ALBERT

Description: Remote handling in nuclear waste management requires a robotic system with precise motion as well as a large workspace. The concept of a small arm mounted on the end of a large arm may satisfy such needs. However, the performance of such a serial configuration lacks payload capacity which is a crucial factor for handling a massive object. Also, this configuration induces more flexibility on the structure. To overcome these problems, the topology of bracing the tip of the small arm (not the large arm) and having an end effector in the middle of the chain is proposed in this paper. Also, control of these cooperating disparate manipulators is accomplished in computer simulations. Thus, this robotic system can have the accuracy of the small arm, and at the same time, it can have the payload capacity and large workspace of the large arm.

Description: This paper concerns the suppression of the vibration of a large flexible robot by inertial forces of a small robot which is located at the tip of the large robot. A controller for generating damping forces to a large robot is designed based on the two time scale model. The controller does not need to calculate the quasi-steady variables and is efficient in computation. Simulation results show the effectiveness of the inertial forces and the controller designed.

Description: The inverse dynamic equation of a flexible manipulator was solved in the time domain. By dividing the inverse system equation into the causal part and the anticausal part, we calculated the torque and the trajectories of all state variables for a given end point trajectory. The interpretation of this method in the frequency domain was explained in detail using the two-sided Laplace transform and the convolution integral. The open loop control of the inverse dynamic method shows an excellent result in simulation. For real applications, a practical control strategy is proposed by adding a feedback tracking control loop to the inverse dynamic feedforward control, and its good experimental performance is presented.

Description: This research seeks to provide an advanced force control strategy for a flexible manipulator. Two main issues with force control of flexible arms are discussed: non-collocation and robustness.

Description: Many applications of robotic and teleoperated manipulator arms require operation in contact and non-contact regimes. This paper deals with both regimes and the transition between them with special attention given to problems of flexibility in the links and drives. This is referred to as contact control. Inverse dynamics is used to plan the tip motion of the flexible link so that the free motion can stop very near the contact surface without collision due to overshoot. Contact must occur at a very low speed since the high frequency impact forces are too sudden to be affected by any feedback generated torques applied to a joint at the other end of the link. The effect of approach velocity and surface properties are discussed. Force tracking is implemented by commands to the deflection states of the link and the contact force. This enables a natural transition between tip position and tip force control that is not possible when the arm is treated as rigid. The effect of feedback gain, force trajectory, and desired final force are of particular interest and are studied. Experimental results are presented on a one link arm and the system performance in the overall contact task is analyzed. Extension to multi-link cases with potential applications are discussed.

Description: Many applications of robotic manipulator arms require operation in contact and noncontact regimes. Control of impact between the arm's tip and the environment has been largely ignored in prior research. The impact phenomena was investigated through simulation and experiment for the realization of the bracing strategy, and the key factors of the behavior were understood well. The approaching velocity is dominant parameter for the magnitude of the impact force. The impact is also affected by the compliance of the environmental surface.

Description: The short term objective of this research is the completion of experimental configuration of the Small Articulated Robot (SAM) and the derivations of the actuator dynamics of the Robotic Arm, Large and Flexible (RALF). In order to control vibrations SAM should have larger bandwidth than that of the vibrations. The bandwidth of SAM consist of 3 parts; structural rigidity, processing speed of controller, and motor speed. The structural rigidity was increased to a reasonably high value by attaching aluminum angles at weak points and replacing thin side plates by thicker ones. The high processing speed of the controller was achieved by using parallel processors (three 68000 process, three interface board, and one main processor (IBM-XT)). Maximum joint speed and acceleration of SAM is known as about 4 rad/s and 15 rad/sq s. Hence SAM can move only .04 rad at 3 Hz which is the natural frequency of RALF. This will be checked by experiment.

Description: Conventional sandwich structure fabrication methods are labor intensive and high in cost. A low cost method is needed to produce lightweight sandwich structures. Sundstrand has developed a series of in situ composite fabrication methods in which the raw materials (skin and core materials) are placed in a closed mold, and the component is produced in one heating cycle. Internal pressure is generated by chemical agents during the thermal cycles, which consolidates the skins and produces the foam core. The finished part is a net-shape composite sandwich structure with skins and a foamed core. The in situ process reduces cost by eliminating several secondary operations that are used in conventional fabrication methods. Further, a strong molecular bond is produced between the core and skin, which eliminates adhesive bonding and prevents a weak bond section in the sandwich structure. In this investigation, we evaluated the feasibility of the in situ process using thermoset materials currently under consideration for commercial airplane fuselage applications, such as keel sections. The materials used were Hercules 855340 toughened epoxy resin in both liquid and powder forms, and 3M Scotchply PR500 resin, manufactured by 3M Corporation, in powder form. We successfully foamed these resins and produced experimental panels with AS-4/855340 Hercules prepreg skins. Chopped fibers were added to the core to increase performance of the foam. Mechanical property testing on these panels showed properties competitive with other foams. Additional experiments are required to optimize the in situ foam core sandwiches for specific properties and applications.

Description: Creep-rupture and tensile tests have been used to evaluate thoriated W-wire reinforced Nb-1 percent Zr alloy matrix composites fabricated via arc-spray monotape technique. A significant creep strength enhancement was observed over the unreinforced matrix alloy while matrix integrity was maintained; the fiber/matrix interface phase is noted to be a strong and ductile W/Nb alloy, which is formed due to the mutual solubility of the constituent metals. High strength, toughness, and thermal stability are demonstrated by this material system, which is also resistant to liquid alkali metal corrosion.

Description: The mechanical behavior of continuous fiber reinforced SiC/RBSN composites with strong and weak interface characteristics is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Effects of fiber/matrix interface debonding (splitting) parallel to the fibers are discussed. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength and work of pull-out are reviewed and used to predict composite response. Experimental results are compared to analytical predictions.

Description: Reaction of Ni-Al alloys within the beta-NiAl phase with CrB2 was studied at 1473 K as a function of Al concentration in the alloy. Reaction of 49-50 at. pct Al alloys with CrB2 occurred by interdiffusion of Ni into CrB2 and Cr into the alloy without forming a new product phase. On the other hand, a new product phase, rich in Ni and B, formed by the reaction of alloys having Al concentrations 48 at. pct or lower with CrB2. The reaction product was observed both at the CrB2/alloy interface and along the alloy grain boundaries.

Description: Three-dimensional element analyses of (0/theta/-theta)s graphite epoxy laminates, where theta = 15, 20, 25, 30, and 45 deg, subjected to axial tensile load, were performed. The interlaminar stresses in the theta/-theta interface were calculated with and without a matrix crack in the central -theta plies. The interlaminar normal stress changes from a small compressive stress when no matrix crack is present to a high tensile stress at the intersection of the matrix crack and the free edge. The analysis of local delamination from the -theta matrix crack indicates a high strain energy release rate and a localized Mode I component near the free edge, within one-ply distance from the matrix crack. To examine the stress state causing the matrix cracking, the maximum principal normal stress in a plane perpendicular to the fiber direction in the -theta ply was calculated in an uncracked laminate. The corresponding shear stress parallel to the fiber was also calculated. The principal normal stress at the laminate edge increased through the ply thickness and reached a very high tensile value at the theta/-theta interface indicating that the crack in the -theta ply may initiate at the theta/-theta interface.

