Engineering topics

Przekop, Adam

Publications and source records attributed to Przekop, Adam.

At least 19 records

NASA NTRS2018

Fabrication of a Composite Tow-Steered Structure for Air-Launch Vehicle Applications

Generation Orbit (GO) is developing the GO Launcher-1 (GO-1), a single stage liquid rocket that is launched from a Gulfstream III carrier aircraft platform. The vehicle is designed as the next generation platform for hypersonic flight testing and suborbital microgravity research. To reduce mass and increase payload, GO partnered with NASA Langley Research Center to design, analyze, optimize, and fabricate a tow-steered manufacturing development unit of a cylindrical section of a liquid oxygen tank. The fabrication process of using the ISAAC (Integrated Structural Assembly of Advanced Composites) system is described. The structural design challenges and the concept design solutions are also presented to provide the context for the fabrication process. The in-situ nondestructive evaluation supporting the effort is also described.

Grenoble, Ray↗

NASA NTRS2016

Design and Use of a Guided Weight Impactor to Impart Barely Visible Impact Damage

Aircraft structure is required to demonstrate satisfaction of the FAR requirements for Category 1, such as barely visible impact damage (BVID). Typical aircraft structure is impacted using a dropped weight impactor, which can impart BVID to the top surface of the structure. A recent test of a multi-bay box (MBB) composite test article, that represents an 80% scale center section of a hybrid wing body aircraft, required impact to be in a direction other than vertical from above, but still in an direction that is normal to the surface. This requirement eliminated the use of the conventional dropped weight impactor. Therefore, a design study was undertaken to determine the most effective way to efficiently and reliably impact the MBB. The chosen design was a guided weight impactor that is gravity driven. This paper describes the design of the guided weight impactor, and presents the results of its use for imparting BVID to the MBB. The guided weight impactor was seen to be a very reliable method to impart BVID, while at the same time having the capability to be highly configurable for use on other aircraft structure that is impacted at a variety of impact energies and from a variety of directions.

Lovejoy, Andrew E.↗

NASA NTRS2016

The Behavior of a Stitched Composite Large-Scale Multi-Bay Pressure Box

NASA has created the Environmentally Responsible Aviation (ERA) Project to develop technologies to reduce impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe to enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company have worked together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composite structures. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building block tests were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. The final step in the building block series of tests is an 80%-scale pressure box representing a portion of the center section of a Hybrid Wing Body (HWB) transport aircraft. The testing of this test article under maneuver and internal pressure loading conditions is the subject of this paper. The experimental evaluation of this article, along with the other building block tests and the accompanying analyses, has demonstrated the viability of a PRSEUS center body for the HWB vehicle. Additionally, much of the development effort is also applicable to traditional tube-and-wing aircraft, advanced aircraft configurations, and other structures where weight and through-the-thickness strength are design considerations.

Jegley, Dawn C.↗

NASA NTRS2016

Finite Element Analysis and Test Results Comparison for the Hybrid Wing Body Center Section Test Article

This report documents the comparison of test measurements and predictive finite element analysis results for a hybrid wing body center section test article. The testing and analysis efforts were part of the Airframe Technology subproject within the NASA Environmentally Responsible Aviation project. Test results include full field displacement measurements obtained from digital image correlation systems and discrete strain measurements obtained using both unidirectional and rosette resistive gauges. Most significant results are presented for the critical five load cases exercised during the test. Final test to failure after inflicting severe damage to the test article is also documented. Overall, good comparison between predicted and actual behavior of the test article is found.

Przekop, Adam↗

NASA NTRS2016

Testing of a Stitched Composite Large-Scale Multi-Bay Pressure Box

NASA has created the Environmentally Responsible Aviation (ERA) Project to develop technologies to reduce aviation's impact on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe to enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company have worked together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composite structures. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together. The PRSEUS concept is designed to maintain residual load carrying capabilities under a variety of damage scenarios. A series of building block tests were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. The final step in the building block series is an 80%-scale pressure box representing a portion of the center section of a Hybrid Wing Body (HWB) transport aircraft. The testing of this article under maneuver load and internal pressure load conditions is the subject of this paper. The experimental evaluation of this article, along with the other building block tests and the accompanying analyses, has demonstrated the viability of a PRSEUS center body for the HWB vehicle. Additionally, much of the development effort is also applicable to traditional tube-and-wing aircraft, advanced aircraft configurations, and other structures where weight and through-the-thickness strength are design considerations.

