Jackson, Justin R.

NASA Technical Reports Server

NASA Composite Technologies for Launch Vehicles
https://ntrs.nasa.gov/search.jsp?R=20190030442 2019-09-26T18:56:42+00:00Z
Marshall supports three of the NASA Mission Areas
Aeronautics 
Research
Human Exploration 
and Operations
Science
Space 
Technology
The National Aeronautics and Space 
Administration
Integrated Capabilities Across TRL* Range
Develop
New Resins
and Fibers
Pre-Pregging of New
Composite Materials
Develop Advanced In-Process, 
In-Situ NDE and Fabrication 
Technologies
TRL 1-3
TRL 7-9
Design and Fabrication of
Advanced Structural Concepts
Post-Cure Characterization
and NDE of Composites
Design, Build and Test 
Proto-flight Structures
TRL 4-6
* TRL = Technology Readiness Level
Manufacture 
Launch Vehicle 
Structures for 
NASA Missions
Basic Research
Technology
Maturation
Applications
LaRC MSFC
Structural Opportunities
Payload Adapter
Payload Adapter
Payload 
Adapter 
(PLA)
SLS Block 1B Configuration
Design Challenges
SLS Payload Adapter ARIANE 5 Adapter
• SLS Payload Adapter design presents unique challenges 
when compared with existing adapters
• PLA will be world’s largest Payload Adapter due to diameter 
of Exploration Upper Stage (EUS)
• Adapter must be stiff enough to preclude dynamic coupling 
with EUS hung stage
• Adapter must meet human rating requirements
• Key Requirements
• Adapt EUS diameter to Payload diameter
• Provide structural interface for Universal Stage 
Adapter (USA)
• React payload and USA loads
• Meet minimum structural frequency value to 
prevent coupling with EUS hung stage
• Accommodate cables between EUS and USA
• Accommodate cables and fluid lines between EUS 
to Payload
• Provide mounting locations for cameras
• Incorporate provisions for venting to minimize 
delta pressure across adapter
• Maximize commonality among adapters 
configurations while accommodating various 
Payloads
• Minimize mass
Develop & Manufacture the Payload Adapter for SLS
• Largest Payload Adapter Ever Built
• Composite Sandwich Construction
• Development of Technologies/Hardware
• Large Scale Manufacturing
• Bolted Joints
• Bonded Joints
• Inspection Techniques 
Payload Adapter
• Our facilities allow for a wide variety of composite projects both automated and 
hand lay-up, with parts ranging in use from process development through 
demonstration and on to flight hardware.  Facilities available include: 
– Filament Winding, 
– Advanced Fiber Placement, 
– Automated Cutting Tables, 
– Large–scale Machining, 
– Tape Wrapping, 
– Cold Storage, 
– Autoclaves, and
– Large Ovens
– CNC Machining
– NDE
– Structural and Mechanical Test
MSFC Composite Facilities
Payload Adapter
Automated Fiber Placement of Panels
3Payload Adapter
NC Trimming at MSFC Finished Panel Section
Payload Adapter
NDI
Panel Joining
Panel Placement
Fully Assembled Structure
3Composite Technologies for Exploration
• Technology Product Capability
– The CTE project will develop and demonstrate critical composites 
technologies with a focus on weight-saving, performance-enhancing 
bonded joint technology for Space Launch System (SLS)-scale composite 
hardware to support future NASA exploration missions. 
• Improve the analytical capabilities required to predict failure modes in 
composite structures. 
• Support SLS payload adapters and fittings by maturing composite bonded 
joint technology and analytical tools to enable risk reduction.
8/6/2019 NASA/Marshall Space Flight Center 12
3Key Technology Challenges
Composite Technologies for Exploration (CTE)
Title Description
Joint Configuration Identify low mass bonded joints for fiber composite launch structures
Model Predictions Establish modeling capabilities that failure predictions of empirical data with low engineering uncertainty. 
Notes: The CTE project has designed a bonded (no fasteners) longitudinal joint. Joint test 
coupons will be fabricated and tested and full-scale joint tests will follow. CTE has designed 
and fabricated a 3D woven resin infused C-channel for circumferential bonded joint 
applications.  C-channel testing pending / upcoming.
The CTE project has down-selected several analytical programs and failure theories. The 
project is currently analyzing joint designs with selected programs and theories. Results of 
joint tests will be used to evaluate analytical approaches.
Composite Technologies for Exploration
Failed AEWC 
Coupon
PFA of AEWC 
Coupon
HEWC 
PRISTINE PFA of HEWC 
Coupon
Fiber Damage 
in Face-sheet ply
HEWT 
PRISTI
NE
PFA of HEWT 
Coupon
Lo
ad
 
