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At least 181 records · Page 10

Buckling Testing and Analysis of Space Shuttle Solid Rocket Motor Cylinders

A series of full-scale buckling tests were performed on the space shuttle Reusable Solid Rocket Motor (RSRM) cylinders. The tests were performed to determine the buckling capability of the cylinders and to provide data for analytical comparison. A nonlinear ANSYS Finite Element Analysis (FEA) model was used to represent and evaluate the testing. Analytical results demonstrated excellent correlation to test results, predicting the failure load within 5%. The analytical value was on the conservative side, predicting a lower failure load than was applied to the test. The resulting study and analysis indicated the important parameters for FEA to accurately predict buckling failure. The resulting method was subsequently used to establish the pre-launch buckling capability of the space shuttle system.

Weidner, Thomas J.↗

Flaw Tolerance in Lap Shear Brazed Joints

Furnace brazing is a joining process used in the aerospace and other industries to produce strong permanent and hermetic structural joints. As in any joining process, brazed joints have various imperfections and defects. At the present time, our understanding of the influence of the internal defects on the strength of the brazed joints is not adequate. The goal of this 3-part investigation is to better understand the properties and failure mechanisms of the brazed joints containing defects. This study focuses on the behavior of the brazed lap shear joints because of their importance in manufacturing aerospace structures. In Part 1, an average shear strength capability and failure modes of the single lap joints are explored. Stainless steel specimens brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the failure loads and the ultimate shear strength with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap widths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. A damage zone criterion is shown to work quite well in understanding the failure of the braze joints. In Part 2, the findings of the Part 1 will be verified on the larger test specimens. Also, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify that behavior of the flawed ductile lap joints is similar to joints with a reduced braze area. Finally, in Part 3, the results obtained in Parts 1 and 2 will be applied to the actual brazed structure to evaluate the load-carrying capability of a structural lap joint containing discontinuities. In addition, a simplified engineering procedure will be offered for the laboratory testing of the lap shear specimens.

Flom, Yury↗

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗

Structural Reliability Using Probability Density Estimation Methods Within NESSUS

A reliability analysis studies a mathematical model of a physical system taking into account uncertainties of design variables and common results are estimations of a response density, which also implies estimations of its parameters. Some common density parameters include the mean value, the standard deviation, and specific percentile(s) of the response, which are measures of central tendency, variation, and probability regions, respectively. Reliability analyses are important since the results can lead to different designs by calculating the probability of observing safe responses in each of the proposed designs. All of this is done at the expense of added computational time as compared to a single deterministic analysis which will result in one value of the response out of many that make up the density of the response. Sampling methods, such as monte carlo (MC) and latin hypercube sampling (LHS), can be used to perform reliability analyses and can compute nonlinear response density parameters even if the response is dependent on many random variables. Hence, both methods are very robust; however, they are computationally expensive to use in the estimation of the response density parameters. Both methods are 2 of 13 stochastic methods that are contained within the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) program. NESSUS is a probabilistic finite element analysis (FEA) program that was developed through funding from NASA Glenn Research Center (GRC). It has the additional capability of being linked to other analysis programs; therefore, probabilistic fluid dynamics, fracture mechanics, and heat transfer are only a few of what is possible with this software. The LHS method is the newest addition to the stochastic methods within NESSUS. Part of this work was to enhance NESSUS with the LHS method. The new LHS module is complete, has been successfully integrated with NESSUS, and been used to study four different test cases that have been proposed by the Society of Automotive Engineers (SAE). The test cases compare different probabilistic methods within NESSUS because it is important that a user can have confidence that estimates of stochastic parameters of a response will be within an acceptable error limit. For each response, the mean, standard deviation, and 0.99 percentile, are repeatedly estimated which allows confidence statements to be made for each parameter estimated, and for each method. Thus, the ability of several stochastic methods to efficiently and accurately estimate density parameters is compared using four valid test cases. While all of the reliability methods used performed quite well, for the new LHS module within NESSUS it was found that it had a lower estimation error than MC when they were used to estimate the mean, standard deviation, and 0.99 percentile of the four different stochastic responses. Also, LHS required a smaller amount of calculations to obtain low error answers with a high amount of confidence than MC. It can therefore be stated that NESSUS is an important reliability tool that has a variety of sound probabilistic methods a user can employ and the newest LHS module is a valuable new enhancement of the program.

