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.

Evaluation of a Highway Bridge Constructed Using High Strength Lightweight Concrete Bridge Girders : final report.

DOT National Transportation Integrated Search

2011-04-01

The use of high performance concretes to provide longer bridge spans has been limited due to the capacity of existing infrastructure to handle the load of the girders during transportation. The use of High Strength Lightweight Concrete (HSLW) can pro...

Evaluation of a highway bridge constructed using high strength lightweight concrete bridge girders.

DOT National Transportation Integrated Search

2011-04-01

The purpose of this research was to characterize the performance of High Strength Lightweight Concrete (HSLW) in precast, prestressed bridge girders and to evaluate their performance in a highway bridge. The mechanical properties and long-term time-d...

Advanced bulk processing of lightweight materials for utilization in the transportation sector

NASA Astrophysics Data System (ADS)

Milner, Justin L.

The overall objective of this research is to develop the microstructure of metallic lightweight materials via multiple advanced processing techniques with potentials for industrial utilization on a large scale to meet the demands of the aerospace and automotive sectors. This work focused on (i) refining the grain structure to increase the strength, (ii) controlling the texture to increase formability and (iii) directly reducing processing/production cost of lightweight material components. Advanced processing is conducted on a bulk scale by several severe plastic deformation techniques including: accumulative roll bonding, isolated shear rolling and friction stir processing to achieve the multiple targets of this research. Development and validation of the processing techniques is achieved through wide-ranging experiments along with detailed mechanical and microstructural examination of the processed material. On a broad level, this research will make advancements in processing of bulk lightweight materials facilitating industrial-scale implementation. Where accumulative roll bonding and isolated shear rolling, currently feasible on an industrial scale, processes bulk sheet materials capable of replacing more expensive grades of alloys and enabling low-temperature and high-strain-rate formability. Furthermore, friction stir processing to manufacture lightweight tubes, made from magnesium alloys, has the potential to increase the utilization of these materials in the automotive and aerospace sectors for high strength - high formability applications. With the increased utilization of these advanced processing techniques will significantly reduce the cost associated with lightweight materials for many applications in the transportation sectors.

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.

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.

Development of a Lightweight, High Strength, Collapsible Hose

DTIC Science & Technology

1989-02-01

they will erupt through the elastomer as the hose exits the extrusion head and result in blistering of the cover and/or the lining. The jacket is...not successful. Extreme blistering of the elastomer occurred as the hose exited the extrusion head. The conclusion was drawn that moisture was not...HIGH STRENGTH, COLLAPSIBLE HOSE ABSTRACT This report documents an exploratory development effort to produce a 6-inch diameter, lightweight, high strength

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.

Optimization study on the primary mirror lightweighting of a remote sensing instrument

NASA Astrophysics Data System (ADS)

Chan, Chia-Yen; Huang, Bo-Kai; You, Zhen-Ting; Chen, Yi-Cheng; Huang, Ting-Ming

2015-07-01

Remote sensing instrument (RSI) is used to take images for ground surface observation, which will be exposed to high vacuum, high temperature difference, gravity, 15 g-force and random vibration conditions and other harsh environments during operation. While designing a RSI optical system, not only the optical quality but also the strength of mechanical structure we should be considered. As a result, an optimization method is adopted to solve this engineering problem. In the study, a ZERODUR® mirror with a diameter of 466 mm has been chosen as the model and the optimization has been executed by combining the computer-aided design, finite element analysis, and parameter optimization software. The optimization is aimed to obtain the most lightweight mirror with maintaining structural rigidity and good optical quality. Finally, the optimum optical mirror with a lightweight ratio of 0.55 is attained successfully.

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.

Material Properties Analysis of Structural Members in Pumpkin Balloons

NASA Technical Reports Server (NTRS)

Sterling, W. J.

2003-01-01

The efficient design, service-life qualification, and reliability predictions for lightweight aerospace structures require careful mechanical properties analysis of candidate structural materials. The demand for high-quality laboratory data is particularly acute when the candidate material or the structural design has little history. The pumpkin-shaped super-pressure balloon presents both challenges. Its design utilizes load members (tendons) extending from apex to base around the gas envelope to achieve a lightweight structure. The candidate tendon material is highly weight-efficient braided HM cord. Previous mechanical properties studies of Zylon have focused on fiber and yarn, and industrial use of the material in tensile applications is limited. For high-performance polymers, a carefully plamed and executed properties analysis scheme is required to ensure the data are relevant to the desired application. Because no directly-applicable testing standard was available, a protocol was developed based on guidelines fiom professional and industry organizations. Due to the liquid-crystalline nature of the polymer, the cord is very stiff, creeps very little, and does not yield. Therefore, the key material property for this application is the breaking strength. The pretension load and gauge length were found to have negligible effect on the measured breaking strength over the ranges investigated. Strain rate was found to have no effect on breaking strength, within the range of rates suggested by the standards organizations. However, at the lower rate more similar to ULDB operations, the strength was reduced. The breaking strength increased when the experiment temperature was decreased from ambient to 183K which is the lowest temperature ULDB is expected to experience. The measured strength under all test conditions was well below that resulting from direct scale-up of fiber strength based on the manufacturers data. This expected result is due to the effects of the braiding process and material ageing.

Lightweight Shield for Centrifuge

NASA Technical Reports Server (NTRS)

Luper, C.

1982-01-01

Centrifuge bowl composed of laminated aluminum offers required combination of high strength at reduced weight. Around outside wall of bowl core of 1/16 inch thick spun aluminum are wrapped two layers of aluminum, each also one-sixteenth inch thick. Layered structure prevents cracks from propagating through wall.

Improving Fatigue Performance of AHSS Welds

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

Feng, Zhili; Yu, Xinghua; Erdman, III, Donald L.

Reported herein is technical progress on a U.S. Department of Energy CRADA project with industry cost-share aimed at developing the technical basis and demonstrate the viability of innovative in-situ weld residual stresses mitigation technology that can substantially improve the weld fatigue performance and durability of auto-body structures. The developed technology would be costeffective and practical in high-volume vehicle production environment. Enhancing weld fatigue performance would address a critical technology gap that impedes the widespread use of advanced high-strength steels (AHSS) and other lightweight materials for auto body structure light-weighting. This means that the automotive industry can take full advantage ofmore » the AHSS in strength, durability and crashworthiness without the concern of the relatively weak weld fatigue performance. The project comprises both technological innovations in weld residual stress mitigation and due-diligence residual stress measurement and fatigue performance evaluation. Two approaches were investigated. The first one was the use of low temperature phase transformation (LTPT) weld filler wire, and the second focused on novel thermo-mechanical stress management technique. Both technical approaches have resulted in considerable improvement in fatigue lives of welded joints made of high-strength steels. Synchrotron diffraction measurement confirmed the reduction of high tensile weld residual stresses by the two weld residual stress mitigation techniques.« less

A Rational Approach to Determine Minimum Strength Thresholds in Novel Structural Materials

NASA Technical Reports Server (NTRS)

Schur, Willi W.; Bilen, Canan; Sterling, Jerry

2003-01-01

Design of safe and survivable structures requires the availability of guaranteed minimum strength thresholds for structural materials to enable a meaningful comparison of strength requirement and available strength. This paper develops a procedure for determining such a threshold with a desired degree of confidence, for structural materials with none or minimal industrial experience. The problem arose in attempting to use a new, highly weight-efficient structural load tendon material to achieve a lightweight super-pressure balloon. The developed procedure applies to lineal (one dimensional) structural elements. One important aspect of the formulation is that it extrapolates to expected probability distributions for long length specimen samples from some hypothesized probability distribution that has been obtained from a shorter length specimen sample. The use of the developed procedure is illustrated using both real and simulated data.

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.

Design of high strength polymer metal interfaces by laser microstructured surfaces

NASA Astrophysics Data System (ADS)

Steinert, P.; Dittes, A.; Schimmelpfennig, R.; Scharf, I.; Lampke, T.; Schubert, A.

2018-06-01

In the areas of automotive, aeronautics and civil structures, lightweight construction is a current and a future need. Thus, multi material design has rapidly grown in importance, especially hybrid materials based on fiber reinforced plastics and aluminum offer great potential. Therefore, mechanical interlocking is a convenient way of designing the interface. Laser structuring is already used to generate a variety of surface topographies leading to high bond strengths. This paper investigates different laser structures aiming on highest joint strengths for aluminum and glass fiber reinforced polyamide 6 interfaces. Self-organizing pin structures comprised by additional micro/nano features as well as drilled hole structures, both ranging on the micrometer range, are compared to corundum blasting as a standard method for surface conditioning. For the presented surface structures, thermal joining and ultrasonic assisted joining are regarded towards their potential for an optimum joint design.

Energy absorption characteristics of lightweight structural member by stacking conditions

NASA Astrophysics Data System (ADS)

Choi, Juho; Yang, Yongjun; Hwang, Woochae; Pyeon, Seokbeom; Min, Hanki; Yeo, Ingoo; Yang, Inyoung

2011-11-01

The recent trend in vehicle design is aimed at improving crash safety and environmental-friendliness. To solve these issues, the needs for lighter vehicle to limit exhaust gas and improve fuel economy has been requested for environmental-friendliness. Automobile design should be made for reduced weight once the safety of vehicle is maintained. In this study, composite structural members were manufactured using carbon fiber reinforced plastic (CFRP) which are representative lightweight structural materials. Carbon fiber has been researched as alternative to metals for lightweight vehicle and better fuel economy. CFRP is an anisotropic material which is the most widely adapted lightweight structural member because of their inherent design flexibility and high specific strength and stiffness. Also, variation of CFRP interface number is important to increase the energy absorption capacity. In this study, one type of circular shaped composite tube was used, combined with reinforcing foam. The stacking condition was selected to investigate the effect of the fiber orientation angle and interface number. The crashworthy behavior of circular composite material tubes subjected to static axial compression under same conditions is reported. The axial static collapse tests were carried out for each section member. The collapse modes and the energy absorption capability of the members were analyzed.

Energy absorption characteristics of lightweight structural member by stacking conditions

NASA Astrophysics Data System (ADS)

Choi, Juho; Yang, Yongjun; Hwang, Woochae; Pyeon, Seokbeom; Min, Hanki; Yeo, Ingoo; Yang, Inyoung

2012-04-01

The recent trend in vehicle design is aimed at improving crash safety and environmental-friendliness. To solve these issues, the needs for lighter vehicle to limit exhaust gas and improve fuel economy has been requested for environmental-friendliness. Automobile design should be made for reduced weight once the safety of vehicle is maintained. In this study, composite structural members were manufactured using carbon fiber reinforced plastic (CFRP) which are representative lightweight structural materials. Carbon fiber has been researched as alternative to metals for lightweight vehicle and better fuel economy. CFRP is an anisotropic material which is the most widely adapted lightweight structural member because of their inherent design flexibility and high specific strength and stiffness. Also, variation of CFRP interface number is important to increase the energy absorption capacity. In this study, one type of circular shaped composite tube was used, combined with reinforcing foam. The stacking condition was selected to investigate the effect of the fiber orientation angle and interface number. The crashworthy behavior of circular composite material tubes subjected to static axial compression under same conditions is reported. The axial static collapse tests were carried out for each section member. The collapse modes and the energy absorption capability of the members were analyzed.

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.

Superalloy Lattice Block Structures

NASA Technical Reports Server (NTRS)

Nathal, M. V.; Whittenberger, J. D.; Hebsur, M. G.; Kantzos, P. T.; Krause, D. L.

2004-01-01

Initial investigations of investment cast superalloy lattice block suggest that this technology will yield a low cost approach to utilize the high temperature strength and environmental resistance of superalloys in lightweight, damage tolerant structural configurations. Work to date has demonstrated that relatively large superalloy lattice block panels can be successfully investment cast from both IN-718 and Mar-M247. These castings exhibited mechanical properties consistent with the strength of the same superalloys measured from more conventional castings. The lattice block structure also accommodates significant deformation without failure, and is defect tolerant in fatigue. The potential of lattice block structures opens new opportunities for the use of superalloys in future generations of aircraft applications that demand strength and environmental resistance at elevated temperatures along with low weight.

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.

Effects of sodium hydroxide (NaOH) solution concentration on fly ash-based lightweight geopolymer

NASA Astrophysics Data System (ADS)

Ibrahim, W. M. W.; Hussin, K.; Abdullah, M. M. A.; Kadir, A. A.; Deraman, L. M.

2017-09-01

In this study, the effects of NaOH concentration on properties of fly ash-based lightweight geopolymer were investigated. Lightweight geopolymer was produced using fly ash as source materials and synthetic foaming agents as air entraining agent. The alkaline solutions used in this study are combination of sodium hydroxide (NaOH) and sodium silicate (Na2SiO3) solution. Different molarities of NaOH solution (6M, 8M, 10M, 12M, and 14M) are taken for preparation of 50 x 50 x 50 mm cubes of lightweight geopolymer. The ratio of fly ash/alkaline solution, Na2SiO3/NaOH solution, foaming agent/water and foam/geopolymer paste were kept constant at 2.0, 2.5, 1:10 and 1:1 respectively. The samples were cured at 80°C for 24 hours and left at room temperature for tested at 7 days of ageing. Physical and mechanical properties such as density, water absorption, compressive strength and microstructure property were determined from the cube dried samples. The results show that the NaOH molarity had effects on the properties of lightweight geopolymer with the optimum NaOH molarity found is 12M due to the high strength of 15.6 MPa, lower water absorption (7.3%) and low density (1440 kg/m3). Microstructure analysis shows that the lightweight geopolymer contain some porous structure and unreacted fly ash particles remains.

Development of lightweight ceramic ablators and arc-jet test results

NASA Technical Reports Server (NTRS)

Tran, Huy K.

1994-01-01

Lightweight ceramic ablators (LCA's) were recently developed at Ames to investigate the use of low density fibrous substrates and organic resins as high temperature, high strength ablative heat shields. Unlike the traditional ablators, LCA's use porous ceramic/carbon fiber matrices as substrates for structural support, and polymeric resins as fillers. Several substrates and resins were selected for the initial studies, and the best performing candidates were further characterized. Three arcjet tests were conducted to determine the LCA's thermal performance and ablation characteristics in a high enthalpy, hypersonic flow environment. Mass loss and recession measurements were obtained for each sample at post test, and the recession rates were determined from high speed motion films. Surface temperatures were also obtained from optical pyrometers.

Production Process for Strong, Light Ceramic Tiles

NASA Technical Reports Server (NTRS)

Holmquist, G. R.; Cordia, E. R.; Tomer, R. S.

1985-01-01

Proportions of ingredients and sintering time/temperature schedule changed. Production process for lightweight, high-strength ceramic insulating tiles for Space Shuttle more than just scaled-up version of laboratory process for making small tiles. Boron in aluminum borosilicate fibers allows fusion at points where fibers contact each other during sintering, thereby greatly strengthening tiles structure.

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.

Strong, Ductile, and Thermally Stable bcc-Mg Nanolaminates.

PubMed

Pathak, Siddhartha; Velisavljevic, Nenad; Baldwin, J Kevin; Jain, Manish; Zheng, Shijian; Mara, Nathan A; Beyerlein, Irene J

2017-08-15

Magnesium has attracted attention worldwide because it is the lightest structural metal. However, a high strength-to-weight ratio remains its only attribute, since an intrinsic lack of strength, ductility and low melting temperature severely restricts practical applications of Mg. Through interface strains, the crystal structure of Mg can be transformed and stabilized from a simple hexagonal (hexagonal close packed hcp) to body center cubic (bcc) crystal structure at ambient pressures. We demonstrate that when introduced into a nanocomposite bcc Mg is far more ductile, 50% stronger, and retains its strength after extended exposure to 200 C, which is 0.5 times its homologous temperature. These findings reveal an alternative solution to obtaining lightweight metals critically needed for future energy efficiency and fuel savings.

Reuse of thermosetting plastic waste for lightweight concrete.

PubMed

Panyakapo, Phaiboon; Panyakapo, Mallika

2008-01-01

This paper presents the utilization of thermosetting plastic as an admixture in the mix proportion of lightweight concrete. Since this type of plastic cannot be melted in the recycling process, its waste is expected to be more valuable by using as an admixture for the production of non-structural lightweight concrete. Experimental tests for the variation of mix proportion were carried out to determine the suitable proportion to achieve the required properties of lightweight concrete, which are: low dry density and acceptable compressive strength. The mix design in this research is the proportion of plastic, sand, water-cement ratio, aluminum powder, and lignite fly ash. The experimental results show that the plastic not only leads to a low dry density concrete, but also a low strength. It was found that the ratio of cement, sand, fly ash, and plastic equal to 1.0:0.8:0.3:0.9 is an appropriate mix proportion. The results of compressive strength and dry density are 4.14N/mm2 and 1395 kg/m3, respectively. This type of concrete meets most of the requirements for non-load-bearing lightweight concrete according to ASTM C129 Type II standard.

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...

Filling material for a buried cavity in a collapse area using light-weighted foam and active feldspar

NASA Astrophysics Data System (ADS)

Cho, Jin Woo; Lee, Ju-hyoung; Kim, Sung-Wook; Choi, Eun-Kyeong

2017-04-01

Concrete which is generally used as filling material for a buried cavity has very high strength but significantly high self-load is considered its disadvantage. If it is used as filling material, the second collapse due to additional load, causing irreversible damage. If light-weighted foam and active feldspar are used to solve this problem, the second collapse can be prevented by reducing of self-load of filling material. In this study, the specimen was produced by mixing light-weighted foam, active feldspar and cement, and changes in the density, unconfined compressive strength and hydraulic conductivity were analyzed. Using the light-weighted foam could enable the adjustment of density of specimen between 0.5 g/cm3 and 1.7 g/cm3, and if the mixing ratio of the light-weighted foam increases, the specimen has more pores and smaller range of cross-sectional area. It is confirmed that it has direct correlation with the density, and if the specimen has more pores, the density of the specimen is lowered. The density of the specimen influences the unconfined compressive strength and the hydraulic conductivity, and it was also confirmed that the unconfined compressive strength could be adjusted between 0.6 MPa and 8 MPa and the hydraulic conductivity could be adjusted between 10-9cm/sec and 10-3cm/sec. These results indicated that we can adjust unconfined compressive strength and hydraulic conductivity of filling materials by changing the mixing amount of lightweight-weighted foam according to the requirements of the field condition. Keywords: filling material, buried cavity, light-weighted foam, feldspar Acknowledgement This research was supported by a Grant from a Strategic Research Project (Horizontal Drilling and Stabilization Technologies for Urban Search and Rescue (US&R) Operation) funded by the Korea Institute of Civil Engineering and Building Technology.

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.

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.

High strength films from oriented, hydrogen-bonded "graphamid" 2D polymer molecular ensembles.

PubMed

Sandoz-Rosado, Emil; Beaudet, Todd D; Andzelm, Jan W; Wetzel, Eric D

2018-02-27

The linear polymer poly(p-phenylene terephthalamide), better known by its tradename Kevlar, is an icon of modern materials science due to its remarkable strength, stiffness, and environmental resistance. Here, we propose a new two-dimensional (2D) polymer, "graphamid", that closely resembles Kevlar in chemical structure, but is mechanically advantaged by virtue of its 2D structure. Using atomistic calculations, we show that graphamid comprises covalently-bonded sheets bridged by a high population of strong intermolecular hydrogen bonds. Molecular and micromechanical calculations predict that these strong intermolecular interactions allow stiff, high strength (6-8 GPa), and tough films from ensembles of finite graphamid molecules. In contrast, traditional 2D materials like graphene have weak intermolecular interactions, leading to ensembles of low strength (0.1-0.5 GPa) and brittle fracture behavior. These results suggest that hydrogen-bonded 2D polymers like graphamid would be transformative in enabling scalable, lightweight, high performance polymer films of unprecedented mechanical performance.

Evaluation of lightweight high performance concrete in bulb-T beams and decks in two bridges on Route 33 in Virginia.

DOT National Transportation Integrated Search

2009-01-01

Lightweight high performance concrete (LWHPC) is expected to provide high strength and high durability along with reduced weight. The purpose of this research was to evaluate and compare the prestressed LWHPC bulb-T beams and decks in two bridge stru...

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.

Strong, Ductile, and Thermally Stable bcc-Mg Nanolaminates

DOE PAGES

Pathak, Siddhartha; Velisavljevic, Nenad; Baldwin, Jon Kevin Scott; ...

2017-08-15

Magnesium has attracted attention worldwide because it is the lightest structural metal. However, a high strength-to-weight ratio remains its only attribute, since an intrinsic lack of strength, ductility and low melting temperature severely restricts practical applications of Mg. Through interface strains, the crystal structure of Mg can be transformed and stabilized from a simple hexagonal (hexagonal close packed hcp) to body center cubic (bcc) crystal structure at ambient pressures. Here, we demonstrate that when introduced into a nanocomposite bcc Mg is far more ductile, 50% stronger, and retains its strength after extended exposure to 200°C, which is 0.5 times itsmore » homologous temperature. These findings reveal an alternative solution to obtaining lightweight metals critically needed for future energy efficiency and fuel savings.« less

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.

High performance carbon fibers from very high molecular weight polyacrylonitrile precursors

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

Morris, E. Ashley; Weisenberger, Matthew C.; Abdallah, Mohamed G.

In this study, carbon fibers are unique reinforcing agents for lightweight composite materials due to their outstanding mechanical properties and low density. Current technologies are capable of producing carbon fibers with 90-95% of the modulus of perfect graphite (~1025 GPa). However, these same carbon fibers possess less than 10% of the theoretical carbon fiber strength, estimated to be about 100 GPa.[1] Indeed, attempts to increase carbon fiber rigidity results in lower breaking strength. To develop advanced carbon fibers with both very high strength and modulus demands a new manufacturing methodology. Here, we report a method of manufacturing high strength, verymore » high modulus carbon fibers from a very high molecular weight (VHMW) polyacrylonitrile (PAN) precursor without the use of nanomaterial additives such as nucleating or structure-templating agents, as have been used by others.[2,3]« less

High performance carbon fibers from very high molecular weight polyacrylonitrile precursors

DOE PAGES

Morris, E. Ashley; Weisenberger, Matthew C.; Abdallah, Mohamed G.; ...

2016-02-02

In this study, carbon fibers are unique reinforcing agents for lightweight composite materials due to their outstanding mechanical properties and low density. Current technologies are capable of producing carbon fibers with 90-95% of the modulus of perfect graphite (~1025 GPa). However, these same carbon fibers possess less than 10% of the theoretical carbon fiber strength, estimated to be about 100 GPa.[1] Indeed, attempts to increase carbon fiber rigidity results in lower breaking strength. To develop advanced carbon fibers with both very high strength and modulus demands a new manufacturing methodology. Here, we report a method of manufacturing high strength, verymore » high modulus carbon fibers from a very high molecular weight (VHMW) polyacrylonitrile (PAN) precursor without the use of nanomaterial additives such as nucleating or structure-templating agents, as have been used by others.[2,3]« less

Nanostructural hierarchy increases the strength of aluminium alloys.

PubMed

Liddicoat, Peter V; Liao, Xiao-Zhou; Zhao, Yonghao; Zhu, Yuntian; Murashkin, Maxim Y; Lavernia, Enrique J; Valiev, Ruslan Z; Ringer, Simon P

2010-09-07

Increasing the strength of metallic alloys while maintaining formability is an interesting challenge for enabling new generations of lightweight structures and technologies. In this paper, we engineer aluminium alloys to contain a hierarchy of nanostructures and possess mechanical properties that expand known performance boundaries-an aerospace-grade 7075 alloy exhibits a yield strength and uniform elongation approaching 1 GPa and 5%, respectively. The nanostructural architecture was observed using novel high-resolution microscopy techniques and comprises a solid solution, free of precipitation, featuring (i) a high density of dislocations, (ii) subnanometre intragranular solute clusters, (iii) two geometries of nanometre-scale intergranular solute structures and (iv) grain sizes tens of nanometres in diameter. Our results demonstrate that this novel architecture offers a design pathway towards a new generation of super-strong materials with new regimes of property-performance space.

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.

Lightweight Concrete : Mechanical Properties : TechBrief

DOT National Transportation Integrated Search

2013-06-01

There is a limited amount of test data on the mechanical properties of high-strength lightweight concrete (LWC) with a concrete unit weight (wc) between that of traditional LWC and normal weight concrete (NWC). Concrete with a wc in this range is als...

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.

Optical and optomechanical ultralightweight C/SiC components

NASA Astrophysics Data System (ADS)

Papenburg, Ulrich; Pfrang, Wilhelm; Kutter, G. S.; Mueller, Claus E.; Kunkel, Bernd P.; Deyerler, Michael; Bauereisen, Stefan

1999-11-01

Optical and optomechanical structures based on silicon carbide (SiC) ceramics are becoming increasingly important for ultra- lightweight optical systems that must work in adverse environments. At IABG and Dornier Satellite Systems (DSS) in Munich, a special form of SiC ceramics carbon fiber reinforced silicon carbide (C/SiCR) has been developed partly under ESA and NASA contracts. C/SiCR is a light-weight, high- strength engineering material that features tunable mechanical and thermal properties. It offers exceptional design freedom due to its reduced brittleness and negligible volume shrinkage during processing in comparison to traditional, powder-based ceramics. Furthermore, its rapid fabrication process produces near-net-shape components using conventional NC machining/milling equipment and, thus, provides substantial schedule, cost, and risk savings. These characteristics allow C/SiCR to overcome many of the problems associated with more traditional optical materials. To date, C/SiCR has been used to produce ultra-lightweight mirrors and reflectors, antennas, optical benches, and monolithic and integrated reference structures for a variety of space and terrestrial applications. This paper describes the material properties, optical system and structural design aspects, the forming and manufacturing process including high-temperature joining technology, precision grinding and cladding techniques, and the performance results of a number of C/SiCR optical components we have built.

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.

A cross-shear deformation for optimizing the strength and ductility of AZ31 magnesium alloys

PubMed Central

Hamad, Kotiba; Ko, Young Gun

2016-01-01

Magnesium alloys have recently attracted great interest due their lightweight and high specific strength. However, because of their hexagonal close-packed structure, they have few active slip systems, resulting in poor ductility and high mechanical anisotropy at room temperature. In the present work, we used a cross-shear deformation imposed by a differential speed rolling (DSR) technique to improve the room temperature strength and ductility of AZ31 magnesium alloy sheets. To introduce the cross-shear deformation, the sheets were rotated 180° around their longitudinal axis between the adjacent passes of DSR. The sheets of the AZ31 alloy subjected to the cross-shear deformation showed a uniform fine microstructure (1.2 ± 0.1 μm) with weak basal textures. The fabricated sheets showed a simultaneous high ultimate tensile strength and elongation-to-failure, i.e., ~333 MPa and ~21%, respectively. These were explained based on the structural features evolved due to the cross-shear deformation by DSR. The high strength was attributed to the uniform fine microstructure, whereas the high ductility was explained based on the basal texture weakening. PMID:27406685

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

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.

Shock Tube Test for Energy Absorbing Materials

DTIC Science & Technology

2013-09-13

rigid and lightweight foam material with a closed-cell structure, and a very high strength-to-weight ratio (7). It is commonly used as a sandwich...including application in helmet liners (8). Zorbium™ is the viscoelastic polyurethane foam used in military helmet suspension system pads (9). 8...viscoelastic polyurethane foam which shows strain rate dependent behavior when compressed. This is displayed by the significant difference in response

Electron Beam Irradiated Intercalated CNT Yarns For Aerospace Applications

NASA Technical Reports Server (NTRS)

Waters, Deborah L.; Gaier, James R.; Williams, Tiffany S.; Lopez Calero, Johnny E.; Ramirez, Christopher; Meador, Michael A.

2015-01-01

Multi-walled CNT yarns have been experimentally and commercially created to yield lightweight, high conductivity fibers with good tensile properties for application as electrical wiring and multifunctional tendons. Multifunctional tendons are needed as the cable structures in tensegrity robots for use in planetary exploration. These lightweight robust tendons can provide mechanical strength for movement of the robot in addition to power distribution and data transmission. In aerospace vehicles, such as Orion, electrical wiring and harnessing mass can approach half of the avionics mass. Use of CNT yarns as electrical power and data cables could reduce mass of the wiring by thirty to seventy percent. These fibers have been intercalated with mixed halogens to increase their specific electrical conductivity to that near copper. This conductivity, combined with the superior strength and fatigue resistance makes it an attractive alternative to copper for wiring and multifunctional tendon applications. Electron beam irradiation has been shown to increase mechanical strength in pristine CNT fibers through increased cross-linking. Both pristine and intercalated CNT yarns have been irradiated using a 5-megavolt electron beam for various durations and the conductivities and tensile properties will be discussed. Structural information obtained using a field emission scanning electron microscope, energy dispersive X-ray spectroscopy (EDS), and Raman spectroscopy will correlate microstructural details with bulk properties.

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.

NT-SiC (new-technology silicon carbide) : Φ 650mm optical space mirror substrate of high-strength reaction-sintered silicon carbide

NASA Astrophysics Data System (ADS)

Suyama, Shoko; Itoh, Yoshiyasu; Tsuno, Katsuhiko; Ohno, Kazuhiko

2005-08-01

Silicon carbide (SiC) is the most advantageous as the material of various telescope mirrors, because of high stiffness, low density, low coefficient of thermal expansion, high thermal conductivity and thermal stability. Newly developed high-strength reaction-sintered silicon carbide (NTSIC), which has two times higher strength than sintered SiC, is one of the most promising candidates for lightweight optical mirror substrate, because of fully dense, lightweight, small sintering shrinkage (+/-1 %), good shape capability and low processing temperature. In this study, 650mm in diameter mirror substrate of NTSIC was developed for space telescope applications. Three developed points describe below. The first point was to realize the lightweight to thin the thickness of green bodies. Ribs down to 3mm thickness can be obtained by strengthen the green body. The second point was to enlarge the mirror size. 650mm in diameter of mirror substrate can be fabricated with enlarging the diameter in order. The final point was to realize the homogeneity of mirror substrate. Some properties, such as density, bending strength, coefficient of thermal expansion, Young's modulus, Poisson's ratio, fracture toughness, were measured by the test pieces cutting from the fabricated mirror substrates.

The Bonding Behavior of co-extruded Aluminum-Titanium-Compounds

NASA Astrophysics Data System (ADS)

Striewe, Barbara; Hunkel, Martin; von Hehl, Axel; Grittner, Norbert

The combination of aluminum and titanium enables the design of lightweight structures with tailor-made properties at global as well as local scale. In this context the co-extrusion process offers a great potential for advanced solutions for long products especially being applied in the aircraft and automobile sector. While titanium alloys show particular high mechanical strength and good corrosion resistance, aluminum alloys provide a considerable high specific bending stiffness along with lower materials costs.

Microstructural Characteristics of High Rate Plastic Deformation in Elektron (trademark) WE43 Magnesium Alloy

DTIC Science & Technology

2012-04-01

extremely lightweight metal , weighing 30% less than aluminum, and 70% less than steel, it also has the highest strength-to-weight ratio among any of the...commonly used non- ferrous and ferrous metallic materials [2]. As magnesium is used more often in structural components, there is an increasing...mechanism of deformation in metals has been shown to be shear localization [6] [7]. The shear localization seen in high strain rate deformation is

Mechanically Strong Lightweight Materials for Aerospace Applications (x-aerogels)

NASA Technical Reports Server (NTRS)

Leventis, Nicholas

2005-01-01

The X-Aerogel is a new NASA-developed strong lightweight material made by reacting the mesoporous surfaces of 3-D networks of inorganic nanoparticles with polymeric crosslinkers. Since the relative amount of the crosslinker and the backbone are comparable, X-Aerogels can be viewed either as aerogels modified by templated accumulation of polymer on the skeletal nanoparticles, or as nanoporous polymers made by templated casting of polymeric precursors on a nanostructured framework. The most striking feature of X-Aerogels is that for a nominal 3-fold increase in density (still a ultralightweight material), the mechanical strength can be up to 300 times higher than the strength of the underlying native aerogel. Thus, X-Aerogels combine a multiple of the specific compressive strength of steel, with the thermal conductivity of styrofoam. XAerogels have been demonstrated with several polymers such as polyurethanes/polyureas, epoxies and polyolefins, while crosslinking of approximately 35 different oxide aerogels yields a wide variety of dimensionally stable, porous lightweight materials with interesting structural, magnetic and optical properties. X-Aerogels are evaluated for cryogenic rocket fuel storage tanks and for Advanced EVA suits, where they will play the dual role of the thermal insulator/structural material. Along the same lines, major impact is also expected by the use of X-Aerogels in structural components/thermal protection for small satellites, spacecrafts, planetary vehicles and habitats.

Bottom-up Design of Three-Dimensional Carbon-Honeycomb with Superb Specific Strength and High Thermal Conductivity.

PubMed

Pang, Zhenqian; Gu, Xiaokun; Wei, Yujie; Yang, Ronggui; Dresselhaus, Mildred S

2017-01-11

Low-dimensional carbon allotropes, from fullerenes, carbon nanotubes, to graphene, have been broadly explored due to their outstanding and special properties. However, there exist significant challenges in retaining such properties of basic building blocks when scaling them up to three-dimensional materials and structures for many technological applications. Here we show theoretically the atomistic structure of a stable three-dimensional carbon honeycomb (C-honeycomb) structure with superb mechanical and thermal properties. A combination of sp 2 bonding in the wall and sp 3 bonding in the triple junction of C-honeycomb is the key to retain the stability of C-honeycomb. The specific strength could be the best in structural carbon materials, and this strength remains at a high level but tunable with different cell sizes. C-honeycomb is also found to have a very high thermal conductivity, for example, >100 W/mK along the axis of the hexagonal cell with a density only ∼0.4 g/cm 3 . Because of the low density and high thermal conductivity, the specific thermal conductivity of C-honeycombs is larger than most engineering materials, including metals and high thermal conductivity semiconductors, as well as lightweight CNT arrays and graphene-based nanocomposites. Such high specific strength, high thermal conductivity, and anomalous Poisson's effect in C-honeycomb render it appealing for the use in various engineering practices.

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

Lightweight protective clothing for the safe handling of high-intensity pressurized lamps

NASA Technical Reports Server (NTRS)

Ewashinka, J. G.

1975-01-01

Five commercially available clothing materials, selected for their high cutting resistance, high strength, light weight and pliability, were tested by exposing them to exploding lamps located less than 60 cm (2 ft) away. Face shield material tested initially was commercial high-strength polycarbonate plastic.

Ballistic Analysis of New Military Grade Magnesium Alloys for Armor Applications

NASA Astrophysics Data System (ADS)

Jones, Tyrone L.; Kondoh, Katsuyoshi

Since 2006, the U.S. Army has been evaluating magnesium (Mg) alloys for ballistic structural applications. While Mg-alloys have been used in military structural applications since WWII, very little research has been done to improve its mediocre ballistic performance. The Army's need for ultra-lightweight armor systems has led to research and development of high strength, high ductility Mg-alloys. The U.S. Army Research Laboratory contracted through International Technology Center-Pacific Contract Number FA-5209-09-P-0158 with the Joining and Welding Research Instituteof Osaka University to develop the next generation of high strength, high ductility Mg-alloys using a novel Spinning Water Atomization Process for rapid solidification. New alloys AMX602 and ZAXE1711 in extruded bar form were characterized for microstructure, mechanical, and ballistic response. Significant increases in ballistic performance were evident when compared to the baseline alloy AZ31B.

Strength properties of cement slurries with lightweights applied in oil and gas wells

NASA Astrophysics Data System (ADS)

Bubnov, A. S.; Boyko, I. A.; Khorev, V. S.

2015-02-01

The article is focused on the cement stone strength properties resulted from lightweight cement slurries that meet GOST-1581-96 (state Standards) requirements. Exfoliated vermiculite, hollow aluminosilicate microspheres (HAMs), diatomite and perlite were used as lightweighting additives.

Strengthening lightweight concrete

NASA Technical Reports Server (NTRS)

Auskern, A.

1972-01-01

Polymer absorption by lightweight concretes to improve bonding between cement and aggregate and to increase strength of cement is discussed. Compressive strength of treated cement is compared with strength of untreated product. Process for producing polymers is described.

Shock Response of Lightweight Adobe Masonry

NASA Astrophysics Data System (ADS)

Sauer, C.; Bagusat, F.; Heine, A.; Riedel, W.

2018-06-01

The behavior of a low density and low-strength building material under shock loading is investigated. The considered material is lightweight adobe masonry characterized by a density of 1.2 g/cm3 and a quasi-static uniaxial compressive strength of 2.8 MPa. Planar-plate-impact (PPI) tests with velocities in between 295 and 950 m/s are performed in order to obtain Hugoniot data and to derive parameters for an equation of state (EOS) that captures the occurring phenomenology of porous compaction and subsequent unloading. The resulting EOS description is validated by comparing the experimental free surface velocity time curves with those obtained by numerical simulations of the performed PPI tests. The non-linear compression behavior, including the pore compaction mechanism, constitutes a main ingredient for modelling the response of adobe to blast and high-velocity impact loading. We hence present a modeling approach for lightweight adobe which can be applied to such high rate loading scenarios in future studies. In general, this work shows that PPI tests on lightweight and low-strength geological materials can be used to extract Hugoniot data despite significant material inhomogeneity. Furthermore, we demonstrate that a homogenous material model is able to numerically describe such a material under shock compression and release with a reasonable accuracy.

Shock Response of Lightweight Adobe Masonry

NASA Astrophysics Data System (ADS)

Sauer, C.; Bagusat, F.; Heine, A.; Riedel, W.

2018-04-01

The behavior of a low density and low-strength building material under shock loading is investigated. The considered material is lightweight adobe masonry characterized by a density of 1.2 g/cm3 and a quasi-static uniaxial compressive strength of 2.8 MPa. Planar-plate-impact (PPI) tests with velocities in between 295 and 950 m/s are performed in order to obtain Hugoniot data and to derive parameters for an equation of state (EOS) that captures the occurring phenomenology of porous compaction and subsequent unloading. The resulting EOS description is validated by comparing the experimental free surface velocity time curves with those obtained by numerical simulations of the performed PPI tests. The non-linear compression behavior, including the pore compaction mechanism, constitutes a main ingredient for modelling the response of adobe to blast and high-velocity impact loading. We hence present a modeling approach for lightweight adobe which can be applied to such high rate loading scenarios in future studies. In general, this work shows that PPI tests on lightweight and low-strength geological materials can be used to extract Hugoniot data despite significant material inhomogeneity. Furthermore, we demonstrate that a homogenous material model is able to numerically describe such a material under shock compression and release with a reasonable accuracy.

Interpretation of dynamic tensile behavior by austenite stability in ferrite-austenite duplex lightweight steels.

PubMed

Park, Jaeyeong; Jo, Min Cheol; Jeong, Hyeok Jae; Sohn, Seok Su; Kwak, Jai-Hyun; Kim, Hyoung Seop; Lee, Sunghak

2017-11-16

Phenomena occurring in duplex lightweight steels under dynamic loading are hardly investigated, although its understanding is essentially needed in applications of automotive steels. In this study, quasi-static and dynamic tensile properties of duplex lightweight steels were investigated by focusing on how TRIP and TWIP mechanisms were varied under the quasi-static and dynamic loading conditions. As the annealing temperature increased, the grain size and volume fraction of austenite increased, thereby gradually decreasing austenite stability. The strain-hardening rate curves displayed a multiple-stage strain-hardening behavior, which was closely related with deformation mechanisms. Under the dynamic loading, the temperature rise due to adiabatic heating raised the austenite stability, which resulted in the reduction in the TRIP amount. Though the 950 °C-annealed specimen having the lowest austenite stability showed the very low ductility and strength under the quasi-static loading, it exhibited the tensile elongation up to 54% as well as high strain-hardening rate and tensile strength (1038 MPa) due to appropriate austenite stability under dynamic loading. Since dynamic properties of the present duplex lightweight steels show the excellent strength-ductility combination as well as continuously high strain hardening, they can be sufficiently applied to automotive steel sheets demanded for stronger vehicle bodies and safety enhancement.

Multifunctional Stiff Carbon Foam Derived from Bread.

PubMed

Yuan, Ye; Ding, Yujie; Wang, Chunhui; Xu, Fan; Lin, Zaishan; Qin, Yuyang; Li, Ying; Yang, Minglong; He, Xiaodong; Peng, Qingyu; Li, Yibin

2016-07-06

The creation of stiff yet multifunctional three-dimensional porous carbon architecture at very low cost is still challenging. In this work, lightweight and stiff carbon foam (CF) with adjustable pore structure was prepared by using flour as the basic element via a simple fermentation and carbonization process. The compressive strength of CF exhibits a high value of 3.6 MPa whereas its density is 0.29 g/cm(3) (compressive modulus can be 121 MPa). The electromagnetic interference (EMI) shielding effectiveness measurements (specific EMI shielding effectiveness can be 78.18 dB·cm(3)·g(-1)) indicate that CF can be used as lightweight, effective shielding material. Unlike ordinary foam structure materials, the low thermal conductivity (lowest is 0.06 W/m·K) with high resistance to fire makes CF a good candidate for commercial thermal insulation material. These results demonstrate a promising method to fabricate an economical, robust carbon material for applications in industry as well as topics regarding environmental protection and improvement of energy efficiency.

Influence of surface modified basalt fiber on strength of cinder lightweight aggregate concrete

NASA Astrophysics Data System (ADS)

Xiao, Liguang; Li, Jiheng; Liu, Qingshun

2017-12-01

In order to improve the bonding and bridging effect between volcanic slag lightweight aggregate concrete cement and basalt fiber, The basalt fiber was subjected to etching and roughening treatment by NaOH solution, and the surface of the basalt fiber was treated with a mixture of sodium silicate and micro-silica powder. The influence of modified basalt fiber on the strength of volcanic slag lightweight aggregate concrete was systematically studied. The experimental results show that the modified basalt fiber volcanic slag lightweight aggregate concrete has a flexural strength increased by 47%, the compressive strength is improved by 16% and the toughness is increased by 27% compared with that of the non-fiber.

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.

Effects of lightweight fly ash aggregate properties on the behavior of lightweight concretes.

PubMed

Kockal, Niyazi Ugur; Ozturan, Turan

2010-07-15

Influence of different lightweight fly ash aggregates on the behavior of concrete mixtures was discussed. The performance characteristics of lightweight concretes (LWCs) and normalweight concrete (NWC) were investigated through compressive strength, modulus of elasticity and splitting tensile strength representing the mechanical behavior; through rapid chloride permeability representing the transport properties and through rapid freezing and thawing cycling representing the durability of concrete. In order to investigate the aggregate-cement paste interfacial transition zone (ITZ), SEM observations were performed. Regression and graphical analysis of the experimental data obtained were also performed. An increase in compressive strength was observed with the increase in oven-dry density. The ratios of splitting tensile strength to compressive strength of lightweight aggregate concretes were found to be similar to that of normalweight concrete. All the 28- and 56-day concrete specimens had a durability factor greater than 85 and 90, respectively, which met the requirement for freezing and thawing durability. 2010 Elsevier B.V. All rights reserved.

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.

In-Situ Characterization of Deformation and Fracture Behavior of Hot-Rolled Medium Manganese Lightweight Steel

NASA Astrophysics Data System (ADS)

Zhao, Zheng-zhi; Cao, Rong-hua; Liang, Ju-hua; Li, Feng; Li, Cheng; Yang, Shu-feng

2018-02-01

The deformation and fracture behavior of hot-rolled medium manganese lightweight (0.32C-3.85Mn-4.18Al-1.53Si) steel was revealed by an in situ tensile test. Deformed δ-ferrite with plenty of cross-parallel deformation bands during in situ tensile tests provides δ-ferrite of good plasticity and ductility, although it is finally featured by the cleavage fracture. The soft and ductile δ-ferrite and high-volume fraction of austenite contribute to the superior mechanical properties of medium manganese lightweight steel heated at 800°C, with a tensile strength of 924 MPa, total elongation of 35.2% and product of the strength and elongation of 32.5 GPa %.

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.

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.

Development of High-Strength Nanostructured Magnesium Alloys for Light-Weight Weapon Systems and Vehicles

DTIC Science & Technology

2014-01-13

strength nanocrystalline Mg-alloys via cryomilling and spark - plasma - sintering , 2) demonstrate the unveil evidence of nanotwins in nanocrystalline...Christopher Melnyk, Wei H. Kao, Jenn-Ming Yang. Cryomilling and spark plasma sintering of nanocrystalline magnesium-based alloy, Journal of Materials...accomplished several important milestones: 1) manufacture of high strength nanocrystalline Mg-alloys via cryomilling and spark plasma sintering (SPS

Cryogenic insulation development

NASA Technical Reports Server (NTRS)

Leonhard, K. E.

1972-01-01

Multilayer insulations for long term cryogenic storage are described. The development effort resulted in an insulation concept using lightweight radiation shields, separated by low conductive Dacron fiber tufts. The insulation is usually referred to as Superfloc. The fiber tufts are arranged in a triangular pattern and stand about .040 in. above the radiation shield base. Thermal and structural evaluation of Superfloc indicated that this material is a strong candidate for the development of high performance thermal protection systems because of its high strength, purge gas evacuation capability during boost, its density control and easy application to a tank.

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.

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.

Development of the Main Wing Structure of a High Altitude Long Endurance UAV

NASA Astrophysics Data System (ADS)

Park, Sang Wook; Shin, Jeong Woo; Kim, Tae-Uk

2018-04-01

To enhance the flight endurance of a HALE UAV, the main wing of the UAV should have a high aspect ratio and low structural weight. Since a main wing constructed with the thin walled and slender components needed for low structural weight can suffer catastrophic failure during flight, it is important to develop a light-weight airframe without sacrificing structural integrity. In this paper, the design of the main wing of the HALE UAV was conducted using spars which were composed of a carbon-epoxy cylindrical tube and bulkheads to achieve both the weight reduction and structural integrity. The spars were sized using numerical analysis considering non-linear deformation under bending moment. Static strength testing of the wing was conducted under the most critical load condition. Then, the experimental results obtained for the wing were compared to the analytical result from the non-linear finite-element analysis. It was found that the developed main wing reduced its structural weight without any failure under the ultimate load condition of the static strength testing.

The HSOB GAIA: a cryogenic high stability cesic optical bench for missions requiring sub-nanometric optical stability

NASA Astrophysics Data System (ADS)

Courteau, Pascal; Poupinet, Anne; Kroedel, Mathias; Sarri, Giuseppe

2017-11-01

Global astrometry, very demanding in term of stability, requires extremely stable material for optical bench. CeSiC developed by ECM and Alcatel Alenia Space for mirrors and high stability structures, offers the best compromise in term of structural strength, stability and very high lightweight capability, with characteristics leading to be insensitive to thermo-elastic at cryogenic T°. The HSOB GAIA study realised by Alcatel Alenia Space under ESA contract aimed to design, develop and test a full scale representative High Stability Optical Bench in CeSiC. The bench has been equipped with SAGEIS-CSO laser metrology system MOUSE1, Michelson interferometer composed of integrated optics with a nm resolution. The HSOB bench has been submitted to an homogeneous T° step under vacuum to characterise the homothetic behaviour of its two arms. The quite negligible inter-arms differential measured with a nm range reproducibility, demonstrates that a complete 3D structure in CeSiC has the same CTE homogeneity as characterisation samples, fully in line with the GAIA need (1pm at 120K). This participates to the demonstration that CeSiC properties at cryogenic T° is fully appropriate to the manufacturing of complex highly stable optical structures. This successful study confirms ECM and Alcatel Alenia Space ability to define and manufacture monolithic lightweight highly stable optical structures, based on inner cells triangular design made only possible by the unique CeSiC manufacturing process.

Steel skin - SMC laminate structures for lightweight automotive manufacturing

NASA Astrophysics Data System (ADS)

Quagliato, Luca; Jang, Changsoon; Murugesan, Mohanraj; Kim, Naksoo

2017-09-01

In the present research work an innovative material, made of steel skin and sheet molding compound core, is presented and is aimed to be utilized for the production of automotive body frames. For a precise description of the laminate structure, the material properties of all the components, including the adhesive utilized as an interlayer, have been carried out, along with the simple tension test of the composite material. The result have shown that the proposed laminate structure has a specific yield strength 114% higher than 6061 T6 aluminum, 34% higher than 7075 T6 aluminum, 186% higher than AISI 304 stainless steel (30HRC) and 42% than SK5 high-strength steel (52HRC), showing its reliability and convenience for the realization of automotive components. After calibrating the material properties of the laminate structure, and utilizing as reference the simple tension results of the laminate structure, the derived material properties have been utilized for the simulation of the mechanical behavior of an automotive B-pillar. The results have been compared with those of a standard B-pillar made of steel, showing that the MS-SMC laminate structure manifests load and impact carry capacity comparable with those of high strength steel, while granting, at least, an 11% weight reduction.

