ALBERT

Description: Experience with many spacecraft configurations boosted by a variety of launch vehicles indicates that the maximum loads experienced throughout most of the structure are inertial in origin. These loads arise from the dynamic elastic response of the flight vehicle to the transient disturbances of launch and flight, and are highly dependent on the dynamic characteristics of both the spacecraft and the launch vehicle. It has proved to be most advantageous, in the analysis of this critical dependency of loads upon vehicle dynamic properties, to establish a mathematical model in terms of normal mode characteristics. In this way, the vibration behavior of an elastomechanical structure (or substructure) can be described by means of the so-called modal or natural degrees of freedom. The conduct of a mode survey test and the use of a suitably test-verified model in loads analyses is essential to the flight worthiness certification process of space systems. The desirability of such tests is confirmed by the fact that, almost invariably, significant deficiencies in the analytical models are revealed by the results. Therefore, this experimental program was undertaken to determine those properties of a solid-propellant rocket motor (SRM) which are required to characterize a dynamic model. Random ambient-excited accelerations were measured at a series of stations along the motor for the purpose of identifying the motor beam-like stiffnesses in bending, shear, and torsion. From a system identification point of view, it is significant that stiffness properties of a subsystem (the motor) are determined from modes of the full system (motor/stand configuration) using mode shape data of the subsystem only. This contrasts with traditional system identification approaches which rely upon complete system mode shapes.

Description: The topics addressed are: (1) phobos power plant; (2) fusion power/propulsion system; (3) surface power from an orbiting spacecraft; (4) RTG replacement; (5) MHD-thermoelectric burst reactor; (6) TAU Voyage power/propulsion device; (7) ESCAPE to ODYSSEY.

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

Description: The Texas A&M Nuclear and Aerospace engineering departments have worked on five different projects for the NASA/USRA Advanced Design Program during the 1987/88 year. The aerospace department worked on two types of lunar tunnelers that would create habitable space. The first design used a heated cone to melt the lunar regolith, and the second used a conventional drill to bore its way through the crust. Both used a dump truck to get rid of waste heat from the reactor as well as excess regolith from the tunneling operation. The nuclear engineering department worked on three separate projects. The NEPTUNE system is a manned, outer-planetary explorer designed with Jupiter exploration as the baseline mission. The lifetime requirement for both reactor and power-conversion systems was twenty years. The second project undertaken for the power supply was a Mars Sample Return Mission power supply. This was designed to produce 2 kW of electrical power for seven years. The design consisted of a General Purpose Heat Source (GPHS) utilizing a Stirling engine as the power conversion unit. A mass optimization was performed to aid in overall design. The last design was a reactor to provide power for propulsion to Mars and power on the surface. The requirements of 300 kW of electrical power output and a mass of less than 10,000 Rg were set. This allowed the reactor and power conversion unit to fit within the Space Shuttle cargo bay.

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: Out-of-plane tensile tests of a woven fabric carbon-carbon composite were performed in a scanning electron microscope equipped with a tensile stage and a videotape recording system. The composite was prepared from T-300 8-harness satin graphite fabric and a phenolic resin. The (0/90/0/90/0 sub 1/2) sub 2 laminate, with a Theta describing the orientation of the warp fibers of the fabric, was cured at 160 C and pyrolized at 871 C. This was followed by four cycles of resin impregnation, curing, and pyrolysis. A micrograph of the cross section of the composite is presented. Inspection of the specimen fracture surface revealed that the filaments had no residual matrix bonded to them. Further inspection revealed that the fracture was interlaminar in nature. Failure occurred where filaments of adjacent plies had the same orientation. Thus it is postulated that improvement in transverse tensile strength of 2-D carbon-carbon depends on the improvement of the filament-matrix bond strength.

Description: Results in the measurement of slowly varying mechanical loading functions on composites using optical time domain reflectometry (OTDR) in imbedded optical fiber during both simulated manufacture and use are reviewed. First, the basic theoretical and experimental principles of the OTDR system are described. Next, the mechanical system of the composite and the imbedded fiber is analyzed. Results of measurement obtained for various loading functions applied to material specimens are then described and system limitations on spatial resolution, strain amplitude sensitivity, and frequency response are explained in terms of the range and resolution limits of the OTDR system.

Description: The damage potentials to the space shuttle orbiter caused by the high velocity particles contained in the exhaust plume of an upper stage is discussed. In particular, the particle size distribution and composition, the velocity of the particles and the expected contribution from shuttle launched upper stages are addressed. Particle size estimates based on historical data are compapred with those derived from upper stage motor performance testing. The particle velocities as determined by the best available plume computational technique are presented. The shuttle is scheduled to launch approximately 135 upper-stages over its lifetime looking at the currently scheduled flights and averaging over a yearly basis yields the contribution of particulates from the uper-stages. On the average, 91,645 llbs of Al2O3 will be ejected on each launch. The analysis to determine how much of this 91,645 lbs will remain in orbit or the decay rate is yet to be accomplished.

Description: The objective of this experiment is to determine the effects of long-term orbital exposure on the materials used in solid-rocket space motors. Specifically, structural materials and propellants from the STAR/PAM-D series motors and the PAM DII/IPSM-II motors will be tested, as well as advanced composite case and nozzle materials planned for future use. The experiment approach is to expose samples of solid-rocket propellant, liner, insulation, case, and nozzle specimens to the space environment and to compare preflight and postflight measurements of various mechanical, chemical, and ballistic properties.

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: The effect of fiber/matrix interactions on the mechanical properties of thermoplastic carbon fiber composites was determined. The experimental approach was a multi-faceted one involving the following areas: characterization of the surface of carbon fibers using X-ray photoelectron spectroscopy (XPS), secondary ion mass spectroscopy (SIMS) and scanning transmission electron microcopy (STEM); determination of the functional groups on carbon fiber surfaces using an elemental tagging scheme - derivatization; determination of the polar and dispersion contribution to the surface energy of carbon fibers by measuring wetting forces in a series of liquids having known polar and dispersion components; and study of the interaction of thermoplastic polymers with carbon surfaces by solution adsorption, STEM and fiber critical length.

Description: Temperature gradients are significant during cure of large area, thick-section composites. Such temperature gradients result in nonuniformly cured parts with high void contents, poor ply compaction, and variations in the fiber/resin distribution. A model was developed to determine the temperature distribution in thick-section autoclave cured composites. Using the model, long with temperature measurements obtained from the thick-section composites, the effects of various processing parameters on the thermal response of the composites were examined. A one-dimensional heat transfer model was constructed for the composite-tool assembly. The governing differential equations and associated boundary conditions describing one-dimensional unsteady heat-conduction in the composite, tool plate, and pressure plate are given. Solution of the thermal model was obtained using an implicit finite difference technique.

