into a slab. The results of the finite element and numerical analysis has showed good agreement. The results show that the proposed composite connection contributes to significant increase to the moment capacity.

Low Velocity Blunt Impact on Lightweight Composite Sandwich Panels

NASA Astrophysics Data System (ADS)

Chan, Monica Kar

There is an increased desire to incorporate more composite sandwich structures into modern aircrafts. Because in-service aircrafts routinely experience impact damage during maintenance due to ground vehicle collision, dropped equipment, or foreign object damage (FOD) impact, it is necessary to understand their impact characteristics, particularly when blunt impact sources create internal damage with little or no external visibility. The objective of this investigation is to explore damage formation in lightweight composite sandwich panels due to low-velocity impacts of variable tip radius and energy level. The correlation between barely visible external dent formation and internal core damage was explored as a function of impact tip radius. A pendulum impactor was used to impact composite sandwich panels having honeycomb core while held in a 165 mm square window fixture. The panels were impacted by hardened steel tips with radii of 12.7, 25.4, 50.8, and 76.2 mm at energy levels ranging from 2 to 14 J. Experimental data showed little dependence of external dent depth on tip radius at very low energies of 2 to 6 J, and thus, there was also little variation in visibility due to tip radius. Four modes of internal core damage were identified. Internal damage span and depth were dependent on impact tip radius. Damage depth was also radius-dependent, but stabilized at constant depth independent of kinetic energy. Internal damage span increased with increasing impact energy, but not with increasing tip radius, suggesting a relationship between maximum damage tip radius with core density/size.

Lightweight aggregate abrasion study.

DOT National Transportation Integrated Search

1963-02-01

The rapid increase in the use of lightweight aggregates in structural concrete has created a number of problems for the Materials Engineer in evaluating this type aggregate. Exhaustive studies are being made of a number of properties of lightweight a...

Optical Spectroscopy of New Materials

NASA Technical Reports Server (NTRS)

White, Susan M.; Arnold, James O. (Technical Monitor)

1993-01-01

Composites are currently used for a rapidly expanding number of applications including aircraft structures, rocket nozzles, thermal protection of spacecraft, high performance ablative surfaces, sports equipment including skis, tennis rackets and bicycles, lightweight automobile components, cutting tools, and optical-grade mirrors. Composites are formed from two or more insoluble materials to produce a material with superior properties to either component. Composites range from dispersion-hardened alloys to advanced fiber-reinforced composites. UV/VIS and FTIR spectroscopy currently is used to evaluate the bonding between the matrix and the fibers, monitor the curing process of a polymer, measure surface contamination, characterize the interphase material, monitor anion transport in polymer phases, characterize the void formation (voids must be minimized because, like cracks in a bulk material, they lead to failure), characterize the surface of the fiber component, and measure the overall optical properties for energy balances.

Integral Radiator and Storage Tank

NASA Technical Reports Server (NTRS)

Burke, Kenneth A.; Miller, John R.; Jakupca, Ian; Sargi,Scott

2007-01-01

A simplified, lightweight system for dissipating heat of a regenerative fuel- cell system would include a heat pipe with its evaporator end placed at the heat source and its condenser end integrated into the wall of the regenerative fuel cell system gas-storage tanks. The tank walls act as heat-radiating surfaces for cooling the regenerative fuel cell system. The system was conceived for use in outer space, where radiation is the only physical mechanism available for transferring heat to the environment. The system could also be adapted for use on propellant tanks or other large-surface-area structures to convert them to space heat-radiating structures. Typically for a regenerative fuel cell system, the radiator is separate from the gas-storage tanks. By using each tank s surface as a heat-radiating surface, the need for a separate, potentially massive radiator structure is eliminated. In addition to the mass savings, overall volume is reduced because a more compact packaging scheme is possible. The underlying tank wall structure provides ample support for heat pipes that help to distribute the heat over the entire tank surface. The heat pipes are attached to the outer surface of each gas-storage tank by use of a high-thermal conductance, carbon-fiber composite-material wrap. Through proper choice of the composite layup, it is possible to exploit the high longitudinal conductivity of the carbon fibers (greater than the thermal conductivity of copper) to minimize the unevenness of the temperature distribution over the tank surface, thereby helping to maximize the overall heat-transfer efficiency. In a prototype of the system, the heat pipe and the composite wrap contribute an average mass of 340 g/sq m of radiator area. Lightweight space radiator panels have a mass of about 3,000 g/sq m of radiator area, so this technique saves almost 90 percent of the mass of separate radiator panels. In tests, the modified surface of the tank was found to have an emissivity of 0.85. The composite wrap remained tightly bound to the surface of the tank throughout the testing in thermal vacuum conditions.

Volume changes in unrestrained structural lightweight concrete.

DOT National Transportation Integrated Search

1964-08-01

In this study a comparator-type measuring system was developed to accurately determine volume change characteristics of one structural lightweight concrete. The specific properties studied were the coefficient of linear thermal expansion and unrestra...

Composite laminate failure parameter optimization through four-point flexure experimentation and analysis

DOE PAGES

Nelson, Stacy; English, Shawn; Briggs, Timothy

2016-05-06

Fiber-reinforced composite materials offer light-weight solutions to many structural challenges. In the development of high-performance composite structures, a thorough understanding is required of the composite materials themselves as well as methods for the analysis and failure prediction of the relevant composite structures. However, the mechanical properties required for the complete constitutive definition of a composite material can be difficult to determine through experimentation. Therefore, efficient methods are necessary that can be used to determine which properties are relevant to the analysis of a specific structure and to establish a structure's response to a material parameter that can only be definedmore » through estimation. The objectives of this paper deal with demonstrating the potential value of sensitivity and uncertainty quantification techniques during the failure analysis of loaded composite structures; and the proposed methods are applied to the simulation of the four-point flexural characterization of a carbon fiber composite material. Utilizing a recently implemented, phenomenological orthotropic material model that is capable of predicting progressive composite damage and failure, a sensitivity analysis is completed to establish which material parameters are truly relevant to a simulation's outcome. Then, a parameter study is completed to determine the effect of the relevant material properties' expected variations on the simulated four-point flexural behavior as well as to determine the value of an unknown material property. This process demonstrates the ability to formulate accurate predictions in the absence of a rigorous material characterization effort. Finally, the presented results indicate that a sensitivity analysis and parameter study can be used to streamline the material definition process as the described flexural characterization was used for model validation.« less

Freestanding three-dimensional graphene/MnO2 composite networks as ultralight and flexible supercapacitor electrodes.

PubMed

He, Yongmin; Chen, Wanjun; Li, Xiaodong; Zhang, Zhenxing; Fu, Jiecai; Zhao, Changhui; Xie, Erqing

2013-01-22

A lightweight, flexible, and highly efficient energy management strategy is needed for flexible energy-storage devices to meet a rapidly growing demand. Graphene-based flexible supercapacitors are one of the most promising candidates because of their intriguing features. In this report, we describe the use of freestanding, lightweight (0.75 mg/cm(2)), ultrathin (<200 μm), highly conductive (55 S/cm), and flexible three-dimensional (3D) graphene networks, loaded with MnO(2) by electrodeposition, as the electrodes of a flexible supercapacitor. It was found that the 3D graphene networks showed an ideal supporter for active materials and permitted a large MnO(2) mass loading of 9.8 mg/cm(2) (~92.9% of the mass of the entire electrode), leading to a high area capacitance of 1.42 F/cm(2) at a scan rate of 2 mV/s. With a view to practical applications, we have further optimized the MnO(2) content with respect to the entire electrode and achieved a maximum specific capacitance of 130 F/g. In addition, we have also explored the excellent electrochemical performance of a symmetrical supercapacitor (of weight less than 10 mg and thickness ~0.8 mm) consisting of a sandwich structure of two pieces of 3D graphene/MnO(2) composite network separated by a membrane and encapsulated in polyethylene terephthalate (PET) membranes. This research might provide a method for flexible, lightweight, high-performance, low-cost, and environmentally friendly materials used in energy conversion and storage systems for the effective use of renewable energy.

Physio-Microstructural Properties of Aerated Cement Slurry for Lightweight Structures

PubMed Central

Salem, Talal; Hamadna, Sameer; Darsanasiri, A. G. N. D.; Soroushian, Parviz; Balchandra, Anagi; Al-Chaar, Ghassan

2018-01-01

Cementitious composites, including ferrocement and continuous fiber reinforced cement, are increasingly considered for building construction and repair. One alternative in processing of these composites is to infiltrate the reinforcement (continuous fibers or chicken mesh) with a flowable cementitious slurry. The relatively high density of cementitious binders, when compared with polymeric binders, are a setback in efforts to introduce cementitious composites as lower-cost, fire-resistant, and durable alternatives to polymer composites. Aeration of the slurry is an effective means of reducing the density of cementitious composites. This approach, however, compromises the mechanical properties of cementitious binders. An experimental program was undertaken in order to assess the potential for production of aerated slurry with a desired balance of density, mechanical performance, and barrier qualities. The potential for nondestructive monitoring of strength development in aerated cementitious slurry was also investigated. This research produced aerated slurries with densities as low as 0.9 g/cm3 with viable mechanical and barrier qualities for production of composites. The microstructure of these composites was also investigated. PMID:29649163

Physio-Microstructural Properties of Aerated Cement Slurry for Lightweight Structures.

PubMed

Almalkawi, Areej T; Salem, Talal; Hamadna, Sameer; Darsanasiri, A G N D; Soroushian, Parviz; Balchandra, Anagi; Al-Chaar, Ghassan

2018-04-12

Cementitious composites, including ferrocement and continuous fiber reinforced cement, are increasingly considered for building construction and repair. One alternative in processing of these composites is to infiltrate the reinforcement (continuous fibers or chicken mesh) with a flowable cementitious slurry. The relatively high density of cementitious binders, when compared with polymeric binders, are a setback in efforts to introduce cementitious composites as lower-cost, fire-resistant, and durable alternatives to polymer composites. Aeration of the slurry is an effective means of reducing the density of cementitious composites. This approach, however, compromises the mechanical properties of cementitious binders. An experimental program was undertaken in order to assess the potential for production of aerated slurry with a desired balance of density, mechanical performance, and barrier qualities. The potential for nondestructive monitoring of strength development in aerated cementitious slurry was also investigated. This research produced aerated slurries with densities as low as 0.9 g/cm³ with viable mechanical and barrier qualities for production of composites. The microstructure of these composites was also investigated.

Pathfinder aircraft in flight

NASA Image and Video Library

1995-07-27

The Pathfinder research aircraft's wing structure was clearly defined as it soared under a clear blue sky during a test flight July 27, 1995, from Dryden Flight Research Center, Edwards, California. The center section and outer wing panels of the aircraft had ribs constructed of thin plastic foam, while the ribs in the inner wing panels are fabricated from lightweight composite material. Developed by AeroVironment, Inc., the Pathfinder was one of several unmanned aircraft being evaluated under NASA's Environmental Research Aircraft and Sensor Technology (ERAST) program.

Wood-Based Nanocomposite Derived by in Situ Formation of Organic-Inorganic Hybrid Polymer within Wood via a Sol-Gel Method.

PubMed

Dong, Xiaoying; Zhuo, Xiao; Wei, Jie; Zhang, Gang; Li, Yongfeng

2017-03-15

Solid wood materials and wood-plastic composites as two kinds of lightweight materials are attracting great interest from academia and industry due to their green and recycling nature. However, the relatively lower specific strength limits their wider applications. In particular, solid wood is vulnerable to moisture and decay fungi in nature, resulting in its poor durability for effectively long-term utilization. Inspired from the porous structure of wood, we propose a new design to build a wood-based nanocomposite with higher specific strength and satisfactory durability by in situ generation of organic-inorganic hybrid polymer within wood via a sol-gel method. The derived composite has 50-1200% improvement of impact toughness, 56-192% improvement of tensile strength, and 110-291% improvement of flexural strength over those of typical wood-plastic composites, respectively; and even 34% improvement of specific tensile strength than that of 36A steel; 208% enhancement of hardness; and 156% enhancement of compression strength than those of compared solid wood, respectively; as well as significantly improved dimensional stability and decay resistance over those of untreated natural wood. Such materials could be potentially utilized as lightweight and high-strength materials for applications in construction and automotive industries. This method could be extended to constitute other inorganic nanomaterials for novel organic-inorganic hybrid polymer within wood.

A novel biomimetic approach to the design of high-performance ceramic/metal composites

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

Launey, Maximilien E.; Munch, Etienne; Alsem, Daan Hein

2009-08-01

The prospect of extending natural biological design to develop new synthetic ceramic-metal composite materials is examined. Using ice-templating of ceramic suspensions and subsequent metal infiltration, we demonstrate that the concept of ordered hierarchical design can be applied to create fine-scale laminated ceramic-metal (bulk) composites that are inexpensive, lightweight and display exceptional damage-tolerance properties. Specifically, Al{sub 2}O{sub 3}/Al-Si laminates with ceramic contents up to approximately 40 vol% and with lamellae thicknesses down to 10 {micro}m were processed and characterized. These structures achieve an excellent fracture toughness of 40 MPa{radical}m at a tensile strength of approximately 300 MPa. Salient toughening mechanisms aremore » described together with further toughening strategies.« less

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Starke, Edgar A., Jr.; Kelly, Robert G.; Scully, John R.; Shiflet, Gary J.; Stoner, Glenn E.; Wert, John A.

1997-01-01

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. Here, we report on progress achieved between July I and December 31, 1996. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies. The accomplishments presented in this report are summarized as follows. Three research areas are being actively investigated, including: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals, (2) Aerospace Materials Science, and (3) Mechanics of Materials for Light Aerospace Structures.

Nondestructive inspection of aerospace composites by a fiber-coupled laser ultrasonics system

NASA Astrophysics Data System (ADS)

Vandenrijt, J.-F.; Languy, F.; Thizy, C.; Georges, M. P.

2017-06-01

Laser ultrasonics is a technique currently studied for nondestructive inspection of aerospace composite structures based on carbon fibers. It combines a pulsed laser impacting the surface generates an ultrasound inside the material, through the nondestructive thermoelastic effect. Second a detection interferometer probes the impacted point in order to measure the displacement of the surface resulting from the emitted ultrasound wave and the echo coming back from the different interfaces of the structure. Laser ultrasonics is of interest for inspecting complex shaped composites. We have studied the possibility of using frequency doubled YAG laser for the generation and which is fiber-coupled, together with a fibercoupled interferometric probe using a YAG laser in the NIR. Our final system is a lightweight probe attached to a robot arm and which is able to scan complex shapes. The performances of the system are compared for different wavelengths of generations. Also we have studied some experimental parameters of interest such as tolerance to angle and focus distance, and different geometries of generation beams. We show some examples of inspection of reference parts with known defects. In particular C-scans of curved composites structures are presented.

Real-time nondestructive evaluation of fiber composite laminates using low-frequency Lamb waves

NASA Astrophysics Data System (ADS)

díAz Valdés, Sergio H.; Soutis, Costas

2002-05-01

Amid the nondestructive evaluation techniques available for the inspection of composite materials, only a few are suitable for implementation while the component is in service. The investigation examines the application of Lamb waves at low-frequency-thickness products for the detection of delaminations in thick composite laminates. Surface-mounted piezoelectric devices were excited with a tone burst to generate elastic waves in the structure. Experiments were carried out on composite beam specimens where wave propagation distances over 2 m were achieved and artificially induced delaminations as small as 1 cm2 were successfully identified. The feasibility of employing piezoelectric devices for the development of smart structures, where a small and lightweight transducer system design is required, has been demonstrated. The resonance spectrum method, which is based on the study of spectra obtained by forced mechanical resonance of samples using sine-sweep excitation, has been proposed as a technique for measuring the Ao Lamb mode phase velocity. The finite-element method was also used to investigate qualitatively the dynamic response of laminates to wave propagation. Several locations and spatial distribution of the actuators were examined showing the advantages of using transducers arrays for the inspection of large structures.

Design and Development of Lightweight Composite Tanks for the Mars Ascent Propulsion Technology

NASA Technical Reports Server (NTRS)

Estrada, Hector

1999-01-01

The investigation presented here focuses on the design and development of lightweight composite tanks for the Mars ascent propulsion technology. The proposed tanks are fabricated using the filament winding technique. The tanks will be used in the experimental permeability characterization of composite pressure vessels pressurized using cryogenic and kerosene fluids. We considered the geometry and composite material tailorability in the preliminary design formulation to obtain an isotensoid tank. The design formulation is based on membrane shell analysis. The tanks also include circular openings at the apex of the end caps for the installation of polar bosses. The development of a polar boss system was also investigated, and led to an innovative polar boss system that applies a uniform pressure on the o-ring gaskets. The permeability of these tanks was also considered and recommendations for improvement are presented.

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

NASA Technical Reports Server (NTRS)

Kim, Jae-Woo; Sauti, Godfrey; Cano, Roberto J.; Wincheski, Russell A.; Ratcliffe, James G.; Czabaj, Michael; Siochi, Emilie J.

2015-01-01

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

Lightweight thermally efficient composite feedlines for the space tug cryogenic propulsion system

NASA Technical Reports Server (NTRS)

Spond, D. E.

1975-01-01

Six liquid hydrogen feedline design concepts were developed for the cryogenic space tug. The feedlines include composite and all-metal vacuum jacketed and nonvacuum jacketed concepts, and incorporate the latest technological developments in the areas of thermally efficient vacuum jacket end closures and standoffs, radiation shields in the vacuum annulus, thermal coatings, and lightweight dissimilar metal flanged joints. The feedline design concepts are evaluated on the basis of thermal performance, weight, cost, reliability, and reusability. Design concepts were proved in a subscale test program. Detail design was completed on the most promising composite feedline concept and an all-metal feedline. Three full scale curved composite feedlines and one all-metal feedline assembly were fabricated and subjected to a test program representative of flight hardware qualification. The test results show that composite feedline technology is fully developed. Composite feedlines are ready for space vehicle application and offer significant reduction in weights over the conventional all-metal feedlines presently used.

CRITICAL MECHANICAL PROPERTIES OF STRUCTURAL LIGHT-WEIGHT CONCRETE AND THE EFFECTS OF THESE PROPERTIES ON THE DESIGN OF THE PAVEMENT STRUCTURE.

DOT National Transportation Integrated Search

1965-01-01

In this study, critical mechanical properties of structural lightweight concrete were determined and utilized in the evaluation of a design of concrete pavements. Also presented are the critical mechanical properties resulting from unrestrained and r...

Multi-material composites prepared by additive manufacturing and melt casting

NASA Astrophysics Data System (ADS)

Murialdo, Maxwell; Sullivan, Kyle; White, Bradley; LLNL MSD Collaboration

2017-06-01

Recent advances in additive manufacturing have disrupted not only means of production, but also have enabled a new parameter space of multiscale materials designs. Understanding the role of architecture to control material response is being investigated for a wide range of applications, from light-weight structural components to energetic materials. In this work, we combine 3D printing of scaffold structures with a subsequent melt-infiltration step to render an architected multi-material composite article. Both the scaffold architecture and material type were investigated. The processing challenges of filling such scaffolds using a melt-infiltration step will be discussed, along with our progress in this area. Using the combined method of printing and casting, we will discuss our path forward for testing the mechanical properties and the high-strain response of our composite architected parts. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. IM release: LLNL-ABS-725497-DRAFT.

High Temperature Aerogels for Thermal Protection Systems

NASA Technical Reports Server (NTRS)

Hurwitz, Frances I.; Mbah, Godfrey C.

2008-01-01

High temperature aerogels in the Al2O3-SiO2 system are being investigated as possible constituents for lightweight integrated thermal protection system (TPS) designs for use in supersonic and hypersonic applications. Gels are synthesized from ethoxysilanes and AlCl3.6H2O, using an epoxide catalyst. The influence of Al:Si ratio, solvent, water to metal and water to alcohol ratios on aerogel composition, morphology, surface area, and pore size distribution were examined, and phase transformation on heat treatment characterized. Aerogels have been fabricated which maintain porous, fractal structures after brief exposures to 1000 C. Incorporation of nanofibers, infiltration of aerogels into SiC foams, use of polymers for crosslinking the aerogels, or combinations of these, offer potential for toughening and integration of TPS with composite structure. Woven fabric composites having Al2O3-SiO2 aerogels as a matrix also have been fabricated. Continuing work is focused on reduction in shrinkage and optimization of thermal and physical properties.

Thermal optimum design for tracking primary mirror of Space Telescope

NASA Astrophysics Data System (ADS)

Pan, Hai-jun; Ruan, Ping; Li, Fu; Wang, Hong-Wei

2011-08-01

In the conventional method, the structural parameters of primary mirror are usually optimized just by the requirement of mechanical performance. Because the influences of structural parameters on thermal stability are not taken fully into account in this simple method, the lightweight optimum design of primary mirror usually brings the bad thermal stability, especially in the complex environment. In order to obtain better thermal stability, a new method about structure-thermal optimum design of tracking primary mirror is discussed. During the optimum process, both the lightweight ratio and thermal stability will be taken into account. The structure-thermal optimum is introduced into the analysis process and commenced after lightweight design as the secondary optimum. Using the engineering analysis of software ANSYS, a parameter finite element analysis (FEA) model of mirror is built. On the premise of appropriate lightweight ratio, the RMS of structure-thermal deformation of mirror surface and lightweight ratio are assigned to be state variables, and the maximal RMS of temperature gradient load to be object variable. The results show that certain structural parameters of tracking primary mirror have different influences on mechanical performance and thermal stability, even they are opposite. By structure-thermal optimizing, the optimized mirror model discussed in this paper has better thermal stability than the old one under the same thermal loads, which can drastically reduce difficulty in thermal control.

The UltraLightweight Technology for Research in Astronomy (ULTRA) Project

NASA Astrophysics Data System (ADS)

Twarog, B. A.; Anthony-Twarog, B. J.; Shawl, S. J.; Hale, R.; Taghavi, R.; Fesen, R.; Etzel, P. B.; Martin, R.; Romeo, R.

2004-12-01

The collaborative focus of four academic departments (Univ. of Kansas Aerospace Engineering, Univ. of Kansas Physics & Astronomy, San Diego State University Astronomy and Dartmouth College Astronomy) and a private industry partner (Composite Mirror Applications, Inc.-CMA, Inc.) is a three-year plan to develop and test UltraLightweight Technology for Research in Astronomy (ULTRA). The ULTRA technology, using graphite fiber composites to fabricate mirrors and telescope structures, offers a versatile and cost-effective tool for optical astronomy, including the economical fabrication and operation of telescopes ranging from small (1m or smaller) aperture for education and research to extremely large (30m+) segmented telescopes (ELTs). The specific goal of this NSF-funded three-year Major Research Instrumentation project is to design, build, and test a 1m-class optical tube assembly (OTA) and mirrors constructed entirely from composites. In the first year of the project, the team has built and is field-testing two 0.4m prototypes to validate the optical surfaces and figures of the mirrors and to test and refine the structural dynamics of the OTA. Preparation for design and construction of the 1m telescope is underway. When completed in late 2005, the ULTRA telescope will be operated remotely from Mt. Laguna Observatory east of San Diego, where it will undergo a period of intensive optical and imaging tests. A 0.4m prototype OTA with mirrors (12 kg total weight) will be on display at the meeting. Support of this work by NSF through grants AST-0320784 and AST-0321247, NASA grant NCC5-600, the University of Kansas, and San Diego State University is gratefully acknowledged.

Modeling, simulation and optimization approaches for design of lightweight car body structures

NASA Astrophysics Data System (ADS)

Kiani, Morteza

Simulation-based design optimization and finite element method are used in this research to investigate weight reduction of car body structures made of metallic and composite materials under different design criteria. Besides crashworthiness in full frontal, offset frontal, and side impact scenarios, vibration frequencies, static stiffness, and joint rigidity are also considered. Energy absorption at the component level is used to study the effectiveness of carbon fiber reinforced polymer (CFRP) composite material with consideration of different failure criteria. A global-local design strategy is introduced and applied to multi-objective optimization of car body structures with CFRP components. Multiple example problems involving the analysis of full-vehicle crash and body-in-white models are used to examine the effect of material substitution and the choice of design criteria on weight reduction. The results of this study show that car body structures that are optimized for crashworthiness alone may not meet the vibration criterion. Moreover, optimized car body structures with CFRP components can be lighter with superior crashworthiness than the baseline and optimized metallic structures.

Application of fiber-reinforced bismaleimide materials to aircraft nacelle structures

NASA Technical Reports Server (NTRS)

Peros, Vasilios; Ruth, John; Trawinski, David

1992-01-01

Existing aircraft engine nacelle structures employ advanced composite materials to reduce weight and thereby increase overall performance. Use of advanced composite materials on existing aircraft nacelle structures includes fiber-reinforced epoxy structures and has typically been limited to regions furthest away from the hot engine core. Portions of the nacelle structure that are closer to the engine require materials with a higher temperature capability. In these portions, existing nacelle structures employ aluminum sandwich construction and skin/stringer construction. The aluminum structure is composed of many detail parts and assemblies and is usually protected by some form of ablative, insulator, or metallic thermal shield. A one-piece composite inner cowl for a new-generation engine nacelle structure has been designed using fiber-reinforced bismaleimide (BMI) materials and honeycomb core in a sandwich construction. The new composite design has many advantages over the existing aluminum structure. Multiple details were integrated into the one-piece composite design, thereby significantly reducing the number of detail parts and fasteners. The use of lightweight materials and the reduction of the number of joints result in a significant weight reduction over the aluminum design; manufacturing labor and the overall number of tools required have also been reduced. Several significant technical issues were addressed in the development of a BMI composite design. Technical evaluation of the available BMI systems led to the selection of a toughened BMI material which was resistant to microcracking under thermal cyclic loading and enhanced the damage tolerance of the structure. Technical evaluation of the degradation of BMI materials in contact with aluminum and other metals validated methods for isolation of the various materials. Graphite-reinforced BMI in contact with aluminum and some steels was found to degrade in salt spray testing. Isolation techniques such as those used for graphite-reinforced epoxy structures were shown to provide adequate protection. The springback and producibility of large BMI structures were evaluated by manufacturing prototype hardware which had the full-scale cross section of the one-piece composite structure.

Stainless-Steel-Foam Structures Evaluated for Fan and Rotor Blades

NASA Technical Reports Server (NTRS)

Lerch, Bradley A.; Raj, Sai V.; Ghosn, Louis J.; Hebsur, Mohan G.; Cosgriff, Laura M.; Min, James B.; Holland, Frederic A., Jr.

2005-01-01

The goal of this project is to use a sandwich structure design, consisting of two stainlesssteel face sheets and a stainless-steel-foam core, to fabricate engine fan and propeller blades. Current fan blades are constructed either of polymer matrix composites (PMCs) or hollow titanium alloys. The PMC blades are expensive and have poor impact resistance on their leading edges, thereby requiring a metallic leading edge to satisfy the Federal Aviation Administration s impact requirements relating to bird strikes. Hollow titanium blades cost more to fabricate because of the intrinsically difficult fabrication issues associated with titanium alloys. However, both these current concepts produce acceptable lightweight fan blades.

A methodology for choosing candidate materials for the fabrication of planetary space suit structures

NASA Technical Reports Server (NTRS)

Jacobs, Gilda

1990-01-01

A study of space suit structures and materials is under way at NASA Ames Research Center, Moffett Field, CA. The study was initiated by the need for a generation of lightweight space suits to be used in future planetary Exploration Missions. This paper provides a brief description of the Lunar and Mars environments and reviews what has been done in the past in the design and development of fabric, metal, and composite suit components in order to establish criteria for comparison of promising candidate materials and space suit structures. Environmental factors and mission scenarios will present challenging material and structural requirements; thus, a program is planned to outline the methodology used to identify materials and processes for producing candidate space suit structures which meet those requirements.

Deployable Soft Composite Structures.

PubMed

Wang, Wei; Rodrigue, Hugo; Ahn, Sung-Hoon

2016-02-19

Deployable structure composed of smart materials based actuators can reconcile its inherently conflicting requirements of low mass, good shape adaptability, and high load-bearing capability. This work describes the fabrication of deployable structures using smart soft composite actuators combining a soft matrix with variable stiffness properties and hinge-like movement through a rigid skeleton. The hinge actuator has the advantage of being simple to fabricate, inexpensive, lightweight and simple to actuate. This basic actuator can then be used to form modules capable of different types of deformations, which can then be assembled into deployable structures. The design of deployable structures is based on three principles: design of basic hinge actuators, assembly of modules and assembly of modules into large-scale deployable structures. Various deployable structures such as a segmented triangular mast, a planar structure comprised of single-loop hexagonal modules and a ring structure comprised of single-loop quadrilateral modules were designed and fabricated to verify this approach. Finally, a prototype for a deployable mirror was developed by attaching a foldable reflective membrane to the designed ring structure and its functionality was tested by using it to reflect sunlight onto to a small-scale solar panel.

