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At least 217 records · Page 12

Development of thermoplastic composite aircraft structures

Efforts focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. In support of these designs, mechanics developments were conducted in two areas. First, a dissipative strain energy approach to material characterization and failure prediction, developed at the Naval Research Laboratory, was evaluated as a design/analysis tool. Second, a finite element formulation for thick composites was developed and incorporated into a lug analysis method which incorporates pin bending effects. Manufacturing concepts were developed for an upper fuel cell cover. A detailed trade study produced two promising concepts: fiber placement and single-step diaphragm forming. Based on the innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldine concepts. Manufacturing techniques included autoclave consolidation, single diaphragm consolidation (SDCC) and roll-forming.

Renieri, Michael P.↗

Mechanical failure probability of glasses in Earth orbit

Results of five years of earth-orbital exposure on mechanical properties of glasses indicate that radiation effects on mechanical properties of glasses, for the glasses examined, are less than the probable error of measurement. During the 5 year exposure, seven micrometeorite or space debris impacts occurred on the samples examined. These impacts were located in locations which were not subjected to effective mechanical testing, hence limited information on their influence upon mechanical strength was obtained. Combination of these results with micrometeorite and space debris impact frequency obtained by other experiments permits estimates of the failure probability of glasses exposed to mechanical loading under earth-orbit conditions. This probabilistic failure prediction is described and illustrated with examples.

Kinser, Donald L.↗

Design, analysis, and testing of a metal matrix composite web/flange intersection

An experimental and analytical program to study the local design details of a typical T-shaped web/flange intersection made from a metal matrix composite is described. Loads creating flange bending were applied to specimens having different designs and boundary conditions. Finite element analyses were conducted on models of the test specimens to predict the structural response. The analyses correctly predict failure load, mode, and location in the fillet material in the intersection region of the web and the flange when specimen quality is good. The test program shows the importance of fabrication quality in the intersection region. The full-scale test program that led to the investigation of this local detail is also described.

Biggers, S. B.↗

Conversion-Integration of MSFC Nonlinear Signal Diagnostic Analysis Algorithms for Realtime Execution of MSFC's MPP Prototype System

NASA's advanced propulsion system Small Scale Magnetic Disturbances/Advanced Technology Development (SSME/ATD) has been undergoing extensive flight certification and developmental testing, which involves large numbers of health monitoring measurements. To enhance engine safety and reliability, detailed analysis and evaluation of the measurement signals are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce the risk of catastrophic system failures and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. During the development of SSME, ASRI participated in the research and development of several advanced non- linear signal diagnostic methods for health monitoring and failure prediction in turbomachinery components. However, due to the intensive computational requirement associated with such advanced analysis tasks, current SSME dynamic data analysis and diagnostic evaluation is performed off-line following flight or ground test with a typical diagnostic turnaround time of one to two days. The objective of MSFC's MPP Prototype System is to eliminate such 'diagnostic lag time' by achieving signal processing and analysis in real-time. Such an on-line diagnostic system can provide sufficient lead time to initiate corrective action and also to enable efficient scheduling of inspection, maintenance and repair activities. The major objective of this project was to convert and implement a number of advanced nonlinear diagnostic DSP algorithms in a format consistent with that required for integration into the Vanderbilt Multigraph Architecture (MGA) Model Based Programming environment. This effort will allow the real-time execution of these algorithms using the MSFC MPP Prototype System. ASRI has completed the software conversion and integration of a sequence of nonlinear signal analysis techniques specified in the SOW for real-time execution on MSFC's MPP Prototype. This report documents and summarizes the results of the contract tasks; provides the complete computer source code; including all FORTRAN/C Utilities; and all other utilities/supporting software libraries that are required for operation.

Jong, Jen-Yi↗

Structural Qualification of Composite Airframes

The development of fundamental approaches for predicting failure and elongation characteristics of fibrous composites are summarized in this document. The research described includes a statistical formulation for individual fiber breakage and fragmentation and clustered fiber breakage, termed macrodefects wherein the aligned composite may represent a structural component such as a reinforcing bar element, a rebar. Experimental work conducted in support of the future exploitation of aligned composite rebar elements is also described. This work discusses the experimental challenges associated with rebar tensile test evaluation and describes initial numerical analyses performed in support of the experimental program.

Kedward, Keith T.↗

Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

BMI Sandwich Wing Box Analysis and Test

A composite sandwich single bay wing box test article was developed by Northrop Grumman and tested recently at NASA Langley Research Center. The objectives for the wing box development effort were to provide a demonstration article for manufacturing scale up of structural concepts related to a high speed transport wing, and to validate the structural performance of the design. The box concept consisted of highly loaded composite sandwich wing skins, with moderately loaded composite sandwich spars. The dimensions of the box were chosen to represent a single bay of the main wing box, with a spar spacing of 30 inches, height of 20 inches constant depth, and length of 64 inches. The bismaleimide facesheet laminates and titanium honeycomb core chosen for this task are high temperature materials able to sustain a 300F service temperature. The completed test article is shown in Figure 1. The tests at NASA Langley demonstrated the structures ability to sustain axial tension and compression loads in excess of 20,000 lb/in, and to maintain integrity in the thermal environment. Test procedures, analysis failure predictions, and test results are presented.

