Thermal-stress-free fasteners for joining orthotropic materials

Hot structures fabricated from orthotropic materials are an attractive design option for future high speed vehicles. Joining subassemblies of these materials with standard cylindrical fasteners can lead to loose joints or highly stressed joints due to thermal stress. A method has been developed to eliminate thermal stresses and maintain a tight joint by shaping the fastener and mating hole. This method allows both materials (fastener and structure), with different coefficients of thermal expansion (CTEs) in each of the three material directions, to expand freely with temperature yet remain in contact. For the assumptions made in the analysis, the joint will remain snug, yet free of thermal stress at any temperature. Finite element analysis was used to verify several thermal-stress-free fasteners and to show that conical fasteners, which are thermal-stress-free for isotropic materials, can reduce thermal stresses for transversely isotropic materials compared to a cylindrical fastener. Equations for thermal-stress-free shapes are presented and typical fastener shapes are shown

Theoretical basis for design of thermal-stress-free fasteners

A theoretical basis was developed for the design of fasteners which are free of thermal stress. A fastener can be shaped to eliminate the thermal stress which would otherwise result from differential thermal expansion between dissimilar fastener and sheet materials for many combinations of isotropic and orthotropic materials. The resulting joint remains snug, yet free of thermal stress at any temperature, if the joint is uniform in temperature, if it is frictionless, and if the coefficients of thermal expansion of the materials do not change with temperature. In general, such a fastener has curved sides; however, if both materials have isotropic coefficients of thermal expansion, a conical fastener is free of thermal stress. Equations are presented for thermal stress free shapes at both initial and final temperature, and typical fastener shapes are shown

Bending Stiffness of Multiwall Sandwich

An analytical and experimental study was carried out to understand the extensional and flexural behavior of multiwall sandwich, a metallic insulation composed of alternate layers of flat and dimpled foil. The multiwall sandwich was structurally analyzed by using several simplifying assumptions combined with a finite element analysis. The simplifying assumptions made in this analysis were evaluated by bending and tensile tests. Test results validate the assumption that flat sheets in compression do not significantly contribute to the flexural stiffness of multiwall sandwich for the multiwall geometry tested. However, calculations show that thicker flat sheets may contribute significantly to bending stiffness and cannot be ignored. Results of this analytical approach compare well with test data; both show that the extensional stiffness of the dimpled sheet in he 0 deg direction is about 30 percent of that for a flat sheet, and that in the 45 deg direction, it is about 10 percent. The analytical and experimental multiwall bending stiffness showed good agreement for the particular geometry tested

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints

Operational modules for space station construction

Identification of an effective space construction concept is a current objective of NASA studies. One concept, described in this memorandum, consists of repetitive use of operational modules, which minimizes on-orbit stay time for the shuttle. A space station constructed of operational modules may benefit from fabrication and system checkout in ground-based facilities, and since the modules are the primary structure of the space station, a minimum of additional structure, and trips and on-orbit stay time of the shuttle are required

Combination structural support and thermal protection system

A combination structural support and thermal protection system is provided. A cured preceramic polymer matrix reinforced with carbon fibers can be used alone or in a multiple component system

Numerical analysis of thermal stresses around fasteners in composite metal foils

The process of composite metal foil manufacturing (CMFM) has reduced a number of limitations associated with commercial additive manufacturing (AM) methods. The existing metal AM machines are restricted by their build envelope and there is a growing market for the manufacture of large parts using AM. These parts are subsequently manufactured in fragments and are fastened together. This paper analyses the thermal stresses around cylindrical fasteners for three layered metal composite parts consisting of aluminium foil, brazing paste and copper foil layers. The investigation aims to examine the mechanical integrity of the metallurgically bonded aluminium/copper foils of 100 micron thickness manufactured in a disc shape. A cylindrical fastener set at an elevated temperature of 100 °C is fitted in the middle of the disc which results in a steady-state thermal distribution. Radial and shear stresses are computed using finite element method which shows that non-zero shear stresses developed by the copper layer inhibit the axial slippage of the fastener and thereby establishing the suitability of rivet joints for CMFM parts

Viability of 3 D Woven Carbon Cloth and Advanced Carbon-Carbon Ribs for Adaptive Deployable Entry Placement Technology (ADEPT) for Future NASA Missions

This paper describes aerothermodynamic and thermal structural testing that demonstrate the viability of three dimensional woven carbon cloth and advanced carbon-carbon (ACC) ribs for use in the Adaptive Deployable Entry Placement Technology (ADEPT). ADEPT is an umbrella-like entry system that is folded for stowage in the launch vehicle's shroud and deployed prior to reaching the atmeopheric interface. A key feature of the ADEPT concept is a lower ballistic coefficient for delivery of a given payload than seen with conventional, rigid body entry systems. The benefits that accrue from the lower ballistic coefficient incllude factor-of-ten reductions of deceleration forces and entry heating. The former enables consideration of new classes of scientific instruments for solar system exploration while the latter enables the design of a more efficient thermal protection system. The carbon cloth base lined for ADEPT has a dual use in that it serves as the thermal protection system and as the "skin" that transfers aerdynamic deceleration loads to its umbrella-like substructure. Arcjet testing described in this paper was conducted for some of the higher heating conditions for a future Venus mission using the ADEPT concept, thereby showing that the carbon cloth can perform in a relevant entry environment. Recently completed the thermal structural testing of the cloth attached to a representative ACC rib design is also described. Finally, this paper describes a preliminary engineering level code, based on the arcjet data, that can be used to estimate cloth thickness for future ADEPT missions and to predict carbon cloth performance in future arcjet tests

A BMP7 variant inhibits tumor angiogenesis in vitro and in vivo through direct modulation of endothelial cell biology

Bone morphogenetic proteins (BMPs), members of the TGF-\u3b2 superfamily, have numerous biological activities including control of growth, differentiation, and vascular development. Using an in vitro co-culture endothelial cord formation assay, we investigated the role of a BMP7 variant (BMP7v) in VEGF, bFGF, and tumor-driven angiogenesis. BMP7v treatment led to disruption of neo-endothelial cord formation and regression of existing VEGF and bFGF cords in vitro. Using a series of tumor cell models capable of driving angiogenesis in vitro, BMP7v treatment completely blocked cord formation. Pre-treatment of endothelial cells with BMP7v significantly reduced their cord forming ability, indicating a direct effect on endothelial cell function. BMP7v activated the canonical SMAD signaling pathway in endothelial cells but targeted gene knockdown using shRNA directed against SMAD4 suggests this pathway is not required to mediate the anti-angiogenic effect. In contrast to SMAD activation, BMP7v selectively decreased ERK and AKT activation, significantly decreased endothelial cell migration and down-regulated expression of critical RTKs involved in VEGF and FGF angiogenic signaling, VEGFR2 and FGFR1 respectively. Importantly, in an in vivo angiogenic plug assay that serves as a measurement of angiogenesis, BMP7v significantly decreased hemoglobin content indicating inhibition of neoangiogenesis. In addition, BMP7v significantly decreased angiogenesis in glioblastoma stem-like cell (GSLC) Matrigel plugs and significantly impaired in vivo growth of a GSLC xenograft with a concomitant reduction in microvessel density. These data support BMP7v as a potent anti-angiogenic molecule that is effective in the context of tumor angiogenesis