Description: The hydraulic actuation system of the space shuttle main engine is discussed. The system consists of five electrohydraulic actuators and a single engine filter used to control the five different propellant valves, which in turn control thrust and mixture ratio of the space shuttle main engine. The hydraulic actuation system provides this control with a precision of 98.7 percent or an error in position no greater than 1.3 percent of full scale rotational travel for critical positions.

Description: The system components and operation of the space shuttle solid rocket booster (SRB) dewatering set are described. The SRB dewatering set consists of a nozzle plug, control console, remote control unit, power distribution unit, umbilical cable, interconnect cables, and various handling and storage items. The nozzle plug (NP) is a remotely controlled, tethered underwater vehicle that is launched from the retrieval vessel (RV) by a crane, descends down the side of the SRB, and is positioned below the SRB nozzle. A TV camera mounted at the top of the NP central core is used by the control console operator to visually guide the NP during descent and docking. The NP is then driven up and locked into the nozzle. Compressed air is passed through the umbilical from the RV, through the NP and into the SRB motor. The water inside the SRB is expelled causing the SRB to rotate to a near horizontal attitude on the surface of the water.

Description: Zero gravity testing in the KC-135 aircraft of flat fold flexible solar array test specimens sufficiently demonstrated the adequacy of the panel design. The aircraft flight crew provided invaluable assistance and significantly contributed to the design and development of the flexible solar array, and ultimately to the potential success of the solar electric propulsion solar array shuttle flight experiment program.

Description: New adhesive-bonded panels are being investigated as a part of an effort to extend and upgrade the 64-m to a 70-m antenna network. Load-deflection tests were conducted on a sample high-precision adhesive-bonded panel for comparison with design criteria. Two computerized structural models were developed in order to predict the deformation patterns under different types of distributed and concentrated loadings. The main purpose was to obtain empirical stiffness factors for the slit beams and girders in the panel structure. With determination and use of the empirical stiffness factors, there is a good agreement between the theoretically predicted deflections and the test measurements. It was also found that the new bonded panels satisfy the stringent design specifications and surface tolerance bounds.

Description: Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of facture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.

Description: The use of advanced composites for space structures is reviewed. Barriers likely to limit further applications of composites are discussed and highlights of research to improve composites are presented. Developments in composites technology which could impact spacecraft systems are reviewed to identify technology needs and opportunities.

Description: Reflector panels for the Large Deployable Reflector (LDR) for a 20m, Earth-orbiting, submillimeter and infrared telescope were designed. The panels must be 1 to 2 m in diameter with surface precision and thermal stability of a few microns, and an areal density of or = 10 kg/sqm. Using a combination of design, analytical modeling, panel fabrication, and testing, two sizes of graphite/epoxy panels were produced. One is 15 sqcm the other 60 sqcm, both weighing 5 to 7 kg/sqm with manufactured surface accuracies of a few tenths of a micron and thermal stability at LDR orbital temperatures of a few microns.

Description: Fiber reinforced plastics were considered for many structural applications in automotive, aerospace and other industries. A major concern was and remains the failure modes associated with the polymer matrix which serves to bind the fibers together and transfer the load through connections, from fiber to fiber and ply to ply. An accelerated characterization procedure for prediction of delayed failures was developed. This method utilizes time-temperature-stress-moisture superposition principles in conjunction with laminated plate theory. Because failures are inherently nonlinear, the testing and analytic modeling for both moduli and strength is based upon nonlinear viscoelastic concepts.

Description: The objective of this experiment is to determine the effect of various lengths of exposure to a space environment on the mechanical properties of selected commercial polymer matrix composite materials. Fiber materials will include graphite, boron, S-glass, and PRD-49. The mechanical properties to be investigated are orthotropic elastic constants, strength parameters (satisfying the tensor polynomial relation), coefficients of thermal expansion, impact resistance, crack propagation, and fracture toughness. In addition, the effect of laminate thickness on property changes will also be investigated.

Description: The objective is to test different types of materials (laminates, thermal coatings, and adhesives) to determine their actual useful lifetime. These experiments will also make is possible to integrate the histories of the thermal and mechanical characteristics into models of the composite structures. The experiment is passive and is located in one of the boxes in a 12-in.-deep peripheral tray with nine other experiments from France. The box will provide protection for the samples from contamination during the launch and reentry phases of the Long Duration Exposure Facility mission. The experiment revolves around four themes of study: thermal coatings, adhesives, dimensional stability, and mechanical characteristics. The various materials will be arranged in six levels within the box, so only the first level will be subjected to direct solar radiation. Each level will consist of plates from which test specimens will be cut after the mission.

Description: The immediate objectives of this experiment are to understand changes in the properties and structure of materials after exposure to the space environment and to compare these changes with predictions based on laboratory experiments. The experiment consists of 19 subexperiments involving a number of DOD laboratories and contractor organizations. In general, the experimental approach with each of the subexperiments will involve comparison of preflight and postflight analyses. Typical analyses will include the measurement of optical properties (reflectance, transmittance, and refractive index), and macrophysical properties. In addition to measuring changes in the macroscopic properties of the returned specimens, microstructural properties will also be examined. Thus, it may be possible to increase our understanding of the changes induced by the environment. This increased understanding can then be used to predict the performance of materials based on knowledge of the space environment and the results of laboratory tests. This experiment will be a coopperative effort and will provide an opportunity for DOD space programs and laboratories to evaluate materials and components after long exposures to the space environment.

Description: The primary objective of this experiment is to accumulate the needed operational data associated with the exposure of graphite-polyimide and graphite-epoxy material to the environments of space. The experiment will be mounted in two 3-in.-deep peripheral trays. Graphite-polyimide specimens will occupy 1 1/3 trays and the graphite-epoxy specimens will occupy two-thirds of a tray. The experiment approach requires two matched sets of specimens with traceable records that are maintained for materials processing and specimen quality. After fabrication, one set of each test specimen will be sectioned and structurally tested to serve as a data baseline. After the flight, the other set of specimens will undergo extensive measurements of mechanical properties for comparison with the original data baseline. Structural testing of the graphite-polyimide specimens will provide strength and elastic data in tension, compression, and shear. Transverse tension microcracking and crack propagation will be evaluated by photomicroscopy. Structural testing of the graphite-epoxy specimens will include verification of laminate, core, adhesive, and fatigue properties as applied to the design and analysis of the payload bay door. Microcracking and crack propagation will also be analyzed by photomicroscopy.

