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Engineering Division USACA– OCTOBER 2009

Engineering Division USACA– OCTOBER 2009. Southern Research. 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

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Engineering Division USACA– OCTOBER 2009

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  1. Engineering DivisionUSACA– OCTOBER 2009

  2. Southern Research • 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

  3. Engineering Division • 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

  4. Materials Characterization • 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

  5. 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

  6. 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

  7. Durability and Oxidation Characterization Variable Atmosphere Temperature Pressure (VATP) Facility - (4000 F @ .05 Atm. Air)

  8. 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 Studies The 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. 9

  9. Initial Results – Good Match to Ambient and Reasonable Elevated Temperature Results

  10. Typical Recent SRI Engineering Efforts • 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) • 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

  11. 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

  12. Other Measurement Capabilities • Permeability • Ambient to 3500° F • High Pressure (incl.. H2) • Effect of loads • Porosity • Hg porosimetry • He Pycnometry • Liquid Absorption • Microscopy • SEM • Optical

  13. Thermal Property Measurements • 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

  14. 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

  15. 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

  16. Thermal Property Measurement Capabilities • Specialized Testing Capabilities • Cryocoolers for cryogenic properties • Thermal conductivity under load. • Vacuum thermal response measurements ATMOSPHERIC PRESSURE TOVACUUM TEMPERATURE OVER 3000 DEGREES (4500)

  17. New Ultrasonic Spectroscopy Technique • Rapidly Swept Wave • Entire Waveform Digitized • FFT of Sweep Gives Flat Spectrum • Bandwidth and Amplitude User Defined Ultrasonic Spectroscopy Modes of Interaction • Attenuation as a Function of Frequency • Dispersion/Defect Interaction • Resonance

  18. 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

  19. Full Service Machining • 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

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