Description: The tensile creep and creep-recovery behavior of a hot-pressed unidirectional SiC-fiber/Si3N4-matrix composite was investigated at 1200 C in air, in order to determine how various sustained and cyclic creep loading histories would influence the creep rate, accumulated creep strain, and the amount of strain recovered upon specimen unloading. The data accumulated indicate that the fundamental damage mode for sustained tensile creep at stresses of 200 and 250 MPa was periodic fiber fracture and that the creep life and the failure mode at 250 MPa were strongly influenced by the rate at which the initial creep stress was applied. Cyclic loading significantly lowered the duration of primary creep and the overall creep-strain accumulation. The implications of the results for microstructural and component design are discussed.

Description: Cavitation of the oil film in a dynamically loaded journal bearing was studied using high-speed photography and pressure measurement simultaneously. Comparison of the visual and pressure data provided considerable insight into the occurence and non-occurrence of cavitation. It was found that (1), cavitation typically occurred in the form of one bubble with the pressure in the cavitation bubble close to the absolute zero; and (2), for cavitation-producing operating conditions, cavitation did not always occur; with the oil film then supporting a tensile stress.

Description: The primary objective of this paper is to evaluate the optical pointing performance of the PSR Moderate Focus-Mission Structure when subjected to both mechanical and thermal disturbances. The mechanical disturbances are based on secondary mirror chopping. Results indicate that dynamic responses of the primary reflector and the secondary reflector subjected to chopping disturbances of the secondary reflector about its center of mass are within the figure maintenance control capabilities. The effects of modal damping, truss-type secondary support, interface boundary constraints, and alternate configurations, are also evaluated in the analysis. Thermal distortions of the structure were also evaluated based on the on-orbit temperature profiles derived from the submillimeter telescope missions. Results from thermal deformation analysis indicate that figure initialization control is needed for the PSR Moderate Focus-Mission. However, a figure maintenance system may not be required if adequate thermal isolation is incorporated into the support truss design for the PSR Moderate Focus-Mission Structure.

Description: This paper describes experimental research being performed at the Jet Propulsion Laboratory to develop and validate control concepts arising out of NASA's Control Structure Interaction program. The facility is meant to be a ground testbed with relevance to a broad class of future precision optical space systems. The objective of the experimental program is to investigate a multi-layer control approach to the maintenance of nanometer level optical pathlength control in the presence of external disturbances and multiple structural resonances. A brief overview of the experimental facility is presented. The control design methodology is discussed, and several experimental results are presented.

Description: Segmented reflectors have been proposed for space-based applications such as optical communication and large-diameter telescopes. An actuation system for mirrors in a space-based segmented mirror array has been developed as part of the National Aeronautics and Space Administration-sponsored Precision Segmented Reflector program. The actuation system, called the Articulated Panel Module (APM), articulates a mirror panel in 3 degrees of freedom in the submicron regime, isolates the panel from structural motion, and simplifies space assembly of the mirrors to the reflector backup truss. A breadboard of the APM has been built and is described. Three-axis modeling, analysis, and testing of the breadboard is discussed.

Description: Microstructural changes occurring during sliding wear of self-mated Al2O3 SiC whisker-reinforced composites were studied using optical, scanning electron microscopy and transmission electron microscopy. Pin-on-disc specimens were slid in air at 2.7 m/s sliding velocity under a 26.5 N load for 1 h. Wear tests were conducted at 23, 600, 800 and 1200 C. Mild wear with a wear factor of 2.4 x 10 exp -7 - 1.5 x 10 exp -6 cu mm /N per m was experienced at all test temperatures. The composite showed evidence of wear by fatigue mechanisms at 800 C and below. Tribochemical reaction (SiC oxidation and reaction of SiO2 and Al2O3) leads to intergranular failure at 1200 C. Distinct microstructural differences existing at each test temperature are reported.

Description: This paper examines the use of a thin layer of Ultra High Molecular Weight Polyethylene (UHMWPE) on the outer surface of carbon/epoxy composite materials as a method of improving impact resistance and damage tolerance through hybridization. Flat 16-ply laminates as well as honeycomb sandwich structures with eight-ply facesheets were tested in this study. Instrumented drop-weight impact testing was used to inflict damage upon the specimens. Evaluation of damage resistance included instrumented impact data, visual examination, C-scanning and compression after impact (CAI) testing. The results show that only one lamina of UHMWPE did not improve the damage tolerance (strength retention) of the 16-ply flat laminate specimens or the honeycomb sandwich beams, however, a modest gain in impact resistance (detectable damage) was found for the honeycomb sandwich specimens that contained an outer layer of UHMWPE.

Description: Chemical and hydrodynamic aspects of wetting and interfacial phenomena during the solidification processing of metal-matrix composites are reviewed. Significant experimental results on fiber-matrix interactions and wetting under equilibrium and non-equilibrium conditions in composites of engineering interest have been compiled, based on a survey of the recent literature. Finally, certain aspects of wetting relevant to stir-casting and infiltration processing of composites are discussed.

Description: The inelastic deformation mechanisms were evaluated for a model titanium-based, fiber-reinforced composite: a beta titanium alloy (Ti-15V-3Al-3Cr-3Sn) reinforced with SiC (SCS-6) fibers. The primary emphasis of this article is to illustrate the sequence in which damage and plasticity evolved for this system. The mechanical responses and the results of detailed microstructural evaluations for the 0(8), 90(8), and +/- 45(2s) line oriented laminates are provided. It is shown that the characteristics of the reaction zone around the fiber play a very important role in the way damage and plasticity evolve, particularly in the microyield regime of deformation, and must be included in any realistic constitutive model. Fiber-matrix debonding was a major damage mode for the off-axis systems. The tension test results are also compared with the predictions of a few constitutive models.

Description: CTE (coefficient of thermal expansion) mismatch-induced stresses as they affect the fiber-matrix bond integrity of Al2O3 fiber-reinforced superalloy composites are examined. Of the three individual stress components, only the radial stress directly affects the integrity of the fiber-matrix interface. It is noted that a compressive radial stress leads to a clamping action on the fiber and is therefore beneficial to the integrity of the fiber-matrix bond. A radial tensile stress, on the other hand, can cause debonding of the fiber from the matrix for a weak fiber-matrix bond.

Description: The role of the fiber matrix interface bond on the transverse ductility of continuous fiber reinforced composites has been investigated. Two specific systems have been considered: an Aluminum alloy matrix reinforced by Alumina fibers, characterized by a strong interface and a Titanium alloy reinforced by coated Silicon Carbide fibers, characterized by a weak interface. A micro-mechanical study indicates that the bond condition has a significant effect on the state of stress in the matrix which in turn dictates the available matrix ductility. The micro-mechanical predictions are in good agreement with the experimental results for the two systems.