Description: This experiment has three objectives. The first and main objective is to detect a possible variation in the coefficient of thermal expansion of composite samples during a 1-year exposure to the near-Earth orbital environment. A second objective is to detect a possible change in the mechanical integrity of composite products, both simple elements and honeycomb sandwich assemblies. A third objective is to compare the behavior of two epoxy resins commonly used in space structural production. The experimental approach is to passively expose samples of epoxy matrix composite materials to the space environment and to compare preflight and postflight measurements of mechanical properties. The experiment will be located in one of the three FRECOPA (French cooperative payload) boxes in a 12-in.-deep peripheral tray that contains nine other experiments from France. The FRECOPA box will protect the samples from contamination during the launch and reentry phases of the mission. The coefficients of thermal expansion are measured on Earth before and after space exposure.

Description: The objective of this experiment is to evaluate the effects of the near-Earth orbital environment on the physical and chemical properties of laminated continuous-filament composites and composites resin films for use in large space structures and advanced spacecraft. The experiment is passive and occupies about one-half of a 6-in.-deep peripheral tray. Specimens of composite materials and polymeric and resin films are arranged above and below the experiment mounting plate to enable both exposure and nonexposure to sunlight. This provides a comparison of the effects of ultraviolet plus vacuum plus thermal cycling and those of vacuum plus thermal cycling on these materials. The experiment tray is thermally isolated from the Long Duration Exposure Facility structure to allow the material specimens to experience a wide range of thermal cycles. Tensile and compression specimens will be used to evaluate the laminated composite materials. A number of the specimens are precut and ready for testing after space exposure, whereas other specimens will be prepared from larger samples.

Description: Graphite-epoxy composites are promising candidates for structural use in space vehicles because of their high strength and elastic modulus properties. The problem of low fracture toughness was solved by use of recently developed techniques of intermittent interlaminar bonding. Before this material can be adapted for space use, however, confidence must be gained that its mechanical properties are not degraded by exposure to the space environment. The objective of this experiment is to test the effect of extended exposure to a space environment on the mechanical properties of a specially toughened T300/5208 graphite-epoxy composite material. Specimens made by recently developed techniques of intermittent interlaminar bonding will be exposed and afterward tested for fracture toughness, tensile strength, and elastic modulus. The approach of this experiment is to provide a frame on which the specimens can be mounted with their flat sides normal to the Long Duration Exposure Facility radius, each specimen with an unobstructed exposure of about 2 pi sr. The specimens will be mounted so that they neither fracture from high stress nor fail from excessive heating during launch and return.

Description: A space based orbital transfer vehicle (SBOTV) and ground based OTV's (GBOTV) are compared for debris protection, space based OTV maintenance provisions, flight performance, onorbit refueling, and launch and return operations. Debris protection has a severe impact on the SBOTV, while the penalty for the GBOTV is much less severe. A key technology issue is the protection capability of composite materials. Onorbit maintenance is critical for SBOTV. Reduction of losses during the various transfers is th maine problem with refueling a SBOTV. Zero-g propellant storage and transfer is an important technology area for SBOTV. A reusable shroud must be developed to return GBOTV's if a Shuttle derivative vehicle is used. The advantage of space basing lies in more efficient use of the launch vehicle. Since most of the mass going to LEO is OTV propellant, and the launches to deliver the SBOTV propellant are generally mass limited, substantially fewer launches are required to support the SBOTV.

Description: Results of the liquid rocket booster study initiated by NASA to define an alternative to solid rocket boosters, are presented. The prime study contractors, Martin Marietta Corporation and General Dynamics, have identified liquid rocket booster configurations that can increase shuttle performance to 70 klb. These boosters will provide improved reliability, hold down, verification prior to vehicle release, engine-out and abort capabilities. Phasing of these boosters into Space Transportation System (STS) operations without adversely affecting flight rate is described.

Description: The redesigned solid rocket motor of the Space Shuttle is described. Improvements over the model that led to the loss of the Space Shuttle Challenger are outlined. Scale and full-size tests carried out to verify the quality of the redesign are described. A unique feature of the test program is the introduction of deliberate flaws into some test articles. Post-flight evaluation of the redesigned boosters show excellent results.

Description: A metal foil liner can be used to seal large area surfaces. Characteristics of the two-layer foil liner are discussed. Micrographs for foil-to-foil, foil-to-composite, visible seams, and hidden seams are examined.

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 in-flight tests and the operational sequences of the Superfluid Helium On-Orbit Transfer (SHOOT) experiment are outlined. These tests include the transfer of superfluid helium at a variety of rates, the transfer into cold and warm receivers, the operation of an extravehicular activity coupling, and tests of a liquid acquisition device. A variety of different types of instrumentation will be required for these tests. These include pressure sensors and liquid flow meters that must operate in liquid helium, accurate thermometry, two types of quantity gauges, and liquid-vapor sensors.

Description: The effect of thickness on the notched strength of three graphite/epoxy laminates is studied. The strength of the laminates is shown to be a function of laminate thickness. The notched strength of (0/+ or - 45/90)ns and (0/90)ns laminates decreased toward asymptotic values with increasing laminate thickness, while that of the (0/+ or - 45)ns laminate increased toward an asymptotic value with increasing laminate thickness. For all three laminate types, the notched strength decreased with increasing notch size, regardless of thickness. The fracture of the thick laminates was essentially uniform and self-similar with the notch. The 'universal' value of the general toughness parameter developed by Poe (1981) successfully predicts the notched strength of the thick laminates.

Description: A methodology is presented for the tension fatigue analysis and life prediction of composite laminates subjected to tension fatigue loading. The methodology incorporates both the generic fracture mechanics characterization of delamination and the assessment of the infuence of damage on laminate fatigue life. Tension fatigue tests were conducted on quasi-isotropic and orthotropic glass epoxy, graphite epoxy, and glass/graphite epoxy hybrid laminates, demonstrating good agreement between measured and predicted lives.

Description: The impact sensitivity of aramide fiber-reinforced aluminum laminates (ARALL) was investigated by testing two types of ARALL (7075 aluminum prestrained and 2024 aluminum not prestrained), via static indentation, and the results were compared to those of sheet aluminum alloys 7075-T6 and 2024-T3 and to a state of the art composite AS6/5245. It was found that the impact resistance of the two ARALL samples was inferior to that of monolithic sheet aluminum samples, although the ARALL material made with 2024-T3 aluminum was superior to that made with 7075-T6 aluminum. The impact damage resistance of ARALL materials was at least equal to that of AS6/5245, and the AS6/5245 had higher residual tension-tension fatigue strength after impact than the ARALL samples. It was also found that the prestraining of the ARALL reduced the fatigue growth of impact damage.

