Engineering topics

Johnson, Theodore F.

Publications and source records attributed to Johnson, Theodore F..

13 records

NASA NTRS2013

Structural Design and Sizing of a Metallic Cryotank Concept

This paper presents the structural design and sizing details of a 33-foot (10 m) metallic cryotank concept used as the reference design to compare with the composite cryotank concepts developed by industry as part of NASA s Composite Cryotank Technology Development (CCTD) Project. The structural design methodology and analysis results for the metallic cryotank concept are reported in the paper. The paper describes the details of the metallic cryotank sizing assumptions for the baseline and reference tank designs. In particular, the paper discusses the details of the cryotank weld land design and analyses performed to obtain a reduced weight metallic cryotank design using current materials and manufacturing techniques. The paper also discusses advanced manufacturing techniques to spin-form the cryotank domes and compares the potential mass savings to current friction stir-welded technology.

Sleight, David W.↗

NASA NTRS2011

Structural Design of Ares V Interstage Composite Structure

Preliminary and detailed design studies were performed to mature composite structural design concepts for the Ares V Interstage structure as a part of NASA s Advanced Composite Technologies Project. Aluminum honeycomb sandwich and hat-stiffened composite panel structural concepts were considered. The structural design and analysis studies were performed using HyperSizer design sizing software and MSC Nastran finite element analysis software. System-level design trade studies were carried out to predict weight and margins of safety for composite honeycomb-core sandwich and composite hat-stiffened skin design concepts. Details of both preliminary and detailed design studies are presented in the paper. For the range of loads and geometry considered in this work, the hat-stiffened designs were found to be approximately 11-16 percent lighter than the sandwich designs. A down-select process was used to choose the most favorable structural concept based on a set of figures of merit, and the honeycomb sandwich design was selected as the best concept based on advantages in manufacturing cost.

Sleigh, David W.↗

NASA NTRS2007

Apparent-Strain Correction for Combined Thermal and Mechanical Testing

Combined thermal and mechanical testing requires that the total strain be corrected for the coefficient of thermal expansion mismatch between the strain gage and the specimen or apparent strain when the temperature varies while a mechanical load is being applied. Collecting data for an apparent strain test becomes problematic as the specimen size increases. If the test specimen cannot be placed in a variable temperature test chamber to generate apparent strain data with no mechanical loads, coupons can be used to generate the required data. The coupons, however, must have the same strain gage type, coefficient of thermal expansion, and constraints as the specimen to be useful. Obtaining apparent-strain data at temperatures lower than -320 F is challenging due to the difficulty to maintain steady-state and uniform temperatures on a given specimen. Equations to correct for apparent strain in a real-time fashion and data from apparent-strain tests for composite and metallic specimens over a temperature range from -450 F to +250 F are presented in this paper. Three approaches to extrapolate apparent-strain data from -320 F to -430 F are presented and compared to the measured apparent-strain data. The first two approaches use a subset of the apparent-strain curves between -320 F and 100 F to extrapolate to -430 F, while the third approach extrapolates the apparent-strain curve over the temperature range of -320 F to +250 F to -430 F. The first two approaches are superior to the third approach but the use of either of the first two approaches is contingent upon the degree of non-linearity of the apparent-strain curve.

Johnson, Theodore F.↗

NASA NTRS2005

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA, Langley Research Center (LaRC) for investigating integrated cryogenic propellant tank systems for a reusable launch vehicle (RLV) are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, thermal protection system (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗

NASA NTRS2005

Assessment of Technologies for the Space Shuttle External Tank Thermal Protection System and Recommendations for Technology Improvement - Part III: Material Property Characterization, Analysis, and Test Methods

The objective of this report is to contribute to the independent assessment of the Space Shuttle External Tank Foam Material. This report specifically addresses material modeling, characterization testing, data reduction methods, and data pedigree. A brief description of the External Tank foam materials, locations, and standard failure modes is provided to develop suitable background information. A review of mechanics based analysis methods from the open literature is used to provide an assessment of the state-of-the-art in material modeling of closed cell foams. Further, this report assesses the existing material property database and investigates sources of material property variability. The report presents identified deficiencies in testing methods and procedures, recommendations for additional testing as required, identification of near-term improvements that should be pursued, and long-term capabilities or enhancements that should be developed.

Gates, Thomas S.↗

NASA NTRS2004

Thermal-Structural Optimization of Integrated Cryogenic Propellant Tank Concepts for a Reusable Launch Vehicle

A next generation reusable launch vehicle (RLV) will require thermally efficient and light-weight cryogenic propellant tank structures. Since these tanks will be weight-critical, analytical tools must be developed to aid in sizing the thickness of insulation layers and structural geometry for optimal performance. Finite element method (FEM) models of the tank and insulation layers were created to analyze the thermal performance of the cryogenic insulation layer and thermal protection system (TPS) of the tanks. The thermal conditions of ground-hold and re-entry/soak-through for a typical RLV mission were used in the thermal sizing study. A general-purpose nonlinear FEM analysis code, capable of using temperature and pressure dependent material properties, was used as the thermal analysis code. Mechanical loads from ground handling and proof-pressure testing were used to size the structural geometry of an aluminum cryogenic tank wall. Nonlinear deterministic optimization and reliability optimization techniques were the analytical tools used to size the geometry of the isogrid stiffeners and thickness of the skin. The results from the sizing study indicate that a commercial FEM code can be used for thermal analyses to size the insulation thicknesses where the temperature and pressure were varied. The results from the structural sizing study show that using combined deterministic and reliability optimization techniques can obtain alternate and lighter designs than the designs obtained from deterministic optimization methods alone.

