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NASA NTRS1998

An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials

Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Pronchick, Stephen W.↗

NASA NTRS2015

Aerodynamic Load Analysis of a Variable Camber Continuous Trailing Edge Flap System on a Flexible Wing Aircraft

This paper presents an investigative aerodynamic analysis conducted on the novel control surface known as a Variable Camber Continuous Trailing Edge Flap (VCCTEF). The VCCTEF is modeled as a control effector on the NASA Generic Transport Model (GTM) where wing flexibility is considered. Aerodynamic modeling of the aircraft is conducted using vortex-lattice method (VLM), and an aeroelastic model of the aircraft that utilizes a coupled finite-element analysis (FEA) vortex-lattice solution is employed. VLM solutions are used to determine quasi-steady aerodynamic loading over the aeroelastic wing structures with VCCTEF. The load data is used to calculate aerodynamic sensitivities to control surface deployment and is also integrated to determine overall hinge moments. This analysis is conducted for different flight conditions, where control sensitivities compare the VCCTEF effectiveness against conventional control surfaces. Hinge moment results provide insight into aeroelastic wing loads, and worst case hinge moments for the VCCTEF can be estimated. Results show that the VCCTEF offers greater control authority than conventional ailerons at cruise, and nominal flap settings are determined for a low-speed take-off condition where the VCCTEF maintains comparable control effectiveness. Worst case hinge moment values are presented, where for a possible VCCTEF configuration, the stiff wing model demonstrates up to a 5.90 percent increase in flap hinge moment relative to a rigid model, and a reduced stiffness model demonstrates up to an 11.42 percent increase.

Aeroelasticity↗

NASA NTRSDate not supplied

TPSAS-NF1676L-26160-DND

The structural performance of two advanced composite tow-steered shells is assessed using experiments and analyses. The fiber angles vary continuously around the shell circumference, and one shell has all 24 tows applied during fabrication, while the second shell uses the fiber placement systems tow drop/add capability to achieve a uniform wall thickness. The shells are tested in compression, and their axial stiffnesses and buckling loads are estimated using linear finite element analyses. Scaled passenger and cargo door cutouts are machined into one side of each shell. Axial stiffnesses and buckling loads of the shells with cutouts are computed using linear finite element analyses. The retested shells carry over 90 percent of the axial stiffness, and 85 percent of the buckling loads, of the shells without cutouts. These small reductions demonstrate the potential of tow steering to mitigate adverse effects of cutouts on the structural performance. The good correlation between experimental buckling loads and linear buckling analyses noted here may result from their circumferential stiffness variation, reducing geometric imperfection sensitivity. Analysis models of both shells were evaluated without and with measured geometric imperfections superposed in different longitudinal orientations. Small variations in prebuckling stiffness and buckling load of the shells are observed.

K C Wu↗

NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

The objectives were to create a capability to simulate curvilinear crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage and to validate with tests. Analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically, while insuring continuous airworthiness, and to design more damage-tolerant aircraft for the next generation. Simulations of crack growth in fuselages were described. The crack tip opening angle (CTOA) fracture criterion, obtained from laboratory tests, was used to predict fracture behavior of fuselage panel tests. Geometrically nonlinear, elastic-plastic, thin shell finite element crack growth analyses were conducted. Comparisons of stress distributions, multiple stable crack growth history, and residual strength between measured and predicted results were made to assess the validity of the methodology. Incorporation of residual plastic deformations and tear strap failure was essential for accurate residual strength predictions. Issue related to predicting crack trajectory in fuselages were also discussed. A directional criterion, including T-stress and fracture toughness orthotropy, was developed. Curvilinear crack growth was simulated in coupon and fuselage panel tests. Both T-stress and fracture toughness orthotropy were essential to predict the observed crack paths. Flapping of fuselages were predicted. Measured and predicted results agreed reasonable well.