Description: Improved performance of heat engines is largely dependent upon maximum cycle temperatures. Tungsten fiber reinforced superalloys (TFRS) are the first of a family of high temperature composites that offer the potential for significantly raising hot component operating temperatures and thus leading to improved heat engine performance. This status review of TFRS research emphasizes the promising property data developed to date, the status of TFRS composite airfoil fabrication technology, and the areas requiring more attention to assure their applicability to hot section components of aircraft gas turbine engines.

Description: NASA's Lewis Research Center is developing a highly automated system for the generation, storage and distribution of electrical power aboard the projected Space Station. This autonomous power system will employ conventional algorithms, enhanced by expert systems, to schedule power, allocate energy, diagnose causes of failure, propose goals, prepare plans for their implementation, evaluate their consequences, and select optimum plans for their execution. While crew-interactive expert systems will be ready for the initial Space Station, total system autonomy is expected to require additional development time.

Description: The relationship between the exploration of space and the availability of abundant power supplies is discussed. It is proposed that nuclear power will be needed to satisfy the power demands of manufacturing facilities in LEO, and power demands for the year 2000 are projected to be 300 KW(e). The capabilities and development of the Space Station are described; the use of nuclear power for the Station and various reactor location configurations are studied. The power requirements that will be necessary for the development of lunar resource bases and the exploration of Mars and other planets are considered; the advantages of nuclear power are examined.

Description: Transient deformation and damage were studied in impacted graphite/epoxy plates. The plates were 8-ply and 16-ply quasi-isotropic laminates clamped around a 12.7 cm diameter circumference. They were instrumented with surface and embedded strain gages and loaded by a 202 gr mass dropped from a height of 1.8 m. The load history and imparted energy were obtained by means of an accelerometer attached to the impactor. Transient strains at various locations through the thickness and at various distances from the loading point were obtained. The characteristic features of the strain records are associated with specific failure modes in the laminate. The deformation history was also correlated with the induced damage as detected by X-radiography and ultrasonics. Impact damage is more extensive in the thicker laminate. Damage takes the form of delaminated strips parallel to the fiber direction in each ply and increasing in length from top to bottom.

Description: The epoxy resins currently in use can slowly absorb moisture from the atmosphere over a long period. This reduces those mechanical properties of composites which depend strongly on the matrix, such as compressive strength and buckling instabilities. The effect becomes greater at elevated temperatures. The paper will discuss new phenomena which occur under simultaneous temperature and moisture variations. An analytical model will also be discussed and documented.

Description: A study was undertaken to investigate the loading rate effect on delamination fracture initiation toughness of a thermoplastic composite. For this purpose, double cantilever beam specimens of graphite/PEEK were tested in a displacement controlled mode using an Instron tensile test machine. Specimens were loaded at various crosshead speeds ranging from 0.05 cm/min to 100 cm/min. The interlaminar fracture toughness was found to decrease with increasing loading rate, and this decrease was more than one hundred percent over the five decades of loading rate employed.

Description: The research conducted by NASA's Aircraft Energy Efficiency Composites program in developing essential technologies for the efficient utilization of composites in the airframe structures of transport aircraft is described. Current activities, present state-of-the-art, production trends in the U.S., and the outlook for major use of composites in primary structures are examined. Special attention is given to application of composites in transport wing and fuselage structures. The projections for the Advanced Tactical Fighter of the late eighties suggest application of composites in the airframe structures to the extent of 50 percent, an all-composite transport could become a reality in the mid-nineties.

Description: Four lay-ups of continuous fiber silicon carbide (SCS2) fiber/aluminum matrix composites were tested to assess fatigue mechanisms including stiffness loss when cycled below their respective fatigue limits. The lay-ups were 0 (sub 8), 0(sub 2)/ + or - 45 (sub 2s), 0/90 (sub 2s), and 0/ + or - 45/90 (subs). The data were compared with predictions from the author's previously published shakedown model which predicts fatigue-induced stiffness loss in metal matrix composites. A fifth lay-up, + or - 45 (sub 2s), was tested to compare shakedown and fatigue limits. The particular batch of silicon-carbide fibers tested in this program had a somewhat lower modulus (340 GPa) than expected and displayed poor bonding to the aluminum matrix. Good agreement was obtained between the stiffness loss model and the test data. The fatigue damage below the fatigue limit was primarily in the form of matrix cracking. The fatigue limit corresponded to the laminate shakedown for the + or - 45 (sub 2s) laminate.

Description: Quasi-isotropic graphite-epoxy laminates (T300/5208) were tested under bolt bearing loads to study failure modes, strengths, and failure energy. Specimens had a range of configurations to produce failures by the three nominal failure modes: tension, shearout, and bearing. Radiographs were made after damage onset and after ultimate load to examine the failure modes. Also, the laminate stresses near the bolt hole calculated for each test specimen configuration, and then used with a failure criterion to analyze the test data. Failures involving extensive bearing damage were found to dissipate significantly more energy than tension dominated failures. The specimen configuration influenced the failure modes and therefore also influenced the failure energy. In the width-to-diameter ratio range of 4 to 5, which is typical of structural joints, a transition from the tension mode to the bearing mode was shown to cause a large increase in failure energy. The failure modes associated with ultimate strength were usually different from those associated with the damage onset. Typical damage sequences involved bearing damage onset at the hole boundary followed by tension damage progressing from the hole boundary.

Description: Fracture behavior of tensile specimens containing through-the-thickness flaws and part-through semi-elliptic surface flaws was investigated. The material was T300/5208 graphite/epoxy, with a stacking sequence 0/+ or - 45/90 sub ns. Laminate thicknesses ranged from 8 to 120 plies. Fracture toughness for specimens with through-the-thickness flaws was a function of laminate thickness. Fracture toughness was also independent of crack size. Fracture toughness for the thick laminates was also independent of specimen geometry (center-cracked tension specimen, compact tension specimen, and three-point bend specimen). Using the asymptotic value of fracture toughness and linear elastic isotropic fracture mechanics, the notched strength of tensile specimens with semi-elliptic surface flaws was predicted. The strength ratio is a function of the flaw depth (a/t) and flaw aspect (a/c) ratios. Comparisons between predicted and experimental strengths are good for large values of a/t. The notched strength of filament wound graphite/epoxy tensile specimens with part-through surface flaws was also predicted.