Johnson, Theodore F.↗

NASA NTRS2003

Accurate Thermal Stresses for Beams: Normal Stress

Formulations for a general theory of thermoelasticity to generate accurate thermal stresses for structural members of aeronautical vehicles were developed in 1954 by Boley. The formulation also provides three normal stresses and a shear stress along the entire length of the beam. The Poisson effect of the lateral and transverse normal stresses on a thermally loaded beam is taken into account in this theory by employing an Airy stress function. The Airy stress function enables the reduction of the three-dimensional thermal stress problem to a two-dimensional one. Numerical results from the general theory of thermoelasticity are compared to those obtained from strength of materials. It is concluded that the theory of thermoelasticity for prismatic beams proposed in this paper can be used instead of strength of materials when precise stress results are desired.

Johnson, Theodore F.↗

NASA NTRS2003

Cryopumping in Cryogenic Insulations for a Reusable Launch Vehicle

Testing at cryogenic temperatures was performed to verify the material characteristics and manufacturing processes of reusable propellant tank cryogenic insulations for a Reusable Launch Vehicle (RLV). The unique test apparatus and test methods developed for the investigation of cryopumping in cryogenic insulations are described. Panel level test specimens with various types of cryogenic insulations were subjected to a specific thermal profile where the temperature varied from -262 C to 21 C. Cryopumping occurred if the interior temperature of the specimen exhibited abnormal temperature fluctuations, such as a sudden decrease in temperature during the heating phase.

Johnson, Theodore F.↗

NASA NTRS2002

Accurate Thermal Stresses for Beams: Normal Stress

Johnson, Theodore F.↗

NASA NTRS2001

High Temperature Polyimide Materials in Extreme Temperature Environments

At the end of the NASA High Speed Research (HSR) Program, NASA Langley Research Center (LaRC) began a program to screen the high-temperature Polymeric Composite Materials (PMCs) characterized by the HSR Durability Program for possible use in Reusable Launch Vehicles (RLVs) operating under extreme temperature conditions. The HSR Program focused on developing material-related technologies to enable a High Speed Civil Transport (HSCT) capable of operating temperatures ranging from 54 C (-65 F) to 177 C (350 F). A high-temperature polymeric resin, PETI-5 was used in the HSR Program to satisfy the requirements for performance and durability for a PMC. For RLVs, it was anticipated that this high temperature material would contribute to reducing the overall weight of a vehicle by eliminating or reducing the thermal protection required to protect the internal structural elements of the vehicle and increasing the structural strain limits. The tests were performed to determine temperature-dependent mechanical and physical proper-ties of IM7/PETI-5 composite over a temperature range from cryogenic temperature -253 C (-423F) to the material's maximum use temperature of 230 C (450 F). This paper presents results from the test program for the temperature-dependent mechanical and physical properties of IM7/PETI-5 composite in the temperature range from -253 C (-423 F) to 27 C (80 F).

Johnson, Theodore F.↗

NASA NTRS2000

2nd Generation RLV Airframe Structures and Materials

The goals and objectives of the project summarized in this viewgraph presentation are the following: (1) Develop and demonstrate verified airframe and cryotank structural design and analysis technologies, including damage tolerance, safety, reliability, and residual strength technologies, robust nonlinear shell and cryotank analysis technologies, high-fidelity analysis and design technologies for local structural detail features and joints, and high-fidelity analysis technologies for sandwich structures; (2) Demonstrate low cost, robust materials and processing, including polymeric matrix composite (PMC) and metallic materials and processing, and refractory composite and metallic hot structures materials and processing; (3) Develop and demonstrate robust airframe structures and validated integrated airframe structural concepts, including low cost fabrication and joining, operations efficient designs and inspection techniques (non-destructive evaluation), scale-up and integrated thermal structure tests, and airframe structures IVHM; (4) Demonstrate low cost, robust repair techniques; and (5) Develop verified integrated airframe structural concepts, including integrated structural concepts.

Johnson, Theodore F.↗

NASA NTRS1998

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA Langley Research Center for investigating integrated cryogenic propellant tank systems for a Reusable Launch Vehicle are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, Thermal Protection System (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗

NASA NTRS1995

Effects of Stiffening and Mechanical Load on Thermal Buckling of Stiffened Cylindrical Shells

A study of thermal buckling of stiffened cylindrical shells with the proportions of a preliminary supersonic transport fuselage design (1970) is presented. The buckling analysis is performed using an axisymmetric shell-of-revolution code, BOSOR4. The effects of combined mechanical (axial loading) and thermal loading (heated skins) are investigated. Results indicate that the location of longitudinal eccentric stiffening has a very large effect on the thermal buckling strength of longitudinally stiffened shells, and on longitudinally stiffened shells with rings.

Johnson, Theodore F.↗