Chen, Chuin-Shan↗

NASA NTRS2011

Prognostics of Power Mosfets Under Thermal Stress Accelerated Aging Using Data-Driven and Model-Based Methodologies

An approach for predicting remaining useful life of power MOSFETs (metal oxide field effect transistor) devices has been developed. Power MOSFETs are semiconductor switching devices that are instrumental in electronics equipment such as those used in operation and control of modern aircraft and spacecraft. The MOSFETs examined here were aged under thermal overstress in a controlled experiment and continuous performance degradation data were collected from the accelerated aging experiment. Dieattach degradation was determined to be the primary failure mode. The collected run-to-failure data were analyzed and it was revealed that ON-state resistance increased as die-attach degraded under high thermal stresses. Results from finite element simulation analysis support the observations from the experimental data. Data-driven and model based prognostics algorithms were investigated where ON-state resistance was used as the primary precursor of failure feature. A Gaussian process regression algorithm was explored as an example for a data-driven technique and an extended Kalman filter and a particle filter were used as examples for model-based techniques. Both methods were able to provide valid results. Prognostic performance metrics were employed to evaluate and compare the algorithms.

Electrolytic capacitors↗

NASA NTRS2017

Near Real-Time Probabilistic Damage Diagnosis Using Surrogate Modeling and High Performance Computing

This work investigates novel approaches to probabilistic damage diagnosis that utilize surrogate modeling and high performance computing (HPC) to achieve substantial computational speedup. Motivated by Digital Twin, a structural health management (SHM) paradigm that integrates vehicle-specific characteristics with continual in-situ damage diagnosis and prognosis, the methods studied herein yield near real-time damage assessments that could enable monitoring of a vehicle's health while it is operating (i.e. online SHM). High-fidelity modeling and uncertainty quantification (UQ), both critical to Digital Twin, are incorporated using finite element method simulations and Bayesian inference, respectively. The crux of the proposed Bayesian diagnosis methods, however, is the reformulation of the numerical sampling algorithms (e.g. Markov chain Monte Carlo) used to generate the resulting probabilistic damage estimates. To this end, three distinct methods are demonstrated for rapid sampling that utilize surrogate modeling and exploit various degrees of parallelism for leveraging HPC. The accuracy and computational efficiency of the methods are compared on the problem of strain-based crack identification in thin plates. While each approach has inherent problem-specific strengths and weaknesses, all approaches are shown to provide accurate probabilistic damage diagnoses and several orders of magnitude computational speedup relative to a baseline Bayesian diagnosis implementation.

Warner, James E.↗

NASA NTRS2004

Design Analysis and Thermo-Mechanical Fatigue of a Polyimide Composite for Combustion Chamber Support

Polyimide composites are being evaluated for use in lightweight support structures designed to preserve the ideal flow geometry within thin shell combustion chambers of future space launch propulsion systems. Principles of lightweight design and innovative manufacturing techniques have yielded a sandwich structure with an outer face sheet of carbon fiber polyimide matrix composite. While the continuous carbon fiber enables laminated skin of high specific stiffness; the polyimide matrix materials ensure that the rigidity and durability is maintained at operation temperatures of 316 C. Significant weight savings over all metal support structures are expected. The protypical structure is the result of ongoing collaboration, between Boeing and NASA-GRC seeking to introduce polyimide composites to the harsh environmental and loads familiar to space launch propulsion systems. Design trade analyses were carried out using relevant closed form solutions, approximations for sandwich beams/panels and finite element analysis. Analyses confirm the significant thermal stresses exist when combining materials whose coefficients of thermal expansion (CTEs) differ by a factor of about 10 for materials such as a polymer composite and metallic structures. The ramifications on design and manufacturing alternatives are reviewed and discussed. Due to stringent durability and safety requirements, serious consideration is being given to the synergistic effects of temperature and mechanical loads. The candidate structure operates at 316 C, about 80% of the glass transition temperature T(sub g). Earlier thermomechanical fatigue (TMF) investigations of chopped fiber polyimide composites made this near to T(sub g), showed that cyclic temperature and stress promoted excessive creep damage and strain accumulation. Here it is important to verify that such response is limited in continuous fiber laminates.