Chamis, Chrisos C.↗

Design Through Manufacturing: The Solid Model - Finite Element Analysis Interface

State-of-the-art computer aided design (CAD) presently affords engineers the opportunity to create solid models of machine parts which reflect every detail of the finished product. Ideally, these models should fulfill two very important functions: (1) they must provide numerical control information for automated manufacturing of precision parts, and (2) they must enable analysts to easily evaluate the stress levels (using finite element analysis - FEA) for all structurally significant parts used in space missions. Today's state-of-the-art CAD programs perform function (1) very well, providing an excellent model for precision manufacturing. But they do not provide a straightforward and simple means of automating the translation from CAD to FEA models, especially for aircraft-type structures. The research performed during the fellowship period investigated the transition process from the solid CAD model to the FEA stress analysis model with the final goal of creating an automatic interface between the two. During the period of the fellowship a detailed multi-year program for the development of such an interface was created. The ultimate goal of this program will be the development of a fully parameterized automatic ProE/FEA translator for parts and assemblies, with the incorporation of data base management into the solution, and ultimately including computational fluid dynamics and thermal modeling in the interface.

Rubin, Carol↗

Predicting the Reliability of Ceramics Under Transient Loads and Temperatures With CARES/Life

A methodology is shown for predicting the time-dependent reliability of ceramic components against catastrophic rupture when subjected to transient thermomechanical loads (including cyclic loads). The methodology takes into account the changes in material response that can occur with temperature or time (i.e., changing fatigue and Weibull parameters with temperature or time). This capability has been added to the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. The code has been modified to have the ability to interface with commercially available finite element analysis (FEA) codes executed for transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Nemeth, Noel N.↗

Fatigue Crack Growth Rate and Stress-Intensity Factor Corrections for Out-of-Plane Crack Growth

Fatigue crack growth rate testing is performed by automated data collection systems that assume straight crack growth in the plane of symmetry and use standard polynomial solutions to compute crack length and stress-intensity factors from compliance or potential drop measurements. Visual measurements used to correct the collected data typically include only the horizontal crack length, which for cracks that propagate out-of-plane, under-estimates the crack growth rates and over-estimates the stress-intensity factors. The authors have devised an approach for correcting both the crack growth rates and stress-intensity factors based on two-dimensional mixed mode-I/II finite element analysis (FEA). The approach is used to correct out-of-plane data for 7050-T7451 and 2025-T6 aluminum alloys. Results indicate the correction process works well for high DeltaK levels but fails to capture the mixed-mode effects at DeltaK levels approaching threshold (da/dN approximately 10(exp -10) meter/cycle).

Forth, Scott C.↗

Packaging Technology for SiC High Temperature Circuits Operable up to 500 Degrees Centigrade

New high temperature low power 8-pin packages have been fabricated using commercial fabrication service. These packages are made of aluminum nitride and 96 percent alumina with Au metallization. The new design of these packages provides the chips inside with EM shielding. Wirebond geometry control has been achieved for precise mechanical tests. Au wirebond samples with 45 degree heel-angle have been tested using wireloop test module. The geometry control improves the consistency of measurement of the wireloop breaking point.Also reported on is a parametric study of the thermomechanical reliability of a Au thick-film based SiC die-attach assembly using nonlinear finite element analysis (FEA) was conducted to optimize the die-attach thermo-mechanical performance for operation at temperatures from room temperature to 500 degrees Centigrade. This parametric study centered on material selection, structure design and process control.

Chen, Lian-Yu↗

Aircraft Structural Mass Property Prediction Using Conceptual-Level Structural Analysis

This paper describes a methodology that extends the use of the Equivalent LAminated Plate Solution (ELAPS) structural analysis code from conceptual-level aircraft structural analysis to conceptual-level aircraft mass property analysis. Mass property analysis in aircraft structures has historically depended upon parametric weight equations at the conceptual design level and Finite Element Analysis (FEA) at the detailed design level. ELAPS allows for the modeling of detailed geometry, metallic and composite materials, and non-structural mass coupled with analytical structural sizing to produce high-fidelity mass property analyses representing fully configured vehicles early in the design process. This capability is especially valuable for unusual configuration and advanced concept development where existing parametric weight equations are inapplicable and FEA is too time consuming for conceptual design. This paper contrasts the use of ELAPS relative to empirical weight equations and FEA. ELAPS modeling techniques are described and the ELAPS-based mass property analysis process is detailed. Examples of mass property stochastic calculations produced during a recent systems study are provided. This study involved the analysis of three remotely piloted aircraft required to carry scientific payloads to very high altitudes at subsonic speeds. Due to the extreme nature of this high-altitude flight regime, few existing vehicle designs are available for use in performance and weight prediction. ELAPS was employed within a concurrent engineering analysis process that simultaneously produces aerodynamic, structural, and static aeroelastic results for input to aircraft performance analyses. The ELAPS models produced for each concept were also used to provide stochastic analyses of wing structural mass properties. The results of this effort indicate that ELAPS is an efficient means to conduct multidisciplinary trade studies at the conceptual design level.