Jegley, Dawn↗

NASA NTRS2016

Imparting Barely Visible Impact Damage to a Stitched Composite Large-Scale Pressure Box

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a concept that was developed by The Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration, which has been a focus of the NASA Environmentally Responsible Aviation Project. The NASA-Boeing structural development for the HWB aircraft culminated in testing of the multi-bay box, which is an 80%-scale representation of the pressurized center-body section. This structure was tested in the NASA Langley Research Center Combined Loads Test System facility. As part of this testing, barely visible impact damage was imparted to the interior and exterior of the test article to demonstrate compliance with a condition representative of the requirements for Category 1 damaged composite structure as defined by the Federal Aviation Regulations. Interior impacts were imparted using an existing spring-loaded impactor, while the exterior impacts were imparted using a newly designed, gravity-driven impactor. This paper describes the impacts to the test article, and the design of the gravitydriven guided-weight impactor. The guided-weight impactor proved to be a very reliable method to impart barely visible impact damage in locations which are not easily accessible for a traditional drop-weight impactor, while at the same time having the capability to be highly configurable for use on other aircraft structures.

Lovejoy, Andrew E.↗

NASA NTRS2016

Testing and Analysis of a Composite Non-Cylindrical Aircraft Fuselage Structure : Severe Damage - Part II

The Environmentally Responsible Aviation Project aimed to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration were not sufficient to achieve the desired metrics. One airframe concept identified by the project as having the potential to dramatically improve aircraft performance was a composite-based hybrid wing body configuration. Such a concept, however, presented inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses a finite element analysis and the testing of a large-scale hybrid wing body center section structure developed and constructed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. Part II of the paper considers the final test to failure of the test article in the presence of an intentionally inflicted severe discrete source damage under the wing up-bending loading condition. Finite element analysis results are compared with measurements acquired during the test and demonstrate that the hybrid wing body test article was able to redistribute and support the required design loads in a severely damaged condition.

Przekop, Adam↗

NASA NTRS2016

Testing and Analysis of a Composite Non-Cylindrical Aircraft Fuselage Structure: Ultimate Design Loads - Part 1

The Environmentally Responsible Aviation Project aimed to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration were not sufficient to achieve the desired metrics. One airframe concept identified by the project as having the potential to dramatically improve aircraft performance was a composite-based hybrid wing body configuration. Such a concept, however, presented inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses finite element analysis and testing of a large-scale hybrid wing body center section structure developed and constructed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. Part I of the paper considers the five most critical load conditions, which are internal pressure only and positive and negative g-loads with and without internal pressure. Analysis results are compared with measurements acquired during testing. Performance of the test article is found to be closely aligned with predictions and, consequently, able to support the hybrid wing body design loads in pristine and barely visible impact damage conditions.

Przekop, Adam↗

NASA NTRS2015

Fiber Optic Rosette Strain Gauge Development and Application on a Large-Scale Composite Structure

A detailed description of the construction, application, and measurement of 196 FO rosette strain gauges that measured multi-axis strain across the outside upper surface of the forward bulkhead component of a multibay composite fuselage test article is presented. A background of the FO strain gauge and the FO measurement system as utilized in this application is given and results for the higher load cases of the testing sequence are shown.

Moore, Jason P.↗

NASA NTRS2015

Nonlinear Analysis and Preliminary Testing Results of a Hybrid Wing Body Center Section Test Article

A large test article was recently designed, analyzed, fabricated, and successfully tested up to the representative design ultimate loads to demonstrate that stiffened composite panels with through-the-thickness reinforcement are a viable option for the next generation large transport category aircraft, including non-conventional configurations such as the hybrid wing body. This paper focuses on finite element analysis and test data correlation of the hybrid wing body center section test article under mechanical, pressure and combined load conditions. Good agreement between predictive nonlinear finite element analysis and test data is found. Results indicate that a geometrically nonlinear analysis is needed to accurately capture the behavior of the non-circular pressurized and highly-stressed structure when the design approach permits local buckling.