Description: Microstructural aspects of alloy solidification within the interstices of porous compacts of platelet-shaped single crystals of alpha-SiC, when the latter are infiltrated with a hot metal under pressure, have been described. Microstructural evidence is presented of selective reorientation of platelets and nonhomogeneous solute distribution under shear of pressurized melt, of constrained growth of primary solid within finite width zones, and of the modulation of coring due to microsegregation as a result of variations in the pore size of compacts.

Description: The vibrations of a flexible rotor are controlled using piezoelectric actuators. The controller includes active analog components and a hybrid interface with a digital computer. The computer utilizes a grid search algorithm to select feedback gains that minimize a vibration norm at a specific operating speed. These gains are then downloaded as active stillnesses and dampings with a linear fit throughout the operating speed range to obtain a very effective vibration control.

Description: An analytical and experimental investigation of a vibratory system with a clearance was conducted. A finite element model and an equivalent single-degree-of-freedom closed-form solution were used to determine the dynamic parameters and response of an experimental structure interacting with a gap. The closed-form solution is obtained by taking advantage of the piecewise linearity of the system. Results from these solution methods are in agreement with experimental data. The results also suggest that the closed-form solution approximates the response of the experimental structure with accuracy greater than that of the finite element model. The closed-form solution was also used to determine the gap size of the structure. The parameter identification procedure utilized in this study appears to be simple to use and can be readily extended to other types of piecewise-linear multi-degree-of-freedom systems.

Description: This paper investigates the unnotched tensile properties of two-dimensional (2D) triaxial braid-reinforced composites both experimentally and analytically. The materials are graphite fibers in an epoxy matrix. Three different reinforcing fiber architectures were considered. There were considerable differences in the observed elastic constants from different size strain gage and extensometer readings. Larger strain gages gave more consistent results and correlated better with the extensometer readings. Experimental strains correlated reasonably well with analytical predictions in the longitudinal, 0 deg, fiber direction but not in the transverse direction. Tensile strength results were not always predictable even in reinforcing directions. Minor changes in braid geometry led to disproportionate strength variations. The unit cell structure of the triaxial braid was discussed with the assistance of computer analysis of the microgeometry. Photomicrographs of braid geometry were used to improve upon the computer graphics representations of unit cells. These unit cells were used to predict the elastic moduli with various degrees of sophistication. The simple and the complex analyses were generally in agreement, but none adequately matched the experimental results for all the braids.

Description: Extensive experimental investigation has been carried out on used flight bearings of the high pressure oxidizer turbopumps (HPOTP) of the space shuttle main engine (SSME) in order to determine the dominant wear modes, their extent, and causes. The paper presents the methodology, various surface analysis techniques used, results, and discussion. The mode largely responsible for premature bearing wear has been identified as adhesive/shear peeling of the upper layers of bearing balls and rings. This mode relies upon the mechanisms of scale formation, breakdown, and removal, all of which are greatly enhanced by the heavy oxidation environment of the HPOTP. Major causes of the high wear rates appear to be lubrication and cooling, both inadequate for the imposed conditions of operation. Numerous illustrations and evidence are provided.

Description: Concerns related to the proper preparation of composite specimens for microstructural analysis are examined. Proper preparation will minimize the amount of surface and subsurface damage at each stage of the procedure so that the microstructural features of the final-polished specimen can be accurately determined as a function of the composite's response to processing, testing, or service conditions. This requires that an optimum combination of abrasive type, size, and bond be applied during each grinding, lapping, and polishing step. Machine settings, such as polishing speed, force, and relative polishing direction, are also important. Guidelines are given for each step of the six-stage specimen preparation process: sectioning, planar grinding, sample integrity, polishing, and etching.

Description: A probabilistic evaluation of an eight ply graphite-epoxy quasi-isotropic laminate was completed using the Integrated Composite Analyzer (ICAN) in conjunction with Monte Carlo simulation and Fast Probability Integration (FPI) techniques. Probabilistic input included fiber and matrix properties, fiber misalignment, fiber volume ratio, void volume ratio, ply thickness and ply layup angle. Cumulative distribution functions (CDFs) for select laminate properties are given. To reduce the number of simulations, a Fast Probability Integration (FPI) technique was used to generate CDFs for the select properties in the absence of fiber misalignment. These CDFs were compared to a second Monte Carlo simulation done without fiber misalignment effects. It was found that FPI requires fewer simulations to obtain the cumulative distribution functions as opposed to Monte Carlo simulation techniques. Furthermore, FPI provides valuable information regarding the sensitivities of composite properties to the constituent properties, fiber volume ratio and void volume ratio.

Description: A modified sedimentation process was used in the production of a functionally gradient material (FGM), NiAl/Al2O3. A simple finite element model was used to guide our design and fabrication efforts by estimating residual stress states as a function of composite structure. This approach could lead to tailored designs that enhance or avoid specific residual stress states. Thermal cycling tests were factored into the model to predict time dependent or steady-state internal temperature and stress profiles. Four-point bend tests were conducted to establish the mechanical load-displacement behavior of a single interlayer FGM at room temperature, 800 and 1000 K. Room temperature bend strength of the FGM was 3-4 times that of the base NiAl. At elevated temperatures, composite fracture occurred in a gradual, noncatastrophic mode involving NiAl retardation of a succession of cracks originating in the alumina face.

Description: Reusable, oxidation protected reinforced carbon carbon (RCC) has been successfully flown on forty Shuttle Orbiter flights. Thermal testing of the silicon carbide coated, reinforced carbon-carbon to determine its oxidation characteristics has been performed in both radiant and convective (plasma arc jet) heating test facilities. Subsurface oxidation of the RCC substrate as a result of oxygen penetrating micro cracks (fizzures) in the coating was characterized as a function of temperature and pressure for both convective and radiant environments. High temperature testing was performed to establish coating recession for over-temperature flight conditions experienced on abort trajectories. Suggested methods for using these test data to establish multi-mission reuse (i.e., mission life) and single mission limits are presented.

Description: The effect of aeroconvective heating environment similar to that observed a spacecraft ascent or reentry from orbit, on the performance of a commercial carbon-reinforced ceramic matrix material specimens of two configurations (orthotropic and quasi-isotropic), fabricated by the Societe Europenne Propulsion (SEP) process was investigated using the NASA Ames Research Center 20 Megawatt Panel Test facility. The performance of the commercial material was compared with the SEP prepared materials. It was found that, whereas the quasi-isotropic SEP specimens exhibited a much higher mass loss rate and a significant dimensional change upon exposure to the thermal environment than did the orthotropic ones, the commercial SEP-like materials did not exhibit these characteristics. There was no greater mass loss rate for the quasi-isotropic specimens, and no dimension changes were observed. The Nicalon reinforced materials in both configurations, as fabricated by SEP or by the commercial source, showed no mass changes and no dimensional changes.

Description: The next generation of hypersonic vehicles (NASP, SSTO) that require reusable thermal protection systems will experience acreage surface temperatures in excess of 1100 C. More important, they will experience a more severe physical environment than the Space Shuttle due to non-pristine launching and landing conditions. As a result, maintenance, inspection, and replacement factors must be more thoroughly incorporated into the design of the TPS. To meet these requirements, an advanced thermal protection system was conceived, designated 'TOPHAT'. This system consists of a toughened outer ceramic matrix composite (CMC) attached to a rigid reusable surface insulator (RSI) which is directly bonded to the surface. The objective of this effort was to evaluate this concept in an aeroconvective environment, to determine the effect of impacts to the CMC material, and to compare the results with existing thermal protection systems.