Deployable Soft Composite Structures

PubMed Central

Wang, Wei; Rodrigue, Hugo; Ahn, Sung-Hoon

2016-01-01

Deployable structure composed of smart materials based actuators can reconcile its inherently conflicting requirements of low mass, good shape adaptability, and high load-bearing capability. This work describes the fabrication of deployable structures using smart soft composite actuators combining a soft matrix with variable stiffness properties and hinge-like movement through a rigid skeleton. The hinge actuator has the advantage of being simple to fabricate, inexpensive, lightweight and simple to actuate. This basic actuator can then be used to form modules capable of different types of deformations, which can then be assembled into deployable structures. The design of deployable structures is based on three principles: design of basic hinge actuators, assembly of modules and assembly of modules into large-scale deployable structures. Various deployable structures such as a segmented triangular mast, a planar structure comprised of single-loop hexagonal modules and a ring structure comprised of single-loop quadrilateral modules were designed and fabricated to verify this approach. Finally, a prototype for a deployable mirror was developed by attaching a foldable reflective membrane to the designed ring structure and its functionality was tested by using it to reflect sunlight onto to a small-scale solar panel. PMID:26892762

Lightweight rovers for Mars science exploration and sample return

NASA Astrophysics Data System (ADS)

Schenker, Paul S.; Sword, Lee F.; Ganino, A. J.; Bickler, Donald B.; Hickey, G. S.; Brown, D. K.; Baumgartner, Eric T.; Matthies, Larry H.; Wilcox, Brian H.; Balch, T.; Aghazarian, H.; Garrett, M. S.

1997-09-01

We report on the development of new mobile robots for Mars exploration missions. These 'lightweight survivable rover (LSR)' systems are of potential interest to both space and terrestrial applications, and are distinguished from more conventional designs by their use of new composite materials, collapsible running gear, integrated thermal-structural chassis, and other mechanical features enabling improved mobility and environmental robustness at reduced mass, volume, and power. Our first demonstrated such rover architecture, LSR-1, introduces running gear based on 2D composite struts and 3D machined composite joints, a novel collapsible hybrid composite-aluminum wheel design, a unit-body structural- thermal chassis with improved internal temperature isolation and stabilization, and a spot-pushbroom laser/CCD sensor enabling accurate, fast hazard detection and terrain mapping. LSR-1 is an approximately .7 $MIL 1.0 meter(Lambda) 2(W X L) footprint six-wheel (20 cm dia.) rocker-bogie geometry vehicle of approximately 30 cm ground clearance, weighing only 7 kilograms with an onboard .3 kilogram multi-spectral imager and spectroscopic photometer. By comparison, NASA/JPL's recently flown Mars Pathfinder rover Sojourner is an 11+ kilogram flight experiment (carrying a 1 kg APXS instrument) having approximately .45 X .6 meter(Lambda) 2(WXL) footprint and 15 cm ground clearance, and about half the warm electronics enclosure (WEE) volume with twice the diurnal temperature swing (-40 to +40 degrees Celsius) of LSR- 1 in nominal Mars environments. We are also developing a new, smaller 5 kilogram class LSR-type vehicle for Mars sample return -- the travel to, localization of, pick-up, and transport back to an Earth return ascent vehicle of a sample cache collected by earlier science missions. This sample retrieval rover R&D prototype has a completely collapsible mobility system enabling rover stowage to approximately 25% operational volume, as well an actively articulated axle, allowing changeable pose of the wheel strut geometry for improved transverse and manipulation characteristics.

Sandwich-structured C/C-SiC composites fabricated by electromagnetic-coupling chemical vapor infiltration.

PubMed

Hu, Chenglong; Hong, Wenhu; Xu, Xiaojing; Tang, Sufang; Du, Shanyi; Cheng, Hui-Ming

2017-10-13

Carbon fiber (CF) reinforced carbon-silicon carbide (C/C-SiC) composites are one of the most promising lightweight materials for re-entry thermal protection, rocket nozzles and brake discs applications. In this paper, a novel sandwich-structured C/C-SiC composite, containing two exterior C/SiC layers, two gradient C/C-SiC layers and a C/C core, has been designed and fabricated by two-step electromagnetic-coupling chemical vapor infiltration (E-CVI) for a 20-hour deposition time. The cross-section morphologies, interface microstructures and SiC-matrix growth characteristics and compositions of the composites were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD), respectively. Microstructure characterization indicates that the SiC growth includes an initial amorphous SiC zone, a gradual crystallization of SiC and grow-up of nano-crystal, and a columnar grain region. The sandwich structure, rapid deposition rate and growth characteristics are attributed to the formation of thermal gradient and the establishment of electromagnetic field in the E-CVI process. The composite possesses low density of 1.84 g/cm 3 , high flexural strength of 325 MPa, and low linear ablation rate of 0.38 μm/s under exposure to 5-cycle oxyacetylene flame for 1000 s at ~1700 °C.

Processing and Material Characterization of Continuous Basalt Fiber Reinforced Ceramic Matrix Composites Using Polymer Derived Ceramics.

NASA Technical Reports Server (NTRS)

Cox, Sarah B.

2014-01-01

The need for high performance vehicles in the aerospace industry requires materials which can withstand high loads and high temperatures. New developments in launch pads and infrastructure must also be made to handle this intense environment with lightweight, reusable, structural materials. By using more functional materials, better performance can be seen in the launch environment, and launch vehicle designs which have not been previously used can be considered. The development of high temperature structural composite materials has been very limited due to the high cost of the materials and the processing needed. Polymer matrix composites can be used for temperatures up to 260C. Ceramics can take much higher temperatures, but they are difficult to produce and form in bulk volumes. Polymer Derived Ceramics (PDCs) begin as a polymer matrix, allowing a shape to be formed and cured and then to be pyrolized in order to obtain a ceramic with the associated thermal and mechanical properties. The use of basalt in structural and high temperature applications has been under development for over 50 years, yet there has been little published research on the incorporation of basalt fibers as a reinforcement in the composites. In this study, continuous basalt fiber reinforced PDCs have been fabricated and tested for the applicability of this composite system as a high temperature structural composite material. The oxyacetylene torch testing and three point bend testing have been performed on test panels and the test results are presented.

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

Fischer, F.J.

As the petroleum industry has moved into deeper and deeper water for the recovery of oil and gas, weight-sensitive floating platforms have replaced stationary, bottom-founded structures. The cost penalty for weight or vertical tension supported by floaters such as tension leg platforms (TLPs) is in the range of $10--20/kg. Hence, there is considerable incentive to reduce the weight of equipment or structural members on these platforms and downward forces exerted on these platforms by production and export risers, and mooring lines. Thus, there are numerous opportunities for utilizing light-weight, high-strength composites. The offshore petroleum industry has acknowledged the desirable performancemore » characteristics of composites for some time but only recently has there been some optimism that composites could be cost-effective. For most, if not all perceived applications, advanced composites are not considered to be technically enabling for current water depths of interest, i.e., 600--1,200m. However, in a very real sense, they may be economically enabling. In particular, they may allow marginal prospects to be developed or may expedite field development subject to capital constraints. The paper discusses composite production risers, break-even costs and savings, and riser tensioners.« less

A review on utilization of textile composites in transportation towards sustainability

NASA Astrophysics Data System (ADS)

Aly, Nermin M.

2017-10-01

Transportation industry is rapidly developing owing to its size and importance which affects on various aspects of life. It includes all the transport means that facilitate mobility of people or goods either by air, land or sea like aircrafts, automotives, ships, trains, etc. The utilization of textiles in this industry is increasing as a result of moving towards achieving sustainability and enhancing performance, comfort and safety. Through substituting heavier materials with textiles of high performance specifications and textile reinforced composites to reduce weight, fuel consumption and CO2 emissions. Composite materials can fulfil the demands for sustainability in the transportation sector through using renewable, recycled and lightweight materials, considering the requirements of each category of transport vehicles. Textiles used in reinforcing composites are diverse including fibers, yarns or fabric preforms such as woven, nonwoven, knitted, braided which varies from 2D to complex 3D structures. This paper presents a brief review on the utilization of textiles in reinforcing composites for various transportation applications to achieve sustainability. Also, discussing the influence of textiles structural parameters like fiber material properties, fabric production technique and construction on their mechanical behaviour. Focusing on researches findings in this area and highlighting some prospects for further developments domestically.

Self-Deploying Trusses Containing Shape-Memory Polymers

NASA Technical Reports Server (NTRS)

Schueler, Robert M.

2008-01-01

Composite truss structures are being developed that can be compacted for stowage and later deploy themselves to full size and shape. In the target applications, these smart structures will precisely self-deploy and support a large, lightweight space-based antenna. Self-deploying trusses offer a simple, light, and affordable alternative to articulated mechanisms or inflatable structures. The trusses may also be useful in such terrestrial applications as variable-geometry aircraft components or shelters that can be compacted, transported, and deployed quickly in hostile environments. The truss technology uses high-performance shape-memory-polymer (SMP) thermoset resin reinforced with fibers to form a helical composite structure. At normal operating temperatures, the truss material has the structural properties of a conventional composite. This enables truss designs with required torsion, bending, and compression stiffness. However, when heated to its designed glass transition temperature (Tg), the SMP matrix acquires the flexibility of an elastomer. In this state, the truss can be compressed telescopically to a configuration encompassing a fraction of its original volume. When cooled below Tg, the SMP reverts to a rigid state and holds the truss in the stowed configuration without external constraint. Heating the materials above Tg activates truss deployment as the composite material releases strain energy, driving the truss to its original memorized configuration without the need for further actuation. Laboratory prototype trusses have demonstrated repeatable self-deployment cycles following linear compaction exceeding an 11:1 ratio (see figure).

Utilization of multiwalled boron nitride nanotubes for the reinforcement of lightweight aluminum ribbons

PubMed Central

2013-01-01

Multiwalled boron nitride nanotubes (BNNTs) have very attractive mechanical and thermal properties, e.g., elasticity, tensile strength, and high resistance to oxidation, and may be considered as ideal reinforcing agents in lightweight metal matrix composites. Herein, for the first time, Al-BNNT ribbons with various BNNT contents (up to 3 wt.%) were fabricated via melt spinning in an argon atmosphere. BNNTs were randomly dispersed within a microcrystalline Al matrix under ribbon casting and led to more than doubling of room-temperature ultimate tensile strength of the composites compared to pure Al ribbons produced at the similar conditions. PMID:23279813

Development of PLA hybrid yarns for biobased self-reinforced polymer composites

NASA Astrophysics Data System (ADS)

Köhler, T.; Gries, T.; Seide, G.

2017-10-01

Lightweight materials are a necessity in various industries. Lightweight design is in the key interest of the mobility sector, e.g. the automotive and aerospace industry. This trend applies also for the consumer industries, e.g. sporting goods. In addition, the worldwide demand for replacing fossil-based materials has led to a significant growth of bioplastics. Due to their low mechanical performance and durability, their use is still limited. Therefore, it is necessary to develop biobased, sustainable polymeric materials with high stiffness, high impact and high durability without impairing recyclability at a similar price level of non-biobased solutions. Biobased self-reinforced polymer composites offer these unique properties.

Physics-Based Design Tools for Lightweight Ceramic Composite Turbine Components with Durable Microstructures

NASA Technical Reports Server (NTRS)

DiCarlo, James A.

2011-01-01

Under the Supersonics Project of the NASA Fundamental Aeronautics Program, modeling and experimental efforts are underway to develop generic physics-based tools to better implement lightweight ceramic matrix composites into supersonic engine components and to assure sufficient durability for these components in the engine environment. These activities, which have a crosscutting aspect for other areas of the Fundamental Aero program, are focusing primarily on improving the multi-directional design strength and rupture strength of high-performance SiC/SiC composites by advanced fiber architecture design. This presentation discusses progress in tool development with particular focus on the use of 2.5D-woven architectures and state-of-the-art constituents for a generic un-cooled SiC/SiC low-pressure turbine blade.

Energy-Absorbing, Lightweight Wheels

NASA Technical Reports Server (NTRS)

Waydo, Peter

2003-01-01

Improved energy-absorbing wheels are under development for use on special-purpose vehicles that must traverse rough terrain under conditions (e.g., extreme cold) in which rubber pneumatic tires would fail. The designs of these wheels differ from those of prior non-pneumatic energy-absorbing wheels in ways that result in lighter weights and more effective reduction of stresses generated by ground/wheel contact forces. These wheels could be made of metals and/or composite materials to withstand the expected extreme operating conditions. As shown in the figure, a wheel according to this concept would include an isogrid tire connected to a hub via spring rods. The isogrid tire would be a stiff, lightweight structure typically made of aluminum. The isogrid aspect of the structure would both impart stiffness and act as a traction surface. The hub would be a thin-walled body of revolution having a simple or compound conical or other shape chosen for structural efficiency. The spring rods would absorb energy and partially isolate the hub and the supported vehicle from impact loads. The general spring-rod configuration shown in the figure was chosen because it would distribute contact and impact loads nearly evenly around the periphery of the hub, thereby helping to protect the hub against damage that would otherwise be caused by large loads concentrated onto small portions of the hub.

Automated Cutting And Drilling Of Composite Parts

NASA Technical Reports Server (NTRS)

Warren, Charles W.

1993-01-01

Proposed automated system precisely cuts and drills large, odd-shaped parts made of composite materials. System conceived for manufacturing lightweight composite parts to replace heavier parts in Space Shuttle. Also useful in making large composite parts for other applications. Includes robot locating part to be machined, positions cutter, and positions drill. Gantry-type robot best suited for task.

Mechanical performance and parameter sensitivity analysis of 3D braided composites joints.

PubMed

Wu, Yue; Nan, Bo; Chen, Liang

2014-01-01

3D braided composite joints are the important components in CFRP truss, which have significant influence on the reliability and lightweight of structures. To investigate the mechanical performance of 3D braided composite joints, a numerical method based on the microscopic mechanics is put forward, the modeling technologies, including the material constants selection, element type, grid size, and the boundary conditions, are discussed in detail. Secondly, a method for determination of ultimate bearing capacity is established, which can consider the strength failure. Finally, the effect of load parameters, geometric parameters, and process parameters on the ultimate bearing capacity of joints is analyzed by the global sensitivity analysis method. The results show that the main pipe diameter thickness ratio γ, the main pipe diameter D, and the braided angle α are sensitive to the ultimate bearing capacity N.

Synthesis and Characterization of Novel Epoxy Geopolymer Hybrid Composites

PubMed Central

Roviello, Giuseppina; Ricciotti, Laura; Ferone, Claudio; Colangelo, Francesco; Cioffi, Raffaele; Tarallo, Oreste

2013-01-01

The preparation and the characterization of novel geopolymer-based hybrid composites are reported. These materials have been prepared through an innovative synthetic approach, based on a co-reticulation in mild conditions of commercial epoxy based organic resins and a metakaolin-based geopolymer inorganic matrix. This synthetic strategy allows the obtainment of a homogeneous dispersion of the organic particles in the inorganic matrix, up to 25% in weight of the resin. The materials obtained present significantly enhanced compressive strengths and toughness with respect to the neat geopolymer, suggesting their wide utilization for structural applications. A preliminary characterization of the porous materials obtained by removing the organic phase from the hybrid composites by means of heat treatments is also reported. Possible applications of these materials in the field of water purification, filtration, or as lightweight insulating materials are envisaged. PMID:28788310

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

Sabau, Adrian S.; Greer, Clayton M.; Chen, Jian

Here, the increasing use of Carbon Fiber-reinforced Polymer matrix Composites (CFPC) and aluminum alloys as lightweight materials in the automotive and aerospace industries demands enhanced surface preparation and control of surface morphology prior to joining. In this study, surfaces of both composite and aluminum were prepared for joining using an Nd:YAG laser in a two-beam interference setup, enabling the (a) structuring of the AL 5182 surface, (b) removal of the resin layer on top of carbon fibers, and (c) structuring of the carbon fibers. CFPC specimens of T700S carbon fiber, Prepreg - T8 3 epoxy, 5 ply thick, 0/90o plaquesmore » were used. The effect of laser fluence, scanning speed, and number of shots-per-spot was investigated on the removal rate of the resin without an excessive damage of the fibers. Optical micrographs, 3D imaging, and scanning electron microscope (SEM) imaging were used to study the effect of the laser processing on surface morphology.« less

Surface decoration of short-cut polyimide fibers with multi-walled carbon nanotubes and their application for reinforcement of lightweight PC/ABS composites

NASA Astrophysics Data System (ADS)

Zhang, Le; Han, Enlin; Wu, Yulun; Wang, Xiaodong; Wu, Dezhen

2018-06-01

The surface decoration of short-cut polyimide (PI) fibers with multi-walled carbon nanotubes (MWCNTs) was performed by fabricating a polydopamine (PDA) coating layer on the fiber surface and then immobilizing MWCNTs onto the coating layer via covalent bonding. This successful surface decoration was confirmed by scanning electron microscopy, X-ray photoelectron spectroscopy, Fourier-transform infrared microscopy and static water contact angle. The application of the surface-decorated PI fibers as reinforcing fibers for reinforcement of polycarbonate (PC)/acrylonitrile-butadiene-styrene copolymer (ABS) alloy was investigated, which indicated that the MWCNTs-decorated PI fibers not only could effectively reinforce the PC/ABS alloy but also generated a significant lightweighting effect on the resulting composites. The maximum mechanical properties were achieved for the composites at a fiber content of 20 wt.% and a fiber length of 3 mm. This significant reinforcement effect is attributed to the enhancement of interaction bonding strength between the fibers and matrix as a result of the surface decoration of PI fibers with MWCNTs. The morphological investigation suggested that fiber rupture was the major energy dissipation mechanism in the tensile and impact failures, whereas fiber debonding and pullout were partly involved in the fracture energy dissipation. In addition, the presence of surface-decorated PI fibers slightly enhanced the thermal stability and load bearing capability of composites. This work can provide a type of high-performance lightweight composite material for automobile and aviation industries.

The high velocity impact loading on symmetrical and woven hybrid composite laminates

NASA Astrophysics Data System (ADS)

Jin, Martin; Richardson, Mel; Zhang, Zhong Yi

2007-07-01

Space structures use fibre composite materials, due to their lightweight. This paper examines the impact response of symmetrical and hybrid composite laminates. Special attention is given to the stacking sequences used. The experimental study of structures has always provided a major contribution to our understanding. Even with the formidable growth in the use and capacity of computing power the need for experimental measurement is as compelling as ever. The design of hybrid composite structures is complicated by the number of design variables and the interaction of the constituents is the composite system. Since it is desirable to experimentally test the design and it is not practical to test a full scale model, the structural/material similitude concept is used to create a small scale model with a similar structural response. In the current study, experimental investigations were carried out to determine the response of four different combinations of hybrid laminates to low-velocity impact loading using an instrumented impact testing machine. Hybrid laminates were fabricated with twill weave carbon fabric and plain weave S2-glass fabric using vacuum assisted resin molding process with SC-15 epoxy resin system. Response of carbon/epoxy and glass/epoxy laminates was also investigated to compare with that of hybrid samples. Square laminates of size 100 mm and nominal thickness of 3 mm were subjected to low-velocity impact loading at four energy levels of 10, 20, 30 and 40 J. Results of the study indicate that there is considerable improvement in the load carrying capability of hybrid composites as compared to carbon/epoxy laminates with slight reduction in stiffness.

Southern Regional Center for Lightweight Innovative Design

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

Horstemeyer, Mark F.; Wang, Paul

The three major objectives of this Phase III project are: To develop experimentally validated cradle-to-grave modeling and simulation tools to optimize automotive and truck components for lightweighting materials (aluminum, steel, and Mg alloys and polymer-based composites) with consideration of uncertainty to decrease weight and cost, yet increase the performance and safety in impact scenarios; To develop multiscale computational models that quantify microstructure-property relations by evaluating various length scales, from the atomic through component levels, for each step of the manufacturing process for vehicles; and To develop an integrated K-12 educational program to educate students on lightweighting designs and impact scenarios.

Aluminum/steel wire composite plates exhibit high tensile strength

NASA Technical Reports Server (NTRS)

1966-01-01

Composite plate of fine steel wires imbedded in an aluminum alloy matrix results in a lightweight material with high tensile strength. Plates have been prepared having the strength of titanium with only 85 percent of its density.

NASA-UVA light aerospace alloy and structures technology program (LA2ST)

NASA Technical Reports Server (NTRS)

Starke, Edgar A., Jr.; Gangloff, Richard P.; Herakovich, Carl T.; Scully, John R.; Shiflet, Gary J.; Stoner, Glenn E.; Wert, John A.

1995-01-01

The NASA-UVa Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. Projects are being conducted by graduate students and faculty advisors in the Department of Materials Science and Engineering, as well as in the Department of Civil Engineering and Applied Mechanics, at the University of Virginia. Here, we report on progress achieved between July 1 and December 31, 1994. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies.

Applying a Stiffened Stitched Concept to Shear-Loaded Structure

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2014-01-01

NASA and The Boeing Company have worked to develop new low-cost, lightweight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft structure, first in the NASA Advanced Composites Technology (ACT) Program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the need for mechanical fasteners is almost eliminated. Stitching also provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. The stitched panel concept used in the ACT program used simple blade-stiffeners as stringers, caps, and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. Comparisons between stitched and unstitched structure and between blade-stiffened and rod-stiffened structure are presented focusing on a panel loaded in shear. Shear loading is representative of spar loading in wing structures.

Review of Current State of the Art and Key Design Issues With Potential Solutions for Liquid Hydrogen Cryogenic Storage Tank Structures for Aircraft Applications

NASA Technical Reports Server (NTRS)

Mital, Subodh K.; Gyekenyesi, John Z.; Arnold, Steven M.; Sullivan, Roy M.; Manderscheid, Jane M.; Murthy, Pappu L. N.

2006-01-01

Due to its high specific energy content, liquid hydrogen (LH2) is emerging as an alternative fuel for future aircraft. As a result, there is a need for hydrogen tank storage systems, for these aircraft applications, that are expected to provide sufficient capacity for flight durations ranging from a few minutes to several days. It is understood that the development of a large, lightweight, reusable cryogenic liquid storage tank is crucial to meet the goals of and supply power to hydrogen-fueled aircraft, especially for long flight durations. This report provides an annotated review (including the results of an extensive literature review) of the current state of the art of cryogenic tank materials, structural designs, and insulation systems along with the identification of key challenges with the intent of developing a lightweight and long-term storage system for LH2. The broad classes of insulation systems reviewed include foams (including advanced aerogels) and multilayer insulation (MLI) systems with vacuum. The MLI systems show promise for long-term applications. Structural configurations evaluated include single- and double-wall constructions, including sandwich construction. Potential wall material candidates are monolithic metals as well as polymer matrix composites and discontinuously reinforced metal matrix composites. For short-duration flight applications, simple tank designs may suffice. Alternatively, for longer duration flight applications, a double-wall construction with a vacuum-based insulation system appears to be the most optimum design. The current trends in liner material development are reviewed in the case that a liner is required to minimize or eliminate the loss of hydrogen fuel through permeation.

Contact Versus Non-Contact Measurement of a Helicopter Main Rotor Composite Blade

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

Luczak, Marcin; Dziedziech, Kajetan; Peeters, Bart

2010-05-28

The dynamic characterization of lightweight structures is particularly complex as the impact of the weight of sensors and instrumentation (cables, mounting of exciters...) can distort the results. Varying mass loading or constraint effects between partial measurements may determine several errors on the final conclusions. Frequency shifts can lead to erroneous interpretations of the dynamics parameters. Typically these errors remain limited to a few percent. Inconsistent data sets however can result in major processing errors, with all related consequences towards applications based on the consistency assumption, such as global modal parameter identification, model-based damage detection and FRF-based matrix inversion in substructuring,more » load identification and transfer path analysis [1]. This paper addresses the subject of accuracy in the context of the measurement of the dynamic properties of a particular lightweight structure. It presents a comprehensive comparative study between the use of accelerometer, laser vibrometer (scanning LDV) and PU-probe (acoustic particle velocity and pressure) measurements to measure the structural responses, with as final aim the comparison of modal model quality assessment. The object of the investigation is a composite material blade from the main rotor of a helicopter. The presented results are part of an extensive test campaign performed with application of SIMO, MIMO, random and harmonic excitation, and the use of the mentioned contact and non-contact measurement techniques. The advantages and disadvantages of the applied instrumentation are discussed. Presented are real-life measurement problems related to the different set up conditions. Finally an analysis of estimated models is made in view of assessing the applicability of the various measurement approaches for successful fault detection based on modal parameters observation as well as in uncertain non-deterministic numerical model updating.« less

Contact Versus Non-Contact Measurement of a Helicopter Main Rotor Composite Blade

NASA Astrophysics Data System (ADS)

Luczak, Marcin; Dziedziech, Kajetan; Vivolo, Marianna; Desmet, Wim; Peeters, Bart; Van der Auweraer, Herman

2010-05-01

The dynamic characterization of lightweight structures is particularly complex as the impact of the weight of sensors and instrumentation (cables, mounting of exciters…) can distort the results. Varying mass loading or constraint effects between partial measurements may determine several errors on the final conclusions. Frequency shifts can lead to erroneous interpretations of the dynamics parameters. Typically these errors remain limited to a few percent. Inconsistent data sets however can result in major processing errors, with all related consequences towards applications based on the consistency assumption, such as global modal parameter identification, model-based damage detection and FRF-based matrix inversion in substructuring, load identification and transfer path analysis [1]. This paper addresses the subject of accuracy in the context of the measurement of the dynamic properties of a particular lightweight structure. It presents a comprehensive comparative study between the use of accelerometer, laser vibrometer (scanning LDV) and PU-probe (acoustic particle velocity and pressure) measurements to measure the structural responses, with as final aim the comparison of modal model quality assessment. The object of the investigation is a composite material blade from the main rotor of a helicopter. The presented results are part of an extensive test campaign performed with application of SIMO, MIMO, random and harmonic excitation, and the use of the mentioned contact and non-contact measurement techniques. The advantages and disadvantages of the applied instrumentation are discussed. Presented are real-life measurement problems related to the different set up conditions. Finally an analysis of estimated models is made in view of assessing the applicability of the various measurement approaches for successful fault detection based on modal parameters observation as well as in uncertain non-deterministic numerical model updating.

Lightweight Phase-Change Material For Solar Power

NASA Technical Reports Server (NTRS)

Stark, Philip

1993-01-01

Lightweight panels containing phase-change materials developed for use as heat-storage elements of compact, lightweight, advanced solar dynamic power system. During high insolation, heat stored in panels via latent heat of fusion of phase-change material; during low insolation, heat withdrawn from panels. Storage elements consist mainly of porous carbon-fiber structures imbued with germanium. Developed for use aboard space station in orbit around Earth, also adapted to lightweight, compact, portable solar-power systems for use on Earth.

Improved Joining of Metal Components to Composite Structures

NASA Technical Reports Server (NTRS)

Semmes, Edmund

2009-01-01

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

The structural characteristics of inflatable beams

NASA Astrophysics Data System (ADS)

Wicker, William J.

1992-08-01

Two inflatable beams are designed and fabricated from polyethylene of ultrahigh molecular weight, and the structures are tested against similar composite and metal-alloy tubes. Specific attention is given to the choice of material that insures material stiffness, good strength-to-weight ratio, creep resistance, and durability. A cloth beam is built from a commercial extended-chain polyethylene fiber, and the inflated beams are tested by means of three- and four-point loading to measure bending and shear deformation. Comparing geometrically similar structures shows that the fabric beams can be about 35 percent as stiff as aluminum for small deflections. The inflatable beams have elastic stiffness coefficients five and two times higher than those for nylon and polyester tubes, respectively. Inflatable structures are concluded to hold promise for lightweight aerospace applications which demand small storage areas.

Ultrathin lightweight plate-type acoustic metamaterials with positive lumped coupling resonant

NASA Astrophysics Data System (ADS)

Ma, Fuyin; Huang, Meng; Wu, Jiu Hui

2017-01-01

The experimental realization and theoretical understanding of a two-dimensional multiple cells lumped ultrathin lightweight plate-type acoustic metamaterials structures have been presented, wherein broadband excellent sound attenuation ability at low frequencies is realized by employing a lumped element coupling resonant effect. The basic unit cell of the metamaterials consists of an ultrathin stiff nylon plate clamped by two elastic ethylene-vinyl acetate copolymer or acrylonitrile butadiene styrene frames. The strong sound attenuation (up to nearly 99%) at low frequencies is experimentally revealed by the precisely designed metamaterials, for which the physical mechanism of the sound attenuation could be explicitly understood using the finite element simulations. As to the designed samples, the lumped effect from the frame compliance leads to a coupling flexural resonance at designable low frequencies. As a result, the whole composite structure become strongly anti-resonant with the incident sound waves, followed by a higher sound attenuation, i.e., the lumped resonant effect has been effectively reversed to be positive from negative for sound attenuation, and the acoustic metamaterial design could be extended to the lumped element containing multiple cells, rather than confined to a single cell.