Curved cap corrugated sheet

NASA Technical Reports Server (NTRS)

Davis, R. C.; Bales, T. T.; Royster, D. M.; Jackson, L. R. (Inventor)

1984-01-01

The report describes a structure for a strong, lightweight corrugated sheet. The sheet is planar or curved and includes a plurality of corrugation segments, each segment being comprised of a generally U-shaped corrugation with a part-cylindrical crown and cap strip, and straight side walls and with secondary corrugations oriented at right angles to said side walls. The cap strip is bonded to the crown and the longitudinal edge of said cap strip extends beyond edge at the intersection between said crown and said side walls. The high strength relative to weight of the structure makes it desirable for use in aircraft or spacecraft.

Increased Tensile Strength of Carbon Nanotube Yarns and Sheets through Chemical Modification and Electron Beam Irradiation

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Williams, Tiffany S.; Baker, James S.; Sola, Francisco; Lebron-Colon, Marisabel; McCorkle, Linda S.; Wilmoth, Nathan G.; Gaier, James; Chen, Michelle; Meador, Michael A.

2014-01-01

The inherent strength of individual carbon nanotubes offers considerable opportunity for the development of advanced, lightweight composite structures. Recent work in the fabrication and application of carbon nanotube (CNT) forms such as yarns and sheets has addressed early nanocomposite limitations with respect to nanotube dispersion and loading; and has pushed the technology toward structural composite applications. However, the high tensile strength of an individual CNT has not directly translated to macro-scale CNT forms where bulk material strength is limited by inter-tube electrostatic attraction and slippage. The focus of this work was to assess post processing of CNT sheet and yarn to improve the macro-scale strength of these material forms. Both small molecule functionalization and e-beam irradiation was evaluated as a means to enhance tensile strength and Youngs modulus of the bulk CNT material. Mechanical testing results revealed a tensile strength increase in CNT sheets by 57 when functionalized, while an additional 48 increase in tensile strength was observed when functionalized sheets were irradiated; compared to unfunctionalized sheets. Similarly, small molecule functionalization increased yarn tensile strength up to 25, whereas irradiation of the functionalized yarns pushed the tensile strength to 88 beyond that of the baseline yarn.

Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure-Property Relationship of a Strongly Bonded Interface

NASA Astrophysics Data System (ADS)

Liu, Bert; Vivek, Anupam; Presley, Michael; Daehn, Glenn S.

2018-03-01

The ability to weld high-strength aluminum to high-strength steel is highly desired for vehicle lightweighting but difficult to attain by conventional means. In this work, vaporizing foil actuator welding was used to successfully weld four Al/Fe combinations consisting of high-strength alloys: AA5052-H32, AA6111-T4, DP980, and 22MnB5. Flyer velocities up to 727 m/s were reached using 10 kJ input energy. In lap-shear testing, samples primarily failed in base aluminum near the aluminum's native strength, showing that the welds were stronger than a base metal and that the base metal was not significantly weakened by the welding process. A particularly strong weld area was studied by transmission electron microscopy to shed light on the microstructural features of strong impact welds. It was found to be characterized by a continuously bonded, fully crystalline interface, extremely fine (nanoscale) grains, mesoscopic as well as microscopic wavy features, and lack of large continuous intermetallic compounds.

The effectiveness of stone ash and volcanic ash of mount Sinabung as a filler on the initial strength of self-compacting concrete

NASA Astrophysics Data System (ADS)

Karolina, R.; Muhammad, W.; Saragih, M. D. S. M.; Mustaqa, T.

2018-02-01

Self Compacting Concrete is a concrete variant that has a high degree of workability and also has great initial strength, but low water cement factor. It is also self-flowable that can be molded on formwork with a very little or no compacted use of compactors. This concrete, using a variety of aggregate sizes, aggregate portions and superplasticizer admixture to achieve a special viscosity that allows it to flow on its own without the aid of a compactor. Lightweight concrete brick is a type of brick made from cement, sand, water, and developers. Lightweight concrete bricks are divided into 2 based on the developed materials used are AAC (Autoclave Aerated Concrete) using aluminum paste and CLC (Cellular Lightweight Concrete) that use Foaming Agent from BASF as a developer material. In this experiment, the lightweight bricks that will be made are CLC type which uses Foaming Agent as the developer material by mixing the Ash Stone produced by Stone Crusher machine which has the density of 2666 kg / m3 as Partial Pair Substitution. In this study the variation of Ash Stone used is 10%, 15%, and 20% of the planned amount of sand. After doing the tasting the result is obtained for 10% variation. Compressive Strength and Absorption Increase will decrease by 25.07% and 39.005% and Variation of 15% compressive strength will decrease by 65,8% and decrease of absorbtion equal to 17,441% and variation of 20% compressive strength will decreased by 67,4 and absorption increase equal to 17,956%.

Using a centrifuge for quality control of pre-wetted lightweight aggregate in internally cured concrete

NASA Astrophysics Data System (ADS)

Miller, Albert E.

Early age shrinkage of cementitious systems can result in an increased potential for cracking which can lead to a reduction in service life. Early age shrinkage cracking can be particularly problematic for high strength concretes, which are often specified due to their high strength and low permeability. However, these high strength concretes frequently exhibit a reduction in the internal relative humidity (RH) due to the hydration reaction (chemical shrinkage) and self-desiccation which results in a bulk shrinkage, termed autogenous shrinkage, which is substantial at early ages. Due to the low permeability of these concretes, standard external curing is not always efficient in addressing this reduction in internal RH since the penetration of water can be limited. Internal curing has been developed to reduce autogenous shrinkage. Internally cured mixtures use internal reservoirs filled with fluid (generally water) that release this fluid at appropriate times to counteract the effects of self-desiccation thereby maintaining a high internal RH. Internally cured concrete is frequently produced in North America using pre-wetted lightweight aggregate. One important aspect associated with preparing quality internally cured concrete is being able to determine the absorbed moisture and surface moisture associated with the lightweight aggregate which enables aggregate moisture corrections to be made for the concrete mixture. This thesis represents work performed to develop a test method using a centrifuge to determine the moisture state of pre-wetted fine lightweight aggregate. The results of the test method are then used in a series of worksheets that were developed to assist field technicians when performing the tests and applying the results to a mixture design. Additionally, research was performed on superabsorbent polymers to assess their ability to be used as an internal curing reservoir.

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

Skin and scales of teleost fish: Simple structure but high performance and multiple functions

NASA Astrophysics Data System (ADS)

Vernerey, Franck J.; Barthelat, Francois

2014-08-01

Natural and man-made structural materials perform similar functions such as structural support or protection. Therefore they rely on the same types of properties: strength, robustness, lightweight. Nature can therefore provide a significant source of inspiration for new and alternative engineering designs. We report here some results regarding a very common, yet largely unknown, type of biological material: fish skin. Within a thin, flexible and lightweight layer, fish skins display a variety of strain stiffening and stabilizing mechanisms which promote multiple functions such as protection, robustness and swimming efficiency. We particularly discuss four important features pertaining to scaled skins: (a) a strongly elastic tensile behavior that is independent from the presence of rigid scales, (b) a compressive response that prevents buckling and wrinkling instabilities, which are usually predominant for thin membranes, (c) a bending response that displays nonlinear stiffening mechanisms arising from geometric constraints between neighboring scales and (d) a robust structure that preserves the above characteristics upon the loss or damage of structural elements. These important properties make fish skin an attractive model for the development of very thin and flexible armors and protective layers, especially when combined with the high penetration resistance of individual scales. Scaled structures inspired by fish skin could find applications in ultra-light and flexible armor systems, flexible electronics or the design of smart and adaptive morphing structures for aerospace vehicles.

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.

Light-Adaptive Supramolecular Nacre-Mimetic Nanocomposites.

PubMed

Zhu, Baolei; Noack, Manuel; Merindol, Remi; Barner-Kowollik, Christopher; Walther, Andreas

2016-08-10

Nature provides design paradigms for adaptive, self-healing, and synergistic high-performance structural materials. Nacre's brick-and-mortar architecture is renowned for combining stiffness, toughness, strength, and lightweightness. Although elaborate approaches exist to mimic its static structure and performance, and to incorporate functionalities for the engineering world, there is a profound gap in addressing adaptable mechanical properties, particularly using remote, quick, and spatiotemporal triggers. Here, we demonstrate a generic approach to control the mechanical properties of nacre-inspired nanocomposites by designing a photothermal energy cascade using colloidal graphene as light-harvesting unit and coupling it to molecularly designed, thermoreversible, supramolecular bonds in the nanoconfined soft phase of polymer/nanoclay nacre-mimetics. The light intensity leads to adaptive steady-states balancing energy uptake and dissipation. It programs the mechanical properties and switches the materials from high stiffness/strength to higher toughness within seconds under spatiotemporal control. We envisage possibilities beyond mechanical materials, for example, light-controlled (re)shaping or actuation in highly reinforced nanocomposites.

Characterization of Thermal and Mechanical Impact on Aluminum Honeycomb Structures

NASA Technical Reports Server (NTRS)

Robinson, Christen M.

2013-01-01

This study supports NASA Kennedy Space Center's research in the area of intelligent thermal management systems and multifunctional thermal systems. This project addresses the evaluation of the mechanical and thermal properties of metallic cellular solid (MCS) materials; those that are lightweight; high strength, tunable, multifunctional and affordable. A portion of the work includes understanding the mechanical properties of honeycomb structured cellular solids upon impact testing under ambient, water-immersed, liquid nitrogen-cooled, and liquid nitrogen-immersed conditions. Additionally, this study will address characterization techniques of the aluminum honeycomb's ability to resist multiple high-rate loadings or impacts in varying environmental conditions, using various techniques for the quantitative and qualitative determination for commercial applicability.

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

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.

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.

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.

Peg supported thermal insulation panel

DOEpatents

Nowobilski, Jeffert J.; Owens, William J.

1985-01-01

A thermal insulation panel which is lightweight, load bearing, accommodates thermal stress, and has excellent high temperature insulation capability comprising high performance insulation between thin metal walls supported by high density, high strength glass pegs made in compliance with specified conditions of time, temperature and pressure.

Experimental study on the strength of double shear timber connection using bamboo dowel fastener

NASA Astrophysics Data System (ADS)

Anshari, Buan; Sugiartha, Wayan; Mahmud, Fathmah; Rofaida, Aryani; Pathurrahman

2017-11-01

Utilization of timber and bamboo as building materials was very promising for now and future. As renewable resources they have high mechanical properties, lightweight, environmentally friendly and economic. Utilization of bamboo as connector was rarely published. Therefore, this study focused on utilization of non-metal material as connector in timber structure especially for beam and column. This research was conducted in the laboratory to examine the strength of double shear timber connection by using glued in rods (bamboo dowel) as connector with variation of adhesive thickness. As control specimen was used bamboo dowel Ø14 mm without adhesive in double shear connection. The results showed that the strength of double shear timber connection by using glued in rods (bamboo dowel) as connector could increased by 41% to resist axial force higher than the control one.

Compressive strength performance of OPS lightweight aggregate concrete containing coal bottom ash as partial fine aggregate replacement

NASA Astrophysics Data System (ADS)

Muthusamy, K.; Mohamad Hafizuddin, R.; Mat Yahaya, F.; Sulaiman, M. A.; Syed Mohsin, S. M.; Tukimat, N. N.; Omar, R.; Chin, S. C.

2018-04-01

Concerns regarding the negative impact towards environment due to the increasing use of natural sand in construction industry and dumping of industrial solid wastes namely coal bottom ash (CBA) and oil palm shell (OPS) has resulted in the development of environmental friendly lightweight concrete. The present study investigates the effect of coal bottom ash as partial fine aggregate replacement towards workability and compressive strength of oil palm shell lightweight aggregate concrete (OPS LWAC). The fresh and mechanical properties of this concrete containing various percentage of coal bottom ash as partial fine aggregate replacement were investigated. The result was compared to OPS LWAC with 100 % sand as a control specimen. The concrete workability investigated by conducting slump test. All specimens were cast in form of cubes and water cured until the testing age. The compressive strength test was carried out at 7 and 28 days. The finding shows that integration of coal bottom ash at suitable proportion enhances the strength of oil palm shell lightweight aggregate concrete.

Railway vehicle body structures

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

Not Available

1985-01-01

The strength and durability of railway vehicle structures is a major topic of engineering research and design. To reflect this importance the Railway Division of the Institution of Mechanical Engineers organised a conference to discuss all matters relating to railway vehicle design. This book presents the papers discussed in that conference. The contents include: Vehicle body design and the UIC's international contribution; LUL prototype 1986 stock - body structure; vehicle structure for the intermediate capacity transmit system vehicles; car body technology of advanced light rapid transit vehicles; concepts, techniques and experience in the idealization of car body structures for finitemore » element analysis; Calcutta metropolitan railway; design for a lightweight diesel multiple unit body; the design of lightweight inter-city coal structures; the BREL international coach body shell structure; new concepts and design techniques versus material standards; structures of BR diesel electric freight locomotives; structural design philosophy for electric locomotives; suspension design for a locomotive with low structural frequencies; freight wagon structures; a finite element study of coal bodyside panels including the effects of joint flexibility; a fresh approach to the problem of car body design strength; energy absorption in automatic couplings and draw gear; passenger vehicle design loads and structural crashworthiness; design of the front part of railway vehicles (in case of frontal impact); the development of a theoretical technique for rail vehicle structural crashworthiness.« less

Flexible and Lightweight Pressure Sensor Based on Carbon Nanotube/Thermoplastic Polyurethane-Aligned Conductive Foam with Superior Compressibility and Stability.

PubMed

Huang, Wenju; Dai, Kun; Zhai, Yue; Liu, Hu; Zhan, Pengfei; Gao, Jiachen; Zheng, Guoqiang; Liu, Chuntai; Shen, Changyu

2017-12-06

Flexible and lightweight carbon nanotube (CNT)/thermoplastic polyurethane (TPU) conductive foam with a novel aligned porous structure was fabricated. The density of the aligned porous material was as low as 0.123 g·cm -3 . Homogeneous dispersion of CNTs was achieved through the skeleton of the foam, and an ultralow percolation threshold of 0.0023 vol % was obtained. Compared with the disordered foam, mechanical properties of the aligned foam were enhanced and the piezoresistive stability of the flexible foam was improved significantly. The compression strength of the aligned TPU foam increases by 30.7% at the strain of 50%, and the stress of the aligned foam is 22 times that of the disordered foam at the strain of 90%. Importantly, the resistance variation of the aligned foam shows a fascinating linear characteristic under the applied strain until 77%, which would benefit the application of the foam as a desired pressure sensor. During multiple cyclic compression-release measurements, the aligned conductive CNT/TPU foam represents excellent reversibility and reproducibility in terms of resistance. This nice capability benefits from the aligned porous structure composed of ladderlike cells along the orientation direction. Simultaneously, the human motion detections, such as walk, jump, squat, etc. were demonstrated by using our flexible pressure sensor. Because of the lightweight, flexibility, high compressibility, excellent reversibility, and reproducibility of the conductive aligned foam, the present study is capable of providing new insights into the fabrication of a high-performance pressure sensor.

Processing bulk natural wood into a high-performance structural material.

PubMed

Song, Jianwei; Chen, Chaoji; Zhu, Shuze; Zhu, Mingwei; Dai, Jiaqi; Ray, Upamanyu; Li, Yiju; Kuang, Yudi; Li, Yongfeng; Quispe, Nelson; Yao, Yonggang; Gong, Amy; Leiste, Ulrich H; Bruck, Hugh A; Zhu, J Y; Vellore, Azhar; Li, Heng; Minus, Marilyn L; Jia, Zheng; Martini, Ashlie; Li, Teng; Hu, Liangbing

2018-02-07

Synthetic structural materials with exceptional mechanical performance suffer from either large weight and adverse environmental impact (for example, steels and alloys) or complex manufacturing processes and thus high cost (for example, polymer-based and biomimetic composites). Natural wood is a low-cost and abundant material and has been used for millennia as a structural material for building and furniture construction. However, the mechanical performance of natural wood (its strength and toughness) is unsatisfactory for many advanced engineering structures and applications. Pre-treatment with steam, heat, ammonia or cold rolling followed by densification has led to the enhanced mechanical performance of natural wood. However, the existing methods result in incomplete densification and lack dimensional stability, particularly in response to humid environments, and wood treated in these ways can expand and weaken. Here we report a simple and effective strategy to transform bulk natural wood directly into a high-performance structural material with a more than tenfold increase in strength, toughness and ballistic resistance and with greater dimensional stability. Our two-step process involves the partial removal of lignin and hemicellulose from the natural wood via a boiling process in an aqueous mixture of NaOH and Na 2 SO 3 followed by hot-pressing, leading to the total collapse of cell walls and the complete densification of the natural wood with highly aligned cellulose nanofibres. This strategy is shown to be universally effective for various species of wood. Our processed wood has a specific strength higher than that of most structural metals and alloys, making it a low-cost, high-performance, lightweight alternative.

Processing bulk natural wood into a high-performance structural material

NASA Astrophysics Data System (ADS)

Song, Jianwei; Chen, Chaoji; Zhu, Shuze; Zhu, Mingwei; Dai, Jiaqi; Ray, Upamanyu; Li, Yiju; Kuang, Yudi; Li, Yongfeng; Quispe, Nelson; Yao, Yonggang; Gong, Amy; Leiste, Ulrich H.; Bruck, Hugh A.; Zhu, J. Y.; Vellore, Azhar; Li, Heng; Minus, Marilyn L.; Jia, Zheng; Martini, Ashlie; Li, Teng; Hu, Liangbing

2018-02-01

Synthetic structural materials with exceptional mechanical performance suffer from either large weight and adverse environmental impact (for example, steels and alloys) or complex manufacturing processes and thus high cost (for example, polymer-based and biomimetic composites). Natural wood is a low-cost and abundant material and has been used for millennia as a structural material for building and furniture construction. However, the mechanical performance of natural wood (its strength and toughness) is unsatisfactory for many advanced engineering structures and applications. Pre-treatment with steam, heat, ammonia or cold rolling followed by densification has led to the enhanced mechanical performance of natural wood. However, the existing methods result in incomplete densification and lack dimensional stability, particularly in response to humid environments, and wood treated in these ways can expand and weaken. Here we report a simple and effective strategy to transform bulk natural wood directly into a high-performance structural material with a more than tenfold increase in strength, toughness and ballistic resistance and with greater dimensional stability. Our two-step process involves the partial removal of lignin and hemicellulose from the natural wood via a boiling process in an aqueous mixture of NaOH and Na2SO3 followed by hot-pressing, leading to the total collapse of cell walls and the complete densification of the natural wood with highly aligned cellulose nanofibres. This strategy is shown to be universally effective for various species of wood. Our processed wood has a specific strength higher than that of most structural metals and alloys, making it a low-cost, high-performance, lightweight alternative.

Effective use of fly ash slurry as fill material.

PubMed

Horiuchi, S; Kawaguchi, M; Yasuhara, K

2000-09-15

A lot of effort has been put into increasing coal ash utilization; however, 50% of total amount is disposed of on land and in the sea. Several attempts have been reported recently concerning slurried coal fly ash use for civil engineering materials, such as for structural fill and backfill. The authors have studied this issue for more than 15 years and reported its potential for (1) underwater fills, (2) light weight backfills, and (3) light weight structural fills, through both laboratory tests and construction works. This paper is an overview of the results obtained for slurry, focusing on the following. (1) Coal fly ash reclaimed by slurry placement shows lower compressibility, higher ground density, and higher strength than by the other methods. This higher strength increases stability against liquefaction during earthquake. (2) Higher stability of the fly ash ground formed by slurry placement is caused by higher density and its self-hardening property. (3) Stability of fly ash reclaimed ground can be increased by increasing density and also by strength enhancement by cement addition. (4) Technical data obtained through a man-made island construction project shows the advantages of fly ash slurry in terms of mechanical properties such as higher stability against sliding failure, sufficient ground strength, and also in terms of cost saving. (5) Concentration in leachates from the placed slurry is lower than the Japanese environmental law. (6) In order to enlarge the fly ash slurry application toward a lightweight fill, mixtures of air foam, cement and fly ash were examined. Test results shows sufficient durability of this material against creep failure. This material was then used as lightweight structural fill around a high-rise building, and showed sufficient quality. From the above data, it can be concluded that coal fly ash slurry can be effectively utilized in civil engineering projects.

Development and characterization of fatigue resistant Aramid reinforced aluminium laminates (ARALL) for fatigue Critical aircraft components

NASA Astrophysics Data System (ADS)

Qaiser, M. H.; Umar, S.; Nauman, S.

2014-06-01

The structural weight of an aircraft has always been a controlling parameter that governs its fuel efficiency and transport capacity. In pursuit of achieving light-weight aircraft structures, high design stress levels have to be adopted and materials with high specific strength such as Aluminum etc. are to be deployed. However, an extensive spectrum of fatigue load exists at the aircraft wings and other aerodynamic components that may cause initiation and propagation of fatigue cracks and concludes in a catastrophic rupture. Fatigue is therefore the limiting design parameter in such cases and materials with high fatigue resistance are then required. A major improvement in the fatigue behavior was observed by laminating Kevlar fibers with Aluminum using epoxy. ARALL (Aramid Reinforced ALuminum Laminates) is a fatigue resistant hybrid composite that consists of layers of thin high strength aluminum alloy sheets surface bonded with aramid fibers. The intact aramid fibers tie up the fatigue cracks, thus reducing the stress intensity factor at the crack tip as a result of which the fatigue properties of can be enhanced with orders of magnitude as compared to monolithic high strength Aluminum alloy sheets. Significant amount of weight savings can be achieved in fatigue critical components in comparison with the traditional materials used in aircraft.

Peg supported thermal insulation panel

DOEpatents

Nowobilski, J.J.; Owens, W.J.

1985-04-30

A thermal insulation panel which is lightweight, load bearing, accommodates thermal stress, and has excellent high temperature insulation capability comprises high performance insulation between thin metal walls supported by high density, high strength glass pegs made in compliance with specified conditions of time, temperature and pressure. 2 figs.

Influence of Elevated Temperatures on Pet-Concrete Properties

NASA Astrophysics Data System (ADS)

Albano, C.; Camacho, N.; Hernández, M.; Matheus, A.; Gutiérrez, A.

2008-08-01

Lightweight aggregate is an important material in reducing the unit weight of concrete complying with special concrete structures of large high-rise buildings. Besides, the use of recycled PET bottles as lightweight aggregate in concrete is an effective contribution for environment preservation. So, the objective of the present work was to study experimentally the flexural strength of the PET -concrete blends and the thermal degradation of the PET in the concrete, when the blends with 10 and 20% in volume of PET were exposed to different temperatures (200, 400, 600 °C). The flexural strength of concrete-PET exposed to a heat source is strongly dependent on the temperature, water/cement ratio, as well as the content and particle size of PET. However, the activation energy is affected by the temperature, location of the PET particles on the slabs and the water/cement ratio. Higher water content originates thermal and hydrolytic degradation on the PET, while on the concrete, a higher vapor pressure which causes an increase in crack formation. The values of the activation energy are higher on the center of the slabs than on the surface, since concrete is a poor heat conductor.

Study on axial strength of a channel-shaped pultruded GFRP member

NASA Astrophysics Data System (ADS)

Matsumoto, Yukihiro; Satake, Chito; Nisida, Kenji

2017-10-01

Fiber reinforced polymers (FRP) are widely used in vehicle and aerospace applications because of their lightweight and high-strength characteristics. Additionally, FRPs are increasingly applied to building structures. However, the elastic modulus of glass fiber reinforced polymers (GFRPs) is lower than that of steel. Hence, the evaluating the buckling strength of GFRP members for design purpose is necessary. The buckling strength is determined by Euler buckling mode as well as local buckling. In this study investigated the compressive strength of GFRP members subjected to axial compression through experiments and theoretical calculations. The adopted GFRP member was a channel-shaped GFRP, which was molded via pultrusion, at various lengths. Although, the mechanical properties as longitudinal elastic modulus and fiber volume fraction and strength of GFRP members subjected, to axial can be easily evaluated, evaluating transverse elastic modulus and shear modulus in typical material tests is difficult in standard section. Therefore the composite law was used in this study. As a result, we confirmed that the axial strength of a GFRP member could be calculated by a theoretical evaluation method utilizing longitudinal elastic modulus and fiber volume fraction.

Graded High-Strength Spring-Steels by a Special Inductive Heat T reatment

NASA Astrophysics Data System (ADS)

Tump, A.; Brandt, R.

2016-03-01

A method for effective lightweight design is the use of materials with high specific strength. As materials e.g. titanium are very expensive, steel is still the most important material for manufacturing automotive components. Steel is cost efficient, easy to recycle and its tensile strength easily exceeds 2,000 MPa by means of modern QT-technology (Quenched and Tempered). Therefore, lightweight design is still feasible in spite of the high density of steel. However, a further increase of tensile strength is limited, especially due to an increasing notch sensitivity and exposure to a corrosive environment. One solution is a special QT-process for steel, which creates a hardness gradient from the surface to the core of the material. This type of tailored material possesses a softer layer, which improves material properties such as fracture toughness and notch sensitivity. This leads to a better resistance to stress corrosion cracking and corrosion fatigue. Due to this optimization, a weight reduction is feasible without the use of expensive alloying elements. To understand the damage mechanism a comprehensive testing procedure was performed on homogeneous and gradient steels. Some results regarding the fracture mechanic behavior of such steels will be discussed.

Utilization of lignite power generation residues for the production of lightweight aggregates.

PubMed

Anagnostopoulos, Iason M; Stivanakis, Victor E

2009-04-15

A novel process is proposed for the utilization of lignite combustion solid residues in the production of inflammable lightweight aggregates (LWA). The process consists of two stages, pelletization and sintering, and carbon contained in BA was used as the process fuel. The main residues bottom ash (BA) and fly ash (FA) from Megalopolis power plant were characterized, mixed in different proportions and treated through pelletization and sintering process. Sintering benefits from combustion of BA carbon content and the product is a hardened porous cake. The energy required for achievement of high temperatures, in the range of 1250 degrees C, was offered by carbon combustion and CO(2) evolution is responsible for porous structure formation. Selected physical properties of sintered material relevant to use as lightweight aggregates were determined, including bulk density, porosity and water absorption. Bulk density varies from 0.83 to 0.91 g/cm(3), porosity varies from 60% to 64% and water absorption varies from 66% to 80%. LWA formed is used for the production of lightweight aggregate concrete (LWAC). Thermal conductivity coefficient varies from 0.25 to 0.37 W/mK (lower than maximum limit 0.43 W/mK) and compressive strength varies from 19 to 23 MPa (higher than minimum limit 17 MPa). The results indicate that sintering of lignite combustion residues is an efficient method of utilization of carbon containing BA and production of LWA for structural and insulating purposes. Carbon content of BA is a key factor in LWA production. Finally, this research work comprises the first proposed application for utilization of BA in Greece.

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.

STARBLADE: STar and Artefact Removal with a Bayesian Lightweight Algorithm from Diffuse Emission

NASA Astrophysics Data System (ADS)

Knollmüller, Jakob; Frank, Philipp; Ensslin, Torsten A.

2018-05-01

STARBLADE (STar and Artefact Removal with a Bayesian Lightweight Algorithm from Diffuse Emission) separates superimposed point-like sources from a diffuse background by imposing physically motivated models as prior knowledge. The algorithm can also be used on noisy and convolved data, though performing a proper reconstruction including a deconvolution prior to the application of the algorithm is advised; the algorithm could also be used within a denoising imaging method. STARBLADE learns the correlation structure of the diffuse emission and takes it into account to determine the occurrence and strength of a superimposed point source.

The development of optimal lightweight truss-core sandwich panels

NASA Astrophysics Data System (ADS)

Langhorst, Benjamin Robert

Sandwich structures effectively provide lightweight stiffness and strength by sandwiching a low-density core between stiff face sheets. The performance of lightweight truss-core sandwich panels is enhanced through the design of novel truss arrangements and the development of methods by which the panels may be optimized. An introduction to sandwich panels is presented along with an overview of previous research of truss-core sandwich panels. Three alternative truss arrangements are developed and their corresponding advantages, disadvantages, and optimization routines are discussed. Finally, performance is investigated by theoretical and numerical methods, and it is shown that the relative structural efficiency of alternative truss cores varies with panel weight and load-carrying capacity. Discrete truss core sandwich panels can be designed to serve bending applications more efficiently than traditional pyramidal truss arrangements at low panel weights and load capacities. Additionally, discrete-truss cores permit the design of heterogeneous cores, which feature unit cells that vary in geometry throughout the panel according to the internal loads present at each unit cell's location. A discrete-truss core panel may be selectively strengthened to more efficiently support bending loads. Future research is proposed and additional areas for lightweight sandwich panel development are explained.

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.

Global carbon benefits of material substitution in passenger cars until 2050 and the impact on the steel and aluminum industries.

PubMed

Modaresi, Roja; Pauliuk, Stefan; Løvik, Amund N; Müller, Daniel B

2014-09-16

Light-weighting of passenger cars using high-strength steel or aluminum is a common emissions mitigation strategy. We provide a first estimate of the global impact of light-weighting by material substitution on GHG emissions from passenger cars and the steel and aluminum industries until 2050. We develop a dynamic stock model of the global car fleet and combine it with a dynamic MFA of the associated steel, aluminum, and energy supply industries. We propose four scenarios for substitution of conventional steel with high-strength steel and aluminum at different rates over the period 2010-2050. We show that light-weighting of passenger cars can become a "gigaton solution": Between 2010 and 2050, persistent light-weighting of passenger cars can, under optimal conditions, lead to cumulative GHG emissions savings of 9-18 gigatons CO2-eq compared to development business-as-usual. Annual savings can be up to 1 gigaton per year. After 2030, enhanced material recycling can lead to further reductions: closed-loop metal recycling in the automotive sector may reduce cumulative emissions by another 4-6 gigatons CO2-eq. The effectiveness of emissions mitigation by material substitution significantly depends on how the recycling system evolves. At present, policies focusing on tailpipe emissions and life cycle assessments of individual cars do not consider this important effect.

Long-term performance of GFRP reinforcement : technical report.

DOT National Transportation Integrated Search

2009-12-01

Significant research has been performed on glass fiber-reinforced polymer (GFRP) concrete reinforcement. : This research has shown that GFRP reinforcement exhibits high strengths, is lightweight, can decrease time of : construction, and is corrosion ...

Energy Absorbing Protective Shroud

NASA Technical Reports Server (NTRS)

Schneider, William C. (Inventor)

2001-01-01

The present invention is a dissipating protection energy system designed to receive and safely dissipate the kinetic energy from high energy fragments. The energy dissipation system dissipates energy transferred to it by the incremental and progressive rupturing at an approximately constant force of strategically placed sacrificial stitching applied to a number of high strength straps, such as an aromatic polyimide fiber of extremely high tensile strength. Thus, the energy dissipation system provides a lightweight device for controlling and dissipating the dangerous and destructive energy stored in high strength fragments released by catastrophic failures of machinery minimizing damage to other critical components.

Ultrastrong steel via minimal lattice misfit and high-density nanoprecipitation

NASA Astrophysics Data System (ADS)

Jiang, Suihe; Wang, Hui; Wu, Yuan; Liu, Xiongjun; Chen, Honghong; Yao, Mengji; Gault, Baptiste; Ponge, Dirk; Raabe, Dierk; Hirata, Akihiko; Chen, Mingwei; Wang, Yandong; Lu, Zhaoping

2017-04-01

Next-generation high-performance structural materials are required for lightweight design strategies and advanced energy applications. Maraging steels, combining a martensite matrix with nanoprecipitates, are a class of high-strength materials with the potential for matching these demands. Their outstanding strength originates from semi-coherent precipitates, which unavoidably exhibit a heterogeneous distribution that creates large coherency strains, which in turn may promote crack initiation under load. Here we report a counterintuitive strategy for the design of ultrastrong steel alloys by high-density nanoprecipitation with minimal lattice misfit. We found that these highly dispersed, fully coherent precipitates (that is, the crystal lattice of the precipitates is almost the same as that of the surrounding matrix), showing very low lattice misfit with the matrix and high anti-phase boundary energy, strengthen alloys without sacrificing ductility. Such low lattice misfit (0.03 ± 0.04 per cent) decreases the nucleation barrier for precipitation, thus enabling and stabilizing nanoprecipitates with an extremely high number density (more than 1024 per cubic metre) and small size (about 2.7 ± 0.2 nanometres). The minimized elastic misfit strain around the particles does not contribute much to the dislocation interaction, which is typically needed for strength increase. Instead, our strengthening mechanism exploits the chemical ordering effect that creates backstresses (the forces opposing deformation) when precipitates are cut by dislocations. We create a class of steels, strengthened by Ni(Al,Fe) precipitates, with a strength of up to 2.2 gigapascals and good ductility (about 8.2 per cent). The chemical composition of the precipitates enables a substantial reduction in cost compared to conventional maraging steels owing to the replacement of the essential but high-cost alloying elements cobalt and titanium with inexpensive and lightweight aluminium. Strengthening of this class of steel alloy is based on minimal lattice misfit to achieve maximal precipitate dispersion and high cutting stress (the stress required for dislocations to cut through coherent precipitates and thus produce plastic deformation), and we envisage that this lattice misfit design concept may be applied to many other metallic alloys.

Ultrastrong steel via minimal lattice misfit and high-density nanoprecipitation.

PubMed

Jiang, Suihe; Wang, Hui; Wu, Yuan; Liu, Xiongjun; Chen, Honghong; Yao, Mengji; Gault, Baptiste; Ponge, Dirk; Raabe, Dierk; Hirata, Akihiko; Chen, Mingwei; Wang, Yandong; Lu, Zhaoping

2017-04-27

Next-generation high-performance structural materials are required for lightweight design strategies and advanced energy applications. Maraging steels, combining a martensite matrix with nanoprecipitates, are a class of high-strength materials with the potential for matching these demands. Their outstanding strength originates from semi-coherent precipitates, which unavoidably exhibit a heterogeneous distribution that creates large coherency strains, which in turn may promote crack initiation under load. Here we report a counterintuitive strategy for the design of ultrastrong steel alloys by high-density nanoprecipitation with minimal lattice misfit. We found that these highly dispersed, fully coherent precipitates (that is, the crystal lattice of the precipitates is almost the same as that of the surrounding matrix), showing very low lattice misfit with the matrix and high anti-phase boundary energy, strengthen alloys without sacrificing ductility. Such low lattice misfit (0.03 ± 0.04 per cent) decreases the nucleation barrier for precipitation, thus enabling and stabilizing nanoprecipitates with an extremely high number density (more than 10 24 per cubic metre) and small size (about 2.7 ± 0.2 nanometres). The minimized elastic misfit strain around the particles does not contribute much to the dislocation interaction, which is typically needed for strength increase. Instead, our strengthening mechanism exploits the chemical ordering effect that creates backstresses (the forces opposing deformation) when precipitates are cut by dislocations. We create a class of steels, strengthened by Ni(Al,Fe) precipitates, with a strength of up to 2.2 gigapascals and good ductility (about 8.2 per cent). The chemical composition of the precipitates enables a substantial reduction in cost compared to conventional maraging steels owing to the replacement of the essential but high-cost alloying elements cobalt and titanium with inexpensive and lightweight aluminium. Strengthening of this class of steel alloy is based on minimal lattice misfit to achieve maximal precipitate dispersion and high cutting stress (the stress required for dislocations to cut through coherent precipitates and thus produce plastic deformation), and we envisage that this lattice misfit design concept may be applied to many other metallic alloys.

Influence of fillers on the alkali activated chamotte

NASA Astrophysics Data System (ADS)

Dembovska, L.; Bumanis, G.; Vitola, L.; Bajare, D.

2017-10-01

Alkali-activated materials (AAM) exhibit remarkable high-temperature resistance which makes them perspective materials for high-temperature applications, for instance as fire protecting and insulating materials in industrial furnaces. Series of experiments were carried out to develop optimum mix proportions of AAM based on chamotte with quartz sand (Q), olivine sand (OL) and firebrick sawing residues (K26) as fillers. Aluminium scrap recycling waste was considered as a pore forming agent and 6M NaOH alkali activation solution has been used. Lightweight porous AAM have been obtained with density in range from 600 to 880 kg/m3 and compressive strength from 0.8 to 2.7 MPa. The XRD and high temperature optical microscopy was used to characterize the performance of AAM. The mechanical, physical and structural properties of the AAM were determined after the exposure to elevated temperatures at 800 and 1000°C. The results indicate that most promising results for AAM were with K26 filler where strength increase was observed while Q and OL filler reduced mechanical properties due to structure deterioration caused by expansive nature of selected filler.

Influence of the welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW-2219-T87

NASA Astrophysics Data System (ADS)

Bachmann, A.; Krutzlinger, M.; Zaeh, M. F.

2018-06-01

Friction Stir Welding (FSW) is an innovative joining technique, which has proven to produce high quality joints in high strength aluminum alloys. Consequently, it is commonly used to manufacture lightweight aerospace structures with stringent requirements. For these structures, it is necessary to ensure a high ultimate tensile strength (UTS). Various studies have reported that the UTS is significantly influenced by the welding parameters. Samples welded with different parameter sets showed a considerably different UTS, despite being free from detectable welding defects (e.g. tunnel defect, voids, or lack of penetration). Based on the observations in the literature, a hypothesis was posed. The welding temperature along with the welding speed determine the UTS of the weld. This study aims to prove this hypothesis experimentally by using temperature-controlled FSW to join plates of EN AW-2219-T87 in butt joint configuration. The welded samples were examined using visual inspection, metallography, X-ray imaging, and uniaxial tensile tests. Finally, a statistical analysis was conducted. Hereby, the hypothesis was confirmed.

Micromechanics of Sea Urchin spines.

PubMed

Tsafnat, Naomi; Fitz Gerald, John D; Le, Hai N; Stachurski, Zbigniew H

2012-01-01

The endoskeletal structure of the Sea Urchin, Centrostephanus rodgersii, has numerous long spines whose known functions include locomotion, sensing, and protection against predators. These spines have a remarkable internal microstructure and are made of single-crystal calcite. A finite-element model of the spine's unique porous structure, based on micro-computed tomography (microCT) and incorporating anisotropic material properties, was developed to study its response to mechanical loading. Simulations show that high stress concentrations occur at certain points in the spine's architecture; brittle cracking would likely initiate in these regions. These analyses demonstrate that the organization of single-crystal calcite in the unique, intricate morphology of the sea urchin spine results in a strong, stiff and lightweight structure that enhances its strength despite the brittleness of its constituent material.

Special Considerations in Selection of Fabric Film Laminates for Use in Inflatable Structures

NASA Technical Reports Server (NTRS)

Said, Magdi A.

1999-01-01

Inflatable structures are gaining wide support in planetary scientific missions as well as commercial applications. For such applications a new class of fabric/film laminates is being considered for use as a structural gas envelope. The emerging composite materials are a result of recent advances in the manufacturing of lightweight, high strength fibers, fabrics and scrims. The lamination of these load-carrying members with the proper gas barriers results in a wide range of materials suitable for various loading and environmental conditions. Polyester-based woven fabrics laminated to thin homogenous film of polyester are an example of this class. This fabric/film laminate is being considered for the development of a material suitable for building large gas envelopes for use in the NASA ultra long duration balloon program (ULDB). Compared to commercial homogenous films, the material provides relatively high strength to weight ratio as well as better resistance to crack and tear propagation, The mechanical, creep and viscoelastic properties of these fabric film laminates have been studied to form a material model. Preliminary analysis indicates that the material is highly viscoelastic. The mechanical properties of this class of materials will be discussed in some details.

Genetic Optimization of a Tensegrity Structure

NASA Technical Reports Server (NTRS)

Taylor, Jaime R.

2002-01-01

Marshall Space Flight Center (MSFC) is charged with developing advanced technologies for space telescopes. The next generation of space optics will be very large and lightweight. Tensegrity structures are built of compressive members (bars), and tensile members (strings). For most materials, the tensile strength of a longitudinal member is larger than its buckling strength; therefore a large stiffness to mass ratio can be achieved by increasing the use of tensile members. Tensegrities are the epitome of lightweight structures, since they take advantage of the larger tensile strength of materials. The compressive members of tensegrity structures are disjoint allowing compact storage of the structure. The structure has the potential to eliminate the requirement for assembly by man in space; it can be deployed by adjustments in its cable tension. A tensegrity structure can be more reliably modeled since none of the individual members experience bending moments. (Members that experience deformation in more than one dimension are much harder to model.) A. Keane and S. Brown designed a satellite boom truss system with an enhanced vibration performance. They started with a standard truss system, then used a genetic algorithm to alter the design, while optimizing the vibration performance. An improvement of over 20,000% in frequency-averaged energy levels was obtained using this approach. In this report an introduction to tensegrity structures is given, along with a description of how to generate the nodal coordinates and connectivity of a multiple stage cylindrical tensegrity structure. A description of how finite elements can be used to develop a stiffness and mass matrix so that the modes of vibration can be determined from the eigenvalue problem is shown. A brief description of a micro genetic algorithm is then presented.

MIC: Magnetically Deployable Structures for Power, Propulsion, Processing, Habitats and Energy Storage at Manned Lunar Bases

NASA Astrophysics Data System (ADS)

Powell, James; Maise, George; Paniagua, John; Rather, John

2007-01-01

MIC (Magnetically Inflated Cables) is a new approach for robotically erecting very large, strong, rigid, and ultra-lightweight structures in space. MIC structures use a network of high current (SC) cables with attached high tensile strength Kevlar or Spectra tethers. MIC is launched as a compact package of coiled SC cables and tethers on a conventional launch vehicle. Once in space the SC cables are electrically energized. The resultant strong outwards magnetic forces expand them and the restraining tethers into a large structure, which can be 100's of meters in size. MIC structures can be configured for many different applications, including solar electric generation, solar thermal propulsion, energy storage, large space telescopes, magnetic shielding for astronauts, etc. The MIC technology components, including high temperature superconductors (HTS), thermal insulation, high strength tethers, and cryogenic refrigerators all exist commercially. Refrigeration requirements are very modest, on the order of 100 watts thermal per kilometer of MIC cable, with an input electric power to the refrigeration system of ~5 kW(e) per km. baseline MIC designs are described for a manned lunar base, including: 1) a 1 MW(e) solar electric system, 2) a high Isp (~900 seconds) solar thermal tug to transport 30 ton payloads between the Earth and the Moon, 3) a 2000 Megajoule electric energy storage system for peaking and emergency power, and 4) a large (~1 km) space telescope.

Advanced ordered intermetallic alloy deployment

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

Liu, C.T.; Maziasz, P.J.; Easton, D.S.

1997-04-01

The need for high-strength, high-temperature, and light-weight materials for structural applications has generated a great deal of interest in ordered intermetallic alloys, particularly in {gamma}-based titanium aluminides {gamma}-based TiAl alloys offer an attractive mix of low density ({approximately}4g/cm{sup 3}), good creep resistance, and high-temperature strength and oxidation resistance. For rotating or high-speed components. TiAl also has a high damping coefficient which minimizes vibrations and noise. These alloys generally contain two phases. {alpha}{sub 2} (DO{sub 19} structure) and {gamma} (L 1{sub 0}), at temperatures below 1120{degrees}C, the euticoid temperature. The mechanical properties of TiAl-based alloys are sensitive to both alloy compositionsmore » and microstructure. Depending on heat-treatment and thermomechanical processing, microstructures with near equiaxed {gamma}, a duplex structure (a mix of the {gamma} and {alpha}{sub 2} phases) can be developed in TiAl alloys containing 45 to 50 at. % Al. The major concern for structural use of TiAl alloys is their low ductility and poor fracture resistance at ambient temperatures. The purpose of this project is to improve the fracture toughness of TiAl-based alloys by controlling alloy composition, microstructure and thermomechanical treatment. This work is expected to lead to the development of TiAl alloys with significantly improved fracture toughness and tensile ductility for structural use.« less

Mechanically Strong, Polymer Cross-linked Aerogels (X-Aerogels)

NASA Technical Reports Server (NTRS)

Leventis, Nicholas

2006-01-01

Aerogels comprise a class of low-density, high porous solid objects consisting of dimensionally quasi-stable self-supported three-dimensional assemblies of nanoparticles. Aerogels are pursued because of properties above and beyond those of the individual nanoparticles, including low thermal conductivity, low dielectric constant and high acoustic impedance. Possible applications include thermal and vibration insulation, dielectrics for fast electronics, and hosting of functional guests for a wide variety of optical, chemical and electronic applications. Aerogels, however, are extremely fragile materials, hence they have found only limited application in some very specialized environments, for example as Cerenkov radiation detectors in certain types of nuclear reactors, aboard spacecraft as collectors of hypervelocity particles (refer to NASA's Stardust program) and as thermal insulators on planetary vehicles on Mars (refer to Sojourner Rover in 1997 and Spirit and Opportunity in 2004). Along these lines, the X-Aerogel is a new NASA-developed strong lightweight material that has resolved the fragility problem of traditional (native) aerogels. X-Aerogels are made by applying a conformal polymer coating on the surfaces of the skeletal nanoparticles of native aerogels (see Scanning Electron Micrographs). Since the relative amounts of the polymeric crosslinker and the backbone are comparable, X-Aerogels can be viewed either as aerogels modified by the templated accumulation of polymer on the skeletal nanoparticles, or as nanoporous polymers made by remplated casting of polymer on a nanostructured framework. The most striking feature of X-Aerogels is that for a nominal 3-fold increase in density (still a ultralighweight material), the mechanical strength can be up to 300 times higher than the strength of the underlying native aerogel. Thus, X-Aerogels combine a multiple of the specific compressive strength of steel, with the the thermal conductivity of styrofoam. X-Aerogels have been demonstrated with several polymers such as polyurethanes/polyureas, epoxies and polyolefins, while crosslinking of approximately 35 different oxide aerogels yields a range of dimensionally stable, porous lightweight materials with unique combinations of structural, magnetic and optical properties. The main theme in materials development for space exploration is multifunction. For example, use of one material for thermal insulation/structural component will free weight for useful payload. In that regard, X-aerogels are evaluated at NASA for cryogenic fuel storage tanks and for spacesuits. Along the same lines, major impact fro X-Aerogels is also expected in commercial applications for thermal/acoustic insulation, in catalytic reformers and converters, in filtration membranes and membranes for fuel cells, as platforms for optical, electrical and magnetic sensors, and as lightweight structural component for aircraft and satellites.

Epitaxial Welding of Carbon Nanotube Networks for Aqueous Battery Current Collectors.

PubMed

Yao, Yonggang; Jiang, Feng; Yang, Chongyin; Fu, Kun Kelvin; Hayden, John; Lin, Chuan-Fu; Xie, Hua; Jiao, Miaolun; Yang, Chunpeng; Wang, Yilin; He, Shuaiming; Xu, Fujun; Hitz, Emily; Gao, Tingting; Dai, Jiaqi; Luo, Wei; Rubloff, Gary; Wang, Chunsheng; Hu, Liangbing

2018-05-17

Carbon nanomaterials are desirable candidates for lightweight, highly conductive, and corrosion-resistant current collectors. However, a key obstacle is their weak interconnection between adjacent nanostructures, which renders orders of magnitude lower electrical conductivity and mechanical strength in the bulk assemblies. Here we report an "epitaxial welding" strategy to engineer carbon nanotubes (CNTs) into highly crystalline and interconnected structures. Solution-based polyacrylonitrile was conformally coated on CNTs as "nanoglue" to physically join CNTs into a network, followed by a rapid high-temperature annealing (>2800 K, overall ∼30 min) to graphitize the polymer coating into crystalline layers that also bridge the adjacent CNTs to form an interconnected structure. The contact-welded CNTs (W-CNTs) exhibit both a high conductivity (∼1500 S/cm) and a high tensile strength (∼120 MPa), which are 5 and 20 times higher than the unwelded CNTs, respectively. In addition, the W-CNTs display chemical and electrochemical stabilities in strong acidic/alkaline electrolytes (>6 mol/L) when potentiostatically stressing at both cathodic and anodic potentials. With these exceptional properties, the W-CNT films are optimal as high-performance current collectors and were demonstrated in the state-of-the-art aqueous battery using a "water-in-salt" electrolyte.

Basalt Fiber for Volcanic Slag Lightweight Aggregate Concrete Research on the Impact of Performance

NASA Astrophysics Data System (ADS)

Xiao, Li-guang; Li, Gen-zhuang

2018-03-01

In order to study the effect of basalt fiber on the mechanical properties and durability of volcanic slag lightweight aggregate concrete, the experimental study on the flexural strength, compressive strength and freeze-thaw resistance of volcanic slag concrete with different basalt fiber content were carried out, the basalt fiber was surface treated with NaOH and water glass, the results show that the surface treatment of basalt fiber can significantly improve the mechanical properties, durability and other properties of volcanic slag lightweight aggregate concrete.

