Engineering Division USACA– OCTOBER 2009
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Transcript of Engineering Division USACA– OCTOBER 2009
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Engineering Division
USACA– OCTOBER 2009
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• Established in 1941 as an independent, not-for-profit (501-c-3) center for scientific research and development
• Headquartered in Birmingham, Alabama• Revenues of $83 million in 2006• Approximately 560 employees• Organized into three divisions:
– Drug Discovery– Drug Development (pre-clinical)– Engineering
Southern Research
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• Main office located in the 82,000 square foot Engineering Research Center
• Locations in Alabama and North Carolina:– Birmingham, Alabama
• (Two locations)– Wilsonville, Alabama– Treyburn, North Carolina
• Four departments:– Systems Development – Mechanics Research– Materials Research– Environment and Energy Research
Engineering Division
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• Materials Characterization is the core technology of Southern Research Engineering Division
• Key technical developments date to mid 1950’s– Gas Bearing Tensile (IR100)– 5500ºF (3030°C) furnace for general use – 6500°F (3590°C) furnace for special applications
• Developments driven by high temperature, brittle material applications– Reentry– Planetary reentry– Nuclear– Launch Vehicles– Aeropropulsion
Materials Characterization
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Mechanical, Thermal, and Physical Properties Characterization
• Mechanical and Subscale Structural Testing– All Mechanical Test Types, Creep, Fatigue– Cryo (-260°C) to Elevated (3030°C) Temps– Subscale & Static Load Tests– Acoustic Emission and Strain Visualization
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Mechanical, Thermal, and Physical Properties Characterization
• Thermal Properties and Analysis Testing– Thermal Conductivity, Expansion, Diffusivity, Specific
Heat, Emissivity– TGA, DSC, DMA
• Physical Properties & NDE– Permeability, Porosity, Chemistry, Microscopy, Moisture
Properties, Density, etc.– Radiography, CT, Ultrasonics, Resistivity, Eddy Current– Mat’l ID, Fingerprinting, Defect Characterization
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Durability and Oxidation Characterization
Variable Atmosphere Temperature Pressure (VATP) Facility - (4000 F @ .05 Atm. Air)
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Elevated Temperature TN-A/P
Objective: Develop a TN-A/P specimen that will successfully evaluate the elevated temperature across ply tension strength of thin composite plate structures.
Approach: Combine FEA and experimental StudiesThe basic specimen design consists of a disc specimen with two circular slots cut in. The OD is held and the ID is put into compression, causing an annulus shaped section of composite isolated between the slots to experience an across ply tensile stress.
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Initial Results – Good Match to Ambient and Reasonable Elevated Temperature Results
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Ulti
mat
e Str
ess (
psi)
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ILT Standard
ILT Annulus
Project: 12135.04.01Material: GE C/SiCTemperature: 75 F, 2500 F, 3000 F
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Typical Recent SRI Engineering Efforts
• CMC Test Development– CMC Design Methodology– Various Hypersonic Vehicle
Materials Developments– MSFC fiber enhancement
• X-43 (First sustained M10 Flight)– Characterization– Analog (LHMEL, Lab)
• X-37 & STS tile Repair– C-SiC characterization– Durability
• Falcon (w/ DARPA, AF)– Thermal insulation tests– Multiparameter tests– Characterization
• MSFC Enhanced Hypersonic Materials Testing Program
• James Webb Space Telescope– Precision thermal Expansion
• Orbiter TPS– RCC characterization and aging– RCC impact damage and repair
• Venus Lander Thermal Testing
• CEV (Orion)– AVCOAT/PICA– Launch Abort System
• Aries I SRM– Ablative Characterization
• Replacement Materials– Rayon (Lyocell w/ MDA)
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Southern Research Engineering Summary
• Leading provider of high-end engineering, testing and evaluation of services to NASA and DOD clients
• Not-for-profit status provides the credibility as independent evaluator and developer of technology platforms
• Flexible and responsive organization that rapidly adapts to changing technology and develops technology for customer needs
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• Permeability– Ambient to 3500° F– High Pressure (incl.. H2)– Effect of loads
• Porosity– Hg porosimetry– He Pycnometry– Liquid Absorption
• Microscopy– SEM– Optical
Other Measurement Capabilities
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• Thermal Expansion Facilities– NIST Quartz Dilatometers (Cryo to 1800° F)– Horizontal Quartz Dilatometers (Cryo to 1800° F)– Graphite Dilatometers (RT to 5000° F)– Optical Thermal Expansion (RT to 5000° F)– Precision Thermal Expansion (20 K to 400 K)– Ring Thermal Expansion (RT to 5000° F)
• Analog – Simulation Facility– LHMEL (USAF)– Quartz Lamps– Oxyacetylene Torch
• Total Normal Emmissivity -100
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Temperature ( °F )
Uni
t The
rmal
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ansi
on (
x 0.