Description: A model is described for predicting the wear behavior of whisker reinforced ceramics. The model was successfully applied to a silicon carbide whisker reinforced alumina ceramic composite subjected to sliding contact. The model compares the friction forces on the whiskers due to sliding, which act to pull or push them out of the matrix, to the clamping or compressive forces on the whiskers due to the matrix, which act to hold the whiskers in the composite. At low temperatures, the whiskers are held strongly in the matrix and are fractured into pieces during the wear process along with the matrix. At elevated temperatures differential thermal expansion between the whiskers and matrix can cause loosening of the whiskers and lead to pullout during the wear process and to higher wear. The model, which represents the combination of elastic stress analysis and a friction heating analysis, predicts a transition temperature at which the strength of the whiskers equals the clamping force holding them in the matrix. Above the transition the whiskers are pulled out of the matrix during sliding, and below the transition the whiskers are simply fractured. The existence of the transition gives rise to a dual wear mode or mechanism behavior for this material which was observed in laboratory experiments. The results from this model correlate well with experimentally observed behavior indicating that the model may be useful in obtaining a better understanding of material behavior and in making material improvements.

Description: An analysis was undertaken to determine the effect of fluid film compressibility on the performance of fluid film bearings. A new version of the Reynolds equation was developed, using a polytropic expansion, for both steady-state and dynamic conditions. Polytropic exponents from 1 (isothermal) to 1000 (approaching an incompressible liquid) were evaluated for two bearing numbers, selected from a range of practical interest for cryogenic application, and without cavitation. Bearing loads were insensitive to fluid compressibility for low bearing numbers, as was expected. The effect of compressibility on attitude angle was significant, even when the bearing number was low. A small amount of fluid compressibility was enough to obtain stable running conditions. Incompressible liquid lacked stability at all conditions. Fluid compressibility can be used to control the bearing dynamic coefficients, thereby influencing the dynamic behavior of the rotor-bearing system.

Description: Analytical models for piezoelectric actuators, adapted from flat plate concepts, are developed for noise and vibration control applications associated with vibrating circular cylinders. The loadings applied to the cylinder by the piezoelectric actuators for the bending and in-plane force models are approximated by line moment and line force distributions, respectively, acting on the perimeter of the actuator patch area. Coupling between the cylinder and interior acoustic cavity is examined by studying the modal spectra, particularly for the low-order cylinder modes that couple efficiently with the cavity at low frequencies. Within the scope of this study, the in-plane force model produced a more favorable distribution of low-order modes, necessary for efficient interior noise control, than did the bending model.

Description: The objective of this study is to determine the energy dissipation processes in polymer-matrix composites during impact of ballistic projectiles. These processes include heat, fiber deformation and breakage, matrix deformation and fracture, and interfacial delamination. In this study, experimental measurements were made, using specialized specimen designs and test methods, to isolate the energy consumed by each of these processes during impact in the ballistic range. Using these experiments, relationships between material parameters and energy dissipation were examined. Composites with the same matrix but reinforced with Kevlar, PE, and graphite fabric were included in this study. These fibers were selected based on the differences in their intrinsic properties. Matrix cracking was found to be one of the most important energy absorption mechanisms during impact, especially in ductile samples such as Spectra-900 PE and Kevlar-49 reinforced polymer. On the contrary, delamination dominated the energy dissipation in brittle composites such as graphite reinforced materials. The contribution from frictional forces was also investigated and the energy partitioning among the different processes evaluated.

Description: The uniaxial response of a continuous fiber elastic-perfectly plastic composite is modeled herein as a two-element composite cylinder. An axisymmetric analytical micromechanics solution is obtained for the rate-independent elastic-plastic response of the two-element composite cylinder subjected to tensile loading in the fiber direction for the case wherein the core fiber is assumed to be a transversely isotropic elastic-plastic material obeying the Tsai-Hill yield criterion, with yielding simulating fiber failure. The matrix is assumed to be an isotropic elastic-plastic material obeying the Tresca yield criterion. It is found that there are three different circumstances that depend on the fiber and matrix properties: fiber yield, followed by matrix yielding; complete matrix yield, followed by fiber yielding; and partial matrix yield, followed by fiber yielding, followed by complete matrix yield. The order in which these phenomena occur is shown to have a pronounced effect on the predicted uniaxial effective composite response.

Description: The traditional approach used in modeling of composites reinforced by three-dimensional (3-D) braids is to assume a simple unit cell geometry of a 3-D braided structure with known fiber volume fraction and orientation. In this article, we first examine 3-D braiding methods in the light of braid structures, followed by the development of geometric models for 3-D braids using a unit cell approach. The unit cell geometry of 3-D braids is identified and the relationship of structural parameters such as yarn orientation angle and fiber volume fraction with the key processing parameters established. The limiting geometry has been computed by establishing the point at which yarns jam against each other. Using this factor makes it possible to identify the complete range of allowable geometric arrangements for 3-D braided preforms. This identified unit cell geometry can be translated to mechanical models which relate the geometrical properties of fabric preforms to the mechanical responses of composite systems.

Description: Several lay-ups of SCS-6/Ti-15-3 composites were investigated. Static and fatigue tests were conducted for both notched and unnotched specimens at room and elevated temperatures. Test results indicated that the stress in the 0 fibers is the controlling factor in fatigue life. The static and fatigue strength of these materials is shown to be dependent on the level of residual stresses and the fiber/ matrix interfacial strength. Fatigue tests of notched specimens showed that cracks can initiate and grow many fiber spacings in the matrix material without breaking fibers. These matrix cracks can significantly reduce the residual strength of notched composite.

Description: The transverse properties of an aluminum alloy metal matrix composite reinforced by continuous alumina fibers have been investigated. The composite is subjected to both mechanical and cyclic thermal loading. The ductility can vary by an order of magnitude according to the operating conditions. For high mechanical and low thermal loading the ductility is small, for low mechanical and high thermal loading the ductility is an order of magnitude higher. Experiments on a beam in bending confirm that the ductility is strongly dependent on the loading conditions. The observations suggest a means of utilizing the inherent ductility of the matrix.

Description: The computer code 'METCAN' (METal matrix Composite ANalyzer) developed at NASA Lewis Research Center can be used to predict the high temperature behavior of metal matrix composites using the room temperature constituent properties. A reference manual that characterizes some common composites is being developed from METCAN generated data. Typical plots found in the manual are shown for graphite/copper. These include plots of stress-strain, elastic and shear moduli, Poisson's ratio, thermal expansion, and thermal conductivity. This manual can be used in the preliminary design of structures and as a guideline for the behavior of other composite systems.