(lb
f)
End 
Shortening 
(in.)
CTE-301-3-AEWC-P-1
CTE-301-3-AEWC-P-3
CTE-301-4-AEWC-P-2
CTE-301-4-AEWC-P-4
CTE-301-4-AEWC-P-5
LL x 2.0 FS = 24.7 Kips 
PFA Load (Pre-Test) = 44.0 Kips 
PFA Load (Post-Test) = 41.8 Kips 
AEWC – PRISTINE COUPONS
Average Failure Load = 40.45 Kips 
HEWC – PRISTINE COUPONS
Lo
ad
 (l
bf
)
End Shortening (in.)
CTE-301-5-HEWC-P-1
CTE-301-9-HEWC-P-1
CTE-301-9-HEWC-P-2
CTE-301-10-HEWC-P-1
CTE-301-10-HEWC-P-2
LL x 2.0 FS = 6.1 Kips 
PFA Load (Pre-Test) = 20.8 Kips 
Average Failure Load = 21.42 Kips 
HT – PRISTINE COUPONS
CTE-300-1-HWT-P-1
CTE-300-1-HWT-P-2
CTE-300-3-HWT-P-1
CTE-300-3-HWT-P-2
Lo
ad
 (l
bf
)
End Displacement (in.)
LL x 2.0 FS = 2.7 Kips 
PFA Load (Pre-Test) = 15 Kips 
Average Failure Load = 15.01 Kips 
Fiber Damage 
in Face-sheet
AEWC 
PRISTIN
E
 Tested 28 pristine 
coupons at Southern 
Research.
 All coupons (pristine) 
failed above CTE Point 
Design Limit Load (LL) 
with 2.0 FS.
 Progressive damage 
analysis (PDA) using 
cohesive zone and 
COSTR damage model 
used to predict joint 
failure.
 Pre-test and post-test 
correlation achieved 
within 7% and 5%, 
respectively, of 
average test data for 
all tests.
Failed HEWC 
Coupon
Failed HT 
Coupon
Composite Technologies for Exploration
Procured process equipment 
for large-scale bonding 
operations.
Corona plasma treatment 
system for high performance, 
consistent surface preparation.
Multi-zone longitudinal 
heating blankets for improved 
scale-up bonding operations.
Developed process parameters 
for out-of-autoclave bonded 
joint cures with hot bonder.
Completed four full-scale 
joints on the Payload Adapter 
Manufacturing Demonstration 
Article (PLA MDA).
Payload Adapter Manufacturing 
Demonstration Article
Bonded Joint 
(during cure)
Hot Bonder
Surface Preparation with 
Corona Plasma Treatment
15
Composite Technologies for Exploration
Aft doubler segment (on 
OML) after cure
Segmented OML doubler 
after cure
Full-length OML doubler 
(via scarf joint between 2 
segments) after cure
Composite Technologies for Exploration
3Space Launch System
Composites Support NASA and the Nation
• All NASA Mission Directorates:  Aeronautics Research, Human Exploration and 
Operations, Science, & Space Technology rely on composite technologies.
• Technology provides important benefits to NASA and Commercial needs plus 
diverse sectors of the economy/enhances global competiveness -- Composites 
are important materials for the future of aerospace strategic leadership.
• Composite technology growth is paramount to pushing the boundaries of space 
travel.


NASA Composite Technologies for Launch Vehicles

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