Description: A detailed analysis of the dynamic stress field in smooth and notched fiber composite (Charpy-type) specimens is reported in this paper. The analysis is performed with the aid of the direct transient response analysis solution sequence of MSC/NASTRAN. Three unidirectional composites were chosen for the study. They are S-Glass/Epoxy, Kevlar/Epoxy and T-300/Epoxy composite systems. The specimens are subjected to an impact load which is modeled as a triangular impulse with a maximum of 2000 lb and a duration of 1 ms. The results are compared with those of static analysis of the specimens subjected to a peak load of 2000 lb. For the geometry and type of materials studied, the static analysis results gave close conservative estimates for the dynamic stresses. Another interesting inference from the study is that the impact induced effects are felt by S-Glass/Epoxy specimens sooner than Kevlar/Epoxy or T-300/Epoxy specimens.

Description: A combined experimental and analytical investigation of an adhesively bonded composite joint was conducted to characterize both the static and fatigue beyond growth mechanism under mode 1 and mixed-mode 1 and 2 loadings. Two bonded systems were studied: graphite/epoxy adherends bonded with EC 3445 and FM-300 adhesives. For each bonded system, two specimen types were tested: a double-cantilever-beam specimen for mode 1 loading and a cracked-lapshear specimen for mixed-mode 1 and 2 loading. In all specimens tested, failure occurred in the form of debond growth. Debonding always occurred in a cohesive manner with EC 3445 adhesive. The FM-300 adhesive debonded in a cohesive manner under mixed-mode 1 and 2 loading, but in a cohesive, adhesive, or combined cohesive and adhesive manner under mode 1 loading. Total strain-energy release rate appeared to be the driving parameter for debond growth under static and fatigue loadings.

Description: Refined models and procedures are described for determining progressive composite fracture in graphite/epoxy angleplied laminates. Unique Lewis Research Center capabilities are utilized including the Real-Time Ultrasonic C-San (RUSCAN) experimental facility and the Composite Durability Structural Analysis (CODSTRAN) computer code. CODSTRAN is used to predict the fracture progression based on composite mechanics, finite element stress analysis, and fracture criteria modules. The RUSCAN facility, CODSTRAN computer code, and scanning electron microscope are used to determine durability and identify failure mechanisms in graphite/epoxy coomposites. Results indicate that RUSCAN/CODSTRAN is an effective method of Studying progressive fracture of composites.

Description: During ground testing of the Space Shuttle Main Engine (SSME), there have been twenty-six major incidents resulting in substantial hardware damage and loss. Historical characteristics, advances in detection technology, and advances in computing technology led to plans for study of an advanced real time SSME test stand failure detection system which would reduce damage and preserve evidence when a failure with major incident potential occurs. This detection system will speed recognition of dangerous engine operation, and quicken the shutdown decision. The scope of this study, SSME characteristics, SSME test history, the problem definition, and some technical issues will be addressed herein.

Description: Experimental analyses were performed for determination of in-plane deformations and shear strains in unidirectional and quasi-isotropic graphite-epoxy beams. Forty-eight-ply beams were subjected to five-point and three-point flexure. Whole-field measurements were recorded at load levels from about 20 percent to more than 90 percent of failure loads. Contour maps of U and W displacement fields were obtained by moire interferometry, using reference gratings of 2400 lines/mm. Clearly defined fringes with fringe orders exceeding 1000 were obtained. Whole-field contour maps of shear strains were obtained. Various anomalous effects were detected in the displacement fields. Their analysis indicated excess shear strains in resin-rich zones in regions of shear tractions; free-edge shear strains in quasi-isotropic specimens in regions of normal stresses, and shear stresses associated with cyclic shear compliances of quasi-isotropic laminates in regions of shear tractions. Their contributions could occur independently or in superposition. Qualitative analyses addressed questions of the effect of specimen overhang, nonlinearity, and characteristics of five-point and three-point flexure tests.

Description: During the past decade, significant progress has been made in the development and refinement of finite element micromechanics analyses of unidirectional composite materials. The current status is summarized here, and example results are presented. These are correlated with available experimental data, and with scanning electron microscope observations.

Description: This work presents the study of Low Velocity Transverse Impact damage of graphite-epoxy T300/5208 composite material. An energy dissipation model was developed to predict the residual strength from fracture mechanics concepts. The specimens, 100 mm diameter clamped plates, were impact damaged by a cantilever-type instrumented 1-inch diameter steel ball. This study was limited to impact velocity 6 m/sec. Rectangular strips, 50 mm x 125 mm, were cut from the impact-damaged specimens so that the impact damage zone was in the center of the strips. These strips were tested to obtain their residual strength. Predictions were compared with the test results.

Description: The combined effects of moisture (M), temperature (T), and strain rate (SR) on the properties of the unidirectional graphite/epoxy composite AS4/3501-6 are investigated experimentally. Longitudinal tensile, in-plane shear, and transverse tensile specimens with moisture content 0 or 1 percent were characterized using standard mechanical tests and the techniques described by Yaniv et al. (1987) at temperatures 23-128 C and strain rates from 5 x 10 to the -6th/sec to 5/sec. The results are presented in graphs and discussed in detail. The longitudinal properties of the composite were found to be generally unaffected by changes in the parameters, whereas transverse and interlaminar properties decreased with increasing T and M at constant SR and the transverse and in-plane shear moduli increased with SR. A time-T-M equivalence principle is used to derive master curves for all the matrix-dominated properties, expressed in terms of a two-variable shift function.

Description: This paper discusses an analytical and experimental study to investigate the thermally induced twist in laminated angle-ply graphite-epoxy tubes. Attention is focused on balanced laminates which, contrary to intuition, exhibit twist when the temperature is changed. The twisting is due to the fact that a lamina with ( a + phi) orientation and a lamina with (a - phi) orientation must be at slightly different radial positions in the twist. The lamina with the greater radial position determines the sense of the twist. Classical lamination theory does not predict this phenomenon, and so as more sophisticated theory must be employed. This paper outlines such as theory, which is based on an generalized plane-deformation elasticity analysis, and presents experimental data to confirm the predictions of the theory. A brief description of the experimental apparatus and procedure used to measure twist is presented.

Description: An indentation test technique for compressively loading the ends of individual fibers to produce debonding has been applied to metal, glass, and glass-ceramic matrix composites; bond strength values at debond initiation are calculated using a finite-element model. Results are correlated with composite longitudinal and interlaminar shear behavior for carbon and Nicalon fiber-reinforced glasses and glass-ceramics including the effects of matrix modifications, processing conditions, and high-temperature oxidation embrittlement. The data indicate that significant bonding to improve off-axis and shear properties can be tolerated before the longitudinal behavior becomes brittle. Residual stress and other mechanical bonding effects are important, but improved analyses and multiaxial interfacial failure criteria are needed to adequately interpret bond strength data in terms of composite performance.