Description: Load-controlled isothermal and nonisothermal fatigue lives of a (0-deg)s SiC/Ti-15-3 were evaluated at temperatures between 150 and 550 C and a target strain range of about 0.45 percent. In nonisothermal fatigue tests, load was first cycled at minimum temperature and then temperature was cycled at zero load. For fatigue tests with peak temperatures at or above 300 C, fatigue life was dramatically reduced compared to that at 150 C. The shortest life was produced by the nonisothermal test with the greatest temperature range (Delta T = 400 C) and highest peak temperature (T(max) = 550 C). Vacuum testing showed that much of the life reduction under isothermal and nonisothermal conditions was related to environmental effects, although the nature of the fatigue-environment interaction was decidedly different for the isothermal and nonisothermal test cycles which were studied.

Description: The purpose was to characterize damage initiation and growth in notched titanium matrix composites at room temperature. Double edge notched or center open hole SCS-6/Ti-15-3 specimens containing 0 deg plies or containing both 0 and 90 deg plies were fatigued. The specimens were tested in the as-fabricated (ASF) and in heat-treated conditions. A local strain criterion using unnotched specimen fatigue data was successful in predicting fatigue damage initiation. The initiation stress level was accurately predicted for both a double edge notched unidirectional specimen and a cross-plied center hole specimen. The fatigue produced long multiple cracks growing from the notches. These fatigue cracks were only in the matrix material and did not break the fibers in their path. The combination of matrix cracking and fiber/matrix debonding appears to greatly reduce the stress concentration around the notches. The laminates that were heat treated showed a different crack growth pattern. In the ASF specimens, matrix cracks had a more tortuous path and showed considerable more crack branching. For the same specimen geometry and cyclic stress, the (0/90/0) laminate with a hole had far superior fatigue resistance than the matrix only specimen with a hole.

Description: A study was made to determine the relevance of impacter shape to nonvisible damage and tensile residual strength of a 36 mm thick graphite/epoxy motor case. The shapes of the impacters were as follows: 12.7 mm and 25.4 mm diameter hemispheres, a sharp corner, and a 6.3 mm diameter bolt-like rod. The investigation revealed that damage initiated when the contact pressure exceeded a critical level. However, the damage was not visible on the surface until an even higher pressure was exceeded. The impact energy to initiate damage or cause visible damage on the surface increased approximately with impacter diameter to the third power. The reduction in strength for nonvisible damage increased with increasing diameter, 9 and 30 percent for the 12.7 mm and 25.4 mm diameter hemispheres, respectively. The corner impacter made visible damage on the surface for even the smallest impact energy. The rod impacter acted like a punch and sliced through the composite. Even so, the critical level of pressure to initiate damage was the same for the rod and hemispherical impacters. Factors of safety for nonvisible damage increased with increasing kinetic energy of impact. The effects of impacter shape on impact force, damage size, damage visibility, and residual tensile strength were predicted quite well assuming Hertzian contact and using maximum stress criteria and a surface crack analysis.

Description: An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of an SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation, and interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens, the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens is attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction.

Description: XD synthesis, powder blending, and hot pressing techniques have been utilized to produce NiAl composites containing 4, 7.5, 15, and 25 vol pct alumina whiskers and hybrid composite materials with 15 vol pct Al2O3 + 10 or 20 vol pct, nominally 1 micron TiB2 particles. The resistance to slow plastic flow was determined at 1200 and 1300 K via compression testing in air under constant velocity conditions. The stress-strain behavior of the intermetallic composites depended on the fraction of second phases where the 4 and 7.5 percent Al2O3 materials flowed at a nominally constant stress after about 2 percent deformation, while all the other composites exhibited diffuse yielding followed by strain softening. The flow stress-strain rate properties increased with volume fraction of Al2O3 whiskers except for the 4 and 7.5 percent materials, which had similar strengths. The hybrid composite NiAl + 15Al2O3 + 10TiB2 was substantially stronger than the materials simply containing alumina. Deformation in these composites can be described by the Kelly and Street model of creep in perfectly bonded, rigid, discontinuous fiber materials.

Description: Major issues and recent advances in the structural dynamics of rotating systems are summarized. The objectives and benefits of such systems are briefly discussed. Directions for future research are suggested.

Description: Fiber push-out tests have been performed on a ceramic matrix composite consisting of carborundum-sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance of about 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled using data obtained here and known fiber strengths to demonstrate the good composite behavior predicted for this material.

Description: Results of an assessment of the public risk associated with the release of carbon fibers from crash-fire accidents of civil aircraft having carbon composite structures are presented. The overall national impact is shown to be extremely low in 1993. Personal injury is found to be extremely unlikely. Based on these findings, the risk of electrical failure from carbon fibers should not prevent the exploitation of composites in aircraft, and additional protection of aircraft avionics to guard aginst carbon fibers is unnecessary.

Description: A fatigue analysis technique developed to predict damage growth in notched laminates is described. Features of the analysis include: criteria to relate matrix failure to cyclic stresses in and between plies; correlation of delamination growth with strain-release rate; and in-plane shear modulus change is related to cyclic shear stresses. A simplified finite element model is used to determine stresses in laminates that contain matrix damage. Failure criteria are integrated with the finite element model to form the fatigue analysis.

Description: The damage tolerance of composites was investigated. Results show that severe degradation in material strength may occur due to impact damage and that reduced strain allowables should be considered to compensate for possible impact damage. The mechanisms of failure involved in impact so that local damage will be reduced and arrest of propagating fracture initiated at impact locations are examined. Compression strength reductions for damage due to impact by a 1.27 cm diameter spherical projectile in thick laminates representative of wing skin panels are presented. Also discussed are the results of concepts recently evaluated to improve damage tolerance. These concepts range from improvements at the materials level to advanced structural configurations designed to arrest or limit the growth of propagating fractures. The results indicate that substantial improvements in the damage tolerance of graphite-epoxy composite structures can be achieved through the proper combination of materials and structural design.

Description: Progress in the development of verified design technology for generic advanced-composite structural components loaded in compression is reported. Generic structural configurations material systems and load ranges of interest for a given application were investigated using structural procedures, structural analysis procedures, and laboratory testing of structural specimens. Both flat and curved composite compression panels that are designed either to be buckling resistant or to have postbuckling strength depending on the expected application of the panels were considered.

Description: The degree of notch sensitivity of composites in compression and whether their failures can be predicted over a wide range of plate and hole sizes. The notch sensitivity of composites is investigated by comparing actual failure loads of laminates with circular holes, with the extreme failure that would be expected from an ideal notch insensitive material and from an ideal notch sensitive material. The predictability question is addressed by applying the point stress failure criterion to a wide range of plate widths and hole sizes and comparing with available experimental data. The severity of impact is explored by comparing strength reductions resulting from impact with those resulting from comparable size circular holes. Finally, comparison is made of the differences to be expected from the effects of cracks and circular holes on failure strength.

Description: The adhesion, friction, and wear properties of materials are reviewed and some of the factors influencing these properties are discussed. The forms of lubrication and types of lubricants will also be discussed.

Description: Research on three classes of materials that show potential for allowing significant increases in operating temperatures in gas turbine engines is discussed. Monolithic ceramics, ceramic matrix composites, and carbon-carbon composites are discussed. Sintering, hot pressing, and densification are discussed.