Sexstone, Matthew G.↗

A Sizing Methodology for the Conceptual Design of Blended-Wing-Body Transports

This paper describes the development of a methodology for sizing Blended-Wing-Body (BWB) transports and how the capabilities of the Flight Optimization System (FLOPS) have been expanded using that methodology. In this approach, BWB transports are sized based on the number of passengers in each class that must fit inside the centerbody or pressurized vessel. Weight estimation equations for this centerbody structure were developed using Finite Element Analysis (FEA). This paper shows how the sizing methodology has been incorporated into FLOPS to enable the design and analysis of BWB transports. Previous versions of FLOPS did not have the ability to accurately represent or analyze BWB configurations in any reliable, logical way. The expanded capabilities allow the design and analysis of a 200 to 450-passenger BWB transport or the analysis of a BWB transport for which the geometry is already known. The modifications to FLOPS resulted in differences of less than 4 percent for the ramp weight of a BWB transport in this range when compared to previous studies performed by NASA and Boeing.

Kimmel, William M.↗

Preform Characterization in VARTM Process Model Development

Vacuum-Assisted Resin Transfer Molding (VARTM) is a Liquid Composite Molding (LCM) process where both resin injection and fiber compaction are achieved under pressures of 101.3 kPa or less. Originally developed over a decade ago for marine composite fabrication, VARTM is now considered a viable process for the fabrication of aerospace composites (1,2). In order to optimize and further improve the process, a finite element analysis (FEA) process model is being developed to include the coupled phenomenon of resin flow, preform compaction and resin cure. The model input parameters are obtained from resin and fiber-preform characterization tests. In this study, the compaction behavior and the Darcy permeability of a commercially available carbon fabric are characterized. The resulting empirical model equations are input to the 3- Dimensional Infiltration, version 5 (3DINFILv.5) process model to simulate infiltration of a composite panel.

Grimsley, Brian W.↗

Unitized Regenerative Fuel Cell System Gas Dryer/Humidifier Analytical Model Development

A lightweight Unitized Regenerative Fuel Cell (URFC) Energy Storage System concept is being developed at the NASA Glenn Research Center (GRC). This Unitized Regenerative Fuel Cell System (URFCS) is unique in that it uses Regenerative Gas Dryers/Humidifiers (RGD/H) that are mounted on the surface of the gas storage tanks that act as the radiators for thermal control of the Unitized Regenerative Fuel Cell System (URFCS). As the gas storage tanks cool down during URFCS charging the RGD/H dry the hydrogen and oxygen gases produced by electrolysis. As the gas storage tanks heat up during URFCS discharging, the RGD/H humidify the hydrogen and oxygen gases used by the fuel cell. An analytical model was developed to simulate the URFCS RGD/H. The model is in the form of a Microsoft (registered trademark of Microsoft Corporation) Excel worksheet that allows the investigation of the RGD/H performance. Finite Element Analysis (FEA) modeling of the RGD/H and the gas storage tank wall was also done to analyze spatial temperature distribution within the RGD/H and the localized tank wall. Test results obtained from the testing of the RGD/H in a thermal vacuum environment were used to corroborate the analyses.

Burke, Kenneth A.↗

Durability and Design Issues of Thermal/environmental Barrier Coatings on Sic/sic Ceramic Matrix Composites Under 1650 C Test Conditions

Ceramic thermal/environmental barrier coatings for SiC-based ceramics will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. However, the coating durability remains a major concern with the ever-increasing temperature requirements. Currently, advanced T/EBC systems, which typically include a high temperature capable zirconia- (or hahia-) based oxide top coat (thermal barrier) on a less temperature capable mullite/barium-strontium-aluminosilicate (BSAS)/Si inner coat (environmental barrier), are being developed and tested for higher temperature capability Sic combustor applications. In this paper, durability of several thermal/environmental barrier coating systems on SiC/SiC ceramic matrix composites was investigated under laser simulated engine thermal gradient cyclic, and 1650 C (3000 F) test conditions. The coating cracking and delamination processes were monitored and evaluated. The effects of temperature gradients and coating configurations on the ceramic coating crack initiation and propagation were analyzed using finite element analysis (FEA) models based on the observed failure mechanisms, in conjunction with mechanical testing results. The environmental effects on the coating durability will be discussed. The coating design approach will also be presented.