Description: Basic types of metal matrix composite (MMC) systems (namely, the particulates-, the whisker/flakes-, and the continuous-fiber-reinforced) are discussed together with the advantages and the disadvantages of each system. Special consideration is given to the new MMC systems under development that meet the needs of aerospace applications and to the properties of stiffness and thermal expansion of these systems. As a family of structural materials, MMCs have great potential for missile airframe applications.

Description: Silsesquioxanes having the general structure RSiO(1.5), where R = methyl, propyl, or phenyl, melt flow at 70 to 100 C. Above 100 C, free OH groups condense. At 225 C further crosslinking occurs, and the materials form thermosets. Pyrolysis, with accompanying loss of volatiles, takes place at nominally 525 C. At higher temperatures, the R group serves as an internal carbon source for carbo-thermal reduction to SiC accompanied by the evolution of CO. By blending silsesquioxanes with varying R groups, both the melt rheology and composition of the fired ceramic can be controlled. Fibers can be spun from the melt which are stable in argon in 1400 C. The silsesquioxanes also were used as matrix precursors for Nicalon and alpha-SiC platelet reinforced composites.

Description: The thermal expansion of continuous carbon-fiber reinforced composites with epoxy-, polyimide-, and borosilicate glass-matrices has been measured and compared. The expansion of a rubber-toughened epoxy-matrix/P75S carbon-fiber composite was very different from the expansion of two different single-phase epoxy-matrix/P75S composites, although all three had the same stacking sequence. Reasonable agreement was obtained between measured thermal expansion data and results from classical laminate theory. Microdamage in the graphite/polyimide laminate, induced by 250 cycles between -156 and 121 C, caused a 53 percent decrease in the coefficient of thermal expansion. The thermal expansion of the graphite/glass laminate was not changed after 100 thermal cycles from -129 to 38 C; however, a residual strain of about 10 x 10 to the -6 was observed for the laminate tested.

Description: An epoxy and carbon fiber composite has been used to produce a light-weight rocket case for the Space Shuttle. A kinetic model is developed which can predict the extent of epoxy conversion during the winding and curing of the case. The model accounts for both chemical and physical kinetics. In the model, chemical kinetics occur exclusively up to the time the transition temperature equals the reaction temperature. At this point the resin begins to solidify and the rate of this process limits the rate of epoxy conversion. A comparison of predicted and actual epoxy conversion is presented for isothermal and temperature programmed cure schedules.

Description: An evaluation is made of technology development prospects for launch vehicle, orbit transfer vehicle, satellite, and planetary exploration spacecraft propulsion systems being contemplated by NASA and its research contractors. Attention is given to such electric propulsion systems as arcjet, pulsed plasma, ion, and resistojet thrusters, as well as to solar thermal heat exchanger powerplants, beamed energy propulsion systems, and ultra-advanced nuclear fission and fusion propulsion concepts.

Description: Composites were fabricated from unidirectional unsized AS-4 carbon fiber and two baseline polyimides: benzophenone dianhydride-3,3'-diaminodiphenylsulfone (PISO2) and benzophenone dianhydride-3,3'-diaminobenzophenone (LARC-TPI). In addition, each polymer solution prior to prepregging was doped with various amounts of crystalline LARC-TPI powder to enhance melt flow during press molding. The 2:1, 1:1, and 1:2 ratios of crystalline to amorphous resin, respectively, were studied in the LARC-TPI system and the 1:2 ratio in the PISO2 system. Matrix characterization, prepreg fabrication/characterization and composite fabrication and physical/mechanical properties are described. The latter include three point short beam shear and flexure, dry and wet, as well as fracture toughness properties in selected compositions.

Description: A brief summary is presented of a NASA study contract and in-house investigation on Growth Space Station missions and appropriate nuclear and solar space electric power systems. By the year 2000 some 300 kWe will be needed for missions and housekeeping power for a 12 to 18 person Station crew. Several Space Station configurations employing nuclear reactor power systems are discussed, including shielding requirements and power transmission schemes. Advantages of reactor power include a greatly simplified Station orientation procedure, greatly reduced occultation of views of the earth and deep space, near elimination of energy storage requirements, and significantly reduced station-keeping propellant mass due to very low drag of the reactor power system. The in-house studies of viable alternative Growth Space Station power systems showed that at 300 kWe a rigid silicon solar cell array with NiCd batteries had the highest specific mass at 275 kg/kWe, with solar Stirling the lowest at 40 kg/kWe. However, when 10 year propellant mass requirements are factored in, the 300 kWe nuclear Stirling exhibits the lowest total mass.

Description: A unified set of composite micromechanics equations is summarized and described. This unified set is for predicting the ply microstresses when the ply stresses are known. The set consists of equations of simple form for predicting three-dimensional stresses (six each) in the matrix, fiber, and interface. Several numerical examples are included to illustrate use and computational effectiveness of the equations in this unified set. Numerical results from these examples are discussed with respect to their significance on microcrack formation and, therefore, damage initiation in fiber composites.

Description: Aramid reinforcement composite materials of equal fiber volume having varied polymer thermoset matrices have been pultruded and flexurally tested to failure. The objective was to improve flexural properties of aramid reinforced pultrusions. Pultrusions of both sized and unsized aramid fiber with four different resin systems were compared to determine the effects of sizing compounds and post-thermal treatments on the flexural strength as an indication of fiber wettability and fiber-to-resin interface bonding. Improvements in flexural strength as the result of pretreatments with sizing solutions used in this study were marginal. The most significant improvements in flexural properties were the results of postcuring. Overall improvements ranged from a low 39,647 Psi(273 Mpa) to a high of 80,390 Psi(554 Mpa), or 103 percent. The fact that post-thermal treatments improved the flexural properties of the four pultrusions indicates that a full cure did not occur in either resin system during the pultrusion process. The increased flexural strengths of the polyester and vinyl ester pultrusions were the most surprising. Based on data presented, the most promising resin system of the four examined (VE 8300, Aropol 7430, Epon 9302, and Epon 9310) for Kevlar reinforced pultrusion is Epon 9310 epoxy.

Description: A number of attractive options are available for the Space Station Power System. These include a photovoltaic system or solar dynamic system for power generation, batteries or fuel cells for energy storage and ac or dc for power management and distribution. These options are being explored during the present preliminary design and definition phase of the Space Station Program. Final selections are presently targeted for January 1986.