Description: The fabrication of several composite structural articles including DC-10 upper aft rudders, L-1011 vertical fins and composite biomedical appliances are discussed. Innovative composite processing methods are included.

Description: Manufacturers are developing composite versions of structural components on existing aircraft. Development involves testing of various material options before selecting one and then extensive testing to develop an adequate data base of material strength and stiffness properties. Design options are narrowed through analysis and a varied spectrum of development tests on small and large subcomponents. In parallel with this, a suitable production process including economical ply preparation and cure at high temperature and pressure is evolved, tools are designed and fabricated, and full scale components are then manufactured for ground qualification tests, flight tests, and airline service. The various tests include many that are required by the FAA for flight certification, which must precede airline service. Inspection and repair methods to insure adequate maintenance in service are also developed.

Description: The fatigue, fracture, and impact behavior of composite materials are investigated. Bolted and bonded joints are included. The solutions developed are generic in scope and are useful for a wide variety of structural applications. The analytical tools developed are used to demonstrate the damage tolerance, impact resistance, and useful fatigue life of structural composite components. Standard tests for screening improvements in materials and constituents are developed.

Description: Because of the immense noise background during the operation of a large engine such as the SSME, the relatively low level unique ball bearing signatures were often buried by the overall machine signal. As a result, the most commonly used bearing failure detection technique, pattern recognition using power spectral density (PSD) constructed from the extracted bearing signals, is rendered useless. Data enhancement techniques were carried out by using a HP5451C Fourier Analyzer. The signal was preprocessed by a Digital Audio Crop. DAC-1024I noise cancelling filter in order to estimate the desired signal corrupted by the backgound noise. Reference levels of good bearings were established. Any deviation of bearing signals from these reference levels indicate the incipient bearing failures.

Description: Confidence in the long term durability of advanced composites is developed through a series of flight service programs. Service experience is obtained by installing secondary and primary composite components on commercial and military transport aircraft and helicopters. Included are spoilers, rudders, elevators, ailerons, fairings and wing boxes on transport aircraft and doors, fairings, tail rotors, vertical fins, and horizontal stabilizers on helicopters. Materials included in the evaluation are boron/epoxy, Kevlar/epoxy, graphite/epoxy and boron/aluminum. Inspection, maintenance, and repair results for the components in service are reported. The effects of long term exposure to laboratory, flight, and outdoor environmental conditions are reported for various composite materials. Included are effects of moisture absorption, ultraviolet radiation, and aircraft fuels and fluids.

Description: Carbon-carbon materials and new oxidation resistant coating developments are discussed. Potential areas of application are highlighted. A short bibliography of selected references is included that describe carbon-carbon materials and related technology in detail.

Description: The relationship between constituent and MMC properties in fatigue loading is investigated with low-cycle fatigue-resistance testing of an alloy Ti-15-3 matrix reinforced with SiC SCS-6 fibers. The fabrication of the composite is described, and specimens are generated that are weak and ductile (WD), strong and moderately ductile (SM), or strong and brittle (SB). Strain is measured during MMC fatigue tests at a constant load amplitude with a load-controlled waveform and during matrix-alloy fatigue tests at a constant strain amplitude using a strain-controlled waveform. The fatigue resistance of the (0)8 SiC/Ti-15-3 composite is found to be slightly influenced by matrix mechanical properties, and the composite- and matrix-alloy fatigue lives are not correlated. This finding is suggested to relate to the different crack-initiation and -growth processes in MMCs and matrix alloys.

Description: A method is presented to minimize the residual matrix stresses in metal matrix composites. Fabrication parameters such as temperature and consolidation pressure are optimized concurrently with the characteristics (i.e., modulus, coefficient of thermal expansion, strength, and interphase thickness) of a fiber-matrix interphase. By including the interphase properties in the fabrication process, lower residual stresses are achievable. Results for an ultra-high modulus graphite (P100)/copper composite show a reduction of 21 percent for the maximum matrix microstress when optimizing the fabrication process alone. Concurrent optimization of the fabrication process and interphase properties show a 41 percent decrease in the maximum microstress. Therefore, this optimization method demonstrates the capability of reducing residual microstresses by altering the temperature and consolidation pressure histories and tailoring the interphase properties for an improved composite material. In addition, the results indicate that the consolidation pressures are the most important fabrication parameters, and the coefficient of thermal expansion is the most critical interphase property.

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

Description: Presented is an analysis and evaluation of a prototype traction-drive joint for robotic manipulators, developed under NASA sponsorship. A dynamic model is developed using the Lagrange formulation. Controllability, observability, dynamic stabiliby, and response characteristics of the joint to test inputs are studied. A linear quadratic regulator (LQR) is implemented on the joint model to determine a basis for evaluating the performance of the traction-drive joint under servo control. An evaluation of the results and directions for future investigations are presented.

Description: The reaction of single-crystal Al2O3 with pure Ti and Ti-Al alloys with different Al concentrations was examined in the temperature range of 1173 to 1573 K. Significant reaction occurred between Al2O3 and the Ti-Al alloys with Al concentrations lower than that corresponding to the gamma-TiAl phase. The reaction mechanism was determined to be simultaneous diffusion of Al and atomic oxygen from Al2O3 into Ti and the Ti-Al alloys.

Description: The nonlinear frequency response characteristics of a geared rotor-bearing system are examined. A three-DOF dynamic model is developed which includes nonlinearities associated with radial clearances in the radial rolling element bearings and backlash between a spur gear pair; linear time-invariant gear meshing stiffness is assumed. The corresponding linear system problem is also solved, and predicted natural frequencies and modes match with finite element method results. The applicability of both analytical and numerical solution techniques to the multi-DOF nonlinear problem is investigated. Satisfactory agreement is found between the theory presented here and the available experimental data. Nonlinear modal interactions and differences between internal static transmission error excitation and external torque excitation are discussed. In addition, parametric studies are performed to understand the effect of system parameters such as bearing stiffness to gear mesh stiffness ratio, alternating to mean force ratio and radial bearing preload to mean force ratio on the nonlinear dynamic behavior.

Description: This investigative program examines leakage testing of elastomeric O-ring seals for a solid rocket casing and provides direction towards an improved nondestructive postassembly test. It also details test equipment for the Space Shuttle systems solid rocket boosters (SRB). The results are useful to designers of hardware for pressure containment vessels which use O-ring seals. Using several subscale seal and groove configuration test fixtures equipped with either two or three O-ring seals in series, seal integrity is investigated with both a pressure decay and flowmeter methods. Both types of test equipment adequately detect the practical range of expected seal leak rates of 1 to 0.0001 sccs. The flowmeter leak test equipment appears to reduce testing time substantially. Limited seal leakage testing is performed on full-sized rocket motor segment seals, a pre-Challenger short stack, providing comparison of bore seals to test specimen bore and face seals. The conclusions are that seal reliability, verified via a performance pressure test, can be affected by temperature, quantity of grease, test pressure, and seal pressure load direction. Potential seal failure scenarios including contamination, seal damage, and sealing surface damage are discussed. Recommendations are made for an improved test procedure.