Palm, Tod↗

Semi-Major Axis Knowledge and GPS Orbit Determination

In recent years spacecraft designers have increasingly sought to use onboard Global Positioning System receivers for orbit determination. The superb positioning accuracy of GPS has tended to focus more attention on the system's capability to determine the spacecraft's location at a particular epoch than on accurate orbit determination, per se. The determination of orbit plane orientation and orbit shape to acceptable levels is less challenging than the determination of orbital period or semi-major axis. It is necessary to address semi-major axis mission requirements and the GPS receiver capability for orbital maneuver targeting and other operations that require trajectory prediction. Failure to determine semi-major axis accurately can result in a solution that may not be usable for targeting the execution of orbit adjustment and rendezvous maneuvers. Simple formulas, charts, and rules of thumb relating position, velocity, and semi-major axis are useful in design and analysis of GPS receivers for near circular orbit operations, including rendezvous and formation flying missions. Space Shuttle flights of a number of different GPS receivers, including a mix of unfiltered and filtered solution data and Standard and Precise Positioning Service modes, have been accomplished. These results indicate that semi-major axis is often not determined very accurately, due to a poor velocity solution and a lack of proper filtering to provide good radial and speed error correlation.

Carpenter, J. Russell↗

Semi-Major Axis Knowledge and GPS Orbit Determination

In recent years spacecraft designers have increasingly sought to use onboard Global Positioning System receivers for orbit determination. The superb positioning accuracy of GPS has tended to focus more attention on the system's capability to determine the spacecraft's location at a particular epoch than on accurate orbit determination, per se. The determination of orbit plane orientation and orbit shape to acceptable levels is less challenging than the determination of orbital period or semi-major axis. It is necessary to address semi-major axis mission requirements and the GPS receiver capability for orbital maneuver targeting and other operations that require trajectory prediction. Failure to determine semi-major axis accurately can result in a solution that may not be usable for targeting the execution of orbit adjustment and rendezvous maneuvers. Simple formulas, charts, and rules of thumb relating position, velocity, and semi-major axis are useful in design and analysis of GPS receivers for near circular orbit operations, including rendezvous and formation flying missions. Space Shuttle flights of a number of different GPS receivers, including a mix of unfiltered and filtered solution data and Standard and Precise Positioning, Service modes, have been accomplished. These results indicate that semi-major axis is often not determined very accurately, due to a poor velocity solution and a lack of proper filtering to provide good radial and speed error correlation.

Carpenter, J. Russell↗

End-to-End Demonstrator of the Safe Affordable Fission Engine (SAFE) 30: Power Conversion and Ion Engine Operation

The Safe Affordable Fission Engine (SAFE) test series addresses Phase 1 Space Fission Systems issues in particular non-nuclear testing and system integration issues leading to the testing and non-nuclear demonstration of a 400-kW fully integrated flight unit. The first part of the SAFE 30 test series demonstrated operation of the simulated nuclear core and heat pipe system. Experimental data acquired in a number of different test scenarios will validate existing computational models, demonstrated system flexibility (fast start-ups, multiple start-ups/shut downs), simulate predictable failure modes and operating environments. The objective of the second part is to demonstrate an integrated propulsion system consisting of a core, conversion system and a thruster where the system converts thermal heat into jet power. This end-to-end system demonstration sets a precedent for ground testing of nuclear electric propulsion systems. The paper describes the SAFE 30 end-to-end system demonstration and its subsystems.

Hrbud, Ivana↗

An End-To-End Test of A Simulated Nuclear Electric Propulsion System

The Safe Affordable Fission Engine (SAFE) test series addresses Phase I Space Fission Systems issues in it particular non-nuclear testing and system integration issues leading to the testing and non-nuclear demonstration of a 400-kW fully integrated flight unit. The first part of the SAFE 30 test series demonstrated operation of the simulated nuclear core and heat pipe system. Experimental data acquired in a number of different test scenarios will validate existing computational models, demonstrated system flexibility (fast start-ups, multiple start-ups/shut downs), simulate predictable failure modes and operating environments. The objective of the second part is to demonstrate an integrated propulsion system consisting of a core, conversion system and a thruster where the system converts thermal heat into jet power. This end-to-end system demonstration sets a precedent for ground testing of nuclear electric propulsion systems. The paper describes the SAFE 30 end-to-end system demonstration and its subsystems.