Thesken, J. C.↗

NASA NTRS1988

Local-global analysis of crack growth in continuously reinforced ceramic matrix composites

The development is described of a mathematical model for predicting the strength and micromechanical failure characteristics of continuously reinforced ceramic matrix composites. The local-globe analysis models the vicinity of a propagating crack tip as a local heterogeneous region (LHR) consisting of spring like representation of the matrix, fibers and interfaces. This region is embedded in an anisotropic continuum (representing the bulk composite) which is modeled by conventional finite elements. Parametric studies are conducted to investigate the effects of LHR size, component properties, interface conditions, etc. on the strength and sequence of the failure processes in the unidirectional composite system. The results are compared with those predicted by the models developed by Marshall et al. (1985) and by Budiansky et al. (1986).

Ballarini, Roberto↗

NASA NTRS1993

Patterns of deformation and volcanic flows associated with lithospheric loading by large volcanoes on Venus

Magellan radar imaging and topography data are now available for a number of volcanoes on Venus greater than 100 km in radius. These data can be examined to reveal evidence of the flexural response of the lithosphere to the volcanic load. On Venus, erosion and sediment deposition are negligible, so tectonic evidence of deformation around large volcanoes should be evident except where buried by very young flows. Radar images reveal that most tectonic features and flow units on the flanks of these volcanoes have predominantly radial orientations. However, both Tepev Mons in Bell Regio and Sapas Mons in Atla Regio exhibit circumferential graben on their flanks. In addition, images reveal several flow units with an annular character around the north and west flanks of Tepev Mons. This pattern most likely results from ponding of flows in an annular flexural moat. Maat Mons in Atla Regio and Sif Mons in Eistla Regio are examples of volcanoes that lack circumferential graben and annular flows; discernible flow units and fractures on these constructs appear to be predominantly radial. Altimetry data can also provide evidence of flexural response. Tepev Mons is partially encircled by depressions that may be sections of a flexural moat that has not been completely filled. The locations of these depressions generally coincide with the annular flows described above. There is weaker evidence for such depressions around Maat Mons as well. The lack of circumferential tectonic features around most volcanoes on Venus might be explained by gradual moat filling and coverage by radial flows. The depressions around Tepev (and possible Maat) may indicate that this process is currently continuing. We use analytic models of plate flexure in an axisymmetric geometry to constrain the elastic plate thickness supporting Tepev Mons. If we consider the outer radius of the ponded flows to be the edge of a moat, we find that models with elastic plate thickness of 10-20 km fit best. Finite element models of a volcanic load detached from the underlying lithosphere predict overthrusting and radial normal faulting at the volcano's edge. Such a mechanism for the formation of radial rift zones on Venus volcanoes would make such features analogous to structures on the flanks of volcanoes on Earth.

Mcgovern, Patrick J.↗

NASA NTRS1975

Program design by a multidisciplinary team

The use of software engineering aids in the design of a structural finite-element analysis computer program for the STAR-100 computer is described. Nested functional diagrams to aid in communication among design team members were used, and a standardized specification format to describe modules designed by various members was adopted. This is a report of current work in which use of the functional diagrams provided continuity and helped resolve some of the problems arising in this long-running part-time project.

Voigt, S.↗

NASA NTRS1987

Finite element methods of analysis for high speed viscous flows

Over the past three years a finite element based procedure for the solution of high speed viscous compressible flows was developed. The approach followed was to compute steady state solutions via a false transient, using an explicit time stepping scheme, and to attempt to improve the solution quality by incorporating adaptive mesh procedures. The main thrust of the work was to continue on the extension of the approach to the solution of some realistic compressible viscous flows. When flows at high Reynolds number are investigated, is soon becomes apparent that explicit techniwues have to be supplemented if they are to deal effectively with the large variations in element size and aspect ratio which characterize the computational grids necessary for adequate resolutin of the primary flow features. For this reason, the Taylor-Galerkin solution algorithm was rewritten in an explicit/implicit form. Solutions were computed for the problems of a flow past a flat plate, M-3, Re-100; shock/boundary layer interaction, M-2, Re-296000; flow over a compression corner, M-11.68, Re246000; and unifrom flow past a circular cylinder, M-6.34, Re-39770. A summary of the results is included and demonstrates the numerical performance of the scheme.