Description: Chemical processes relevant to the stability and processing of SiC-reinforced Si3N4 composites have been examined from thermochemical considerations. The thermodynamic stabilities of various interfaces, such as SiC-Si3N4, SiC-Si3N4-Si2ON2, and SiC-Si3N4-SiO2, have been examined as a function of temperature, and the temperatures above which these interfaces become unstable have been calculated. The degradation of SiC during the processing of the composite has been examined. The processing routes considered in this study include the reaction bonded silicon nitride (RBSN) process and the pressure-assisted sintering processes with suitable sintering additives.

Description: The paper proposes a reduced-order analytical model of a spur gear pair which consists of two identical spur gears, two identical flexible shafts, and four identical rolling element bearings of a given radial stiffness. The error associated with the undamped eigensolution is estimated by a comparison with a benchmark finite element model.

Description: The interfacial reaction between NiAl and Nb2Be17 (used as a reinforcement for the alloy) was studied by measuring diffusion bonding of NiAl and Nb2Be17 plates in a hot press under a vacuum of 10 exp -5 atm. It was found that, after 2 hrs of hot pressing at 1373 K, the reaction between NiAl and Nb2Be17 was extensive. A 40 to 50-micron-thick reaction zone consisted of three distinct layers at the NiAl/Nb2Be17 interface: layer A next to Nb2Be17, layer B in the middle, and layer C next to NiAl. Results of analysis of the reaction layers using energy dispersive spectroscopy (EDS) were inconclusive because of the inabiliaty of EDS to detect Be.

Description: A two-material composite cylinder model (CCM) was considered for the study of the mechanical behavior at different temperatures of a fiber-reinforced silicon carbide/aluminum (SiC/Al) composite. An elastoplastic analysis of the model was performed in which the fiber was assumed to be linear elastic and the matrix elastoplastic with work-hardening. The analysis was based on the deformation theory of plasticity in conjunction with the von-Mises yield criterion. Experimental stress-strain curves of an SiC/Al composite were obtained at 24 and 288 C (75 and 550 F). The complete three-dimensional stress distribution in the composite using the CCM was determined. It was found that, in addition to longitudinal stresses, transverse stresses in both the fiber and the matrix were developed as a result of the different Poisson's ratios of the two materials. The transverse stresses, although much smaller than the longitudinal stresses, contributed to the plastic deformation of the matrix. The experimental stress-strain curves were favorably compared with the theoretical predictions.

Description: The lubrication characteristic of a fluid with solid particles is studied using the continuum theory of mixtures. The governing equations are formulated and appropriate boundary conditions are introduced for an arbitrary-shaped lubricant film thickness. As a special case, closed-form analytical perturbation solutions for pressure and shear stress are obtained for a mixture of a conventional oil and solid particles with small values of solid-volume fraction sheared in the clearance space of an infinitely long slider bearing. It is found that when compared with a pure fluid, the mixture of the fluid and solid generates a higher pressure and therefore a higher load-carrying capacity with the added advantage of a reduction in the coefficient of friction.

Description: The dynamic behavior of multistage gear transmission system, with the effects of gear-box-induced vibrations and rotor mass-imbalances is analyzed. The model method, using undamped frequencies and planar mode shapes, is used to reduce the degree-of-freedom of the system. The various rotor-bearing stages as well as lateral and torsional vibrations of each individual stage are coupled through localized gear-mesh-tooth interactions. Gear-box vibrations are coupled to the gear stage dynamics through bearing support forces. Transient and steady state dynamics of lateral and torsional vibrations of the geared system are examined in both time and frequency domain. A typical three-staged geared system is used as an example. Effects of mass-imbalance and gear box vibrations on the system dynamic behavior are presented in terms of modal excitation functions for both lateral and torsional vibrations. Operational characteristics and conclusions are drawn from the results presented.

Description: Debonding of the fiber-matrix interface is a major cause for the degradation of the mechanical properties and the loss of thermal conductivity of fiber-reinforced composites. This paper discusses two analytical approaches for modeling the thermal conduction problem of composites. One is based on the concept of modeling the thermal barrier by an equivalent heat transfer coefficient at the fiber-matrix interface, as described by Hasselman and Johnson (1987) and Benveniste and Miloh (1986). The other approach, suggested by Hatta and Taya (1986), is by treating a composite with debonded interface as a coated-fiber composite. The major advantage of the latter aproach is that the thickness of the fiber coating can be realistically modeled depending upon the extent of degradation of the composite with the thermal conductivity of the coating as that of air.

Description: This paper conceptualizes a powder lubrication mechanisms which closely resembles that of a hydrodynamic fluid film. Based on the observations of past investigations and on the author's experiments, it is postulated that a layered shearing of the compacted powder generates velocity, density, and temperature profiles akin to fluid film bearings. Thus, a lubricant consisting of a fine powder unserted either deliberately or one generated by the water of the mating surfaces, constitutes a viable lubricant that generates the required flows and pressures to prevent contact between the surfaces.

Description: Procedures for the preliminary design for composite adhesive joints are described. Typical joints, their respective free body diagrams, and approximate equations for estimating the stresses in each of these typical joints are summarized. Equations are also presented to check the critical conditions of the joint such as minimum length, maximum adhesive shear stress, and peel-off stress. To illustrate the procedure, sample designs are described in step-by-step fashion for a butt joint with single doubler subjected to static loads, cyclic loads, and environmental effects. The results show that unsymmetric adhesive joints are inefficient and should be avoided, and hygrothermal environments and cyclic loads dramatically reduce the structural integrity of the joint and require several joint lengths compared with those for static load with no environmental effects.

Description: The effect of the crosslink density of the matrix on physical and mechanical properties of a graphite-fiber-reinforced PMR (for polymerization of monomer reactants) polyimide composites during isothermal aging was investigated in experiments where unidirectional composite specimens of Celion 6000/PMR-P1 were isothermally exposed at 288 C in air for various time periods up to 5000 hrs. It was found that, as the crosslink density increased, the glass transition temperature, density, and elevated-temperature interlaminar shear strength of a composite increased, while the initial moisture absorption and the coefficient of thermal expansion decreased. However, after reaching the highest possible matrix crosslink density, several of the composite properties began to deteriorate rapidly.

Description: Temperature-frequency dependence of alpha, beta, and gamma transitions was determined using a Rheometrics dynamic spectrometer on a series of unidirectional Celion 6000/N-phenylnadimide (PN) modified PMR polyimide composites. The objective was to see if any correlations exist between crosslinked network structure and dynamic mechanical properties. Variation in crosslinked network structures was achieved by altering the polyimide formulation through addition of various quantities of PN into the standard PMR-15 composition. As a control, PMR-15 composite system exhibited well-defined alpha, beta, and gamma transitions in the regions of 360, 100, and -120 C, respectively. Their activation energies were estimated to be 232, 60, and 14 kcal/mole, respectively. Increasing the amount of PN concentration caused lowering of the activation energies of the three relaxations, a decrease of the glass transition temperature, and increasing intensities of the three damping peaks, compared to the control PMR-15 counterpart. These dynamic mechanical responses were in agreement with formation of a more flexible copolymer from PN and PMR-15 prepolymer.