VanDyke, Melissa↗

New Directions in Space Operations Services in Support of Interplanetary Exploration

To gain access to the necessary operational processes and data in support of NASA's Lunar/Mars Exploration Initiative, new services, adequate levels of computing cycles and access to myriad forms of data must be provided to onboard spacecraft and ground based personnel/systems (earth, lunar and Martian) to enable interplanetary exploration by humans. These systems, cycles and access to vast amounts of development, test and operational data will be required to provide a new level of services not currently available to existing spacecraft, on board crews and other operational personnel. Although current voice, video and data systems in support of current space based operations has been adequate, new highly reliable and autonomous processes and services will be necessary for future space exploration activities. These services will range from the more mundane voice in LEO to voice in interplanetary travel which because of the high latencies will require new voice processes and standards. New services, like component failure predictions based on data mining of significant quantities of data, located at disparate locations, will be required. 3D or holographic representation of onboard components, systems or family members will greatly improve maintenance, operations and service restoration not to mention crew morale. Current operational systems and standards, like the Internet Protocol, will not able to provide the level of service required end to end from an end point on the Martian surface like a scientific instrument to a researcher at a university. Ground operations whether earth, lunar or Martian and in flight operations to the moon and especially to Mars will require significant autonomy that will require access to highly reliable processing capabilities, data storage based on network storage technologies. Significant processing cycles will be needed onboard but could be borrowed from other locations either ground based or onboard other spacecraft. Reliability will be a key factor with onboard and distributed backup processing an absolutely necessary requirement. Current cluster processing/Grid technologies may provide the basis for providing these services. An overview of existing services, future services that will be required and the technologies and standards required to be developed will be presented. The purpose of this paper will be to initiate a technological roadmap, albeit at a high level, of current voice, video, data and network technologies and standards (which show promise for adaptation or evolution) to what technologies and standards need to be redefined, adjusted or areas where new ones require development. The roadmap should begin the differentiation between non manned and manned processes/services where applicable. The paper will be based in part on the activities of the CCSDS Monitor and Control working group which is beginning the process of standardization of the these processes. Another element of the paper will be based on an analysis of current technologies supporting space flight processes and services at JSC, MSFC, GSFC and to a lesser extent at KSC. Work being accomplished in areas such as Grid computing, data mining and network storage at ARC, IBM and the University of Alabama at Huntsville will be researched and analyzed.

Bradford, Robert N.↗

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗

Hybrid Bearing Prognostic Test Rig

The NASA Glenn Research Center has developed a new Hybrid Bearing Prognostic Test Rig to evaluate the performance of sensors and algorithms in predicting failures of rolling element bearings for aeronautics and space applications. The failure progression of both conventional and hybrid (ceramic rolling elements, metal races) bearings can be tested from fault initiation to total failure. The effects of different lubricants on bearing life can also be evaluated. Test conditions monitored and recorded during the test include load, oil temperature, vibration, and oil debris. New diagnostic research instrumentation will also be evaluated for hybrid bearing damage detection. This paper summarizes the capabilities of this new test rig.

Dempsey, Paula J.↗

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗

Application of Video Image Correlation Techniques to the Space Shuttle External Tank Foam Materials

Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.

Hilburger, Mark W.↗

Using ABAQUS Scripting Interface for Materials Evaluation and Life Prediction

An ABAQUS script has been written to aid in the evaluation of the mechanical behavior of viscoplastic materials. The purposes of the script are to: handle complex load histories; control load/displacement with alternate stopping criteria; predict failure and life; and verify constitutive models. Material models from the ABAQUS library may be used or the UMAT routine may specify mechanical behavior. User subroutines implemented include: UMAT for the constitutive model; UEXTERNALDB for file manipulation; DISP for boundary conditions; and URDFIL for results processing. Examples presented include load, strain and displacement control tests on a single element model. The tests are creep with a life limiting strain criterion, strain control with a stress limiting cycle and a complex interrupted cyclic relaxation test. The techniques implemented in this paper enable complex load conditions to be solved efficiently with ABAQUS.

Powers, Lynn M.↗

Valve Health Monitoring System Utilizing Smart Instrumentation

The valve monitoring system is a stand alone unit with network capabilities for integration into a higher level health management system. The system is designed for aiding in failure predictions of high-geared ball valves and linearly actuated valves. It performs data tracking and archiving for identifying degraded performance. The data collection types are cryogenic cycles, total cycles, inlet temperature, body temperature torsional strain, linear bonnet strain, preload position, total travel and total directional changes. Events are recorded and time stamped in accordance with the IRIG B True Time. The monitoring system is designed for use in a Class 1 Division II explosive environment. The basic configuration consists of several instrumentation sensor units and a base station. The sensor units are self contained microprocessor controlled and remotely mountable in three by three by two inches. Each unit is potted in a fire retardant substance without any cavities and limited to low operating power for maintaining safe operation in a hydrogen environment. The units are temperature monitored to safeguard against operation outside temperature limitations. Each contains 902-928 MHz band digital transmitters which meet Federal Communication Commission's requirements and are limited to a 35 foot transmission radius for preserving data security. The base-station controller correlates data from the sensor units and generates data event logs on a compact flash memory module for database uploading. The entries are also broadcast over an Ethernet network. Nitrogen purged National Electrical Manufactures Association (NEMA) Class 4 enclosures are used to house the base-station

Jensen, Scott L.↗