A study on atomic diffusion behaviours in an Al-Mg compound casting process

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

Liu, Yongning; Chen, Yiqing; Yang, Chunhui, E-mail: r.yang@uws.edu.au

Al and Mg alloys are main lightweight alloys of research interest and they both have superb material properties, i.e., low density and high specific strength, etc. Being different from Al alloys, the corrosion of Mg alloys is much more difficult to control. Therefore to combine merits of these two lightweight alloys as a composite-like structure is an ideal solution through using Al alloys as a protective layer for Mg alloys. Compound casting is a realistic technique to manufacture such a bi-metal structure. In this study, a compound casting technique is employed to fabricate bi-layered samples using Al and Mg andmore » then the samples are analysed using electron probe micro-analyzer (EPMA) to determine diffusion behaviours between Al and Mg. The diffusion mechanism and behaviours between Al and Mg are studied numerically at atomic scale using molecular dynamics (MD) and parametric studies are conducted to find out influences of ambient temperature and pressure on the diffusion behaviours between Al and Mg. The results obtained clearly show the effectiveness of the compound casting process to increase the diffusion between Al and Mg and thus create the Al-base protection layer for Mg.« less

Cryogenic performance of single polymer polypropylene composites

NASA Astrophysics Data System (ADS)

Atli-Veltin, Bilim

2018-03-01

The main objective of the experimental study detailed in this paper is to investigate the performance of fully recyclable, lightweight, low-cost, thermoplastic Polypropylene (PP) composite tapes at low temperatures. Coupons made of [±45] and [0/90] laminates are subjected to tensile and 3-point bending tests at room temperature as well as at -196 °C. In addition to that, cryogenic low velocity impact tests at 268 J and 777 J impact energies are performed on tubular structures. The results are indicating that the laminates made of PP tapes have sufficient ductility for cryogenic applications. Low velocity impact tests showed that the viscoelastic behavior of the material is preserved, even at such low temperatures and more than 72% of impact energy is absorbed by the material.

Hybrid Heat Exchangers

NASA Technical Reports Server (NTRS)

Tu, Jianping Gene; Shih, Wei

2010-01-01

A hybrid light-weight heat exchanger concept has been developed that uses high-conductivity carbon-carbon (C-C) composites as the heat-transfer fins and uses conventional high-temperature metals, such as Inconel, nickel, and titanium as the parting sheets to meet leakage and structural requirements. In order to maximize thermal conductivity, the majority of carbon fiber is aligned in the fin direction resulting in 300 W/m.K or higher conductivity in the fin directions. As a result of this fiber orientation, the coefficient of thermal expansion (CTE) of the C-C composite in both non-fiber directions matches well with the CTE of various high-temperature metal alloys. This allows the joining of fins and parting sheets by using high-temperature braze alloys.

CFRP composite mirrors for space telescopes and their micro-dimensional stability

NASA Astrophysics Data System (ADS)

Utsunomiya, Shin; Kamiya, Tomohiro; Shimizu, Ryuzo

2010-07-01

Ultra-lightweight and high-accuracy CFRP (carbon fiber reinforced plastics) mirrors for space telescopes were fabricated to demonstrate their feasibility for light wavelength applications. The CTE (coefficient of thermal expansion) of the all- CFRP sandwich panels was tailored to be smaller than 1×10-7/K. The surface accuracy of mirrors of 150 mm in diameter was 1.8 um RMS as fabricated and the surface smoothness was improved to 20 nm RMS by using a replica technique. Moisture expansion was considered the largest in un-predictable surface preciseness errors. The moisture expansion affected not only homologous shape change but also out-of-plane distortion especially in unsymmetrical compositions. Dimensional stability due to the moisture expansion was compared with a structural mathematical model.

Design of lightweight broadband microwave absorbers in the X-band based on (polyaniline/MnNiZn ferrite) nanocomposites

NASA Astrophysics Data System (ADS)

Ali, Nassim Nasser; Al-Qassar Bani Al-Marjeh, Rama; Atassi, Yomen; Salloum, Akil; Malki, Adnan; Jafarian, Mojtaba

2018-05-01

We present the design of novel, lightweight, broadband microwave absorbers based on polyaniline/Mn0.1Ni0.45Zn0.45Fe2O4 (PANI/MnNiZn ferrite) nanocomposites. The ferrite is synthesized by sol-gel technique. Then, the polymer is deposited by in-situ chemical oxidative polymerization. The structural and morphological characterizations of the composites are investigated by SEM, XRD, FT-IR and UV-vis spectroscopy. The functional characterization is performed by measuring the dc-conductivity and microwave absorption characteristics in the X-band. The absorbers exhibit broad bandwidths under -10 dB ranging from 2.60 to 3.74 GHz and low surface density ranging from 2.5 to 3.1 kg/m2. The absorber of 3.74 GHz bandwidth has a minimum reflection loss of -31.32 dB at 11.13 GHz with a matching thickness of 3 mm and a low loading in paraffin of only 25% w/w.

CeSiCò - a new technology for lightweight and cost effective space instruments structures and mirrors

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Krödel, Matthias

2017-11-01

Alcatel Alenia Space and ECM have jointly developed a new ceramic material to produce lightweight, stiff, stable and cost effective structures and mirrors for space instrument the CesicÒ. Its intrinsic properties, added to ample manufacturing capabilities allow to manufacture stiff and lightweight cost effective mirrors and structure for space instruments. Different scale 1 flight representative CesicÒ optical structures have been manufactured and successfully tested under very strong dynamic environment and cryogenic condition down to 30K CesicÒ is also envisaged for large and lightweight space telescopes mirrors, a large CesicÒ 1 meter class mirror with an area mass of less than 25 Kg/m2 has been sized again launch loads and WFE performance and manufactured. CesicÒ applicability for large focal plane have been demonstrated through different scale 1 breadboards. Based on these successful results, AlcatelAleniaSpace and ECM are now in position to propose for space this technology with new innovative concepts thanks to the CesicÒ manufacturing capabilities. CesicÒ has therefore been selected for the structure and mirrors parts of a flight instrument payload and the manufacturing of the flight hardware is already underway. An high temperature high gain lightweight antenna breadboard is also under manufacturing for Bepi colombo mission. CesicÒ is therefore a good candidate for future challenging space instruments and is currently proposed for Japan and US space projects.

Lightweighting Automotive Materials for Increased Fuel Efficiency and Delivering Advanced Modeling and Simulation Capabilities to U.S. Manufacturers

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

Hale, Steve

Abstract The National Center for Manufacturing Sciences (NCMS) worked with the U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL), to bring together research and development (R&D) collaborations to develop and accelerate the knowledgebase and infrastructure for lightweighting materials and manufacturing processes for their use in structural and applications in the automotive sector. The purpose/importance of this DOE program: • 2016 CAFÉ standards. • Automotive industry technology that shall adopt the insertion of lightweighting material concepts towards manufacturing of production vehicles. • Development and manufacture of advanced research tools for modeling and simulation (M&S) applications to reduce manufacturing andmore » material costs. • U.S. competitiveness that will help drive the development and manufacture of the next generation of materials. NCMS established a focused portfolio of applied R&D projects utilizing lightweighting materials for manufacture into automotive structures and components. Areas that were targeted in this program: • Functionality of new lightweighting materials to meet present safety requirements. • Manufacturability using new lightweighting materials. • Cost reduction for the development and use of new lightweighting materials. The automotive industry’s future continuously evolves through innovation, and lightweight materials are key in achieving a new era of lighter, more efficient vehicles. Lightweight materials are among the technical advances needed to achieve fuel/energy efficiency and reduce carbon dioxide (CO2) emissions: • Establish design criteria methodology to identify the best materials for lightweighting. • Employ state-of-the-art design tools for optimum material development for their specific applications. • Match new manufacturing technology to production volume. • Address new process variability with new production-ready processes.« less

Surface Control of Cold Hibernated Elastic Memory Self-Deployable Structure

NASA Technical Reports Server (NTRS)

Sokolowski, Witold M.; Ghaffarian, Reza

2006-01-01

A new class of simple, reliable, lightweight, low packaging volume and cost, self-deployable structures has been developed for use in space and commercial applications. This technology called 'cold hibernated elastic memory' (CHEM) utilizes shape memory polymers (SMP)in open cellular (foam) structure or sandwich structures made of shape memory polymer foam cores and polymeric composite skins. Some of many potential CHEM space applications require a high precision deployment and surface accuracy during operation. However, a CHEM structure could be slightly distorted by the thermo-mechanical processing as well as by thermal space environment Therefore, the sensor system is desirable to monitor and correct the potential surface imperfection. During these studies, the surface control of CHEM smart structures was demonstrated using a Macro-Fiber Composite (MFC) actuator developed by the NASA LaRC and US Army ARL. The test results indicate that the MFC actuator performed well before and after processing cycles. It reduced some residue compressive strain that in turn corrected very small shape distortion after each processing cycle. The integrated precision strain gages were detecting only a small flat shape imperfection indicating a good recoverability of original shape of the CHEM test structure.

Lightweight solar concentrator structures, phase 2

NASA Technical Reports Server (NTRS)

Williams, Brian E.; Kaplan, Richard B.

1993-01-01

This report summarizes the results of the program conducted by Ultramet under SBIR Phase 2 Contract NAS3-25418. The objective of this program was to develop lightweight materials and processes for advanced high accuracy Space Solar Concentrators using rigidized foam for the substrate structure with an integral optical surface.

Influence of Impact Damage on Carbon-Epoxy Stiffener Crippling

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2010-01-01

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structure. In this concept a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. By adding unidirectional carbon rods to the top of stiffeners, the panel becomes more structurally efficient. This combination produces a more damage tolerant design. This document describes the results of experimentation on PRSEUS specimens loaded in unidirectional compression subjected to impact damage and loaded in fatigue and to failure. A comparison with analytical predictions for pristine and damaged specimens is included.

Vibration Damping Analysis of Lightweight Structures in Machine Tools

PubMed Central

Aggogeri, Francesco; Borboni, Alberto; Merlo, Angelo; Pellegrini, Nicola; Ricatto, Raffaele

2017-01-01

The dynamic behaviour of a machine tool (MT) directly influences the machining performance. The adoption of lightweight structures may reduce the effects of undesired vibrations and increase the workpiece quality. This paper aims to present and compare a set of hybrid materials that may be excellent candidates to fabricate the MT moving parts. The selected materials have high dynamic characteristics and capacity to dampen mechanical vibrations. In this way, starting from the kinematic model of a milling machine, this study evaluates a number of prototypes made of Al foam sandwiches (AFS), Al corrugated sandwiches (ACS) and composite materials reinforced by carbon fibres (CFRP). These prototypes represented the Z-axis ram of a commercial milling machine. The static and dynamical properties have been analysed by using both finite element (FE) simulations and experimental tests. The obtained results show that the proposed structures may be a valid alternative to the conventional materials of MT moving parts, increasing machining performance. In particular, the AFS prototype highlighted a damping ratio that is 20 times greater than a conventional ram (e.g., steel). Its application is particularly suitable to minimize unwanted oscillations during high-speed finishing operations. The results also show that the CFRP structure guarantees high stiffness with a weight reduced by 48.5%, suggesting effective applications in roughing operations, saving MT energy consumption. The ACS structure has a good trade-off between stiffness and damping and may represent a further alternative, if correctly evaluated. PMID:28772653

Advances in Micromechanics Modeling of Composites Structures for Structural Health Monitoring

NASA Astrophysics Data System (ADS)

Moncada, Albert

Although high performance, light-weight composites are increasingly being used in applications ranging from aircraft, rotorcraft, weapon systems and ground vehicles, the assurance of structural reliability remains a critical issue. In composites, damage is absorbed through various fracture processes, including fiber failure, matrix cracking and delamination. An important element in achieving reliable composite systems is a strong capability of assessing and inspecting physical damage of critical structural components. Installation of a robust Structural Health Monitoring (SHM) system would be very valuable in detecting the onset of composite failure. A number of major issues still require serious attention in connection with the research and development aspects of sensor-integrated reliable SHM systems for composite structures. In particular, the sensitivity of currently available sensor systems does not allow detection of micro level damage; this limits the capability of data driven SHM systems. As a fundamental layer in SHM, modeling can provide in-depth information on material and structural behavior for sensing and detection, as well as data for learning algorithms. This dissertation focuses on the development of a multiscale analysis framework, which is used to detect various forms of damage in complex composite structures. A generalized method of cells based micromechanics analysis, as implemented in NASA's MAC/GMC code, is used for the micro-level analysis. First, a baseline study of MAC/GMC is performed to determine the governing failure theories that best capture the damage progression. The deficiencies associated with various layups and loading conditions are addressed. In most micromechanics analysis, a representative unit cell (RUC) with a common fiber packing arrangement is used. The effect of variation in this arrangement within the RUC has been studied and results indicate this variation influences the macro-scale effective material properties and failure stresses. The developed model has been used to simulate impact damage in a composite beam and an airfoil structure. The model data was verified through active interrogation using piezoelectric sensors. The multiscale model was further extended to develop a coupled damage and wave attenuation model, which was used to study different damage states such as fiber-matrix debonding in composite structures with surface bonded piezoelectric sensors.

Artificial lightweight aggregates as utilization for future ashes - A case study.

PubMed

Sarabèr, Angelo; Overhof, Robert; Green, Terry; Pels, Jan

2012-01-01

In the future, more electricity in the Netherlands will be produced using coal with co-combustion. Due to this, the generated annual ash volume will increase and the chemical composition will be influenced. One of the options for utilization if present markets are saturated and for use of fly ashes with different compositions, is as raw material for lightweight aggregates. This was selected as one of the best utilizations options regarding potential ash volume to be applied, environmental aspects and status of technology. Because of this, a study has been performed to assess the potential utilization of fly ash for the production of lightweight aggregate. Lightweight aggregate has been produced in a laboratory scale rotary kiln. The raw material consisted of class F fly ash with high free lime content. An addition of 8% clay was necessary to get green pellets with sufficient green strength. The basic properties of the produced lightweight aggregate and its behaviour in concrete have been investigated. The concrete has a good compressive strength and its leaching behaviour meets the most stringent requirements of Dutch environmental regulations. The carbon foot print of concrete will be negatively influenced if only the concrete itself is taken into account, but the reduction of the volume weight has advantages regarding design, transport emissions and isolation properties which may counteract this. In the Dutch situation the operational costs are higher than expected potential selling price for the LWA, which implies that the gate fee for the fly ash is negative. Copyright © 2011 Elsevier Ltd. All rights reserved.

Reusable LH2 tank technology demonstration through ground test

NASA Technical Reports Server (NTRS)

Bianca, C.; Greenberg, H. S.; Johnson, S. E.

1995-01-01

The paper presents the project plan to demonstrate, by March 1997, the reusability of an integrated composite LH2 tank structure, cryogenic insulation, and thermal protection system (TPS). The plan includes establishment of design requirements and a comprehensive trade study to select the most suitable Reusable Hydrogen Composite Tank system (RHCTS) within the most suitable of 4 candidate structural configurations. The 4 vehicles are winged body with the capability to deliver 25,000 lbs of payload to a circular 220 nm, 51.6 degree inclined orbit (also 40,000 lbs to a 28.5 inclined 150 nm orbit). A prototype design of the selected RHCTS is established to identify the construction, fabrication, and stress simulation and test requirements necessary in an 8 foot diameter tank structure/insulation/TPS test article. A comprehensive development test program supports the 8 foot test article development and involves the composite tank itself, cryogenic insulation, and integrated tank/insulation/TPS designs. The 8 foot diameter tank will contain the integrated cryogenic insulation and TPS designs resulting from this development and that of the concurrent lightweight durable TPS program. Tank ground testing will include 330 cycles of LH2 filling, pressurization, body loading, depressurization, draining, and entry heating.

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.

Repair & Strengthening of Distressed/Damaged Ends of Prestressed Beams with FRP Composites

DOT National Transportation Integrated Search

2018-02-01

Over the past few decades, fiber reinforced polymer (FRP) composites have emerged as a lightweight and efficient material used for the repair and retrofit of concrete infrastructures. FRP can be applied to concrete as either externally bonded laminat...

Experimental Modal Analysis and Dynaic Strain Fiber Bragg Gratings for Structural Health Monitoring of Composite Aerospace Structures

NASA Astrophysics Data System (ADS)

Panopoulou, A.; Fransen, S.; Gomez Molinero, V.; Kostopoulos, V.

2012-07-01

The objective of this work is to develop a new structural health monitoring system for composite aerospace structures based on dynamic response strain measurements and experimental modal analysis techniques. Fibre Bragg Grating (FBG) optical sensors were used for monitoring the dynamic response of the composite structure. The structural dynamic behaviour has been numerically simulated and experimentally verified by means of vibration testing. The hypothesis of all vibration tests was that actual damage in composites reduces their stiffness and produces the same result as mass increase produces. Thus, damage was simulated by slightly varying locally the mass of the structure at different zones. Experimental modal analysis based on the strain responses was conducted and the extracted strain mode shapes were the input for the damage detection expert system. A feed-forward back propagation neural network was the core of the damage detection system. The features-input to the neural network consisted of the strain mode shapes, extracted from the experimental modal analysis. Dedicated training and validation activities were carried out based on the experimental results. The system showed high reliability, confirmed by the ability of the neural network to recognize the size and the position of damage on the structure. The experiments were performed on a real structure i.e. a lightweight antenna sub- reflector, manufactured and tested at EADS CASA ESPACIO. An integrated FBG sensor network, based on the advantage of multiplexing, was mounted on the structure with optimum topology. Numerical simulation of both structures was used as a support tool at all the steps of the work. Potential applications for the proposed system are during ground qualification extensive tests of space structures and during the mission as modal analysis tool on board, being able via the FBG responses to identify a potential failure.

Experimental study on microstructure characters of foamed lightweight soil

NASA Astrophysics Data System (ADS)

Qiu, Youqiang; Li, Yongliang; Li, Meixia; Liu, Yaofu; Zhang, Liujun

2018-01-01

In order to verify the microstructure of foamed lightweight soil and its characters of compressive strength, four foamed lightweight soil samples with different water-soild ratio were selected and the microstructure characters of these samples were scanned by electron microscope. At the same time, the characters of compressive strength of foamed lightweight soil were analyzed from the microstructure. The study results show that the water-soild ratio has a prominent effect on the microstructure and compressive strength of foamed lightweight soil, with the decrease of water-solid ratio, the amount and the perforation of pores would be reduced significantly, thus eventually forming a denser and fuller interior structure. Besides, the denser microstructure and solider pore-pore wall is benefit to greatly increase mechanical intensity of foamed lightweight soil. In addition, there are very few acicular ettringite crystals in the interior of foamed lightweight soil, its number is also reduced with the decrease in water-soild ratio.

Scaling laws for light-weight optics

NASA Technical Reports Server (NTRS)

Valente, Tina M.

1990-01-01

Scaling laws for light-weight optical systems are examined. A cubic relationship between mirror diameter and weight has been suggested and used by many designers of optical systems as the best description for all light-weight mirrors. A survey of existing light-weight systems in the open literature has been made to clarify this issue. Fifty existing optical systems were surveyed with all varieties of light-weight mirrors including glass and beryllium structured mirrors, contoured mirrors, and very thin solid mirrors. These mirrors were then categorized and weight to diameter ratio was plotted to find a best fit curve for each case. A best fitting curve program tests nineteen different equations and ranks a 'goodness of fit' for each of these equations. The resulting relationship found for each light-weight mirror category helps to quantify light-weight optical systems and methods of fabrication and provides comparisons between mirror types.

Analysis of hazardous substances released during CFRP laser processing

NASA Astrophysics Data System (ADS)

Hustedt, Michael; Walter, Juergen; Bluemel, Sven; Jaeschke, Peter; Kaierle, Stefan

2017-02-01

Due to their outstanding mechanical properties, in particular their high specific strength parallel to the carbon fibers, carbon fiber reinforced plastics (CFRP) have a high potential regarding resource-efficient lightweight construction. Consequently, these composite materials are increasingly finding application in important industrial branches such as aircraft, automotive and wind energy industry. However, the processing of these materials is highly demanding. On the one hand, mechanical processing methods such as milling or drilling are sometimes rather slow, and they are connected with notable tool wear. On the other hand, thermal processing methods are critical as the two components matrix and reinforcement have widely differing thermophysical properties, possibly leading to damages of the composite structure in terms of pores or delamination. An emerging innovative method for processing of CFRP materials is the laser technology. As principally thermal method, laser processing is connected with the release of potentially hazardous, gaseous and particulate substances. Detailed knowledge of these process emissions is the basis to ensure the protection of man and the environment, according to the existing legal regulations. This knowledge will help to realize adequate protective measures and thus strengthen the development of CFRP laser processing. In this work, selected measurement methods and results of the analysis of the exhaust air and the air at the workplace during different laser processes with CFRP materials are presented. The investigations have been performed in the course of different cooperative projects, funded by the German Federal Ministry of Education and Research (BMBF) in the course of the funding initiative "Photonic Processes and Tools for Resource-Efficient Lightweight Structures".

Applications of Polymer Matrix Syntactic Foams

NASA Astrophysics Data System (ADS)

Gupta, Nikhil; Zeltmann, Steven E.; Shunmugasamy, Vasanth Chakravarthy; Pinisetty, Dinesh

2013-11-01

A collection of applications of polymer matrix syntactic foams is presented in this article. Syntactic foams are lightweight porous composites that found their early applications in marine structures due to their naturally buoyant behavior and low moisture absorption. Their light weight has been beneficial in weight sensitive aerospace structures. Syntactic foams have pushed the performance boundaries for composites and have enabled the development of vehicles for traveling to the deepest parts of the ocean and to other planets. The high volume fraction of porosity in syntactic foams also enabled their applications in thermal insulation of pipelines in oil and gas industry. The possibility of tailoring the mechanical and thermal properties of syntactic foams through a combination of material selection, hollow particle volume fraction, and hollow particle wall thickness has helped in rapidly growing these applications. The low coefficient of thermal expansion and dimensional stability at high temperatures are now leading their use in electronic packaging, composite tooling, and thermoforming plug assists. Methods have been developed to tailor the mechanical and thermal properties of syntactic foams independent of each other over a wide range, which is a significant advantage over other traditional particulate and fibrous composites.

A non-asymptotic model of dynamics of honeycomb lattice-type plates

NASA Astrophysics Data System (ADS)

Cielecka, Iwona; Jędrysiak, Jarosław

2006-09-01

Lightweight structures, consisted of special composite material systems like sandwich plates, are often used in aerospace or naval engineering. In composite sandwich plates, the intermediate core is usually made of cellular structures, e.g. honeycomb micro-frames, reinforcing static and dynamic properties of these plates. Here, a new non-asymptotic continuum model of honeycomb lattice-type plates is shown and applied to the analysis of dynamic problems. The general formulation of the model for periodic lattice-type plates of an arbitrary lay-out was presented by Cielecka and Jędrysiak [Journal of Theoretical and Applied Mechanics 40 (2002) 23-46]. This model, partly based on the tolerance averaging method developed for periodic composite solids by Woźniak and Wierzbicki [Averaging techniques in thermomechanics of composite solids, Wydawnictwo Politechniki Częstochowskiej, Częstochowa, 2000], takes into account the effect of the length microstructure size on the dynamic plate behaviour. The shown method leads to the model equations describing the above effect for honeycomb lattice-type plates. These equations have the form similar to equations for isotropic cases. The dynamic analysis of such plates exemplifies this effect, which is significant and cannot be neglected. The physical correctness of the obtained results is also discussed.

High-Performance Metal/Carbide Composites with Far-From-Equilibrium Compositions and Controlled Microstructures

PubMed Central

Hu, Liangfa; O’Neil, Morgan; Erturun, Veysel; Benitez, Rogelio; Proust, Gwénaëlle; Karaman, Ibrahim; Radovic, Miladin

2016-01-01

The prospect of extending existing metal-ceramic composites to those with the compositions that are far from thermodynamic equilibrium is examined. A current and pressure-assisted, rapid infiltration is proposed to fabricate composites, consisting of reactive metallic and ceramic phases with controlled microstructure and tunable properties. An aluminum (Al) alloy/Ti2AlC composite is selected as an example of the far-from-equilibrium systems to fabricate, because Ti2AlC exists only in a narrow region of the Ti-Al-C phase diagram and readily reacts with Al. This kind of reactive systems challenges conventional methods for successfully processing corresponding metal-ceramic composites. Al alloy/Ti2AlC composites with controlled microstructures, various volume ratios of constituents (40/60 and 27/73) and metallic phase sizes (42–83 μm, 77–276 μm, and 167–545 μm), are obtained using the Ti2AlC foams with different pore structures as preforms for molten metal (Al alloy) infiltration. The resulting composites are lightweight and display exceptional mechanical properties at both ambient and elevated temperatures. These structures achieve a compressive strength that is 10 times higher than the yield strength of the corresponding peak-aged Al alloy at ambient temperature and 14 times higher at 400 °C. Possible strengthening mechanisms are described, and further strategies for improving properties of those composites are proposed. PMID:27752106

High-Glass-Transition-Temperature Polyimides Developed for Reusable Launch Vehicle Applications

NASA Technical Reports Server (NTRS)

Chuang, Kathy; Ardent, Cory P.

2002-01-01

Polyimide composites have been traditionally used for high-temperature applications in aircraft engines at temperatures up to 550 F (288 C) for thousands of hours. However, as NASA shifts its focus toward the development of advanced reusable launch vehicles, there is an urgent need for lightweight polymer composites that can sustain 600 to 800 F (315 to 427 C) for short excursions (hundreds of hours). To meet critical vehicle weight targets, it is essential that one use lightweight, high-temperature polymer matrix composites in propulsion components such as turbopump housings, ducts, engine supports, and struts. Composite materials in reusable launch vehicle components will heat quickly during launch and reentry. Conventional composites, consisting of layers of fabric or fiber-reinforced lamina, would either blister or encounter catastrophic delamination under high heating rates above 300 C. This blistering and delamination are the result of a sudden volume expansion within the composite due to the release of absorbed moisture and gases generated by the degradation of the polymer matrix. Researchers at the NASA Glenn Research Center and the Boeing Company (Long Beach, CA) recently demonstrated a successful approach for preventing this delamination--the use of three-dimensional stitched composites fabricated by resin infusion.

Vegetable fibres from agricultural residues as thermo-mechanical reinforcement in recycled polypropylene-based green foams.

PubMed

Ardanuy, Mònica; Antunes, Marcelo; Velasco, José Ignacio

2012-02-01

Novel lightweight composite foams based on recycled polypropylene reinforced with cellulosic fibres obtained from agricultural residues were prepared and characterized. These composites, initially prepared by melt-mixing recycled polypropylene with variable fibre concentrations (10-25 wt.%), were foamed by high-pressure CO(2) dissolution, a clean process which avoids the use of chemical blowing agents. With the aim of studying the influence of the fibre characteristics on the resultant foams, two chemical treatments were applied to the barley straw in order to increase the α-cellulose content of the fibres. The chemical composition, morphology and thermal stability of the fibres and composites were analyzed. Results indicate that fibre chemical treatment and later foaming of the composites resulted in foams with characteristic closed-cell microcellular structures, their specific storage modulus significantly increasing due to the higher stiffness of the fibres. The addition of the fibres also resulted in an increase in the glass transition temperature of PP in both the solid composites and more significantly in the foams. Copyright © 2011 Elsevier Ltd. All rights reserved.

Mitigating Settlement of Structures founded on Peat

NASA Astrophysics Data System (ADS)

Wijeyesekera, D. C.; Numbikannu, L.; Ismail, T. N. H. T.; Bakar, I.

2016-07-01

Observations made of two common failures of structures founded on peat/organic soil in Johor, Malaysia is presented. Critical evaluation of current lightweight fill technology to mitigate such settlement is also discussed. Lightweight technology, such as Expanded Polystyrene (EPS), has been used in construction on soft yielding ground for decades. Regrettably, some published information of EPS failures to perform on construction sites are also cited in this paper. This paper outlines some concepts leading to the development of an alternative innovative lightweight fill is that the idealised cellular structure of the GCM permit free flow of water and complemented by the mat structure which evens out any differential settlement A further highlight of this paper is the monitoring of the field performance of this lightweight fill (GCM) as a feasible alternative to fill weight reduction on yielding ground.. Hence, a prime research objective was to compare the fill settlements observed with 1m high fill of surcharge loading on peat ground (comparison of the case of using a partial 0.6m high GCM and that of a total of 1m of conventional sand backfill).

Design, fabrication, and test of lightweight shell structure, phase 2

NASA Technical Reports Server (NTRS)

1974-01-01

A cylindrical shell skirt structure 4.57 m (180 in.) in diameter and 3.66 m (144 in.) high was subjected to a design and analysis study using a wide variety of structural materials and concepts. The design loading of 1225.8 N/cm (700 lb/in.) axial compression and 245.2 N/cm (140 lb/in.) torsion is representative of that expected on a typical space tug skirt section. Structural concepts evaluated included honeycomb sandwich, truss, isogrid, and skin/stringer/frame. The materials considered included a wide variety of structural metals as well as glass, graphite, and boron-reinforced composites. The most unique characteristic of the candidate designs is that they involve the use of very thin-gage material. Fabrication and structural test of small panels and components representative of many of the candidate designs served to demonstrate proposed fabrication techniques and to verify design and analysis methods.

Silicon Carbide Technologies for Lightweighted Aerospace Mirrors

DTIC Science & Technology

2008-09-01

Silicon Carbide Technologies for Lightweighted Aerospace Mirrors Lawrence E. Matson (1) Ming Y. Chen (1) Brett deBlonk (2) Iwona A...glass and beryllium to produce lightweighted aerospace mirror systems has reached its limits due to the long lead times, high processing costs...for making mirror structural substrates, figuring and finishing technologies being investigated to reduce cost time and cost, and non-destructive

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.