Nano-casted Metal Oxide Aerogels as Dual Purpose Structural Components for Space Exploration

NASA Technical Reports Server (NTRS)

Vassilaras, Plousia E.

2004-01-01

NASA missions and space exploration rely on strong, ultra lightweight materials. Such materials are needed for building up past and present space vehicles such as the Sojourner Rover (1997) or the two MERs (2003), but also for a number of components and/or systems including thermal insulators, Solar Sails, Rigid Aeroshells, and Ballutes. The purpose of my internship here at Glenn Research Center is to make dual purpose materials; materials that in addition to being lightweight have electronic, photophysical and magnetic properties and, therefore, act as electronic components and sensors as well as structural components. One type of ultra lightweight material of great interest is aerogels, which have densities ranging from 0.003 g/cc to 0.8 g/cc . However, aerogels are extremely fragile and, as a result, have limited practical applications. Recently, Glenn Research Center has developed a process of nano-casting polymers onto the inorganic network of silica-based aerogels increasing the strength 300 fold while only increasing the density 3 fold. By combining the process of nano-casting polymers with inorganic oxide networks other than silica, we are actively pursuing lightweight dual purpose materials. To date, thirty different inorganic oxide aerogels have been prepared using either standard sol-gel chemistry or a non-alkoxide method involving metal chloride precursors and an epoxide; epichlorohydrin, propylene oxide or trimethylene oxide, as proton scavengers. More importantly, preliminary investigations show that the residual surface hydroxyl groups on each of these inorganic oxide aerogels can be successfully crosslinked with urethane. In addition to characterizing physical and mechanical properties such as density, strength and flexibility, each of these metal oxide aerogels are being characterized for thermal and electronic conductivity and magnetic and optical properties.

Laser hybrid joining of plastic and metal components for lightweight components

NASA Astrophysics Data System (ADS)

Rauschenberger, J.; Cenigaonaindia, A.; Keseberg, J.; Vogler, D.; Gubler, U.; Liébana, F.

2015-03-01

Plastic-metal hybrids are replacing all-metal structures in the automotive, aerospace and other industries at an accelerated rate. The trend towards lightweight construction increasingly demands the usage of polymer components in drive trains, car bodies, gaskets and other applications. However, laser joining of polymers to metals presents significantly greater challenges compared with standard welding processes. We present recent advances in laser hybrid joining processes. Firstly, several metal pre-structuring methods, including selective laser melting (SLM) are characterized and their ability to provide undercut structures in the metal assessed. Secondly, process parameter ranges for hybrid joining of a number of metals (steel, stainless steel, etc.) and polymers (MABS, PA6.6-GF35, PC, PP) are given. Both transmission and direct laser joining processes are presented. Optical heads and clamping devices specifically tailored to the hybrid joining process are introduced. Extensive lap-shear test results are shown that demonstrate that joint strengths exceeding the base material strength (cohesive failure) can be reached with metal-polymer joining. Weathering test series prove that such joints are able to withstand environmental influences typical in targeted fields of application. The obtained results pave the way toward implementing metalpolymer joints in manufacturing processes.

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.

Investigation on the cold rolling and structuring of cold sprayed copper-coated steel sheets

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Wiesner, S.; Gerdt, L.; Senge, S.; Hirt, G.

2017-03-01

A current driving force of research is lightweight design. One of the approaches to reduce the weight of a component without causing an overall stiffness decrease is the use of multi-material components. One of the main challenges of this approach is the low bonding strength between different materials. Focusing on steel-aluminum multi-material components, thermally sprayed copper coatings can come into use as a bonding agent between steel sheets and high pressure die cast aluminum to improve the bonding strength. This paper presents a combination of cold gas spraying of copper coatings and their subsequent structuring by rolling as surface pretreatment method of the steel inserts. Therefore, flat rolling experiments are performed with samples in “as sprayed” and heat treated conditions to determine the influence of the rolling process on the bond strength and the formability of the coating. Furthermore, the influence of the rolling on the roughness and the hardness of the coating was examined. In the next step, the coated surface was structured, to create a surface topology suited for a form closure connection in a subsequent high-pressure die casting process. No cracks were observed after the cold rolling process with a thickness reduction of up to ε = 14 % for heat treated samples. Structuring of heat treated samples could be realized without delamination and cracking.

Lightweight, High Strength Metals With Enhanced Radiation Shielding - Technology Advancing Partnerships Challenge Project

NASA Technical Reports Server (NTRS)

Wright, Maria Clara (Compiler)

2015-01-01

The Technology Advancing Partnership (TAP) Challenge will seek to foster innovation throughout the Center by allowing the KSC workforce to identify a specific technology idea that needs improvement and to then work with an external partner to develop that technology. This Challenge will enable competitive partnerships with outside entities that will increase the value by bringing leveraged resources. The selected proposal from the University of Florida will develop new lightweight technologies with radiation mitigation for spacecraft.

Modelling and Analysis Capabilities for Lightweight Masts

DTIC Science & Technology

2001-02-01

manufactured by Astro Aerospace Corporation in Carpinteria, California for NASA’s Johnson Space Center in Houston. The mast structure was a 750 mm...step iii. Design Parameters • Design variables Moduli: E11, E22, E33, G12, G23, G13, ᝼, ជ, ᝽ Strengths: FXT, FXC , FYT, FYC, FZT, FZC, FXY

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.

Ballistic Fracturing of Carbon Nanotubes.

PubMed

Ozden, Sehmus; Machado, Leonardo D; Tiwary, ChandraSekhar; Autreto, Pedro A S; Vajtai, Robert; Barrera, Enrique V; Galvao, Douglas S; Ajayan, Pulickel M

2016-09-21

Advanced materials with multifunctional capabilities and high resistance to hypervelocity impact are of great interest to the designers of aerospace structures. Carbon nanotubes (CNTs) with their lightweight and high strength properties are alternative to metals and/or metallic alloys conventionally used in aerospace applications. Here we report a detailed study on the ballistic fracturing of CNTs for different velocity ranges. Our results show that the highly energetic impacts cause bond breakage and carbon atom rehybridizations, and sometimes extensive structural reconstructions were also observed. Experimental observations show the formation of nanoribbons, nanodiamonds, and covalently interconnected nanostructures, depending on impact conditions. Fully atomistic reactive molecular dynamics simulations were also carried out in order to gain further insights into the mechanism behind the transformation of CNTs. The simulations show that the velocity and relative orientation of the multiple colliding nanotubes are critical to determine the impact outcome.

Effects of Oil Palm Shell Coarse Aggregate Species on High Strength Lightweight Concrete

PubMed Central

Yew, Ming Kun; Bin Mahmud, Hilmi; Ang, Bee Chin; Yew, Ming Chian

2014-01-01

The objective of this study was to investigate the effects of different species of oil palm shell (OPS) coarse aggregates on the properties of high strength lightweight concrete (HSLWC). Original and crushed OPS coarse aggregates of different species and age categories were investigated in this study. The research focused on two OPS species (dura and tenera), in which the coarse aggregates were taken from oil palm trees of the following age categories (3–5, 6–9, and 10–15 years old). The results showed that the workability and dry density of the oil palm shell concrete (OPSC) increase with an increase in age category of OPS species. The compressive strength of specimen CD3 increases significantly compared to specimen CT3 by 21.8%. The maximum achievable 28-day and 90-day compressive strength is 54 and 56 MPa, respectively, which is within the range for 10–15-year-old crushed dura OPS. The water absorption was determined to be within the range for good concrete for the different species of OPSC. In addition, the ultrasonic pulse velocity (UPV) results showed that the OPS HSLWC attain good condition at the age of 3 days. PMID:24982946

Structural Verification of the Space Shuttle's External Tank Super LightWeight Design: A Lesson in Innovation

NASA Technical Reports Server (NTRS)

Otte, Neil

1997-01-01

The Super LightWeight Tank (SLWT) team was tasked with a daunting challenge from the outset: boost the payload capability of the Shuttle System by safely removing 7500 lbs. from the existing 65,400 lb. External Tank (ET). Tools they had to work with included a promising new Aluminum Lithium alloy, the concept of a more efficient structural configuration for the Liquid Hydrogen (LH2) tank, and a highly successful, mature Light Weight Tank (LWT) program. The 44 month schedule which the SLWT team was given for the task was ambitious by any measure. During this time the team had to not only design, build, and verify the new tank, but they also had to move a material from the early stages of development to maturity. The aluminum lithium alloy showed great promise, with an approximately 29% increase in yield strength, 15% increase in ultimate strength, 5 deg/O increase in modulus and 5 deg/O decrease in density when compared to the current 2219 alloy. But processes had to be developed and brought under control, manufacturing techniques perfected, properties characterized, and design allowable generated. Because of the schedule constraint, this material development activity had to occur in parallel with design and manufacturing. Initial design was performed using design allowable believed to be achievable with the Aluminum Lithium alloy system, but based on limited test data. Preliminary structural development tests were performed with material still in the process of iteration. This parallel path approach posed obvious challenges and risks, but also allowed a unique opportunity for interaction between the structures and materials disciplines in the formulation of the material.

Creep of high-strength normal and lightweight concrete.

DOT National Transportation Integrated Search

2004-01-01

In addition to immediate elastic deformations, concrete undergoes time-dependent deformations that must be considered in design. Creep is defined as the time-dependent deformation resulting from a sustained stress. Shrinkage deformation is the time-d...

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.

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.

High-Pressure Lightweight Thrusters

NASA Technical Reports Server (NTRS)

Holmes, Richard; McKechnie, Timothy; Shchetkovskiy, Anatoliy; Smirnov, Alexander

2013-01-01

Returning samples of Martian soil and rock to Earth is of great interest to scientists. There were numerous studies to evaluate Mars Sample Return (MSR) mission architectures, technology needs, development plans, and requirements. The largest propulsion risk element of the MSR mission is the Mars Ascent Vehicle (MAV). Along with the baseline solid-propellant vehicle, liquid propellants have been considered. Similar requirements apply to other lander ascent engines and reaction control systems. The performance of current state-ofthe- art liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure. Pump-fed propulsion is suggested for a single-stage bipropellant MAV. Achieving a 90-percent stage propellant fraction is thought to be possible on a 100-kg scale, including sufficient thrust for lifting off Mars. To increase the performance of storable bipropellant rocket engines, a high-pressure, lightweight combustion chamber was designed. Iridium liner electrodeposition was investigated on complex-shaped thrust chamber mandrels. Dense, uniform iridium liners were produced on chamber and cylindrical mandrels. Carbon/carbon composite (C/C) structures were braided over iridium-lined mandrels and densified by chemical vapor infiltration. Niobium deposition was evaluated for forming a metallic attachment flange on the carbon/ carbon structure. The new thrust chamber was designed to exceed state-of-the-art performance, and was manufactured with an 83-percent weight savings. High-performance C/Cs possess a unique set of properties that make them desirable materials for high-temperature structures used in rocket propulsion components, hypersonic vehicles, and aircraft brakes. In particular, more attention is focused on 3D braided C/Cs due to their mesh-work structure. Research on the properties of C/Cs has shown that the strength of composites is strongly affected by the fiber-matrix interfacial bonding, and that weakening interface realizes pseudo-plastic behavior with significant increase in the tensile strength. The investigation of high-temperature strength of C/Cs under high-rate heating (critical for thrust chambers) shows that tensile and compression strength increases from 70 MPa at room temperature to 110 MPa at 1,773 K, and up to 125 MPa at 2,473 K. Despite these unique properties, the use of C/Cs is limited by its high oxidation rate at elevated temperatures. Lining carbon/carbon chambers with a thin layer of iridium or iridium and rhenium is an innovative way to use proven refractory metals and provide the oxidation barrier necessary to enable the use of carbon/ carbon composites. Due to the lower density of C/Cs as compared to SiC/SiC composites, an iridium liner can be added to the C/C structure and still be below the overall thruster weight. Weight calculations show that C/C, C/C with 50 microns of Ir, and C/C with 100 microns of Ir are of less weight than alternative materials for the same construction.

The mechanical and physical properties of concrete containing polystyrene beads as aggregate and palm oil fuel ash as cement replacement material

NASA Astrophysics Data System (ADS)

Adnan, Suraya Hani; Abadalla, Musab Alfatih Salim; Jamellodin, Zalipah

2017-10-01

One of the disadvantages of normal concrete is the high self-weight of the concrete. Density of the normal concrete is in the range of 2200 kg/m3 to 2600 kg/ m3. This heavy self-weight make it as an uneconomical structural material. Advantages of expended polystyrene beads in lightweight concrete is its low in density which can reduce the dead load (self-weight) Improper disposal of the large quantity of palm oil fuel ash which has been produced may contribute to environmental problem in future. In this study, an alternative of using palm oil fuel ash as a cement replacement material is to improve the properties of lightweight concrete. The tests conducted in this study were slump test, compression strength, splitting tensile and water absorption test. These samples were cured under water curing condition for 7, 28 and 56 days before testing. Eight types of mixtures were cast based on percentage (25%, 50%) of polystyrene beads replacement for control samples and (25%, 50%) of polystyrene beads by different ratio 10%, 15%, and 20% replacement of palm oil fuel ash, respectively. Samples with 25% polystyrene beads and 10% palm oil fuel ash obtained the highest compressive strength which is 16.8 MPa, and the splitting tensile strength is 1.57 MPa. The water absorption for samples 25%, 50% polystyrene and 20% palm oil fuel ash is 3.89% and 4.67%, respectively which is lower compared to control samples.

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.

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.

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.

Enabling lightweight designs by a new laser based approach for joining aluminum to steel

NASA Astrophysics Data System (ADS)

Brockmann, Rüdiger; Kaufmann, Sebastian; Kirchhoff, Marc; Candel-Ruiz, Antonio; Müllerschön, Oliver; Havrilla, David

2015-03-01

As sustainability is an essential requirement, lightweight design becomes more and more important, especially for mobility. Reduced weight ensures more efficient vehicles and enables better environmental impact. Besides the design, new materials and material combinations are one major trend to achieve the required weight savings. The use of Carbon Fiber Reinforced Plastics (abbr. CFRP) is widely discussed, but so far high volume applications are rarely to be found. This is mainly due to the fact that parts made of CFRP are much more expensive than conventional parts. Furthermore, the proper technologies for high volume production are not yet ready. Another material with a large potential for lightweight design is aluminum. In comparison to CFRP, aluminum alloys are generally more affordable. As aluminum is a metallic material, production technologies for high volume standard cutting or joining applications are already developed. In addition, bending and deep-drawing can be applied. In automotive engineering, hybrid structures such as combining high-strength steels with lightweight aluminum alloys retain significant weight reduction but also have an advantage over monolithic aluminum - enhanced behavior in case of crash. Therefore, since the use of steel for applications requiring high mechanical properties is unavoidable, methods for joining aluminum with steel parts have to be further developed. Former studies showed that the use of a laser beam can be a possibility to join aluminum to steel parts. In this sense, the laser welding process represents a major challenge, since both materials have different thermal expansion coefficients and properties related to the behavior in corrosive media. Additionally, brittle intermetallic phases are formed during welding. A promising approach to welding aluminum to steel is based on the use of Laser Metal Deposition (abbr. LMD) with deposit materials in the form of powders. Within the present work, the advantages of this approach in comparison to conventional processes, as well as expected limitations are described.

Micromechanics of Sea Urchin Spines

PubMed Central

Tsafnat, Naomi; Fitz Gerald, John D.; Le, Hai N.; Stachurski, Zbigniew H.

2012-01-01

The endoskeletal structure of the Sea Urchin, Centrostephanus rodgersii, has numerous long spines whose known functions include locomotion, sensing, and protection against predators. These spines have a remarkable internal microstructure and are made of single-crystal calcite. A finite-element model of the spine’s unique porous structure, based on micro-computed tomography (microCT) and incorporating anisotropic material properties, was developed to study its response to mechanical loading. Simulations show that high stress concentrations occur at certain points in the spine’s architecture; brittle cracking would likely initiate in these regions. These analyses demonstrate that the organization of single-crystal calcite in the unique, intricate morphology of the sea urchin spine results in a strong, stiff and lightweight structure that enhances its strength despite the brittleness of its constituent material. PMID:22984468

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.

Analysis of Stainless Steel Sandwich Panels with a Metal Foam Core for Lightweight Fan Blade Design

NASA Technical Reports Server (NTRS)

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

2004-01-01

The quest for cheap, low density and high performance materials in the design of aircraft and rotorcraft engine fan and propeller blades poses immense challenges to the materials and structural design engineers. The present study investigates the use of a sandwich foam fan blade mae up of solid face sheets and a metal foam core. The face sheets and the metal foam core material were an aerospace grade precipitation hardened 17-4 PH stainless steel with high strength and high toughness. The resulting structures possesses a high stiffness while being lighter than a similar solid construction. The material properties of 17-4 PH metal foam are reviewed briefly to describe the characteristics of sandwich structure for a fan blade application. A vibration analysis for natural frequencies and a detailed stress analysis on the 17-4 PH sandwich foam blade design for different combinations of kin thickness and core volume are presented with a comparison to a solid titanium blade.

Noninvasive 3D Visualization of Defects and Crack Propagation in Layered Foam Structures by Phase Contrast Microimaging

NASA Technical Reports Server (NTRS)

Hu, Z. W.; DeCarlo, F.

2006-01-01

Applications of polymeric foams in our modern society continue to grow because of their light weight, high strength, excellent thermal and mechanical insulation, and the ease of engineering. Among others, closed-cell foam has been structurally used for thermally insulating the shuttle external tank. However, internal defects of the foams were difficult to observe non-invasively due to limited sensitivity to the low-density structures possessed by traditional imaging tools such as computed X-ray tomography By combining phase contrast X-ray imaging with pressure loading, we succeeded in precisely mapping intact cellular structure and defects inside the bulk of layered foam and visualizing its subsequent response to the pressure in three-dimensional space. The work demonstrated a powerfir1 approach for yielding insight into underlying problems in lightweight cellular materials otherwise unobtainable.

Replication of Low Density Electroformed Normal Incidence Optics

NASA Technical Reports Server (NTRS)

Ritter, Joseph M.; Burdine, Robert (Technical Monitor)

2001-01-01

Replicated electroformed light-weight nickel alloy mirrors can have high strength, low areal density (less than 3kg/m2), smooth finish, and controllable alloy composition. Progress at NASA MSFC SOMTC in developing normal incidence replicated Nickel mirrors will be reported.

Development of a precision, six-axis laboratory dynamometer

NASA Technical Reports Server (NTRS)

Champagne, P. J.; Cordova, S. A.; Jacoby, M. S.; Lorell, K. R.

1992-01-01

This paper describes the design, fabrication, test, and operation of a unique six axis force/torque dynamometer The specimen table used to hold components under test is supported in a full six axis kinematic mount. Support struts fabricated from high strength steel with special integral two axis flexures link the specimen table to the load cell transducers. Realtime force/torque coordinate transform, root mean squared calculation, and data averaging, and color six axis display with controllable scaling are provided by a specially programmed desktop computer. The extensive structural analysis and design optimization required to obtain a stiff, well damped, lightweight structure is described in detail. Geometric optimization of the kinematic mount and fabrication details of the struts are also described.

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.

The Feasibility of Palm Kernel Shell as a Replacement for Coarse Aggregate in Lightweight Concrete

NASA Astrophysics Data System (ADS)

Itam, Zarina; Beddu, Salmia; Liyana Mohd Kamal, Nur; Ashraful Alam, Md; Issa Ayash, Usama

2016-03-01

Implementing sustainable materials into the construction industry is fast becoming a trend nowadays. Palm Kernel Shell is a by-product of Malaysia’s palm oil industry, generating waste as much as 4 million tons per annum. As a means of producing a sustainable, environmental-friendly, and affordable alternative in the lightweight concrete industry, the exploration of the potential of Palm Kernel Shell to be used as an aggregate replacement was conducted which may give a positive impact to the Malaysian construction industry as well as worldwide concrete usage. This research investigates the feasibility of PKS as an aggregate replacement in lightweight concrete in terms of compressive strength, slump test, water absorption, and density. Results indicate that by using PKS for aggregate replacement, it increases the water absorption but decreases the concrete workability and strength. Results however, fall into the range acceptable for lightweight aggregates, hence it can be concluded that there is potential to use PKS as aggregate replacement for lightweight concrete.

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

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.

The beetle elytron plate: a lightweight, high-strength and buffering functional-structural bionic material.

PubMed

Zhang, Xiaoming; Xie, Juan; Chen, Jinxiang; Okabe, Yoji; Pan, Longcheng; Xu, Mengye

2017-06-30

To investigate the characteristics of compression, buffering and energy dissipation in beetle elytron plates (BEPs), compression experiments were performed on BEPs and honeycomb plates (HPs) with the same wall thickness in different core structures and using different molding methods. The results are as follows: 1) The compressive strength and energy dissipation capacity in the BEP are 2.44 and 5.0 times those in the HP, respectively, when the plates are prepared using the full integrated method (FIM). 2) The buckling stress is directly proportional to the square of the wall thickness (t). Thus, for core structures with equal wall thicknesses, although the core volume of the BEP is 42 percent greater than that of the HP, the mechanical properties of the BEP are several times higher than those of the HP. 3) It is also proven that even when the single integrated method (SIM) is used to prepare BEPs, the properties discussed above remain superior to those of HPs by a factor of several; this finding lays the foundation for accelerating the commercialization of BEPs based on modern manufacturing processes.

Study on light weight design of truss structures of spacecrafts

NASA Astrophysics Data System (ADS)

Zeng, Fuming; Yang, Jianzhong; Wang, Jian

2015-08-01

Truss structure is usually adopted as the main structure form for spacecrafts due to its high efficiency in supporting concentrated loads. Light-weight design is now becoming the primary concern during conceptual design of spacecrafts. Implementation of light-weight design on truss structure always goes through three processes: topology optimization, size optimization and composites optimization. During each optimization process, appropriate algorithm such as the traditional optimality criterion method, mathematical programming method and the intelligent algorithms which simulate the growth and evolution processes in nature will be selected. According to the practical processes and algorithms, combined with engineering practice and commercial software, summary is made for the implementation of light-weight design on truss structure for spacecrafts.

Strength analysis and lightweight research of a fertilizing and soil covering vehicle

NASA Astrophysics Data System (ADS)

Sun, Heng-Hui; Zhang, Zheng-Yong; Liu, Yang; Xu, Hai-Ming; Chen, En-Wei

2018-03-01

In this paper, parametric modeling is carried out for the frame part of a kind of fertilizing and soil covering vehicle to define boundary conditions such as load, constraint, etc. when the frame is under the working condition of normal full load. ANSYS software is used to produce finite element model of frame, and to analyze and solve the model, so as to obtain stress and stain variation diagram of each part of frame under working condition of normal full load. The calculation result shows that: the structure of frame is able to meet the strength requirement, and the maximum value of stress is located at joint between frame and external hinge, which should be appropriately improved in thickening way. According to the result of finite element, the scheme with size optimization is employed to design the frame in lightweight way. The research result of this paper provides the theoretical basis for the design of frame of fertilizing and soil covering vehicle, which has deep theoretical significance and application value.

New developments in aluminum for aircraft and automobiles

NASA Technical Reports Server (NTRS)

Petit, Jocelyn I.

1994-01-01

A common bond for the aircraft and automobile industry is the need for cost-efficient, lightweight structures such as provided by aluminum based materials. The topics are presented in viewgraph form and cover the following: new developments in aluminum for aircraft and automobiles; forces shaping future automotive materials needs; aluminum strength/weakness versus competitive materials; evolution of aluminum aerospace alloys; forces shaping future aircraft materials needs; fiber/metal structural laminates; and property requirements for jetliner and military transport applications.

Incremental electrohydraulic forming - A new approach for the manufacture of structured multifunctional sheet metal blanks

NASA Astrophysics Data System (ADS)

Djakow, Eugen; Springer, Robert; Homberg, Werner; Piper, Mark; Tran, Julian; Zibart, Alexander; Kenig, Eugeny

2017-10-01

Electrohydraulic Forming (EHF) processes permit the production of complex, sharp-edged geometries even when high-strength materials are used. Unfortunately, the forming zone is often limited as compared to other sheet metal forming processes. The use of a special industrial-robot-based tool setup and an incremental process strategy could provide a promising solution for this problem. This paper describes such an innovative approach using an electrohydraulic incremental forming machine, which can be employed to manufacture the large multifunctional and complex part geometries in steel, aluminium, magnesium and reinforced plastic that are employed in lightweight constructions or heating elements.

Structural testing for static failure, flutter and other scary things

NASA Technical Reports Server (NTRS)

Ricketts, R. H.

1983-01-01

Ground test and flight test methods are described that may be used to highlight potential structural problems that occur on aircraft. Primary interest is focused on light-weight general aviation airplanes. The structural problems described include static strength failure, aileron reversal, static divergence, and flutter. An example of each of the problems is discussed to illustrate how the data acquired during the tests may be used to predict the occurrence of the structural problem. While some rules of thumb for the prediction of structural problems are given the report is not intended to be used explicitly as a structural analysis handbook.

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.

Production of lightweight aggregates from washing aggregate sludge and fly ash

NASA Astrophysics Data System (ADS)

González-Corrochano, Beatriz; Alonso-Azcárate, Jacinto; Rodas, Magdalena

2010-05-01

Increasing generation of wastes is one of the main environmental problems in industrialised countries. Heat treatment at high temperatures can convert some types of wastes into ceramic products with a wide range of microstructural features and properties (Bethanis et al., 2004). A lightweight aggregate (LWA) is a granular material with a bulk density (bd) not exceeding 1.20 g/cm3 or with a particle density not exceeding 2.00 g/cm3 (UNE-EN-13055-1, 2003). They have become a focus of interest because the low particle density and the low bulk density entail a decrease in the load transmitted to the ground, and less work and effort are required to transport them (De' Gennaro et al., 2004). The benefits associated with these low densities, which are due to the formation of voids and pores, are very good thermal and acoustic insulation and materials with a good resistance to fire (Benbow, 1987; Fakhfakh et al., 2007). The objective was to recycle fly ash, used motor oil from cars and mineral wastes from washing aggregate sludge, in order to obtain a usable material such as lightweight aggregates, and also to ensure that they are of good quality for different applications. Raw materials have been physically, chemically and mineralogically characterized. On the basis of the results obtained, they were mixed, milled to a grain size of less than 200 μm (Yasuda, 1991), formed into pellets, pre-heated for 5 min and sintered in a rotary kiln at 1150°C, 1175°C, 1200°C and 1225°C for 10 and 15 min at each temperature (Theating). Effects of raw material characteristics, heating temperature and dwell time on the following LWAs properties were determined: loss on ignition (LOI), bloating index (BI), loose bulk density (bd), apparent and dry particle density (ad, dd), voids (H), water absorption (WA24h) and compressive strength (S). The products obtained were lightweight aggregates in accordance with norm UNE-EN-13055-1 (bd ≤1.20 g/cm3 or particle density ≤2.00 g/cm3). LWAs manufactured with 75%:25% and 50%:50% proportions of washing aggregate sludge:fly ash, heated at different temperatures and dwell times, were expanded LWAs (BI > 0). They showed the lowest loose bulk density, the lowest dry and apparent particle density, the lowest water absorption and the highest compressive strength. The possible applications of sintered pellets, taking into consideration compressive strength and water absorption values, could be similar to those of Arlita G3 (insulation, geotechnical applications, gardening and/or horticulture) and/or Arlita F3 (prefabricated lightweight structures and insulation lightweight concretes), two varieties of the most widely marketed LWAs in Spain. References - Benbow, J., September 1987. Mineral in fire protection construction support market. Industrial Minerals, 61-73. - Bethanis, S., Cheeseman, C.R., Sollars, C.J., 2004. Effect of sintering temperature on the properties and leaching of incinerator bottom ash. Waste Management and Research 22 (4), 255-264. - De' Gennaro, R., Cappelletti, P., Cerri, G., De' Gennaro, M., Dondi, M., Langella, A., 2004. Zeolitic tuffs as raw materials for lightweight aggregates. Applied Clay Science 25 (1-2), 71-81. - Fakhfakh, E., Hajjaji, W., Medhioub, M., Rocha, F., López-Galindo, A., Setti, M.,Kooli, F., Zargouni, F., Jamoussi, F., 2007. Effects of sand addition on production of lightweight aggregates from Tunisian smectite-rich clayey rocks. Applied Clay Science 35, 228-237. - UNE-EN-13055-1, 2003. Lightweight aggregates - lightweight aggregates for concrete, mortar and grout. - Yasuda, Y., 1991. Sewage-sludge utilization in Tokyo. Water Science and Technology 23 (10-12), 1743-1752.

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.

Experimental Investigation of the Effect of Manufactured Sand and Lightweight Sand on the Properties of Fresh and Hardened Self-Compacting Lightweight Concretes.

PubMed

Zhu, Yiyun; Cui, Hongzhi; Tang, Waiching

2016-08-29

Self-compacting lightweight concrete (SCLC) is a promising construction material for building applications, but most SCLCs today are made with river sand (RS). There is an increasing demand for environmental protection, as well as materials with a high strength/density ratio. The manufactured sand (MS) and lightweight sand (LS) as fine aggregates in cement-based composite materials have been receiving more attention among researchers. However, there is not much information about the effects of MS and LS on the properties of the fresh and hardened SCLCs. In this paper, the properties of fresh and hardened SCLC made with MS and LS were investigated by a series of experiments. SCLCs made with RS served as the control in this study. The test results show that increasing the sand ratio (from 0.40-0.50) decreased the filling ability and led to an increased T 50 time, which is the time spent for the concrete to reach the 500 mm spread circle, for all of the fresh SCLCs. Although the passing ability of MS-SCLCs and LS-SCLCs is not as good as RS-SCLCs, their results are still within an acceptable range. The ratio of mechanical properties to density was found to increase with an increase of the sand ratio for all of the hardened SCLCs. MS-SCLCs presented the highest compressive strength among all of the SCLCs studied. Although the mean compressive strength of LS-SCLCs is lower than those of the other two SCLCs by 8%, their strength to density ratio is higher than others by 15%, and the ratio increases remarkably with the increase of the sand ratio. Permeability test results showed that the permeability coefficient of MS-SCLC is remarkably lower than that of LS-SCLC, but slightly higher than that of RS-SCLC.

Experimental Investigation of the Effect of Manufactured Sand and Lightweight Sand on the Properties of Fresh and Hardened Self-Compacting Lightweight Concretes

PubMed Central

Zhu, Yiyun; Cui, Hongzhi; Tang, Waiching

2016-01-01

Self-compacting lightweight concrete (SCLC) is a promising construction material for building applications, but most SCLCs today are made with river sand (RS). There is an increasing demand for environmental protection, as well as materials with a high strength/density ratio. The manufactured sand (MS) and lightweight sand (LS) as fine aggregates in cement-based composite materials have been receiving more attention among researchers. However, there is not much information about the effects of MS and LS on the properties of the fresh and hardened SCLCs. In this paper, the properties of fresh and hardened SCLC made with MS and LS were investigated by a series of experiments. SCLCs made with RS served as the control in this study. The test results show that increasing the sand ratio (from 0.40–0.50) decreased the filling ability and led to an increased T50 time, which is the time spent for the concrete to reach the 500 mm spread circle, for all of the fresh SCLCs. Although the passing ability of MS-SCLCs and LS-SCLCs is not as good as RS-SCLCs, their results are still within an acceptable range. The ratio of mechanical properties to density was found to increase with an increase of the sand ratio for all of the hardened SCLCs. MS-SCLCs presented the highest compressive strength among all of the SCLCs studied. Although the mean compressive strength of LS-SCLCs is lower than those of the other two SCLCs by 8%, their strength to density ratio is higher than others by 15%, and the ratio increases remarkably with the increase of the sand ratio. Permeability test results showed that the permeability coefficient of MS-SCLC is remarkably lower than that of LS-SCLC, but slightly higher than that of RS-SCLC. PMID:28773857

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

Chen, Xiaoming; Ke, Changhong, E-mail: xqwang@uga.edu, E-mail: cke@binghamton.edu; Zhang, Liuyang

We investigate the mechanical strength of boron nitride nanotube (BNNT) polymer interfaces by using in situ electron microscopy nanomechanical single-tube pull-out techniques. The nanomechanical measurements show that the shear strengths of BNNT-epoxy and BNNT-poly(methyl methacrylate) interfaces reach 323 and 219 MPa, respectively. Molecular dynamics simulations reveal that the superior load transfer capacity of BNNT-polymer interfaces is ascribed to both the strong van der Waals interactions and Coulomb interactions on BNNT-polymer interfaces. The findings of the extraordinary mechanical strength of BNNT-polymer interfaces suggest that BNNTs are excellent reinforcing nanofiller materials for light-weight and high-strength polymer nanocomposites.

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

NASA Technical Reports Server (NTRS)

Doggett, William R.; Dorsey, John T.; Jones, Thomas C.; King, Bruce

2014-01-01

An invention of a new and novel space robotic manipulator is described. By using a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening, this new robotic manipulator architecture achieves compact packaging, high strength, stiffness and dexterity while being very lightweight compared to conventional manipulators. The manipulator is also very modular; easy to scale for different reach, load and stiffness requirements; enabling customization for a diverse set of applications. Novel features of the new manipulator concept are described as well as some of the approaches to implement these design features. Two diverse applications are presented to show the versatility of the concept. First generation prototype hardware was designed, manufactured and has been assembled into a working manipulator that is being used to refine and extend development efforts.

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.

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).

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.

Electron beam welding of aircraft structures. [joining of titanium alloy wing structures on F-14 aircraft

NASA Technical Reports Server (NTRS)

Witt, R. H.

1972-01-01

Requirements for advanced aircraft have led to more extensive use of titanium alloys and the resultant search for joining processes which can produce lightweight, high strength airframe structures efficiently. As a result, electron beam welding has been investigated. The following F-14A components are now being EB welded in production and are mainly annealed Ti-6Al-4V except for the upper wing cover which is annealed Ti-6Al-6V-2Sn: F-14A wing center section box, and F-14A lower and upper wing covers joined to wing pivot fitting assemblies. Criteria for selection of welding processes, the EB welding facility, development work on EB welding titanium alloys, and F-14A production and sliding seal electron beam welding are reported.

Biologically-Inspired Control for a Planetary Exploration Tensegrity Robot

NASA Technical Reports Server (NTRS)

Leroy, Marc

2017-01-01

Tensegrity structures are becoming increasingly popular as mechanical structures for robots. Their inherent compliance makes them extremely robust to environmental disturbances, and their design allows them to have a high strength-to-weight ratio whilst being lightweight compared to traditional robots. For these reasons they would be of interest to the aerospace industry, particularly for planetary exploration. However, being such compliant structures thanks to their network of elastic elements also means that their control is not an easy task. Relying solely on traditional control strategies to generate efficient locomotion would surely be near impossible due to the complex oscillatory motions and nonlinear interactions of its members. The goal of this project was to use bio-inspired control techniques to generate locomotion for a tensegrity icosahedron, namely the SUPERball project of the Intelligent Robotics Group of NASA Ames Research Center.

Carbonized Micro- and Nanostructures: Can Downsizing Really Help?

PubMed Central

Naraghi, Mohammad; Chawla, Sneha

2014-01-01

In this manuscript, we discuss relationships between morphology and mechanical strength of carbonized structures, obtained via pyrolysis of polymeric precursors, across multiple length scales, from carbon fibers (CFs) with diameters of 5–10 μm to submicron thick carbon nanofibers (CNFs). Our research points to radial inhomogeneity, skin–core structure, as a size-dependent feature of polyacrylonitrile-based CFs. This inhomogeneity is a surface effect, caused by suppressed diffusion of oxygen and stabilization byproducts during stabilization through skin. Hence, reducing the precursor diameters from tens of microns to submicron appears as an effective strategy to develop homogeneous carbonized structures. Our research establishes the significance of this downsizing in developing lightweight structural materials by comparing intrinsic strength of radially inhomogeneous CFs with that of radially homogeneous CNF. While experimental studies on the strength of CNFs have targeted randomly oriented turbostratic domains, via continuum modeling, we have estimated that strength of CNFs can reach 14 GPa, when the basal planes of graphitic domains are parallel to nanofiber axis. The CNFs in our model are treated as composites of amorphous carbon (matrix), reinforced with turbostratic domains, and their strength is predicted using Tsai–Hill criterion. The model was calibrated with existing experimental data. PMID:28788651

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

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.

Application of lap laser welding technology on stainless steel railway vehicles

NASA Astrophysics Data System (ADS)

Wang, Hongxiao; Wang, Chunsheng; He, Guangzhong; Li, Wei; Liu, Liguo

2016-10-01

Stainless steel railway vehicles with so many advantages, such as lightweight, antirust, low cost of maintenance and simple manufacturing process, so the production of high level stainless steel railway vehicles has become the development strategy of European, American and other developed nations. The current stainless steel railway vehicles body and structure are usually assembled by resistance spot welding process. The weak points of this process are the poor surface quality and bad airtight due to the pressure of electrodes. In this study, the partial penetration lap laser welding process was investigated to resolve the problems, by controlling the laser to stop at the second plate in the appropriate penetration. The lap laser welding joint of stainless steel railway vehicle car body with partial penetration has higher strength and surface quality than those of resistance spot welding joint. The biggest problem of lap laser welding technology is to find the balance of the strength and surface quality with different penetrations. The mechanism of overlap laser welding of stainless steel, mechanical tests, microstructure analysis, the optimization of welding parameters, analysis of fatigue performance, the design of laser welding stainless steel railway vehicles structure and the development of non-destructive testing technology were systematically studied before lap laser welding process to be applied in manufacture of railway vehicles. The results of the experiments and study show that high-quality surface state and higher fatigue strength can be achieved by the partial penetration overlap laser welding of the side panel structure, and the structure strength of the car body can be higher than the requirements of En12663, the standard of structural requirements of railway vehicles bodies. Our company has produced the stainless steel subway and high way railway vehicles by using overlap laser welding technology. The application of lap laser welding will be a big change of railway vehicles manufacturing technology.

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.

Honeycomb-Fin Heat Sink

NASA Technical Reports Server (NTRS)

Rippel, Wally E.

1989-01-01

Improved finned heat sink for electronic components more lightweight, inexpensive, and efficient. Designed for use with forced air, easily scaled up to dissipate power up to few hundred watts. Fins are internal walls of aluminum honeycomb structure. Cell structure gives strength to thin aluminum foil. Length of channels chosen for thermodynamic efficency; columns of cells combined in any reasonable number because flowing air distributed to all. Heat sink cools nearly as effectively at ends as near its center, no matter how many columns of cells combined.

The Pack Method for Compressive Tests of Thin Specimens of Materials Used in Thin-Wall Structures

NASA Technical Reports Server (NTRS)

Aitchison, C S; Tuckerman, L B

1939-01-01

The strength of modern lightweight thin-wall structures is generally limited by the strength of the compression members. An adequate design of these members requires a knowledge of the compressive stress-strain graph of the thin-wall material. The "pack" method was developed at the National Bureau of Standards with the support of the National Advisory Committee for Aeronautics to make possible a determination of compressive stress-strain graphs for such material. In the pack test an odd number of specimens are assembled into a relatively stable pack, like a "pack of cards." Additional lateral stability is obtained from lateral supports between the external sheet faces of the pack and outside reactions. The tests seems adequate for many problems in structural research.

Lightweight Towed Howitzer Demonstrator. Phase 1 and Partial Phase 2. Volume A. Overview.

DTIC Science & Technology

1987-04-01

Reliability Floyd Manson............................... Test Plans Errol Quick................................. Systems Engrnq Coordi nati on Bob Schmidt ...FMC Structur*1 Verification o Beam stress calculations on the supporting trails which allow 70kpsi in a quasi-isotropic lay up of graphite epoxy...addressed utilizing a damage tolerant design criteria. o Strength calculations are questionable because of the dry room temperature values used. The

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.

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%.

High-Strength Nanotwinned Al Alloys with 9R Phase.

PubMed

Li, Qiang; Xue, Sichuang; Wang, Jian; Shao, Shuai; Kwong, Anthony H; Giwa, Adenike; Fan, Zhe; Liu, Yue; Qi, Zhimin; Ding, Jie; Wang, Han; Greer, Julia R; Wang, Haiyan; Zhang, Xinghang

2018-03-01

Light-weight aluminum (Al) alloys have widespread applications. However, most Al alloys have inherently low mechanical strength. Nanotwins can induce high strength and ductility in metallic materials. Yet, introducing high-density growth twins into Al remains difficult due to its ultrahigh stacking-fault energy. In this study, it is shown that incorporating merely several atomic percent of Fe solutes into Al enables the formation of nanotwinned (nt) columnar grains with high-density 9R phase in Al(Fe) solid solutions. The nt Al-Fe alloy coatings reach a maximum hardness of ≈5.5 GPa, one of the strongest binary Al alloys ever created. In situ uniaxial compressions show that the nt Al-Fe alloys populated with 9R phase have flow stress exceeding 1.5 GPa, comparable to high-strength steels. Molecular dynamics simulations reveal that high strength and hardening ability of Al-Fe alloys arise mainly from the high-density 9R phase and nanoscale grain sizes. © 2018 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Materials Needs for Future In-Space Propulsion Systems

NASA Technical Reports Server (NTRS)

Johnson, Les

2006-01-01

NASA's In-Space Propulsion Technology Project is developing the next generation of in-space propulsion systems in support of robotic exploration missions throughout the solar system. The propulsion technologies being developed are non-traditional and have stressing materials performance requirements. Earth-storable bipropellant performance is constrained by temperature limitations of the columbium used in the chamber. Iridium/rhenium (Ir/Re) is now available and has been implemented in initial versions of Earth- Storable rockets with specific impulses about 10 seconds higher than columbium rocket chambers. New chamber fabrication methods that improve process and performance of Ir/Re and other promising material systems are needed. The solar sail is a propellantless propulsion system that gains momentum by reflecting sunlight. The sails need to be very large in area (from 10000 sq m up to 62500 sq m) yet be very lightweight in order to achieve adequate accelerations for realistic mission times. Lightweight materials that can be manufactured in thicknesses of less than 1 micron and that are not harmed by the space environment are desired. Blunt Body Aerocapture uses aerodynamic drag to slow an approaching spacecraft and insert it into a science orbit around any planet or moon with an atmosphere. The spacecraft is enclosed by a rigid aeroshell that protects it from the entry heating and aerodynamic environment. Lightweight, high-temperature structural systems, adhesives, insulators, and ablatives are key components for improving aeroshell efficiencies at heating rates of 1000-2000 W/sq cm and beyond. Inflatable decelerators in the forms of ballutes and inflatable aeroshells will use flexible polymeric thin film materials, high temperature fabrics, and structural adhesives. The inflatable systems will be tightly packaged during cruise and will be inflated prior to entry interface at the destination. Materials must maintain strength and flexibility while packaged at cold temperatures (-100 C) for up to 10 years and then withstand the high temperatures (500 C) encountered during aerocapture.

Geopolymer lightweight bricks manufactured from fly ash and foaming agent

NASA Astrophysics Data System (ADS)

Ibrahim, Wan Mastura Wan; Hussin, Kamarudin; Abdullah, Mohd Mustafa Al Bakri; Kadir, Aeslina Abdul

2017-04-01

This paper deals with the development of lightweight geopolymer bricks by using foaming agent and fly ash. The mix parameters analysed through a laboratory experiment with fix ratio of sodium silicate/sodium hydroxide solution mass ratio 2.5, fly ash/alkaline activator solution mass ratio 2.0, foaming agent/paste mass ratio 1:2 and molarity of sodium hydroxide solution used was 12M. Different curing temperature (Room Temperature, 60, 80) and foaming agent/water mass ratio (1:10 and 1:20) were studied. Compressive strength, density analysis, and water absorption has been investigated. The results show that the foamed geopolymer bricks with a lower foam/water mass ratio (1:10)and high curing temperature (80°C) leading to a better properties. Mixtures with a low density of around 1420 kg/m3 and a compressive strength of around 10 MPa were achieved.

Lightweight alumina refractory aggregate. Final report

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

Swansiger, T.G.; Pearson, A.

1996-07-16

Objective was to develop a lightweight, high alumina refractory aggregate for use in various high performance insulating (low thermal conductivity) refractory applications (e.g., in the aluminium, glass, cement, and iron and steel industries). A new aggregate process was developed through bench and pilot-scale experiments involving extrusion of a blend of calcined and activated alumina powders and organic extrusion aids and binders. The aggregate, with a bulk density approaching 2.5 g/cc, exhibited reduced thermal conductivity and adequate fired strength compared to dense tabular aggregate. Refractory manufacturers were moderately enthusiastic over the results. Alcoa prepared an economic analysis for producing lightweight aggregate,more » based on a retrofit of this process into existing Alcoa production facilities. However, a new, competing lightweight aggregate material was developed by another company; this material (Plasmal{trademark})had a significantly more favorable cost base than the Alcoa/DOE material, due to cheap raw materials and fewer processing steps. In late 1995, Alcoa became a distributor of Plasmal. Alcoa estimated that {ge}75% of the market originally envisioned for the Alcoa/DOE aggregate would be taken by Plasmal. Hence, it was decided to terminate the contract without the full- scale demonstration.« 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.

Laser beam welding of new ultra-high strength and supra-ductile steels

NASA Astrophysics Data System (ADS)

Dahmen, Martin

2015-03-01

Ultra-high strength and supra-ductile are entering fields of new applications. Those materials are excellent candidates for modern light-weight construction and functional integration. As ultra-high strength steels the stainless martensitic grade 1.4034 and the bainitic steel UNS 53835 are investigated. For the supra-ductile steels stand two high austenitic steels with 18 and 28 % manganese. As there are no processing windows an approach from the metallurgical base on is required. Adjusting the weld microstructure the Q+P and the QT steels require weld heat treatment. The HSD steel is weldable without. Due to their applications the ultra-high strength steels are welded in as-rolled and strengthened condition. Also the reaction of the weld on hot stamping is reflected for the martensitic grades. The supra-ductile steels are welded as solution annealed and work hardened by 50%. The results show the general suitability for laser beam welding.

Shear strength of a PCBT-53 girder fabricated with lightweight self-consolidating concrete.

DOT National Transportation Integrated Search

2009-01-01

Lightweight self-consolidating concrete (LWSCC) is advantageous in the bridge industry because members fabricated with this material have a significantly lower self weight and in its fresh state, LWSCC has a low viscosity that eliminates the need for...

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Whittenberger, J. Daniel; Krause, David L.

2003-01-01

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (4 g/cm3) in comparison to superalloys (8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

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

Self-adaptive formation of uneven node spacings in wild bamboo

NASA Astrophysics Data System (ADS)

Shima, Hiroyuki; Sato, Motohiro; Inoue, Akio

2016-02-01

Bamboo has a distinctive structure wherein a long cavity inside a cylindrical woody section is divided into many chambers by stiff diaphragms. The diaphragms are inserted at nodes and thought to serve as ring stiffeners for bamboo culms against the external load; if this is the case, the separation between adjacent nodes should be configured optimally in order to enhance the mechanical stability of the culms. Here, we reveal the hitherto unknown blueprint of the optimal node spacings used in the growth of wild bamboo. Measurement data analysis together with theoretical formulations suggest that wild bamboos effectively control their node spacings as well as other geometric parameters in accord with the lightweight and high-strength design concept.

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.

Analysis of properties laser welded RAK 40/70 steel sheets

NASA Astrophysics Data System (ADS)

Evin, E.; Tomáš, M.; Fujda, M.

2017-11-01

Both, the ecological production and operation of vehicles demand using such materials for deformation zones’ structural parts, which show some specific properties and use innovative technologies to process them. Specific requirements for functionality (strength, stiffness, deformation work, fatigue properties) are closely linked to processability (formability). In the paper are presented results for multiphase TRIP steel RAK40/70 when welded by pulse solid-state fiber laser YLS-5000. Based on microstructure analysis in the fusion zone and heat affected zone the welding parameters were optimised. The influence of laser welding on the strength and deformation properties was verified by characteristics of strength, stiffness and deformation work, as they were calculated from mechanical properties measured by tensile test and three-point bending test. The knowledge gathered in the field of laser welding influence on the strength and deformation properties of multiphase TRIP steel RAK40/70 should help designers when design the lightweight structural parts of the car body.

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.

Interrelated chemical-microstructural-nanomechanical variations in the structural units of the cuttlebone of Sepia officinalis

NASA Astrophysics Data System (ADS)

North, L.; Labonte, D.; Oyen, M. L.; Coleman, M. P.; Caliskan, H. B.; Johnston, R. E.