Source record↗

NASA NTRS1996

Baseline acoustic levels of the NASA Active Noise Control Fan rig

Extensive measurements of the spinning acoustic mode structure in the NASA 48 inch Active Noise Control Fan (ANCF) test rig have been taken. A continuously rotating microphone rake system with a least-squares data reduction technique was employed to measure these modes in the inlet and exhaust. Farfield directivity patterns in an anechoic environment were also measured at matched corrected rotor speeds. Several vane counts and spacings were tested over a range of rotor speeds. The Eversman finite element radiation code was run with the measured in-duct modes as input and the computed farfield results were compared to the experimentally measured directivity pattern. The experimental data show that inlet spinning mode measurements can be made very accurately. Exhaust mode measurements may have wake interference, but the least-squares reduction does a good job of rejecting the non-acoustic pressure. The Eversman radiation code accurately extrapolates the farfield levels and directivity pattern when all in-duct modes are included.

Sutliff, Daniel L.↗

NASA NTRS2001

Entropy generation method to quantify thermal comfort

The present paper presents a thermodynamic approach to assess the quality of human-thermal environment interaction and quantify thermal comfort. The approach involves development of entropy generation term by applying second law of thermodynamics to the combined human-environment system. The entropy generation term combines both human thermal physiological responses and thermal environmental variables to provide an objective measure of thermal comfort. The original concepts and definitions form the basis for establishing the mathematical relationship between thermal comfort and entropy generation term. As a result of logic and deterministic approach, an Objective Thermal Comfort Index (OTCI) is defined and established as a function of entropy generation. In order to verify the entropy-based thermal comfort model, human thermal physiological responses due to changes in ambient conditions are simulated using a well established and validated human thermal model developed at the Institute of Environmental Research of Kansas State University (KSU). The finite element based KSU human thermal computer model is being utilized as a "Computational Environmental Chamber" to conduct series of simulations to examine the human thermal responses to different environmental conditions. The output from the simulation, which include human thermal responses and input data consisting of environmental conditions are fed into the thermal comfort model. Continuous monitoring of thermal comfort in comfortable and extreme environmental conditions is demonstrated. The Objective Thermal Comfort values obtained from the entropy-based model are validated against regression based Predicted Mean Vote (PMV) values. Using the corresponding air temperatures and vapor pressures that were used in the computer simulation in the regression equation generates the PMV values. The preliminary results indicate that the OTCI and PMV values correlate well under ideal conditions. However, an experimental study is needed in the future to fully establish the validity of the OTCI formula and the model. One of the practical applications of this index is that could it be integrated in thermal control systems to develop human-centered environmental control systems for potential use in aircraft, mass transit vehicles, intelligent building systems, and space vehicles.

Models, Biological↗

NASA NTRS2003

NASA Tech Briefs, October 2003

Topics covered include: Cryogenic Temperature-Gradient Foam/Substrate Tensile Tester; Flight Test of an Intelligent Flight-Control System; Slat Heater Boxes for Thermal Vacuum Testing; System for Testing Thermal Insulation of Pipes; Electrical-Impedance-Based Ice-Thickness Gauges; Simulation System for Training in Laparoscopic Surgery; Flasher Powered by Photovoltaic Cells and Ultracapacitors; Improved Autoassociative Neural Networks; Toroidal-Core Microinductors Biased by Permanent Magnets; Using Correlated Photons to Suppress Background Noise; Atmospheric-Fade-Tolerant Tracking and Pointing in Wireless Optical Communication; Curved Focal-Plane Arrays Using Back-Illuminated High-Purity Photodetectors; Software for Displaying Data from Planetary Rovers; Software for Refining or Coarsening Computational Grids; Software for Diagnosis of Multiple Coordinated Spacecraft; Software Helps Retrieve Information Relevant to the User; Software for Simulating a Complex Robot; Software for Planning Scientific Activities on Mars; Software for Training in Pre-College Mathematics; Switching and Rectification in Carbon-Nanotube Junctions; Scandia-and-Yttria-Stabilized Zirconia for Thermal Barriers; Environmentally Safer, Less Toxic Fire-Extinguishing Agents; Multiaxial Temperature- and Time-Dependent Failure Model; Cloverleaf Vibratory Microgyroscope with Integrated Post; Single-Vector Calibration of Wind-Tunnel Force Balances; Microgyroscope with Vibrating Post as Rotation Transducer; Continuous Tuning and Calibration of Vibratory Gyroscopes; Compact, Pneumatically Actuated Filter Shuttle; Improved Bearingless Switched-Reluctance Motor; Fluorescent Quantum Dots for Biological Labeling; Growing Three-Dimensional Corneal Tissue in a Bioreactor; Scanning Tunneling Optical Resonance Microscopy; The Micro-Arcsecond Metrology Testbed; Detecting Moving Targets by Use of Soliton Resonances; and Finite-Element Methods for Real-Time Simulation of Surgery.