Impedance-Based Structural Health Monitoring for Composite Laminates at Cryogenic Environments

NASA Technical Reports Server (NTRS)

Tseng, Kevin

2003-01-01

One of the important ways of increasing the payload in a reusable launch vehicle (RLV) is to replace heavy metallic materials by lightweight composite laminates. Among various parts and systems of the RLV, this project focuses on tanks containing cryogenic fuel. Historically, aluminum alloys have been used as the materials to construct fuel tanks for launch vehicles. To replace aluminum alloys with composite laminates or honeycomb materials, engineers have to make sure that the composites are free of defects before, during, and after launch. In addition to robust design and manufacturing procedures, the performance of the composite structures needs to be monitored constantly.In recent years, the impedance-based health monitoring technique has shown its promise in many applications. This technique makes use of the special properties of smart piezoelectric materials to identify the change of material properties due to the nucleation and progression of damage. The piezoceramic patch serves as a sensor and an actuator simultaneously. The piezoelectric patch is bonded onto an existing structure or embedded into a new structure and electrically excited at high frequencies. The signature (impedance or admittance) is extracted as a function of the exciting frequency and is compared with the baseline signature of the healthy state. The damage is quantified using root mean square deviation (RMSD) in the impedance signatures with respect to the baseline signature. A major advantage of this technique is that the procedure is nondestructive in nature and does not perturb the properties and performance of the materials and structures. This project aims at applying the impedance-based nondestructive testing technique to the damage identification of composite laminates at cryogenic temperature.

Design, fabrication, and structural testing of a lightweight shadow shield for deep-space application

NASA Technical Reports Server (NTRS)

Miao, D.; Barber, J. R.; Dewitt, R. L.

1977-01-01

Two full-scale, lightweight, double-sheeted shadow shields were developed as the primary element of a deep-space thermal protection system for liquid-hydrogen propellant tankage. The thermal and mechanical considerations used in s, the method of fabrication, and the environmental testing results on a prototype shield are discussed. Testing consisted of a transient cooldown period, a prolonged cold soak, and a transient warmup. The mechanical and thermal analyses used in the shield design are sufficient to produce a lightweight rugged shadow shield assembly that is structurally adequate for its intended application.

Preliminary Analysis of the 30-m UltraBoom Flight Test

NASA Technical Reports Server (NTRS)

Agnes, Gregory S.; Abelson, Robert D.; Miyake, Robert; Lin, John K. H.; Welsh, Joe; Watson, Judith J.

2005-01-01

Future NASA missions require long, ultra-lightweight booms to enable solar sails, large sunshields, and other gossamer-type spacecraft structures. The space experiment discussed in this paper will flight validate the non-traditional ultra lightweight rigidizable, inflatable, isogrid structure utilizing graphite shape memory polymer (GR/SMP) called UltraBoom(TradeMark). The focus of this paper is the analysis of the 3-m ground test article. The primary objective of the mission is to show that a combination of ground testing and analysis can predict the on-orbit performance of an ultra lightweight boom that is scalable, predictable, and thermomechanically stable.

Passive damping of composite blades using embedded piezoelectric modules or shape memory alloy wires: a comparative study

NASA Astrophysics Data System (ADS)

Bachmann, F.; de Oliveira, R.; Sigg, A.; Schnyder, V.; Delpero, T.; Jaehne, R.; Bergamini, A.; Michaud, V.; Ermanni, P.

2012-07-01

Emission reduction from civil aviation has been intensively addressed in the scientific community in recent years. The combined use of novel aircraft engine architectures such as open rotor engines and lightweight materials offer the potential for fuel savings, which could contribute significantly in reaching gas emissions targets, but suffer from vibration and noise issues. We investigated the potential improvement of mechanical damping of open rotor composite fan blades by comparing two integrated passive damping systems: shape memory alloy wires and piezoelectric shunt circuits. Passive damping concepts were first validated on carbon fibre reinforced epoxy composite plates and then implemented in a 1:5 model of an open rotor blade manufactured by resin transfer moulding (RTM). A two-step process was proposed for the structural integration of the damping devices into a full composite fan blade. Forced vibration measurements of the plates and blade prototypes quantified the efficiency of both approaches, and their related weight penalty.

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.

Substrate structures for InP-based devices

DOEpatents

Wanlass, Mark W.; Sheldon, Peter

1990-01-01

A substrate structure for an InP-based semiconductor device having an InP based film is disclosed. The substrate structure includes a substrate region having a lightweight bulk substrate and an upper GaAs layer. An interconnecting region is disposed between the substrate region and the InP-based device. The interconnecting region includes a compositionally graded intermediate layer substantially lattice-matched at one end to the GaAs layer and substantially lattice-matched at the opposite end to the InP-based film. The interconnecting region further includes a dislocation mechanism disposed between the GaAs layer and the InP-based film in cooperation with the graded intermediate layer, the buffer mechanism blocking and inhibiting propagation of threading dislocations between the substrate region, and the InP-based device.

NASA-UVA light aerospace alloy and structures technology program (LA2ST)

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Starke, Edger A., Jr.

1996-01-01

This progress report covers achievements made between January 1 and June 30, 1966 on the NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. . The accomplishments presented in this report are: (1) Mechanical and Environmental Degradation Mechanisms in Advanced Light Metals, (2) Aerospace Materials Science, and (3) Mechanics of Materials for Light Aerospace Structures. Collective accomplishments between January and June of 1996 include: 4 journal or proceedings publications, 1 NASA progress report, 4 presentations at national technical meetings, and 2 PhD dissertations published.

Ultra lightweight PMMA-based composite plates with robust super-hydrophobic surfaces.

PubMed

Pareo, Paola; De Gregorio, Gian Luca; Manca, Michele; Pianesi, Maria Savina; De Marco, Luisa; Cavallaro, Francesco; Mari, Margherita; Pappadà, Silvio; Ciccarella, Giuseppe; Gigli, Giuseppe

2011-11-15

Extremely lightweight plates made of an engineered PMMA-based composite material loaded with hollow glass micro-sized spheres, nano-sized silica particles and aluminum hydroxide prismatic micro-flakes were realized by cast molding. Their interesting bulk mechanical properties were combined to properly tailored surface topography compatible with the achievement of a superhydrophobic behavior after the deposition of a specifically designed hydrophobic coating. With this aim, we synthesized two different species of fluoromethacrylic polymers functionalized with methoxysilane anchoring groups to be covalently grafted onto the surface protruding inorganic fillers. By modulating the feed composition of the reacting monomers, it was possible to combine the hydrophobic character of the polymer with an high adhesion strength to the substrate and hence to maximize both the water contact angle (up to 157°) and the durability of the easy-to-clean effect (up to 2000 h long outdoor exposure). Copyright © 2011 Elsevier Inc. All rights reserved.

KSC-08pd2650

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians clean contamination from the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2651

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician cleans contamination from the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2648

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician cleans contamination from the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2649

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician cleans contamination from the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2647

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the Super Lightweight Interchangeable Carrier, or SLIC, is uncovered so that technicians can clean contaminants found earlier. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

Stealing the Sword: Limiting Terrorist Use of Advanced Conventional Weapons

DTIC Science & Technology

2007-01-01

ammunition, are combined (see Figure 2.9 for a handgun concept that features four barrels , two with lethal and two with nonlethal ammunition). Other...Weapons Figure 2.9 A Four- Barreled Concept Handgun Mortar Systems Mortars have long been regarded as cheap, lightweight, short-range artillery. Mortars are...Terrorists? 37 manner).63 An example of an advance in lightweight materials for mor- tars is the development of the carbon fiber composite barrel in the

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

David Kisailus; Lara Estroff; Himadri S. Gupta

The technical presentations and discussions at this symposium disseminated and assessed current research and defined future directions in biomaterials research, with a focus on structure-function relationships in biological and biomimetic composites. The invited and contributed talks covered a diverse range of topics from fundamental biology, physics, chemistry, and materials science to potential applications in developing areas such as light-weight composites, multifunctional and smart materials, biomedical engineering, and nanoscaled sensors. The invited speakers were chosen to create a stimulating program with a mixture of established and junior faculty, industrial and academic researchers, and American and international experts in the field. Thismore » symposium served as an excellent introduction to the area for younger scientists (graduate students and post-doctoral researchers). Direct interactions between participants also helped to promote potential future collaborations involving multiple disciplines and institutions.« less

Generate an Optimum Lightweight Legs Structure Design Based on Critical Posture in A-FLoW Humanoid Robot

NASA Astrophysics Data System (ADS)

Luthfi, A.; Subhan, K. A.; Eko H, B.; Sanggar, D. R.; Pramadihanto, D.

2018-04-01

Lightweight construction and energy efficiency play an important role in humanoid robot development. The application of computer-aided engineering (CAE) in the development process is one of the possibilities to achieve the appropriate reduction of the weight. This paper describes a method to generate an optimum lightweight legs structure design based on critical posture during walking locomotion in A-FLoW Humanoid robot.The criticalposture can be obtained from the highest forces and moments in each joint of the robot body during walking locomotion. From the finite element analysis (FEA) result can be realized leg structure design of A-FLoW humanoid robot with a maximum displacement value of 0.05 mmand weight reduction about 0.598 Kg from the thigh structure and a maximum displacement value of 0,13 mmand weight reduction about 0.57 kg from the shin structure.

Pathfinder Photogrammetry Research for Ultra-Lightweight and Inflatable Space Structures

NASA Technical Reports Server (NTRS)

Giersch, Louis Roy Miller

2001-01-01

The defining characteristic of ultra-lightweight and inflatable space structures is that they are both very large and very low mass. This makes standard contacting methods of measurement (e.g. attaching accelerometers) impractical because the dynamics of the structure would be changed by the mass of the contacting instrument. Optical measurements are therefore more appropriate. Photogrammetry is a leading candidate for the optical analysis of gossamer structures because it allows for the measurement of a large number of points, is amenable to time sequences, and offers the potential for a high degree of accuracy. The purpose of this thesis is to develop the methodology and determine the effectiveness of a photogrammetry system in measuring ultra-lightweight and inflatable space structures. The results of this thesis will be considered in the design of an automated photogrammetry system for the l6m-diameter vacuum chamber at the NASA Langley Research Center.

Structurally Integrated Antenna Concepts for HALE UAVs

NASA Technical Reports Server (NTRS)

Cravey, Robin L.; Vedeler, Erik; Goins, Larry; Young, W. Robert; Lawrence, Roland W.

2006-01-01

This technical memorandum describes work done in support of the Multifunctional Structures and Materials Team under the Vehicle Systems Program's ITAS (Integrated Tailored Aero Structures) Project during FY 2005. The Electromagnetics and Sensors Branch (ESB) developed three ultra lightweight antenna concepts compatible with HALE UAVs (High Altitude Long Endurance Unmanned Aerial Vehicles). ESB also developed antenna elements that minimize the interaction between elements and the vehicle to minimize the impact of wing flexure on the EM (electromagnetic) performance of the integrated array. In addition, computer models were developed to perform phase correction for antenna arrays whose elements are moving relative to each other due to wing deformations expected in HALE vehicle concepts. Development of lightweight, conformal or structurally integrated antenna elements and compensating for the impact of a lightweight, flexible structure on a large antenna array are important steps in the realization of HALE UAVs for microwave applications such as passive remote sensing and communications.

Analysis of the mechanical behavior of single wall carbon nanotubes by a modified molecular structural mechanics model incorporating an advanced chemical force field

NASA Astrophysics Data System (ADS)

Eberhardt, Oliver; Wallmersperger, Thomas

2018-03-01

The outstanding properties of carbon nanotubes (CNTs) keep attracting the attention of researchers from different fields. CNTs are promising candidates for applications e.g. in lightweight construction but also in electronics, medicine and many more. The basis for the realization of the manifold applications is a detailed knowledge of the material properties of the carbon nanotubes. In particular for applications in lightweight constructions or in composites, the knowledge of the mechanical behavior of the CNTs is of vital interest. Hence, a lot of effort is put into the experimental and theoretical determination of the mechanical material properties of CNTs. Due to their small size, special techniques have to be applied. In this research, a modified molecular structural mechanics model for the numerical determination of the mechanical behavior of carbon nanotubes is presented. It uses an advanced approach for the geometrical representation of the CNT structure while the covalent bonds in the CNTs are represented by beam elements. Furthermore, the model is specifically designed to overcome major drawbacks in existing molecular structural mechanics models. This includes energetic consistency with the underlying chemical force field. The model is developed further to enable the application of a more advanced chemical force field representation. The developed model is able to predict, inter alia, the lateral and radial stiffness properties of the CNTs. The results for the lateral stiffness are given and discussed in order to emphasize the progress made with the presented approach.

Process of constructing a lightweight x-ray flight mirror assembly

NASA Astrophysics Data System (ADS)

McClelland, Ryan S.; Biskach, Michael P.; Chan, Kai-Wing; Espina, Rebecca A.; Hohl, Bruce R.; Saha, Timo T.; Zhang, William W.

2014-07-01

Lightweight and high resolution optics are needed for future space-based x-ray telescopes to achieve advances in highenergy astrophysics. NASA's Next Generation X-ray Optics (NGXO) project has made significant progress towards building such optics, both in terms of maturing the technology for spaceflight readiness and improving the angular resolution. Technology Development Modules (TDMs) holding three pairs of mirrors have been regularly and repeatedly integrated and tested both for optical performance and mechanical strength. X-ray test results have been improved over the past year from 10.3 arc-seconds Half Power Diameter (HPD) to 8.3 arc-seconds HPD. A vibration test has been completed to NASA standard verification levels showing the optics can survive launch and pointing towards improvements in strengthening the modules through redundant bonds. A Finite Element Analysis (FEA) study was completed which shows the mirror distortion caused by bonding is insensitive to the number of bonds. Next generation TDMs, which will demonstrate a lightweight structure and mount additional pairs of mirrors, have been designed and fabricated. The light weight of the module structure is achieved through the use of E-60 Beryllium Oxide metal matrix composite material. As the angular resolution of the development modules has improved, gravity distortion during horizontal x-ray testing has become a limiting factor. To address this issue, a facility capable of testing in the vertical orientation has been designed and planned. Test boring at the construction site suggest standard caisson construction methods can be utilized to install a subterranean vertical vacuum pipe. This facility will also allow for the testing of kinematically mounted mirror segments, which greatly reduces the effect of bonding displacements. A development platform demonstrating the feasibility of kinematically mounting mirror segments has been designed, fabricated, and successfully tested.

Wood-based Tri-Axial Sandwich Composite Materials: Design, Fabrication, Testing, Modeling and Application

Treesearch

Jinghao Li; John F. Hunt; Shaoqin Gong; Zhiyong Cai

2014-01-01

As the demand for sustainable materials increases, there are unique challenges and opportunities to develop light-weight green composites materials for a wide range of applications. Thus wood-based composite materials from renewable forests may provide options for some niche applications while helping to protect our environment. In this paper, the wood-based tri-axial...

Investigation on Wall Panel Sandwiched With Lightweight Concrete

NASA Astrophysics Data System (ADS)

Lakshmikandhan, K. N.; Harshavardhan, B. S.; Prabakar, J.; Saibabu, S.

2017-08-01

The rapid population growth and urbanization have made a massive demand for the shelter and construction materials. Masonry walls are the major component in the housing sector and it has brittle characteristics and exhibit poor performance against the uncertain loads. Further, the structure requires heavier sections for carrying the dead weight of masonry walls. The present investigations are carried out to develop a simple, lightweight and cost effective technology for replacing the existing wall systems. The lightweight concrete is developed for the construction of sandwich wall panel. The EPS (Expanded Polystyrene) beads of 3 mm diameter size are mixed with concrete and developed a lightweight concrete with a density 9 kN/m3. The lightweight sandwich panel is cast with a lightweight concrete inner core and ferrocement outer skins. This lightweight wall panel is tested for in-plane compression loading. A nonlinear finite element analysis with damaged plasticity model is carried out with both material and geometrical nonlinearities. The experimental and analytical results were compared. The finite element study predicted the ultimate load carrying capacity of the sandwich panel with reasonable accuracy. The present study showed that the lightweight concrete is well suitable for the lightweight sandwich wall panels.

Applying a Stitched, Rod-Stiffened Concept to Heavily Loaded Structure

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2013-01-01

NASA and the Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft wing structure, first in the NASA Advanced Composites Technology (ACT) program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the labor associated with panel fabrication and assembly can be significantly reduced and the need for mechanical fasteners is almost eliminated. Stitching provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. Stitching also reduces part count, and therefore, cost of the structure. The stitched panel concept used in the ACT program in the 1990's used simple blade-stiffeners as stringers, caps and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. A comparison between the blade-stiffened structure and PRSEUS is presented focusing on highly loaded structure and demonstrating improved weight reduction.

Effect of lightweight aggregates prepared from fly ash on lightweight concrete performances

NASA Astrophysics Data System (ADS)

Punlert, S.; Laoratanakul, P.; Kongdee, R.; Suntako, R.

2017-09-01

Lightweight aggregates were prepared from fly ash of by-products from the paper industry. The influence of the ratio of clay to fly ash and processing conditions on lightweight aggregates properties were investigated. It was found that the amount of fly ash directly affected to porosity of lightweight aggregates. Lightweight aggregates with the ratio of clay to fly ash at 80:20 wt% using the sintering temperature at 1210°C exhibits bulk density of 1.66 g cm-3, compressive strength of 25 MPa and water absorption of 0.55%. The replacement of coarse aggregates with lightweight aggregates at 100 wt% for concrete production showed the ultimate properties of concrete with density of 1780 g cm-3, water absorption of 3.55%, compressive strength of 40.94 MPa and thermal conductivity of 0.77 W m-1K-1. The concrete had more than 25% weight reduction while keeping a similar compressive strength to an ordinary concrete. This is revealed that lightweight aggregates could be applied into structural concrete because it was able to reduce work load and increase safety factor of construction.

Flush-mounting technique for composite beams

NASA Technical Reports Server (NTRS)

Harman, T. C.; Kay, B. F.

1980-01-01

Procedure permits mounting of heavy parts to surface of composite beams without appreciably weakening beam web. Web is split and held apart in region where attachment is to be made by lightweight precast foam filler. Bolt hole penetrates foam rather than web, and is secured by barrelnut in transverse bushing through web.

Cylindrical Piezoelectric Fiber Composite Actuators

NASA Technical Reports Server (NTRS)

Allison, Sidney G.; Shams, Qamar A.; Fox, Robert L.

2008-01-01

The use of piezoelectric devices has become widespread since Pierre and Jacques Curie discovered the piezoelectric effect in 1880. Examples of current applications of piezoelectric devices include ultrasonic transducers, micro-positioning devices, buzzers, strain sensors, and clocks. The invention of such lightweight, relatively inexpensive piezoceramic-fiber-composite actuators as macro fiber composite (MFC) actuators has made it possible to obtain strains and displacements greater than those that could be generated by prior actuators based on monolithic piezoceramic sheet materials. MFC actuators are flat, flexible actuators designed for bonding to structures to apply or detect strains. Bonding multiple layers of MFC actuators together could increase force capability, but not strain or displacement capability. Cylindrical piezoelectric fiber composite (CPFC) actuators have been invented as alternatives to MFC actuators for applications in which greater forces and/or strains or displacements may be required. In essence, a CPFC actuator is an MFC or other piezoceramic fiber composite actuator fabricated in a cylindrical instead of its conventional flat shape. Cylindrical is used here in the general sense, encompassing shapes that can have circular, elliptical, rectangular or other cross-sectional shapes in the planes perpendicular to their longitudinal axes.

Ultra-lightweight optics for laser communications

NASA Astrophysics Data System (ADS)

Vukobratovich, Daniel

1990-07-01

Recent applications of the very light Al/SiC metal-matrix composite SXA in the construction of telescopes for use as receiver antennas in optical intersatellite communication systems are reviewed and illustrated with drawings and diagrams. Data on the mechanical properties (specific stiffness, fundamental frequency, dynamic response, and fracture toughness) and the thermal expansion, distortion, and diffusivity of SXA are compared with those for Al 6016-T6, Be I-70A, SiC, and Zerodur in tables, and the advantages of SXA structural foams of density 250-500 kg/cu m are indicated. The criteria evaluated for optimization of the mirror shape and the overall telescope design are discussed, and four prototype Cassegrain telescopes (with Meinel or Dall truss structures) are described in detail.

Report of the Asilomar 3 LDR Workshop

NASA Technical Reports Server (NTRS)

Mahoney, M. J. (Editor)

1988-01-01

The conclusions and recommendations of the workshop held to study technology development issues critical to the Large Deployable Reflector (LDR) are summarized. LDR is to be a dedicated, orbiting, astronomical observatory, operating at wavelengths from 30 to 1000 microns, a spectral region where the Earth's atmosphere is almost completely opaque. Because it will have a large, segmented, passively cooled aperture, LDR addresses a wide range of technology areas. These include lightweight, low cost, structural composite reflector panels, primary support structures, wavefront sensing and adaptive optics, thermal background management, and integrated vibration and pointing control systems. The science objectives for LDR present instrument development challenges for coherent and direct arrayed detectors which can operate effectively at far infrared and submillimeter wavelengths, and for sub-Kelvin cryogenic systems.

Development of lightweight aluminum compression panels reinforced by boron-epoxy infiltrated extrusions

NASA Technical Reports Server (NTRS)

Roy, P. A.; Mcelman, J. A.; Henshaw, J.

1973-01-01

Analytical and experimental studies were performed to evaluate the structural efficiencies afforded by the selective reinforcement of conventional aluminum compression panels with unidirectional boron epoxy composite materials. A unique approach for selective reinforcement was utilized called boron/epoxy infiltration. This technique uses extruded metal sections with preformed hollow voids into which unidirectional boron filaments are drawn and subsequently infiltrated with resin to form an integral part. Simplified analytical models were developed to investigate the behavior of stiffener webs with reinforced flanges. Theoretical results are presented demonstrating the effects of transverse shear, of the reinforcement, flange eccentricity and torsional stiffness in such construction. A series of 55 tests were conducted on boron-infiltrated rods and extruded structural sections.

Analysis and sizing of Mars aerobrake structure

NASA Technical Reports Server (NTRS)

Raju, I. S.; Craft, W. J.

1993-01-01

A cone-sphere aeroshell structure for aerobraking into Martian atmosphere is studied. Using this structural configuration, a space frame load-bearing structure is proposed. To generate this structure efficiently and to perform a variety of studies of several configurations, a mesh generator that utilizes only a few configurational parameters is developed. A finite element analysis program that analyzes space frame structures was developed. A sizing algorithm that arrives at a minimum mass configuration was developed and integrated into the finite element analysis program. A typical 135-ft-diam aerobrake configuration was analyzed and sized. The minimum mass obtained in this study using high modulus graphite/epoxy composite material members is compared with the masses obtained from two other aerobrake structures using lightweight erectable tetrahedral truss and part-spherical truss configurations. Excellent agreement for the minimum mass was obtained with the three different aerobrake structures. Also, the minimum mass using the present structure was obtained when the supports were not at the base but at about 75 percent of the base diameter.

Cooled Ceramic Matrix Composite Propulsion Structures Demonstrated

NASA Technical Reports Server (NTRS)

Jaskowiak, Martha H.; Dickens, Kevin W.

2005-01-01

NASA's Next Generation Launch Technology (NGLT) Program has successfully demonstrated cooled ceramic matrix composite (CMC) technology in a scramjet engine test. This demonstration represented the world s largest cooled nonmetallic matrix composite panel fabricated for a scramjet engine and the first cooled nonmetallic composite to be tested in a scramjet facility. Lightweight, high-temperature, actively cooled structures have been identified as a key technology for enabling reliable and low-cost space access. Tradeoff studies have shown this to be the case for a variety of launch platforms, including rockets and hypersonic cruise vehicles. Actively cooled carbon and CMC structures may meet high-performance goals at significantly lower weight, while improving safety by operating with a higher margin between the design temperature and material upper-use temperature. Studies have shown that using actively cooled CMCs can reduce the weight of the cooled flow-path component from 4.5 to 1.6 lb/sq ft and the weight of the propulsion system s cooled surface area by more than 50 percent. This weight savings enables advanced concepts, increased payload, and increased range. The ability of the cooled CMC flow-path components to operate over 1000 F hotter than the state-of-the-art metallic concept adds system design flexibility to space-access vehicle concepts. Other potential system-level benefits include smaller fuel pumps, lower part count, lower cost, and increased operating margin.

Simplified analytical model and balanced design approach for light-weight wood-based structural panel in bending

Treesearch

Jinghao Li; John F. Hunt; Shaoqin Gong; Zhiyong Cai

2016-01-01

This paper presents a simplified analytical model and balanced design approach for modeling lightweight wood-based structural panels in bending. Because many design parameters are required to input for the model of finite element analysis (FEA) during the preliminary design process and optimization, the equivalent method was developed to analyze the mechanical...

LIGHTWEIGHT GREEN ROOF SYSTEMS

EPA Science Inventory

Applying a Lightweight Green Roof System to a building can achieve in managing storm water runoff, decreasing heat gain, yielding energy savings, and mitigating the heat island effect. Currently, Most green roof systems are considerably heavy and require structural reinforceme...

Light weight, high-speed, and self-powered wireless fiber optic sensor (WiFOS) structural health monitor system for avionics and aerospace environments

NASA Astrophysics Data System (ADS)

Mendoza, Edgar A.; Kempen, Cornelia; Sun, Sunjian; Esterkin, Yan

2014-09-01

This paper describes recent progress towards the development of an innovative light weight, high-speed, and selfpowered wireless fiber optic sensor (WiFOS™) structural health monitor system suitable for the onboard and in-flight unattended detection, localization, and classification of load, fatigue, and structural damage in advanced composite materials commonly used in avionics and aerospace systems. The WiFOS™ system is based on ROI's advancements on monolithic photonic integrated circuit microchip technology, integrated with smart power management, on-board data processing, wireless data transmission optoelectronics, and self-power using energy harvesting tools such as solar, vibration, thermoelectric, and magneto-electric. The self-powered, wireless WiFOS™ system offers a versatile and powerful SHM tool to enhance the reliability and safety of avionics platforms, jet fighters, helicopters, commercial aircraft that use lightweight composite material structures, by providing comprehensive information about the structural integrity of the structure from a large number of locations. Immediate SHM applications are found in rotorcraft and aircraft, ships, submarines, and in next generation weapon systems, and in commercial oil and petrochemical, aerospace industries, civil structures, power utilities, portable medical devices, and biotechnology, homeland security and a wide spectrum of other applications.

Digital Morphing Wing: Active Wing Shaping Concept Using Composite Lattice-Based Cellular Structures.

PubMed

Jenett, Benjamin; Calisch, Sam; Cellucci, Daniel; Cramer, Nick; Gershenfeld, Neil; Swei, Sean; Cheung, Kenneth C

2017-03-01

We describe an approach for the discrete and reversible assembly of tunable and actively deformable structures using modular building block parts for robotic applications. The primary technical challenge addressed by this work is the use of this method to design and fabricate low density, highly compliant robotic structures with spatially tuned stiffness. This approach offers a number of potential advantages over more conventional methods for constructing compliant robots. The discrete assembly reduces manufacturing complexity, as relatively simple parts can be batch-produced and joined to make complex structures. Global mechanical properties can be tuned based on sub-part ordering and geometry, because local stiffness and density can be independently set to a wide range of values and varied spatially. The structure's intrinsic modularity can significantly simplify analysis and simulation. Simple analytical models for the behavior of each building block type can be calibrated with empirical testing and synthesized into a highly accurate and computationally efficient model of the full compliant system. As a case study, we describe a modular and reversibly assembled wing that performs continuous span-wise twist deformation. It exhibits high performance aerodynamic characteristics, is lightweight and simple to fabricate and repair. The wing is constructed from discrete lattice elements, wherein the geometric and mechanical attributes of the building blocks determine the global mechanical properties of the wing. We describe the mechanical design and structural performance of the digital morphing wing, including their relationship to wind tunnel tests that suggest the ability to increase roll efficiency compared to a conventional rigid aileron system. We focus here on describing the approach to design, modeling, and construction as a generalizable approach for robotics that require very lightweight, tunable, and actively deformable structures.