2017-11-01

"Cuttlebone," the internalized shell found in all members of the cephalopod family Sepiidae, is a sophisticated buoyancy device combining high porosity with considerable strength. Using a complementary suite of characterization tools, we identified significant structural, chemical, and mechanical variations across the different structural units of the cuttlebone: the dorsal shield consists of two stiff and hard layers with prismatic mineral organization which encapsulate a more ductile and compliant layer with a lamellar structure, enriched with organic matter. A similar organization is found in the chambers, which are separated by septa, and supported by meandering plates ("pillars"). Like the dorsal shield, septa contain two layers with lamellar and prismatic organization, respectively, which differ significantly in their mechanical properties: layers with prismatic organization are a factor of three stiffer and up to a factor of ten harder than those with lamellar organization. The combination of stiff and hard, and compliant and ductile components may serve to reduce the risk of catastrophic failure, and reflect the role of organic matter for the growth process of the cuttlebone. Mechanically "weaker" units may function as sacrificial structures, ensuring a stepwise failure of the individual chambers in cases of overloading, allowing the animals to retain near-neutral buoyancy even with partially damaged cuttlebones. Our findings have implications for our understanding of the structure-property-function relationship of cuttlebone, and may help to identify novel bioinspired design strategies for light-weight yet high-strength foams.

The effect of welding line heat-affected-zone on the formability of tube hydroforming process

NASA Astrophysics Data System (ADS)

ChiuHuang, Cheng-Kai; Hsu, Cheng-En; Lee, Ping-Kun

2016-08-01

Tube hydroforming has been used as a lightweight design approach to reduce CO2 emission for the automotive industry. For the high strength steel tube, the strength and quality of the welding line is very important for a successful tube hydroforming process. This paper aims to investigate the effect of the welding line's strength and the width of the heat-affected zone on the tube thinning during the hydroforming process. The simulation results show that both factors play an important role on the thickness distribution during the tube expansion.

Design and mechanical analysis of a 3D-printed biodegradable biomimetic micro air vehicle wing

NASA Astrophysics Data System (ADS)

Salami, E.; Ganesan, P. B.; Ward, T. A.; Viyapuri, R.; Romli, F. I.

2016-10-01

The biomimetic micro air vehicles (BMAV) are unmanned, micro-scaled aircraft that are bio-inspired from flying organisms to achieve the lift and thrust by flapping their wings. There are still many technological challenges involved with designing the BMAV. One of these is designing the ultra-lightweight materials and structures for the wings that have enough mechanical strength to withstand continuous flapping at high frequencies. Insects achieve this by having chitin-based, wing frame structures that encompass a thin, film membrane. The main objectives of this study are to design a biodegradable BMAV wing (inspired from the dragonfly) and analyze its mechanical properties. The dragonfly-like wing frame structure was bio-mimicked and fabricated using a 3D printer. A chitosan nanocomposite film membrane was applied to the BMAV wing frames through casting method. Its mechanical performance was analyzed using universal testing machine (UTM). This analysis indicates that the tensile strength and Young's modulus of the wing with a membrane is nearly double that of the wing without a membrane, which allow higher wing beat frequencies and deflections that in turn enable a greater lifting performance.

Ultralight, scalable nano-architected metamaterials (Conference Presentation)

NASA Astrophysics Data System (ADS)

Zheng, Xiaoyu R.

2017-04-01

It has been a long research and engineering pursuit to create lightweight and mechanically robust and energy efficient materials with interconnected porosity. These cellular materials are desirable for a broad range of applications including structural components, lightweight transportation, heat exchange, catalyst supports, battery electrodes and biomaterials. However, the required outstanding properties have remained elusive on lightweight materials (<10kg/m3), constrained by the inherent coupling of material properties and the lack of suitable processes to generate these artificial materials. For example, graphene aerogels have among the lowest record densities 1kg/m^3, but their strength have been degraded to tens to hundreds of Pascal (<10^-8 of that of carbon nanotubes). The attainment of low density has come with a price -- significant reduction of bulk scale properties. We present the design, manufacturing and defect tolerance study of a new class of ultralight, three-dimensional multi-functional architected materials. These 3D bulk metamaterials (polymer, metal, ceramic and combinations thereof) possess weight density comparable to that of carbon aerogel, but with over 10^4 higher stiffness and strength. By designing and studying their hierarchical architectures, material compositions and feature sizes spanning multiple length-scales, we create a wide range of decoupled material properties such as programmable stiffness, tunable strength and fracture toughness as well as programmable possion ratio. With the possibility of incorporating precise control of topological architectures across length-scale sets as well as prediction and optimization of their defect tolerance, we enter into a paradigm where nanoscale material properties can be harnessed and made accessible in large scale objects, opening a wide range of applications of these materials in energy, health care and flexible electronics.

Progress on high-performance rapid prototype aluminum mirrors

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Myrick, Bruce H.

2017-05-01

Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

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).

Manufacturing and Characterization of Ti6Al4V Lattice Components Manufactured by Selective Laser Melting

PubMed Central

Campanelli, Sabina L.; Contuzzi, Nicola; Ludovico, Antonio D.; Caiazzo, Fabrizia; Cardaropoli, Francesco; Sergi, Vincenzo

2014-01-01

The paper investigates the fabrication of Selective Laser Melting (SLM) titanium alloy Ti6Al4V micro-lattice structures for the production of lightweight components. Specifically, the pillar textile unit cell is used as base lattice structure and alternative lattice topologies including reinforcing vertical bars are also considered. Detailed characterizations of dimensional accuracy, surface roughness, and micro-hardness are performed. In addition, compression tests are carried out in order to evaluate the mechanical strength and the energy absorbed per unit mass of the lattice truss specimens made by SLM. The built structures have a relative density ranging between 0.2234 and 0.5822. An optimization procedure is implemented via the method of Taguchi to identify the optimal geometric configuration which maximizes peak strength and energy absorbed per unit mass. PMID:28788707

Effect of palm oil fuel ash on compressive strength of palm oil boiler stone lightweight aggregate concrete

NASA Astrophysics Data System (ADS)

Muthusamy, K.; Zamri, N. A.; Kusbiantoro, A.; Lim, N. H. A. S.; Ariffin, M. A. Mohd

2018-04-01

Both palm oil fuel ash (POFA) and palm oil boiler stone (POBS) are by-products which has been continuously generated by local palm oil mill in large amount. Both by products is usually disposed as profitless waste and considered as nuisance to environment. The present research investigates the workability and compressive strength performance of lightweight aggregate concrete (LWAC) made of palm oil boiler stone (POBS) known as palm oil boiler stone lightweight aggregate concrete (POBS LWAC) containing various content of palm oil fuel ash. The control specimen that is POBS LWAC of grade 60 were produced using 100% OPC. Then, another 4 mixes were prepared by varying the POFA percentage from 10%, 20%, 30% and 40% by weight of cement. Fresh mixes were subjected to slump test to determine its workability before casted in form of cubes. Then, all specimens were subjected to water curing up to 28 days and then tested for its compressive strength. It was found out that utilizing of optimum amount of POFA in POBS LWAC would improve the workability and compressive strength of the concrete. However, inclusion of POFA more than optimum amount is not recommended as it will increase the water demand leading to lower workability and strength reduction.

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).

Laser Weldability of High-Strength Al-Zn Alloys and Its Improvement by the Use of an Appropriate Filler Material

NASA Astrophysics Data System (ADS)

Enz, Josephin; Riekehr, Stefan; Ventzke, Volker; Huber, Norbert; Kashaev, Nikolai

2016-06-01

Heat-treatable Al-Zn alloys are promising candidates for use as structural lightweight materials in automotive and aircraft applications. This is mainly due to their high strength-to-density ratio in comparison to conventionally employed Al alloys. Laser beam welding is an efficient method for producing joints with high weld quality and has been established in the industry for many years. However, it is well known that aluminum alloys with a high Zn content or, more precisely, with a high (Zn + Mg + Cu) content are difficult to fusion weld due to the formation of porosity and hot cracks. The present study concerns the laser weldability of these hard-to-weld Al-Zn alloys. In order to improve weldability, it was first necessary to understand the reasons for weldability problems and to identify crucial influencing factors. Based on this knowledge, it was finally possible to develop an appropriate approach. For this purpose, vanadium was selected as additional filler material. Vanadium exhibits favorable thermophysical properties and, thereby, can improve the weldability of Al-Zn alloys. The effectiveness of the approach was verified by its application to several Al-Zn alloys with differing amounts of (Zn + Mg + Cu).

Lightweight, Ultra-High-Temperature, CMC-Lined Carbon/Carbon Structures

NASA Technical Reports Server (NTRS)

Wright, Matthew J.; Ramachandran, Gautham; Williams, Brian E.

2011-01-01

Carbon/carbon (C/C) is an established engineering material used extensively in aerospace. The beneficial properties of C/C include high strength, low density, and toughness. Its shortcoming is its limited usability at temperatures higher than the oxidation temperature of carbon . approximately 400 C. Ceramic matrix composites (CMCs) are used instead, but carry a weight penalty. Combining a thin laminate of CMC to a bulk structure of C/C retains all of the benefits of C/C with the high temperature oxidizing environment usability of CMCs. Ultramet demonstrated the feasibility of combining the light weight of C/C composites with the oxidation resistance of zirconium carbide (ZrC) and zirconium- silicon carbide (Zr-Si-C) CMCs in a unique system composed of a C/C primary structure with an integral CMC liner with temperature capability up to 4,200 F (.2,315 C). The system effectively bridged the gap in weight and performance between coated C/C and bulk CMCs. Fabrication was demonstrated through an innovative variant of Ultramet fs rapid, pressureless melt infiltration processing technology. The fully developed material system has strength that is comparable with that of C/C, lower density than Cf/SiC, and ultra-high-temperature oxidation stability. Application of the reinforced ceramic casing to a predominantly C/C structure creates a highly innovative material with the potential to achieve the long-sought goal of long-term, cyclic high-temperature use of C/C in an oxidizing environment. The C/C substructure provided most of the mechanical integrity, and the CMC strengths achieved appeared to be sufficient to allow the CMC to perform its primary function of protecting the C/C. Nozzle extension components were fabricated and successfully hot-fire tested. Test results showed good thermochemical and thermomechanical stability of the CMC, as well as excellent interfacial bonding between the CMC liner and the underlying C/C structure. In particular, hafnium-containing CMCs on C/C were shown to perform well at temperatures exceeding 3,500 F (.1,925 C). The melt-infiltrated CMC-lined C/C composites offered a lower density than Cf/SiC. The melt-infiltrated composites offer greater use temperature than Cf/SiC because of the more refractory ceramic matrices and the C/C substructure provides greater high-temperature strength. The progress made in this work will allow multiple high-temperature components used in oxidizing environments to take advantage of the low density and high strength of C/C combined with the high-temperature oxidation resistance of melt-infiltrated CMCs.

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.

A lightweight, high strength dexterous manipulator for commercial applications

NASA Technical Reports Server (NTRS)

Marzwell, Neville I.; Schena, Bruce M.; Cohan, Steve M.

1991-01-01

The concept, design, and features are described of a lightweight, high strength, modular robot manipulator being developed for space and commercial applications. The manipulator has seven fully active degrees of freedom and is fully operational in 1 G. Each of the seven joints incorporates a unique drivetrain design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. Feedback sensors provide position, velocity, torque, and motor winding temperature information at each joint. This sensing system is also designed to be single fault tolerant. The manipulator consists of five modules (not including gripper). These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly and/or disassembly for reconfiguration, transport, or servicing. The manipulator is a completely enclosed assembly, with no exposed components or wires. Although the initial prototype will not be space qualified, the design is well suited to meeting space requirements. The control system provides dexterous motion by controlling the endpoint location and arm pose simultaneously. Potential applications are discussed.

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.

Lightweight telescopes for lunar observatories

NASA Astrophysics Data System (ADS)

Rozelot, J. P.; Bingham, R.; Walker, D.

1994-06-01

Future optical observatories in space will require telescopes of very high resolution. To satisfy this demand, technology must be developed for large mirrors capable of diffraction-limited imaging. Conventional monolithic glass substrates (light-weight or not) have serious limitations for future development. In particular, glass is susceptible to fracture during ground-handling, transport and launch. An alternative solution is aluminium. It has lower cost, increased strength, easier and safer methods of fixing, amongst other advantages. It is readily lightweighted and can be produced with good polishing quality with nickel coating. We foresee applications for satellite telescope for astronomy, remote sensing, surveys of asteroids and debris in space. Furthermore, this technology is ideally suitable for lunar mounted interferometric experiments - as mirrors can be easily replicate, saving cost - and for telescopes deployed on planetary surfaces. Some results from the European Eureka Large Active Mirrors in Aluminium (LAMA) are here presented, which show the feasibility of such systems.

Mechanical properties and flexure behaviour of lightweight foamed concrete incorporating coir fibre

NASA Astrophysics Data System (ADS)

Mohamad, Noridah; Afif Iman, Muhamad; Othuman Mydin, M. A.; Samad, A. A. A.; Rosli, J. A.; Noorwirdawati, A.

2018-04-01

This paper presents an experimental investigation on the mechanical properties and flexural behaviour of lightweight foamed concrete (LFC) with added coir fibre as filler. The compressive strength (Pt), tensile strength (Ft), modulus of elasticity (E), ultimate load and crack pattern of the foamed concrete were determined. The coir fibre was added to the foamed concrete mixture at 0.1%, 0.2% and 0.3% of the total weight of cement. Effects of various percentage of coir fibre used on foam concrete’s mechanical and properties and flexural behaviour were studied and analysed. It was found that the increase percentage of fibre resulted in increase in compressive strength, tensile strength and modulus of elasticity of LFC mixture. LFC with added coir of 0.3% experienced the smallest crack propagation.

The influence of aggregates type on W/C ratio on the strength and other properties of concrete

NASA Astrophysics Data System (ADS)

Malaiskiene, J.; Skripkiunas, G.; Vaiciene, M.; Karpova, E.

2017-10-01

The influence of different types of aggregates and W/C ratio on concrete properties is analysed. In order to achieve this aim, lightweight (with expanded clay aggregate) and normal concrete (with gravel aggregate) mixtures are prepared with different W/C ratios. Different W/C ratios are selected by reducing the amount of cement when the amount of water is constant. The following properties of concrete have been determined: density, compressive strength and water absorption. Additionally, the statistical data analysis is performed and influence of aggregate type and W/C ratio on concrete properties is determined. The empirical equations indicating dependence between concrete strength and W/C and strength of aggregate are obtained for normal concrete and light-weight concrete.

Analysis of the possibilities of using dielectric foam in the construction of composite high voltage post-insulators

NASA Astrophysics Data System (ADS)

Mączka, T.; Paściak, G.; Jarski, A.; Piątek, M.

2016-02-01

This paper presents the construction and basic performance parameters of the innovative tubular construction of high voltage composite insulator filled with the lightweight foamed electroinsulating material. The possibility of using of the commercially available expanding foams for preparing the lightweight foamed dielectric materials was analysed. The expanding foams of silicone RTV and compositions based on epoxy resin and LSR silicone were taken into account. The lightweight foamed dielectric materials were prepared according to the own foaming technology. In this work the experimental results on the use of the selected foams for the preparing of the lightweight filling materials to the tubular structure of composite insulator of 110 kV are presented.

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

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.

Experimental Study for Structural Behaviour of Precast Lightweight Panel (PLP) Under Flexural Load

NASA Astrophysics Data System (ADS)

Goh, W. I.; Mohamad, N.; Tay, Y. L.; Rahim, N. H. A.; Jhatial, A. A.; Samad, A. A. A.; Abdullah, R.

2017-06-01

Precast lightweight concrete slab is first fabricated in workshop or industrial before construction and then transported to site and installed by skilled labour. It can reduce construction time by minimizing user delay and time for cast-in-situ to increase workability and efficiency. is environmental friendly and helps in resource reduction. Although the foamed concrete has low compressive strength compared to normal weight concrete but it has excellent thermal insulation and sound absorption. It is environmental friendly and helps in resource reduction. To determine the material properties of foamed concrete, nine cubes and six cylindrical specimens were fabricated and the results were recorded. In this study, structural behaviour of precast lightweight panel (PLP) with dry density of 1800 kg/m3 was tested under flexural load. The results were recorded and analysed in terms of ultimate load, crack pattern, load-deflection profiles and strain distribution. Linear Voltage Displacement Transducers (LVDT) and strain gauges were used to determine the deflection and strain distribution of PLP. The theoretical and experimental ultimate load of PLP was analysed and recorded to be 70 and 62 kN respectively, having a difference of 12.9%. Based on the results, it can be observed that PLP can resist the adequate loading. Thus, it can be used in precast industry for construction purposes.

CESIC: a new technology for lightweight and cost effective space instrument structures and mirrors

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Kroedel, Matthias R.

2005-08-01

For some years Alcatel Space has been interested in the development of a new material to produce lightweight, stiff, stable and cost effective structures and mirrors for space instrument. Cesic from ECM has been selected for its intrinsic properties (high specific modulus, high conductivity, quite low thermal expansion coefficient and high fracture toughness for a ceramic material), added to ample manufacturing capabilities. Under ESA responsibility, a flight representative optical bench of Cesic has been designed, manufactured and tested. The optical bench has been submitted with success to intensive vibration tests up to 80 g on shaker without problem and was tested down to 30 K showing very high stability. Cesic is also envisaged for large and lightweight space telescope mirrors. Coatings on the Cesic substrate have been developed and qualified for the most stringent optical needs. To prove the lightweight capability, a large Cesic mirror D=950 mm with an area mass of less than 25 kg/m2 has been designed, sized again launch loads and WFE performance, and then manufactured. Cesic is also envisaged for large future focal plane holding a large number of detectors assuring high stability thanks to its high thermal conductivity. A full size Cesic focal plane has been already successfully built and tested. Based on these successful results, Alcatel Space is now in position to propose for space projects this technology mastered in common with ECM both for mirrors and structures with new innovative concepts thanks to the manufacturing capabilities of this technology.

Achieving high strength and high ductility in magnesium alloy using hard-plate rolling (HPR) process

NASA Astrophysics Data System (ADS)

Wang, Hui–Yuan; Yu, Zhao–Peng; Zhang, Lei; Liu, Chun–Guo; Zha, Min; Wang, Cheng; Jiang, Qi–Chuan

2015-11-01

Magnesium alloys are highly desirable for a wide range of lightweight structural components. However, rolling Mg alloys can be difficult due to their poor plasticity, and the strong texture yielded from rolling often results in poor plate forming ability, which limits their further engineering applications. Here we report a new hard-plate rolling (HPR) route which achieves a large reduction during a single rolling pass. The Mg-9Al-1Zn (AZ91) plates processed by HPR consist of coarse grains of 30-60 μm, exhibiting a typical basal texture, fine grains of 1-5 μm and ultrafine (sub) grains of 200-500 nm, both of the latter two having a weakened texture. More importantly, the HPR was efficient in gaining a simultaneous high strength and uniform ductility, i.e., ~371 MPa and ~23%, respectively. The superior properties should be mainly attributed to the cooperation effect of the multimodal grain structure and weakened texture, where the former facilitates a strong work hardening while the latter promotes the basal slip. The HPR methodology is facile and effective, and can avoid plate cracking that is prone to occur during conventional rolling processes. This strategy is applicable to hard-to-deform materials like Mg alloys, and thus has a promising prospect for industrial application.

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".

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.

Experimental study on the warm forming and quenching behavior for hot stamping of high-strength aluminum alloys

NASA Astrophysics Data System (ADS)

Degner, J.; Horn, A.; Merklein, M.

2017-09-01

Within the last decades, stringent regulations on fuel consumption, CO2 emissions and product recyclability forced the automotive sector to implement new strategies within the field of car body manufacturing. Due to their low density and good corrosion resistance, aluminum became one of the most relevant lightweight materials. Recently, especially high- strength aluminum alloys for structural components gained importance. Since the low formability of these alloys limits their application, there is a need for novel process strategies in order to enhance the forming behavior. One promising approach is the hot stamping of aluminum alloys. The combination of quenching and forming in one step after solution heat treatment leads to a significant improvement of the formability. Furthermore, higher manufacturing accuracy can be achieved due to reduced spring back. Within this contribution, the influence of forming temperature on the subsequent material behavior and the heat transfer during quenching will be analyzed. Therefore, the mechanical and thermal material characteristics such as flow behavior and heat transfer coefficient during hot stamping are investigated.

Mechanical Behavior of Fabric-Film Laminates

NASA Technical Reports Server (NTRS)

Said, Magdi S.

1999-01-01

Inflatable structures are gaining wide support in planetary scientific missions as well as commercial applications. For such applications a new class of materials made of laminating thin homogenous films to lightweight fabrics are being considered us structura1 gas envelops. The emerging composite materials are a result of recent advances in the manufacturing cf 1ightweight, high strength fibers, fabrics and scrims. The lamination of these load-carrying members with the proper gas barrier film results in wide range of materials suitable for various loading and environmental conditions. Polyester - based woven fabrics laminated to thin homogeneus film of polyester (Maylar) is an example of this class. This fabric/ film laminate is being considered for the development a material suitable for building large gas envelopes for use in the NASA Ultra Long Duration Balloon Program (ULDB). Compared to commercial homogeneus films, the material provides relatively high strength to weight ratio as well as better resistance to crack and tear propagation. The purpose of this papers is to introduce the mechanical behavior of this class of multi-layers composite and to highlight some of the concerns observed during the characterization of these laminate composites.

Thermally sprayed prepregs for thixoforging of UD fiber reinforced light metal MMCs

NASA Astrophysics Data System (ADS)

Silber, Martin; Wenzelburger, Martin; Gadow, Rainer

2007-04-01

Low density and good mechanical properties are the basic requirements for lightweight structures in automotive and aerospace applications. With their high specific strength and strain to failure values, aluminum alloys could be used for such applications. Only the insufficient stiffness and thermal and fatigue strength prevented their usage in high-end applications. One possibility to solve this problem is to reinforce the light metal with unidirectional fibers. The UD fiber allows tailoring of the reinforcement to meet the direction of the component's load. In this study, the production of thermally sprayed prepregs for the manufacturing of continuous fiber reinforced MMC by thixoforging is analysed. The main aim is to optimize the winding procedure, which determines the fiber strand position and tension during the coating process. A method to wind and to coat the continuous fibers with an easy-to-use handling technique for the whole manufacturing process is presented. The prepregs were manufactured by producing arc wire sprayed AlSi6 coatings on fibers bundles. First results of bending experiments showed appropriate mechanical properties.

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.

Influences on the formability and mechanical properties of 7000-aluminum alloys in hot and warm forming

NASA Astrophysics Data System (ADS)

Behrens, B.-A.; Nürnberger, F.; Bonk, C.; Hübner, S.; Behrens, S.; Vogt, H.

2017-09-01

Aluminum alloys of the 7000 series possess high lightweight potential due to their high specific tensile strength combined with a good ultimate elongation. For this reason, hot-formed boron-manganese-steel parts can be substituted by these alloys. Therefore, the application of these aluminum alloys for structural car body components is desired to decrease the weight of the body in white and consequently CO2 emissions during vehicle operation. These days, the limited formability at room temperature limits an application in the automobile industry. By increasing the deformation temperature, formability can be improved. In this study, two different approaches to increase the formability of these alloys by means of higher temperatures were investigated. The first approach is a warm forming route to form sheets in T6 temper state with high tensile strength at temperatures between 150 °C and 300 °C. The second approach is a hot forming route. Here, the material is annealed at solution heat treatment temperature and formed directly after the annealing step. Additionally, a quench step is included in the forming stage. After the forming and quenching step, the sheets have to be artificially aged to achieve the high specific tensile strength. In this study, several parameters in the presented process routes, which influence the formability and the mechanical properties, have been investigated for the aluminum alloys EN AW7022 and EN AW7075.

High performance aluminum–cerium alloys for high-temperature applications

DOE PAGES

Sims, Zachary C.; Rios, Orlando R.; Weiss, David; ...

2017-08-01

Light-weight high-temperature alloys are important to the transportation industry where weight, cost, and operating temperature are major factors in the design of energy efficient vehicles. Aluminum alloys fill this gap economically but lack high-temperature mechanical performance. Alloying aluminum with cerium creates a highly castable alloy, compatible with traditional aluminum alloy additions, that exhibits dramatically improved high-temperature performance. These compositions display a room temperature ultimate tensile strength of 400 MPa and yield strength of 320 MPa, with 80% mechanical property retention at 240 °C. A mechanism is identified that addresses the mechanical property stability of the Al-alloys to at least 300more » °C and their microstructural stability to above 500 °C which may enable applications without the need for heat treatment. Lastly, neutron diffraction under load provides insight into the unusual mechanisms driving the mechanical strength.« less

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.

Study on the Effect of Straw Fiber on the Performance of Volcanic Slag Concrete

NASA Astrophysics Data System (ADS)

Xiao, Li-guang; Liu, Xi-xu

2018-03-01

In this paper, the effects of straw fiber on the working performance, mechanical properties and frost resistance of volcanic slag lightweight aggregate concrete were studied. The experimental results show that the straw fiber is subjected to surface carbonization treatment and mixed into the volcanic slag light aggregate concrete. The flexural strength and fracture pressure ratio of volcanic slag lightweight aggregate concrete are improved obviously Improved volcanic slag lightweight aggregate concrete brittleness improves toughness. Carbonized straw fiber greatly improves the frost resistance of volcanic slag lightweight aggregate concrete. So that the volcanic slag light aggregate concrete freeze-thaw cycle can reach 300 times.

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.

Design Concept for a Reusable/Propellantless MXER Tether Space Transportation System

NASA Technical Reports Server (NTRS)

McCandless, B., II; Kustas, F. m.; Marshall, L. S.; Lytle, W. B.; Hansen, N. P.

2005-01-01

The Momentum Exchange/Electrodynamic Reboost (MXER) tether facility is a transformational concept that significantly reduces the fuel requirements (and associated costs) in transferring payloads above low earth orbit (LEO). Facility reboost is accomplished without propellant by driving current against a voltage created by a conducting tether's interaction with the Earth's magnetic field (electrodynamic reboost). This system can be used for transferring a variety of payloads (scientific, cargo, and human space vehicles) to multiple destinations including geosynchronous transfer orbit, the Moon or Mars. MXER technology advancement requires development in two key areas: survivable, high tensile strength non-conducting tethers and reliable, lightweight payload catch/release mechanisms. Fundamental requirements associated with the MXER non-conducting strength tether and catch mechanism designs will be presented. Key requirements for the tether design include high specific-strength (tensile strength/material density), material survivability to the space environment (atomic oxygen and ultraviolet radiation), and structural survivability to micrometeoroid/orbital debris (MM/OD) impacts. The driving mechanism key,gequirements include low mass-to-capture-volume ratio, positional and velocity error tolerance, and operational reliability. Preliminary tether and catch mechanism design criteria are presented, which have been used as guidelines to "screen" and down-select initial concepts. Candidate tether materials and protective coatings are summarized along with their performance in simulated space environments (e.g., oxygen plasma, thermal cycling). A candidate catch mechanism design concept is presented along with examples of demonstration hardware.

Bone mineral density, rib pain and other features of the female athlete triad in elite lightweight rowers

PubMed Central

Dimitriou, Lygeri; Weiler, Richard; Lloyd-Smith, Rebecca; Turner, Antony; Heath, Luke; James, Nic; Reid, Anna

2014-01-01

Objective To determine bone mineral density (BMD) and the associations among BMD, menstrual history, disordered eating (DE), training history, intentional weight loss (IWL) and rib pain for the first time in female lightweight rowers. Setting 9 lightweight rowing clubs, UK. Participants 29 Caucasian female lightweight rowers volunteered. 21 (12 active, 9 retired) completed the study. Inclusion criteria: female lightweight rowers aged over 18 years. Exclusion criteria: participants with a history of bone disease, used medications known to influence BMD or if they were pregnant, lactating or postmenopausal. Main outcome measures Dual-energy X-ray absorptiometry measured total body (TB) composition and BMD at the spine, femoral neck (FN), radius and TB. DE, oligomenorrhoea/amenorrhoea years; rib pain and training history. Results DE was reported in six of the rowers. The active with DE started rowing younger (p<0.05) than those without, and their amount of IWL was associated with Eating Attitudes Test-26 score (p<0.05). Some participants reported a history of oligomenorrhoea/amenorrhoea 17 (76%) and/or rib pain 7 (32%) with those with rib pain having lower spine and TB Z-scores (p<0.05) than those without. Those with oligomenorrhoea/amenorrhoea had lower spine Z-scores (p<0.01) than those without. Twelve participants had low BMD; three at spine; one at FN; and eight at radius. Thirteen per cent of mean total training hours (18.6±9.1 h/week) were spent strength training (2.4±2.2 h/week). Conclusions Upper body exercises incorporating multidimensional high peak bone strain were not reported and may need to be considered in their strength training to improve radial BMD. Results suggest IWL and high-level training at a young age increases the likelihood of DE and there may be a lack of quality nutritional support for these athletes. Thus, multidisciplinary sport science support should be offered at a young age and perhaps also to consider changing the weight rules to prevent the development of the Triad. PMID:24523427

Structural-functional integrated concrete with macro-encapsulated inorganic PCM

NASA Astrophysics Data System (ADS)

Mohseni, Ehsan; Tang, Waiching; Wang, Zhiyu

2017-09-01

Over the last few years the application of thermal energy storage system incorporating phase change materials (PCMs) to foster productivity and efficiency of buildings energy has grown rapidly. In this study, a structural-functional integrated concrete was developed using macro-encapsulated PCM-lightweight aggregate (LWA) as partial replacement (25 and 50% by volume) of coarse aggregate in control concrete. The PCM-LWA was prepared by incorporation of an inorganic PCM into porous LWAs through vacuum impregnation. The mechanical and thermal performance of PCM-LWA concrete were studied. The test results revealed that though the compressive strength of concrete with PCM-LWA was lower than the control concrete, but ranged from 22.02 MPa to 42.88 MPa which above the minimum strength requirement for structural application. The thermal performance test indicated that macro-encapsulated PCM-LWA has underwent the phase change transition reducing the indoor temperature.

Sucrose Treated Carbon Nanotube and Graphene Yarns and Sheets

NASA Technical Reports Server (NTRS)

Sauti, Godfrey (Inventor); Kim, Jae-Woo (Inventor); Siochi, Emilie J. (Inventor); Wise, Kristopher E. (Inventor)

2017-01-01

Consolidated carbon nanotube or graphene yarns and woven sheets are consolidated through the formation of a carbon binder formed from the dehydration of sucrose. The resulting materials, on a macro-scale are lightweight and of a high specific modulus and/or strength. Sucrose is relatively inexpensive and readily available, and the process is therefore cost-effective.

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

Design of an autonomous teleoperated cargo transporting vehicle for lunar base operations

NASA Technical Reports Server (NTRS)

Holt, James; Lao, Tom; Monali, Nkoy

1989-01-01

At the turn of the century NASA plans to begin construction of a lunar base. The base will likely consist of developed areas (i.e., habitation, laboratory, landing and launching sites, power plant) separated from each other due to safety considerations. The Self-Repositioning Track Vehicle (SRTV) was designed to transport cargo between these base facilities. The SRTV operates by using two robotic arms to raise and position segments of track upon which the vehicle travels. The SRTV utilizes the semiautonomous mobility (SAM) method of teleoperation; actuator-controlled interlocking track sections; two robotic arms each with five degrees of freedom; and these materials: titanium for structural members and aluminum for shell members, with the possible use of light-weight, high-strength composites.

Development of lightweight aggregates from stone cutting sludge, plastic wastes and sepiolite rejections for agricultural and environmental purposes.

PubMed

Moreno-Maroto, José Manuel; González-Corrochano, Beatriz; Alonso-Azcárate, Jacinto; Rodríguez, Luis; Acosta, Anselmo

2017-09-15

Three different wastes have been assessed for lightweight aggregate (LWA) manufacturing: granite and marble sludge (COR), sepiolite rejections (SEP) and polyethylene-hexene thermoplastics (P). A preliminary study of the physical and chemical properties of the raw materials was carried out to design proper batches. It was mixed 10% SEP with 90% COR to confer plasticity, and in turn, 0, 2.5, 5 and 10% (w/w) of P was added to check its suitability as a bloating agent. The mixtures were milled, kneaded with water, extruded, shaped into pellets, oven-dried and finally fired at 1100, 1125 and 1150 °C for 4, 8 and 16 min. The main technological properties of the aggregates related to bloating, density, porosity, loss on ignition, water absorption and compressive strength were measured. Scanning Electron Microscopy was used to study the microstructure of some LWAs. 23 out of 29 types of aggregate were lightweight, although neither bloating effect was observed, nor the typical cellular structure comprised of shell and core with relatively large pores was obtained, but a structure consisting of micropores and microchannels. The increase of temperature and time of firing involved a greater sintering, which in turn was translated into higher shrinkage, density and compressive strength values, but less porosity and water absorption. The addition of P did not involve any improvement, indeed it caused a significant decrease in compressive strength. The LWA sintered without P at the minimum time (4 min) and temperature of firing (1100 °C) was selected to assess its water suction capability. The results pointed out that this LWA could be suitable in hydroponics and/or water filtration systems, even better than the commercial LWA Arlita G3. A new and most environment-friendly perspective in LWA industry arises from here, promoting LWA production at relative low temperatures (prior to significant sintering occurs) and using non-plastic silty wastes instead of clays as major components. Copyright © 2017 Elsevier Ltd. All rights reserved.

Damage Mechanisms and Mechanical Properties of High-Strength Multiphase Steels.

PubMed

Heibel, Sebastian; Dettinger, Thomas; Nester, Winfried; Clausmeyer, Till; Tekkaya, A Erman

2018-05-09

The usage of high-strength steels for structural components and reinforcement parts is inevitable for modern car-body manufacture in reaching lightweight design as well as increasing passive safety. Depending on their microstructure these steels show differing damage mechanisms and various mechanical properties which cannot be classified comprehensively via classical uniaxial tensile testing. In this research, damage initiation, evolution and final material failure are characterized for commercially produced complex-phase (CP) and dual-phase (DP) steels in a strength range between 600 and 1000 MPa. Based on these investigations CP steels with their homogeneous microstructure are characterized as damage tolerant and hence less edge-crack sensitive than DP steels. As final fracture occurs after a combination of ductile damage evolution and local shear band localization in ferrite grains at a characteristic thickness strain, this strain measure is introduced as a new parameter for local formability. In terms of global formability DP steels display advantages because of their microstructural composition of soft ferrite matrix including hard martensite particles. Combining true uniform elongation as a measure for global formability with the true thickness strain at fracture for local formability the mechanical material response can be assessed on basis of uniaxial tensile testing incorporating all microstructural characteristics on a macroscopic scale. Based on these findings a new classification scheme for the recently developed high-strength multiphase steels with significantly better formability resulting of complex underlying microstructures is introduced. The scheme overcomes the steel designations using microstructural concepts, which provide no information about design and production properties.

Brittle intermetallic compound makes ultrastrong low-density steel with large ductility.

PubMed

Kim, Sang-Heon; Kim, Hansoo; Kim, Nack J

2015-02-05

Although steel has been the workhorse of the automotive industry since the 1920s, the share by weight of steel and iron in an average light vehicle is now gradually decreasing, from 68.1 per cent in 1995 to 60.1 per cent in 2011 (refs 1, 2). This has been driven by the low strength-to-weight ratio (specific strength) of iron and steel, and the desire to improve such mechanical properties with other materials. Recently, high-aluminium low-density steels have been actively studied as a means of increasing the specific strength of an alloy by reducing its density. But with increasing aluminium content a problem is encountered: brittle intermetallic compounds can form in the resulting alloys, leading to poor ductility. Here we show that an FeAl-type brittle but hard intermetallic compound (B2) can be effectively used as a strengthening second phase in high-aluminium low-density steel, while alleviating its harmful effect on ductility by controlling its morphology and dispersion. The specific tensile strength and ductility of the developed steel improve on those of the lightest and strongest metallic materials known, titanium alloys. We found that alloying of nickel catalyses the precipitation of nanometre-sized B2 particles in the face-centred cubic matrix of high-aluminium low-density steel during heat treatment of cold-rolled sheet steel. Our results demonstrate how intermetallic compounds can be harnessed in the alloy design of lightweight steels for structural applications and others.

Development of lightweight reinforced plastic laminates for spacecraft interior applications

NASA Technical Reports Server (NTRS)

Hertz, J.

1975-01-01

Lightweight, Kevlar - reinforced laminating systems that are non-burning, generate little smoke in the space shuttle environment, and are physically equivalent to the fiberglass/polyimide system used in the Apollo program for non-structural cabin panels, racks, etc. Resin systems representing five generic classes were screened as matrices for Kevlar 49 reinforced laminates. Of the systems evaluated, the polyimides were the most promising with the phenolics a close second. Skybond 703 was selected as the most promising resin candidate. With the exception of compression strength, all program goals of physical and mechanical properties were exceeded. Several prototype space shuttle mobility and translation handrail segments were manufactured using Kevlar/epoxy and Kevlar-graphite/epoxy. This application shows significant weight savings over the baseline aluminum configuration used previous. The hybrid Kevlar-graphite/epoxy is more suitable from a processing standpoint.

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.

Evaluation of circularity error in drilling of syntactic foam composites

NASA Astrophysics Data System (ADS)

Ashrith H., S.; Doddamani, Mrityunjay; Gaitonde, Vinayak

2018-04-01

Syntactic foams are widely used in structural applications of automobiles, aircrafts and underwater vehicles due to their lightweight properties combined with high compression strength and low moisture absorption. Structural application requires drilling of holes for assembly purpose. In this investigation response surface methodology based mathematical models are used to analyze the effects of cutting speed, feed, drill diameter and filler content on circularity error both at entry and exit level in drilling of glass microballoon reinforced epoxy syntactic foam. Experiments are conducted based on full factorial design using solid coated tungsten carbide twist drills. The parametric analysis reveals that circularity error is highly influenced by drill diameter followed by spindle speed at the entry and exit level. Parametric analysis also reveals that increasing filler content decreases circularity error by 13.65 and 11.96% respectively at entry and exit levels. Average circularity error at the entry level is found to be 23.73% higher than at the exit level.

Scratch-resistant, highly conductive, and high-strength carbon nanotube-based composite yarns.

PubMed

Liu, Kai; Sun, Yinghui; Lin, Xiaoyang; Zhou, Ruifeng; Wang, Jiaping; Fan, Shoushan; Jiang, Kaili

2010-10-26

High-strength and conductive carbon nanotube (CNT) yarns are very attractive in many potential applications. However, there is a difficulty when simultaneously enhancing the strength and conductivity of CNT yarns. Adding some polymers into CNT yarns to enhance their strength will decrease their conductivity, while treating them in acid or coating them with metal nanoparticles to enhance their conductivity will reduce their strength. To overcome this difficulty, here we report a method to make high-strength and highly conductive CNT-based composite yarns by using a continuous superaligned CNT (SACNT) yarn as a conductive framework and then inserting polyvinyl alcohol (PVA) into the intertube spaces of the framework through PVA/dimethyl sulphoxide solution to enhance the strength of yarns. The as-produced CNT/PVA composite yarns possess very high tensile strengths up to 2.0 GPa and Young's moduli more than 120 GPa, much higher than those of the CNT/PVA yarns reported. The electric conductivity of as-produced composite yarns is as high as 9.2 × 10(4) S/m, comparable to HNO(3)-treated or Au nanoparticle-coated CNT yarns. These composite yarns are flexible, lightweight, scratch-resistant, very stable in the lab environment, and resistant to extremely humid ambient and as a result can be woven into high-strength and heatable fabrics, showing potential applications in flexible heaters, bullet-proof vests, radiation protection suits, and spacesuits.

Aerogel: Tile Composites Toughen a Brittle Superinsulation

NASA Technical Reports Server (NTRS)

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

1998-01-01

Pure aerogels, though familiar in the laboratory for decades as exotic lightweight insulators with unusual physical properties, have had limited industrial applications due to their low strength and high brittleness. Composites formed of aerogels and the ceramic fiber matrices like those used as space shuttle tiles bypass the fragility of pure aerogels and can enhance the performance of space shuttle tiles in their harsh operating environment. Using a layer of aerogel embedded in a tile may open up a wide range of applications where thermal insulation, gas convection control and mechanical strength matter.

Aerogel: Tile Composites Toughen a Brittle Superinsulation

NASA Technical Reports Server (NTRS)

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

1998-01-01

Pure aerogels, though familiar in the laboratory for decades as exotic lightweight insulators with unusual physical properties, have had limited industrial applications due to their low strength and high brittleness. Composites formed of aerogels and the ceramic fiber matrices used as space shuttle tiles bypass the fragility of pure aerogels and can enhance the performance of space shuttle tiles in their harsh operating environment. Using a layer of aerogel embedded in a tile may open up a wide range of applications where thermal insulation, gas convection control and mechanical strength matter.

Investigation on Suitability of Natural Fibre as Replacement Material for Table Tennis Blade

NASA Astrophysics Data System (ADS)

Arifin, A. M. T.; Fahrul Hassan, M.; Ismail, A. E.; Zulafif Rahim, M.; Rasidi Ibrahim, M.; Haq, R. H. Abdul; Rahman, M. N. A.; Yunos, M. Z.; Amin, M. H. M.

2017-08-01

This paper presents an investigation of suitability natural fibre as replacement material for table tennis blade, due to low cost, lightweight and apparently environmentally. Nowadays, natural fibre are one of the materials often used in replaced the main material on manufacturing sector, such as automotive, and construction. The objective of this study is to investigate and evaluate the suitability natural fiber materials to replace wood as a structure on table tennis blade. The mechanical properties of the different natural fibre material were examined, and correlated with characteristic of table tennis blade. The natural fibre selected for the study are kenaf (Hibiscus Cannabinus), jute, hemp, sisal (Agave Sisalana) and ramie. A further comparison was made with the corresponding properties of each type of natural fiber using Quality Function Deployment (QFD) and Theory of Inventive Problem Solving (TRIZ). TRIZ has been used to determine the most appropriate solution in producing table tennis blade. The results showed the most appropriate solution in producing table tennis blade using natural fibre is kenaf natural fibre. The selected on suitability natural fibre used as main structure on table tennis blade are based on the characteristics need for good performance of table tennis blade, such as energy absorption, lightweight, strength and hardness. Therefore, it shows an opportunity for replacing existing materials with a higher strength, lower cost alternative that is environmentally friendly.

Lightweight Structures

NASA Technical Reports Server (NTRS)

Whittenberger, J. Daniel

2001-01-01

Present structural concepts for hot static structures are conventional "sheet & stringer" or truss core construction. More weight-efficient concepts such as honeycomb and lattice block are being investigated, in combination with both conventional superalloys and TiAl. Development efforts for components made from TiAl sheet are centered on lower cost methods for sheet and foil production, plus alloy development for higher temperature capability. A low-cost casting technology recently developed for aluminum and steel lattice blocks has demonstrated the required higher strength and stiffness, with weight efficiency approach- ing honeycombs. The current effort is based on extending the temperature capability by developing lattice block materials made from IN-718 and Mar-M247.

Design, Construction, and Testing of Lightweight X-ray Mirror Modules

NASA Technical Reports Server (NTRS)

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

2013-01-01

Lightweight and high resolution optics are needed for future space-based X-ray telescopes to achieve advances in high-energy astrophysics. The Next Generation X-ray Optics (NGXO) team at NASA GSFC is nearing mission readiness for a 10 arc-second Half Power Diameter (HPD) slumped glass mirror technology while laying the groundwork for a future 1-2 arc-second technology based on polished silicon mirrors. Technology Development Modules (TDMs) have been designed, fabricated, integrated with mirrors segments, and extensively tested to demonstrate technology readiness. Tests include X-ray performance, thermal vacuum, acoustic load, and random vibration. The thermal vacuum and acoustic load environments have proven relatively benign, while the random vibration environment has proven challenging due to large input amplification at frequencies above 500 Hz. Epoxy selection, surface preparation, and larger bond area have increased bond strength while vibration isolation has decreased vibration amplification allowing for space launch requirements to be met in the near term. The next generation of TDMs, which demonstrates a lightweight structure supporting more mirror segments, is currently being fabricated. Analysis predicts superior performance characteristics due to the use of E-60 Beryllium-Oxide Metal Matrix Composite material, with only a modest cost increase. These TDMs will be larger, lighter, stiffer, and stronger than the current generation. Preliminary steps are being taken to enable mounting and testing of 1-2 arc-second mirror segments expected to be available in the future. A Vertical X-ray Test Facility (VXTF) will minimize module gravity distortion and allow for less constrained mirror mounts, such as fully kinematic mounts. Permanent kinematic mounting into a modified TDM has been demonstrated to achieve 2 arc-second level distortion free alignment.

The processing and heterostructuring of silk with light

NASA Astrophysics Data System (ADS)

Sidhu, Mehra S.; Kumar, Bhupesh; Singh, Kamal P.

2017-09-01

Spider silk is a tough, elastic and lightweight biomaterial, although there is a lack of tools available for non-invasive processing of silk structures. Here we show that nonlinear multiphoton interactions of silk with few-cycle femtosecond pulses allow the processing and heterostructuring of the material in ambient air. Two qualitatively different responses, bulging by multiphoton absorption and plasma-assisted ablation, are observed for low- and high-peak intensities, respectively. Plasma ablation allows us to make localized nanocuts, microrods, nanotips and periodic patterns with minimal damage while preserving molecular structure. The bulging regime facilitates confined bending and microwelding of silk with materials such as metal, glass and Kevlar with strengths comparable to pristine silk. Moreover, analysis of Raman bands of microwelded joints reveals that the polypeptide backbone remains intact while perturbing its weak hydrogen bonds. Using this approach, we fabricate silk-based functional topological microstructures, such as Mobiüs strips, chiral helices and silk-based sensors.

The processing and heterostructuring of silk with light.

PubMed

Sidhu, Mehra S; Kumar, Bhupesh; Singh, Kamal P

2017-09-01

Spider silk is a tough, elastic and lightweight biomaterial, although there is a lack of tools available for non-invasive processing of silk structures. Here we show that nonlinear multiphoton interactions of silk with few-cycle femtosecond pulses allow the processing and heterostructuring of the material in ambient air. Two qualitatively different responses, bulging by multiphoton absorption and plasma-assisted ablation, are observed for low- and high-peak intensities, respectively. Plasma ablation allows us to make localized nanocuts, microrods, nanotips and periodic patterns with minimal damage while preserving molecular structure. The bulging regime facilitates confined bending and microwelding of silk with materials such as metal, glass and Kevlar with strengths comparable to pristine silk. Moreover, analysis of Raman bands of microwelded joints reveals that the polypeptide backbone remains intact while perturbing its weak hydrogen bonds. Using this approach, we fabricate silk-based functional topological microstructures, such as Mobiüs strips, chiral helices and silk-based sensors.

Prevention of crack in stretch flanging process using hot stamping technique

NASA Astrophysics Data System (ADS)

Syafiq, Y. Mohd; Hamedon, Z.; Azila Aziz, Wan; Razlan Yusoff, Ahmad

2017-10-01

Demand for enhancing of passenger safety as well as weight reduction of automobiles has increased the use of high strength steel sheets. As a sheet metal is a lightweight having high strength is suitable for producing automotive parts such as white body panel. The stretch flanging of the high strength steel sheet is a problem due to high springback and easy to crack. This study uses three methods to stretch flange the sheets; using lubricants, shear-edge polishing and hot stamping. The effectiveness of these methods will be measured by comparing the flange length of each methods can achieved. For stretch flange with lubricant and polished sheared edge, the flange length failed to achieve the target 15 mm while hot stamping improved the formability of the sheet and preventing the occurrence of the springback and crack. Hot stamping not only improved formability of the sheet but also transformed the microstructure into martensite thus improve the hardness and the strength of the sheet after been quenched with the dies.

Properties of lightweight aggregate concrete prepared with PVC granules derived from scraped PVC pipes.

PubMed

Kou, S C; Lee, G; Poon, C S; Lai, W L

2009-02-01

This paper aims to investigate the fresh and hardened properties of lightweight aggregate concretes that are prepared with the use of recycled plastic waste sourced from scraped PVC pipes to replace river sand as fine aggregates. A number of laboratory prepared concrete mixes were tested, in which river sand was partially replaced by PVC plastic waste granules in percentages of 0%, 5%, 15%, 30% and 45% by volume. Two major findings are identified. The positive side shows that the concrete prepared with a partial replacement by PVC was lighter (lower density), was more ductile (greater Poisson's ratios and reduced modulus of elasticity), and had lower drying shrinkage and higher resistance to chloride ion penetration. The negative side reveals that the workability, compressive strength and tensile splitting strength of the concretes were reduced. The results gathered would form a part of useful information for recycling PVC plastic waste in lightweight concrete mixes.

