Special Coverage

Distributed Propulsion Concepts and Superparamagnetic Energy Harvesting Hummingbird Engine
Aerofoam
Wet Active Chevron Nozzle for Controllable Jet Noise Reduction
Magnetic Relief Valve
Locking Mechanism for a Flexible Composite Hinge
Active Aircraft Pylon Noise Control System
Unmanned Aerial Systems Traffic Management
Method of Bonding Dissimilar Materials
Sonar Inspection Robot System
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Optimizing EBM Alloy 718 Material for Aerospace Components

Electronic Beam Melting (EBM) is a leading AM technology that aerospace companies are implementing for production. To leverage the capabilities of EBM, new materials such as Alloy 718 have been developed. Alloy 718 is a nickel-chromium based super alloy ideal for high temperature and corrosive environments, with excellent mechanical properties at elevated temperatures.

Posted in: White Papers, Aerospace, Manufacturing & Prototyping, Materials

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In-Situ Formation of Reinforcement Phases in Ultra-High- Temperature Ceramic Composites

This technology could be used in re-entry vehicles, reusable launch vehicles, hypersonic vehicle leading edges, and commercial spacecraft.Future-generation materials for use on space transportation vehicles require substantial improvements in material properties leading to increased reliability and safety, as well as intelligent design to allow for current materials to meet future needs. Ultra-high-temperature ceramics (UHTC), composed primarily of metal diborides, are candidate materials for sharp leading edges on hypersonic re-entry vehicles. NASA has demonstrated that it is possible to form high-aspect-ratio reinforcement phases in-situ during the processing step for both ceramic composites and UHTCs. Initial characterization of these systems has demonstrated that crack deflection along the matrix-reinforcement interface is observed yielding a system of improved toughness over the baseline system, leading to improved mechanical performance. The reinforced composites should therefore reduce the risk of catastrophic failure over current UHTC systems.

Posted in: Briefs, Coatings & Adhesives, Materials

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Multi-Phase Ceramic System

Bearing surfaces are typically either metal-on-metal (MOM), ceramic-on-ceramic (COC), or metal-on-polyethylene (MOP). MOM and MOP couplings have the drawback that metallic or polyethylene particles can sometimes separate from the couplings, which can cause significant problems, particularly in a hip or joint replacement. COC couplings are less likely to lose particles due to wear, which makes them more biocompatible, but they are more susceptible to fracture. COC couplings also have a tendency to squeak as they move. Innovators at NASA’s Glenn Research Center have developed a technique using rare earth elements to fabricate a dual-phase ceramic composite that combines a wear-resistant phase and a solid-state lubricant phase. The result is a coupling material that, compared to currently used materials, exhibits a tenfold reduction in the friction coefficient, a sixfold reduction in wear, and a significant reduction in debris caused by wear. Glenn’s groundbreaking rare-earth aluminate composite has considerable potential, not only in biomedical applications, but also in commercial and industrial sectors.

Posted in: Briefs, Ceramics, Materials

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Minimally Machined HoneySiC Panels and T300 HoneySiC

The materials are intended for low areal density and near-zero CTE optomechanical structures.The primary purpose of this work is to develop and demonstrate technologies to manufacture ultra-low-cost precision optical systems for very large x-ray, UV/optical, or infrared telescopes.

Posted in: Briefs, Coatings & Adhesives, Materials

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Flexible Volumetric Structure

These composite elastic skins can be tailored for specific applications.NASA’s Langley Research Center has developed composite elastic skins for covering shape-changing (morphable) structures. These skins are intended especially for use on advanced aircraft that change shapes in order to assume different aerodynamic properties. Examples of aircraft shape changes include growth or shrinkage of bumps, conformal changes in wing planforms, cambers, twists, and bending of integrated leading and trailing-edge flaps. Prior to this invention, there was no way of providing smooth aerodynamic surfaces capable of large deflections while maintaining smoothness and sufficient rigidity.

Posted in: Briefs, Coatings & Adhesives, Materials

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Aeroplastic Composites

Aeroplastic refers to a family of polymeric composites with properties that provide a significant reduction in heat transfer. These composites reduce the thermal conductivity of the base polymer resin between 20%-50% without changing its mechanical properties or modifying the original techniques for processing those polymers. The composites can be made into fibers, molded, or otherwise processed into usable articles. Aeroplastic composites are superior alternatives to prior composite materials with respect to both their thermal conductivity and physical properties.

Posted in: Briefs, Coatings & Adhesives, Materials

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Simulating Composite Structures

Layered composites are often the materials of choice when a manufacturer must reduce the weight (lightweight) of a component or system to increase fuel efficiency while maintaining strength. Composites are often used in automobiles, aircraft, ships and wind turbines for this purpose. But because their strength and performance depend upon the thickness, layer structure, orientation and other factors, determining how composite structures will perform in real-world conditions is not as easy as it is for metallic components of the same shape. Read this white paper to learn how you can use ANSYS Composite PrepPost to perform layup simulations to optimize composites for strength, durability and light weight.

Posted in: White Papers, Manufacturing & Prototyping, Composites, Materials

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