Digital Morphing Wing: Active Wing Shaping Concept Using Composite Lattice-Based Cellular Structures

PubMed Central

Jenett, Benjamin; Calisch, Sam; Cellucci, Daniel; Cramer, Nick; Gershenfeld, Neil; Swei, Sean

2017-01-01

Abstract We describe an approach for the discrete and reversible assembly of tunable and actively deformable structures using modular building block parts for robotic applications. The primary technical challenge addressed by this work is the use of this method to design and fabricate low density, highly compliant robotic structures with spatially tuned stiffness. This approach offers a number of potential advantages over more conventional methods for constructing compliant robots. The discrete assembly reduces manufacturing complexity, as relatively simple parts can be batch-produced and joined to make complex structures. Global mechanical properties can be tuned based on sub-part ordering and geometry, because local stiffness and density can be independently set to a wide range of values and varied spatially. The structure's intrinsic modularity can significantly simplify analysis and simulation. Simple analytical models for the behavior of each building block type can be calibrated with empirical testing and synthesized into a highly accurate and computationally efficient model of the full compliant system. As a case study, we describe a modular and reversibly assembled wing that performs continuous span-wise twist deformation. It exhibits high performance aerodynamic characteristics, is lightweight and simple to fabricate and repair. The wing is constructed from discrete lattice elements, wherein the geometric and mechanical attributes of the building blocks determine the global mechanical properties of the wing. We describe the mechanical design and structural performance of the digital morphing wing, including their relationship to wind tunnel tests that suggest the ability to increase roll efficiency compared to a conventional rigid aileron system. We focus here on describing the approach to design, modeling, and construction as a generalizable approach for robotics that require very lightweight, tunable, and actively deformable structures. PMID:28289574

A turtle-like swimming robot using a smart soft composite (SSC) structure

NASA Astrophysics Data System (ADS)

Kim, Hyung-Jung; Song, Sung-Hyuk; Ahn, Sung-Hoon

2013-01-01

This paper describes the development of a biomimetic swimming robot based on the locomotion of a marine turtle. To realize the smooth, soft flapping motions of this type of turtle, a novel actuator was also developed, using a smart soft composite (SSC) structure that can generate bending and twisting motions in a simple, lightweight structure. The SSC structure is a composite consisting of an active component to generate the actuation force, a passive component to determine the twisting angle of the structure, and a matrix to combine the components. The motion of such a structure can be designed by specifying the angle between a filament of the scaffold structure and a shape-memory alloy (SMA) wire. The bending and twisting motion of the SSC structure is explained in terms of classical laminate theory, and cross-ply and angled-ply structures were fabricated to evaluate its motion. Finally, the turtle-like motion of a swimming robot was realized by employing a specially designed SSC structure. To mimic the posterior positive twisting angle of a turtle’s flipper during the upstroke, the SMA wire on the upper side was offset, and a positive ply-angled scaffold was used. Likewise, for the anterior negative twisting angle of the flipper during the downstroke, an offset SMA wire on the lower side and a positive ply-angled scaffold were also required. The fabricated flipper’s length is 64.3 mm and it realizes 55 mm bending and 24° twisting. The resulting robot achieved a swimming speed of 22.5 mm s-1.

The effect of interlaminar graphene nano-sheets reinforced e-glass fiber/ epoxy on low velocity impact response of a composite plate

NASA Astrophysics Data System (ADS)

Al-Maharma, A. Y.; Sendur, P.

2018-05-01

In this study, we compare the inter-laminar effect of graphene nano-sheets (GNSs) and CNTs on the single and multiple dynamic impact response of E-glass fiber reinforced epoxy composite (GFEP). In the comparisons, raw GFEP composite is used as baseline for quantifying the improvement on the dynamic impact response. For that purpose, finite element based models are developed for GNSs on GFEP, graphene coating on glass fibers, inter-laminar composite of CNTs reinforced polyester at 7.5 vol%, and combinations of all these reinforcements. Comparisons are made on three metrics: (i) total deformation, (ii) the contact force, and (iii) internal energy of the composite plate. The improvement on axial modulus (E1) of GFEP reinforced with one layer of GNS (0.5 wt%) without polyester at lamination sequence of [0]8 is 29.4%, which is very close to the improvement of 31% on storage modulus for multi-layer graphene with 0.5 wt% reinforced E-glass/epoxy composite at room temperature. Using three GNSs (1.5 wt%) reinforced polyester composite as interlaminar layer results in an improvement of 57.1% on E1 of GFEP composite. The simulation results reveal that the interlaminar three GNSs/polyester composite at mid-plane of GFEP laminated composite can significantly improve the dynamic impact resistance of GFEP structure compared to the other aforementioned structural reinforcements. Reinforcing GFEP composite with three layers of GNSs/polyester composite at mid-plane results in an average of 35% improvement on the dynamic impact resistance for healthy and damaged composite plate under low velocity impacts of single and multiple steel projectiles. This model can find application in various areas including structural health monitoring, fire retardant composite, and manufacturing of high strength and lightweight mechanical parts such as gas tank, aircraft wings and wind turbine blades.

Glass/Epoxy Door Panel for Automobiles

NASA Technical Reports Server (NTRS)

Bauer, J. L. JR.

1985-01-01

Lightweight panel cost-effective. Integrally-molded intrusion strap key feature of composite outer door panel. Strap replaces bulky and heavy steel instrusion beam of conventional door. Standard steel inner panel used for demonstration purposes. Door redesigned to exploit advantages of composite outer panel thinner. Outer panel for automobilie door, made of glass/epoxy composite material, lighter than conventional steel door panel, meets same strength requirements, and less expensive.

Sound transmission through finite lightweight multilayered structures with thin air layers.

PubMed

Dijckmans, A; Vermeir, G; Lauriks, W

2010-12-01

The sound transmission loss (STL) of finite lightweight multilayered structures with thin air layers is studied in this paper. Two types of models are used to describe the vibro-acoustic behavior of these structures. Standard transfer matrix method assumes infinite layers and represents the plane wave propagation in the layers. A wave based model describes the direct sound transmission through a rectangular structure placed between two reverberant rooms. Full vibro-acoustic coupling between rooms, plates, and air cavities is taken into account. Comparison with double glazing measurements shows that this effect of vibro-acoustic coupling is important in lightweight double walls. For infinite structures, structural damping has no significant influence on STL below the coincidence frequency. In this frequency region, the non-resonant transmission or so-called mass-law behavior dominates sound transmission. Modal simulations suggest a large influence of structural damping on STL. This is confirmed by experiments with double fiberboard partitions and sandwich structures. The results show that for thin air layers, the damping induced by friction and viscous effects at the air gap surfaces can largely influence and improve the sound transmission characteristics.

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.

In-process, non-destructive, dynamic testing of high-speed polymer composite rotors

NASA Astrophysics Data System (ADS)

Kuschmierz, Robert; Filippatos, Angelos; Günther, Philipp; Langkamp, Albert; Hufenbach, Werner; Czarske, Jürgen; Fischer, Andreas

2015-03-01

Polymer composite rotors are lightweight and offer great perspectives in high-speed applications such as turbo machinery. Currently, novel rotor structures and materials are investigated for the purpose of increasing machine efficiency and lifetime, as well as allowing for higher dynamic loads. However, due to the complexity of the composite materials an in-process measurement system is required. This allows for monitoring the evolution of damages under dynamic loads, for testing and predicting the structural integrity of composite rotors in process. In rotor design, it can be used for calibrating and improving models, simulating the dynamic behaviour of polymer composite rotors. The measurement system is to work non-invasive, offer micron uncertainty, as well as a high measurement rate of several tens of kHz. Furthermore, it must be applicable at high surface speeds and under technical vacuum. In order to fulfil these demands a novel laser distance measurement system was developed. It provides the angle resolved measurement of the biaxial deformation of a fibre-reinforced polymer composite rotor with micron uncertainty at surface speeds of more than 300 m/s. Furthermore, a simulation procedure combining a finite element model and a damage mechanics model is applied. A comparison of the measured data and the numerically calculated data is performed to validate the simulation towards rotor expansion. This validating procedure can be used for a model calibration in the future. The simulation procedure could be used to investigate different damage-test cases of the rotor, in order to define its structural behaviour without further experiments.

Influence of Aerogel Morphology and Reinforcement Architecture on Gas Convection in Aerogel Composites

NASA Technical Reports Server (NTRS)

Hurwitz, Frances I.; Meyer, Matthew; Guo, Haiquan; Rogers, Richard B.; DeMange, Jeffrey J.; Richardson, Hayley

2016-01-01

A variety of thermal protection applications require lightweight insulation capable of withstanding temperatures well above 900 C. Aerogels offer extremely low-density thermal insulation due to their mesoporous structure, which inhibits both gas convection and solid conduction. Silica aerogel systems are limited to use temperatures of 600-700 C, above which they sinter. Alumina aerogels maintain a porous structure to higher temperatures than silica, before transforming to -alumina and densifying. We have synthesized aluminosilicate aerogels capable of maintaining higher surface areas at temperatures above 1100 C than an all-alumina aerogel using -Boehmite as the aluminum source and tetraethoxysilane (TEOS) as the silicon source. The pore structure of these aerogels varies with thermal exposure temperature and time, as the aluminosilicate undergoes a variety of phase changes to form transition aluminas. Transformation to -alumina is inhibited by incorporation of silica into the alumina lattice. The aerogels are fragile, but can be reinforced using a large variety of ceramic papers, felts or fabrics. The objective of the current study is to characterize the influence of choice of reinforcement and architecture on gas permeability of the aerogel composites in both the as fabricated condition and following thermal exposure, as well as understand the effects of incorporating hydrophobic treatments in the composites.

Nondestructive Evaluation of Adhesive Bonds via Ultrasonic Phase Measurements

NASA Technical Reports Server (NTRS)

Haldren, Harold A.; Perey, Daniel F.; Yost, William T.; Cramer, K. Elliott; Gupta, Mool C.

2016-01-01

The use of advanced composites utilizing adhesively bonded structures offers advantages in weight and cost for both the aerospace and automotive industries. Conventional nondestructive evaluation (NDE) has proved unable to reliably detect weak bonds or bond deterioration during service life conditions. A new nondestructive technique for quantitatively measuring adhesive bond strength is demonstrated. In this paper, an ultrasonic technique employing constant frequency pulsed phased-locked loop (CFPPLL) circuitry to monitor the phase response of a bonded structure from change in thermal stress is discussed. Theoretical research suggests that the thermal response of a bonded interface relates well with the quality of the adhesive bond. In particular, the effective stiffness of the adhesive-adherent interface may be extracted from the thermal phase response of the structure. The sensitivity of the CFPPLL instrument allows detection of bond pathologies that have been previously difficult-to-detect. Theoretical results with this ultrasonic technique on single epoxy lap joint (SLJ) specimens are presented and discussed. This technique has the potential to advance the use of adhesive bonds - and by association, advanced composite structures - by providing a reliable method to measure adhesive bond strength, thus permitting more complex, lightweight, and safe designs.

An experimental study of mechanical behavior of natural fiber reinforced polymer matrix composites

NASA Astrophysics Data System (ADS)

Ratna, Sanatan; Misra, Sheelam

2018-05-01

Fibre-reinforced polymer composites have played a dominant role for a long time in a variety of applications for their high specific strength and modulus. The fibre which serves as a reinforcement in reinforced plastics may be synthetic or natural. Past studies show that only synthetic fibres such as glass, carbon etc., have been used in fibre reinforced plastics. Although glass and other synthetic fibre-reinforced plastics possess high specific strength, their fields of application are very limited because of their inherent higher cost of production. In this connection, an investigation has been carried out to make use of horse hair, an animal fibre abundantly available in India. Animal fibres are not only strong and lightweight but also relatively very cheaper than mineral fibre. The present work describes the development and characterization of a new set of animal fiber based polymer composites consisting of horse hair as reinforcement and epoxy resin. The newly developed composites are characterized with respect to their mechanical characteristics. Experiments are carried out to study the effect of fibre length on mechanical behavior of these epoxy based polymer composites. Composite made form horse hair can be used as a potential reinforcing material for many structural and non-structural applications. This work can be further extended to study other aspects of such composites like effect of fiber content, loading pattern, fibre treatment on mechanical behavior of horse hair based polymer horse hair.

Thermal Response Of Composite Insulation

NASA Technical Reports Server (NTRS)

Stewart, David A.; Leiser, Daniel B.; Smith, Marnell; Kolodziej, Paul

1988-01-01

Engineering model gives useful predictions. Pair of reports presents theoretical and experimental analyses of thermal responses of multiple-component, lightweight, porous, ceramic insulators. Particular materials examined destined for use in Space Shuttle thermal protection system, test methods and heat-transfer theory useful to chemical, metallurgical, and ceramic engineers needing to calculate transient thermal responses of refractory composites.

Lightweight Ceramic Composition of Carbon Silicon Oxygen and Boron

NASA Technical Reports Server (NTRS)

Leiser, Daniel B. (Inventor); Hsu, Ming-Ta (Inventor); Chen, Timothy S. (Inventor)

1997-01-01

Lightweight, monolithic ceramics resistant to oxidation in air at high temperatures are made by impregnating a porous carbon preform with a sol which contains a mixture of tetraethoxysilane, dimethyldiethoxysilane and trimethyl borate. The sol is gelled and dried on the carbon preform to form a ceramic precursor. The precursor is pyrolyzed in an inert atmosphere to form the ceramic which is made of carbon, silicon, oxygen and boron. The carbon of the preform reacts with the dried gel during the pyrolysis to form a component of the resulting ceramic. The ceramic is of the same size, shape and form as the carbon precursor. Thus, using a porous, fibrous carbon precursor, such as a carbon felt, results in a porous, fibrous ceramic. Ceramics of the invention are useful as lightweight tiles for a reentry spacecraft.

Surface Characterization of Carbon Fiber Polymer Composites and Aluminum Alloys After Laser Interference Structuring

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Greer, Clayton M.; Chen, Jian; Warren, Charles D.; Daniel, Claus

2016-07-01

The increasing use of carbon fiber-reinforced polymer matrix composites (CFPC) and aluminum alloys as lightweight materials in the automotive and aerospace industries demands enhanced surface preparation and control of surface morphology prior to joining. In this study, surfaces of both composite and aluminum were prepared for joining using an Nd:YAG laser in a two-beam interference setup, enabling the (1) structuring of the AL 5182 surface, (2) removal of the resin layer on top of carbon fibers, and (3) structuring of the carbon fibers. CFPC specimens of T700S carbon fiber, Prepreg—T83 epoxy, 5 ply thick, 0°/90° plaques were used. The effects of laser fluence, scanning speed, and number of shots-per-spot were investigated on the removal rate of the resin without an excessive damage of the fibers. Optical micrographs, 3D imaging, and scanning electron microscope imaging were used to study the effect of the laser processing on the surface morphology. It was found that an effective resin ablation and a low density of broken fibers for CFPC specimens was attained using laser fluences of 1-2 J/cm2 and number of 2-4 pulses per spot. A relatively large area of periodic line structures due to energy interference were formed on the aluminum surface at laser fluences of 12 J/cm2 and number of 4-6 pulses per spot.

Micro-Organ Devices

NASA Technical Reports Server (NTRS)

Gonda, Steven R.; Leslie, Julia; Chang, Robert C.; Starly, Binil; Sun, Wei; Culbertson, Christopher; Holtorf, Heidi

2009-01-01

Micro-organ devices (MODs) are being developed to satisfy an emerging need for small, lightweight, reproducible, biological-experimentati on apparatuses that are amenable to automated operation and that imp ose minimal demands for resources (principally, power and fluids). I n simplest terms, a MOD is a microfluidic device containing a variety of microstructures and assemblies of cells, all designed to mimic a complex in vivo microenvironment by replicating one or more in vivo micro-organ structures, the architectures and composition of the extr acellular matrices in the organs of interest, and the in vivo fluid flows. In addition to microscopic flow channels, a MOD contains one or more micro-organ wells containing cells residing in microscopic e xtracellular matrices and/or scaffolds, the shapes and compositions o f which enable replication of the corresponding in vivo cell assembl ies and flows.

Development of Metal Matrix Composites for NASA's Advanced Propulsion Systems

NASA Technical Reports Server (NTRS)

Lee, J.; Elam, S.

2001-01-01

The state-of-the-art development of several Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The goal is to provide an overview of NASA-Marshall Space Flight Center's on-going activities in MMC components for advanced liquid rocket engines such as the X-33 vehicle's Aerospike engine and X-34's Fastrac engine. The focus will be on lightweight, low cost, and environmental compatibility with oxygen and hydrogen of key MMC materials, within each of NASA's new propulsion application, that will provide a high payoff for NASA's Reusable Launch Vehicles and space access vehicles. In order to fabricate structures from MMC, effective joining methods must be developed to join MMC to the same or to different monolithic alloys. Therefore, a qualitative assessment of MMC's welding and joining techniques will be outlined.

Mechanical Attachment of Reusable Surface Insulation to Space Shuttle Primary Structure

NASA Technical Reports Server (NTRS)

Fleck, R. W.; Lehman, J. K.

1973-01-01

Three methods of attaching surface insulation tiles to shuttle primary structure have been proposed: direct bond, mechanical attachment, and subpanels with standoffs. The direct bond approach is lightweight but is difficult to refurbish and inspect. The subpanel approach is heavier but allows for easy refurbishment since subpanels are easily removed and replaced. The mechanical attachment approach allows easy refurbishment and inspection and is lightweight when an efficient insulator is used between surface insulation tiles and primary structure.

Helping Aircraft Engines Lighten Up

NASA Technical Reports Server (NTRS)

2004-01-01

High-temperature polyimide/carbon fiber matrix composites are developed by the Polymers Branch at NASA's Glenn Research Center. These materials can withstand high temperatures and have good processing properties, which make them particularly useful for jet and rocket engines and for components such as fan blades, bushings, and duct segments. Applying polyimide composites as components for aerospace structures can lead to substantial vehicle weight reductions. A typical polyimide composite is made up of layers of carbon or glass fibers glued together by a high-temperature polymer to make the material strong, stiff, and lightweight. Organic molecules containing carbon, nitrogen, oxygen, and hydrogen within the polyimide keep the material s density low, resulting in the light weight. The strength of a component or part made from a polyimide comes mainly from the reinforcing high-strength fibers. The strength of the carbon fibers coupled with the stiffness of polyimides allows engineers to make a very rigid structure without it being massive. Another benefit of a polyimide s suitability for aerospace applications is its reduced need for machining. When polyimide parts are removed from a mold, they are nearly in their final shape. Usually, very little machining is needed before a part is ready for use.

Portable Ultrasonic Guided Wave Inspection with MACRO Fiber Composite Actuators

NASA Astrophysics Data System (ADS)

Haig, A.; Mudge, P.; Catton, P.; Balachandran, W.

2010-02-01

The development of portable ultrasonic guided wave transducer arrays that utilize Macro Fiber Composite actuators (MFCs) is described. Portable inspection equipment can make use of ultrasonic guided waves to rapidly screen large areas of many types of engineering structures for defects. The defect finding performance combined with the difficulty of application determines how much the engineering industry makes use of this non-destructive, non-disruptive technology. The developments with MFCs have the potential to make considerable improvements in both these aspects. MFCs are highly efficient because they use interdigital electrodes to facilitate the extensional, d33 displacement mode. Their fiber composite design allows them to be thin, lightweight, flexible and durable. The flexibility affords them conformance with curved surfaces, which can facilitate good mechanical coupling. The suitability of a given transducer for Long Range Ultrasonic Testing is governed by the nature and amplitude of the displacement that it excites/senses in the contact area of the target structure. This nature is explored for MFCs through directional sensitivity analysis and empirical testing. Housing methods that facilitate non-permanent coupling techniques are discussed. Finally, arrangements of arrays of MFCs for the guided wave inspection of plates and pipes are considered and some broad design criteria are given.

Aerospace materials

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

Dornheim, M.A.

1991-04-01

A comprehensive evaluation is made of the development trends in high performance advanced aerospace structural materials applications. It is noted that the anticipated predominance of thermoplastic composite-matrix polymers in the F-22/F-23 ATF propotypes has not materialized, due both to their high materials and processing costs and the emergence of a more tractable high operating temperature thermoset, BMI, whose toughness characteristics are of the order of those associated with thermoplastics. No more than 15 percent of F-22 weight is thermoplastics; the F-23 use of such resins is nill. Throughout the advanced nonmetallics industry, reduced DOD procurements have come to represent slowmore » growth and the prospect of consolidation. Also, such lightweight Al-based metallics as the Al-Li alloys have posed a major market-share challenge to polymeric composites, as in the case of the C-17 airlifter's 6,269 lbs of such Al-Li alloys as 2090, largely in cargo floor and ramp bulkhead structures. The EFA fighter makes frequent use of SPF-DB Ti alloys in combat damage-critical components. Metal-matrix composites employing titanium aluminide matrices will be extensively used in the X-30 hypersonic aircraft program.« less

Lightweight orthotic appliances

NASA Technical Reports Server (NTRS)

Baucom, R. M.; St. Clair, T. L.

1976-01-01

Graphite-filament reinforced polymer materials are used in applications requiring high tensile strength and modulus. Superior properties of graphite composite materials permit fabrication of supports that are considerably lighter, thinner, and stiffer than conventional components.

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

Sabau, Adrian

Joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products could become less expensive and the joints more robust because of a new method that harnesses a laser’s power and precision.

A computational analysis of the ballistic performance of light-weight hybrid composite armors

NASA Astrophysics Data System (ADS)

Grujicic, M.; Pandurangan, B.; Koudela, K. L.; Cheeseman, B. A.

2006-11-01

The ability of hybrid light-weight fiber-reinforced polymer-matrix composite laminate armor to withstand the impact of a fragment simulating projectile (FSP) is investigated using a non-linear dynamics transient computational analysis. The hybrid armor is constructed using various combinations and stacking sequences of a high-strength/high-stiffness carbon fiber-reinforced epoxy (CFRE) and a high-ductility/high-toughness Kevlar fiber-reinforced epoxy (KFRE) composite laminates of different thicknesses. The results obtained indicate that at a fixed thickness of the armor both the stacking sequence and the number of CFRE/KFRE laminates substantially affect the ballistic performance of the armor. Specifically, it is found that the armor consisting of one layer of KFRE and one layer of CFRE, with KFRE laminate constituting the outer surface of the armor, possesses the maximum resistance towards the projectile-induced damage and failure. The results obtained are rationalized using an analysis of the elastic wave reflection and transmission behavior at the inter-laminate and laminate/air interfaces.

Fatigue Behavior Degradation due to the Interlaminar Conditions in Lightweight Piezoelectric Composite Actuator (lipca)

NASA Astrophysics Data System (ADS)

Kim, Cheol-Woong; Yoon, Kwang-Joon

The advanced piezoelectric ceramic composite actuator, which is called LIPCA (LIghtweight Piezoelectric Composite Actuator), replaced the Al foil and stainless steel in THUNDER with the FRP and the optimization of the laminate configuration was performed to maximize the stress transfer and the fiber bridging effect. This study evaluated the fatigue characteristics in LIPCA under the resonance frequency, and the changes of its interlaminar phase were also evaluated. Beside, the residual stress distribution was estimated. In conclusions, firstly, comparing with the fatigue life of LIPCA without the artificial delamination (intact LIPCA), the fatigue life of LIPCA embedded by the artificial delamination was decreased up to 50%. Secondly, the micro void growth and the coalescence of epoxy were actively made at the interlaminar phase subject to the large tensile stress. Finally, it was known that the harmonic configuration between the compressive residuals stress and the tensile one was made. The requirement of the performance displacement increment was satisfied.

KSC-08pd2656

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians finish replacing the protective cover over the Super Lightweight Interchangeable Carrier, or SLIC. The cover was removed to clean the carrier of contaminants found Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2643

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician uncovers the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2646

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians inspect areas of the Super Lightweight Interchangeable Carrier, or SLIC, for contamination. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2641

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the payload canister is moved on the floor for loading of the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2653

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, the protective cover is being replaced on the Super Lightweight Interchangeable Carrier, or SLIC. The cover was removed to clean the carrier of contaminants found Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2645

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians inspect areas of the Super Lightweight Interchangeable Carrier, or SLIC, for contamination. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2655

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician works to replace the protective cover on the Super Lightweight Interchangeable Carrier, or SLIC. The cover was removed to clean the carrier of contaminants found Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2654

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician works to replace the protective cover on the Super Lightweight Interchangeable Carrier, or SLIC. The cover was removed to clean the carrier of contaminants found Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2657

NASA Image and Video Library

2008-09-18

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians finish replacing the protective cover over the Super Lightweight Interchangeable Carrier, or SLIC. The cover was removed to clean the carrier of contaminants found Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2642

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, a technician begins uncovering the Super Lightweight Interchangeable Carrier, or SLIC. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

KSC-08pd2644

NASA Image and Video Library

2008-09-17

CAPE CANAVERAL, Fla. - In the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center, technicians inspect areas of the Super Lightweight Interchangeable Carrier, or SLIC, for contamination. Contamination discovered Sept. 17 during preparations to deliver NASA's Hubble Space Telescope servicing payload to Launch Pad 39A will be removed. Cleanliness is extremely important for space shuttle Atlantis’ STS-125 mission to Hubble, and the teams have insured that the SLIC is ready to fly. The SLIC, which holds battery module assemblies for servicing of the Hubble Space Telescope on the STS-125 mission, is built with state-of-the-art, lightweight, composite materials - carbon fiber with a cyanate ester resin and a titanium metal matrix composite. These composites have greater strength-to-mass ratios than the metals typically used in spacecraft design. The carrier is one of four being transferred to Launch Pad 39A. At the pad, the carriers will be loaded into Atlantis’ payload bay. Launch of Atlantis is targeted for Oct. 10. Photo credit: NASA/Jack Pfaller

Niobium Carbide-Reinforced Al Matrix Composites Produced by High-Energy Ball Milling

NASA Astrophysics Data System (ADS)

Travessa, Dilermando Nagle; Silva, Marina Judice; Cardoso, Kátia Regina

2017-06-01

Aluminum and its alloys are key materials for the transportation industry as they contribute to the development of lightweight structures. The dispersion of hard ceramic particles in the Al soft matrix can lead to a substantial strengthening effect, resulting in composite materials exhibiting interesting mechanical properties and inspiring their technological use in sectors like the automotive and aerospace industries. Powder metallurgy techniques are attractive to design metal matrix composites, achieving a homogeneous distribution of the reinforcement into the metal matrix. In this work, pure aluminum has been reinforced with particles of niobium carbide (NbC), an extremely hard and stable refractory ceramic. Its use as a reinforcing phase in metal matrix composites has not been deeply explored. Composite powders produced after different milling times, with 10 and 20 vol pct of NbC were produced by high-energy ball milling and characterized by scanning electron microscopy and by X-ray diffraction to establish a relationship between the milling time and size, morphology, and distribution of the particles in the composite powder. Subsequently, an Al/10 pct NbC composite powder was hot extruded into cylindrical bars. The strength of the obtained composite bars is comparable to the commercial high-strength, aeronautical-grade aluminum alloys.

'NASA Invention of the Year' Controls Noise and Vibration

NASA Technical Reports Server (NTRS)

2007-01-01

Developed at NASA's Langley Research Center, the Macro-Fiber Composite (MFC) is designed to control vibration, noise, and deflections in composite structural beams and panels. Smart Material Corporation specializes in the development of piezocomposite components, and licensed the MFC technology from Langley in 2002. To date, Smart Material Corporation has sold MFCs to over 120 customers, including such industry giants as Volkswagen, Toyota, Honda, BMW, General Electric, and the tennis company, HEAD. The company estimates that its customers have filed at least 100 patents for their various unique uses of the technology. In addition, the company's product portfolio has grown to include piezoceramic fibers and fiber composites, piezoceramic actuators and sensors, and test equipment for these products. It also offers a compact, lightweight power system for MFC testing and validation. Consumer applications already on the market include piezoelectric systems as part of audio speakers, phonograph cartridges and microphones, and recreational products requiring vibration control, such as skis, snowboards, baseball bats, hockey sticks, and tennis racquets.

Hybrid Gear Performance Under Loss-of-Lubrication Conditions

NASA Technical Reports Server (NTRS)

Laberge, Kelsen E.; Berkebile, Stephen P.; Handschuh, Robert F.; Roberts, Gary D.

2017-01-01

Hybrid composite gear technology is being investigated to increase power density in rotorcraft drive systems. These gears differ from conventional steel gears in that the structural web material is replaced with a lightweight carbon fiber composite. Past studies have focused on performance of this technology under normal operating conditions, however, for this technology to be viable it must also withstand adverse conditions. The study presented here evaluates the performance of hybrid gears under loss-of-lubrication conditions in NASA Glenn Research Centers Contact Fatigue Test Facility. Two experiments are presented using small-scale 3.5 inch (8.9 cm) pitch diameter hybrid gears and compared to a baseline steel gear pair. Results of these tests show that there are limitations to the use of a hexagonal interlock pattern between the steel and composite. There is also evidence that the presence of polymer in the gear during an oil out event has a potential to increase time to failure. Further studies are planned to expand on these initial findings.

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.

Nanotube Production and Applications at Johnson Space Center

NASA Technical Reports Server (NTRS)

Nikolaev, Pavel; Files, Bradley; Arepalli, Sivaram; Scott, Carl; Holmes, William; Nicholson, Leonard S. (Technical Monitor)

2000-01-01

Promise of applications of carbon nanotubes has led to an intense effort at NASA/JSC, especially in the area of nanotube composites. Using the extraordinary mechanical strength of nanotubes, NASA hopes to design this revolutionary lightweight material for use in aerospace applications. Current research focuses on structural polymeric materials to attempt to lower the weight of spacecraft necessary for interplanetary missions. Other applications of nanotubes are also of interest for energy storage, gas storage, nanoelectronics, field emission, and biomedical applications. In pursuit of these goals, we have set up both laser and arc production processes for nanotubes. An in-depth diagnostic study of the plasma plume in front of the laser target has been studied to try to determine nanotube growth mechanisms. Complementary studies of characterization of nanotube product have added to knowledge of growth conditions. Results of our preliminary experiments in incorporating nanotubes into composites will be presented. Morphology and mechanical properties of the nanotubes composites will be discussed.