Przekop, Adam↗

NASA NTRS2015

Development of Stitched Composite Structure for Advanced Aircraft

NASA has created the Environmentally Responsible Aviation Project to develop technologies which will reduce the impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe that will enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company are working together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composites. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building blocks were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. These building blocks addressed tension, compression, and pressure loading conditions. The emphasis of the development work has been to assess the loading capability, damage arrestment features, repairability, post-buckling behavior, and response of PRSEUS flat panels to out-of plane pressure loading. The results of this building-block program from coupons through an 80%-scale pressure box have demonstrated the viability of a PRSEUS center body for the Hybrid Wing Body (HWB) transport aircraft. This development program shows that the PRSEUS benefits are also applicable to traditional tube-andwing aircraft, those of advanced configurations, and other structures where weight and through-the-thickness strength are design considerations. An overview of the development of PRSEUS technology for commercial transport aircraft is the subject of this paper.

Jegley, Dawn↗

NASA NTRS2015

Vibroacoustic Tailoring of a Rod-Stiffened Composite Fuselage Panel with Multidisciplinary Considerations

An efficient multi-objective design tailoring procedure seeking to improve the vibroacoustic performance of a fuselage panel while maintaining or reducing weight is presented. The structure considered is the pultruded rod stitched efficient unitized structure, a highly integrated composite structure concept designed for a noncylindrical, next-generation flight vehicle fuselage. Modifications to a baseline design are evaluated within a six-parameter design space including spacing, flange width, and web height for both frame and stringer substructure components. The change in sound power radiation attributed to a design change is predicted using finite-element models sized and meshed for analyses in the 500 Hz, 1 kHz, and 2 kHz octave bands. Three design studies are carried out in parallel while considering a diffuse acoustic field excitation and two types of turbulent boundary-layer excitation. Kriging surrogate models are used to reduce the computational costs of resolving the vibroacoustic and weight objective Pareto fronts. The resulting Pareto optimal designs are then evaluated under a static pressurization ultimate load to assess structural strength and stability. Results suggest that choosing alternative configurations within the considered design space can reduce weight and improve vibroacoustic performance without compromising strength and stability of the structure under the static load condition considered, but the tradeoffs are significantly influenced by the spatial characteristics of the assumed excitation field.

Allen, Albert R.↗

NASA NTRS2014

Analysis and Testing of a Metallic Repair Applicable to Pressurized Composite Aircraft Structure

Development of repair technology is vital to the long-term application of new structural concepts on aircraft structure. The design, analysis, and testing of a repair concept applicable to a stiffened composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure was recently completed. The damage scenario considered was a mid-bay to mid-bay saw-cut with a severed stiffener, flange, and skin. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from tension and pressure panel tests conducted to validate both the repair concept and finite element analysis techniques used in the design effort. Simulation and experimental strain and displacement results show good correlation, indicating that the finite element modeling techniques applied in the effort are an appropriate compromise between required fidelity and computational effort. Static tests under tension and pressure loadings proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. Furthermore, the pressure repair panel was subjected to 55,000 pressure load cycles to verify that the design can withstand a life cycle representative for a transport category aircraft. These findings enable upward revision of the stress allowables that had been kept at an overly-conservative level due to concerns associated with repairability of the panels. This conclusion enables more weight efficient structural designs utilizing the composite concept under investigation.

Przekop, Adam↗

NASA NTRS2014

Evaluation of a Metallic Repair on a Rod-Stiffened Composite Panel

A design and analysis of a repair concept applicable to a stiffened composite panel based on the pultruded rod stitched efficient unitized structure was recently completed.The damage scenario considered was a midbay-to-midbay saw-cut with a severed stiffener, flange, and skin. Advanced modeling techniques such as mesh-independent definition of compliant fasteners and elastic-plastic material properties for metal parts were used in the finite-element analysis supporting the design effort. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from a tension panel test conducted to validate both the repair concept and finite element analysis techniques used in the design effort. The test proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. This conclusion enables upward revision of the stress allowables that had been kept at an overly conservative level due to concerns associated with repairability of the panels. Correlation of test data with finite-element analysis results is also presented and assessed.