Source record↗

NASA NTRS2011

Comprehensive Forced Response Analysis of J2X Turbine Bladed-Discs with 36- Degree Variation in CFD Loading

At NASA/MSFC, Structural Dynamics personnel continue to perform advanced analysis for the turbomachinery in the J2X Rocket Engine, which is under consideration for the new Space Launch System. One of the most challenging analyses in the program is predicting turbine blade structural capability. Resonance was predicted by modal analysis, so comprehensive forced response analyses using high fidelity cyclic symmetric finite element models were initiated as required. Analysis methodologies up to this point have assumed the flow field could be fully described by a sector, so the loading on every blade would be identical as it travelled through it. However, in the J2X the CFD flow field varied over the 360 deg of a revolution because of the flow speeds and tortuous axial path. MSFC therefore developed a complex procedure using Nastran Dmap's and Matlab scripts to apply this circumferentially varying loading onto the cyclically symmetric structural models to produce accurate dynamic stresses for every blade on the disk. This procedure is coupled with static, spin, and thermal loading to produce high cycle fatigue safety factors resulting in much more accurate analytical assessments of the blades.

Elrod, David↗

NASA NTRS1985

Prediction of Acoustical Response of Three-dimensional Cavities Using an Indirect Boundary Element Method

A technique which characterizes the acoustics of generalized cavities with the minimum model possible is developed. All boundary element methods have two advantages over finite element methods: (1) the models are smaller; and (2) the assumed variable behavior, inherent in the method to allow discretization, is harmonic rather than polynomial. Further, IBEM often requires one rather than two numerical boundary integrals as required by DBEM. Thus, a quadratic, isoparametric IBEM program was developed. The source distribution in this solution is continuous and quadratically variable rather than continuous and constant. The program was also formulated to include the additional capability of interior point sources and impedance boundary conditions. To test the quadratic, isoparametric IBEM program, several simple cavity enclosure problems where studied. Results are shown.

Bernhard, R. J.↗

NASA NTRS1999

Cryotank Skin/Stringer Bondline Analysis

The need for light weight structure for advanced launch systems have presented great challenges and led to the usage of composites materials in a variety of structural assemblies where joining of two or more components is imperative. Although joints can be mechanically bolted, adhesive bonding has always been a very desirable method for joining the composite components, particularly for the cryotank systems, to achieve maximum structural efficiency. This paper presents the analytical approach resulted from the conceptual development of the DC-Y composite cryotank, conducted under the NASA/Boeing NRA 8-12 Partnership, to support the continued progress of SSTO (Single-Stage-To-Orbit) concepts. One of the critical areas of design was identified as the bonded interface between the skin (tank wall) and stringer. The approach to analyze this critical area will be illustrated through the steps which were used to evaluate the structural integrity of the bondline. Detailed finite element models were developed and numerous coupon test data were also gathered as part of the approach. Future plan is to incorporate this approach as a building block in analyzing bondline for the cryotank systems of RLVs (Reusable Launch Vehicles).

Nguyen, Bao↗

NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