NASA Out-of-Autoclave Process Technology Development

NASA Technical Reports Server (NTRS)

Johnston, Norman, J.; Clinton, R. G., Jr.; McMahon, William M.

2000-01-01

Polymer matrix composites (PMCS) will play a significant role in the construction of large reusable launch vehicles (RLVs), mankind's future major access to low earth orbit and the international space station. PMCs are lightweight and offer attractive economies of scale and automated fabrication methodology. Fabrication of large RLV structures will require non-autoclave methods which have yet to be matured including (1) thermoplastic forming: heated head robotic tape placement, sheet extrusion, pultrusion, molding and forming; (2) electron beam curing: bulk and ply-by-ply automated placement; (3) RTM and VARTM. Research sponsored by NASA in industrial and NASA laboratories on automated placement techniques involving the first 2 categories will be presented.

The long-term behavior of lightweight and heavyweight meshes used to repair abdominal wall defects is determined by the host tissue repair process provoked by the mesh.

PubMed

Pascual, Gemma; Hernández-Gascón, Belén; Rodríguez, Marta; Sotomayor, Sandra; Peña, Estefania; Calvo, Begoña; Bellón, Juan M

2012-11-01

Although heavyweight (HW) or lightweight (LW) polypropylene (PP) meshes are widely used for hernia repair, other alternatives have recently appeared. They have the same large-pore structure yet are composed of polytetrafluoroethylene (PTFE). This study compares the long-term (3 and 6 months) behavior of meshes of different pore size (HW compared with LW) and composition (PP compared with PTFE). Partial defects were created in the lateral wall of the abdomen in New Zealand White rabbits and then repaired by the use of a HW or LW PP mesh or a new monofilament, large-pore PTFE mesh (Infinit). At 90 and 180 days after implantation, tissue incorporation, gene and protein expression of neocollagens (reverse transcription-polymerase chain reaction/immunofluorescence), macrophage response (immunohistochemistry), and biomechanical strength were determined. Shrinkage was measured at 90 days. All three meshes induced good host tissue ingrowth, yet the macrophage response was significantly greater in the PTFE implants (P < .05). Collagen 1/3 mRNA levels failed to vary at 90 days yet in the longer term, the LW meshes showed the reduced genetic expression of both collagens (P < .05) accompanied by increased neocollagen deposition, indicating more efficient mRNA translation. After 90-180 days of implant, tensile strengths and elastic modulus values were similar for all 3 implants (P > .05). Host collagen deposition is mesh pore size dependent whereas the macrophage response induced is composition dependent with a greater response shown by PTFE. In the long term, macroporous meshes show comparable biomechanical behavior regardless of their pore size or composition. Copyright © 2012 Mosby, Inc. All rights reserved.

Scaling laws for light weight optics, studies of light weight mirrors mounting and dynamic mirror stress, and light weight mirror and mount designs

NASA Technical Reports Server (NTRS)

Vukobratovich, Daniel; Richard, Ralph M.; Valente, Tina M.; Cho, Myung K.

1990-01-01

Scaling laws for light-weight optical systems are examined. A cubic relationship between mirror diameter and weight has been suggested and used by many designers of optical systems as the best description for all light-weight mirrors. A survey of existing light-weight systems in the open literature was made to clarify this issue. Fifty existing optical systems were surveyed with all varieties of light-weight mirrors including glass and beryllium structured mirrors, contoured mirrors, and very thin solid mirrors. These mirrors were then categorized and weight to diameter ratio was plotted to find a best curve for each case. A best fitting curve program tests nineteen different equations and ranks a goodness-to-fit for each of these equations. The resulting relationship found for each light-weight mirror category helps to quantify light-weight optical systems and methods of fabrication and provides comparisons between mirror types.

Mechanical Properties of Steel Fiber Reinforced all Lightweight Aggregate Concrete

NASA Astrophysics Data System (ADS)

Yang, Y. M.; Li, J. Y.; Zhen, Y.; Nie, Y. N.; Dong, W. L.

2018-05-01

In order to study the basic mechanical properties and failure characteristics of all lightweight aggregate concrete with different volume of steel fiber (0%, 1%, 2%), shale ceramsite is used as light coarse aggregate. The shale sand is made of light fine aggregate and mixed with different volume of steel fiber, and the mix proportion design of all lightweight aggregate concrete is carried out. The cubic compressive strength, axial compressive strength, flexural strength, splitting strength and modulus of elasticity of steel fiber all lightweight aggregate concrete were studied. Test results show that the incorporation of steel fiber can restrict the cracking of concrete, improve crack resistance; at the same time, it shows good plastic deformation ability and failure morphology. It lays a theoretical foundation for further research on the application of all lightweight aggregate concrete in structural systems.

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

NASA Technical Reports Server (NTRS)

Pereira, J. Michael; Emmerling, William; Seng, Silvia; Frankenberger, Charles; Ruggeri, Charles R.; Revilock, Duane M.; Carney, Kelly S.

2015-01-01

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test predictions. This paper documents the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

Unveiling the Semicoherent Interface with Definite Orientation Relationships between Reinforcements and Matrix in Novel Al3BC/Al Composites.

PubMed

Zhao, Yongfeng; Qian, Zhao; Ma, Xia; Chen, Houwen; Gao, Tong; Wu, Yuying; Liu, Xiangfa

2016-10-05

High-strength lightweight Al-based composites are promising materials for a wide range of applications. To provide high performance, a strong bonding interface for effective load transfer from the matrix to the reinforcement is essential. In this work, the novel Al 3 BC reinforced Al composites have been in situ fabricated through a liquid-solid reaction method and the bonding interface between Al 3 BC and Al matrix has been unveiled. The HRTEM characterizations on the Al 3 BC/Al interface verify it to be a semicoherent bonding structure with definite orientation relationships: (0001) Al 3 BC //(11̅1) Al ;[112̅0] Al 3 BC //[011] Al . Periodic arrays of geometrical misfit dislocations are also observed along the interface at each (0001) Al 3 BC plane or every five (11̅1) Al planes. This kind of interface between the reinforcement and the matrix is strong enough for effective load transfer, which would lead to the evidently improved strength and stiffness of the introduced new Al 3 BC/Al composites.

Thermally Conductive Metal-Tube/Carbon-Composite Joints

NASA Technical Reports Server (NTRS)

Copeland, Robert J.

2004-01-01

An improved method of fabricating joints between metal and carbon-fiber-based composite materials in lightweight radiators and heat sinks has been devised. Carbon-fiber-based composite materials have been used in such heat-transfer devices because they offer a combination of high thermal conductivity and low mass density. Metal tubes are typically used to carry heat-transfer fluids to and from such heat-transfer devices. The present fabrication method helps to ensure that the joints between the metal tubes and the composite-material parts in such heat-transfer devices have both (1) the relatively high thermal conductances needed for efficient transfer of heat and (2) the flexibility needed to accommodate differences among thermal expansions of dissimilar materials in operation over wide temperature ranges. Techniques used previously to join metal tubes with carbon-fiber-based composite parts have included press fitting and bonding with epoxy. Both of these prior techniques have been found to yield joints characterized by relatively high thermal resistances. The present method involves the use of a solder (63 percent Sn, 37 percent Pb) to form a highly thermally conductive joint between a metal tube and a carbon-fiber-based composite structure. Ordinarily, the large differences among the coefficients of thermal expansion of the metal tube, solder, and carbon-fiber-based composite would cause the solder to pull away from the composite upon post-fabrication cooldown from the molten state. In the present method, the structure of the solder is modified (see figure) to enable it to deform readily to accommodate the differential thermal expansion.

Lightweight high performance ceramic material

DOEpatents

Nunn, Stephen D [Knoxville, TN

2008-09-02

A sintered ceramic composition includes at least 50 wt. % boron carbide and at least 0.01 wt. % of at least one element selected from the group consisting of Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy Ho, Er, Tm, Yb, and Lu, the sintered ceramic composition being characterized by a density of at least 90% of theoretical density.

First bridge structure with lightweight high-performance concrete beams and deck in Virginia.

DOT National Transportation Integrated Search

2005-01-01

This study involved the construction and early performance of the first bridge in Virginia constructed with lightweight high-performance concrete (LWHPC) having a density of 120 lb/ft3 in the beams and deck. The design strength and permeability were ...

Strain Monitoring of Flexible Structures

NASA Technical Reports Server (NTRS)

Litteken, Douglas A.

2017-01-01

One of the biggest challenges facing NASA's deep space exploration goals is structural mass. A long duration transit vehicle on a journey to Mars, for example, requires a large internal volume for cargo, supplies and crew support. As with all space structures, a large pressure vessel is not enough. The vehicle also requires thermal, micro-meteoroid, and radiation protection, a navigation and control system, a propulsion system, and a power system, etc. As vehicles get larger, their associated systems also get larger and more complex. These vehicles require larger lift capacities and force the mission to become extremely costly. In order to build large volume habitable vehicles, with only minimal increases in launch volume and mass, NASA is developing lightweight structures. Lightweight structures are made from non-metallic materials including graphite composites and high strength fabrics and could provide similar or better structural capability than metals, but with significant launch volume and mass savings. Fabric structures specifically, have been worked by NASA off and on since its inception, but most notably in the 1990's with the TransHAB program. These TransHAB developed structures use a layered material approach to form a pressure vessel with integrated thermal and micro-meteoroid and orbital debris (MMOD) protection. The flexible fabrics allow the vessel to be packed in a small volume during launch and expand into a much larger volume once in orbit. NASA and Bigelow Aerospace recently installed the first human-rated inflatable module on the International Space Station (ISS), known as the Bigelow Expandable Activity Module (BEAM) in May of 2016. The module provides a similar internal volume to that of an Orbital ATK Cygnus cargo vehicle, but with a 77% launch volume savings. As lightweight structures are developed, testing methods are vital to understanding their behavior and validating analytical models. Common techniques can be applied to fabric materials, such as tensile testing, fatigue testing, and shear testing, but common measurement techniques cannot be used on fabric. Measuring strain in a material and during a test is a critical parameter for an engineer to monitor the structure during the test and correlate to an analytical model. The ability to measure strain in fabric structures is a challenge for NASA. Foil strain gauges, for example, are commonplace on metallic structures testing, but are extremely difficult to interface with a fabric substrate. New strain measuring techniques need to be developed for use with fabric structures. This paper investigates options for measuring strain in fabric structures for both ground testing and in-space structural health monitoring. It evaluates current commercially available options and outlines development work underway to build custom measurement solutions for NASA's fabric structures.

Super flame-retardant lightweight rime-like carbon-phenolic nanofoam

PubMed Central

Cheng, Haiming; Hong, Changqing; Zhang, Xinghong; Xue, Huafei; Meng, Songhe; Han, Jiecai

2016-01-01

The desire for lightweight nanoporous materials with high-performance thermal insulation and efficient anti-ablation resistance for energy conservation and thermal protection/insulation has greatly motivated research and development recently. The main challenge to synthesize such lightweight materials is how to balance the relationship of low thermal conductivity and flame retardancy. Herein, we propose a new concept of lightweight “rime-like” structured carbon-phenolic nanocomposites to solve this problem, where the 3D chopped network-structured carbon fiber (NCF) monoliths are incorporated with nanoporous phenolic aerogel to retain structural and functional integrity. The nanometer-scaled porous phenolic (NP) was synthesized through polymerization-induced phase separation and ambient pressure drying using phenolic resin (PR) solution as reaction source, ethylene glycol (EG) as solvent and hexamethylenetetramine (HMTA) as catalyst. We demonstrate that the as-prepared NCF-NP nanocomposite exhibits with a low density of 0.25–0.35 g/cm3, low thermal conductivity of 0.125 Wm−1K−1 and outstanding flame retardancy exceeding 2000 °C under arc-jet wind tunnel simulation environment. Our results show that the synthesis strategy is a promising approach for producing nanocomposites with excellent high-temperature heat blocking property. PMID:27629114

Super flame-retardant lightweight rime-like carbon-phenolic nanofoam

NASA Astrophysics Data System (ADS)

Cheng, Haiming; Hong, Changqing; Zhang, Xinghong; Xue, Huafei; Meng, Songhe; Han, Jiecai

2016-09-01

The desire for lightweight nanoporous materials with high-performance thermal insulation and efficient anti-ablation resistance for energy conservation and thermal protection/insulation has greatly motivated research and development recently. The main challenge to synthesize such lightweight materials is how to balance the relationship of low thermal conductivity and flame retardancy. Herein, we propose a new concept of lightweight “rime-like” structured carbon-phenolic nanocomposites to solve this problem, where the 3D chopped network-structured carbon fiber (NCF) monoliths are incorporated with nanoporous phenolic aerogel to retain structural and functional integrity. The nanometer-scaled porous phenolic (NP) was synthesized through polymerization-induced phase separation and ambient pressure drying using phenolic resin (PR) solution as reaction source, ethylene glycol (EG) as solvent and hexamethylenetetramine (HMTA) as catalyst. We demonstrate that the as-prepared NCF-NP nanocomposite exhibits with a low density of 0.25-0.35 g/cm3, low thermal conductivity of 0.125 Wm-1K-1 and outstanding flame retardancy exceeding 2000 °C under arc-jet wind tunnel simulation environment. Our results show that the synthesis strategy is a promising approach for producing nanocomposites with excellent high-temperature heat blocking property.

Broadband low-frequency sound isolation by lightweight adaptive metamaterials

NASA Astrophysics Data System (ADS)

Liao, Yunhong; Chen, Yangyang; Huang, Guoliang; Zhou, Xiaoming

2018-03-01

Blocking broadband low-frequency airborne noises is highly desirable in lots of engineering applications, while it is extremely difficult to be realized with lightweight materials and/or structures. Recently, a new class of lightweight adaptive metamaterials with hybrid shunting circuits has been proposed, demonstrating super broadband structure-borne bandgaps. In this study, we aim at examining their potentials in broadband sound isolation by establishing an analytical model that rigorously combines the piezoelectric dynamic couplings between adaptive metamaterials and acoustics. Sound transmission loss of the adaptive metamaterial is investigated with respect to both the frequency and angular spectrum to demonstrate their sound-insulation effects. We find that efficient sound isolation can indeed be pursued in the broadband bi-spectrum for not only the case of the small resonator's periodicity where only one mode relevant to the mass-spring resonance exists, but also for the large-periodicity scenario, so that the total weight can be even lighter, in which the multiple plate-resonator coupling modes appear. In the latter case, the negative spring stiffness provided by the piezoelectric stack has been utilized to suppress the resonance-induced high acoustic transmission. Such kinds of adaptive metamaterials could open a new approach for broadband noise isolation with extremely lightweight structures.

Life Cycle Assessment of Vehicle Lightweighting: Novel Mathematical Methods to Estimate Use-Phase Fuel Consumption.

PubMed

Kim, Hyung Chul; Wallington, Timothy J; Sullivan, John L; Keoleian, Gregory A

2015-08-18

Lightweighting is a key strategy to improve vehicle fuel economy. Assessing the life-cycle benefits of lightweighting requires a quantitative description of the use-phase fuel consumption reduction associated with mass reduction. We present novel methods of estimating mass-induced fuel consumption (MIF) and fuel reduction values (FRVs) from fuel economy and dynamometer test data in the U.S. Environmental Protection Agency (EPA) database. In the past, FRVs have been measured using experimental testing. We demonstrate that FRVs can be mathematically derived from coast down coefficients in the EPA vehicle test database avoiding additional testing. MIF and FRVs calculated for 83 different 2013 MY vehicles are in the ranges 0.22-0.43 and 0.15-0.26 L/(100 km 100 kg), respectively, and increase to 0.27-0.53 L/(100 km 100 kg) with powertrain resizing to retain equivalent vehicle performance. We show how use-phase fuel consumption can be estimated using MIF and FRVs in life cycle assessments (LCAs) of vehicle lightweighting from total vehicle and vehicle component perspectives with, and without, powertrain resizing. The mass-induced fuel consumption model is illustrated by estimating lifecycle greenhouse gas (GHG) emission benefits from lightweighting a grille opening reinforcement component using magnesium or carbon fiber composite for 83 different vehicle models.

Development of advanced lightweight containment systems

NASA Technical Reports Server (NTRS)

Stotler, C.

1981-01-01

Parametric type data were obtained on advanced lightweight containment systems. These data were used to generate design methods and procedures necessary for the successful development of such systems. The methods were then demonstrated through the design of a lightweight containment system for a CF6 size engine. The containment concept evaluated consisted basically of a lightweight structural sandwich shell wrapped with dry Kevlar cloth. The initial testing was directed towards the determination of the amount of Kevlar required to result in threshold containment for a specific set of test conditions. A relationship was then developed between the thickness required and the energy of the released blade so that the data could be used to design for conditions other than those tested.

Concept Definition Study for In-Space Structural Characterization of a Lightweight Solar Array

NASA Technical Reports Server (NTRS)

Woods-Vedeler, Jessica A.; Pappa, Richard S.; Jones, Thomas W.; Spellman, Regina; Scott, Willis; Mockensturm, Eric M.; Liddle, Donn; Oshel, Ed; Snyder, Michael

2002-01-01

A Concept Definition Study (CDS) was conducted to develop a proposed "Lightweight High-Voltage Stretched-Lens Concentrator Solar Array Experiment" under NASA's New Millennium Program Space Technology-6 (NMP ST-6) activity. As part of a multi-organizational team, NASA Langley Research Center's role in this proposed experiment was to lead Structural Characterization of the solar array during the flight experiment. In support of this role, NASA LaRC participated in the CDS to de.ne an experiment for static, dynamic, and deployment characterization of the array. In this study, NASA LaRC traded state-of-the-art measurement approaches appropriate for an in-space, STS-based flight experiment, provided initial analysis and testing of the lightweight solar array and lens elements, performed a lighting and photogrammetric simulation in conjunction with JSC, and produced an experiment concept definition to meet structural characterization requirements.

Deposition and Characterization of HVOF Thermal Sprayed Functionally Graded Coatings Deposited onto a Lightweight Material

NASA Astrophysics Data System (ADS)

Hasan, M.; Stokes, J.; Looney, L.; Hashmi, M. S. J.

2009-02-01

There is a significant interest in lightweight materials (like aluminum, magnesium, titanium, and so on) containing a wear resistance coating, in such industries as the automotive industry, to replace heavy components with lighter parts in order to decrease vehicle weight and increase fuel efficiency. Functionally graded coatings, in which the composition, microstructure, and/or properties vary gradually from the bond coat to the top coat, may be applied to lightweight materials, not only to decrease weight, but also to enhance components mechanical properties by ensuring gradual microstructural (changes) together with lower residual stress. In the current work, aluminum/tool-steel functionally graded coatings were deposited onto lightweight aluminum substrates. The graded coatings were then characterized in terms of residual stress and hardness. Results show that residual stress increased with an increase in deposition thickness and a decrease in number of layers. However, the hardness also increased with an increase in deposition thickness and decrease in number of layers. Therefore, an engineer must compromise between the hardness and stress values while designing a functionally graded coating-substrate system.

Application of Glass Fiber Waste Polypropylene Aggregate in Lightweight Concrete – thermal properties

NASA Astrophysics Data System (ADS)

Citek, D.; Rehacek, S.; Pavlik, Z.; Kolisko, J.; Dobias, D.; Pavlikova, M.

2018-03-01

Actual paper focus on thermal properties of a sustainable lightweight concrete incorporating high volume of waste polypropylene aggregate as partial substitution of natural aggregate. In presented experiments a glass fiber reinforced polypropylene (GFPP) which is a by-product of PP tubes production, partially substituted fine natural silica aggregate in 10, 20, 30, 40 and 50 mass %. Results were compared with a reference concrete mix without plastic waste in order to quantify the effect of GFPP use on concrete properties. Main material physical parameters were studied (bulk density, matrix density without air content, and particle size distribution). Especially a thermal transport and storage properties of GFPP were examined in dependence on compaction time. For the developed lightweight concrete, thermal properties were accessed using transient impulse technique, where the measurement was done in dependence on moisture content (from the fully water saturated state to dry state). It was found that the tested lightweight concrete should be prospective construction material possessing improved thermal insulation function and the reuse of waste plastics in concrete composition was beneficial both from the environmental and financial point of view.

Life cycle assessment of vehicle lightweighting: a physics-based model of mass-induced fuel consumption.

PubMed

Kim, Hyung Chul; Wallington, Timothy J

2013-12-17

Lightweighting is a key strategy used to improve vehicle fuel economy. Replacing conventional materials (e.g., steel) with lighter alternatives (e.g., aluminum, magnesium, and composites) decreases energy consumption and greenhouse gas (GHG) emissions during vehicle use, but often increases energy consumption and GHG emissions during materials and vehicle production. Assessing the life-cycle benefits of mass reduction requires a quantitative description of the mass-induced fuel consumption during vehicle use. A new physics-based method for estimating mass-induced fuel consumption (MIF) is proposed. We illustrate the utility of this method by using publicly available data to calculate MIF values in the range of 0.2-0.5 L/(100 km 100 kg) based on 106 records of fuel economy tests by the U.S. Environmental Protection Agency for 2013 model year vehicles. Lightweighting is shown to have the most benefit when applied to vehicles with high fuel consumption and high power. Use of the physics-based model presented here would place future life cycle assessment studies of vehicle lightweighting on a firmer scientific foundation.

Multifunctional Structures for High-Energy Lightweight Load-Bearing Storage

NASA Technical Reports Server (NTRS)

Loyselle, Patricia L.

2018-01-01

This is a pull-up banner of the Multifunctional Structures for High-Energy Lightweight Load-bearing Storage (M-SHELLS) technology that will be on display at the SciTech Conference in January 2018. Efforts in Multifunctional Structures for High Energy Load-Bearing Storage (M-Shells) are pushing the boundaries of development for hybrid electric propulsion for future commercial aeronautical transport. The M-Shells hybrid material would serve as the power/energy storage of the vehicle and provide structural integrity, freeing up usable volume and mass typically occupied by bulky batteries. The ultimate goal is to demonstrate a system-level mass savings with a multifunctional structure with energy storage.

Carbon Nanotube-Reinforced Aluminum Matrix Composites Produced by High-Energy Ball Milling

NASA Astrophysics Data System (ADS)

Travessa, Dilermando N.; da Rocha, Geovana V. B.; Cardoso, Kátia R.; Lieblich, Marcela

2017-05-01

Although multiwall carbon nanotubes (MWCNT) are promising materials to strengthen lightweight aluminum matrix composites, their dispersion into the metallic matrix is challenge. In the present work, MWCNT were dispersed into age-hardenable AA6061 aluminum alloy by high-energy ball milling and the blend was subsequently hot-extruded. The composite bars obtained were heat-treated by solution heat treatment at 520 °C and artificially aged at 177 °C for 8 h, in order to reach the T6 temper. Special attention was given to the integrity of the MWCNT along the entire composite production. The microstructure of the obtained bars was evaluated by optical and scanning electron microscopy, and the mechanical properties were evaluated by Vickers microhardness tests. Raman spectroscopy, x-ray diffraction and transmission electron microscopy were employed to evaluate the structural integrity of MWCNT. It was found that milling time is critical to reach a proper dispersion of the reinforcing phase. The composite hardness increased up to 67% with the dispersion of 2% in weight of MWCNT, when comparing with un-reinforced bars produced by similar route. However, age hardening was not observed in composite bars after heat treatment. It was also found that MWCNT continuously degraded along the process, being partially converted into Al4C3 in the final composite.

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.

Bioinspired large-scale aligned porous materials assembled with dual temperature gradients

PubMed Central

Bai, Hao; Chen, Yuan; Delattre, Benjamin; Tomsia, Antoni P.; Ritchie, Robert O.

2015-01-01

Natural materials, such as bone, teeth, shells, and wood, exhibit outstanding properties despite being porous and made of weak constituents. Frequently, they represent a source of inspiration to design strong, tough, and lightweight materials. Although many techniques have been introduced to create such structures, a long-range order of the porosity as well as a precise control of the final architecture remain difficult to achieve. These limitations severely hinder the scale-up fabrication of layered structures aimed for larger applications. We report on a bidirectional freezing technique to successfully assemble ceramic particles into scaffolds with large-scale aligned, lamellar, porous, nacre-like structure and long-range order at the centimeter scale. This is achieved by modifying the cold finger with a polydimethylsiloxane (PDMS) wedge to control the nucleation and growth of ice crystals under dual temperature gradients. Our approach could provide an effective way of manufacturing novel bioinspired structural materials, in particular advanced materials such as composites, where a higher level of control over the structure is required. PMID:26824062

Failure at Frame-Stringer Intersections in PRSEUS Panels

NASA Technical Reports Server (NTRS)

Jegley, Dawn C.

2012-01-01

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structures. In this concept a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. By adding unidirectional carbon rods to the top of stiffeners, the panel becomes more structurally efficient. This combination produces a more damage tolerant design. This study focuses on the intersection between the rod-stiffener and the foam-filled frame in a PRSEUS specimen. Compression loading is considered, which induces stress concentrations at the intersection point that can lead to failures. An experiment with accompanying analysis for a single-frame specimen is described, followed by a parametric study of simple reinforcements to reduce strains in the intersection region.

Carbon nanofiber reinforced epoxy matrix composites and syntactic foams - mechanical, thermal, and electrical properties

NASA Astrophysics Data System (ADS)

Poveda, Ronald Leonel

The tailorability of composite materials is crucial for use in a wide array of real-world applications, which range from heat-sensitive computer components to fuselage reinforcement on commercial aircraft. The mechanical, electrical, and thermal properties of composites are highly dependent on their material composition, method of fabrication, inclusion orientation, and constituent percentages. The focus of this work is to explore carbon nanofibers (CNFs) as potential nanoscale reinforcement for hollow particle filled polymer composites referred to as syntactic foams. In the present study, polymer composites with high weight fractions of CNFs, ranging from 1-10 wt.%, are used for quasi-static and high strain rate compression analysis, as well as for evaluation and characterization of thermal and electrical properties. It is shown that during compressive characterization of vapor grown carbon nanofiber (CNF)/epoxy composites in the strain rate range of 10-4-2800 s-1, a difference in the fiber failure mechanism is identified based on the strain rate. Results from compression analyses show that the addition of fractions of CNFs and glass microballoons varies the compressive strength and elastic modulus of epoxy composites by as much as 53.6% and 39.9%. The compressive strength and modulus of the syntactic foams is also shown to generally increase by a factor of 3.41 and 2.96, respectively, with increasing strain rate when quasi-static and high strain rate testing data are compared, proving strain rate sensitivity of these reinforced composites. Exposure to moisture over a 6 month period of time is found to reduce the quasi-static and high strain rate strength and modulus, with a maximum of 7% weight gain with select grades of CNF/syntactic foam. The degradation of glass microballoons due to dealkalization is found to be the primary mechanism for reduced mechanical properties, as well as moisture diffusion and weight gain. In terms of thermal analysis results, the coefficient of thermal expansion (CTE) of CNF/epoxy and CNF/syntactic foam composites reinforced with glass microballoons decrease by as much as 11.6% and 38.4%. The experimental CTE values for all of the composites also fit within the bounds of established analytical models predicting the CTE of fiber and particle-reinforced composites. Further thermal studies through dynamic mechanical analysis demonstrated increased thermal stability and damping capability, where the maximum use and glass transition temperatures increase as much as 27.1% and 25.0%, respectively. The electrical properties of CNF reinforced composites are evaluated as well, where the electrical impedance decreases and the dielectric constant increases with addition of CNFs. Such behavior occurs despite the presence of epoxy and glass microballoons, which serve as insulative phases. Such results are useful in design considerations of lightweight composite materials used in weight saving, compressive strength, and damage tolerance applications, such as lightweight aircraft structure reinforcement, automobile components, and buoyancy control with marine submersibles. The results of the analyses have also evaluated certain factors for environmental exposure and temperature extremes, as well as considerations for electronics packaging, all of which have also played a role in shaping avant-garde composite structure designs for efficient, versatile, and long-life service use.

Fatigue damage prognosis of internal delamination in composite plates under cyclic compression loadings using affine arithmetic as uncertainty propagation tool

NASA Astrophysics Data System (ADS)

Gbaguidi, Audrey J.-M.

Structural health monitoring (SHM) has become indispensable for reducing maintenance costs and increasing the in-service capacity of a structure. The increased use of lightweight composite materials in aircraft structures drastically increased the effects of fatigue induced damage on their critical structural components and thus the necessity to predict the remaining life of those components. Damage prognosis, one of the least investigated fields in SHM, uses the current damage state of the system to forecast its future performance by estimating the expected loading environments. A successful damage prediction model requires the integration of technologies in areas like measurements, materials science, mechanics of materials, and probability theories, but most importantly the quantification of uncertainty in all these areas. In this study, Affine Arithmetic is used as a method for incorporating the uncertainties due to the material properties into the fatigue life prognosis of composite plates subjected to cyclic compressive loadings. When loadings are compressive in nature, the composite plates undergo repeated buckling-unloading of the delaminated layer which induces mixed modes I and II states of stress at the tip of the delamination in the plates. The Kardomateas model-based prediction law is used to predict the growth of the delamination, while the integration of the effects of the uncertainties for modes I and II coefficients in the fatigue life prediction model is handled using Affine arithmetic. The Mode I and Mode II interlaminar fracture toughness and fatigue characterization of the composite plates are first experimentally studied to obtain the material coefficients and fracture toughness, respectively. Next, these obtained coefficients are used in the Kardomateas law to predict the delamination lengths in the composite plates while using Affine Arithmetic to handle their uncertainties. At last, the fatigue characterization of the composite plates during compressive-buckling loadings is experimentally studied, and the delamination lengths obtained are compared with the predicted values to check the performance of Affine Arithmetic as an uncertainty propagation tool.