001
in/in
) TE-AP-03 Run: K534-153 Density: 1.7134 gm/cm³
TE-AP-04 Run: K534-154 Density: 1.7093 gm/cm³
Quartz Dilatometer
Red symbols represent data measured after cooling to room temperature
Across Ply Thermal Expansion for Silica Phenolic
Thermal Property Measurements
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1/16" THICK ALUMINIM SHEET
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FREQUENCY (MHz)
MA
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Non-destructive Characterization
• Radiography– Collimated
• Computed tomography• Ultrasonics
– Velocity– Pulse echo– Attenuation
• Electrical resistivity• Eddy current• Metrology
• Defect detection• Material identification• Material fingerprinting• Physical properties
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Radiant Facility II
• Infrared heat source by Research, Inc.• Up to 12 x 9” heated area• Up to fifteen 2000 W / 240 V bulbs• Water-cooled, polished aluminum reflector• Capable of temperature or flux control• Data logging with Agilent 34970A and Labview• Horizontal
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Thermal Property Measurement Capabilities
Specialized Testing Capabilities
• Cryocoolers for cryogenic properties
• Thermal conductivity under load.
• Vacuum thermal response measurements
SPECIMENEDM GRAPHITEHEARTH GRAPHITEELEMENT GRAPHITEZIRCAR (???)MIN KSTAINLESS STEELCOPPER
10 INCHES
ATMOSPHERIC PRESSURE TOVACUUMTEMPERATURE OVER 3000 DEGREES (4500)
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New Ultrasonic Spectroscopy Technique
Rapidly Swept Wave Entire Waveform Digitized FFT of Sweep Gives Flat Spectrum Bandwidth and Amplitude User Defined
Attenuation as a Function of Frequency Dispersion/Defect Interaction Resonance
N o rm alized In p ut Sp ectrum fo r 0.5 to 2.25 MH z C om p ared to T rad itio nal Bro adb an d In pu t Sp ectrum
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SRI Ult rasonicSpectrosco py
Traditio nal Bro adba nd
Ultrasonic Spectroscopy Modes of Interaction
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Precision Metrology
• Ordered Scanner– Measures Z height along an X-Y grid– Specular & Diffuse– Multiple systems some using
confocal and some triangulation– 2 mil accuracy
• Portable CMM– 8 foot Ø measurement volume– 1 mil accuracy with hard point probe– 3 mil accuracy with laser line
scanner
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• SRI has secure machine shop capability to machine specimens, test hardware and set-ups
• Materials machined include metals, graphites, ceramics, carbon-carbon composites, polymer composites, ceramic composites, metal matrix composites and others
• Machine tools– High-speed CNC, 3 Axis Vertical Machining Center
• X, Y, Z travel = 60, 29,26 inches• 20 tool magazine capacity
– CNC, 3 Axis Turning Center• 10” chuck x 60” center• 12 tool turrent with live tooling
– High-precision lathes (10 – 21” swing)– Wire EDM (Electro Discharge Machining)– Bridgeport milling machines– OD grinders– Full Welding Capabilities– Metal Fabrication Shop
Full Service Machining