The analysis of mechanical properties of non autoclaved aerated concrete with the substitution of fly ash and bottom ash

NASA Astrophysics Data System (ADS)

Karolina, R.; Muhammad, F.

2018-02-01

Based on PP. No.85 of 1999 on the management of hazardous and toxic (B3), fly ash and bottom ash wastes are categorized into B3 waste because there are heavy metal oxide contents that can pollute the environment. One form of environmental rescue that can be applied is to utilize waste fly ash and bottom ash in the manufacture of concrete. In this research, fly ash and bottom ash waste are used as substitution of cement and fine aggregate to make lightweight concrete. The purpose of this research is to know the mechanical properties of non-autoclaved aerated lightweight concrete (NAAC) with FA and BA substitution to cement and fine aggregate which is expected to improve the quality of concrete. The NAAC lightweight concrete in this study is divided into 4 categories: normal NAAC lightweight concrete, NAAC lightweight NAAC substituted concrete with FA, NAAC lightweight concrete substituted with BA, and NAAC combined light weight from FA and BA with variations of 10%, 20% And 30%. The test specimen used in cylindrical shape, which was tested at the age of 28 days, amounted to 90 pieces and consisted of 10 variations. Each variation amounted to 9 samples. Based on the test results with FA and BA substitutions of 10%, 20%, and 30%, the highest compressive strength was achieved in samples with FA 30% of 12.687 MPa, maximum tensile strength achieved in samples with FA 30% of 1,540 MPa, The highest absorption was achieved in normal NAAC of 5.66%. Based on the weight of the contents of all samples, samples can be categorized in lightweight concrete, since the weight of the contents is less than 1900 kg / m3.

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.

Fabrication of Lightweight Radiation Shielding Composite Materials by Field Assisted Sintering Technique (FAST)

NASA Technical Reports Server (NTRS)

Prasad, Narasimha; Trivedi, Sudhir; Chen, Henry; Kutcher, Susan; Zhang, Dajie; Singh, Jogender

2017-01-01

Advances in radiation shielding technologies are needed to protect humans and electronic components from all threats of space radiation over long durations. In this paper, we report on the use of the innovative and novel fabrication technology known as Field Assisted Sintering Technology (FAST) to fabricate lightweight material with enhanced radiation shielding strength to safeguard humans and electronics suitable for next generation space exploration missions. The base materials we investigated were aluminum (Al), the current standard material for space hardware, and Ultra-High Molecular Weight Polyethylene (UHMWPE), which has high hydrogen content and resistance to nuclear reaction from neutrons, making it a good shielding material for both gamma radiation and particles. UHMWPE also has high resistance to corrosive chemicals, extremely low moisture sensitivity, very low coefficient of friction, and high resistance to abrasion. We reinforced the base materials by adding high density (ie, high atomic weight) metallic material into the composite. These filler materials included: boron carbide (B4C), tungsten (W), tungsten carbide (WC) and gadolinium (Gd).

Finite element analysis of composites materials for aerospace applications

NASA Astrophysics Data System (ADS)

Nurhaniza, M.; Ariffin, M. K. A.; Ali, Aidy; Mustapha, F.; Noraini, A. W.

2010-05-01

Composites materials are intended to be used more extensively as an alternative of aluminum structure in aircraft and aerospace applications. This is due to their attractive properties as high strength-to-weight ratio and stiffness-to-weight ratio. Besides that it clarifies the growing interest for composites materials due to advantages of lightweight, high strength, high stiffness, superior fatigue life, tremendous corrosion resistance and low cost manufacturing. In this study, a finite element analysis (FEA) of fiberglass unidirectional E-type was analyzed in the framework of ABAQUS finite element commercial software. The analysis was done to quantify the mechanical properties and response of unidirectional E-glass in term of tensile, compression and thermal responses. From the analysis, the maximum and minimum values of stress and strain for E-glass 21xK43 Gevetex and Silenka E-glass 1200tex were obtained and stress-strain curve is presented. The ultimate load of failure, elastic behavior, tensile strength and other properties for each laminated plates under tensile and thermal-stress are determined from stress-strain curves. The simulation will run twice for each material where the first simulation based on orientation angles of 45° for ply-1, -45° for ply-2 and 90° for ply-3 while the second simulation, the orientation angles is 0° for all plies. The simulation is successfully conducted and verified by experimental data.

Materials Needs for Future In-space Propulsion Systems

NASA Technical Reports Server (NTRS)

Johnson, Charles Les

2008-01-01

NASA is developing the next generation of in-space propulsion systems in support of robotic exploration missions throughout the solar system. The propulsion technologies being developed are non-traditional and have stressing materials performance requirements. (Chemical Propulsion) Earth-storable chemical bipropellant performance is constrained by temperature limitations of the columbium used in the chamber. Iridium/rhenium (Ir/Re) is now available and has been implemented in initial versions of Earth-Storable rockets with specific impulses (Isp) about 10 seconds higher than columbium rocket chambers. New chamber fabrication methods that improve process and performance of Ir/Re and other promising material systems are needed. (Solar Sail Propulsion) The solar sail is a propellantless propulsion system that gains momentum by reflecting sunlight. The sails need to be very large in area (from 10000 m2 up to 62500 m2) yet be very lightweight in order to achieve adequate accelerations for realistic mission times. Lightweight materials that can be manufactured in thicknesses of less than 1 micron and that are not harmed by the space environment are desired. (Aerocapture) Blunt Body Aerocapture uses aerodynamic drag to slow an approaching spacecraft and insert it into a science orbit around any planet or moon with an atmosphere. The spacecraft is enclosed by a rigid aeroshell that protects it from the entry heating and aerodynamic environment. Lightweight, high-temperature structural systems, adhesives, insulators, and ablatives are key components for improving aeroshell efficiencies at heating rates of 1000-2000 W/cu cm and beyond. Inflatable decelerators in the forms of ballutes and inflatable aeroshells will use flexible polymeric thin film materials, high temperature fabrics, and structural adhesives. The inflatable systems will be tightly packaged during cruise and will be inflated prior to entry interface at the destination. Materials must maintain strength and flexibility while packaged at cold temperatures (_100oC) for up to 10 years and then withstand the high temperatures (500oC) encountered during aerocapture. The presentation will describe the status of each propulsion technology and summarize the materials needed for their implementation.

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.

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.

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

Multi-component lightweight gearwheels with deep-drawn wheel body for automotive applications

NASA Astrophysics Data System (ADS)

Benkert, Tim; Hiller, Maria; Volk, Wolfram

2017-09-01

Multi-component gearwheels offer great lightweight opportunities for automotive applications. An assembly of a gear ring and a wheel body joined by press fit replaces the monolithic gearwheel. To save weight, the wheel body uses lightweight design. This lightweight design influences the assembled gearwheel’s mechanical properties like stiffness, weight and torque capacity. Further, the wheel body material influences the mentioned properties as well. In this paper, the effects of the lightweight wheel body manufactured by deep-drawing on the mechanical properties of the assembled gearwheel are investigated. Three different wheel body designs are examined regarding their stiffness and weight compared to a reference gearwheel. Using the best design, the influence of five materials with increasing yield strength on the maximum torque the gearwheel can transmit is studied. All research is done virtually using Abaqus 6.12-3.

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

NASA Technical Reports Server (NTRS)

Krause, David L.; Whittenberger, J. Daniel

2002-01-01

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

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.

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.

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

NASA Technical Reports Server (NTRS)

Johnson, Theodore F.; Natividad, Roderick; Rivers, H. Kevin; Smith, Russell

1998-01-01

Analytical and experimental studies conducted at the NASA Langley Research Center for investigating integrated cryogenic propellant tank systems for a Reusable Launch Vehicle are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, Thermal Protection System (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

NASA Technical Reports Server (NTRS)

Johnson, Theodore F.; Natividad, Roderick; Rivers, H. Kevin; Smith, Russell W.

2005-01-01

Analytical and experimental studies conducted at the NASA, Langley Research Center (LaRC) for investigating integrated cryogenic propellant tank systems for a reusable launch vehicle (RLV) are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, thermal protection system (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Tailored interphase structure for improved strength and energy absorption of composites

NASA Astrophysics Data System (ADS)

Gao, Xiao

Fiber reinforced polymeric composites are lightweight, high-strength and high impact-resistant materials used widely for various applications. It has been shown that the mechanical performance of composites are dependent on the interphase, a three-dimensional region of nanometer size in the vicinity of the fiber-matrix boundary that possesses properties different from those of either the fiber reinforcement or the matrix resin and governs the load transfer from matrix to fiber. This research conducts a systematic study on glass fiber-epoxy interphase structure by tailoring adhesion between constituents and the creation of textures to control strength and energy absorption through mechanical interlocking between glass fiber and epoxy matrix. Our objective is to establish the foundation for microstructural design and optimization of the composite's structural and impact performance. Two ways of roughening the glass fiber surface have been studied to create the mechanical interlocking between fiber and resin; the first technique involves forming in-situ islands on the glass fiber surface by using silane blends of Glycidoxypropyltrimethoxy silane (GPS) and Tetraethoxy silane (TEOS); the second technique applies a silane coupling agents based sizing with the incorporation of silica nanoparticles (Ludox TMA, 22 nm) onto the fiber surface. The microdroplet test was selected to characterize the influence of adhesion and mechanical interlocking effects on interphase properties of different sizing sized glass fiber reinforced epoxy systems. A suitable data reduction scheme enables the strength and specified energy absorbed due to debonding, dynamic sliding, and quasi-static sliding to be quantified. In order to validate the effect of tailored interphase structure, which is induced by creating mechanical interlocking between fiber and resin, on macroscopic composite properties, composite panels were made from these four different sizing sized glass fibers and tested using the punch shear test. The composite panel made from the hybrid sizing sized glass fiber exhibited improved strength and energy absorption consistent with the trends in micromechanical measurements. Through all failure stages under macromechanical testing, hybrid sizing sized glass fiber/epoxyamine composite panel shows an increase in the strength and total energy absorption by 13% and 26%, respectively, compared to the compatible sizing sized baseline. Both micromechanical and macromechanical tests demonstrate the significant influence of tailoring the interphase structure on improving the impact performance of the composites. The hybrid sizing with the incorporation of nanoparticles, in particular, can greatly improve the impact resistance (i.e. energy absorption) of composites without sacrificing its structural performance (i.e. strength).

The effect of different parameters on the development of compressive strength of oil palm shell geopolymer concrete.

PubMed

Kupaei, Ramin Hosseini; Alengaram, U Johnson; Jumaat, Mohd Zamin

2014-01-01

This paper presents the experimental results of an on-going research project on geopolymer lightweight concrete using two locally available waste materials--low calcium fly ash (FA) and oil palm shell (OPS)--as the binder and lightweight coarse aggregate, respectively. OPS was pretreated with three different alkaline solutions of sodium hydroxide (NaOH), potassium hydroxide, and sodium silicate as well as polyvinyl alcohol (PVA) for 30 days; afterwards, oil palm shell geopolymer lightweight concrete (OPSGPC) was cast by using both pretreated and untreated OPSs. The effect of these solutions on the water absorption of OPS, and the development of compressive strength in different curing conditions of OPSGPC produced by pretreated OPS were investigated; subsequently the influence of NaOH concentration, alkaline solution to FA ratio (A/FA), and different curing regimes on the compressive strength and density of OPSGPC produced by untreated OPS was inspected. The 24-hour water absorption value for OPS pretreated with 20% and 50% PVA solution was about 4% compared to 23% for untreated OPS. OPSGPC produced from OPS treated with 50% PVA solution produced the highest compressive strength of about 30 MPa in ambient cured condition. The pretreatment with alkaline solution did not have a significant positive effect on the water absorption of OPS aggregate and the compressive strength of OPSGPC. The result revealed that a maximum compressive strength of 32 MPa could be obtained at a temperature of 65°C and curing period of 4 days. This investigation also found that an A/FA ratio of 0.45 has the optimum amount of alkaline liquid and it resulted in the highest level of compressive strength.

The Effect of Different Parameters on the Development of Compressive Strength of Oil Palm Shell Geopolymer Concrete

PubMed Central

Kupaei, Ramin Hosseini; Alengaram, U. Johnson; Jumaat, Mohd Zamin

2014-01-01

This paper presents the experimental results of an on-going research project on geopolymer lightweight concrete using two locally available waste materials—low calcium fly ash (FA) and oil palm shell (OPS)—as the binder and lightweight coarse aggregate, respectively. OPS was pretreated with three different alkaline solutions of sodium hydroxide (NaOH), potassium hydroxide, and sodium silicate as well as polyvinyl alcohol (PVA) for 30 days; afterwards, oil palm shell geopolymer lightweight concrete (OPSGPC) was cast by using both pretreated and untreated OPSs. The effect of these solutions on the water absorption of OPS, and the development of compressive strength in different curing conditions of OPSGPC produced by pretreated OPS were investigated; subsequently the influence of NaOH concentration, alkaline solution to FA ratio (A/FA), and different curing regimes on the compressive strength and density of OPSGPC produced by untreated OPS was inspected. The 24-hour water absorption value for OPS pretreated with 20% and 50% PVA solution was about 4% compared to 23% for untreated OPS. OPSGPC produced from OPS treated with 50% PVA solution produced the highest compressive strength of about 30 MPa in ambient cured condition. The pretreatment with alkaline solution did not have a significant positive effect on the water absorption of OPS aggregate and the compressive strength of OPSGPC. The result revealed that a maximum compressive strength of 32 MPa could be obtained at a temperature of 65°C and curing period of 4 days. This investigation also found that an A/FA ratio of 0.45 has the optimum amount of alkaline liquid and it resulted in the highest level of compressive strength. PMID:25531006

Lightweight flywheel containment

DOEpatents

Smith, James R.

2001-01-01

A lightweight flywheel containment composed of a combination of layers of various material which absorb the energy of a flywheel structural failure. The various layers of material act as a vacuum barrier, momentum spreader, energy absorber, and reaction plate. The flywheel containment structure has been experimentally demonstrated to contain carbon fiber fragments with a velocity of 1,000 m/s and has an aerial density of less than 6.5 g/square centimeters. The flywheel containment, may for example, be composed of an inner high toughness structural layer, and energy absorbing layer, and an outer support layer. Optionally, a layer of impedance matching material may be utilized intermediate the flywheel rotor and the inner high toughness layer.

Lightweight flywheel containment

DOEpatents

Smith, James R.

2004-06-29

A lightweight flywheel containment composed of a combination of layers of various material which absorb the energy of a flywheel structural failure. The various layers of material act as a vacuum barrier, momentum spreader, energy absorber, and reaction plate. The flywheel containment structure has been experimentally demonstrated to contain carbon fiber fragments with a velocity of 1,000 m/s and has an aerial density of less than 6.5 g/square centimeters. The flywheel containment, may for example, be composed of an inner high toughness structural layer, and energy absorbing layer, and an outer support layer. Optionally, a layer of impedance matching material may be utilized intermediate the flywheel rotor and the inner high toughness layer.

FY2017 Materials Annual Progress Report

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

Wu, Felix; Gibbs, Jerry; Kleinbaum, Sarah

The Materials Technology subprogram supports the Vehicle Technology Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced Lightweight Materials research enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacingmore » cast iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25 percent weight reduction for light-duty vehicles including body, chassis, and interior as compared to a 2012 baseline at no more than a $5/lb-saved increase in cost; and (2) validate a 25 percent improvement in high temperature (300°C) component strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency light-duty engines.« less

Lightweight Open-Cell Scaffolds from Sea Urchin Spines with Superior Material Properties for Bone Defect Repair.

PubMed

Cao, Lei; Li, Xiaokang; Zhou, Xiaoshu; Li, Yong; Vecchio, Kenneth S; Yang, Lina; Cui, Wei; Yang, Rui; Zhu, Yue; Guo, Zheng; Zhang, Xing

2017-03-22

Sea urchin spines (Heterocentrotus mammillatus), with a hierarchical open-cell structure similar to that of human trabecular bone and superior mechanical property (compressive strength ∼43.4 MPa) suitable for machining to shape, were explored for potential applications of bone defect repair. Finite element analyses reveal that the compressive stress concentrates along the dense growth rings and dissipates through strut structures of the stereoms, indicating that the exquisite mesostructures play an important role in high strength-to-weight ratios. The fracture strength of magnesium-substituted tricalcium phosphate (β-TCMP) scaffolds produced by hydrothermal conversion of urchin spines is about 9.3 MPa, comparable to that of human trabecular bone. New bone forms along outer surfaces of β-TCMP scaffolds after implantation in rabbit femoral defects for one month and grows into the majority of the inner open-cell spaces postoperation in three months, showing tight interface between the scaffold and regenerative bone tissue. Fusion of beagle lumbar facet joints using a Ti-6Al-4V cage and β-TCMP scaffold can be completed within seven months with obvious biodegradation of the β-TCMP scaffold, which is nearly completely degraded and replaced by newly formed bone ten months after implantation. Thus, sea urchin spines suitable for machining to shape have advantages for production of biodegradable artificial grafts for bone defect repair.

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.

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.

Lightweight Exoskeletons with Controllable Actuators

NASA Technical Reports Server (NTRS)

Bar-Cohen, Yoseph; Mavrodis, Constantinos; Melli-Huber, Juan; Fisch, Avi (Alan)

2004-01-01

A proposed class of lightweight exoskeletal electromechanical systems would include electrically controllable actuators that would generate torques and forces that, depending on specific applications, would resist and/or assist wearers movements. The proposed systems would be successors to relatively heavy, bulky, and less capable human-strength-amplifying exoskeletal electromechanical systems that have been subjects of research during the past four decades. The proposed systems could be useful in diverse applications in which there are needs for systems that could be donned or doffed easily, that would exert little effect when idle, and that could be activated on demand: examples of such applications include (1) providing controlled movement and/or resistance to movement for physical exercise and (2) augmenting wearers strengths in the performance of military, law-enforcement, and industrial tasks. An exoskeleton according to the proposal would include adjustable lightweight graphite/epoxy struts and would be attached to the wearer's body by belts made of hook-and-pile material. At selected rotary and linear joints, the exoskeleton would be fitted, variously, with lightweight, low-power-consumption rotary and linear brakes, clutches, and motors. The exoskeleton would also be equipped with electronic circuitry for monitoring, control, and possibly communication with external electronic circuits that would perform additional monitoring and control functions.

Optimisation of the geometry of the drill bit and process parameters for cutting hybrid composite/metal structures in new aircrafts

NASA Astrophysics Data System (ADS)

Isbilir, Ozden

Owing to their desirable strength-to-weight characteristics, carbon fibre reinforced polymer composites have been favourite materials for structural applications in different industries such as aerospace, transport, sports and energy. They provide a weight reduction in whole structure and consequently decrease fuel consumption. The use of lightweight materials such as titanium and its alloys in modern aircrafts has also increased significantly in the last couple of decades. Titanium and its alloys offer high strength/weight ratio, high compressive and tensile strength at high temperatures, low density, excellent corrosion resistance, exceptional erosion resistance, superior fatigue resistance and relatively low modulus of elasticity. Although composite/metal hybrid structures are increasingly used in airframes nowadays, number of studies regarding drilling of composite/metal stacks is very limited. During drilling of multilayer materials different problems may arise due to very different attributes of these materials. Machining conditions of drilling such structures play an important role on tool wear, quality of holes and cost of machining.. The research work in this thesis is aimed to investigate drilling of CFRP/Ti6Al4V hybrid structure and to optimize process parameters and drill geometry. The research work consist complete experimental study including drilling tests, in-situ and post measurements and related analysis; and finite element analysis including fully 3-D finite element models. The experimental investigations focused on drilling outputs such as thrust force, torque, delamination, burr formation, surface roughness and tool wear. An algorithm was developed to analyse drilling induced delamination quantitatively based on the images. In the numerical analysis, novel 3-D finite element models of drilling of CFRP, Ti6Al4V and CFRP/Ti6Al4V hybrid structure were developed with the use of 3-D complex drill geometries. A user defined subroutine was developed to model material and failure behaviour of CFRP. The effects of process parameters on drilling outputs have been investigated and compared with the experimental results. The influences of drill bit geometries have been simulated in this study..

Utilization of fly ash as partial sand replacement in oil palm shell lightweight aggregate concrete

NASA Astrophysics Data System (ADS)

Nazrin Akmal, A. Z. Muhammad; Muthusamy, K.; Mat Yahaya, F.; Hanafi, H. Mohd; Nur Azzimah, Z.

2017-11-01

Realization on the increasing demand for river sand supply in construction sector has inspired the current research to find alternative material to reduce the use of natural sand in oil palm shell lightweight aggregate concrete (OPS LWAC) production. The existence of fly ash, a by-product generated from coal power plant, which pose negative impact to the environment when it is disposed as waste, were used in this research. The effect of fly ash content as partial sand replacement towards workability and compressive strength of OPS lightweight aggregate concrete were investigated. Four concrete mixes containing various percentage of fly ash that are 0%, 10%, 20% and 30% by weight of sand were used in the experimental work. All mixes were cast in form of cubes before subjected to water curing until the testing age. Compressive strength test were conducted at 1, 3, 7 and 28 days. The finding shows that the workability of the OPS LWAC decreases when more fly ash are used as sand replacement. It was found that adding of 10% fly ash as sand replacement content resulted in better compressive strength of OPS LWAC, which is higher than the control mix.

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

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.

Hypervelocity Impact Experiments on Epoxy/Ultra-High Molecular Weight Polyethylene Composite Panels Reinforced with Nanotubes

NASA Technical Reports Server (NTRS)

Khatiwada, Suman; Laughman, Jay W.; Armada, Carlos A.; Christiansen, Eric L.; Barrera, Enrique V.

2012-01-01

Advanced composites with multi-functional capabilities are of great interest to the designers of aerospace structures. Polymer matrix composites (PMCs) reinforced with high strength fibers provide a lightweight and high strength alternative to metals and metal alloys conventionally used in aerospace architectures. Novel reinforcements such as nanofillers offer potential to improve the mechanical properties and add multi-functionality such as radiation resistance and sensing capabilities to the PMCs. This paper reports the hypervelocity impact (HVI) test results on ultra-high molecular weight polyethylene (UHMWPE) fiber composites reinforced with single-walled carbon nanotubes (SWCNT) and boron nitride nanotubes (BNNT). Woven UHMWPE fabrics, in addition to providing excellent impact properties and high strength, also offer radiation resistance due to inherent high hydrogen content. SWCNT have exceptional mechanical and electrical properties. BNNT (figure 1) have high neutron cross section and good mechanical properties that add multi-functionality to this system. In this project, epoxy based UHMWPE composites containing SWCNT and BNNT are assessed for their use as bumper shields and as intermediate plates in a Whipple Shield for HVI resistance. Three composite systems are prepared to compare against one another: (I) Epoxy/UHMWPE, (II) Epoxy/UHMWPE/SWCNT and (III) Epoxy/UHMWPE/SWCNT/BNNT. Each composite is a 10.0 by 10.0 by 0.11 cm3 panel, consisting of 4 layers of fabrics arranged in cross-ply orientation. Both SWCNT and BNNT are 0.5 weight % of the fabric preform. Hypervelocity impact tests are performed using a two-stage light gas gun at Rice University

Wind turbine with automatic pitch and yaw control

DOEpatents

Cheney, Jr., Marvin Chapin; Spierings, Petrus A. M.

1978-01-01

A wind turbine having a flexible central beam member supporting aerodynamic blades at opposite ends thereof and fabricated of uni-directional high tensile strength material bonded together into beam form so that the beam is lightweight, and has high tensile strength to carry the blade centrifugal loads, low shear modulus to permit torsional twisting thereof for turbine speed control purposes, and adequate bending stiffness to permit out-of-plane deflection thereof for turbine yard control purposes. A selectively off-set weighted pendulum member is pivotally connected to the turbine and connected to the beam or blade so as to cause torsional twisting thereof in response to centrifugal loading of the pendulum member for turbine speed control purposes.

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.

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.

Laser-welded Dissimilar Steel-aluminum Seams for Automotive Lightweight Construction

NASA Astrophysics Data System (ADS)

Schimek, M.; Springer, A.; Kaierle, S.; Kracht, D.; Wesling, V.

By reducing vehicle weight, a significant increase in fuel efficiency and consequently a reduction in CO 2 emissions can be achieved. Currently a high interest in the production of hybrid weld seams between steel and aluminum exists. Previous methods as laser brazing are possible only by using fluxes and additional materials. Laser welding can be used to join steel and aluminum without the use of additives. With a low penetration depth increases in tensile strength can be achieved. Recent results from laser welded overlap seams show that there is no compromise in strength by decreasing penetration depth in the aluminum.

An investigation on the use of shredded waste PET bottles as aggregate in lightweight concrete.

PubMed

Akçaözoğlu, Semiha; Atiş, Cengiz Duran; Akçaözoğlu, Kubilay

2010-02-01

In this work, the utilization of shredded waste Poly-ethylene Terephthalate (PET) bottle granules as a lightweight aggregate in mortar was investigated. Investigation was carried out on two groups of mortar samples, one made with only PET aggregates and, second made with PET and sand aggregates together. Additionally, blast-furnace slag was also used as the replacement of cement on mass basis at the replacement ratio of 50% to reduce the amount of cement used and provide savings. The water-binder (w/b) ratio and PET-binder (PET/b) ratio used in the mixtures were 0.45 and 0.50, respectively. The size of shredded PET granules used in the preparation of mortar mixtures were between 0 and 4 mm. The results of the laboratory study and testing carried out showed that mortar containing only PET aggregate, mortar containing PET and sand aggregate, and mortars modified with slag as cement replacement can be drop into structural lightweight concrete category in terms of unit weight and strength properties. Therefore, it was concluded that there is a potential for the use of shredded waste PET granules as aggregate in the production of structural lightweight concrete. The use of shredded waste PET granules due to its low unit weight reduces the unit weight of concrete which results in a reduction in the death weight of a structural concrete member of a building. Reduction in the death weight of a building will help to reduce the seismic risk of the building since the earthquake forces linearly dependent on the dead-weight. Furthermore, it was also concluded that the use of industrial wastes such as PET granules and blast-furnace slag in concrete provides some advantages, i.e., reduction in the use of natural resources, disposal of wastes, prevention of environmental pollution, and energy saving.

An investigation on the use of shredded waste PET bottles as aggregate in lightweight concrete

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

Akcaoezoglu, Semiha, E-mail: sakcaozoglu@nigde.edu.t; Atis, Cengiz Duran; Akcaoezoglu, Kubilay

2010-02-15

In this work, the utilization of shredded waste Poly-ethylene Terephthalate (PET) bottle granules as a lightweight aggregate in mortar was investigated. Investigation was carried out on two groups of mortar samples, one made with only PET aggregates and, second made with PET and sand aggregates together. Additionally, blast-furnace slag was also used as the replacement of cement on mass basis at the replacement ratio of 50% to reduce the amount of cement used and provide savings. The water-binder (w/b) ratio and PET-binder (PET/b) ratio used in the mixtures were 0.45 and 0.50, respectively. The size of shredded PET granules usedmore » in the preparation of mortar mixtures were between 0 and 4 mm. The results of the laboratory study and testing carried out showed that mortar containing only PET aggregate, mortar containing PET and sand aggregate, and mortars modified with slag as cement replacement can be drop into structural lightweight concrete category in terms of unit weight and strength properties. Therefore, it was concluded that there is a potential for the use of shredded waste PET granules as aggregate in the production of structural lightweight concrete. The use of shredded waste PET granules due to its low unit weight reduces the unit weight of concrete which results in a reduction in the death weight of a structural concrete member of a building. Reduction in the death weight of a building will help to reduce the seismic risk of the building since the earthquake forces linearly dependant on the dead-weight. Furthermore, it was also concluded that the use of industrial wastes such as PET granules and blast-furnace slag in concrete provides some advantages, i.e., reduction in the use of natural resources, disposal of wastes, prevention of environmental pollution, and energy saving.« less

Damage Mechanisms and Mechanical Properties of High-Strength Multiphase Steels

PubMed Central

Heibel, Sebastian; Dettinger, Thomas; Nester, Winfried; Tekkaya, A. Erman

2018-01-01

The usage of high-strength steels for structural components and reinforcement parts is inevitable for modern car-body manufacture in reaching lightweight design as well as increasing passive safety. Depending on their microstructure these steels show differing damage mechanisms and various mechanical properties which cannot be classified comprehensively via classical uniaxial tensile testing. In this research, damage initiation, evolution and final material failure are characterized for commercially produced complex-phase (CP) and dual-phase (DP) steels in a strength range between 600 and 1000 MPa. Based on these investigations CP steels with their homogeneous microstructure are characterized as damage tolerant and hence less edge-crack sensitive than DP steels. As final fracture occurs after a combination of ductile damage evolution and local shear band localization in ferrite grains at a characteristic thickness strain, this strain measure is introduced as a new parameter for local formability. In terms of global formability DP steels display advantages because of their microstructural composition of soft ferrite matrix including hard martensite particles. Combining true uniform elongation as a measure for global formability with the true thickness strain at fracture for local formability the mechanical material response can be assessed on basis of uniaxial tensile testing incorporating all microstructural characteristics on a macroscopic scale. Based on these findings a new classification scheme for the recently developed high-strength multiphase steels with significantly better formability resulting of complex underlying microstructures is introduced. The scheme overcomes the steel designations using microstructural concepts, which provide no information about design and production properties. PMID:29747417

Development of lightweight fire retardant, low-smoke, high-strength, thermally stable aircraft floor paneling

NASA Technical Reports Server (NTRS)

Arnold, D. B.; Burnside, J. V.; Hajari, J. V.

1976-01-01

Fire resistance mechanical property tests were conducted on sandwich configurations composed of resin-fiberglass laminates bonded with adhesives to Nomex honeycomb core. The test results were compared to proposed and current requirements for aircraft floor panel applications to demonstrate that the fire safety of the airplane could be improved without sacrificing mechanical performance of the aircraft floor panels.

The Development of Lightweight Commercial Vehicle Wheels Using Microalloying Steel

NASA Astrophysics Data System (ADS)

Lu, Hongzhou; Zhang, Lilong; Wang, Jiegong; Xuan, Zhaozhi; Liu, Xiandong; Guo, Aimin; Wang, Wenjun; Lu, Guimin

Lightweight wheels can reduce weight about 100kg for commercial vehicles, and it can save energy and reduce emission, what's more, it can enhance the profits for logistics companies. The development of lightweight commercial vehicle wheels is achieved by the development of new steel for rim, the process optimization of flash butt welding, and structure optimization by finite element methods. Niobium micro-alloying technology can improve hole expansion rate, weldability and fatigue performance of wheel steel, and based on Niobium micro-alloying technology, a special wheel steel has been studied whose microstructure are Ferrite and Bainite, with high formability and high fatigue performance, and stable mechanical properties. The content of Nb in this new steel is 0.025% and the hole expansion rate is ≥ 100%. At the same time, welding parameters including electric upsetting time, upset allowance, upsetting pressure and flash allowance are optimized, and by CAE analysis, an optimized structure has been attained. As a results, the weight of 22.5in×8.25in wheel is up to 31.5kg, which is most lightweight comparing the same size wheels. And its functions including bending fatigue performance and radial fatigue performance meet the application requirements of truck makers and logistics companies.

X-Ray Optics at NASA Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

O'Dell, Stephen L.; Atkins, Carolyn; Broadway, David M.; Elsner, Ronald F.; Gaskin, Jessica A.; Gubarev, Mikhail V.; Kilaru, Kiranmayee; Kolodziejczak, Jeffery J.; Ramsey, Brian D.; Roche, Jacqueline M.;

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.

A high-specific-strength and corrosion-resistant magnesium alloy

NASA Astrophysics Data System (ADS)

Xu, Wanqiang; Birbilis, Nick; Sha, Gang; Wang, Yu; Daniels, John E.; Xiao, Yang; Ferry, Michael

2015-12-01

Ultra-lightweight alloys with high strength, ductility and corrosion resistance are desirable for applications in the automotive, aerospace, defence, biomedical, sporting and electronic goods sectors. Ductility and corrosion resistance are generally inversely correlated with strength, making it difficult to optimize all three simultaneously. Here we design an ultralow density (1.4 g cm-3) Mg-Li-based alloy that is strong, ductile, and more corrosion resistant than Mg-based alloys reported so far. The alloy is Li-rich and a solute nanostructure within a body-centred cubic matrix is achieved by a series of extrusion, heat-treatment and rolling processes. Corrosion resistance from the environment is believed to occur by a uniform lithium carbonate film in which surface coverage is much greater than in traditional hexagonal close-packed Mg-based alloys, explaining the superior corrosion resistance of the alloy.

A high-specific-strength and corrosion-resistant magnesium alloy.

PubMed

Xu, Wanqiang; Birbilis, Nick; Sha, Gang; Wang, Yu; Daniels, John E; Xiao, Yang; Ferry, Michael

2015-12-01

Ultra-lightweight alloys with high strength, ductility and corrosion resistance are desirable for applications in the automotive, aerospace, defence, biomedical, sporting and electronic goods sectors. Ductility and corrosion resistance are generally inversely correlated with strength, making it difficult to optimize all three simultaneously. Here we design an ultralow density (1.4 g cm(-3)) Mg-Li-based alloy that is strong, ductile, and more corrosion resistant than Mg-based alloys reported so far. The alloy is Li-rich and a solute nanostructure within a body-centred cubic matrix is achieved by a series of extrusion, heat-treatment and rolling processes. Corrosion resistance from the environment is believed to occur by a uniform lithium carbonate film in which surface coverage is much greater than in traditional hexagonal close-packed Mg-based alloys, explaining the superior corrosion resistance of the alloy.

Low-Cost, High-Performance Combustion Chamber

NASA Technical Reports Server (NTRS)

Fortini, Arthur J.

2015-01-01

Ultramet designed and fabricated a lightweight, high-temperature combustion chamber for use with cryogenic LOX/CH4 propellants that can deliver a specific impulse of approx.355 seconds. This increase over the current 320-second baseline of nitrogen tetroxide/monomethylhydrazine (NTO/MMH) will result in a propellant mass decrease of 55 lb for a typical lunar mission. The material system was based on Ultramet's proven oxide-iridium/rhenium architecture, which has been hot-fire tested with stoichiometric oxygen/hydrogen for hours. Instead of rhenium, however, the structural material was a niobium or tantalum alloy that has excellent yield strength at both ambient and elevated temperatures. Phase I demonstrated alloys with yield strength-to-weight ratios more than three times that of rhenium, which will significantly reduce chamber weight. The starting materials were also two orders of magnitude less expensive than rhenium and were less expensive than the C103 niobium alloy commonly used in low-performance engines. Phase II focused on the design, fabrication, and hot-fire testing of a 12-lbf thrust class chamber with LOX/CH4, and a 100-lbf chamber for LOX/CH4. A 5-lbf chamber for NTO/MMH also was designed and fabricated.

The mechanics and design of a lightweight three-dimensional graphene assembly

PubMed Central

Qin, Zhao; Jung, Gang Seob; Kang, Min Jeong; Buehler, Markus J.

2017-01-01

Recent advances in three-dimensional (3D) graphene assembly have shown how we can make solid porous materials that are lighter than air. It is plausible that these solid materials can be mechanically strong enough for applications under extreme conditions, such as being a substitute for helium in filling up an unpowered flight balloon. However, knowledge of the elastic modulus and strength of the porous graphene assembly as functions of its structure has not been available, preventing evaluation of its feasibility. We combine bottom-up computational modeling with experiments based on 3D-printed models to investigate the mechanics of porous 3D graphene materials, resulting in new designs of carbon materials. Our study reveals that although the 3D graphene assembly has an exceptionally high strength at relatively high density (given the fact that it has a density of 4.6% that of mild steel and is 10 times as strong as mild steel), its mechanical properties decrease with density much faster than those of polymer foams. Our results provide critical densities below which the 3D graphene assembly starts to lose its mechanical advantage over most polymeric cellular materials. PMID:28070559

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.

Effect of basaltic pumice aggregate addition on the material properties of fly ash based lightweight geopolymer concrete

NASA Astrophysics Data System (ADS)

Top, Soner; Vapur, Hüseyin

2018-07-01

In this study, fly ash (FA) based geopolymer (GP) concretes were produced by using a mixture of basaltic pumice (BP) aggregates and a fly ash (Class F) for lightweight concrete production. ANOVA Yates' test technique was applied to find out the effective curing parameters. BP aggregates were ground four different fractions of particle sizes as -12 + 4 mm, -4+0.425 mm, -0.425 + 0 mm and the one containing the size distribution of Turkish Standard 802. Also, effects of the curing time in the oven were investigated. The uniaxial compressive strength (UCS) (20-55 MPa), the point load strength (4-14 kN), the water absorption (1.05%-17%), the Mohs hardness (5.5-3) and the sonic speed values (4.12-2.72 km/sn) were measured. Stress-strain curves were graphed. The density of the concrete ranged from 1700 kg/m3 to 1792 kg/m3 which confirm the lightweight concretes.

Development of Structural Energy Storage for Aeronautics Applications

NASA Technical Reports Server (NTRS)

Santiago-Dejesus, Diana; Loyselle, Patricia L.; Demattia, Brianne; Bednarcyk, Brett; Olson, Erik; Smith, Russell; Hare, David

2017-01-01

The National Aeronautics and Space Administration (NASA) has identified Multifunctional Structures for High Efficiency Lightweight Load-bearing Storage (M-SHELLS) as critical to development of hybrid gas-electric propulsion for commercial aeronautical transport in the N+3 timeframe. The established goals include reducing emissions by 80 and fuel consumption by 60 from todays state of the art. The advancement will enable technology for NASA Aeronautics Research Mission Directorates (ARMD) Strategic Thrust 3 to pioneer big leaps in efficiency and environmental performance for ultra-efficient commercial transports, as well as Strategic Thrust 4 to pioneer low-carbon propulsion technology in the transition to that scheme. The M-SHELLS concept addresses the hybrid gas-electric highest risk with its primary objective: to save structures energy storage system weight for future commercial hybrid electric propulsion aircraft by melding the load-carrying structure with energy storage in a single material. NASA's multifunctional approach also combines supercapacitor and battery chemistries in a synergistic energy storage arrangement in tandem with supporting good mechanical properties. The arrangement provides an advantageous combination of specific power, energy, and strength.

Braided Composite Technologies for Rotorcraft Structures

NASA Technical Reports Server (NTRS)

Jessie, Nathan

2015-01-01

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, +/-60deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Braided Composite Technologies for Rotorcraft Structures

NASA Technical Reports Server (NTRS)

Jessie, Nathan

2014-01-01

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, plus or minus 60 deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Improved design of support for large aperture space lightweight mirror

NASA Astrophysics Data System (ADS)

Wang, Chao; Ruan, Ping; Liu, Qimin

2013-08-01

In order to design a kind of rational large aperture space mirror which can adapt to the space gravity and thermal environment, by taking the choice of material, the lightweight of the mirror and the design of support into account in detail, a double-deck structure with traditional flexible hinge was designed, then the analytical mathematical model of the mirror system was established. The design adopts six supports on back. in order to avoid the constraints, mirror is connected to three middle transition pieces through six flexible hinges, and then the three transition pieces are connected to support plate through another three flexible hinges. However, the initial structure is unable to reach the expected design target and needs to be made further adjustments. By improving and optimizing the original structure, a new type of flexible hinge in the shape of the letter A is designed finally. Compared with the traditional flexible hinge structure, the new structure is simpler and has less influence on the surface figure accuracy of mirror. By using the finite element analysis method, the static and dynamic characteristics as well as the thermal characteristics of the mirror system are analyzed. Analysis results show that the maximum PV value is 37 nm and the maximum RMS value is 10.4 nm when gravity load is applied. Furthermore, the maximum PV value is 46 nm and the maximum RMS value is 10.5 nm under the load case of gravity coupled with 4℃ uniform temperature rise. The results satisfy the index of optical design. The first order natural frequency of the mirror component is 130 Hz according to the conclusion obtained by modal analytical solution, so the mirror structure has high enough fundamental frequency. And, the structural strength can meet the demand under the overload and the random vibration environment respectively. It indicates that the mirror component structure has enough dynamic, static stiffness and thermal stability, meeting the design requirements.

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

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.

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.

Recent advances in lightweight, filament-wound composite pressure vessel technology

NASA Technical Reports Server (NTRS)

Lark, R. F.

1977-01-01

A review of recent advances is presented for lightweight, high performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single cycle burst and cyclic fatigue loading. Filament wound fiber/epoxy composite vessels were made from S glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessels structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all titanium pressure vessels. Significant findings in each area are summarized.

Utilization of sewage sludge in the manufacture of lightweight aggregate.

PubMed

Franus, Małgorzata; Barnat-Hunek, Danuta; Wdowin, Magdalena

2016-01-01

This paper presents a comprehensive study on the possibility of sewage sludge management in a sintered ceramic material such as a lightweight aggregate. Made from clay and sludge lightweight aggregates were sintered at two temperatures: 1100 °C (name of sample LWA1) and 1150 °C (name of sample LWA2). Physical and mechanical properties indicate that the resulting expanded clay aggregate containing sludge meets the basic requirements for lightweight aggregates. The presence of sludge supports the swelling of the raw material, thereby causing an increase in the porosity of aggregates. The LWA2 has a lower value of bulk particle density (0.414 g/cm(3)), apparent particle density (0.87 g/cm(3)), and dry particle density (2.59 g/cm(3)) than it is in the case of LWA1 where these parameters were as follows: bulk particle density 0.685 g/cm(3), apparent particle density 1.05 g/cm(3), and dry particle density 2.69 g/cm(3). Water absorption and porosity of LWA1 (WA = 14.4 %, P = 60 %) are lower than the LWA2 (WA = 16.2 % and P = 66 %). This is due to the higher heating temperature of granules which make the waste gases, liberating them from the decomposition of organic sewage sludge. The compressive strength of LWA2 aggregate is 4.64 MPa and for LWA1 is 0.79 MPa. Results of leaching tests of heavy metals from examined aggregates have shown that insoluble metal compounds are placed in silicate and aluminosilicate structure of the starting materials (clays and sludges), whereas soluble substances formed crystalline skeleton of the aggregates. The thermal synthesis of lightweight aggregates from clay and sludge mixture is a waste-free method of their development.

Cellular Magnesium Matrix Foam Composites for Mechanical Damping Applications

NASA Astrophysics Data System (ADS)

Shunmugasamy, Vasanth Chakravarthy; Mansoor, Bilal; Gupta, Nikhil

2016-01-01

The damping characteristics of metal alloys and metal matrix composites are relevant to the automotive, aerospace, and marine structures. Use of lightweight materials can help in increasing payload capacity and in decreasing fuel consumption. Lightweight composite materials possessing high damping capabilities that can be designed as structural members can greatly benefit in addressing these needs. In this context, the damping properties of lightweight metals such as aluminum and magnesium and their respective composites have been studied in the existing literature. This review focuses on analyzing the damping properties of aluminum and magnesium alloys and their cellular composites. The damping properties of various lightweight alloys and composites are compared on the basis of their density to understand the potential for weight saving in structural applications. Magnesium alloys are observed to possess better damping properties in comparison to aluminum. However, aluminum matrix syntactic foams reinforced with silicon carbide hollow particles possess a damping capacity and density comparable to magnesium alloy. By using the data presented in the study, composites with specific compositions and properties can be selected for a given application. In addition, the comparison of the results helps in identifying the areas where attention needs to be focused to address the future needs.

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.

Process Optimization of Dual-Laser Beam Welding of Advanced Al-Li Alloys Through Hot Cracking Susceptibility Modeling

NASA Astrophysics Data System (ADS)

Tian, Yingtao; Robson, Joseph D.; Riekehr, Stefan; Kashaev, Nikolai; Wang, Li; Lowe, Tristan; Karanika, Alexandra

2016-07-01

Laser welding of advanced Al-Li alloys has been developed to meet the increasing demand for light-weight and high-strength aerospace structures. However, welding of high-strength Al-Li alloys can be problematic due to the tendency for hot cracking. Finding suitable welding parameters and filler material for this combination currently requires extensive and costly trial and error experimentation. The present work describes a novel coupled model to predict hot crack susceptibility (HCS) in Al-Li welds. Such a model can be used to shortcut the weld development process. The coupled model combines finite element process simulation with a two-level HCS model. The finite element process model predicts thermal field data for the subsequent HCS hot cracking prediction. The model can be used to predict the influences of filler wire composition and welding parameters on HCS. The modeling results have been validated by comparing predictions with results from fully instrumented laser welds performed under a range of process parameters and analyzed using high-resolution X-ray tomography to identify weld defects. It is shown that the model is capable of accurately predicting the thermal field around the weld and the trend of HCS as a function of process parameters.

Development of a double beam process for joining aluminum and steel

NASA Astrophysics Data System (ADS)

Frank, Sascha

2014-02-01

Multi-material structures pose an attractive option for overcoming some of the central challenges in lightweight design. An exceptionally high potential for creating cost-effective lightweight solutions is attributed to the combination of steel and aluminum. However, these materials are also particularly difficult to join due to their tendency to form intermetallic compounds (IMCs). The growth of these compounds is facilitated by high temperatures and long process times. Due to their high brittleness, IMCs can severely weaken a joint. Thus, it is only possible to create durable steel-aluminum joints when the formation of IMCs can be limited to a non-critical level. To meet this goal, a new joining method has been designed. The method is based on the combination of a continuous wave (pw) and a pulsed laser (pw) source. Laser beams from both sources are superimposed in a common process zone. This makes it possible to apply the advantages of laser brazing to mixed-metal joints without requiring the use of chemical fluxes. The double beam technology was first tested in bead-on-plate experiments using different filler wire materials. Based on the results of these tests, a process for joining steel and aluminum in a double-flanged configuration is now being developed. The double flanged seams are joined using zinc- or aluminum-based filler wires. Microsections of selected seams show that it is possible to achieve good base material wetting while limiting the growth of IMCs to acceptable measures. In addition, the results of tensile tests show that high joint strengths can be achieved.

Export Controls and the U.S. Defense Industrial Base. Volume 1. Summary Report, and Volume 2. Appendices

DTIC Science & Technology

2007-01-01

producers still have a reservoir of intellectual property , product capabilities and process know-how built over several decades. These historical...remarkable properties superior to conventional materials (ultra lightweight, high strength and stiffness). Characteristics of these materials important to...with enforcement of trade agreements and intellectual property (IP) rights. Accordingly, the report recommends more federal support for S&T and

Export Control and the U.S. Defense Industrial Base - Revised. Volume 1: Summary Report and Volume 2: Appendices

DTIC Science & Technology

2008-10-01

advanced materials, US producers still have a reservoir of intellectual property , product capabilities and process know-how built over several...while providing remarkable properties superior to conventional materials (ultra lightweight, high strength and stiffness). Characteristics of these...investor and tax environment; and • A level playing field, with enforcement of trade agreements and intellectual property (IP) rights. Accordingly, the

The future challenge for aeropropulsion

NASA Technical Reports Server (NTRS)

Rosen, Robert; Bowditch, David N.

1992-01-01

NASA's research in aeropropulsion is focused on improving the efficiency, capability, and environmental compatibility for all classes of future aircraft. The development of innovative concepts, and theoretical, experimental, and computational tools provide the knowledge base for continued propulsion system advances. Key enabling technologies include advances in internal fluid mechanics, structures, light-weight high-strength composite materials, and advanced sensors and controls. Recent emphasis has been on the development of advanced computational tools in internal fluid mechanics, structural mechanics, reacting flows, and computational chemistry. For subsonic transport applications, very high bypass ratio turbofans with increased engine pressure ratio are being investigated to increase fuel efficiency and reduce airport noise levels. In a joint supersonic cruise propulsion program with industry, the critical environmental concerns of emissions and community noise are being addressed. NASA is also providing key technologies for the National Aerospaceplane, and is studying propulsion systems that provide the capability for aircraft to accelerate to and cruise in the Mach 4-6 speed range. The combination of fundamental, component, and focused technology development underway at NASA will make possible dramatic advances in aeropropulsion efficiency and environmental compatibility for future aeronautical vehicles.

Influence of aggregate type and chemical admixtures on frost resistance of lightweight mortars

NASA Astrophysics Data System (ADS)

Klimek, Beata; Widomski, Marcin K.; Barnat-Hunek, Danuta

2017-07-01

The aim of studies presented in this paper covered analyses of type of lightweight aggregate as well as aeration and hydrophobic admixtures influence on absorbability and frost resistance of heat-insulating mortars applied in the energy-efficient construction. In the presented research, expanded perlite (EP) and expanded clay aggregate (ceramsite) were used as lightweight aggregates. The measurements of the basic mechanical and physical characteristics of tested mortars were performed, including, inter alia, compressive and flexural tensile strength, density, effective (open) and total porosity, absorbability, thermal conductivity as well as frost resistance after 25 cycles of freezing and thawing. Substitution of some part of sand fraction by the lightweight aggregates, expanded clay aggregate or perlite, resulted in changes in physical properties of the tested mortars. The observed decrease in density (specific weight), coefficient of heat transport and strength parameters were simultaneously accompanied by the increase in absorbability. Researches concerning frost resistance of mortars containing ceramsite and perlite showed the improved frost resistance of mortar utilizing perlite. Most of the tested mortars shoved satisfactory frost resistance, only samples of mortar containing ceramsite and aeration admixture were destroyed. The significant influence of aerating admixture on frost resistance of mortars was determined. Hydrophobic siloxanes addition failed to adequately protect the mortars against frost erosion, regardless the type of applied aggregate.