Description: The ram impact of low earth orbital atomic oxygen causes oxidation of spacecraft materials including polymers such as polyimides. The rate of oxidation is sufficiently high to potentially compromise the long term durability of Kapton solar array blankets. Ion beam sputter deposited atomic oxygen protective coatings of aluminum oxide, silicon dioxide, and codeposited silicon dioxide with small amounts of polytetrafluoroethylene were evaluated both in RF plasma asher tests and in low earth orbit. Deposition techniques, mechanical properties, and atomic oxygen protection performance are presented.

Description: The solar array for the Venus Radar Mapper mission will operate in the high temperature, high intensity conditions of a low Venus orbit environment. To fulfill the performance requirements in this environment at minimum cost and mass while maximizing power density and packing factor on the panel surface, several features were introduced into the design. These features included the use of optical surface reflectors (OSR's) to reduce the operating temperature; new adhesives for conductive bonding of OSR's to avoid electrostatic discharges; custom-designed large area cells and novel shunt diode circuit and panel power harness configurations.

Description: Three-dimensional finite-element analyses are used to assess the accuracy of simplified composite micromechanics equations (SME) for hygral, thermal, and mechanical properties of unidirectional composites with orthotropic fibers. The properties predicted by the SME are in reasonably good agreement with those predicted by the three-dimensional finite-element analyses. This correlation demonstrates that the SME can be used with confidence in predicting the hygral, thermal, and mechanical behavior of unidirectional fiber composites.

Description: An experimental study is made of the effect of electron irradiation (10 to the 10th rad), simulating a 30-year geosynchronous orbit exposure, on the fracture toughness of a graphite/epoxy composite, T300/934. The double cantilever beam (DBC) test is used to determine Mode I (peel) critical strain energy release rate and the edge delamination tension (EDT) test is used to determine mixed Mode I and II (peel and shear) critical strain energy release rate. It is found that the electron interaction of the epoxy matrix material enhances the fracture toughness properties of the composite and that the test temperature has a significant effect on the fracture toughness of both baseline and irradiated material.

Description: The feasibility of fabricating full-scale fan blades from superhybrid composites (SHC) for use large, commercial gas turbine engines was evaluated. The type of blade construction selected was a metal-spar/SHC-shell configuration, in which the outer shell was adhesively bonded to a short, internal, titanium spar. Various aspects of blade fabrication, inspection, and quality assurance procedures developed in the investigation are described. It is concluded that the SHC concept is feasible for the fabrication of prototype, full-scale, metal-spar/SHC-shell fan blades that have good structural properties and meet dimensional requirements.

Description: Larger, more complex spacecraft of the future such as a manned Space Station will require electric power systems of 100 kW and more, orders of magnitude greater than the present state of the art. Power systems at this level will have a significant impact on the spacecraft design. Historically, long-lived spacecraft have relied on silicon solar cell arrays, a nickel-cadmium storage battery and operation at 28 V dc. These technologies lead to large array areas and heavy batteries for a Space Station application. This, in turn, presents orbit altitude maintenance, attitude control, energy management and launch weight and volume constraints. Size (area) and weight of such a power system can be reduced if new higher efficiency conversion and lighter weight storage technologies are used. Several promising technology options including concentrator solar photovoltaic arrays, solar thermal dynamic and ultimately nuclear dynamic systems to reduce area are discussed. Also, higher energy storage systems such as nickel-hydrogen and the regenerative fuel cell (RFC) and higher voltage power distribution which add system flexibility, simplicity and reduce weight are examined. Emphasis placed on the attributes and development status of emerging technologies that are sufficiently developed so that they could be available for flight use in the early to mid 1990's.

Description: The paper considers the present status of solar thermal dynamic space power technologies and projects the various attributes of these systems into the future, to the years 2000 and 2010. By the year 2000, collector weights should decrease from 1.25 kg/sq m (1985 value) to about 1.0 kg/sq m. The specific weight is also expected to decrease from 6.0 kg/kw. By the year 2010, slight improvements in the free piston Stirling energy conversion system are postulated with efficiencies reaching 32 percent. In addition, advanced concentrator concepts should be operational.

Description: The regenerative fuel cell, a candidate technology for the Space Station's energy storage system, is described. An advanced development program was initiated to design, manufacture, and integrate a regenerative fuel cell Space Station prototype (RFC SSP). The RFC SSP incorporates long-life fuel cell technology, increased cell area for the fuel cells, and high voltage cell stacks for both units. The RFC SSP's potential for integration with the Space Station's life support and propulsion systems is discussed.

Description: The Space Station power system selection process is described with attention given to management organization and technical considerations. A hybrid power system was chosen because of the large life cycle cost savings. The power management and distribution system that was chosen was the 400 Hz system.

Description: A preliminary feasibility assessment of the integration of reactor power system concepts with a projected growth Space Station architecture was conducted to address a variety of installation, operational, disposition and safety issues. A previous NASA sponsored study, which showed the advantages of Space Station - attached concepts, served as the basis for this study. A study methodology was defined and implemented to assess compatible combinations of reactor power installation concepts, disposal destinations, and propulsion methods. Three installation concepts that met a set of integration criteria were characterized from a configuration and operational viewpoint, with end-of-life disposal mass identified. Disposal destinations that met current aerospace nuclear safety criteria were identified and characterized from an operational and energy requirements viewpoint, with delta-V energy requirement as a key parameter. Chemical propulsion methods that met current and near-term application criteria were identified and payload mass and delta-V capabilities were characterized. These capabilities were matched against concept disposal mass and destination delta-V requirements to provide a feasibility of each combination.

Description: The regenerative fuel cell system (RFCS), designed for application to the Space Station energy storage system, is based on state-of-the-art alkaline electrolyte technology and incorporates a dedicated fuel cell system (FCS) and water electrolysis subsystem (WES). In the present study, emphasis is placed on the WES portion of the RFCS. To ensure RFCS availability for the Space Station, the RFCS Space Station Prototype design was undertaken which included a 46-cell 0.93 cu m static feed water electrolysis module and three integrated mechanical components.

Description: Under NASA sponsorship, JPL is developing advanced, high rate Li-SOCl2 cells for future space missions. As part of this effort, Li-SOCl2 cells of various designs were examined for performance and safety. The cells differed from one another in several aspects, such as: nature of carbon cathode, catalysts, cell configuration, case polarity, and safety devices. Performance evaluation included constant-current discharge over a range of currents and temperatures. Abuse-testing consisted of shortcircuiting, charging, and over-discharge. Energy densities greater than 300 Wh/Kg at the C/2 rate were found for some designs. A cell design featuring a high-surface-area carbon cathode was found to deliver nearly 500 Wh/Kg at moderate discharge rates. Temperature influenced the performance significantly.