Description: This paper describes a new high-temperature friction and wear test apparatus (tribometer). The tribometer can be used as a pin-on-disk or pin-on-ring configuration and is specially designed to measure the tribological properties of ceramics and high temperature metallic alloys from room temperature to 1200 C. Sliding mode can be selected to be either unidirectional at velocities up to 22 m/sec or oscillating at frequencies up to 4.6 Hz and amplitudes up to + or - 60 deg. The test atmosphere is established by a controlled flow rate of a purge gas. All components within the test chamber are compatible with oxidizing, inert or reducing gases.

Description: A numerical transient solution of the hydrodynamically lubricated point contact problem is obtained using the ball-on-plane model. Results, which include the variation of the minimum film thickness and phase-lag with time as functions of excitation frequency, are compared with the analytic solution of the transient step bearing problem with the same dynamic loading function.

Description: Silicon carbide SCS-6 fibers in a Ti24A1 + 11Nb matrix were subjected to off axis loading in a 'thin-slice' pushout test, resulting in various combinations of shear, radial compression, and tension along the fibers as a function of orientation angle. The load necessary for debonding decreased as the orientation angle increased, whereas the average frictional sliding stress after 60 s of sliding remained relatively constant for orientation angles less than 30 deg. Analyses of the specimen bending stresses and of the contact stresses by finite element modeling and thin plate theory are presented.

Description: Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (nine cycles at 4.2K) and superfluid helium temperature (four cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10 exp -9 std cu cm/s, during testing.

Description: Twenty-four different epoxy resin systems were evaluated by a variety of test techniques to identify materials that exhibited improved impact damage tolerance in graphite/epoxy composite laminates. Forty-eight-ply composite panels of five of the material systems were able to sustain 100 m/s impact by a 1.27-cm-diameter aluminum projectile while statically loaded to strains of 0.005. Of the five materials with the highest tolerance to impact, two had elastomeric additives, two had thermoplastic additives, and one had a vinyl modifier; all the five systems used bisphenol A as the base resin. An evaluation of test results shows that the laminate damage tolerance is largely determined by the resin tensile properties, and that improvements in laminate damage tolerance are not necessarily made at the expense of room-temperature mechanical properties. The results also suggest that a resin volume fraction of 40 percent or greater may be required to permit the plastic flow between fibers necessary for improved damage tolerance.

Description: Statistical analysis and multiple regression were used to determine and quantify the significant hygrothermomechanical variables which influence the tensile durability/life (cycle loading, fatigue) of boron-fiber/epoxy-matrix (B/E) and high-modulus-fiber/epoxy-matrix (HMS/E) composites. The use of the multiple regression analysis reduced the variables from fifteen, assumed initially, to six or less with a probability of greater than 0.999. The reduced variables were used to derive predictive models for compression and intralaminar shear durability/life of B/E and HMS/E composites assuming isoparametric fatigue behavior. The predictive models were subsequently generalized to predict the durability/life of graphite/fiber-r generalized model is of simple form, predicts conservative values compared with measured data and should be adequate for use in preliminary designs. Previously announced in STAR as N82-14287

Description: For an investigation of problems of composites at high strain rates with dominant wave propagation effects, such as dynamically loaded composite jet engine blades, the longitudinal, transverse, and in-plane shear properties of unidirectional SP 288/AS graphite/epoxy were measured at various strain rates ranging from quasi-static to over 500/s. The test specimens were rings 10.16 cm in diameter, 2.54 cm long, 6 to 8 plies thick, and with fibers at 0, 90, and 10 deg off-axis. Quasi-static testing was conducted in a fixture which applies hydraulic pressure to the ring specimens, and dynamic testing was conducted by applying an internal pressure pulse through a liquid in a special fixture. Dynamic stress-strain curves are presented. For the 0-deg specimens, the modulus increases with strain up to 20 percent of the static value. The modulus and strength increase sharply in the 90-deg rings with strain rate reaching values two to three times the corresponding static rate.

Description: A convenient procedure is described to determine the hygral behavior (moisture expansion coefficients and moisture stresses) of angleplied fiber composites using a pocket calculator. The procedure consists of equations and appropriate graphs for various (+ or - theta) ply combinations. These graphs present reduced stiffness and moisture expansion coefficients as functions of (+ or - theta) in order to simplify and expedite the use of the equations. The procedure is applicable to all types of balanced, symmetric fiber composites including interply and intraply hybrids. The versatility and generality of the procedure is illustrated using several step-by-step numerical examples. Previously announced in STAR as N82-16181

Description: The topics discussed include the following: telepresence, telerobotics, teleoperators, man machine systems, robot control, and remote control.

Description: This report describes a thermal-vacuum outgassing model and test protocol for predicting outgassing times and dimensional changes for polymer matrix composites. Experimental results derived from 'control' samples are used to provide the basis for analytical predictions to compare with the outgassing response of Long Duration Exposure Facility (LDEF) flight samples. Coefficient of thermal expansion (CTE) data are also presented. In addition, an example is given illustrating the dimensional change of a 'zero' CTE laminate due to moisture outgassing.

Description: Bolts and rivets provide a means of load transfer in the construction of aircraft. However, they give rise to stress concentrations and are often the source and location of static and fatigue failures. Furthermore, fastener holes are prone to cracks during take-off and landing. These cracks present the most common origin of structural failures in aircraft. Therefore, accurate determination of the contact stresses associated with such loaded holes in mechanically fastened joints is essential to reliable strength evaluation and failure prediction. As the laminate is subjected to loading, the contact region, whose extent is not known, develops between the fastener and the hole boundary through this contact region, which consists of slip and no-slip zones due to friction. The presence of the unknown contact stress distribution over the contact region between the pin and the composite laminate, material anisotropy, friction between the pin and the laminate, pin-hole clearance, combined bearing-bypass and shear loading, and finite geometry of the laminate result in a complex non-linear problem. In the case of bearing-bypass loading in compression, this non-linear problem is further complicated by the presence of dual contact regions. Previous research concerning the analysis of mechanical joints subjected to combined bearing-bypass and shear loading is non-existent. In the case of bearing-bypass loading only, except for the study conducted by Naik and Crews (1991), others employed the concept of superposition which is not valid for this non-linear problem. Naik and Crews applied a linear finite element analysis with conditions along the pin-hole contact region specified as displacement constraint equations. The major shortcoming of this method is that the variation of the contract region as a function of the applied load should be known a priori. Also, their analysis is limited to symmetric geometry and material systems, and frictionless boundary conditions. Since the contact stress distribution and the contact region are not known a priori, they did not directly impose the boundary conditions appropriate for modelling the contact and on-contact regions between the fastener and the hole. Furthermore, finite element analysis is not suitable for iterative design calculations for optimizing laminate construction in the presence of fasteners under complex loading conditions. In this study, the solution method developed by Madenci and Ileri (1992a,b) has been extended to determine the contact stresses in mechanical joints under combined bearing-bypass and shear loading, and bearing-bypass loading in compression resulting in dual contact regions.