Zhu, Dong-Ming↗

Unitized Regenerative Fuel Cell System Dryer-Humidifier Analytical Model Development

A Unitized Regenerative Fuel Cell (URFC) Energy Storage System is being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses regenerative gas dryers/humidifiers that are mounted on the surface of the gas storage tanks that act as the radiators for thermal control of the URFC system. As the gas storage tanks cool down during URFC charging the regenerative gas dryers/humidifiers dry the hydrogen and oxygen gases produced by electrolysis. As the gas storage tanks heat up during URFC discharging, the regenerative gas dryers/humidifiers humidify the hydrogen and oxygen gases used by fuel cell. An analytical model was developed to simulate the URFC system's regenerative gas dryers/humidifiers. The model is in the form of an EXCEL@ worksheet that allows the investigation of the regenerative gas dryers/humidifier performance as a function of time and position within the regenerative gas dryers/humidifiers, as well as other key system variables. Finite Element Analysis (FEA) modeling of the regenerative gas dryers/humidifier and gas storage tank wall was also done to analyze spatial temperature distribution within the regenerative gas dryers/humidifiers and the localized tank wall. Test results obtained from the testing of the regenerative gas dryers/humidifiers in a thermal vacuum environment were used to corroborate the analyses.

Burke, Kenneth A.↗

Structural Analysis and Test Comparison of a 20-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive test program was implemented to advance the technology readiness level of the solar sail design. These tests consisted of solar sail component, subsystem, and sub-scale system ground tests that simulated the aspects of the space environment such as vacuum and thermal conditions. In July 2005, a 20-m four-quadrant solar sail system test article was tested in the NASA Glenn Research Center s Space Power Facility to measure its static and dynamic structural responses. Key to the maturation of solar sail technology is the development of validated finite element analysis (FEA) models that can be used for design and analysis of solar sails. A major objective of the program was to utilize the test data to validate the FEA models simulating the solar sail ground tests. The FEA software, ABAQUS, was used to perform the structural analyses to simulate the ground tests performed on the 20-m solar sail test article. This paper presents the details of the FEA modeling, the structural analyses simulating the ground tests, and a comparison of the pretest and post-test analysis predictions with the ground test results for the 20-m solar sail system test article. The structural responses that are compared in the paper include load-deflection curves and natural frequencies for the beam structural assembly and static shape, natural frequencies, and mode shapes for the solar sail membrane. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were unmeasured initial conditions in the test set-up.

Sleight, David W.↗

Damage Tolerance Analysis of Space Shuttle External Tank Lug Fillet Welds Using NASGRO

The damage tolerance of the External Tank (ET) lug welds were reassessed because of an increase in the loads due to the removal of the protuberance air load (PAT.,) ramp. The analysis methods included detailed finite element analysis (FEA) of the ET welded lugs and FEA of the lug weld test configuration. The FEA results were used as input to the crack growth analysis code NASGRO to calculate the mission life capability of the ET lug welds and to predict the number of cycles to failure in the lug weld testing. The presentation presents the method of transferring the FEM results to the NASGRO model and gives correlations between FEM and NASGRO stress intensity calculations.

Allen, Phillip A.↗

Study of ripple formation in unidirectionally-tensioned membranes

The study of membrane behavior is one of the areas of interest in the development of ultralightweight and lightweight structures for space applications. Utilization of membranes as loadcarrying components or support structure for antenna patch-arrays, collectors, sun-shades and solar-sail reflective surfaces brings about a variety of challenges that require understanding of the ripple-formation phenomenology, development of reliable test and analysis techniques, and solution methods for challenges related to the intended applications. This paper presents interim results from a study on the behavior of unidirectionally tensioned flat and singly-curved membranes. It focuses on preliminary experimental work to explore formation of ripples' and on finite element analysis (FEA) to correlate and predict their formation on thin polyimide membrane models.

radar↗

Three-Dimensional Field Solutions for Multi-Pole Cylindrical Halbach Arrays in an Axial Orientation

This article presents three-dimensional B field solutions for the cylindrical Halbach array in an axial orientation. This arrangement has applications in the design of axial motors and passive axial magnetic bearings and couplers. The analytical model described here assumes ideal magnets with fixed and uniform magnetization. The field component functions are expressed as sums of 2-D definite integrals that are easily computed by a number of mathematical analysis software packages. The analysis is verified with sample calculations and the results are compared to equivalent results from traditional finite-element analysis (FEA). The field solutions are then approximated for use in flux linkage and induced EMF calculations in nearby stator windings by expressing the field variance with angular displacement as pure sinusoidal function whose amplitude depends on radial and axial position. The primary advantage of numerical implementation of the analytical approach presented in the article is that it lends itself more readily to parametric analysis and design tradeoffs than traditional FEA models.

Thompson, William K.↗