Development of lightweight concrete mixes for construction industry at the state of Arkansas

NASA Astrophysics Data System (ADS)

Almansouri, Mohammed Abdulwahab

As the construction industry evolved, the need for more durable, long lasting infrastructure increased. Therefore, more efforts have been put to find new methods to improve the properties of the concrete to prolong the service life of the structural elements. One of these methods is the use of lightweight aggregate as an internal curing agent to help reducing self-desiccation and shrinkage. This research studied the effects of using locally available lightweight aggregate (expanded clay), as a partial replacement of normal weight aggregate in the concrete matrix. The concrete mixtures contained lightweight aggregate with a replacement percentage of 12.5, 25, 37.5, and 50 percent by volume. Fresh properties as well as compressive strength, modulus of rupture, and drying shrinkage were measured. While was effective in reducing drying shrinkage, the use of lightweight aggregate resulted in slightly reducing both the compressive strength and modulus of rupture.

Comparing optical test methods for a lightweight primary mirror of a space-borne Cassegrain telescope

NASA Astrophysics Data System (ADS)

Lin, Wei-Cheng; Chang, Shenq-Tsong; Yu, Zong-Ru; Lin, Yu-Chuan; Ho, Cheng-Fong; Huang, Ting-Ming; Chen, Cheng-Huan

2014-09-01

A Cassegrain telescope with a 450 mm clear aperture was developed for use in a spaceborne optical remote-sensing instrument. Self-weight deformation and thermal distortion were considered: to this end, Zerodur was used to manufacture the primary mirror. The lightweight scheme adopted a hexagonal cell structure yielding a lightweight ratio of 50%. In general, optical testing on a lightweight mirror is a critical technique during both the manufacturing and assembly processes. To prevent unexpected measurement errors that cause erroneous judgment, this paper proposes a novel and reliable analytical method for optical testing, called the bench test. The proposed algorithm was used to distinguish the manufacturing form error from surface deformation caused by the mounting, supporter and gravity effects for the optical testing. The performance of the proposed bench test was compared with a conventional vertical setup for optical testing during the manufacturing process of the lightweight mirror.

Mechanical Properties of Triaxial Braided Carbon/Epoxy Composites

NASA Technical Reports Server (NTRS)

Bowman, C. L.; Roberts, G. D.; Braley, M. S.; Xie, M.; Booker, M. J.

2003-01-01

In an on-going effort to increase the safety and efficiency of turbine engines, the National Aeronautics and Space Administration is exploring lightweight alternatives to the metal containment structures that currently encase commercial jet engines. Epoxy reinforced with braided carbon fibers is a candidate structural material which may be suitable for an engine case. This paper reports flat-coupon mechanical-property experiments performed to compliment previously reported subcomponent impact testing and analytical simulation of containment structures. Triaxial-braid T700/5208 epoxy and triaxial-braid T700/M36 toughened epoxy composites were evaluated. Also, two triaxial-braid architectures (0 +/- 60 deg., 0 +/- 45 deg.) with the M36 resin were evaluated through tension, compression, and shear testing. Tensile behavior was compared between standard straight-sided specimens (ASTM D3039) and bowtie specimens. Both double-notch shear (ASTM D3846) and Iosepescu (ASTM D5379) tests were performed as well. The M36/0 +/- 45 deg. configuration yield the best response when measurements were made parallel to the axial tows. Conversely, the M36/0 +/- 60 deg. configuration was best when measurements were made perpendicular to the axial tows. The results were used to identify critical properties and to augment the analysis of impact experiments.

Validation Tests of Fiber Optic Strain-Based Operational Shape and Load Measurements

NASA Technical Reports Server (NTRS)

Bakalyar, John A.; Jutte, Christine

2012-01-01

Aircraft design has been progressing toward reduced structural weight to improve fuel efficiency, increase performance, and reduce cost. Lightweight aircraft structures are more flexible than conventional designs and require new design considerations. Intelligent sensing allows for enhanced control and monitoring of aircraft, which enables increased structurally efficiency. The NASA Dryden Flight Research Center (DFRC) has developed an instrumentation system and analysis techniques that combine to make distributed structural measurements practical for lightweight vehicles. Dryden's Fiber Optic Strain Sensing (FOSS) technology enables a multitude of lightweight, distributed surface strain measurements. The analysis techniques, referred to as the Displacement Transfer Functions (DTF) and Load Transfer Functions (LTF), use surface strain values to calculate structural deflections and operational loads. The combined system is useful for real-time monitoring of aeroelastic structures, along with many other applications. This paper describes how the capabilities of the measurement system were demonstrated using subscale test articles that represent simple aircraft structures. Empirical FOSS strain data were used within the DTF to calculate the displacement of the article and within the LTF to calculate bending moments due to loads acting on the article. The results of the tests, accuracy of the measurements, and a sensitivity analysis are presented.

Material requirements for the High Speed Civil Transport

NASA Technical Reports Server (NTRS)

Stephens, Joseph R.; Hecht, Ralph J.; Johnson, Andrew M.

1993-01-01

Under NASA-sponsored High Speed Research (HSR) programs, the materials and processing requirements have been identified for overcoming the environmental and economic barriers of the next generation High Speed Civil Transport (HSCT) propulsion system. The long (2 to 5 hours) supersonic cruise portion of the HSCT cycle will place additional durability requirements on all hot section engine components. Low emissions combustor designs will require high temperature ceramic matrix composite liners to meet an emission goal of less than 5g NO(x) per Kg fuel burned. Large axisymmetric and two-dimensional exhaust nozzle designs are now under development to meet or exceed FAR 36 Stage III noise requirements, and will require lightweight, high temperature metallic, intermetallic, and ceramic matrix composites to reduce nozzle weight and meet structural and acoustic component performance goals. This paper describes and discusses the turbomachinery, combustor, and exhaust nozzle requirements of the High Speed Civil Transport propulsion system.

A Two-Way Spinoff

NASA Technical Reports Server (NTRS)

1982-01-01

Gougeon Brothers, Inc. successfully applied their boat building expertise to a NASA problem in wind turbine development. NASA and the department of Energy began experimenting with large wind turbine machines as an energy alternative to fossil fuels. During the development of a first generation wind turbine generator known as MOD-OA, Lewis Research Center faced the problem of supersize rotor blades made of metal that kept failing under stress. Using the techniques they had developed for fabricating wood composite structures, the Gougeon Brothers went on to build several sets of blades for the MOD-OA system; all worked successfully. Gougeon Brothers acquired new know-how during the course of studying rotor blade aerodynamics which they applied to their boat building. They developed the innovative "aerodynamic mast" for sailboats. Their mast, a strong, lightweight wood composite which needs no supporting rigging and is free to rotate with the wind, could cut a ship's fuel cost by as much as 40 percent.

Casting of weldable graphite/magnesium metal matrix composites with built-in metallic inserts

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.; Kashalikar, Uday; Majkowski, Patricia

1994-01-01

Technology innovations directed at the advanced development of a potentially low cost and weldable graphite/magnesium metal matrix composites (MMC) through near net shape pressure casting are described. These MMC components uniquely have built-in metallic inserts to provide an innovative approach for joining or connecting other MMC components through conventional joining techniques such as welding, brazing, mechanical fasteners, etc. Moreover, the metallic inserts trapped within the MMC components can be made to transfer the imposed load efficiently to the continuous graphite fiber reinforcement thus producing stronger, stiffer, and more reliable MMC components. The use of low pressure near net shape casting is economical compared to other MMC fabrication processes. These castable and potentially weldable MMC components can provide great payoffs in terms of high strength, high stiffness, low thermal expansion, lightweight, and easily joinable MMC components for several future NASA space structural, industrial, and commercial applications.

Reinforced Honeycomb Panels

NASA Technical Reports Server (NTRS)

Bhat, Balakrishna T.; Akutagawa, Wesley; Wang, Taylor G.; Barber, Dan

1989-01-01

New honeycomb panel structure has increased strength and stiffness with little increase in weight. Some or all of walls of honeycomb cells reinforced with honeycomb panels having smaller cells, lightweight foam, or other reinforcing material. Strong, lightweight reinforced panels used in aircraft, car and truck bodies, cabinets for equipment and appliances, and buildings.

Experimental verification of a model of a two-link flexible, lightweight manipulator. M.S. Thesis

NASA Technical Reports Server (NTRS)

Huggins, James David

1988-01-01

Experimental verification is presented for an assumed modes model of a large, two link, flexible manipulator design and constructed in the School of Mechanical Engineering at Georgia Institute of Technology. The structure was designed to have typical characteristics of a lightweight manipulator.

Solar cell submodule design facilitates assembly of lightweight arrays

NASA Technical Reports Server (NTRS)

Yasui, R. K.

1966-01-01

Solar cell submodules with bus bars that leave tabs along one end of the submodule and wires with raised portions along the other end are assembled by interlocking the tabs and wires of adjacent submodules. This structural design is lightweight and reliable and requires no metallic substructure.

Triboluminescent Materials for Smart Optical Damage Sensors for Space Applications

NASA Technical Reports Server (NTRS)

Aggarwal, Mohan D.; Penn, Benjamin G.; Miller, Jim

2007-01-01

Triboluminescence is light that is produced by pressure, friction or mechanical shock. New composite materials are constantly being reengi neered in an effort to make lightweight spacecrafts for various NASA missions. For these materials there is interest in monitoring the con dition of the composite in real time to detect any delamination or cr acking due to damage, fatigue or external forces. Methods of periodic inspection of composite structures for mechanical damage such as ult rasonic testing are rather mature. However, there is a need to develop a new technique of damage detection for composites, which could dete ct cracking or delamination from any desired location within a materi al structure in real time. This could provide a valuable tool in the confident use of composite materials for various space applications. Recently, triboluminnescent materials have been proposed as smart sen sors of structural damage. To sense the damage, these materials can b e epoxy bonded or coated in a polymer matrix or embedded in a composi te host structure. When the damage or fracture takes place in the hos t structure, it will lead to the fracture of triboluminescent crystal s resulting in a light emission. This will warn, in real time, that a structural damage has occurred. The triboluminescent emission of the candidate phosphor has to be sufficiently bright, so that the light signal reaching from the point of fracture to the detector through a fiber optic cable is sufficiently strong to be detected. There are a large number of triboluminescent materials, but few satisfy the above criterion. Authors have synthesized a Eu based organic material know n as Europium tetrakis (dibenzoylmethide) triethylammonium .(EuD(sub 4)TEA), one of the bright triboluminescent materials, which is a pote ntial candidate for application as a damage sensor and could be made into a wireless sensor with the addition of microchip, antenna and el ectronics. Preliminary results on the synthesis and characterization of this material shall be presented.

Direct formation of reduced graphene oxide and 3D lightweight nickel network composite foam by hydrohalic acids and its application for high-performance supercapacitors.

PubMed

Huang, Haifu; Tang, Yanmei; Xu, Lianqiang; Tang, Shaolong; Du, Youwei

2014-07-09

Here, a novel graphene composite foam with 3D lightweight continuous and interconnected nickel network was successfully synthesized by hydroiodic (HI) acid using nickel foam as substrate template. The graphene had closely coated on the backbone of the 3D nickel conductive network to form nickel network supported composite foam without any polymeric binder during the HI reduction of GO process, and the nickel conductive network can be maintained even in only a small amount of nickel with 1.1 mg/cm(2) and had replaced the traditional current collector nickel foam (35 mg/cm(2)). In the electrochemical measurement, a supercapacitor device based on the 3D nickel network and graphene composite foam exhibited high rate capability of 100 F/g at 0.5 A/g and 86.7 F/g at 62.5 A/g, good cycle stability with capacitance retention of 95% after 2000 cycles, low internal resistance (1.68 Ω), and excellent flexible properties. Furthermore, the gravimetric capacitance (calculated using the total mass of the electrode) was high up to 40.9 F/g. Our work not only demonstrates high-quality graphene/nickel composite foam, but also provides a universal route for the rational design of high performance of supercapacitors.

Fe-Al-Mn-C lightweight structural alloys: a review on the microstructures and mechanical properties.

PubMed

Kim, Hansoo; Suh, Dong-Woo; Kim, Nack J

2013-02-01

Adding a large amount of light elements such as aluminum to steels is not a new concept recalling that several Fe-Al-Mn-C alloys were patented in 1950s for replacement of nickel or chromium in corrosion resistance steels. However, the so-called lightweight steels or low-density steels were revisited recently, which is driven by demands from the industry where steel has served as a major structural material. Strengthening without loss of ductility has been a triumph in steel research, but lowering the density of steel by mixing with light elements will be another prospect that may support the competitiveness against emerging alternatives such as magnesium alloys. In this paper, we review recent studies on lightweight steels, emphasizing the concept of alloy design for microstructures and mechanical properties. The influence of alloying elements on the phase constituents, mechanical properties and the change of density is critically reviewed. Deformation mechanisms of various lightweight steels are discussed as well. This paper provides a reason why the success of lightweight steels is strongly dependent on scientific achievements even though alloy development is closely related to industrial applications. Finally, we summarize some of the main directions for future investigations necessary for vitalizing this field of interest.

Fe–Al–Mn–C lightweight structural alloys: a review on the microstructures and mechanical properties

PubMed Central

Kim, Hansoo; Suh, Dong-Woo; Kim, Nack J

2013-01-01

Adding a large amount of light elements such as aluminum to steels is not a new concept recalling that several Fe–Al–Mn–C alloys were patented in 1950s for replacement of nickel or chromium in corrosion resistance steels. However, the so-called lightweight steels or low-density steels were revisited recently, which is driven by demands from the industry where steel has served as a major structural material. Strengthening without loss of ductility has been a triumph in steel research, but lowering the density of steel by mixing with light elements will be another prospect that may support the competitiveness against emerging alternatives such as magnesium alloys. In this paper, we review recent studies on lightweight steels, emphasizing the concept of alloy design for microstructures and mechanical properties. The influence of alloying elements on the phase constituents, mechanical properties and the change of density is critically reviewed. Deformation mechanisms of various lightweight steels are discussed as well. This paper provides a reason why the success of lightweight steels is strongly dependent on scientific achievements even though alloy development is closely related to industrial applications. Finally, we summarize some of the main directions for future investigations necessary for vitalizing this field of interest. PMID:27877553

Microdesigning of Lightweight/High Strength Ceramic Materials

DTIC Science & Technology

1989-07-31

Continue on reverse if necessary and identiy by block number) FIELD GROUP SUB- GROUP Ceramics, Composite Materials, Colloidal Processing Iii 19. ABSTRACT...to identify key processing parameters that affect the microstructure of the composite material. The second section describes experimental results in...results of the significant theoretical effort made in our group . Theoretical models of particle-particle interaction, particle-polymer interaction

INVESTIGATION OF TITANIUM BONDED GRAPHITE FOAM COMPOSITES FOR MICRO ELECTRONIC MECHANICAL SYSTEMS (MEMS) APPLICATIONS

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

Menchhofer, Paul A.

PiMEMS Inc. (Santa Barbara, CA) in collaboration with ORNL investigated the use of Titanium Bonded Graphite Foam Composites (TBGC) for thermal mitigation in Micro Electronic Mechanical Systems (MEMS) applications. Also considered were potentially new additive manufacturing routes to producing novel high surface area micro features and diverse shaped heat transfer components for numerous lightweight MEMs applications.

Conformal and embedded IDT microsensors for health monitoring of structures

NASA Astrophysics Data System (ADS)

Varadan, Vijay K.; Varadan, Vasundara V.

2000-06-01

MEMS are currently being applied to the structural health monitoring of critical aircraft components and composites. The approach integrates acoustic emission, strain gauges, MEMS accelerometers and vibration monitoring aircraft components with a known history of catastrophic failure due to fracture. Recently a combination of the need for safety in the air and the desire to control costs is encouraging the use of in-flight monitoring of aircraft components and systems using light-weight, wireless and cost effective microsensors and MEMS. An in-situ aircraft structural health monitoring system, with sensors embedded in the composite structure or surface-mounted on the structure, would permit the timely detection of damage in aircraft. Micromachining offers the potential for fabricating a range of microsensor and MEMS for structural applications including load, vibration and acoustics characterization and monitoring. Such microsensors are extremely small; they can be embedded into structural materials, can be mass-produced and are therefore potentially cheap. The smart sensors are being developed using the standard microelectronics and micromachining in conjunction with novel Penn State wireless communication systems suitable for condition monitoring of aircraft structures in-flight. The main application areas of this investigation include continuos monitoring of a) structural integrity of aging aircraft, b) fatigue cracking, c) corrosion, d) deflection and strain of aircraft structures, wings, and rotorblades, e) impact damage, f) delamination and g) location and propagation of cracks. In this paper we give an overview of wireless programmable microsensors and MEMS and their associated driving electronics for such applications.

Advanced Ceramic-Metallic Composites for Lightweight Vehicle Braking Systems

DOT National Transportation Integrated Search

2012-09-11

According to the Federal Transit Administration Strategic Research Plan [1]: Researching technologies to reduce vehicle weight can also lead to important reductions in fuel consumption and emissions. The power required to accelerate a bus and over...

Thermo-mechanical performance of precision C/SiC mounts

NASA Astrophysics Data System (ADS)

Goodman, William A.; Mueller, Claus E.; Jacoby, Marc T.; Wells, Jim D.

2001-12-01

For complex shaped, lightweight, high precision opto- mechanical structures that must operate in adverse environments and over wide ranges of temperature, we consider IABG's optical grade silicon carbide composite ceramic (C/SiC) as the material of choice. C/SiC employs conventional NC machining/milling equipment to rapidly fabricate near-net shape parts, providing substantial schedule, cost, and risk savings for high precision components. Unlike powder based SiC ceramics, C/SiC does not experience significant shrinkage during processing, nor does it suffer from incomplete densification. If required, e.g. for large-size components, a fully-monolithic ceramic joining technique can be applied. Generally, the thermal and mechanical properties of C/SiC are tunable in certain ranges by modifying certain process steps. This paper focuses on the thermo-mechanical performance of new, high precision mounts designed by Schafer Corporation and manufactured by IABG. The mounts were manufactured using standard optical grade C/SiC (formulation internally called A-3). The A-3 formulation has a near-perfect CTE match with silicon, making it the ideal material to athermally support Schafer produced Silicon Lightweight Mirrors (SLMs) that will operate in a cryogenic environment. Corresponding thermo- mechanical testing and analysis is presented in this manuscript.

Computer design synthesis of a below knee-Syme prosthesis

NASA Technical Reports Server (NTRS)

Elangovan, P. T.; Ghista, D. N.; Alwar, R. S.

1979-01-01

A detailed design synthesis analysis of the BK Syme prosthesis is provided, to determine the socket's cutout orientation size and shape, cutout fillet shape, socket wall thickness distribution and the reinforced fiber distribution in the socket wall, for a minimally stressed structurally safe lightweight prosthesis. For analysis purposes, the most adverse socket loading is obtained at the push-off stage of gait; this loading is idealized as an axial in-plane loading on the bottom edge of the circular cylindrical socket shell whose top edge is considered fixed. Finite element stress analysis of the socket shell (with uniform and graded wall thickness) are performed for various orientations of the cutout and for various types of corner fillets. A lateral cutout with a streamline fillet is recommended. The wall material (i.e., thickness) distribution is determined so as to minimize the stresses, while ensuring that the wall material's stress limits are not exceeded. For such a maximally stressed lightweight socket shell, the panels in the neighborhood of the cutout are checked to ensure that they do not buckle under their acquired stresses. A fiber-reinforced laminated composite socket shell is also analyzed in order to recommend optimum variables in orientations and densities of reinforcing fibers.

Lab Demonstration of the Hybrid Doppler Wind Lidar (HDWL) Transceiver

NASA Technical Reports Server (NTRS)

Marx, Catherine T.; Gentry, Bruce; Jordan, Patrick; Dogoda, Peter; Faust, Ed; Kavaya, Michael

2013-01-01

The recommended design approach for the 3D Tropospheric Winds mission is a hybrid Doppler lidar which combines the best elements of both a coherent aerosol Doppler lidar operating at 2 micron and a direct detection molecular Doppler lidar operating at 0.355 micron. In support of the mission, we built a novel, compact, light-weighted multi-field of view transceiver where multiple telescopes are used to cover the required four fields of view. A small mechanism sequentially selects both the "transmit" and "receive" fields of view. The four fields are combined to stimulate both the 0.355 micron receiver and the 2 micron receiver. This version is scaled (0.2 micron diameter aperture) from the space-based version but still demonstrates the feasibility of the hybrid approach. The primary mirrors were conventionally light-weighted and coated with dielectric, high reflectivity coatings with high laser damage thresholds at both 2 micron and 0.355 micron. The mechanical structure and mounts were fabricated from composites to achieve dimensional stability while significantly reducing the mass. In the laboratory, we demonstrated the system level functionality at 0.355 micron and at 2 micron raising the Technology Readiness Level (TRL) from 2 to 4.

Lab Demonstration of the Hybrid Doppler Wind Lidar (HDWL) Transceiver

NASA Technical Reports Server (NTRS)

Marx, Catherine T.; Gentry, Bruce; Jordan, Patrick; Dogoda, Peter; Faust, Ed; Kavaya, Michael

2013-01-01

The recommended design approach for the 3D Tropospheric Winds mission is a hybrid Doppler lidar which combines the best elements of both a coherent aerosol Doppler lidar operating at 2 microns and a direct detection molecular Doppler lidar operating at 0.355 microns. In support of the mission, we built a novel, compact, light-weighted multi-field of view transceiver where multiple telescopes are used to cover the required four fields of view. A small mechanism sequentially selects both the "transmit" and "receive" fields of view. The four fields are combined to stimulate both the 0.355 micron receiver and the 2 micron receiver. This version is scaled (0.2 m diameter aperture) from the space-based version but still demonstrates the feasibility of the hybrid approach. The primary mirrors were conventionally light-weighted and coated with dielectric, high reflectivity coatings with high laser damage thresholds at both 2 microns and 0.355 microns. The mechanical structure and mounts were fabricated from composites to achieve dimensional stability while significantly reducing the mass. In the laboratory, we demonstrated the system level functionality at 0.355 microns and at 2 microns, raising the Technology Readiness Level (TRL) from 2 to 4.

Shell tile thermal protection system

NASA Technical Reports Server (NTRS)

Macconochie, I. O.; Lawson, A. G.; Kelly, H. N. (Inventor)

1984-01-01

A reusable, externally applied thermal protection system for use on aerospace vehicles subject to high thermal and mechanical stresses utilizes a shell tile structure which effectively separates its primary functions as an insulator and load absorber. The tile consists of structurally strong upper and lower metallic shells manufactured from materials meeting the thermal and structural requirements incident to tile placement on the spacecraft. A lightweight, high temperature package of insulation is utilized in the upper shell while a lightweight, low temperature insulation is utilized in the lower shell. Assembly of the tile which is facilitated by a self-locking mechanism, may occur subsequent to installation of the lower shell on the spacecraft structural skin.

Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization.

PubMed

Robertson, Ian D; Yourdkhani, Mostafa; Centellas, Polette J; Aw, Jia En; Ivanoff, Douglas G; Goli, Elyas; Lloyd, Evan M; Dean, Leon M; Sottos, Nancy R; Geubelle, Philippe H; Moore, Jeffrey S; White, Scott R

2018-05-01

Thermoset polymers and composite materials are integral to today's aerospace, automotive, marine and energy industries and will be vital to the next generation of lightweight, energy-efficient structures in these enterprises, owing to their excellent specific stiffness and strength, thermal stability and chemical resistance 1-5 . The manufacture of high-performance thermoset components requires the monomer to be cured at high temperatures (around 180 °C) for several hours, under a combined external pressure and internal vacuum 6 . Curing is generally accomplished using large autoclaves or ovens that scale in size with the component. Hence this traditional curing approach is slow, requires a large amount of energy and involves substantial capital investment 6,7 . Frontal polymerization is a promising alternative curing strategy, in which a self-propagating exothermic reaction wave transforms liquid monomers to fully cured polymers. We report here the frontal polymerization of a high-performance thermoset polymer that allows the rapid fabrication of parts with microscale features, three-dimensional printed structures and carbon-fibre-reinforced polymer composites. Precise control of the polymerization kinetics at both ambient and elevated temperatures allows stable monomer solutions to transform into fully cured polymers within seconds, reducing energy requirements and cure times by several orders of magnitude compared with conventional oven or autoclave curing approaches. The resulting polymer and composite parts possess similar mechanical properties to those cured conventionally. This curing strategy greatly improves the efficiency of manufacturing of high-performance polymers and composites, and is widely applicable to many industries.

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

NASA Technical Reports Server (NTRS)

Pereira, J. Michael; Emmerling, William; Seng, Silvia; Frankenberger, Charles; Ruggeri, Charles R.; Revilock, Duane M.; Carney, Kelly S.

2016-01-01

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. LS-DYNA® was used to predict the thickness of the composite shield required to prevent blade penetration. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test LS-DYNA predictions. This paper documents the analysis conducted to predict the required thickness of a composite shield, the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

Vacuum jacketed composite propulsion feedlines for cryogenic launch and space vehicles, volume 1. [development of glass fiber composite for strength and protection from handling damage

NASA Technical Reports Server (NTRS)

Spond, D. E.; Laintz, D. J.; Hall, C. A.; Dulaigh, D. E.

1974-01-01

Thin metallic liners that provide leak-free service in cryogenic propulsion systems are overwrapped with a glass-fiber composite that provides strength and protection from handling damage. The resultant tube is lightweight, strong, and has a low thermal flux. The inside commodity flow line and the outside vacuum jacket were fabricated using this method. Several types of vacuum jackets were fabricated and tested at operating temperatures from 294 to 21 K (+70 to minus 423 F) and operating pressure up to 69 N/cm2 (100 psi). The primary objective of the program was to develop vacuum jacket concepts, using previously developed concepts for the inner line. All major program objectives were met resulting in a design concept that is adaptable to a wide range of aerospace vehicle requirements. Major items of development included convolution of thin metallic sections up to 46 cm (18 in.) in diameter, design and fabrication of an extremely lightweight tension membrane concept for the vacuum jacket, and analytical tools that predict the failure mode and levels.

Optimal design of a thermally stable composite optical bench

NASA Technical Reports Server (NTRS)

Gray, C. E., Jr.

1985-01-01

The Lidar Atmospheric Sensing Experiment will be performed aboard an ER-2 aircraft; the lidar system used will be mounted on a lightweight, thermally stable graphite/epoxy optical bench whose design is presently subjected to analytical study and experimental validation. Attention is given to analytical methods for the selection of such expected laminate properties as the thermal expansion coefficient, the apparent in-plane moduli, and ultimate strength. For a symmetric laminate in which one of the lamina angles remains variable, an optimal lamina angle is selected to produce a design laminate with a near-zero coefficient of thermal expansion. Finite elements are used to model the structural concept of the design, with a view to the optical bench's thermal structural response as well as the determination of the degree of success in meeting the experiment's alignment tolerances.

Innovative Structural Materials and Sections with Strain Hardening Cementitious Composites

NASA Astrophysics Data System (ADS)

Dey, Vikram

The motivation of this work is based on development of new construction products with strain hardening cementitious composites (SHCC) geared towards sustainable residential applications. The proposed research has three main objectives: automation of existing manufacturing systems for SHCC laminates; multi-level characterization of mechanical properties of fiber, matrix, interface and composites phases using servo-hydraulic and digital image correlation techniques. Structural behavior of these systems were predicted using ductility based design procedures using classical laminate theory and structural mechanics. SHCC sections are made up of thin sections of matrix with Portland cement based binder and fine aggregates impregnating continuous one-dimensional fibers in individual or bundle form or two/three dimensional woven, bonded or knitted textiles. Traditional fiber reinforced concrete (FRC) use random dispersed chopped fibers in the matrix at a low volume fractions, typically 1-2% to avoid to avoid fiber agglomeration and balling. In conventional FRC, fracture localization occurs immediately after the first crack, resulting in only minor improvement in toughness and tensile strength. However in SHCC systems, distribution of cracking throughout the specimen is facilitated by the fiber bridging mechanism. Influence of material properties of yarn, composition, geometry and weave patterns of textile in the behavior of laminated SHCC skin composites were investigated. Contribution of the cementitious matrix in the early age and long-term performance of laminated composites was studied with supplementary cementitious materials such as fly ash, silica fume, and wollastonite. A closed form model with classical laminate theory and ply discount method, coupled with a damage evolution model was utilized to simulate the non-linear tensile response of these composite materials. A constitutive material model developed earlier in the group was utilized to characterize and correlate the behavior of these structural composites under uniaxial tension and flexural loading responses. Development and use of analytical models enables optimal design for application of these materials in structural applications. Another area of immediate focus is the development of new construction products from SHCC laminates such as angles, channels, hat sections, closed sections with optimized cross sections. Sandwich composites with stress skin-cellular core concept were also developed to utilize strength and ductility of fabric reinforced skin in addition to thickness, ductility, and thermal benefits of cellular core materials. The proposed structurally efficient and durable sections promise to compete with wood and light gage steel based sections for lightweight construction and panel application.