Computer aided flexible envelope designs

NASA Technical Reports Server (NTRS)

Resch, R. D.

1975-01-01

Computer aided design methods are presented for the design and construction of strong, lightweight structures which require complex and precise geometric definition. The first, flexible structures, is a unique system of modeling folded plate structures and space frames. It is possible to continuously vary the geometry of a space frame to produce large, clear spans with curvature. The second method deals with developable surfaces, where both folding and bending are explored with the observed constraint of available building materials, and what minimal distortion result in maximum design capability. Alternative inexpensive fabrication techniques are being developed to achieve computer defined enclosures which are extremely lightweight and mathematically highly precise.

Mechanical Behavior of Three-Dimensional Braided Nickel-Based Superalloys Synthesized via Pack Cementation

NASA Astrophysics Data System (ADS)

Lippitz, Nicolas; Erdeniz, Dinc; Sharp, Keith W.; Dunand, David C.

2018-03-01

Braided tubes of Ni-based superalloys are fabricated via three-dimensional (3-D) braiding of ductile Ni-20Cr (wt pct) wires followed by post-textile gas-phase alloying with Al and Ti to create, after homogenization and aging, γ/ γ' strengthened lightweight, porous structures. Tensile tests reveal an increase in strength by 100 MPa compared to as-braided Ni-20Cr (wt pct). An interrupted tensile test, combined with X-ray tomographic scans between each step, sheds light on the failure behavior of the braided superalloy tubes.

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.

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.

Nanocrystalline zirconia can be amorphized by ion irradiation.

PubMed

Meldrum, A; Boatner, L A; Ewing, R C

2002-01-14

Nanocrystalline composites are finding applications in high-radiation environments due to their excellent mechanical and electronic properties. We show, however, that at the smallest particle sizes, radiation damage effects can be so strongly enhanced that under the right conditions, materials that have never been made amorphous can become highly susceptible to irradiation-induced amorphization. Because light-weight, high-strength nanocomposites are potential materials for spacecraft shielding and sensor systems, these fundamental results have significant implications for the design and selection of materials to be used in environments where a large ion flux will be encountered.

A novel method based on selective laser sintering for preparing high-performance carbon fibres/polyamide12/epoxy ternary composites

NASA Astrophysics Data System (ADS)

Zhu, Wei; Yan, Chunze; Shi, Yunsong; Wen, Shifeng; Liu, Jie; Wei, Qingsong; Shi, Yusheng

2016-09-01

A novel method based on selective laser sintering (SLS) process is proposed for the first time to prepare complex and high-performance carbon fibres/polyamide12/epoxy (CF/PA12/EP) ternary composites. The procedures are briefly described as follows: prepare polyamide12 (PA12) coated carbon fibre (CF) composite powder; build porous green parts by SLS; infiltrate the green parts with high-performance thermosetting epoxy (EP) resin; and finally cure the resin at high temperature. The obtained composites are a ternary composite system consisting of the matrix of novolac EP resin, the reinforcement of CFs and the transition thin layer of PA12 with a thickness of 595 nm. The SEM images and micro-CT analysis prove that the ternary system is a three-dimensional co-continuous structure and the reinforcement of CFs are well dispersed in the matrix of EP with the volume fraction of 31%. Mechanical tests show that the composites fabricated by this method yield an ultimate tensile strength of 101.03 MPa and a flexural strength of 153.43 MPa, which are higher than those of most of the previously reported SLS materials. Therefore, the process proposed in this paper shows great potential for manufacturing complex, lightweight and high-performance CF reinforced composite components in aerospace, automotive industries and other areas.

A novel method based on selective laser sintering for preparing high-performance carbon fibres/polyamide12/epoxy ternary composites

PubMed Central

Zhu, Wei; Yan, Chunze; Shi, Yunsong; Wen, Shifeng; Liu, Jie; Wei, Qingsong; Shi, Yusheng

2016-01-01

A novel method based on selective laser sintering (SLS) process is proposed for the first time to prepare complex and high-performance carbon fibres/polyamide12/epoxy (CF/PA12/EP) ternary composites. The procedures are briefly described as follows: prepare polyamide12 (PA12) coated carbon fibre (CF) composite powder; build porous green parts by SLS; infiltrate the green parts with high-performance thermosetting epoxy (EP) resin; and finally cure the resin at high temperature. The obtained composites are a ternary composite system consisting of the matrix of novolac EP resin, the reinforcement of CFs and the transition thin layer of PA12 with a thickness of 595 nm. The SEM images and micro-CT analysis prove that the ternary system is a three-dimensional co-continuous structure and the reinforcement of CFs are well dispersed in the matrix of EP with the volume fraction of 31%. Mechanical tests show that the composites fabricated by this method yield an ultimate tensile strength of 101.03 MPa and a flexural strength of 153.43 MPa, which are higher than those of most of the previously reported SLS materials. Therefore, the process proposed in this paper shows great potential for manufacturing complex, lightweight and high-performance CF reinforced composite components in aerospace, automotive industries and other areas. PMID:27650254

Analysis of Stainless Steel Sandwich Panels with a Metal Foam Care for Lightweight Fan Blade Design

NASA Technical Reports Server (NTRS)

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

2004-01-01

The quest for cheap, low density and high performance materials in the design of aircraft and rotorcraft engine fan and propeller blades poses immense challenges to the materials and structural design engineers. Traditionally, these components have been fabricated using expensive materials such as light weight titanium alloys, polymeric composite materials and carbon-carbon composites. The present study investigates the use of P sandwich foam fan blade made up of solid face sheets and a metal foam core. The face sheets and the metal foam core material were an aerospace grade precipitation hardened 17-4 PH stainless steel with high strength and high toughness. The stiffness of the sandwich structure is increased by separating the two face sheets by a foam core. The resulting structure possesses a high stiffness while being lighter than a similar solid construction. Since the face sheets carry the applied bending loads, the sandwich architecture is a viable engineering concept. The material properties of 17-4 PH metal foam are reviewed briefly to describe the characteristics of the sandwich structure for a fan blade application. A vibration analysis for natural frequencies and P detailed stress analysis on the 17-4 PH sandwich foam blade design for different combinations of skin thickness and core volume %re presented with a comparison to a solid titanium blade.

Improving Thermal Insulation Properties for Prefabricated Wall Components Made Of Lightweight Aggregate Concrete with Open Structure

NASA Astrophysics Data System (ADS)

Abramski, Marcin

2017-10-01

Porous concrete is commonly used in civil engineering due to its good thermal insulation properties in comparison with normal concrete and high compression strength in comparison with other building materials. Reducing of the concrete density can be obviously obtained by using lightweight aggregate (e.g. pumice). The concrete density can be further minimized by using specially graded coarse aggregate and little-to-no fine aggregates. In this way a large number of air voids arise. The aggregate particles are coated by a cement paste and bonded together with it just in contact points. Such an extremely porous concrete, called ‘lightweight aggregate concrete with open structure’ (LAC), is used in some German plants to produce prefabricated wall components. They are used mainly in hall buildings, e.g. supermarkets. The need of improving thermal insulation properties was an inspiration for the prefabrication plant managers, engineers and a scientific staff of the Technical University of Kaiserslautern / Germany to realise an interesting project. Its aim was to reduce the heat transfer coefficient for the wall components. Three different wall structure types were designed and compared in full-scale laboratory tests with originally produced wall components in terms of load-carrying capacity and stiffness. The load was applied perpendicularly to the wall plane. As the components are not originally used for load-bearing walls, but for curtain walls only, the wind load is the main load for them. The wall components were tested in horizontal position and the load was applied vertically. Totally twelve wall components 8.00 × 2.00 × 0.25m (three for every series) were produced in the prefabrication plant and tested in the University of Kaiserslautern laboratory. The designed and tested components differed from each other in the amount of expanded polystyrene (EPS), which was placed in the plant inside the wall structure. The minimal amount of it was designed in the original wall component type. Besides, two improved types of prefabricated wall had built-in steel lattice girders. The failure mode was the same for all the tested components: diagonal cracks occurred on the sides of each component due to their insufficient shear-force-capacity. The span deflection was measured during all the tests by means of LVDTs. Load-carrying capacities obtained in the tests were for all wall structure types similar and much higher (many times) than internal forces (i.e. bending moments and shear forces) calculated for a wind load acting on a typical hall building according to the German codes. An increased amount of EPS (up to 30 per cent in volume) did not influence significantly the wall structural strength. The use of the steel lattice girders caused some technological problems and led to a quality loss of the produced components. The future use of the lattice girders would require a change in the production process: it would have to be more labour consuming.

A study on the strength of an armour-grade aluminum under high strain-rate loading

NASA Astrophysics Data System (ADS)

Appleby-Thomas, G. J.; Hazell, P. J.

2010-06-01

The aluminum alloy 5083 in tempers such as H32 and H131 is an established light-weight armour material. While its dynamic response under high strain-rates has been investigated elsewhere, little account of the effect of material orientation has been made. In addition, little information on its strength under such loadings is available in the literature. Here, both the longitudinal and lateral components of stress have been measured using embedded manganin stress gauges during plate-impact experiments on samples with the rolling direction aligned both orthogonal and parallel to the impact axis. The Hugoniot elastic limit, spall, and shear strengths were investigated for incident pressures in the range 1-8 GPa, providing an insight into the response of this alloy under shock loading. Further, the time dependence of lateral stress behind the shock front was investigated to give an indication of material response.

Shear transfer in concrete reinforced with carbon fibers

NASA Astrophysics Data System (ADS)

El-Mokadem, Khaled Mounir

2001-10-01

Scope and method of study. The research started with preliminary tests and studies on the behavior and effect of carbon fibers in different water solutions and mortar/concrete mixes. The research work investigated the use of CF in the production of concrete pipes and prestressed concrete double-tee sections. The research then focused on studying the effect of using carbon fibers on the direct shear transfer of sand-lightweight reinforced concrete push-off specimens. Findings and conclusions. In general, adding carbon fibers to concrete improved its tensile characteristics but decreased its compressive strength. The decrease in compressive strength was due to the decrease in concrete density as fibers act as three-dimensional mesh that entrapped air. The decrease in compressive strength was also due to the increase in the total surface area of non-cementitious material in the concrete. Sand-lightweight reinforced concrete push-off specimens with carbon fibers had lower shear carrying capacity than those without carbon fibers for the same cement content in the concrete. Current building codes and specifications estimate the shear strength of concrete as a ratio of the compressive strength. If applying the same principals then the ratio of shear strength to compressive strength for concrete reinforced with carbon fibers is higher than that for concrete without carbon fibers.

Optimization of process parameters during carbonization for improved carbon fibre strength

NASA Astrophysics Data System (ADS)

Köhler, T.; Pursche, F.; Burscheidt, P.; Seide, G.; Gries, T.

2017-10-01

Based on their extraordinary properties, carbon fibres nowadays play a significant role in modern industries. In the last years carbon fibres are increasingly used for lightweight constructions in the energy or the transportation industry. However, a bigger market penetration of carbon fibres is still hindered by high prices (~ 22 /kg) [3]. One crucial step in carbon fibre production is the process of carbonization of stabilized fibres. However, the cause effect relationships of carbonization are nowadays not fully understood. Therefore, the main goal of this research work is the quantification of the cause-effect relationships of process parameters like temperature and residence time on carbon fibre strength.

Topology Optimization of Lightweight Lattice Structural Composites Inspired by Cuttlefish Bone

NASA Astrophysics Data System (ADS)

Hu, Zhong; Gadipudi, Varun Kumar; Salem, David R.

2018-03-01

Lattice structural composites are of great interest to various industries where lightweight multifunctionality is important, especially aerospace. However, strong coupling among the composition, microstructure, porous topology, and fabrication of such materials impedes conventional trial-and-error experimental development. In this work, a discontinuous carbon fiber reinforced polymer matrix composite was adopted for structural design. A reliable and robust design approach for developing lightweight multifunctional lattice structural composites was proposed, inspired by biomimetics and based on topology optimization. Three-dimensional periodic lattice blocks were initially designed, inspired by the cuttlefish bone microstructure. The topologies of the three-dimensional periodic blocks were further optimized by computer modeling, and the mechanical properties of the topology optimized lightweight lattice structures were characterized by computer modeling. The lattice structures with optimal performance were identified.

Durability of Geopolymer Lightweight Concrete Infilled LECA in Seawater Exposure

NASA Astrophysics Data System (ADS)

Razak, R. A.; Abdullah, M. M. A. B.; Yahya, Z.; Hamid, M. S. A.

2017-11-01

This paper describes a development of lightweight concrete using lightweight expanded clay aggregate (LECA) in fly ash (FA) based geopolymer immersed in seawater. The objective of this research is to compare the performance of geopolymer concrete (GPC) with ordinary Portland cement (OPC) concrete infilled lightweight expanded clay aggregate (LECA) in seawater exposure. Geopolymer concrete is produced by using alkaline activator to activate the raw material, FA. The highest compressive strength of this study is 42.0 MPa at 28 days and 49.8 MPa at 60 days. The density for this concrete is in the range of 1580 kg/m3 to 1660 kg/m3. The result for water absorption is in the range of 6.82% to 14.72%. However, the test results of weight loss is in the range between 0.30% to 0.43%.

The influence of triggers geometry upon the stiffness of cylindrical thin walled tubes

NASA Astrophysics Data System (ADS)

Soica, Adrian; Radu, Gheorghe N.

2014-06-01

Today's automobile manufacturers are increasingly using lightweight materials to reduce weight; these include plastics, composites, aluminium, magnesium alloys, and also new types of high strength steels. Many of these materials have limited strength or ductility, therefore in many cases the rupture being serious consequences during crashes, underscore Picketta et al. in their studies. Automotive structures must deform plastically in a short period of time, a few milliseconds, to absorb the crash energy in a controllable manner. It must be light and enable economically mass-production [1]. FE models rapidly gained acceptance among engineers. Many other factors facilitated the development of vehicle models by shell finite elements since most of the geometry of the structural surfaces was already on computer graphic files. Kee Poong Kim and Hoon Huh emphasize that the crashworthiness of each vehicle part needs to be evaluated at the initial stage of design for good performance of an assembled vehicle. As the dynamic behaviour of structural members is different from the static one, the crashworthiness of the vehicle structures has to be assessed by impact analysis. The paper analyzes the influence of trigger geometry upon the compression of thin-walled cylindrical tubes. Simulations performed on a simple model showed the dependence between triggers area and deformation times as well as the maximum deformations obtained for various speeds at which the simulations ware carried out. Likewise, the geometry of trigger leads to different results.

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.

Flexible high-temperature dielectric materials from polymer nanocomposites.

PubMed

Li, Qi; Chen, Lei; Gadinski, Matthew R; Zhang, Shihai; Zhang, Guangzu; Li, Haoyu; Iagodkine, Elissei; Haque, Aman; Chen, Long-Qing; Jackson, Tom; Wang, Qing

2015-07-30

Dielectric materials, which store energy electrostatically, are ubiquitous in advanced electronics and electric power systems. Compared to their ceramic counterparts, polymer dielectrics have higher breakdown strengths and greater reliability, are scalable, lightweight and can be shaped into intricate configurations, and are therefore an ideal choice for many power electronics, power conditioning, and pulsed power applications. However, polymer dielectrics are limited to relatively low working temperatures, and thus fail to meet the rising demand for electricity under the extreme conditions present in applications such as hybrid and electric vehicles, aerospace power electronics, and underground oil and gas exploration. Here we describe crosslinked polymer nanocomposites that contain boron nitride nanosheets, the dielectric properties of which are stable over a broad temperature and frequency range. The nanocomposites have outstanding high-voltage capacitive energy storage capabilities at record temperatures (a Weibull breakdown strength of 403 megavolts per metre and a discharged energy density of 1.8 joules per cubic centimetre at 250 degrees Celsius). Their electrical conduction is several orders of magnitude lower than that of existing polymers and their high operating temperatures are attributed to greatly improved thermal conductivity, owing to the presence of the boron nitride nanosheets, which improve heat dissipation compared to pristine polymers (which are inherently susceptible to thermal runaway). Moreover, the polymer nanocomposites are lightweight, photopatternable and mechanically flexible, and have been demonstrated to preserve excellent dielectric and capacitive performance after intensive bending cycles. These findings enable broader applications of organic materials in high-temperature electronics and energy storage devices.

Flexible high-temperature dielectric materials from polymer nanocomposites

NASA Astrophysics Data System (ADS)

Li, Qi; Chen, Lei; Gadinski, Matthew R.; Zhang, Shihai; Zhang, Guangzu; Li, Haoyu; Haque, Aman; Chen, Long-Qing; Jackson, Tom; Wang, Qing

2015-07-01

Dielectric materials, which store energy electrostatically, are ubiquitous in advanced electronics and electric power systems. Compared to their ceramic counterparts, polymer dielectrics have higher breakdown strengths and greater reliability, are scalable, lightweight and can be shaped into intricate configurations, and are therefore an ideal choice for many power electronics, power conditioning, and pulsed power applications. However, polymer dielectrics are limited to relatively low working temperatures, and thus fail to meet the rising demand for electricity under the extreme conditions present in applications such as hybrid and electric vehicles, aerospace power electronics, and underground oil and gas exploration. Here we describe crosslinked polymer nanocomposites that contain boron nitride nanosheets, the dielectric properties of which are stable over a broad temperature and frequency range. The nanocomposites have outstanding high-voltage capacitive energy storage capabilities at record temperatures (a Weibull breakdown strength of 403 megavolts per metre and a discharged energy density of 1.8 joules per cubic centimetre at 250 degrees Celsius). Their electrical conduction is several orders of magnitude lower than that of existing polymers and their high operating temperatures are attributed to greatly improved thermal conductivity, owing to the presence of the boron nitride nanosheets, which improve heat dissipation compared to pristine polymers (which are inherently susceptible to thermal runaway). Moreover, the polymer nanocomposites are lightweight, photopatternable and mechanically flexible, and have been demonstrated to preserve excellent dielectric and capacitive performance after intensive bending cycles. These findings enable broader applications of organic materials in high-temperature electronics and energy storage devices.

Anisotropic, lightweight, strong, and super thermally insulating nanowood with naturally aligned nanocellulose

PubMed Central

Li, Tian; Song, Jianwei; Zhao, Xinpeng; Yang, Zhi; Pastel, Glenn; Xu, Shaomao; Jia, Chao; Dai, Jiaqi; Chen, Chaoji; Gong, Amy; Jiang, Feng; Yao, Yonggang; Fan, Tianzhu; Yang, Bao; Wågberg, Lars; Yang, Ronggui; Hu, Liangbing

2018-01-01

There has been a growing interest in thermal management materials due to the prevailing energy challenges and unfulfilled needs for thermal insulation applications. We demonstrate the exceptional thermal management capabilities of a large-scale, hierarchal alignment of cellulose nanofibrils directly fabricated from wood, hereafter referred to as nanowood. Nanowood exhibits anisotropic thermal properties with an extremely low thermal conductivity of 0.03 W/m·K in the transverse direction (perpendicular to the nanofibrils) and approximately two times higher thermal conductivity of 0.06 W/m·K in the axial direction due to the hierarchically aligned nanofibrils within the highly porous backbone. The anisotropy of the thermal conductivity enables efficient thermal dissipation along the axial direction, thereby preventing local overheating on the illuminated side while yielding improved thermal insulation along the backside that cannot be obtained with isotropic thermal insulators. The nanowood also shows a low emissivity of <5% over the solar spectrum with the ability to effectively reflect solar thermal energy. Moreover, the nanowood is lightweight yet strong, owing to the effective bonding between the aligned cellulose nanofibrils with a high compressive strength of 13 MPa in the axial direction and 20 MPa in the transverse direction at 75% strain, which exceeds other thermal insulation materials, such as silica and polymer aerogels, Styrofoam, and wool. The excellent thermal management, abundance, biodegradability, high mechanical strength, low mass density, and manufacturing scalability of the nanowood make this material highly attractive for practical thermal insulation applications. PMID:29536048

Study on Topology Optimization Design, Manufacturability, and Performance Evaluation of Ti-6Al-4V Porous Structures Fabricated by Selective Laser Melting (SLM)

PubMed Central

Xu, Yangli; Zhang, Dongyun; Zhou, Yan; Wang, Weidong; Cao, Xuanyang

2017-01-01

The combination of topology optimization (TOP) and selective laser melting (SLM) provides the possibility of fabricating the complex, lightweight and high performance geometries overcoming the traditional manufacturing “bottleneck”. This paper evaluates the biomechanical properties of porous structures with porosity from 40% to 80% and unit cell size from 2 to 8 mm, which are designed by TOP and manufactured by SLM. During manufacturability exploration, three typical structures including spiral structure, arched bridge structure and structures with thin walls and small holes are abstracted and investigated, analyzing their manufacturing limits and forming reason. The property tests show that dynamic elastic modulus and compressive strength of porous structures decreases with increases of porosity (constant unit cell size) or unit cell size (constant porosity). Based on the Gibson-Ashby model, three failure models are proposed to describe their compressive behavior, and the structural parameter λ is used to evaluate the stability of the porous structure. Finally, a numerical model for the correlation between porous structural parameters (unit cell size and porosity) and elastic modulus is established, which provides a theoretical reference for matching the elastic modulus of human bones from different age, gender and skeletal sites during innovative medical implant design and manufacturing. PMID:28880229

Study on Topology Optimization Design, Manufacturability, and Performance Evaluation of Ti-6Al-4V Porous Structures Fabricated by Selective Laser Melting (SLM).

PubMed

Xu, Yangli; Zhang, Dongyun; Zhou, Yan; Wang, Weidong; Cao, Xuanyang

2017-09-07

The combination of topology optimization (TOP) and selective laser melting (SLM) provides the possibility of fabricating the complex, lightweight and high performance geometries overcoming the traditional manufacturing "bottleneck". This paper evaluates the biomechanical properties of porous structures with porosity from 40% to 80% and unit cell size from 2 to 8 mm, which are designed by TOP and manufactured by SLM. During manufacturability exploration, three typical structures including spiral structure, arched bridge structure and structures with thin walls and small holes are abstracted and investigated, analyzing their manufacturing limits and forming reason. The property tests show that dynamic elastic modulus and compressive strength of porous structures decreases with increases of porosity (constant unit cell size) or unit cell size (constant porosity). Based on the Gibson-Ashby model, three failure models are proposed to describe their compressive behavior, and the structural parameter λ is used to evaluate the stability of the porous structure. Finally, a numerical model for the correlation between porous structural parameters (unit cell size and porosity) and elastic modulus is established, which provides a theoretical reference for matching the elastic modulus of human bones from different age, gender and skeletal sites during innovative medical implant design and manufacturing.

Influence of the heat treatment condition of alloy AlCu4Mg1 on the microstructure and properties of anodic oxide layers

NASA Astrophysics Data System (ADS)

Morgenstern, R.; Dietrich, D.; Sieber, M.; Lampke, T.

2017-03-01

Due to their outstanding specific mechanical properties, high-strength, age-hardenable aluminum alloys offer a high potential for lightweight security-related applications. However, the use of copper-alloyed aluminum is limited because of their susceptibility to selective corrosion and their low wear resistance. These restrictions can be overcome and new applications can be opened up by the generation of protective anodic aluminum oxide layers. In contrast to the anodic oxidation of unalloyed aluminum, oxide layers produced on copper-rich alloys exhibit a significantly more complex pore structure. It is the aim of the investigation to identify the influence of microstructural parameters such as size and distribution of the strengthening precipitations on the coating microstructure. The aluminum alloy EN AW-2024 (AlCu4Mg1) in different heat treatment conditions serves as substrate material. The influence of the strengthening precipitations’ size and distribution on the development of the pore structure is investigated by the use of high-resolution scanning electron microscopy. Integral coating properties are characterized by non-destructive and light-microscopic thickness measurements and instrumented indentation tests.

Cesic: optomechanical technology last development results and new HBCesic highly light weighted space mirror development including corrective function 7th international conference on space optics, october 2008

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Kroedel, Mathias

2017-11-01

Thales-Alenia-Space and ECM has developed a new SiC ceramic composite to produce very lightweight space mirrors and structure. Cesicmade by ECM has been selected for its own intrinsic properties ( high specific Young modulus, high conductivity , low CTE, high strength for a ceramics) and its large manufacturing capabilities. Recently a full monolithic space instrument for earth observation, with a monolithic Cesicstructure and with Cesicmirrors has been designed, manufactured and space qualified and is now ready for launch. The Cesictelescope assembly has been tested under shock environment, vibration loads, and full qualification thermal environment. All these qualification tests were done directly on the flight model. Extensive development has been also performed to design, size, manufacture and test a very light weight reflector shell made as a single part. This 1 meter reflective shell has an areal density of less than 10 Kg/m2 has been manufactured with its surface grounded to the bi parabolic shape. Such challenging areal density has requested a very thin skin associated with a ribs thickness of less than 2mm. In order to demonstrate the high stability and strength of Cesicthe reflector has been tested successfully under very aggressive environment up to 350°C and also an acoustic test with flight representative levels was successfully performed. To produce future very lightweight space mirrors ECM develop with the support of Thales-Alenia-Space since some years an improved version of Cesicceramic, called HB-Cesic©. HB-Cesicmade by ECM is developed for its higher intrinsic properties, Young modulus, strength and especially its direct polishing capabilities down to 3 nm micro-roughness. One of the major targets for this development was also to overcome size limitations of the C/C raw material of currently around 1x1 m to produce mirror up to 3,5 m diameter out of a single C/C raw material block. Under ESA study a 600 mm mirror with a surface density of only 18 Kg/m2 has been designed, sized and manufactured and is currently under polishing at SESO. The polishing to a micro-roughness of far less than 20 nm RMS without expensive overcoatings has been already validated on mirrors up to 800 mm. This 600 mm mirror will be polished to a WFE of less than 20 nm, and afterwards the mirror will be tested under cryogenic environment to measure the WFE evolution between ambient and cryo. The mirror is equipped with a system for focus and astigmatism modification. During the cryo test this system will be activated at cryo temperature to also demonstrate the function of this system. This correction system is developed for future large mirrors for interferometric nulling or aperture synthesis missions like the Darwin mission . For such missions very large and very lightweight mirrors up to 3,5 m diameter with an areal density of less than 25 Kg/m2 are required and thank to the HBCesictechnology such performance is now feasible.

Development of lightweight, fire-retardant, low-smoke, high-strength, thermally stable aircraft floor paneling

NASA Technical Reports Server (NTRS)

Anderson, R. A.; Ougland, R. M.; Karch, R. J.

1978-01-01

Extensive fire resistance and mechanical property tests were conducted on sandwich configurations composed of resin-fiberglass laminates bonded with adhesive to Nomex honeycomb and foam core. The test results were used to select a combination of materials that would improve the fire safety of the airplane without sacrificing mechanical performance of the aircraft floor panels. A test panel is being service evaluated in a commercial aircraft.

Microdesigning of Lightweight/High Strength Ceramic Materials.

DTIC Science & Technology

1987-08-30

if applicable) AFSSR NC Grant No. AFOSR-83-0375 8c. ADDRESS( Cft , State. and ZIP Code) 10 SOURCE OF FUNDING NUMBERS Bd.40PROGRAMO IPROJECT I TASK...The Adsorption of Pohmethacrvfic Acid from Solut.on.- Ph.D. Thesis . Polytechnic Institute of Brooklyn (1961). I5. R. J. Hunter. Zeta Potential in...Hasz. ’Surface Reactions and Electrical Double Layer Properties of Ceramic Ox. ides in Aqueous Solution,* M.S. Thesis . Massachusetts Institute of

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.

Cellulose nanowhiskers and nanofibers from biomass for composite applications

NASA Astrophysics Data System (ADS)

Wang, Tao

2011-12-01

Biological nanocomposites such as plant cell wall exhibit high mechanical properties at a light weight. The secret of the rigidity and strength of the cell wall lies in its main structural component -- cellulose. Native cellulose exists as highly-ordered microfibrils, which are just a few nanometers wide and have been found to be stiffer than many synthetic fibers. In the quest for sustainable development around the world, using cellulose microfibrils from plant materials as renewable alternatives to conventional reinforcement materials such as glass fibers and carbon fibers is generating particular interest. In this research, by mechanical disintegration and by controlled chemical hydrolysis, both cellulose nanofibers and nanowhiskers were extracted from the cell wall of an agricultural waste, wheat straw. The reinforcement performances of the two nanofillers were then studied and compared using the water-soluble polyvinyl alcohol (PVOH) as a matrix material. It was found that while both of these nanofillers could impart higher stiffness to the polymer, the nanofibers from biomass were more effective in composite reinforcement than the cellulose crystals thanks to their large aspect ratio and their ability to form interconnected network structures through hydrogen bonding. One of the biggest challenges in the development of cellulose nanocomposites is achieving good dispersion. Because of the high density of hydroxyl groups on the surface of cellulose, it remains a difficult task to disperse cellulose nanofibers in many commonly used polymer matrices. The present work addresses this issue by developing a water-based route taking advantage of polymer colloidal suspensions. Combining cellulose nanofibers with one of the most important biopolymers, poly(lactic acid) (PLA), we have prepared nanocomposites with excellent fiber dispersion and improved modulus and strength. The bio-based nanocomposites have a great potential to serve as light-weight structural materials for automotive, medical, and other applications.

Process Simulation of Aluminium Sheet Metal Deep Drawing at Elevated Temperatures

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

Winklhofer, Johannes; Trattnig, Gernot; Lind, Christoph

Lightweight design is essential for an economic and environmentally friendly vehicle. Aluminium sheet metal is well known for its ability to improve the strength to weight ratio of lightweight structures. One disadvantage of aluminium is that it is less formable than steel. Therefore complex part geometries can only be realized by expensive multi-step production processes. One method for overcoming this disadvantage is deep drawing at elevated temperatures. In this way the formability of aluminium sheet metal can be improved significantly, and the number of necessary production steps can thereby be reduced. This paper introduces deep drawing of aluminium sheet metalmore » at elevated temperatures, a corresponding simulation method, a characteristic process and its optimization. The temperature and strain rate dependent material properties of a 5xxx series alloy and their modelling are discussed. A three dimensional thermomechanically coupled finite element deep drawing simulation model and its validation are presented. Based on the validated simulation model an optimised process strategy regarding formability, time and cost is introduced.« less

Active Structural Acoustic Control as an Approach to Acoustic Optimization of Lightweight Structures

DTIC Science & Technology

2001-06-01

appropriate approach based on Statistical Energy Analysis (SEA) would facilitate investigations of the structural behavior at a high modal density. On the way...higher frequency investigations an approach based on the Statistical Energy Analysis (SEA) is recommended to describe the structural dynamic behavior

Nanolattices: An Emerging Class of Mechanical Metamaterials.

PubMed

Bauer, Jens; Meza, Lucas R; Schaedler, Tobias A; Schwaiger, Ruth; Zheng, Xiaoyu; Valdevit, Lorenzo

2017-10-01

In 1903, Alexander Graham Bell developed a design principle to generate lightweight, mechanically robust lattice structures based on triangular cells; this has since found broad application in lightweight design. Over one hundred years later, the same principle is being used in the fabrication of nanolattice materials, namely lattice structures composed of nanoscale constituents. Taking advantage of the size-dependent properties typical of nanoparticles, nanowires, and thin films, nanolattices redefine the limits of the accessible material-property space throughout different disciplines. Herein, the exceptional mechanical performance of nanolattices, including their ultrahigh strength, damage tolerance, and stiffness, are reviewed, and their potential for multifunctional applications beyond mechanics is examined. The efficient integration of architecture and size-affected properties is key to further develop nanolattices. The introduction of a hierarchical architecture is an effective tool in enhancing mechanical properties, and the eventual goal of nanolattice design may be to replicate the intricate hierarchies and functionalities observed in biological materials. Additive manufacturing and self-assembly techniques enable lattice design at the nanoscale; the scaling-up of nanolattice fabrication is currently the major challenge to their widespread use in technological applications. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

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.

Validation of a unique concept for a low-cost, lightweight space-deployable antenna structure

NASA Technical Reports Server (NTRS)

Freeland, R. E.; Bilyeu, G. D.; Veal, G. R.

1993-01-01

An experiment conducted in the framework of a NASA In-Space Technology Experiments Program based on a concept of inflatable deployable structures is described. The concept utilizes very low inflation pressure to maintain the required geometry on orbit and gravity-induced deflection of the structure precludes any meaningful ground-based demonstrations of functions performance. The experiment is aimed at validating and characterizing the mechanical functional performance of a 14-m-diameter inflatable deployable reflector antenna structure in the orbital operational environment. Results of the experiment are expected to significantly reduce the user risk associated with using large space-deployable antennas by demonstrating the functional performance of a concept that meets the criteria for low-cost, lightweight, and highly reliable space-deployable structures.

Performance of fly ash based geopolymer incorporating palm kernel shell for lightweight concrete

NASA Astrophysics Data System (ADS)

Razak, Rafiza Abd; Abdullah, Mohd Mustafa Al Bakri; Yahya, Zarina; Jian, Ang Zhi; Nasri, Armia

2017-09-01

A concrete which cement is totally replaced by source material such as fly ash and activated by highly alkaline solutions is known as geopolymer concrete. Fly ash is the most common source material for geopolymer because it is a by-product material, so it can get easily from all around the world. An investigation has been carried out to select the most suitable ingredients of geopolymer concrete so that the geopolymer concrete can achieve the desire compressive strength. The samples were prepared to determine the suitable percentage of palm kernel shell used in geopolymer concrete and cured for 7 days in oven. After that, other samples were prepared by using the suitable percentage of palm kernel shell and cured for 3, 14, 21 and 28 days in oven. The control sample consisting of ordinary Portland cement and palm kernel shell and cured for 28 days were prepared too. The NaOH concentration of 12M, ratio Na2SiO3 to NaOH of 2.5, ratio fly ash to alkaline activator solution of 2.0 and ratio water to geopolymer of 0.35 were fixed throughout the research. The density obtained for the samples were 1.78 kg/m3, water absorption of 20.41% and the compressive strength of 14.20 MPa. The compressive strength of geopolymer concrete is still acceptable as lightweight concrete although the compressive strength is lower than OPC concrete. Therefore, the proposed method by using fly ash mixed with 10% of palm kernel shell can be used to design geopolymer concrete.

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.

Experimental studies on the enhanced performance of lightweight oil recovery using a combined electrocoagulation and magnetic field processes.

PubMed

Liu, Yang; Yang, Jie; Jiang, Wenming; Chen, Yimei; Yang, Chaojiang; Wang, Tianyu; Li, Yuxing

2018-08-01

On marine oil spill, inflammable lightweight oil has characteristics of explosion risk and contamination of marine enviroment, therefore treatment of stable emulsion with micron oil droplets is urgent. This study aimed to propose a combined electrocoagulation and magnetic field processes to enhance performance of lightweight oil recovery with lower energy consumption. The effects of current density, electrolysis time, strength and direction of magnetic field on the overall treatment efficiency of the reactor were explored. Furthermore, the comparison between coupling device and only electrocoagulation through tracking oil removal in nine regions between the electrodes. The results were shown that the permanent magnets applied was found to enhance demulsification process within electrocoagulation reactor. For a given current density of 60 A m -2 at 16 min, Lorentz force downward was proved to promote the sedimentation of coagulants. As the magnetic field strength increases from 20 to 60 mT, oil removal efficiency was observed to increase and then decrease, and simultaneously energy consumption reduced and then present constantly. The results were found that the magnetic field strength of 40 mT was optimal within electrocoagulation reactor, which can not only diminishe difference of mass transfer rate along the height of vertical plate but also consume lowest energy. Copyright © 2018 Elsevier Ltd. All rights reserved.

Super-Strong, Super-Stiff Macrofibers with Aligned, Long Bacterial Cellulose Nanofibers.

PubMed

Wang, Sha; Jiang, Feng; Xu, Xu; Kuang, Yudi; Fu, Kun; Hitz, Emily; Hu, Liangbing

2017-09-01

With their impressive properties such as remarkable unit tensile strength, modulus, and resistance to heat, flame, and chemical agents that normally degrade conventional macrofibers, high-performance macrofibers are now widely used in various fields including aerospace, biomedical, civil engineering, construction, protective apparel, geotextile, and electronic areas. Those macrofibers with a diameter of tens to hundreds of micrometers are typically derived from polymers, gel spun fibers, modified carbon fibers, carbon-nanotube fibers, ceramic fibers, and synthetic vitreous fibers. Cellulose nanofibers are promising building blocks for future high-performance biomaterials and textiles due to their high ultimate strength and stiffness resulting from a highly ordered orientation along the fiber axis. For the first time, an effective fabrication method is successfully applied for high-performance macrofibers involving a wet-drawing and wet-twisting process of ultralong bacterial cellulose nanofibers. The resulting bacterial cellulose macrofibers yield record high tensile strength (826 MPa) and Young's modulus (65.7 GPa) owing to the large length and the alignment of nanofibers along fiber axis. When normalized by weight, the specific tensile strength of the macrofiber is as high as 598 MPa g -1 cm 3 , which is even substantially stronger than the novel lightweight steel (227 MPa g -1 cm 3 ). © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Ultrafine-grained Aluminm and Boron Carbide Metal Matrix Composites

NASA Astrophysics Data System (ADS)

Vogt, Rustin

Cryomilling is a processing technique used to generate homogenously distributed boron carbide (B4C) particulate reinforcement within an ultrafine-grained aluminum matrix. The motivation behind characterizing a composite consisting of cryomilled aluminum B4C metal matrix composite is to design and develop a high-strength, lightweight aluminum composite for structural and high strain rate applications. Cryomilled Al 5083 and B4C powders were synthesized into bulk composite by various thermomechanical processing methods to form plate and extruded geometries. The effects of processing method on microstructure and mechanical behavior for the final consolidated composite were investigated. Cryomilling for extended periods of time in liquid nitrogen has shown to increase strength and thermal stability. The effects associated with cryomilling with stearic acid additions (as a process-control agent) on the degassing behavior of Al powders is investigated and results show that the liberation of compounds associated with stearic acid were suppressed in cryomilled Al powders. The effect of thermal expansion mismatch strain on strengthening due to geometrically necessary dislocations resulting from quenching is investigated and found not to occur in bulk cryomilled Al 5083 and B 4C composites. Previous cryomilled Al 5083 and B4C composites have exhibited ultrahigh strength associated with considerable strain-to-failure (>14 pct.) at high strain rates (>103/s) during mechanical testing, but only limited strain-to-failure (˜0.75 pct.) at quasi-static strain rates (10-3/s). The increased strain to failure at high strain rates is attributed to micro-flaw developments, including kinking, extensive axial splitting, and grain growth were observed after high strain rate deformation, and the significance of these mechanisms is considered.

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.

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.

Telescoping Solar Array Concept for Achieving High Packaging Efficiency

NASA Technical Reports Server (NTRS)

Mikulas, Martin; Pappa, Richard; Warren, Jay; Rose, Geoff

2015-01-01

Lightweight, high-efficiency solar arrays are required for future deep space missions using high-power Solar Electric Propulsion (SEP). Structural performance metrics for state-of-the art 30-50 kW flexible blanket arrays recently demonstrated in ground tests are approximately 40 kW/cu m packaging efficiency, 150 W/kg specific power, 0.1 Hz deployed stiffness, and 0.2 g deployed strength. Much larger arrays with up to a megawatt or more of power and improved packaging and specific power are of interest to mission planners for minimizing launch and life cycle costs of Mars exploration. A new concept referred to as the Compact Telescoping Array (CTA) with 60 kW/cu m packaging efficiency at 1 MW of power is described herein. Performance metrics as a function of array size and corresponding power level are derived analytically and validated by finite element analysis. Feasible CTA packaging and deployment approaches are also described. The CTA was developed, in part, to serve as a NASA reference solar array concept against which other proposed designs of 50-1000 kW arrays for future high-power SEP missions could be compared.

Microsphere Insulation Panels

NASA Technical Reports Server (NTRS)

Mohling, R.; Allen, M.; Baumgartner, R.

2006-01-01

Microsphere insulation panels (MIPs) have been developed as lightweight, longlasting replacements for the foam and vacuum-jacketed systems heretofore used for thermally insulating cryogenic vessels and transfer ducts. The microsphere core material of a typical MIP consists of hollow glass bubbles, which have a combination of advantageous mechanical, chemical, and thermal-insulation properties heretofore available only separately in different materials. In particular, a core filling of glass microspheres has high crush strength and low density, is noncombustible, and performs well in soft vacuum.

The Use of Additive Manufacturing for Fabrication of Multi-Function Small Satellite Structures

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

Horais, Brian J; Love, Lonnie J; Dehoff, Ryan R

2013-01-01

The use of small satellites in constellations is limited only by the growing functionality of smallsats themselves. Additive manufacturing provides exciting new design opportunities for development of multifunction CubeSat structures that integrate such functions as propulsion and thermal control into the satellite structures themselves. Manufacturing of these complex multifunction structures is now possible in lightweight, high strength, materials such as titanium by using existing electron beam melting additive manufacturing processes. However, the use of today's additive manufacturing capabilities is often cost-prohibitive for small companies due to the large capital investments required. To alleviate this impediment the U.S. Department of Energymore » has established a Manufacturing Demonstration Facility (MDF) at their Oak Ridge National Laboratory (ORNL) in Tennessee that provides industry access to a broad range of energy-efficient additive manufacturing equipment for collaborative use by both small and large organizations. This paper presents a notional CubeSat multifunction design that integrates the propulsion system into a three-unit (3U) CubeSat structure. The full-scale structure has been designed and fabricated at the ORNL MDF. The use of additive manufacturing for spacecraft fabrication is opening up many new possibilities in design and fabrication capabilities for what had previously been impossible structures to fabricate.« less

Investigation of Vehicle Rear Under Run Protection Device (RUPD) Using Aluminium Foam

NASA Astrophysics Data System (ADS)

Nagaraj Goud, B.; pachori, Avinash

2017-08-01

Whenever the passenger cars meet with accidents with the heavy duty truck from rear, it will tend to penetrate under the truck bed called truck trailer under-ride crash. This is responsible for the thousands of accidents, causing severe injuries and spot death. This is mostly due to the lack of effective guarding system. The Present paper gives an importance on energy absorption mechanism of a Rear under Run Protection Device (RUPD) under crash effect of the truck. The aim of the study is to replace Steel RUPD with aluminum foam, which promises an improvement of vehicle crashworthiness as well as to reduce weight of the vehicle. The aluminum foam is selected due to the high specific strength and specific stiffness. This inborn character makes it a promising candidate in the modern lightweight structures in the automotive engineering which can contribute to the improvement of mileage in addition to safety of the occupants.

Effects of Annealing Treatment Prior to Cold Rolling on Delayed Fracture Properties in Ferrite-Austenite Duplex Lightweight Steels

NASA Astrophysics Data System (ADS)

Sohn, Seok Su; Song, Hyejin; Kim, Jung Gi; Kwak, Jai-Hyun; Kim, Hyoung Seop; Lee, Sunghak

2016-02-01

Tensile properties of recently developed automotive high-strength steels containing about 10 wt pct of Mn and Al are superior to other conventional steels, but the active commercialization has been postponed because they are often subjected to cracking during formation or to the delayed fracture after formation. Here, the delayed fracture behavior of a ferrite-austenite duplex lightweight steel whose microstructure was modified by a batch annealing treatment at 1023 K (750 °C) prior to cold rolling was examined by HCl immersion tests of cup specimens, and was compared with that of an unmodified steel. After the batch annealing, band structures were almost decomposed as strong textures of {100}<011> α-fibers and {111}<112> γ-fibers were considerably dissolved, while ferrite grains were refined. The steel cup specimen having this modified microstructure was not cracked when immersed in an HCl solution for 18 days, whereas the specimen having unmodified microstructure underwent the delayed fracture within 1 day. This time delayed fracture was more critically affected by difference in deformation characteristics such as martensitic transformation and deformation inhomogeneity induced from concentration of residual stress or plastic strain, rather than the difference in initial microstructures. The present work gives a promise for automotive applications requiring excellent mechanical and delayed fracture properties as well as reduced specific weight.

Flywheel rotor and containment technology development for FY 1982

NASA Astrophysics Data System (ADS)

Kulkarni, S. V.

1982-12-01

The status of technology development for an efficient, economical, and practical composite flywheel having an energy density of 88 Wh/kg (20 to 25 E Wh/lb) and an energy storge capacity of approximately 1 kWh is reported. Progress is also reported in the development of a fail-safe, lightweight, and low cost composite containment for the flywheel. One containment design was selected for prototype fabrication and testing. Flywheel rotor cyclic test capability was also demonstrated and evaluated. High strength Kevlar and graphite fibers are being studied. Tests of the elastomeric bond between the rotor and hub indicate that the bond strength exceeds the minimum torque requirements for automobile applications.

FACT, Mega-ROSA, SOLAROSA

NASA Technical Reports Server (NTRS)

Spence, Brian; White, Steve; Schmid, Kevin; Douglas Mark

2012-01-01

The Flexible Array Concentrator Technology (FACT) is a lightweight, high-performance reflective concentrator blanket assembly that can be used on flexible solar array blankets. The FACT concentrator replaces every other row of solar cells on a solar array blanket, significantly reducing the cost of the array. The modular design is highly scalable for the array system designer, and exhibits compact stowage, good off-pointing acceptance, and mass/cost savings. The assembly s relatively low concentration ratio, accompanied by a large radiative area, provides for a low cell operating temperature, and eliminates many of the thermal problems inherent in high-concentration-ratio designs. Unlike other reflector technologies, the FACT concentrator modules function on both z-fold and rolled flexible solar array blankets, as well as rigid array systems. Mega-ROSA (Mega Roll-Out Solar Array) is a new, highly modularized and extremely scalable version of ROSA that provides immense power level range capability from 100 kW to several MW in size. Mega-ROSA will enable extremely high-power spacecraft and SEP-powered missions, including space-tug and largescale planetary science and lunar/asteroid exploration missions. Mega-ROSA's inherent broad power scalability is achieved while retaining ROSA s solar array performance metrics and missionenabling features for lightweight, compact stowage volume and affordability. This innovation will enable future ultra-high-power missions through lowcost (25 to 50% cost savings, depending on PV and blanket technology), lightweight, high specific power (greater than 200 to 400 Watts per kilogram BOL (beginning-of-life) at the wing level depending on PV and blanket technology), compact stowage volume (greater than 50 kilowatts per cubic meter for very large arrays), high reliability, platform simplicity (low failure modes), high deployed strength/stiffness when scaled to huge sizes, and high-voltage operation capability. Mega-ROSA is adaptable to all photovoltaic and concentrator flexible blanket technologies, and can readily accommodate standard multijunction and emerging ultra-lightweight IMM (inverted metamorphic) photovoltaic flexible blanket assemblies, as well as ENTECHs Stretched Lens Array (SLA) and DSSs (Deployable Space Systems) FACT, which allows for cost reduction at the array level.

Review of beetle forewing structures and their biomimetic applications in China: (I) On the structural colors and the vertical and horizontal cross-sectional structures.

PubMed

Chen, Jinxiang; Xie, Juan; Wu, Zhishen; Elbashiry, Elsafi Mohamed Adam; Lu, Yun

2015-10-01

This paper discusses the progress made in China in terms of the structural colors, microstructure and mechanical properties of the beetle forewing. 1) The forewing microstructures can be classified into six phases, the first three of which are characterized by sandwich, multilayer and fiber layer structures, respectively. The fracture behaviors resulting from these three phases suggest that different scale microstructures or coupled adjacent scale microstructures can determine the macroscopic mechanical behavior of the forewing. 2) The forewing colors are derived from three features: regulation of the structural parameters of the internal optical structures, i.e., a sculpted multilayer composite two-dimensional nanopillar structure grating system; scattering on the three-dimensional surface of the bowl-shaped structure; and reversible color changes due to changes in the physical microstructure of fluffs. Their formation mechanisms were clarified, and fibers with ecological biomimetic structural colors have been developed. 3) Beetles exhibit a lightweight sectional frame structure with a trabecular core structure. Both of the joints on the left and right are concave-convex butt-joint structures with burrs, which provide an efficient docking mechanism with high intensity. The forewing of dichotoma exhibits a non-equiangular layered structure, which results in anisotropy in its tensile strength. Finally, the authors propose potential new research directions for the next 20 years. Copyright © 2015 Elsevier B.V. All rights reserved.