Description: The performance of a 12 V, 40 ampere-hour bipolar battery during various charge current, discharge current, temperature, and pressure operating conditions is investigated. The cell voltages, temperatures, ampere-hours, and watt-hours derived from the charge/discharge cycle tests are studied. Consideration is given to battery voltage and discharge capacity as a function of discharge current, the correlation between energy delivered on a discharge and battery temperature, battery voltage response to pulse discharges, and the voltage-temperature relationship. The data reveal that the bipolar Ni-H battery is applicable to high power systems.

Description: Two solar array designs developed for the Advanced Photovoltaic Solar Array program are described. The goal of the program is to develop solar arrays with higher mass specific power and power density and good robustness. The specific design requirements are: a beginning-of-life value of 130 W/kg, and end-of-life goals of 105 W/kg and 110 W/sq m. The two array-wing designs consisted of a single blanket. The differences in the blanket material (25 micron-thick Kapton versus 50 micron-thick carbon-loaded Kapton), solar cells (100 micron-thick wrap around versus 50 micron-thick 2 x 4 cm planar contact cells), and performance objectives (proposed industry requirements versus mission objectives) of the two designs are examined.

Description: The development of ultrathin silicon solar cell array modules from initial design to flight testing is discussed. Three 80-cell modules were subjected to the thermal soak test, the LEO thermal cycle test, and the solar array flight experiment, and six 48-cell welded modules were evaluated in the geosynchronous orbit thermal cycle test. It is observed that the electrical performance of the modules was not affected by the different environmental conditions. The automatic assembly of the cell modules, in particular the welding and solar cell glassing operation, is described. The specific power capabilities of Kapton, Kapton-Kevlar-Kapton, Kapton-graphite-Kapton, and Kapton-graphite-aluminum honeycomb-graphite solar array designs are assessed.

Description: The power systems for the Space Station manned core and platforms that have been selected in definition studies are described in this paper. The selected system for the platforms uses silicon arrays and Ni-H2 batteries. The power system for the manned core is a hybrid employing arrays and batteries identical to those on the platform along with solar dynamic modules using either Brayton or organic Rankine engines. The power system requirements, candidate technologies, and configurations that were considered, and the basis for selection, are discussed.

Description: Advanced aircraft engine research within NASA Lewis is being focused on propulsion systems for subsonic, supersonic, and hypersonic aircraft. Each of these flight regimes requires different types of engines, but all require advanced materials to meet their goals of performance, thrust-to-weight ratio, and fuel efficiency. The high strength/weight and stiffness/weight properties of resin, metal, and ceramic matrix composites will play an increasingly key role in meeting these performance requirements. At NASA Lewis, research is ongoing to apply graphite/polyimide composites to engine components and to develop polymer matrices with higher operating temperature capabilities. Metal matrix composites, using magnesium, aluminum, titanium, and superalloy matrices, are being developed for application to static and rotating engine components, as well as for space applications, over a broad temperature range. Ceramic matrix composites are also being examined to increase the toughness and reliability of ceramics for application to high-temperature engine structures and components.

Description: Crystallinities as low as 16 percent have been estimated by determination of the interplanar spacing on PET/carbonaceous filament composites with resin content of aobut 25 percent w/w using wide-angle X-ray scattering (WAXS) in the angular range 2 theta = 16-18 deg. The diffraction pattern of the carbonaceous reinforcements masks the major reflections of the resin, and the resin content and the crystallinity are kept low to make the simulation reasonable.

Description: Each Common Module (CM) of the Space Station must be capable of handling a 50 kW electricity supply, 25 kW for transmission and 25 kW for consumption. The power must be handled and managed by on-board systems, a necessity that dovetails with the objectives of Public Law 98-371, which mandates that the Space Station push the state of the art of automation and AI. Expert systems will be needed to handle the large data flow for the power system and to ensure that the system degrades gracefully. Features of the first expert systems expected for the power system, i.e., a dynamic load planner/scheduler and energy storage subsystem management, fault diagnosis/analysis, health status/trend analysis, and orbital replacement advisor expert systems, are described. Finally, growth Space Station expert systems applications are discussed.

Description: Static crushing tests were conducted on tube specimens fabricated from graphite/epoxy, Kevlar/epoxy and hybrid combinations of graphite-Kevlar/epoxy to examine the influence the fiber and matrix constitutive properties and laminate architecture have on energy absorption. Fiber and matrix ultimate failure strain were determined to significantly effect energy absorption. The energy absorption capability of high ultimate failure strain materials (AS-6/F185 and AS-6/HST-7) was less than materials having lower ultimate failure strain. Lamina stacking sequence had up to a 300 percent change in energy absorption for the materials tested. Hybridizing with graphite and Kevlar reinforcements resulted in materials with high energy absorption capabilities that have postcrushing integrity.

Description: Past and future progress in the performance of control systems for large, liquid rocket engines typified such as current state-of-the-art, the Shuttle Main Engine (SSME), is discussed. Details of the first decade of efforts, which culminates in the F-1 and J-2 Saturn engines control systems, are traced, noting problem modes and improvements which were implemented to realize the SSME. Future control system designs, to accommodate the requirements of operation of engines for a heavy lift launch vehicle, an orbital transfer vehicle and the aerospace plane, are summarized. Generic design upgrades needed include an expanded range of fault detection, maintenance as-needed instead of as-scheduled, reduced human involvement in engine operations, and increased control of internal engine states. Current NASA technology development programs aimed at meeting the future control system requirements are described.

Description: Studies were conducted to establish the effects of specimen geometry on the thermo-oxidative stability and the mechanical properties retention of unidirectional Celion 12000 graphite fiber reinforced PMR-15 polyimide composites. Weight loss, flexural strength and interlaminar shear strength are measured at isothermal aging times as long as 1639 hr at a temperature of 316 C for three different specimen geometries. It is found that the three different types of specimen surfaces exhibit different values of weight loss/unit area. The mechanical properties retention is also found to be dependent on geometry for these composites. The interlaminar shear strength decreases significantly over the complete range of aging times. The flexural strength retention starts showing geometric dependency after about 1000 hr of aging at 316 C. Weight loss fluxes, associated with the three different types of exposed surfaces, are calculated and used to develop an empirical mathematical model for predicting the weight loss behavior of unidirectional composites of arbitrary geometries. Data are presented comparing experimentally determined weight loss with weight loss values predicted using the empirical model.