Przekop, Adam↗

NASA NTRS2014

Nonlinear Finite Element Analysis of a Composite Non-Cylindrical Pressurized Aircraft Fuselage Structure

The Environmentally Responsible Aviation Project aims to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration are not sufficient to achieve the desired metrics. One of the airframe concepts that might dramatically improve aircraft performance is a composite-based hybrid wing body configuration. Such a concept, however, presents inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses a nonlinear finite element analysis of a large-scale test article being developed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. There are specific reasons why geometrically nonlinear analysis may be warranted for the hybrid wing body flat panel structure. In general, for sufficiently high internal pressure and/or mechanical loading, energy related to the in-plane strain may become significant relative to the bending strain energy, particularly in thin-walled areas such as the minimum gage skin extensively used in the structure under analysis. To account for this effect, a geometrically nonlinear strain-displacement relationship is needed to properly couple large out-of-plane and in-plane deformations. Depending on the loading, this nonlinear coupling mechanism manifests itself in a distinct manner in compression- and tension-dominated sections of the structure. Under significant compression, nonlinear analysis is needed to accurately predict loss of stability and postbuckled deformation. Under significant tension, the nonlinear effects account for suppression of the out-of-plane deformation due to in-plane stretching. By comparing the present results with the previously published preliminary linear analysis, it is demonstrated in the present paper that neglecting nonlinear effects for the structure and loads of interest can lead to appreciable loss in analysis fidelity.

Przekop, Adam↗

NASA NTRS2013

Testing and Analysis Validation of a Metallic Repair Applied to a PRSEUS Tension Panel

A design and analysis of a repair concept applicable to a stiffened composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure was recently completed. The damage scenario considered was a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. Advanced modeling techniques such as mesh-independent definition of compliant fasteners and elastic-plastic material properties for metal parts were utilized in the finite element analysis supporting the design effort. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from a tension panel test conducted to validate both the repair concept and finite element analysis techniques used in the design effort. The test proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. This conclusion enables upward revision of the stress allowables that had been kept at an overly-conservative level due to concerns associated with repairability of the panels. Correlation of test data with finite element analysis results is also presented and assessed.

Przekop, Adam↗

NASA NTRS2013

Analysis of a Hybrid Wing Body Center Section Test Article

The hybrid wing body center section test article is an all-composite structure made of crown, floor, keel, bulkhead, and rib panels utilizing the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) design concept. The primary goal of this test article is to prove that PRSEUS components are capable of carrying combined loads that are representative of a hybrid wing body pressure cabin design regime. This paper summarizes the analytical approach, analysis results, and failure predictions of the test article. A global finite element model of composite panels, metallic fittings, mechanical fasteners, and the Combined Loads Test System (COLTS) test fixture was used to conduct linear structural strength and stability analyses to validate the specimen under the most critical combination of bending and pressure loading conditions found in the hybrid wing body pressure cabin. Local detail analyses were also performed at locations with high stress concentrations, at Tee-cap noodle interfaces with surrounding laminates, and at fastener locations with high bearing/bypass loads. Failure predictions for different composite and metallic failure modes were made, and nonlinear analyses were also performed to study the structural response of the test article under combined bending and pressure loading. This large-scale specimen test will be conducted at the COLTS facility at the NASA Langley Research Center.

Wu, Hsi-Yung T.↗

NASA NTRS2012

Vibroacoustic Characterization of a New Hybrid Wing-Body Fuselage Concept

A lighter, more robust airframe design is required to withstand the loading inherent to next generation non cylindrical commercial airliners. The Pultruded Rod Stitched Efficient Unitized Structure concept, a highly integrated composite design involving a stitched and co-cured substructure, has been developed to meet such requirements. While this structure has been shown to meet the demanding out-of-plane loading requirements of the flat-sided pressurized cabin design, there are concerns that the stiff co-cured details will result in relatively high acoustic radiation efficiencies at frequencies well below the thin skin acoustic coincidence frequency. To address this concern and establish a set of baseline vibroacoustic characteristics, a representative test panel was fabricated and a suite of tests were conducted that involved measurements of panel vibration and radiated sound power during point force and diffuse acoustic field excitations. Experimental results are shown and compared with Finite Element and Statistical Energy Analysis model predictions through the use of modal and energy correlation techniques among others. The behavior of the structure subject to turbulent boundary layer excitation is also numerically examined.

Allen, Albert R.↗