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...

Structural sizing of a solar powered aircraft

NASA Technical Reports Server (NTRS)

Hall, D. W.; Hall, S. A.

1984-01-01

The development of sizing algorithms for very lightweight aircraft structure was studied. Three types of bracing schemes were analyzed and fully cantilevered strut bracing and wire bracing and scaling rules were determined. It is found that wire bracing provides the lightest wing structure for solar high altitude powered platforms.

Lightweight bladder lined pressure vessels

DOEpatents

Mitlitsky, Fred; Myers, Blake; Magnotta, Frank

1998-01-01

A lightweight, low permeability liner for graphite epoxy composite compressed gas storage vessels. The liner is composed of polymers that may or may not be coated with a thin layer of a low permeability material, such as silver, gold, or aluminum, deposited on a thin polymeric layer or substrate which is formed into a closed bladder using torispherical or near torispherical end caps, with or without bosses therein, about which a high strength to weight material, such as graphite epoxy composite shell, is formed to withstand the storage pressure forces. The polymeric substrate may be laminated on one or both sides with additional layers of polymeric film. The liner may be formed to a desired configuration using a dissolvable mandrel or by inflation techniques and the edges of the film seamed by heat sealing. The liner may be utilized in most any type of gas storage system, and is particularly applicable for hydrogen, gas mixtures, and oxygen used for vehicles, fuel cells or regenerative fuel cell applications, high altitude solar powered aircraft, hybrid energy storage/propulsion systems, and lunar/Mars space applications, and other applications requiring high cycle life.

Precision forging technology for aluminum alloy

NASA Astrophysics Data System (ADS)

Deng, Lei; Wang, Xinyun; Jin, Junsong; Xia, Juchen

2018-03-01

Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

Recent advances in lightweight, filament-wound composite pressure vessel technology

NASA Technical Reports Server (NTRS)

Lark, R. F.

1977-01-01

A review of recent advances is presented for lightweight, high-performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single-cycle burst and cyclic fatigue loading. Filament-wound fiber/epoxy composite vessels were made from S-glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessel structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all-titanium pressure vessels. Significant findings in each area are summarized including data from current NASA-Lewis Research Center contractual and in-house programs.

Apparatus for forming a continuous lightweight multicell material

NASA Technical Reports Server (NTRS)

Wang, Taylor G. (Inventor); Elleman, Daniel D. (Inventor); Kendall, James M., Jr. (Inventor)

1984-01-01

An apparatus is described for producing a lightweight structural material (12), by forming gas-filled shells (38) of molten material from a matrix of nozzles (22) that form shells of very uniform size at very uniform rates. The matrix of molten shells coalesce into a multi-cell material of controlled cellular structure. The shells can be of two different sizes (38, 44) that are interspersed, to form a multicell material that has a regular cell pattern but which avoids planes of weakness and localized voids. The gas (50) in the shells can be under a high pressure, and can be a fire extinguishing gas.

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

The recovery of Zn and Pb and the manufacture of lightweight bricks from zinc smelting slag and clay.

PubMed

Hu, Huiping; Deng, Qiufeng; Li, Chao; Xie, Yue; Dong, Zeqin; Zhang, Wei

2014-04-30

Novel lightweight bricks have been produced by sintering mixes of zinc smelting slag and clay. A two-stage sintered process has been proposed to recovery of Zn and Pb and reutilization of the zinc smelting slag. In the first stage of the process, called reduction and volatilization procedure, zinc and lead were reduced by the carbon contained in the zinc smelting slag and volatilized into the dust, and the dust can be used as a secondary zinc resource. In the second stage of the process, called oxidation sintering procedure, a lightweight brick was produced. Samples containing up to 60 wt.% zinc smelting slag and 40 wt.% kaolin clay were reduced at 1050°C for 6h, and then sintered at 1050°C for 4h. The recoveries of Zn and Pb from the brick are 94.5 ± 0.6% and 97.6 ± 0.2%, respectively. Low bulk density (1.42 g cm(-3)) and relatively high compressive strength (2 2MPa) sintered bricks were produced, and the leaching toxicity of the sintered bricks was below the regulatory thresholds of Chinese National Standards. Copyright © 2014 Elsevier B.V. All rights reserved.

Structural Evolution and Atom Clustering in β-SiAlON: β-Si 6–z Al z O z N 8–z

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

Cozzan, Clayton; Griffith, Kent J.; Laurita, Geneva

2017-02-06

SiAlON ceramics, solid solutions based on the Si 3N 4 structure, are important, lightweight structural materials with intrinsically high strength, high hardness, and high thermal and chemical stability. Described by the chemical formula β-Si 6–zAl zO zN 8–z, from a compositional viewpoint, these materials can be regarded as solid solutions between Si 3N 4 and Al 3O 3N. A key aspect of the structural evolution with increasing Al and O (z in the formula) is to understand how these elements are distributed on the β-Si 3N 4 framework. The average and local structural evolution of highly phase-pure samples of β-Simore » 6–zAl zO zN 8–z with z = 0.050, 0.075, and 0.125 are studied here, using a combination of X-ray diffraction, NMR studies, and density functional theory calculations. Synchrotron X-ray diffraction establishes sample purity and indicates subtle changes in the average structure with increasing Al content in these compounds. Solid-state magic-angle-spinning 27Al NMR experiments, coupled with detailed ab initio calculations of NMR spectra of Al in different AlO qN 4–q tetrahedra (0 ≤ q ≤ 4), reveal a tendency of Al and O to cluster in these materials. Independently, the calculations suggest an energetic preference for Al–O bond formation, instead of a random distribution, in the β-SiAlON system.« less

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.

A review on the effect of welding on the corrosion of magnesium alloys

NASA Astrophysics Data System (ADS)

Mohamed, N. S.; Alias, J.

2017-10-01

Welding is an important joining technique for lightweight alloys with their increasing applications in aerospace, aircraft, automotive, electronics and other industries. The applications of lightweight alloys particularly magnesium alloys increased rapidly due to their beneficial properties such as low density, high strength-to-mass ratio, good dimensional stability, electromagnetic shielding and good recyclability. The effect of welding on the corrosion of magnesium alloys are reviewed in this paper, which closely related to the developed microstructure by the welding process. The paper focuses particularly on friction stir and laser welding. The basic principles of friction stir and laser welding are discussed, to present the likelihood of defects which significantly affect the corrosion of magnesium alloy. The finding in corrosion demonstrated the morphology of corrosion occurrence on each welded region, and observation on the potential and current values are also included.

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...

Design and fabrication of Rene 41 advanced structural panels. [their performance under axial compression, shear, and bending loads

NASA Technical Reports Server (NTRS)

Greene, B. E.; Northrup, R. F.

1975-01-01

The efficiency was investigated of curved elements in the design of lightweight structural panels under combined loads of axial compression, inplane shear, and bending. The application is described of technology generated in the initial aluminum program to the design and fabrication of Rene 41 panels for subsequent performance tests at elevated temperature. Optimum designs for two panel configurations are presented. The designs are applicable to hypersonic airplane wing structure, and are designed specifically for testing at elevated temperature in the hypersonic wing test structure located at the NASA Flight Research Center. Fabrication methods developed to produce the Rene panels are described, and test results of smaller structural element specimens are presented to verify the design and fabrication methods used. Predicted strengths of the panels under several proposed elevated temperature test load conditions are presented.

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.

Characterization of Multifunctional Carbon Nanotube Yarns: In-situ Strain Sensing and Composite Reinforcement

NASA Astrophysics Data System (ADS)

Page, Christian David

A large body of scientific research and development worldwide has focused on the unprecedented structural/functional properties of carbon nanotubes (CNT), yet translation of these unique properties of CNTs to macroscopic materials has been slow to develop. CNT yarns are an appealing application for CNTs; their lightweight and small diameter can allow for them to be embedded into composite materials. Since the individual nanotubes have shown to have incredibly high strength, stiffness, and strain sensitivity, CNT yarns have the potential to be highly effective for in-situ structural health monitoring of advanced materials and structures. This work identifies the sources for losses in strength and electromechanical sensitivity. This is done by first understanding the physics involved with a CNT yarn under axial strain. Since this material is not a Newtonian solid, the stress-strain relationships are dissimilar to conventional materials, exhibiting a three zone behavior. This is present in both the stress-strain and resistance-strain relationships. A tensile test performed in-situ within a scanning electron microscope showed that the diameter of the yarn reduced greatly during tension, which indicates that the volume is not constant; therefore, the intratube/intrabundle load transfer efficiency and electrical conductivity change significantly under strain. Observation of this phenomenon helps elucidate the source for loss in the translation from nanoscopic CNTs to the macroscopic CNT yarns. Following the observation that the CNT yarn is not a solid body mechanics system, investigation into the long-standing field of textile engineering helped to identify that the CNT yarn structural hierarchy should be re-evaluated. Literary review reveals that the predominant base morphology of CNT yarns is bundles of CNTs as opposed to individual CNTs. Furthermore, in conventional textiles, it is well known that the base morphology (in textiles this is the "fiber") will bundle together during twisting. For CNT yarns, this level is referred to as packs since the title "bundle" has already been widely used as the grouping of individual CNTs. The utilization of conventional textile mechanics is supported by the congruent stress strain curves of cotton/wool yarns and CNT yarns. With this new perspective, sources of strength losses can be identified and, in most cases, quantified. Deterministic and statistical textile models are used to enumerate three top-level parameters which affect the yarn's strength. This approach offers guidance for future work to be done in the field of CNT yarns, including the growth of raw CNT forests, the spinning procedures involved, and any post-processing steps that may arise that can mitigate these losses that are extremely degrading to the CNT yarn mechanical strength. The strength of the yarn is a direct reflection of the quality of the yarn's structure. These morphological properties across the nano, meso, and macro scales have an effect on other physical properties such as electromechanical sensitivity. Improving the strength will also improve the yarn's ability to serve as a strain gage. Coupled with its appealing size, these yarns will be an effective in-situ embedded strain sensor. In conclusion, high quality CNT yarns with minimized strength losses show promise for structural health monitoring of advanced materials and structures since they can be both strongly reinforcing and electromechanically sensitive.

Ultra-High Temperature Materials Characterization for Space and Missile Applications

NASA Technical Reports Server (NTRS)

Rogers, Jan; Hyers, Robert

2007-01-01

Numerous advanced space and missile technologies including propulsion systems require operations at high temperatures. Some very high-temperature materials are being developed to meet these needs, including refractory metal alloys, carbides, borides, and silicides. System design requires data for materials properties at operating temperatures. Materials property data are not available at the desired operating temperatures for many materials of interest. The objective of this work is to provide important physical property data at ultra-high temperatures. The MSFC Electrostatic Levitation (ESL) facility can provide measurements of thermophysical properties which include: creep strength, emissivity, density and thermal expansion. ESL uses electrostatic fields to position samples between electrodes during processing and characterization experiments. Samples float between the electrodes during studies and are free from any contact with a container or test apparatus. This provides a high purity environment for the study of high-temperature, reactive materials. ESL can be used to process a wide variety of materials including metals, alloys, ceramics, glasses and semiconductors. A system for the determination of total hemispherical emissivity is being developed for the MSFC ESL facility by AZ Technology Inc. The instrument has been designed to provide emissivity measurements for samples during ESL experiments over the temperature range 700-3400K. A novel non-contact technique for the determination of high-temperature creep strength has been developed. Data from selected ESL-based characterization studies will be presented. The ESL technique could advance space and missile technologies by advancing the knowledge base and the technology readiness level for ultra-high temperature materials. Applications include non-eroding nozzle materials and lightweight, high-temperature alloys for turbines and structures.

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.

Advanced solar panel designs

NASA Technical Reports Server (NTRS)

Ralph, E. L.; Linder, E.

1995-01-01

This paper describes solar cell panel designs that utilize new hgih efficiency solar cells along with lightweight rigid panel technology. The resulting designs push the W/kg and W/sq m parameters to new high levels. These new designs are well suited to meet the demand for higher performance small satellites. This paper reports on progress made on two SBIR Phase 1 contracts. One panel design involved the use of large area (5.5 cm x 6.5 cm) GaAs/Ge solar cells of 19% efficiency combined with a lightweight rigid graphite fiber epoxy isogrid substrate configuration. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power level of 60 W/kg with a potential of reaching 80 W/kg. The second panel design involved the use of newly developed high efficiency (22%) dual junction GaInP2/GaAs/Ge solar cells combined with an advanced lightweight rigid substrate using aluminum honeycomb core with high strength graphite fiber mesh facesheets. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power of 105 W/kg and 230 W/sq m. This paper will address the construction details of the panels and an a analysis of the component weights. A strawman array design suitable for a typical small-sat mission is described for each of the two panel design technologies being studied. Benefits in respect to weight reduction, area reduction, and system cost reduction are analyzed and compared to conventional arrays.

Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion - an Overview

NASA Astrophysics Data System (ADS)

Thomä, M.; Wagner, G.; Straß, B.; Conrad, C.; Wolter, B.; Benfer, S.; Fürbeth, W.

2016-03-01

Due to the steadily increasing demand on innovative manufacturing processes, modern lightweight construction concepts become more and more important. Especially joints of dissimilar metals offer a variety of advantages due to their high potential for lightweight construction. The focus of the investigations was Al/Mg-joints. Friction Stir Welding (FSW) is an efficient process to realize high strength joints between these materials in ductile condition. Furthermore, for a simultaneous transmission of power ultrasound during the FSW-process (US-FSW) a positive effect on the achievable tensile strength of the Al/Mg-joints was proven. In the present work the industrial used die cast alloys EN AC-48000 (AlSi12CuNiMg) and AZ80 (MgAl8Zn) were joined by a machining center modified especially for Ultrasound Supported Friction Stir Welding. The appearing welding zone and the formation of intermetallic phases under the influence of power ultrasound were examined in particular. In order to identify optimal process parameters extensive preliminary process analyzes have been carried out. Following this, an ultrasound-induced more intensive stirring of the joining zone and as a result of this a considerably modified intermetallic zone was detected. At the same time an increase of the tensile strength of about 25% for US-FSW-joints and for fatigue an up to three times higher number of cycles to failure in comparison to a conventional welding process was observed. Moreover, detailed corrosion analyzes have shown that especially the welding zone was influenced by the corrosive attack. To expand and deepen the knowledge of the US-FSW-process further material combinations such as Ti/Steel and Al/Steel will be considered in future.

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...

Properties of concrete containing foamed concrete block waste as fine aggregate replacement

NASA Astrophysics Data System (ADS)

Muthusamy, K.; Budiea, A. M. A.; Zaidan, A. L. F.; Rasid, M. H.; Hazimmah, D. S.

2017-11-01

Environmental degradation due to excessive sand mining dumping at certain places and disposal of foamed concrete block waste from lightweight concrete producing industry are issues that should be resolved for a better and cleaner environment of the community. Thus, the main intention of this study is to investigate the potential of foamed concrete block waste as partial sand replacement in concrete production. The foamed concrete waste (FCW) used in this research that were supplied by a local lightweight concrete producing industry. The workability and compressive strength of concrete containing various percentage of foamed concrete waste as partial sand replacement has been investigated. Prior to the use, the foamed concrete waste were crushed to produce finer particles. Six concrete mixes containing various content of crushed foamed concrete waste that are 0%, 10%, 20%, 30%, 40% and 50% were used in this experimental work. Then the prepared specimens were placed in water curing until the testing age. Compressive strength test and flexural strength tests were conducted at 7, 14 and 28 days. The result shows that integration of crushed foamed concrete waste as partial sand replacement in concrete reduces the mix workability. It is interesting to note that both compressive strength and flexural strength of concrete improves when 30% crushed foamed concrete waste is added as partial sand replacement.

On the Formation of Lightweight Nanocrystalline Aluminum Alloys by Electrodeposition

DOE PAGES

Hilty, Robert D.; Masur, Lawrence J.

2017-08-08

New nanocrystalline aluminum alloys have been fabricated by electrodeposition. These are thermodynamically stable alloys of Al-Mn and Al-Zr with grain sizes < 100nm. Al-Mn and Al-Zr alloys are characterized here showing high strength (up to 1350 MPa) and hardness (up to 450 HVN) while maintaining the specific gravity of Al. Smooth and dense deposits plated from ionic liquids, such as EMIM:Cl (1-Ethyl-3-methylimidazolium chloride), can develop to thicknesses of 1mm or more.

Valorization of lignite combustion residues and ferroalumina in the production of aggregates.

PubMed

Anagnostopoulos, I M; Stivanakis, V E; Angelopoulos, G N; Papamantellos, D C

2010-02-15

The present research study investigates the synergy of industrial solid by-products from lignite combustion (fly ash and bottom ash) and aluminum production (ferroalumina) in the production of lightweight aggregates (LWA). The process consists of two stages, pelletization and sintering. Bottom ash (BA) is used as the principal raw material in mixtures while ferroalumina (FAL) is added in lower percentages (5-30 wt%). BA carbon content is used as the fuel of sintering process in high temperatures, around 1250 degrees C, and gas generation is responsible for porous structure formation. Physical properties such as porosity, water absorption and bulk density, of sintering products are measured. Increase of FAL percentage in sintering mixtures results in decrease of porosity from 61% to 35% and of water absorption from 61% to 21% and in increase of bulk density from 1.02 g/cm(3) to 1.80 g/cm(3) of the produced aggregates. Aggregates produced by FAL addition up to 20 wt% are characterized as LWA. Aggregates formed are used in the production of concrete specimens. Compressive strength of concrete increases by increasing FAL addition in aggregates from 5 wt% to 15 wt% (highest strength value), while decrease by increasing FAL addition from 20 wt% to 30 wt%. FAL addition in lignite ashes sintering mixtures (up to 15 wt%) is considered as an important parameter for enhancing aggregates strength.

Study on mechanical properties of steel honeycomb panel three-point bending specimen under in-plane and out-plane transverse dynamic impact load

NASA Astrophysics Data System (ADS)

Zou, Guangping; Chang, Zhongliang; Xia, Xingyou; Zhang, Xueyi

2010-03-01

The metal honeycomb material has high strength and high stiffness, as a high-performance sandwich panel, it is an ideal lightweight structural material, and widely used in aviation, aerospace, shipbuilding and other fields. In this paper, the improved SHPB instrument is used for testing the in-plane and out-plane mechanical properties of the steel honeycomb panel three-point bending specimen, and also compare the results with the static in-plane and out-plane three-point bending experiments results which is tested by the INSTRON 4505 electronic universal testing machine, and then study the mechanical properties of the steel honeycomb panel three-point bending specimen under transverse dynamic impact load. From the results it can be see that, for the out-plane three point bending experiment, L direction mechanical properties is better than the W direction, and the honeycomb core play an important role during the specimen deformation, while for the in-plane three point bending experiment, the honeycomb core mechanical role is not distinctness.

Avian Feathers: An Examination of Lightweight Resilience and Bioinspired Designs

NASA Astrophysics Data System (ADS)

Sullivan, Tarah Naoe

In bird flight, the majority of the wing surface consists of highly refined and hierarchically organized beta-keratinous feathers. Thus, flight feathers contain ingenious combinations of components that optimize lift, stiffness, aerodynamics, and damage resistance. Their design involves two main parts: a central shaft which prescribes stiffness and lateral vanes that allow for the capture of air. Within the feather vane, barbs branch from the shaft and barbules branch from barbs, forming a flat surface and ensuring lift. Microhooks at the end of barbules hold barbs tightly together, providing a close-knit, unified structure and enabling repair of the vane through the reattachment of un-hooked junctions. In this dissertation, unique aspects of feather architecture are explored to uncover principles translatable to the design of modern aerospace materials and structures. Specifically, understudied aspects of the feather's lightweight yet resilient properties are investigated. This research has revealed several novel characteristics of the feather. Allometric scaling relationships are developed linking the geometry of a bird's wing components to its flight characteristics and total mass. Barbule spacing within the feather vane is found to be 8-16 microm for birds ranging from 0.02-11 kg. Additionally, it is discovered that strength is recovered with the shape recovery property of feathers, and a mechanism for this phenomenon is proposed. Barbule adhesion within the vane is found to prevent barbs from twisting in flexure, maintaining the vane's stiffness, and the extent to which unzipping these connections affects the feather's ability to capture air is related to barb shape. Directional permeability of the feather vane is experimentally confirmed and related to the intricate microstructure of barbules. Lastly, the exceptional architecture of the feather motivated the design of novel bioinspired structures with tailored and unique properties. The avian feather serves as an excellent springboard for designs that can be adapted to enhance synthetic materials and structures.

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

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

Carter, Jon T.; Wang, Gerry; Luo, Alan

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improvemore » the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.« less

Mechanical and Tear Properties of Fabric/Film Laminates

NASA Technical Reports Server (NTRS)

Said, Magdi A.

1998-01-01

Films reinforced with woven fabrics are being considered for the development of a material suitable for long duration scientific balloons under a program managed by the National Aeronautics and Space Administration (NASA). Recently developed woven fabrics provide a relatively high strength to weight ratio compared to standard homogenous films. Woven fabrics also have better crack propagation resistance and rip stop capabilities when compared to homogenous lightweight, high strength polymeric films such as polyester and nylon. If joining is required, such as in the case of scientific balloons, woven fabrics have the advantage over polymeric thin films to utilize traditional textile methods as well as other techniques including hot sealing, adhesion, and ultrasonic means. Woven fabrics, however, lack the barrier properties required for helium filled scientific balloons, therefore lamination with homogenous films is required to provide the gas barrier capabilities required in these applications.

Fuel-Cell Structure Prevents Membrane Drying

NASA Technical Reports Server (NTRS)

Mcelroy, J.

1986-01-01

Embossed plates direct flows of reactants and coolant. Membrane-type fuel-cell battery has improved reactant flow and heat removal. Compact, lightweight battery produces high current and power without drying of membranes.

Lightweight electrically-powered flexible thermal laminate. [made of metal and nonconductive yarns

NASA Technical Reports Server (NTRS)

Dawn, F. S.; Sauers, D. G. (Inventor)

1978-01-01

Cross-layered woven or unwoven yarns are used to provide an active thermal control mechanism for spacecraft use. One set of yarns is composed of flexible electrically conductive metal fibers which are capable of being resistance heated by the application of voltage. Another set of yarns, nonconductive and flexible, provides mechanical strength and precludes the passage of electrical current between the metal yarns by virtue of the spacing between them. A lightweight, electrically nonconductive film is bonded to the cross-layered yarns to protect the metal yarns from the elements (minimize electrical shorts from moisture such as rain), to provide additional strength to the fabric, and to prevent conductive loss of heat in nonvacuum applications. The nonconductive film is metalized on its obverse side to provide a more uniform heat load distribution.

Bone density and the lightweight skeletons of birds.

PubMed

Dumont, Elizabeth R

2010-07-22

The skeletons of birds are universally described as lightweight as a result of selection for minimizing the energy required for flight. From a functional perspective, the weight (mass) of an animal relative to its lift-generating surfaces is a key determinant of the metabolic cost of flight. The evolution of birds has been characterized by many weight-saving adaptations that are reflected in bone shape, many of which strengthen and stiffen the skeleton. Although largely unstudied in birds, the material properties of bone tissue can also contribute to bone strength and stiffness. In this study, I calculated the density of the cranium, humerus and femur in passerine birds, rodents and bats by measuring bone mass and volume using helium displacement. I found that, on average, these bones are densest in birds, followed closely by bats. As bone density increases, so do bone stiffness and strength. Both of these optimization criteria are used in the design of strong and stiff, but lightweight, manmade airframes. By analogy, increased bone density in birds and bats may reflect adaptations for maximizing bone strength and stiffness while minimizing bone mass and volume. These data suggest that both bone shape and the material properties of bone tissue have played important roles in the evolution of flight. They also reconcile the conundrum of how bird skeletons can appear to be thin and delicate, yet contribute just as much to total body mass as do the skeletons of terrestrial mammals.

Large aperture telescope technology: a design for an active lightweight multi-segmented fold-out space mirror

NASA Astrophysics Data System (ADS)

Thompson, S. J.; Doel, A. P.; Whalley, M.; Edeson, R.; Edeson, R.; Tosh, I.; Poyntz-Wright, O.; Atad-Ettedgui, E.; Montgomery, D.; Nawasra, J.

2017-11-01

Large aperture telescope technology (LATT) is a design study for a differential lidar (DIAL) system; the main investigation being into suitable methods, technologies and materials for a 4-metre diameter active mirror that can be stowed to fit into a typical launch vehicle (e.g. ROKOT launcher with 2.1-metre diameter cargo) and can self-deploy - in terms of both leaving the space vehicle and that the mirrors unfold and self-align to the correct optical form within the tolerances specified. The primary mirror requirements are: main wavelength of 935.5 nm, RMS corrected wavefront error of λ/6, optical surface roughness better than 5 nm, areal density of less than 16 kg/m2 and 1-2 mirror shape corrections per orbit. The primary mirror consists of 7 segments - a central hexagonal mirror and 6 square mirror petals which unfold to form the 4-meter diameter aperture. The focus of the UK LATT consortium for this European Space Agency (ESA) funded project is on using lightweighted aluminium or carbon-fibre-composite materials for the mirror substrate in preference to more traditional materials such as glass and ceramics; these materials have a high strength and stiffness to weight ratio, significantly reducing risk of damage due to launch forces and subsequent deployment in orbit. We present an overview of the design, which includes suitable actuators for wavefront correction, petal deployment mechanisms and lightweight mirror technologies. Preliminary testing results from manufactured lightweight mirror samples will also be summarised.

Superior Ballistic Impact Resistance Achieved by the Co-Base Alloy Haynes 25

NASA Technical Reports Server (NTRS)

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

2003-01-01

The fan case in a jet engine is required to contain a fan blade in the rare event of a blade loss during operation. Because of its function, the fan case is the largest structural component in high-bypass-ratio turbofan engines used in commercial aircraft. Therefore, the use of lighter and stronger materials would be advantageous in most engines and is practically a necessity in the latest generation of high-bypass engines. Small panels, 7 in. wide by 7 in. long, of a number of metallic alloys were impact tested at room temperature with a 0.50-caliber blunt-nose titanium alloy projectile at the NASA Glenn Research Center (ref. 1). These metallic systems included several high-strength aluminum (Al) alloys, Al-based laminates, aluminum metal matrix composites (Al-MMCs), nickel-base superalloys (Inconel 718 and 625), several titanium (Ti) alloys in different heat treated conditions, 304L stainless steel, a stainless-steel-based laminate, and a high strength steel (Nitronic 60). It was determined that a simple Co-base alloy (Haynes 25) had the best impact resistance on an areal weight basis. Haynes 25 was at least 10 percent better than IMI 550, the best titanium alloy tested to date, and it was far superior to other metals, especially at higher impact velocities (greater than 1100 ft/sec). Because this material could be ideal for fan containment applications in supersonic aircraft as a replacement for titanium, impact tests were also conducted at 371 oC and compared with results from alloys tested at elevated temperature under previous programs (i.e., Inconel 718, Ti-6242, M-152, Timetal 21S, and Aeromet 100). Although cobalt-base alloys are used in some high-temperature engine applications, to our knowledge they are not used in any containment systems. Advantages of cobalt over titanium include lower cost, easier processing, better high-temperature strength, and no fire hazard if tip rub occurs. Future plans include testing of lightweight sandwich panels with Haynes 25 as a core material in the form of a foam or lattice block structure and scaling up the current tests by using blade-simulating projectiles impacting large plates and half rings.

Improving UV Resistance of High Performance Fibers

NASA Astrophysics Data System (ADS)

Hassanin, Ahmed

High performance fibers are characterized by their superior properties compared to the traditional textile fibers. High strength fibers have high modules, high strength to weight ratio, high chemical resistance, and usually high temperature resistance. It is used in application where superior properties are needed such as bulletproof vests, ropes and cables, cut resistant products, load tendons for giant scientific balloons, fishing rods, tennis racket strings, parachute cords, adhesives and sealants, protective apparel and tire cords. Unfortunately, Ultraviolet (UV) radiation causes serious degradation to the most of high performance fibers. UV lights, either natural or artificial, cause organic compounds to decompose and degrade, because the energy of the photons of UV light is high enough to break chemical bonds causing chain scission. This work is aiming at achieving maximum protection of high performance fibers using sheathing approaches. The sheaths proposed are of lightweight to maintain the advantage of the high performance fiber that is the high strength to weight ratio. This study involves developing three different types of sheathing. The product of interest that need be protected from UV is braid from PBO. First approach is extruding a sheath from Low Density Polyethylene (LDPE) loaded with different rutile TiO2 % nanoparticles around the braid from the PBO. The results of this approach showed that LDPE sheath loaded with 10% TiO2 by weight achieved the highest protection compare to 0% and 5% TiO2. The protection here is judged by strength loss of PBO. This trend noticed in different weathering environments, where the sheathed samples were exposed to UV-VIS radiations in different weatheromter equipments as well as exposure to high altitude environment using NASA BRDL balloon. The second approach is focusing in developing a protective porous membrane from polyurethane loaded with rutile TiO2 nanoparticles. Membrane from polyurethane loaded with 4% rutile TiO2 nanoparticles showed excellent protection of braid from PBO. Only 7.5% strength loss was observed. To optimize the degree of protection of the sheath loaded with UV blocker particles, computational models were developed to optimize the protective layer thickness/weight and the amount of UV particles that provide the maximum protection with lightest weight of the protective layer and minimum amount of UV particles. The simulated results were found to be higher that the experimental results due to the tendency of nanoparticles to be agglomerated in real experiments. The third approach to achieve a maximum protection with the minimum weight added is constructing a sleeve from SpectraRTM (Ultra High Molecular Weight Polyethylene (UHMWPE) high performance fiber), which is known to resist UV, woven fabric. Covering the braid from PBO fiber with Spectra RTM woven fabric provide hybrid structure with two compatible components that can share the load and thus maintain the high strength to weight ratio. Although the SpectraRTM fabric had maximum cover factor, 20 % of visible light and about 15 % of UV were able to penetrate the fabric. This transmittance of UV-VIS light negatively affected the protection performance of the SpectraRTM woven fabric layer. It is thought that SpectraRTM fabric be coated with a thin layer (mentioned earlier) containing UV blocker for additional protection while maintain strength contribution to the hybrid structure. To maximize the strength to weight ratio of the hybrid structure (with core from PBO braid and sheath from SpectraRTM woven fabric) an established finite element model was utilized. The theoretical results using the finite element theory indicated that by controlling the bending rigidity of the filling yarn of the SpectraRTM fabric, the extension at peak load of woven fabric in warp direction (loading direction) could be controlled to match the braid extension at peak load. The match in the extension at peak load of the two components of the hybrid structure allowed the maximum strength to weight ratio. Thus, the SpectraRTM woven layer could achieve both the protection from UV and the load share in the hybrid structure.

Advanced Metal Foam Structures for Outer Space

NASA Technical Reports Server (NTRS)

Hanan, Jay; Johnson, William; Peker, Atakan

2005-01-01

A document discusses a proposal to use advanced materials especially bulk metallic glass (BMG) foams in structural components of spacecraft, lunar habitats, and the like. BMG foams, which are already used on Earth in some consumer products, are superior to conventional metal foams: BMG foams have exceptionally low mass densities and high strength-to-weight ratios and are more readily processable into strong, lightweight objects of various sizes and shapes. These and other attractive properties of BMG foams would be exploited, according to the proposal, to enable in situ processing of BMG foams for erecting and repairing panels, shells, containers, and other objects. The in situ processing could include (1) generation of BMG foams inside prefabricated deployable skins that would define the sizes and shapes of the objects thus formed and (2) thermoplastic deformation of BMG foams. Typically, the generation of BMG foams would involve mixtures of precursor chemicals that would be subjected to suitable pressure and temperature schedules. In addition to serving as structural components, objects containing or consisting of BMG foams could perform such functions as thermal management, shielding against radiation, and shielding against hypervelocity impacts of micrometeors and small debris particles.

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.

Computer Simulation of Fracture in Aerogels

NASA Technical Reports Server (NTRS)

Good, Brian S.

2006-01-01

Aerogels are of interest to the aerospace community primarily for their thermal properties, notably their low thermal conductivities. While the gels are typically fragile, recent advances in the application of conformal polymer layers to these gels has made them potentially useful as lightweight structural materials as well. In this work, we investigate the strength and fracture behavior of silica aerogels using a molecular statics-based computer simulation technique. The gels' structure is simulated via a Diffusion Limited Cluster Aggregation (DLCA) algorithm, which produces fractal structures representing experimentally observed aggregates of so-called secondary particles, themselves composed of amorphous silica primary particles an order of magnitude smaller. We have performed multi-length-scale simulations of fracture in silica aerogels, in which the interaction b e e n two secondary particles is assumed to be described by a Morse pair potential parameterized such that the potential range is much smaller than the secondary particle size. These Morse parameters are obtained by atomistic simulation of models of the experimentally-observed amorphous silica "bridges," with the fracture behavior of these bridges modeled via molecular statics using a Morse/Coulomb potential for silica. We consider the energetics of the fracture, and compare qualitative features of low-and high-density gel fracture.

Advanced Aerospace Materials by Design

NASA Technical Reports Server (NTRS)

Srivastava, Deepak; Djomehri, Jahed; Wei, Chen-Yu

2004-01-01

The advances in the emerging field of nanophase thermal and structural composite materials; materials with embedded sensors and actuators for morphing structures; light-weight composite materials for energy and power storage; and large surface area materials for in-situ resource generation and waste recycling, are expected to :revolutionize the capabilities of virtually every system comprising of future robotic and :human moon and mars exploration missions. A high-performance multiscale simulation platform, including the computational capabilities and resources of Columbia - the new supercomputer, is being developed to discover, validate, and prototype next generation (of such advanced materials. This exhibit will describe the porting and scaling of multiscale 'physics based core computer simulation codes for discovering and designing carbon nanotube-polymer composite materials for light-weight load bearing structural and 'thermal protection applications.

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...

Optimization of the gypsum-based materials by the sequential simplex method

NASA Astrophysics Data System (ADS)

Doleželová, Magdalena; Vimmrová, Alena

2017-11-01

The application of the sequential simplex optimization method for the design of gypsum based materials is described. The principles of simplex method are explained and several examples of the method usage for the optimization of lightweight gypsum and ternary gypsum based materials are given. By this method lightweight gypsum based materials with desired properties and ternary gypsum based material with higher strength (16 MPa) were successfully developed. Simplex method is a useful tool for optimizing of gypsum based materials, but the objective of the optimization has to be formulated appropriately.

Utilization of fly ash and ultrafine GGBS for higher strength foam concrete

NASA Astrophysics Data System (ADS)

Gowri, R.; Anand, K. B.

2018-02-01

Foam concrete is a widely accepted construction material, which is popular for diverse construction applications such as, thermal insulation in buildings, lightweight concrete blocks, ground stabilization, void filling etc. Currently, foam concrete is being used for structural applications with a density above 1800kg/m3. This study focuses on evolving mix proportions for foam concrete with a material density in the range of 1200 kg/m3 to 1600 kg/m3, so as to obtain strength ranges that will be sufficient to adopt it as a structural material. Foam concrete is made lighter by adding pre-formed foam of a particular density to the mortar mix. The foaming agent used in this study is Sodium Lauryl Sulphate and in order to densify the foam generated, Sodium hydroxide solution at a normality of one is also added. In this study efforts are made to make it a sustainable construction material by incorporating industrial waste products such as ultrafine GGBS as partial replacement of cement and fly ash for replacement of fine aggregate. The fresh state and hardened state properties of foam concrete at varying proportions of cement, sand, water and additives are evaluated. The proportion of ultrafine GGBS and fly ash in the foam concrete mix are varied aiming at higher compressive strength. Studies on air void-strength relationship of foam concrete are also included in this paper.

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.

Cryogenic Fracture Toughness Improvement for the Super Lightweight Tank's Main Structural Alloy

NASA Technical Reports Server (NTRS)

Chen, P. S.; Stanton, W. P.

2002-01-01

Marshall Space Flight Center has developed a two-step (TS) artificial aging technique that can significantly enhance cryogenic fracture toughness and resistance to stress corrosion cracking (SCC) in aluminum-copper-lithium alloy 2195. The new TS aging treatment consists of exposures at 132 C (270 F)/20 hr + 138 C (280 F)/42 hr, which can be readily applied to flight hardware production. TS aging achieves the same yield strength levels as conventional aging, while providing much improved ductility in the short transverse direction. After TS aging, five previously rejected lots of alloy 2195 (lots 950M029B, 960M030F, 960M030J, 960M030K, and 960M030L) passed simulated service testing for use in the super lightweight tank program. Each lot exhibited higher fracture toughness at cryogenic temperature than at ambient temperature. Their SCC resistance was also enhanced. All SCC specimens passed the minimum 10-day requirement in 3.5-percent sodium chloride alternate immersion at a stress of 45 ksi. The SCC lives ranged from 57 to 83 days, with an average of 70 days.

Mechanical Properties of Lightweight Porous Magnesium Processed Through Powder Metallurgy

NASA Astrophysics Data System (ADS)

Zou, Ning; Li, Qizhen

2018-02-01

Porous magnesium (Mg) samples with various overall porosities (28.4 ± 1.8%, 35.5 ± 2.5%, 45.4 ± 1.9%, and 62.4 ± 2.2%) were processed through powder metallurgy and characterized to study their mechanical properties. Different porosities were obtained by utilizing different mass fractions of space holder camphene. Camphene was removed by sublimation before sintering and contributed to processing porous Mg with high purity and small average pore size. The average pore size increased from 5.2 µm to 15.1 µm with increase of the porosity from 28.4 ± 1.8% to 62.4 ± 2.2%. Compressive strain-stress data showed that the strain hardening rate, yield strength, and ultimate compressive strength decreased with increase of the porosity. The theoretical yield strength of porous Mg obtained using the Gibson-Ashby model agreed with experimental data.

Method of casting patterned dielectric structures

DOEpatents

Poco, John F.; Hrubesh, Lawrence W.

2001-01-01

A pattern of dielectric structures are formed directly on a substrate in a single step using sol-gel chemistry and molding procedures. The resulting dielectric structures are useful in vacuum applications for electronic devices. Porous, lightweight structures having a high aspect ratio that are suitable for use as spacers between the faceplate and baseplate of a field emission display can be manufactured using this method.

Innovative and Highly Productive Joining Technologies for Multi-Material Lightweight Car Body Structures

NASA Astrophysics Data System (ADS)

Meschut, G.; Janzen, V.; Olfermann, T.

2014-05-01

Driven by increasing costs for energy and raw material and especially by the European CO2-emission laws, automotive industry faces the challenge to develop more lightweight and at the same time still rigid and crash-stable car bodies, that are affordable for large-scale production. The implementation of weight-reduced constructions depends not only on the availability of lightweight materials and related forming technologies, but also on cost-efficient and reliable joining technologies suitable for multi-material design. This article discusses the challenges and requirements for these technologies, based on the example of joining aluminium with press-hardened boron steels, what is considered as a very important material combination for affordable future lightweight mobility. Besides a presentation of recent developments for extending the process limits of conventional mechanical joining methods, new promising technologies such as resistance element welding are introduced. In addition, the performance, advantages, and disadvantages of the presented technologies are compared and discussed.

Megavolt, Multigigawatt Pulsed Plasma Switch

NASA Technical Reports Server (NTRS)

Lee, Ja H.; Choi, Sang H.; Song, Kyo D.

1996-01-01

Plasma switch proposed for use in high-voltage, high-current pulse power system. Designed not only to out-perform conventional spark-gap switch but also relatively compact and lightweight. Features inverse-pinch configuration to prevent constriction of current sheets into filaments, plus multiple-ring-electrode structure to resist high-voltage breakdown.

Engineering properties of lightweight geopolymer synthesized from coal bottom ash and rice husk ash

NASA Astrophysics Data System (ADS)

Thang, Nguyen Hoc; Hoa, Nguyen Ngoc; Quyen, Pham Vo Thi Ha; Tuyen, Nguyen Ngoc Kim; Anh, Tran Vu Thao; Kien, Pham Trung

2018-04-01

Geopolymer technology was developed by Joseph Davidovits in 1970s based on reactions among alumino-silicate resources in high alkaline conditions. Geopolymer has been recently gaining attention as an alternative binder for Ordinary Portland cement (OPC) due to its low energy and CO2 burden. The raw materials used for geopolymerization normally contain high SiO2 and Al2O3 in the chemical compositions such as meta-kaoline, rice husk ash, fly ash, bottom ash, blast furnace slag, red mud, and others. Moreover, in this paper, coal bottom ash (CBA) and rice husk ash (RHA), which are industrial and agricultural wastes, respectively, were used as raw materials with high alumino-silicate resources. Both CBA and RHA were mixed with sodium hydroxide (NaOH) solution for 20 minutes to obtain the geopolymer pastes. The pastes were filled in 5-cm cube molds according to ASTM C109/C109M 99, and then cured at room condition for hardening of the geopolymer specimens. After 24 hours, the specimens were removed out of the molds and continuously cured at room condition for 27 days. The geopolymer-based materials were then tested for engineering properties such as compressive strength (MPa), volumetric weight (kg/m3), and water absorption (kg/m3). Results indicated that the material can be considered lightweight with volumetric weight from 1192 to 1425 kg/m3; compressive strength at 28 days is in the range of 12.38 to 37.41 MPa; and water absorption is under 189.92 kg/m3.

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.

Micromechanics of Amorphous Metal/Polymer Hybrid Structures with 3D Cellular Architectures: Size Effects, Buckling Behavior, and Energy Absorption Capability.

PubMed

Mieszala, Maxime; Hasegawa, Madoka; Guillonneau, Gaylord; Bauer, Jens; Raghavan, Rejin; Frantz, Cédric; Kraft, Oliver; Mischler, Stefano; Michler, Johann; Philippe, Laetitia

2017-02-01

By designing advantageous cellular geometries and combining the material size effects at the nanometer scale, lightweight hybrid microarchitectured materials with tailored structural properties are achieved. Prior studies reported the mechanical properties of high strength cellular ceramic composites, obtained by atomic layer deposition. However, few studies have examined the properties of similar structures with metal coatings. To determine the mechanical performance of polymer cellular structures reinforced with a metal coating, 3D laser lithography and electroless deposition of an amorphous layer of nickel-boron (NiB) is used for the first time to produce metal/polymer hybrid structures. In this work, the mechanical response of microarchitectured structures is investigated with an emphasis on the effects of the architecture and the amorphous NiB thickness on their deformation mechanisms and energy absorption capability. Microcompression experiments show an enhancement of the mechanical properties with the NiB thickness, suggesting that the deformation mechanism and the buckling behavior are controlled by the brittle-to-ductile transition in the NiB layer. In addition, the energy absorption properties demonstrate the possibility of tuning the energy absorption efficiency with adequate designs. These findings suggest that microarchitectured metal/polymer hybrid structures are effective in producing materials with unique property combinations. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

CRUX: a Compliant Robotic Upper-Extremity eXosuit for Lightweight, Portable, Multi-DoF Muscular Augmentation

NASA Technical Reports Server (NTRS)

Lessard, Steven; Pansodtee, Pattawong; Robbins, Ash; Baltaxe-Admony, Leya Breanna; Teodorescu, Mircea; Kurniawan,Sri; Agogino, Adrian; Kurniawan, Sri

2017-01-01

Wearable robots can potentially offer their users enhanced stability and strength. These augmentations are ideally designed to actuate harmoniously with the users movements and provide extra force as needed. The creation of such robots, however, is particularly challenging due to the complexity of the underlying human body. In this paper, we present a compliant, robotic exosuit for upper-extremities called CRUX. This exosuit, inspired by tensegrity models of the human arm, features a lightweight (1.3 kg), flexible design for portability. We also show how CRUX maintains full flexibility of the upper-extremities for its users while providing multi- DoF augmentative strength to the major muscles of the arm, as evident by tracking the heart rate of an individual exercising said arm. Exosuits such as CRUX may be useful in physical therapy and in extreme environments where users are expected to exert their bodies to the fullest extent.

Characterization of a High Strength, Refractory High Entropy Alloy, AlMo0.5NbTa0.5TiZr

NASA Astrophysics Data System (ADS)

Jensen, Jacob

High entropy alloys (HEAs) are a relatively new class of materials that have garnered significant interest over the last decade due to their intriguing balance of properties including high strength, toughness, and corrosion resistance. In contrast to conventional alloy systems, HEAs are based on four or more principal elements with near equimolar concentrations and tend to have simple microstructures due to the preferential formation of solid solution phases. HEAs appear to offer new pathways to lightweighting in structural applications, new alloys for elevated temperature components, and new magnetic materials, but more thorough characterization studies are needed to assess the viability of the recently developed multicomponent materials. One such HEA, AlMo0.5NbTa0.5TiZr, was selected to be the basis for this characterization study in part due to its strength at elevated temperatures (sigma0.2 = 1600 MPa at T = 800 °C) and low density compared with commercially available Ni-based superalloys. The refractory element containing HEA composition was developed in order to balance the high temperature strength of the refractory elements with the desirable properties achieved by the high entropy alloying design approach for potential use in aerospace thermal protection and structural applications. Ingots of AlMo0.5NbTa0.5TiZr were cast by vacuum arc melting followed by hot isostatic pressing (HIP) and homogenization at 1400 °C for 24 hrs with a furnace cool of 10 °C/min. The resulting microstructure was characterized at multiple length scales using x-ray diffraction (XRD), scanning transmission electron microscopy (SEM), conventional and scanning transmission electron microscopy (TEM and STEM), and x-ray energy dispersive spectroscopy (XEDS). The microstructure was found to consist of a periodic, coherent two phase mixture, where a disordered bcc phase is aligned orthogonally in an ordered B2 phase. Through microstructural evolution heat treatment studies, the nanoscale interpenetrating microstructure was discovered to form via a conditional spinodal reaction pathway involving a congruent ordering transformation preceding spinodal decomposition. In order to gain a comprehensive understanding of the true morphology of these phases and obtain a novel perspective of 3D elemental segregation in the HEA, STEM-high angle annular darkfield (HAADF) micrographs and XEDS spectral images were utilized in the tomographic reconstruction of the microstructure, which was inherently difficult to observe through conventional characterization techniques. The microstructure of the alloy was ultimately refined by incremental variations to the base alloy composition in an effort to remove deleterious intermetallic phases adversely affecting ductility. Despite the excellent compressive strength across a wide range of temperatures and the ability to tailor the microstructure by compositional modifications, microstructural and phase transformations in the desired operating temperature range indicate that the AlMo0.5NbTa0.5TiZr alloy may not be a suitable material for high temperature aerospace structural components.

Mg-Al-Ca In-Situ Composites with a Refined Eutectic Structure and Their Compressive Properties

NASA Astrophysics Data System (ADS)

Shi, Ling-Ling; Xu, Jian; Ma, Evan

2008-05-01

In a series of Mg x (Al2Ca)100- x (76 ≤ x ≤ 87) ternary alloys near the Mg-(Mg,Al)2Ca pseudo-binary eutectic point, different phases and morphologies based on ultrafine eutectic microstructure have been obtained by controlling the composition and changing the cooling rate via either induction melting or copper mold casting. For 81 ≤ x ≤ 87, the chill-cast alloys with ductile Mg dendrites embedded in an ultrafine [Mg + (Mg,Al)2Ca] eutectic matrix exhibit gradually increased fracture strength from 415 to 491 MPa with the decrease of Mg content. At x = 79, the Mg79Al14Ca7 alloy contains hard (Mg,Al)2Ca precipitates coexisting with ductile Mg dendrite, dispersed in the strong eutectic matrix. This alloy exhibits the highest compressive fracture strength (600 MPa), and the specific strength reaches 3.4 × 105 N·m·kg-1. The alloys all exhibit substantial plastic strain (5 to 6 pct). The attainment of such a combination of strength and plasticity is an interesting and useful step in improving the mechanical properties of lightweight Mg alloys.