A non-orthogonal material model of woven composites in the preforming process

DOE PAGES

Zhang, Weizhao; Ren, Huaqing; Liang, Biao; ...

2017-05-04

Woven composites are considered as a promising material choice for lightweight applications. An improved non-orthogonal material model that can decouple the strong tension and weak shear behaviour of the woven composite under large shear deformation is proposed for simulating the preforming of woven composites. The tension, shear and compression moduli in the model are calibrated using the tension, bias-extension and bending experiments, respectively. The interaction between the composite layers is characterized by a sliding test. The newly developed material model is implemented in the commercial finite element software LS-DYNA® and validated by a double dome study.

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

Yusufoglu, Yusuf

Nature offers many exciting ideas and inspiration for the development of new materials and processes. The toughness of spider silk, the strength and lightweight of bone, and the adhesion abilities of the gecko's feet are some of the many examples of highperformance natural materials, which have attracted the interest of scientist to duplicate their properties in man-made materials. Materials found in nature combine many inspiring properties such as miniaturization, sophistication, hierarchical organization, hybridization, and adaptability. In all biological systems, whether very basic or highly complex, nature provides a multiplicity of materials, architectures, systems and functions. Generally, the architectural configurations andmore » material characteristics are the important features that have been duplicated from nature for building synthetic structural composites.« less

Advanced solar concentrator: Preliminary and detailed design

NASA Technical Reports Server (NTRS)

Bell, D. M.; Maraschin, R. A.; Matsushita, M. T.; Erskine, D.; Carlton, R.; Jakovcevic, A.; Yasuda, A. K.

1981-01-01

A single reflection point focusing two-axis tracking paraboloidal dish with a reflector aperture diameter of approximately 11 m has a reflective surface made up of 64 independent, optical quality gores. Each gore is a composite of a thin backsilvered mirror glass face sheet continuously bonded to a contoured substrate of lightweight, rigid cellular glass. The use of largely self-supporting gores allows a significant reduction in the weight of the steel support structure as compared to alternate design concepts. Primary emphasis in the preliminary design package for the low-cost, low-weight, mass producible concentrator was placed on the design of the higher cost subsystems. The outer gore element was sufficiently designed to allow fabrication of prototype gores.

Efficient, Multi-Scale Designs Take Flight

NASA Technical Reports Server (NTRS)

2003-01-01

Engineers can solve aerospace design problems faster and more efficiently with a versatile software product that performs automated structural analysis and sizing optimization. Collier Research Corporation's HyperSizer Structural Sizing Software is a design, analysis, and documentation tool that increases productivity and standardization for a design team. Based on established aerospace structural methods for strength, stability, and stiffness, HyperSizer can be used all the way from the conceptual design to in service support. The software originated from NASA s efforts to automate its capability to perform aircraft strength analyses, structural sizing, and weight prediction and reduction. With a strategy to combine finite element analysis with an automated design procedure, NASA s Langley Research Center led the development of a software code known as ST-SIZE from 1988 to 1995. Collier Research employees were principal developers of the code along with Langley researchers. The code evolved into one that could analyze the strength and stability of stiffened panels constructed of any material, including light-weight, fiber-reinforced composites.

Edgewise Compression Testing of STIPS-0 (Structurally Integrated Thermal Protection System)

NASA Technical Reports Server (NTRS)

Brewer, Amy R.

2011-01-01

The Structurally Integrated Thermal Protection System (SITPS) task was initiated by the NASA Hypersonics Project under the Fundamental Aeronautics Program to develop a structural load-carrying thermal protection system for use in aerospace applications. The initial NASA concept for SITPS consists of high-temperature composite facesheets (outer and inner mold lines) with a light-weight insulated structural core. An edgewise compression test was performed on the SITPS-0 test article at room temperature using conventional instrumentation and methods in order to obtain panel-level mechanical properties and behavior of the panel. Three compression loadings (10, 20 and 37 kips) were applied to the SITPS-0 panel. The panel behavior was monitored using standard techniques and non-destructive evaluation methods such as photogrammetry and acoustic emission. The elastic modulus of the SITPS-0 panel was determined to be 1.146x106 psi with a proportional limit at 1039 psi. Barrel-shaped bending of the panel and partial delamination of the IML occurred under the final loading.

Optical Coating Performance and Thermal Structure Design for Heat Reflectors of JWST Electronic Control Unit

NASA Technical Reports Server (NTRS)

Quijada, Manuel A.; Threat, Felix; Garrison, Matt; Perrygo, Chuck; Bousquet, Robert; Rashford, Robert

2008-01-01

The James Webb Space Telescope (JWST) consists of an infrared-optimized Optical Telescope Element (OTE) that is cooled down to 40 degrees Kelvin. A second adjacent component to the OTE is the Integrated Science Instrument Module, or ISIM. This module includes the electronic compartment, which provides the mounting surfaces and ambient thermally controlled environment for the instrument control electronics. Dissipating the 200 watts generated from the ISIM structure away from the OTE is of paramount importance so that the spacecraft's own heat does not interfere with the infrared light detected from distant cosmic sources. This technical challenge is overcome by a thermal subsystem unit that provides passive cooling to the ISIM control electronics. The proposed design of this thermal radiator consists of a lightweight structure made out of composite materials and low-emittance metal coatings. In this paper, we will present characterizations of the coating emittance, bidirectional reflectance, and mechanical structure design that will affect the performance of this passive cooling system.

Advanced design for lightweight structures: Review and prospects

NASA Astrophysics Data System (ADS)

Braga, Daniel F. O.; Tavares, S. M. O.; da Silva, Lucas F. M.; Moreira, P. M. G. P.; de Castro, Paulo M. S. T.

2014-08-01

Current demand for fuel efficient aircraft has been pushing the aeronautical sector to develop ever more lightweight designs while keeping safe operation and required structural strength. Along with light-weighting, new structural design concepts have also been established in order to maintain the aircraft in service for longer periods of time, with high reliability levels. All these innovations and requirements have led to deeply optimized aeronautical structures contributing to more sustainable air transport. This article reviews the major design philosophies which have been employed in aircraft structures, including safe-life, fail-safe and damage tolerance taking into account their impact on the structural design. A brief historical review is performed in order to analyse what led to the development of each philosophy. Material properties are related to each of the design philosophies. Damage tolerant design has emerged as the main structural design philosophy in aeronautics, requiring deep knowledge on materials fatigue and corrosion strength, as well as potential failure modes and non-destructive inspection techniques, particularly minimum detectable defect and scan times. A discussion on the implementation of structural health monitoring and self-healing structures within the current panorama of structures designed according to the damage tolerant philosophy is presented. This discussion is aided by a review of research on these two subjects. These two concepts show potential for further improving safety and durability of aircraft structures.

Testing Composites

NASA Technical Reports Server (NTRS)

1981-01-01

A device for testing composites for strength characteristics has been developed by Acoustic Emission Technology Corporation. Called the Model 206AU, the system is lightweight and portable. It is comprised of three sections. The "pulser" section injects ultrasonic waves into the material under test. A receiver picks up the simulated stress waves as they pass through the material and relays the signals to the acoustic emission section, where they are electronically analyzed.

Geometrically Nonlinear Finite Element Analysis of a Composite Space Reflector

NASA Technical Reports Server (NTRS)

Lee, Kee-Joo; Leet, Sung W.; Clark, Greg; Broduer, Steve (Technical Monitor)

2001-01-01

Lightweight aerospace structures, such as low areal density composite space reflectors, are highly flexible and may undergo large deflection under applied loading, especially during the launch phase. Accordingly, geometrically nonlinear analysis that takes into account the effect of finite rotation may be needed to determine the deformed shape for a clearance check and the stress and strain state to ensure structural integrity. In this study, deformation of the space reflector is determined under static conditions using a geometrically nonlinear solid shell finite element model. For the solid shell element formulation, the kinematics of deformation is described by six variables that are purely vector components. Because rotational angles are not used, this approach is free of the limitations of small angle increments. This also allows easy connections between substructures and large load increments with respect to the conventional shell formulation using rotational parameters. Geometrically nonlinear analyses were carried out for three cases of static point loads applied at selected points. A chart shows results for a case when the load is applied at the center point of the reflector dish. The computed results capture the nonlinear behavior of the composite reflector as the applied load increases. Also, they are in good agreement with the data obtained by experiments.

Light, Strong Insulating Tiles

NASA Technical Reports Server (NTRS)

Cordia, E.; Schirle, J.

1987-01-01

Improved lightweight insulating silica/aluminum borosilicate/silicon carbide tiles combine increased tensile strength with low thermal conductivity. Changes in composition substantially improve heat-insulating properties of silica-based refractory tile. Silicon carbide particles act as high-emissivity radiation scatterers in tile material.

Replication of Low Density Electroformed Normal Incidence Optics

NASA Technical Reports Server (NTRS)

Ritter, Joseph M.

2000-01-01

Replicated electroformed light-weight nickel alloy mirrors can have high strength, low areal density (<3kg/m2), smooth finish, and controllable alloy composition. Progress at NASA MSFC SOMTC in developing normal incidence replicated Nickel mirrors will be reported.

Fiber Bragg Grating Sensor System for Monitoring Smart Composite Aerospace Structures

NASA Technical Reports Server (NTRS)

Moslehi, Behzad; Black, Richard J.; Gowayed, Yasser

2012-01-01

Lightweight, electromagnetic interference (EMI) immune, fiber-optic, sensor- based structural health monitoring (SHM) will play an increasing role in aerospace structures ranging from aircraft wings to jet engine vanes. Fiber Bragg Grating (FBG) sensors for SHM include advanced signal processing, system and damage identification, and location and quantification algorithms. Potentially, the solution could be developed into an autonomous onboard system to inspect and perform non-destructive evaluation and SHM. A novel method has been developed to massively multiplex FBG sensors, supported by a parallel processing interrogator, which enables high sampling rates combined with highly distributed sensing (up to 96 sensors per system). The interrogation system comprises several subsystems. A broadband optical source subsystem (BOSS) and routing and interface module (RIM) send light from the interrogation system to a composite embedded FBG sensor matrix, which returns measurand-dependent wavelengths back to the interrogation system for measurement with subpicometer resolution. In particular, the returned wavelengths are channeled by the RIM to a photonic signal processing subsystem based on powerful optical chips, then passed through an optoelectronic interface to an analog post-detection electronics subsystem, digital post-detection electronics subsystem, and finally via a data interface to a computer. A range of composite structures has been fabricated with FBGs embedded. Stress tensile, bending, and dynamic strain tests were performed. The experimental work proved that the FBG sensors have a good level of accuracy in measuring the static response of the tested composite coupons (down to submicrostrain levels), the capability to detect and monitor dynamic loads, and the ability to detect defects in composites by a variety of methods including monitoring the decay time under different dynamic loading conditions. In addition to quasi-static and dynamic load monitoring, the system can capture acoustic emission events that can be a prelude to structural failure, as well as piezoactuator-induced ultrasonic Lamb-waves-based techniques as a basis for damage detection.

Rational construction of a 3D hierarchical NiCo2O4/PANI/MF composite foam as a high-performance electrode for asymmetric supercapacitors.

PubMed

Cui, Fen; Huang, Yunpeng; Xu, Le; Zhao, Yan; Lian, Jiabiao; Bao, Jian; Li, Huaming

2018-04-19

A 3D hierarchical NiCo2O4/PANI/MF composite foam with a macroporous 3D skeleton, a conductive PANI coating and highly electrochemically active NiCo2O4 nanosheets is synthesized as a lightweight and low-cost electrode material. Due to the collaborative contribution of all the components, the prepared composite foam exhibits excellent capacitive performances when incorporated into an asymmetric supercapacitor.

A comparison of performance of lightweight mirrors

NASA Technical Reports Server (NTRS)

Cho, Myung K.; Richard, Ralph M.; Hileman, Edward A.

1990-01-01

Four lightweight solid contoured back mirror shapes (a double arch, a single arch, a modified single arch, and a double concave mirror) and a cellular sandwich lightweight meniscus mirror, have been considered for the primary mirror of the Space Infrared Telescope Facility (SIRTF). A parametric design study using these shapes for the SIRTF 40 inch primary mirror with a focal ratio f/2 is presented. Evaluations of the optical performance and fundamental frequency analyses are performed to compare relative merits of each mirror configuration. Included in these are structural, optical, and frequency analyses for (1) different back contour shapes, (2) different number and location of the support points, and (3) two gravity orientations (ZENITH and HORIZON positions). The finite element program NASTRAN is used to obtain the structural deflections of the optical surface. For wavefront error analysis, FRINGE and PCFRINGE programs are used to evaluate the optical performance. A scaling law relating the optical and structural performance for various mirror contoured back shapes is developed.

Assessing inspection sensitivity as it relates to damage tolerance in composite rotor hubs

NASA Astrophysics Data System (ADS)

Roach, Dennis P.; Rackow, Kirk

2001-08-01

Increasing niche applications, growing international markets, and the emergence of advanced rotorcraft technology are expected to greatly increase the population of helicopters over the next decade. In terms of fuselage fatigue, helicopters show similar trends as fixed-wing aircraft. The highly unsteady loads experienced by rotating wings not only directly affect components in the dynamic systems but are also transferred to the fixed airframe structure. Expanded use of rotorcraft has focused attention on the use of new materials and the optimization of maintenance practices. The FAA's Airworthiness Assurance Center (AANC) at Sandia National Labs has joined with Bell Helicopter andother agencies in the rotorcraft industry to evaluate nondestructive inspection (NDI) capabilities in light of the damage tolerance of assorted rotorcraft structure components. Currently, the program's emphasis is on composite rotor hubs. The rotorcraft industry is constantly evaluating new types of lightweight composite materials that not only enhance the safety and reliability of rotor components but also improve performance and extended operating life as well. Composite rotor hubs have led to the use of bearingless rotor systems that are less complex and require less maintenance than their predecessors. The test facility described in this paper allows the structural stability and damage tolerance of composite hubs to be evaluated using realistic flight load spectrums of centrifugal force and bending loads. NDI was integrated into the life-cycle fatigue tests in order to evaluate flaw detection sensitivity simultaneously wiht residual strength and general rotor hub peformance. This paper will describe the evolving use of damage tolerance analysis (DTA) to direct and improve rotorcraft maintenance along with the related use of nondestructive inspections to manage helicopter safety. OVeralll, the data from this project will provide information to improve the producibility, inspectability, serviceability, and cost effectively of rotorcraft components.

The utilization of stone ash on cellular lightweight concrete

NASA Astrophysics Data System (ADS)

Karolina, R.; Sianipar, Y. G. C.

2018-02-01

Lightweight concrete brick is a brick which made of cement, sand, water, and foam as the basic composition. This brick are divided into 2, based on the foam used such as AAC (Autoclave Aerated Concrete) that use aluminium paste and CLC(Cellular Lightweight Concrete) that use foaming agent from BASF as its foaming material. In this trial, the lightweight brick that are ging to be use are the CLC with foaming agent as its foaming material with the mixture of stone ash that are produced by the Stone Crusher with spesific gravity 2666 kg/m3 as their partly sand substitution . In this research, the stone ash variant that are used are 10%, 15%, and 20% from the amount of sand that planned before. After casting, the result of the 10% will receive a reduction of compressive strength while an increasing in absorption as 25.07% and 39.005% and the 15% variant will recieve a reduction of compressive strength as much as 65.8% and a reduction of absorption as much as 17.441% and the 20% variant will recieve a reduction of compressive strength as much as 67.4% while an increasing of absorption as much as 17.956%.

Foamed lightweight materials made from mixed scrap metal waste powder and sewage sludge ash.

PubMed

Wang, Kuen-Sheng; Chiou, Ing-Jia

2004-10-01

The porous properties and pozzolanic effects of sewage sludge ash (SSA) make it possible to produce lightweight materials. This study explored the effects of different metallic foaming agents, made from waste aluminium products, on the foaming behaviours and engineering characteristics, as well as the microstructure of sewage sludge ash foamed lightweight materials. The results indicated that aluminium powder and mixed scrap metal waste powder possessed similar chemical compositions. After proper pre-treatment, waste aluminium products proved to be ideal substitutes for metallic foaming agents. Increasing the amount of mixed scrap metal waste by 10-15% compared with aluminium powder would produce a similar foaming ratio and compressive strength. The reaction of the metallic foaming agents mainly produced pores larger than 10 microm, different from the hydration reaction of cement that produced pores smaller than 1 microm mostly. To meet the requirements of the lightweight materials characteristics and the compressive strength, the amount of SSA could be up to 60-80% of the total solids. An adequate amount of aluminium powder is 0.5-0.9% of the total solids. Increasing the fineness of the mixed scrap metal waste powder could effectively reduce the amount required and improve the foaming ratio.

Life-cycle energy and greenhouse gas emission benefits of lightweighting in automobiles: review and harmonization.

PubMed

Kim, Hyung Chul; Wallington, Timothy J

2013-06-18

Replacing conventional materials (steel and iron) with lighter alternatives (e.g., aluminum, magnesium, and composites) decreases energy consumption and greenhouse gas (GHG) emissions during vehicle use but may increase energy consumption and GHG emissions during vehicle production. There have been many life cycle assessment (LCA) studies on the benefits of vehicle lightweighting, but the wide variety of assumptions used makes it difficult to compare results from the studies. To clarify the benefits of vehicle lightweighting we have reviewed the available literature (43 studies). The GHG emissions and primary energy results from 33 studies that passed a screening process were harmonized using a common set of assumptions (lifetime distance traveled, fuel-mass coefficient, secondary weight reduction factor, fuel consumption allocation, recycling rate, and energy intensity of materials). After harmonization, all studies indicate that using aluminum, glass-fiber reinforced plastic, and high strength steel to replace conventional steel decreases the vehicle life cycle energy use and GHG emissions. Given the flexibility in options implied by the variety of materials available and consensus that these materials have substantial energy and emissions benefits, it seems likely that lightweighting will be used increasingly to improve fuel economy and reduce life cycle GHG emissions from vehicles.

Thermal properties of light-weight concrete with waste polypropylene aggregate

NASA Astrophysics Data System (ADS)

Záleská, Martina; Pokorný, Jaroslav; Pavlíková, Milena; Pavlík, Zbyšek

2017-07-01

Thermal properties of a sustainable light-weight concrete incorporating high volume of waste polypropylene as partial substitution of natural aggregate were studied in the paper. Glass fiber reinforced polypropylene (GFPP), a by-product of PP tubes production, partially substituted fine natural silica aggregate in 10, 20, 30, 40, and 50 mass%. In order to quantify the effect of GFPP use on concrete properties, a reference concrete mix without plastic waste was studied as well. For the applied GFPP, bulk density, matrix density, and particle size distribution were measured. Specific attention was paid to thermal transport and storage properties of GFPP that were examined in dependence on compaction time. For the developed light-weight concrete, thermal properties were accessed using transient impulse technique, whereas the measurement was done in dependence on moisture content, from the dry state to fully water saturated state. Additionally, the investigated thermal properties were plotted as function of porosity. The tested light-weight concrete was found to be prospective construction material possessing improved thermal insulation function. Moreover, the reuse of waste plastics in concrete composition was beneficial both from the environmental and financial point of view considering plastics low biodegradability and safe disposal.

An applied investigation of kenaf-based fiber/polymer composites as potential lightweight materials for automotive components

NASA Astrophysics Data System (ADS)

Du, Yicheng

Natural fibers have the potential to replace glass fibers in fiber-reinforced composite applications. However, the natural fibers' intrinsic properties cause these issues: (1) the mechanical property variation; (2) moisture uptake by natural fibers and their composites; (3) lack of sound, cost-effective, environment-friendly fiber-matrix compounding processes; (4) incompatibility between natural fibers and polymer matrices; and (5) low heat-resistance of natural fibers and their composites. This dissertation systematically studied the use of kenaf bast fiber bundles, obtained via a mechanical retting method, as a light-weight reinforcement material for fiber-reinforced thermoset polymer composites for automotive applications. Kenaf bast fiber bundle tensile properties were tested, and the effects of locations in the kenaf plant, loading rates, retting methods, and high temperature treatments and their durations on kenaf bast fiber bundle tensile properties were evaluated. A process has been developed for fabricating high fiber loading kenaf bast fiber bundle-reinforced unsaturated polyester composites. The generated composites possessed high elastic moduli and their tensile strengths were close to specification requirements for glass fiber-reinforced sheet molding compounds. Effects of fiber loadings and lengths on resultant composite's tensile properties were evaluated. Fiber loadings were very important for composite tensile modulus. Both fiber loadings and fiber lengths were important for composite tensile strengths. The distributions of composite tensile, flexural and impact strengths were analyzed. The 2-parameter Weibull model was found to be the most appropriate for describing the composite strength distributions and provided the most conservative design values. Kenaf-reinforced unsaturated polyester composites were also proved to be more cost-effective than glass fiber-reinforced SMCs at high fiber loadings. Kenaf bast fiber bundle-reinforced composite's water absorption properties were tested. Surface-coating and edge-sealing significantly reduced composite water resistance properties. Encapsulation was a practical method to improve composite water resistance properties. The molding pressure and styrene concentrations on composite and matrix properties were evaluated. Laser and plasma treatment improved fiber-to-matrix adhesion.

Recent developments in multi-layer flat knitting technology for waste free production of complex shaped 3D-reinforcing structures for composites

NASA Astrophysics Data System (ADS)

Trümper, W.; Lin, H.; Callin, T.; Bollengier, Q.; Cherif, C.; Krzywinski, S.

2016-07-01

Constantly increasing prices for raw materials and energy as well as the current discourse on the reduction of CO2-emissions places a special emphasis on the advantages of lightweight constructions and its resource conserving production methods. Fibre-reinforced composites are already seeing a number of applications in automobile, energy and mechanical engineering. Future applications within the named areas require greater material and energy efficiency and therefore manufacturing methods for textile preforms and lightweight constructions enabling an optimal arrangement of the reinforcing fibres while in the same time limiting waste to a minimum. One manufacturing method for textile reinforced preforms fulfilling quite many of the named requirements is the multilayer weft knitting technology. Multilayer weft knitted fabrics containing straight reinforcing yarns at least in two directions. The arrangement of these yarns is fixed by the loop yarn. Used yarn material in each knitting row is adaptable e. g. according to the load requirements or for the local integration of sensors. Draping properties of these fabrics can be varied within a great range and through this enabling draping of very complex shaped 3D-preforms without wrinkles from just one uncut fabric. The latest developments at ITM are concentrating on the development of a full production chain considering the 3D-CAD geometry, the load analysis, the generation of machine control programs as well as the development of technology and machines to enable the manufacturing of innovative net shape 3D-multilayer weft knitted fabrics such as complex shaped spacer fabrics and tubular fabrics with biaxial reinforcement.

NASA Tech Briefs, October 2013

NASA Technical Reports Server (NTRS)

2013-01-01

Topics include: A Short-Range Distance Sensor with Exceptional Linearity; Miniature Trace Gas Detector Based on Microfabricated Optical Resonators; Commercial Non-Dispersive Infrared Spectroscopy Sensors for Sub-Ambient Carbon Dioxide Detection; Fast, Large-Area, Wide-Bandgap UV Photodetector for Cherenkov Light Detection; Mission Data System Java Edition Version 7; Adaptive Distributed Environment for Procedure Training (ADEPT); LEGEND, a LEO-to-GEO Environment Debris Model; Electronics/Computers; Millimeter-Wave Localizers for Aircraft-to-Aircraft Approach Navigation; Impedance Discontinuity Reduction Between High-Speed Differential Connectors and PCB Interfaces; SpaceCube Version 1.5; High-Pressure Lightweight Thrusters; Non-Magnetic, Tough, Corrosion- and Wear-Resistant Knives From Bulk Metallic Glasses and Composites; Ambient Dried Aerogels; Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing; Passivation of Flexible YBCO Superconducting Current Lead With Amorphous SiO2 Layer; Propellant-Flow-Actuated Rocket Engine Igniter; Lightweight Liquid Helium Dewar for High-Altitude Balloon Payloads; Method to Increase Performance of Foil Bearings Through Passive Thermal Management; Unibody Composite Pressurized Structure; JWST Integrated Science Instrument Module Alignment Optimization Tool; Radar Range Sidelobe Reduction Using Adaptive Pulse Compression Technique; Digitally Calibrated TR Modules Enabling Real-Time Beamforming SweepSAR Architectures; Electro-Optic Time-to-Space Converter for Optical Detector Jitter Mitigation; Partially Transparent Petaled Mask/Occulter for Visible-Range Spectrum; Educational NASA Computational and Scientific Studies (enCOMPASS); Coarse-Grain Bandwidth Estimation Scheme for Large-Scale Network; Detection of Moving Targets Using Soliton Resonance Effect; High-Efficiency Nested Hall Thrusters for Robotic Solar System Exploration; High-Voltage Clock Driver for Photon-Counting CCD Characterization; Development of the Code RITRACKS; and Enabling Microliquid Chromatography by Microbead Packing of Microchannels.

United States Automotive Materials Partnership LLC (USAMP)

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

United States Automotive Materials Partnership

2011-01-31

The United States Automotive Materials Partnership LLC (USAMP) was formed in 1993 as a partnership between Chrysler Corporation, Ford Motor Company, and General Motors Corporation. Since then the U.S. Department of Energy (DOE) has supported its activities with funding and technical support. The mission of the USAMP is to conduct vehicle-oriented research and development in materials and materials processing to improve the competitiveness of the U.S. Auto Industry. Its specific goals are: (1) To conduct joint research to further the development of lightweight materials for improved automotive fuel economy; and (2) To work with the Federal government to explore opportunitiesmore » for cooperative programs with the national laboratories, Federal agencies such as the DOE and universities. As a major component of the DOE's Office of FreedomCAR and Vehicle Technologies Program (FCVT) collaboration with the USAMP, the Automotive Lightweighting Materials (ALM) program focuses on the development and validation of advanced materials and manufacturing technologies to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. The FCVT was announced in FY 2002 and implemented in FY 2003, as a successor of the Partnership for a New Generation of Vehicles (PNGV), largely addressed under the first Cooperative Agreement. This second USAMP Cooperative Agreement with the DOE has expanded a unique and valuable framework for collaboratively directing industry and government research efforts toward the development of technologies capable of solving important societal problems related to automobile transportation. USAMP efforts are conducted by the domestic automobile manufacturers, in collaboration with materials and manufacturing suppliers, national laboratories, universities, and other technology or trade organizations. These interactions provide a direct route for implementing newly developed materials and technologies, and have resulted in significant technical successes to date, as discussed in the individual project summary final reports. Over 70 materials-focused projects have been established by USAMP, in collaboration with participating suppliers, academic/non-profit organizations and national laboratories, and executed through its original three divisions: the Automotive Composites Consortium (ACC), the Automotive Metals Division (AMD), and Auto/Steel Partnership (A/SP). Two new divisions were formed by USAMP in 2006 to drive research emphasis on integration of structures incorporating dissimilar lightweighting materials, and on enabling technology for nondestructive evaluation of structures and joints. These new USAMP divisions are: Multi-Material Vehicle Research and Development Initiative (MMV), and the Non-Destructive Evaluation Steering Committee (NDE). In cooperation with USAMP and the FreedomCAR Materials Technical Team, a consensus process has been established to facilitate the development of projects to help move leveraged research to targeted development projects that eventually migrate to the original equipment manufacturers (OEMs) as application engineering projects. Research projects are assigned to one of three phases: concept feasibility, technical feasibility, and demonstration feasibility. Projects are guided through ongoing monitoring and USAMP offsite reviews, so as to meet the requirements of each phase before they are allowed to move on to the next phase. As progress is made on these projects, the benefits of lightweight construction and enabling technologies will be transferred to the supply base and implemented in production vehicles. The single greatest barrier to automotive use of lightweight materials is their high cost; therefore, priority is given to activities aimed at reducing costs through development of new materials, forming technologies, and manufacturing processes. The emphasis of the research projects reported in this document was largely on applied research and evaluation of mass savings opportunities through the aggressive application of lightweight materials, advanced computational methods, and the demonstration of production capable manufacturing processes intended for high-volume applications, all directed towards the FreedomCAR Program goals. Priority lightweighting materials include advanced high-strength steels (AHSS), aluminum, magnesium, titanium, and composites such as metal-matrix materials, and glass- and carbon-fiber-reinforced thermosets and thermoplastics. Besides developing valuable new design and material property information, several projects have extensively used computer-based product modeling and simulation technologies to optimize designs and materials usage while addressing the cost-performance issues. The purpose of this Summary Final Closeout Report is to document the successes, degree of progress, technology dissemination efforts, and lessons learned.« less