Mechanical and Microstructural Evaluations of Lightweight Aggregate Geopolymer Concrete before and after Exposed to Elevated Temperatures

PubMed Central

Abdulkareem, Omar A.; Abdullah, Mohd Mustafa Al Bakri; Hussin, Kamarudin; Ismail, Khairul Nizar; Binhussain, Mohammed

2013-01-01

This paper presents the mechanical and microstructural characteristics of a lightweight aggregate geopolymer concrete (LWAGC) synthesized by the alkali-activation of a fly ash source (FA) before and after being exposed to elevated temperatures, ranging from 100 to 800 °C. The results show that the LWAGC unexposed to the elevated temperatures possesses a good strength-to-weight ratio compared with other LWAGCs available in the published literature. The unexposed LWAGC also shows an excellent strength development versus aging times, up to 365 days. For the exposed LWAGC to the elevated temperatures of 100 to 800 °C, the results illustrate that the concretes gain compressive strength after being exposed to elevated temperatures of 100, 200 and 300 °C. Afterward, the strength of the LWAGC started to deteriorate and decrease after being exposed to elevated temperatures of 400 °C, and up to 800 °C. Based on the mechanical strength results of the exposed LWAGCs to elevated temperatures of 100 °C to 800 °C, the relationship between the exposure temperature and the obtained residual compressive strength is statistically analyzed and achieved. In addition, the microstructure investigation of the unexposed LWAGC shows a good bonding between aggregate and mortar at the interface transition zone (ITZ). However, this bonding is subjected to deterioration as the LWAGC is exposed to elevated temperatures of 400, 600 and 800 °C by increasing the microcrack content and swelling of the unreacted silicates. PMID:28788339

Mechanical and Microstructural Evaluations of Lightweight Aggregate Geopolymer Concrete before and after Exposed to Elevated Temperatures.

PubMed

Abdulkareem, Omar A; Abdullah, Mohd Mustafa Al Bakri; Hussin, Kamarudin; Ismail, Khairul Nizar; Binhussain, Mohammed

2013-10-09

This paper presents the mechanical and microstructural characteristics of a lightweight aggregate geopolymer concrete (LWAGC) synthesized by the alkali-activation of a fly ash source (FA) before and after being exposed to elevated temperatures, ranging from 100 to 800 °C. The results show that the LWAGC unexposed to the elevated temperatures possesses a good strength-to-weight ratio compared with other LWAGCs available in the published literature. The unexposed LWAGC also shows an excellent strength development versus aging times, up to 365 days. For the exposed LWAGC to the elevated temperatures of 100 to 800 °C, the results illustrate that the concretes gain compressive strength after being exposed to elevated temperatures of 100, 200 and 300 °C. Afterward, the strength of the LWAGC started to deteriorate and decrease after being exposed to elevated temperatures of 400 °C, and up to 800 °C. Based on the mechanical strength results of the exposed LWAGCs to elevated temperatures of 100 °C to 800 °C, the relationship between the exposure temperature and the obtained residual compressive strength is statistically analyzed and achieved. In addition, the microstructure investigation of the unexposed LWAGC shows a good bonding between aggregate and mortar at the interface transition zone (ITZ). However, this bonding is subjected to deterioration as the LWAGC is exposed to elevated temperatures of 400, 600 and 800 °C by increasing the microcrack content and swelling of the unreacted silicates.

Lightweight bladder lined pressure vessels

DOEpatents

Mitlitsky, F.; Myers, B.; Magnotta, F.

1998-08-25

A lightweight, low permeability liner is described for graphite epoxy composite compressed gas storage vessels. The liner is composed of polymers that may or may not be coated with a thin layer of a low permeability material, such as silver, gold, or aluminum, deposited on a thin polymeric layer or substrate which is formed into a closed bladder using tori spherical or near tori spherical end caps, with or without bosses therein, about which a high strength to weight material, such as graphite epoxy composite shell, is formed to withstand the storage pressure forces. The polymeric substrate may be laminated on one or both sides with additional layers of polymeric film. The liner may be formed to a desired configuration using a dissolvable mandrel or by inflation techniques and the edges of the film sealed by heat sealing. The liner may be utilized in most any type of gas storage system, and is particularly applicable for hydrogen, gas mixtures, and oxygen used for vehicles, fuel cells or regenerative fuel cell applications, high altitude solar powered aircraft, hybrid energy storage/propulsion systems, and lunar/Mars space applications, and other applications requiring high cycle life. 19 figs.

Structure-processing correlations and mechanical properties in freeze-cast Ti-6Al-4V with highly aligned porosity and a lightweight Ti-6Al-4V-PMMA composite with excellent energy absorption capability

DOE PAGES

Weaver, Jordan S.; Kalidindi, Surya R.; Wegst, Ulrike G. K.

2017-02-12

In contrast to freeze-cast ceramics and polymers, few freeze-cast metals have been described, to date. This systematic study on structure-processing correlations in freeze-cast Ti-6Al-4V scaffolds reports how processing parameters determine the architecture formed during the directional solidification of water-based metal slurries and after sintering. Additionally, sedimentation in the slurry during freezing and volume shrinkage during burnout and sintering were found to significantly affect both structure and properties of the scaffolds. In using two freezing rates, 1 and 10 °C min -1, two water-based polymer solutions as binders (chitosan and carboxymethyl cellulose) and two different metal volume fractions in the slurry,more » 20 and 30 vol%, Ti-6Al-4V scaffolds could be prepared with pore length, width, and porosity ranging from 41 to 523 μm, 14.5–76.5 μm, and 65 to 34%, respectively. Their compressive strength, stiffness, and toughness (work to 20% strain) fall in the range of 83–412 MPa, 7–29 GPa, and 14–122 MJ m -3, respectively. In order to improve the properties a select composition was infiltrated with poly(methyl methacrylate). This increased the average yield strength by a factor of 2.3 from 83 to 193 MPa and the average toughness (work to 50% strain) by a factor of 2.7 from 28.1 to 76.8 MJ m -3.« less

Structure-processing correlations and mechanical properties in freeze-cast Ti-6Al-4V with highly aligned porosity and a lightweight Ti-6Al-4V-PMMA composite with excellent energy absorption capability

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

Weaver, Jordan S.; Kalidindi, Surya R.; Wegst, Ulrike G. K.

In contrast to freeze-cast ceramics and polymers, few freeze-cast metals have been described, to date. This systematic study on structure-processing correlations in freeze-cast Ti-6Al-4V scaffolds reports how processing parameters determine the architecture formed during the directional solidification of water-based metal slurries and after sintering. Additionally, sedimentation in the slurry during freezing and volume shrinkage during burnout and sintering were found to significantly affect both structure and properties of the scaffolds. In using two freezing rates, 1 and 10 °C min -1, two water-based polymer solutions as binders (chitosan and carboxymethyl cellulose) and two different metal volume fractions in the slurry,more » 20 and 30 vol%, Ti-6Al-4V scaffolds could be prepared with pore length, width, and porosity ranging from 41 to 523 μm, 14.5–76.5 μm, and 65 to 34%, respectively. Their compressive strength, stiffness, and toughness (work to 20% strain) fall in the range of 83–412 MPa, 7–29 GPa, and 14–122 MJ m -3, respectively. In order to improve the properties a select composition was infiltrated with poly(methyl methacrylate). This increased the average yield strength by a factor of 2.3 from 83 to 193 MPa and the average toughness (work to 50% strain) by a factor of 2.7 from 28.1 to 76.8 MJ m -3.« less

Reducing Structural Weight and Increasing Protection in Simple Structures Subjected to Blast Loads

DTIC Science & Technology

2014-08-12

centric vehicle structures that make the operation of the vehicle both comfortable and safe for the soldiers. Furthermore, a lighter weight vehicle...supporting forces. Therefore, a key design challenge is to develop lightweight occupant-centric vehicle structures that can provide high levels of...protection against explosive threats. In this paper, concepts for using materials, damping and other mechanisms to design structures with unique dynamic

Optically Transparent Wood from a Nanoporous Cellulosic Template: Combining Functional and Structural Performance.

PubMed

Li, Yuanyuan; Fu, Qiliang; Yu, Shun; Yan, Min; Berglund, Lars

2016-04-11

Optically transparent wood (TW) with transmittance as high as 85% and haze of 71% was obtained using a delignified nanoporous wood template. The template was prepared by removing the light-absorbing lignin component, creating nanoporosity in the wood cell wall. Transparent wood was prepared by successful impregnation of lumen and the nanoscale cellulose fiber network in the cell wall with refractive-index-matched prepolymerized methyl methacrylate (MMA). During the process, the hierarchical wood structure was preserved. Optical properties of TW are tunable by changing the cellulose volume fraction. The synergy between wood and PMMA was observed for mechanical properties. Lightweight and strong transparent wood is a potential candidate for lightweight low-cost, light-transmitting buildings and transparent solar cell windows.

A Novel Application of Eddy Current Braking for Functional Strength Training during Gait

PubMed Central

Washabaugh, Edward P.; Claflin, Edward S.; Gillespie, R. Brent; Krishnan, Chandramouli

2016-01-01

Functional strength training is becoming increasingly popular when rehabilitating individuals with neurological injury such as stroke or cerebral palsy. Typically, resistance during walking is provided using cable robots or weights that are secured to the distal shank of the subject. However, there exists no device that is wearable and capable of providing resistance across the joint, allowing over ground gait training. In this study, we created a lightweight and wearable device using eddy current braking to provide resistance to the knee. We then validated the device by having subjects wear it during a walking task through varying resistance levels. Electromyography and kinematics were collected to assess the biomechanical effects of the device on the wearer. We found that eddy current braking provided resistance levels suitable for functional strength training of leg muscles in a package that is both lightweight and wearable. Applying resistive forces at the knee joint during gait resulted in significant increases in muscle activation of many of the muscles tested. A brief period of training also resulted in significant aftereffects once the resistance was removed. These results support the feasibility of the device for functional strength training during gait. Future research is warranted to test the clinical potential of the device in an injured population. PMID:26817456

A Novel Application of Eddy Current Braking for Functional Strength Training During Gait.

PubMed

Washabaugh, Edward P; Claflin, Edward S; Gillespie, R Brent; Krishnan, Chandramouli

2016-09-01

Functional strength training is becoming increasingly popular when rehabilitating individuals with neurological injury such as stroke or cerebral palsy. Typically, resistance during walking is provided using cable robots or weights that are secured to the distal shank of the subject. However, there exists no device that is wearable and capable of providing resistance across the joint, allowing over ground gait training. In this study, we created a lightweight and wearable device using eddy current braking to provide resistance to the knee. We then validated the device by having subjects wear it during a walking task through varying resistance levels. Electromyography and kinematics were collected to assess the biomechanical effects of the device on the wearer. We found that eddy current braking provided resistance levels suitable for functional strength training of leg muscles in a package that is both lightweight and wearable. Applying resistive forces at the knee joint during gait resulted in significant increases in muscle activation of many of the muscles tested. A brief period of training also resulted in significant aftereffects once the resistance was removed. These results support the feasibility of the device for functional strength training during gait. Future research is warranted to test the clinical potential of the device in an injured population.

Failure mode prediction for composite structural insulated panels with MgO board facings

NASA Astrophysics Data System (ADS)

Smakosz, Łukasz; Kreja, Ireneusz

2018-01-01

Sandwich panels are readily used in civil engineering due to their high strength to weight ratio and the ease and speed of assembly. The idea of a sandwich section is to combine thin and durable facings with a light-weight core and the choice of materials used allows obtaining the desired behaviour. Panels in consideration consist of MgO (magnesium oxide) board facings and expanded polystyrene core and are characterized by immunity to biological corrosion, a high thermal insulation and a relatively low impact on environment. Customizing the range of panels to meet market needs requires frequent size changes, leading to different failure modes, which are identified in a series of costly full-scale laboratory tests. A nonlinear numerical model was created with a use of a commercial ABAQUS code and a user-defined procedure, which is able to reproduce observed failure mechanisms; its parameters were established on the basis of small-scale tests and numerical experiments. The model was validated by a comparison with the results of the full-scale bending and compression tests. The results obtained were in satisfactory agreement with the test data.

Micro- and nanostructure characterization and imaging of TWIP and unalloyed steels

NASA Astrophysics Data System (ADS)

Batista, L.; Rabe, U.; Hirsekorn, S.

2012-05-01

New design concepts for constructing light-weight and crash resistant transportation systems require the development of high strength and supra-ductile steels with enhanced energy absorption and reduced specific weight. TWIP steels combine these properties, a consequence of intensive mechanical twinning. To understand the mechanisms, related microstructures and local material properties are probed by AFAM, nanoindentation, and EBSD. The morphology of a cementite phase controls the macroscopic mechanical and magnetic properties of steels. Cementite embedded in a ferrite matrix is characterized by AFAM and MFM.

NERVA turbopump bearing retainer fabrication on nonmetallic retainer

NASA Technical Reports Server (NTRS)

Accinelli, J. B.

1972-01-01

The need for a low-wear, lightweight, high strength bearing retainer material with a radiation degradation threshold of 10 to the 9th power rads (C) prompted development of nonmetallic reinforced polymers of the following types: (1) polybenzimidazole, (2) polyimide, and (3) polyquinoxaline. Retainers were machined from tubular laminates (billets), including reinforcement by either glass or graphite fabric or filament. Fabrication of billets involves hot preimpregnation of the reinforcement fabric or filament with polymer followed by wrapping this prepreg over a heated mandrel to form a tube with the required thickness and length.

Selective laser melting of hypereutectic Al-Si40-powder using ultra-short laser pulses

NASA Astrophysics Data System (ADS)

Ullsperger, T.; Matthäus, G.; Kaden, L.; Engelhardt, H.; Rettenmayr, M.; Risse, S.; Tünnermann, A.; Nolte, S.

2017-12-01

We investigate the use of ultra-short laser pulses for the selective melting of Al-Si40-powder to fabricate complex light-weight structures with wall sizes below 100 μ {m} combined with higher tensile strength and lower thermal expansion coefficient in comparison to standard Al-Si alloys. During the cooling process using conventional techniques, large primary silicon particles are formed which impairs the mechanical and thermal properties. We demonstrate that these limitations can be overcome using ultra-short laser pulses enabling the rapid heating and cooling in a non-thermal equilibrium process. We analyze the morphology characteristics and micro-structures of single tracks and thin-walled structures depending on pulse energy, repetition rate and scanning velocity utilizing pulses with a duration of 500 {fs} at a wavelength of 1030 {nm}. The possibility to specifically change and optimize the microstructure is shown.

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-Throughput Combinatorial Development of High-Entropy Alloys For Light-Weight Structural Applications

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

Van Duren, Jeroen K; Koch, Carl; Luo, Alan

The primary limitation of today’s lightweight structural alloys is that specific yield strengths (SYS) higher than 200MPa x cc/g (typical value for titanium alloys) are extremely difficult to achieve. This holds true especially at a cost lower than 5dollars/kg (typical value for magnesium alloys). Recently, high-entropy alloys (HEA) have shown promising SYS, yet the large composition space of HEA makes screening compositions complex and time-consuming. Over the course of this 2-year project we started from 150 billion compositions and reduced the number of potential low-density (<5g/cc), low-cost (<5dollars/kg) high-entropy alloy (LDHEA) candidates that are single-phase, disordered, solid-solution (SPSS) to amore » few thousand compositions. This was accomplished by means of machine learning to guide design for SPSS LDHEA based on a combination of recursive partitioning, an extensive, experimental HEA database compiled from 24 literature sources, and 91 calculated parameters serving as phenomenological selection rules. Machine learning shows an accuracy of 82% in identifying which compositions of a separate, smaller, experimental HEA database are SPSS HEA. Calculation of Phase Diagrams (CALPHAD) shows an accuracy of 71-77% for the alloys supported by the CALPHAD database, where 30% of the compiled HEA database is not supported by CALPHAD. In addition to machine learning, and CALPHAD, a third tool was developed to aid design of SPSS LDHEA. Phase diagrams were calculated by constructing the Gibbs-free energy convex hull based on easily accessible enthalpy and entropy terms. Surprisingly, accuracy was 78%. Pursuing these LDHEA candidates by high-throughput experimental methods resulted in SPSS LDHEA composed of transition metals (e.g. Cr, Mn, Fe, Ni, Cu) alloyed with Al, yet the high concentration of Al, necessary to bring the mass density below 5.0g/cc, makes these materials hard and brittle, body-centered-cubic (BCC) alloys. A related, yet multi-phase BCC alloy, based on Al-Cr-Fe-Ni, shows compressive strain >10% and specific compressive yield strength of 229 MPa x cc/g, yet does not show ductility in tensile tests due to cleavage. When replacing Cr in Al-Cr-Fe-based 4- and 5-element LDHEA with Mn, hardness drops 2x. Combined with compression test results, including those on the ternaries Al-Cr-Fe and Al-Mn-Fe suggest that Al-Mn-Fe-based LDHEA are still worth pursuing. These initial results only represent one compressive stress-strain curve per composition without any property optimization. As such, reproducibility needs to be followed by optimization to show their full potential. When including Li, Mg, and Zn, single-phase Li-Mg-Al-Ti-Zn LDHEA has been found with a specific ultimate compressive strength of 289MPa x cc/g. Al-Ti-Mn-Zn showed a specific ultimate compressive strength of 73MPa x cc/g. These initial results after hot isostatic pressing (HIP) of the ball-milled powders represent the lower end of what is possible, since no secondary processing (e.g. extrusion) has been performed to optimize strength and ductility. Compositions for multi-phase (e.g. dual-phase) LDHEA were identified largely by automated searches through CALPHAD databases, while screening for large face-centered-cubic (FCC) volume fractions, followed by experimental verification. This resulted in several new alloys. Li-Mg-Al-Mn-Fe and Mg-Mn-Fe-Co ball-milled powders upon HIP show specific ultimate compressive strengths of 198MPa x cc/g and 45MPa x cc/g, respectively. Several malleable quarternary Al-Zn-based alloys have been found upon arc/induction melting, yet with limited specific compressive yield strength (<75 MPa x cc/g). These initial results are all without any optimization for strength and/or ductility. High-throughput experimentation allowed us to triple the existing experimental HEA database as published in the past 10 years in less than 2 years which happened at a rate 10x higher than previous methods. Furthermore, we showed that high-throughput thin-film combinatorial methods can be used to get insight in isothermal phase diagram slices. Although it is straightforward to map hardness as a function of composition for sputtered, thin-film, compositional gradients by nano-indentation and compare the results to micro-indentation on bulk samples, the simultaneous impact of composition, roughness, film density, and microstructure on hardness requires monitoring all these properties as a function of location on the compositional gradient, including dissecting the impact of these 4 factors on the hardness map. These additional efforts impact throughput significantly. This work shows that a lot of progress has been made over the years in predicting phase formation that aids the discovery of new alloys, yet that a lot of work needs to be done to predict phases more accurately for LDHEA, whether done by CALPHAD or by other means. More importantly, more work needs to be done to predict mechanical properties of novel alloys, like yield strength, and ductility. Furthermore, this work shows that there is a need for the generation of an empirical alloy database covering strategic points in a multi-dimensional composition space to allow for faster and more accurate predictive interpolations to identify the oasis in the dessert more quickly. Finally, this work suggests that it is worth pursuing a ductile alloy with a SYS > 300 MPa x cc/g in a mass density range of 6-7 g/cc, since the chances for a single-phase or majority-phase FCC increase significantly. Today’s lightweight steels are in this density range.« less

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.

Fe-Mn(Al, Si) TWIP steel - strengthening characteristics and weldability

NASA Astrophysics Data System (ADS)

Podany, P.; Koukolikova, M.; Kubina, T.; Prochazka, R.; Franc, A.

2017-02-01

Twinning Induced Plasticity steel, or TWIP steel, has had increased interest in recent years from various industry sectors. This is due to it being lightweight, strong, and ductile; which are all properties that are useful in the automotive and aerospace industries. These steels potentially can offer lighter weight vehicles and parts with increased strength and other mechanical properties. This combination could offer greater fuel efficiency and performance while at the same time improving the safety features of the vehicle. This steel is characterised by being a high alloy steel, specifically having a high manganese content. It also has a fully austenitic microstructure at room temperature, which is a unique characteristic. But, for TWIP steel to be useful in various industrial sectors, it must have good weldability. This paper deals with the description of the strengthening due to the cold rolling on experimental heats of manganese steel with TRIP/TWIP effect. Impacts on microstructure, yield strength and tensile strength are described. Also, the weldability of experimental TWIP steel by studying the properties of weld joints after laser welding is described.

Efficient Hardware Implementation of the Lightweight Block Encryption Algorithm LEA

PubMed Central

Lee, Donggeon; Kim, Dong-Chan; Kwon, Daesung; Kim, Howon

2014-01-01

Recently, due to the advent of resource-constrained trends, such as smartphones and smart devices, the computing environment is changing. Because our daily life is deeply intertwined with ubiquitous networks, the importance of security is growing. A lightweight encryption algorithm is essential for secure communication between these kinds of resource-constrained devices, and many researchers have been investigating this field. Recently, a lightweight block cipher called LEA was proposed. LEA was originally targeted for efficient implementation on microprocessors, as it is fast when implemented in software and furthermore, it has a small memory footprint. To reflect on recent technology, all required calculations utilize 32-bit wide operations. In addition, the algorithm is comprised of not complex S-Box-like structures but simple Addition, Rotation, and XOR operations. To the best of our knowledge, this paper is the first report on a comprehensive hardware implementation of LEA. We present various hardware structures and their implementation results according to key sizes. Even though LEA was originally targeted at software efficiency, it also shows high efficiency when implemented as hardware. PMID:24406859

Characteristics of joining and hybrid composite forging of aluminum solid parts and galvanized steel sheets

NASA Astrophysics Data System (ADS)

Wesling, V.; Treutler, K.; Bick, T.; Stonis, M.; Langner, J.; Kriwall, M.

2018-06-01

In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving composite hybrid forging has been developed. In this process, an aluminum solid part and a steel sheet were formed in a single step and joined at the same time with zinc as brazing material. For this purpose, the zinc was applied by hot dipping on the aluminum in order to produce a connection via this layer in a forming process, under pressure and heat. Due to the formed intermediate layer of zinc, the formation of the Fe-Al intermetallic phases and the contact corrosion are excluded. By determining the mathematical relationships between joining parameters and the connection properties the strength of a specific joint geometry could be adjusted to reach the level of conventional joining techniques. In addition to the presentation of the joint properties, the influence of the joining process on the structure of the involved materials is also shown. Furthermore, the failure behavior under static tensile and shear stress will be shown.

Poco Graphite Inc. SuperSiC 0.25m Mirror Cryogenic Test Result

NASA Technical Reports Server (NTRS)

Eng, Ron; Stahl, Phil; Hogue, Bill; Hadaway, James

2004-01-01

SuperSiC, a low areal density material, developed by POCO Graphite, have been used as mirror substrate for high energy lasers, laser radar systems, surveillance, telescopes, scan mirrors and satellites. SuperSiC has excellent thermal properties and cryogenic stability. It exhibits exceptional polishability for reflective optics with high strength, stiffness, and excellent thermal conductivity. A lightweighted 0.2-diameter polished SuperSic mirror was tested at cryogenic temperature at NASMSFC. Optical test results showed 6nm cry0 deformation from ambient to 30 degrees Kelvin and little to no change in its surface figure due to cry0 cycling.

Rekindled vision of hypersonic travel

NASA Technical Reports Server (NTRS)

Colladay, Raymond S.

1987-01-01

NASA has joined with the DOD to conduct the National Aerospace Plane (NASP) program, whose experimental test vehicle will be designated the X-30. NASP will study the X-30's takeoff from a runway under its own power, acceleration to high Mach number on the basis of airbreathing propulsion, emergence into LEO, reentry into the earth atmosphere, and descent to a powered horizontal landing. NASP will thereby generate technology base data for three distinct types of aircraft: upper-atmosphere hypersonic-cruise aircraft, LEO space transports, and military transatmospheric vehicles. The current concept-validation phase of NASP focuses on airbreathing propulsion, lightweight/high-strength heat-resistant materials, and computational fluid dynamics.

Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components

NASA Technical Reports Server (NTRS)

Bednarcyk, Brett A.

2005-01-01

This document is the final report for the project entitled, "Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components," funded under the NRA entitled "Cross-Enterprise Technology Development Program" issued by the NASA Office of Space Science in 2000. The project was funded in 2001, and spanned a four year period from March, 2001 to February, 2005. Through enhancements to and synthesis of unique, state of the art structural mechanics and micromechanics analysis software, a new multi-scale tool has been developed that enables design, analysis, and sizing of advance lightweight composite and smart materials and structures from the full vehicle, to the stiffened structure, to the micro (fiber and matrix) scales. The new software tool has broad, cross-cutting value to current and future NASA missions that will rely on advanced composite and smart materials and structures.

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

Energy-momentum conserving higher-order time integration of nonlinear dynamics of finite elastic fiber-reinforced continua

NASA Astrophysics Data System (ADS)

Erler, Norbert; Groß, Michael

2015-05-01

Since many years the relevance of fibre-reinforced polymers is steadily increasing in fields of engineering, especially in aircraft and automotive industry. Due to the high strength in fibre direction, but the possibility of lightweight construction, these composites replace more and more traditional materials as metals. Fibre-reinforced polymers are often manufactured from glass or carbon fibres as attachment parts or from steel or nylon cord as force transmission parts. Attachment parts are mostly subjected to small strains, but force transmission parts usually suffer large deformations in at least one direction. Here, a geometrically nonlinear formulation is necessary. Typical examples are helicopter rotor blades, where the fibres have the function to stabilize the structure in order to counteract large centrifugal forces. For long-run analyses of rotor blade deformations, we have to apply numerically stable time integrators for anisotropic materials. This paper presents higher-order accurate and numerically stable time stepping schemes for nonlinear elastic fibre-reinforced continua with anisotropic stress behaviour.

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.

Corrosion Performance of New Generation Aluminum-Lithium Alloys for Aerospace Applications

NASA Astrophysics Data System (ADS)

Moran, James P.; Bovard, Francine S.; Chrzan, James D.; Vandenburgh, Peter

Over the past several years, a new generation of aluminum-lithium alloys has been developed. These alloys are characterized by excellent strength, low density, and high modulus of elasticity and are therefore of interest for lightweight structural materials applications particularly for construction of current and future aircraft. These new alloys have also demonstrated significant improvements in corrosion resistance when compared with the legacy and incumbent alloys. This paper documents the superior corrosion resistance of the current commercial tempers of these materials and also discusses the corrosion performance as a function of the degree of artificial aging. Results from laboratory corrosion tests are compared with results from exposures in a seacoast atmosphere to assess the predictive capability of the laboratory tests. The correlations that have been developed between the laboratory tests and the seacoast exposures provide confidence that a set of available methods can provide an accurate assessment of the corrosion performance of this new generation of alloys.

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

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

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 New Cementitious Caterials by Alkaline Activating Industrial by-Products

NASA Astrophysics Data System (ADS)

Fernández-Jimenez, A.; García-Lodeiro, I.; Palomo, A.

2015-11-01

The alkaline activation of aluminosiliceous industrial by-products such as blast furnace slag and fly ash is widely known to yield binders whose properties make them comparable to or even stronger and more durable than ordinary Portland cement. The present paper discusses activation fundamentals (such as the type and concentration of alkaline activator and curing conditions) as well as the structure of the cementitious gels formed (C-A-S-H, N-A-S-H). The durability and strength of these systems make these materials apt for use in many industrial applications, such as precast concrete elements (masonery blocks, railroad sleepers), protective coatings for materials with low fire ratings and lightweight elements.

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.

Structural Benchmark Tests of Composite Combustion Chamber Support Completed

NASA Technical Reports Server (NTRS)

Krause, David L.; Thesken, John C.; Shin, E. Eugene; Sutter, James K.

2005-01-01

A series of mechanical load tests was completed on several novel design concepts for extremely lightweight combustion chamber support structures at the NASA Glenn Research Center (http://www.nasa.gov/glenn/). The tests included compliance evaluation, preliminary proof loadings, high-strain cyclic testing, and finally residual strength testing of each design (see the photograph on the left). Loads were applied with single rollers (see the photograph on the right) or pressure plates (not shown) located midspan on each side to minimize the influence of contact stresses on corner deformation measurements. Where rollers alone were used, a more severe structural loading was produced than the corresponding equal-force pressure loading: the maximum transverse shear force existed over the entire length of each side, and the corner bending moments were greater than for a distributed (pressure) loading. Failure modes initiating at the corner only provided a qualitative indication of the performance limitations since the stress state was not identical to internal pressure. Configurations were tested at both room and elevated temperatures. Experimental results were used to evaluate analytical prediction tools and finite-element methodologies for future work, and they were essential to provide insight into the deformation at the corners. The tests also were used to assess fabrication and bonding details for the complicated structures. They will be used to further optimize the design of the support structures for weight performance and the efficacy of corner reinforcement.

Self Healing Fibre-reinforced Polymer Composites: an Overview

NASA Astrophysics Data System (ADS)

Bond, Ian P.; Trask, Richard S.; Williams, Hugo R.; Williams, Gareth J.

Lightweight, high-strength, high-stiffness fibre-reinforced polymer composite materials are leading contenders as component materials to improve the efficiency and sustainability of many forms of transport. For example, their widespread use is critical to the success of advanced engineering applications, such as the Boeing 787 and Airbus A380. Such materials typically comprise complex architectures of fine fibrous reinforcement e.g. carbon or glass, dispersed within a bulk polymer matrix, e.g. epoxy. This can provide exceptionally strong, stiff, and lightweight materials which are inherently anisotropic, as the fibres are usually arranged at a multitude of predetermined angles within discrete stacked 2D layers. The direction orthogonal to the 2D layers is usually without reinforcement to avoid compromising in-plane performance, which results in a vulnerability to damage in the polymer matrix caused by out-of-plane loading, i.e. impact. Their inability to plastically deform leaves only energy absorption via damage creation. This damage often manifests itself internally within the material as intra-ply matrix cracks and inter-ply delaminations, and can thus be difficult to detect visually. Since relatively minor damage can lead to a significant reduction in strength, stiffness and stability, there has been some reticence by designers for their use in safety critical applications, and the adoption of a `no growth' approach (i.e. damage propagation from a defect constitutes failure) is now the mindset of the composites industry. This has led to excessively heavy components, shackling of innovative design, and a need for frequent inspection during service (Richardson 1996; Abrate 1998).

A lightweight low-frequency sound insulation membrane-type acoustic metamaterial

NASA Astrophysics Data System (ADS)

Lu, Kuan; Wu, Jiu Hui; Guan, Dong; Gao, Nansha; Jing, Li

2016-02-01

A novel membrane-type acoustic metamaterial with a high sound transmission loss (STL) at low frequencies (⩽500Hz) was designed and the mechanisms were investigated by using negative mass density theory. This metamaterial's structure is like a sandwich with a thin (thickness=0.25mm) lightweight flexible rubber material within two layers of honeycomb cell plates. Negative mass density was demonstrated at frequencies below the first natural frequency, which results in the excellent low-frequency sound insulation. The effects of different structural parameters of the membrane on the sound-proofed performance at low frequencies were investigated by using finite element method (FEM). The numerical results show that, the STL can be modulated to higher value by changing the structural parameters, such as the membrane surface density, the unite cell film shape, and the membrane tension. The acoustic metamaterial proposed in this study could provide a potential application in the low-frequency noise insulation.

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.

In situ observation of high-pressure phase transition in silicon carbide under shock loading using ultrafast x-ray diffraction

NASA Astrophysics Data System (ADS)

Tracy, Sally June

2017-06-01

SiC is an important high-strength ceramic material used for a range of technological applications, including lightweight impact shielding and abrasives. SiC is also relevant to geology and planetary science. It may be a host of reduced carbon in the Earth's interior and also occurs in meteorites and impact sites. SiC has also been put forward as a possible major constituent in the proposed class of extra-solar planets known as carbon planets. Previous studies have used wave profile measurements to identify a phase transition under shock loading near 1 Mbar, but lattice-level structural information was not obtained. Here we present the behavior of silicon carbide under shock loading as investigated through a series of time-resolved pump-probe x-ray diffraction measurements up to 200 GPa. Our experiments were conducted at the Materials in Extreme Conditions beamline of the Linac Coherent Light Source. In situ x-ray diffraction data on shock-compressed SiC was collected using a free electron laser source combined with a pulsed high-energy laser. These measurements allow for the determination of time-dependent atomic arrangements, demonstrating that the wurtzite phase of SiC transforms directly to the B1 structure. Our measurements also reveal details of the material texture evolution under shock loading and release.

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.

Integrated Computational Materials Engineering Development of Advanced High Strength Steel for Lightweight Vehicles

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

Hector, Jr., Louis G.; McCarty, Eric D.

The goal of the ICME 3GAHSS project was to successfully demonstrate the applicability of Integrated Computational Materials Engineering (ICME) for the development and deployment of third generation advanced high strength steels (3GAHSS) for immediate weight reduction in passenger vehicles. The ICME approach integrated results from well-established computational and experimental methodologies to develop a suite of material constitutive models (deformation and failure), manufacturing process and performance simulation modules, a properties database, as well as the computational environment linking them together for both performance prediction and material optimization. This is the Final Report for the ICME 3GAHSS project, which achieved the fol-lowingmore » objectives: 1) Developed a 3GAHSS ICME model, which includes atomistic, crystal plasticity, state variable and forming models. The 3GAHSS model was implemented in commercially available LS-DYNA and a user guide was developed to facilitate use of the model. 2) Developed and produced two 3GAHSS alloys using two different chemistries and manufacturing processes, for use in calibrating and validating the 3GAHSS ICME Model. 3) Optimized the design of an automotive subassembly by substituting 3GAHSS for AHSS yielding a design that met or exceeded all baseline performance requirements with a 30% mass savings. A technical cost model was also developed to estimate the cost per pound of weight saved when substituting 3GAHSS for AHSS. The project demonstrated the potential for 3GAHSS to achieve up to 30% weight savings in an automotive structure at a cost penalty of up to $0.32 to $1.26 per pound of weight saved. The 3GAHSS ICME Model enables the user to design 3GAHSS to desired mechanical properties in terms of strength and ductility.« less

Mechanical Properties of Lightweight Concrete Using Recycled Cement-Sand Brick as Coarse Aggregates Replacement

NASA Astrophysics Data System (ADS)

Joohari, Ilya; Farhani Ishak, Nor; Amin, Norliyati Mohd

2018-03-01

This paper presents the result of replacing natural course aggregate with recycled cement-sand brick (CSB) towards the mechanical properties of concrete. Natural aggregates were used in this study as a control sample to compare with recycled coarse aggregates. This study was also carried to determine the optimum proportion of coarse aggregates replacement to produce lightweight concrete. Besides, this study was conducted to observe the crack and its behaviour development during the mechanical testing. Through this study, four types of concrete mixed were prepared, which were the control sample, 25%, 50% and 75% replacement of CSB. The test conducted to determine the effectiveness of recycled CSB as coarse aggregates replacement in this study were slump test, density measurement, compression test, and flexural test and. The strength of concrete was tested at 7 days and 28 days of curing. From the results obtained, the optimum proportion which produced the highest strength is 25% replacement of recycled CSB. The compressive and flexural strength has decreased by 10%-12% and 4%-34% respectively compared to the control sample. The presence of recycled coarse aggregates in sample has decreased the density of concrete by 0.8%-3% compared to the control sample.

Effect of Peat on Physicomechanical Properties of Cemented Brick

PubMed Central

Hashim, Roslan; Kurnia, Ryan

2014-01-01

The popularity of low cost, lightweight, and environmentally affable masonry unit in building industry carries the need to investigate more flexible and adaptable brick component as well as to retain the requirements confirmed in building standards. In this study, potential use of local materials used as lightweight building materials in solving the economic problems of housing has been investigated. Experimental studies on peat added bricks have been carried out. It demonstrates the physicomechanical properties of bricks and investigates the influence of peat, sand, and cement solid bricks to the role of various types of constructional applications. The achieved compressive strength, spitting strength, flexural strength, unit weight, and ultrasonic pulse velocity are significantly reduced and the water absorption is increased with percentage wise replacement of peat as aggregate in the samples. The maximum 20% of (% mass) peat content meets the requirements of relevant well-known international standards. The experimental values illustrate that, the 44% volumetric replacement with peat did not exhibit any sudden brittle fracture even beyond the ultimate loads and a comparatively smooth surface is found. The application of peat as efficient brick substance shows a potential to be used for wall and a viable solution in the economic buildings design. PMID:24982941

Architected cellular ceramics with tailored stiffness via direct foam writing

NASA Astrophysics Data System (ADS)

Muth, Joseph T.; Dixon, Patrick G.; Woish, Logan; Gibson, Lorna J.; Lewis, Jennifer A.

2017-02-01

Hierarchical cellular structures are ubiquitous in nature because of their low-density, high-specific properties, and multifunctionality. Inspired by these systems, we created lightweight ceramic architectures composed of closed-cell porous struts patterned in the form of hexagonal and triangular honeycombs by direct foam writing. The foam ink contains bubbles stabilized by attractive colloidal particles suspended in an aqueous solution. The printed and sintered ceramic foam honeycombs possess low relative density (˜6%). By tailoring their microstructure and geometry, we created honeycombs with different modes of deformation, exceptional specific stiffness, and stiffness values that span over an order of magnitude. This capability represents an important step toward the scalable fabrication of hierarchical porous materials for applications, including lightweight structures, thermal insulation, tissue scaffolds, catalyst supports, and electrodes.

Architected cellular ceramics with tailored stiffness via direct foam writing

PubMed Central

Muth, Joseph T.; Dixon, Patrick G.; Woish, Logan; Gibson, Lorna J.; Lewis, Jennifer A.

2017-01-01

Hierarchical cellular structures are ubiquitous in nature because of their low-density, high-specific properties, and multifunctionality. Inspired by these systems, we created lightweight ceramic architectures composed of closed-cell porous struts patterned in the form of hexagonal and triangular honeycombs by direct foam writing. The foam ink contains bubbles stabilized by attractive colloidal particles suspended in an aqueous solution. The printed and sintered ceramic foam honeycombs possess low relative density (∼6%). By tailoring their microstructure and geometry, we created honeycombs with different modes of deformation, exceptional specific stiffness, and stiffness values that span over an order of magnitude. This capability represents an important step toward the scalable fabrication of hierarchical porous materials for applications, including lightweight structures, thermal insulation, tissue scaffolds, catalyst supports, and electrodes. PMID:28179570

Fabrication of cellular materials

NASA Astrophysics Data System (ADS)

Prud'homme, Robert K.; Aksay, Ilhan A.; Garg, Rajeev

1996-02-01

Nature uses cellular materials in applications requiring strength while, simultaneously, minimizing raw materials requirements. Minimizing raw materials is efficient both in terms of the energy expended by the organism to synthesize the structure and in terms of the strength- to-weight ratio of the structure. Wood is the most obvious example of cellular bio-materials, and it is the focus of other presentations in this symposium. The lightweight bone structure of birds is another excellent example where weight is a key criterion. The anchoring foot of the common muscle [Mytilus edulis] whereby it attaches itself to objects is a further example of a biological system that uses a foam to fill space and yet conserve on raw materials. In the case of the muscle the foam is water filled and the foot structure distributes stress over a larger area so that the strength of the byssal thread from which it is suspended is matched to the strength of interfacial attachment of the foot to a substrate. In these examples the synthesis and fabrication of the cellular material is directed by intercellular, genetically coded, biochemical reactions. The resulting cell sizes are microns in scale. Cellular materials at the next larger scale are created by organisms at the next higher level of integration. For example an African tree frog lays her eggs in a gas/fluid foam sack she builds on a branch overhanging a pond. The outside of the foam sack hardens in the sun and prevents water evaporation. The foam structure minimizes the amount of fluid that needs to be incorporated into the sack and minimizes its weight. However, as far as the developing eggs are concerned, they are in an aqueous medium, i.e. the continuous fluid phase of the foam. After precisely six days the eggs hatch, and the solidified outer wall re-liquefies and dumps the emerging tadpoles into the pond below. The bee honeycomb is an example of a cellular material with exquisite periodicity at millimeter length scales. The cellular structure provides strength through geometric regularity and functions as both honey storage vessels and incubators.

Comparative study of aerogels obtained from differently prepared nanocellulose fibers.

PubMed

Chen, Wenshuai; Li, Qing; Wang, Youcheng; Yi, Xin; Zeng, Jie; Yu, Haipeng; Liu, Yixing; Li, Jian

2014-01-01

This article describes the fabrication of nanocellulose fibers (NCFs) with different morphologies and surface properties from biomass resources as well as their self-aggregation into lightweight aerogels. By carefully modulating the nanofibrillation process, four types of NCFs could be readily fabricated, including long aggregated nanofiber bundles, long individualized nanofibers with surface C6 -carboxylate groups, short aggregated nanofibers, and short individualized nanofibers with surface sulfate groups. Free-standing lightweight aerogels were obtained from the corresponding aqueous NCF suspensions through freeze-drying. The structure of the aerogels could be controlled by manipulating the type of NCFs and the concentration of their suspensions. A possible mechanism for the self-aggregation of NCFs into two- or three-dimensional aerogel nanostructures was further proposed. Owing to web-like structure, high porosity, and high surface reactivity, the NCF aerogels exhibited high mechanical flexibility and ductility, and excellent properties for water uptake, removal of dye pollutants, and the use as thermal insulation materials. The aerogels also displayed sound-adsorption capability at high frequencies. Copyright © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Bendable X-ray Optics for High Resolution Imaging

NASA Technical Reports Server (NTRS)

Gubarev, M.; Ramsey, B.; Kilaru, K.; Atkins, C.; Broadway, D.

2014-01-01

Current state-of the-art for x-ray optics fabrication calls for either the polishing of massive substrates into high-angular-resolution mirrors or the replication of thin, lower-resolution, mirrors from perfectly figured mandrels. Future X-ray Missions will require a change in this optics fabrication paradigm in order to achieve sub-arcsecond resolution in light-weight optics. One possible approach to this is to start with perfectly flat, light-weight surface, bend it into a perfect cone, form the desired mirror figure by material deposition, and insert the resulting mirror into a telescope structure. Such an approach is currently being investigated at MSFC, and a status report will be presented detailing the results of finite element analyses, bending tests and differential deposition experiments.

Effects of porosity on shock-induced melting of honeycomb-shaped Cu nanofoams

NASA Astrophysics Data System (ADS)

Zhao, Fengpeng

Metallic foams are of fundamental and applied interests in various areas, including structure engineering (e.g., lightweight structural members and energy absorbers), and shock physics (e.g., as laser ablators involving shock-induced melting and vaporization).Honeycomb-shaped metallic foams consist of regular array of hexagonal cells in two dimensions and have extensive applications and represent a unique, simple yet useful model structure for exploring mechanisms and making quantitative assessment. We investigate shock-induced melting in honeycomb-shaped Cu nanofoams with extensive molecular dynamics simulations. A total of ten porosities (phi) are explored, ranging from 0 to 0.9 at an increment of 0.1. Upon shock compression, void collapse induces local melting followed by supercooling for sufficiently high porosity at low shock strengths. While superheating of solid remnants occurs for sufficiently strong shocks at phi<0.1. Both supercooling of melts and superheating of solid remnants are transient, and the equilibrated shock states eventually fall on the equilibrium melting curve for partial melting. However, phase equilibrium has not been achieved on the time scale of simulations in supercooled Cu liquid (from completely melted nanofoams). The temperatures for incipient and complete melting are related to porosity via a power law and approach the melting temperature at zero pressure as phi tends to 1.

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

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.

High-flexibility, noncollapsing lightweight hose

DOEpatents

Williams, David A.

1993-01-01

A high-flexibility, noncollapsing, lightweight, large-bore, wire-reinforced hose is inside fiber-reinforced PVC tubing that is flexible, lightweight, and abrasion resistant. It provides a strong, kink- and collapse-free conduit for moving large quantities of dangerous fluids, e.g., removing radioactive waste water or processing chemicals.

High-flexibility, noncollapsing lightweight hose

DOEpatents

Williams, D.A.

1993-04-20

A high-flexibility, noncollapsing, lightweight, large-bore, wire-reinforced hose is inside fiber-reinforced PVC tubing that is flexible, lightweight, and abrasion resistant. It provides a strong, kink- and collapse-free conduit for moving large quantities of dangerous fluids, e.g., removing radioactive waste water or processing chemicals.

Aluminum-Alloy-Matrix/Alumina-Reinforcement Composites

NASA Technical Reports Server (NTRS)

Kashalikar, Uday; Rozenoyer, Boris

2004-01-01

Isotropic composites of aluminum-alloy matrices reinforced with particulate alumina have been developed as lightweight, high-specific-strength, less-expensive alternatives to nickel-base and ferrous superalloys. These composites feature a specific gravity of about 3.45 grams per cubic centimeter and specific strengths of about 200 MPa/(grams per cubic centimeter). The room-temperature tensile strength is 100 ksi (689 MPa) and stiffness is 30 Msi (206 GPa). At 500 F (260 C), these composites have shown 80 percent retention in strength and 95 percent retention in stiffness. These materials also have excellent fatigue tolerance and tribological properties. They can be fabricated in net (or nearly net) sizes and shapes to make housings, pistons, valves, and ducts in turbomachinery, and to make structural components of such diverse systems as diesel engines, automotive brake systems, and power-generation, mining, and oil-drilling equipment. Separately, incorporation of these metal matrix composites within aluminum gravity castings for localized reinforcement has been demonstrated. A composite part of this type can be fabricated in a pressure infiltration casting process. The process begins with the placement of a mold with alumina particulate preform of net or nearly net size and shape in a crucible in a vacuum furnace. A charge of the alloy is placed in the crucible with the preform. The interior of the furnace is evacuated, then the furnace heaters are turned on to heat the alloy above its liquidus temperature. Next, the interior of the furnace is filled with argon gas at a pressure about 900 psi (approximately equal to 6.2 MPa) to force the molten alloy to infiltrate the preform. Once infiltrated, the entire contents of the crucible can be allowed to cool in place, and the composite part recovered from the mold.

Production and Characterization of Carbon Nanotubes and Nanotube-Based Composites

NASA Technical Reports Server (NTRS)

Nikolaev, Pavel; Arepalli, Sivaram; Holmes, William; Gorelik, Olga; Files, Brad; Scott, Carl; Santos, Beatrice; Mayeaux, Brian; Victor, Joe

1999-01-01

The Nobel Prize winning discovery of the Buckuball (C60) in 1985 at Rice University by a group including Dr. Richard Smalley led to the whole new class of carbon allotropes including fullerenes and nanotubes. Especially interesting from many viewpoints are single-walled carbon nanotubes, which structurally are like a single graphitic sheet wrapped around a cylinder and capped at the ends. This cylinders have diameter as small as 0.5 - 2 nm (1/100,000th the diameter of a human hair) and are as long as 0.1 - 1 mm. Nanotubes are really individual molecules and believed to be defect-free, leading to high tensile strength despite their low density. Additionally, these fibers exhibit electrical conductivity as high as copper, thermal conductivity as high as diamond, strength 100 times higher than steel at one-sixth the weight, and high strain to failure. Thus it is believed that developments in the field of nanotechnology will lead to stronger and lighter composite materials for next generation spacecraft. Lack of a bulk method of production is the primary reason nanotubes are not used widely today. Toward this goal JSC nanotube team is exploring three distinct production techniques: laser ablation, arc discharge and chemical vapor deposition (CVD, in collaboration with Rice University). In laser ablation technique high-power laser impinges on the piece of carbon containing small amount of catalyst, and nanotubes self-assemble from the resulting carbon vapor. In arc generator similar vapor is created in arc discharge between carbon electrodes with catalyst. In CVD method nanotubes grow at much lower temperature on small catalyst particles from carbon-containing feedstock gas (methane or carbon monoxide). As of now, laser ablation produces cleanest material, but mass yield is rather small. Arc discharge produces grams of material, but purity is low. CVD technique is still in baby steps, but preliminary results look promising, as well as perspective of scaling the process up. We are also working on necessary purification of nanotubes. Applications of nanotubes are in such various fields as lightweight composites, molecular electronics, energy storage (electrodes in Li ion batteries), flat panel displays, conductive polymers, etc. JSC nanotube team is focused on development of lightweight materials. We work on the injection thermoset epoxies reinforced with nanotubes. Early results show good wetting of nanotube surface with epoxy, which is very important. More research will be possible as more nanotubes become available.

CRUX: A compliant robotic upper-extremity exosuit for lightweight, portable, multi-joint muscular augmentation.

PubMed

Lessard, Steven; Pansodtee, Pattawong; Robbins, Ash; Baltaxe-Admony, Leya Breanna; Trombadore, James M; Teodorescu, Mircea; Agogino, Adrian; Kurniawan, Sri

2017-07-01

Wearable robots can potentially offer their users enhanced stability and strength. These augmentations are ideally designed to actuate harmoniously with the user's movements and provide extra force as needed. The creation of such robots, however, is particularly challenging due to the underlying complexity of the human body. In this paper, we present a compliant, robotic exosuit for upper extremities called CRUX. This exosuit, inspired by tensegrity models of the human arm, features a lightweight (1.3 kg), flexible multi-joint design for portable augmentation. We also illustrate how CRUX maintains the full range of motion of the upper-extremities for its users while providing multi-DoF strength amplification to the major muscles of the arm, as evident by tracking the heart rate of an individual exercising said arm. Exosuits such as CRUX may be useful in physical therapy and in extreme environments where users are expected to exert their bodies to the fullest extent.