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The use of a low density, polyurethane based foam to suppress a fire and to provide protection for the structure of an aircraft or spacecraft is discussed. The mechanism by which foams provide protection from heat and create a nonflammable surface is described. Various materials and their application to specific types of structures are examined.
A technology review and assessment of modeling and analysis efforts underway in support of a safe return to flight of the thermal protection system (TPS) for the Space Shuttle external tank (ET) are summarized. This review and assessment effort focuses on the structural modeling and analysis practices employed for ET TPS foam design and analysis and on identifying analysis capabilities needed in the short-term and long-term. The current understanding of the relationship between complex flight environments and ET TPS foam failure modes are reviewed as they relate to modeling and analysis. A literature review on modeling and analysis of TPS foam material systems is also presented. Finally, a review of modeling and analysis tools employed in the Space Shuttle Program is presented for the ET TPS acreage and close-out foam regions. This review includes existing simplified engineering analysis tools are well as finite element analysis procedures.
A technology review and assessment of modeling and analysis efforts underway in support of a safe return to flight of the thermal protection system (TPS) for the Space Shuttle external tank (ET) are summarized. This review and assessment effort focuses on the structural modeling and analysis practices employed for ET TPS foam design and analysis and on identifying analysis capabilities needed in the short-term and long-term. The current understanding of the relationship between complex flight environments and ET TPS foam failure modes are reviewed as they relate to modeling and analysis. A literature review on modeling and analysis of TPS foam material systems is also presented. Finally, a review of modeling and analysis tools employed in the Space Shuttle Program is presented for the ET TPS acreage and close-out foam regions. This review includes existing simplified engineering analysis tools are well as finite element analysis procedures.
Design of lightweight structures and thermal protection systems for hypersonic vehicles depend on accurate prediction of aerothermal loads, structural temperatures and their gradients, and structural deformations and stresses. Concentration is on an alternative meshing technique which generates an entirely new adaptive unstructured mesh based on the solution obtained from the earlier mesh. The technique combined with the finite element method has been shown to significantly improve the efficiency and accuracy of the fluid, thermal, and structural analyses. Current capability of the adaptive unstructured meshing technique for the integrated fluid-thermal-structural analysis is described first. The technique was extended to transient thermal analysis of structures with time-dependent adaptive meshing to capture the detailed temperature response with a minimum number of unknowns and computational cost. Both linear and higher-order finite elements are implemented to demonstrate the generality of the technique and to investigate their solution accuracy. Currently, the adaptive meshing technique is being developed for plane structures that can be modeled with membrane elements and built-up structures modeled with membrane and bending elements. The capability of the technique to these different disciplinary problems is demonstrated by several examples.
The Survivable, Affordable, Reparable Airframe Program (SARAP) will develop/produce new structural design concepts with lower structural weight, reduced manufacturing complexity and development time, increased readiness, and improved threat protection. These new structural concepts will require advanced field capable inspection technologies to help meet the SARAP structural objectives. In the area of repair, damage assessment using nondestructive inspection (NDI) is critical to identify repair location and size. The purpose of this work is to conduct an assessment of new and emerging NDI methods that can potentially satisfy the SARAP program goals.
The interplay between matter particles and gauge fields in physical spaces with nontrivial geometries can lead to novel topological quantum matter. However, detailed microscopic mechanisms are often obscure, and unconventional spaces are generally challenging to construct in solids. Highly controllable atomic systems can quantum simulate such physics, even those inaccessible in other platforms. Here, we realize a Bose-Einstein condensate (BEC) on a synthetic cylindrical surface subject to a net radial synthetic magnetic flux. We observe a symmetry-protected topological band structure emerging on this Hall cylinder but disappearing in the planar counterpart. BEC’s transport observed as Bloch oscillations in the band structure is analogous to traveling on a Möbius strip in the momentum space, revealing topological band crossings protected by a nonsymmorphic symmetry. We demonstrate that breaking this symmetry induces a topological transition manifested as gap opening at band crossings, and further manipulate the band structure and BEC’s transport by controlling the axial synthetic magnetic flux. Our work opens the door for using atomic quantum simulators to explore intriguing topological phenomena intrinsic in unconventional spaces.
An existing liquid engine test stand at the AF Astronautics Laboratory was refurbished and extensively modified to accommodate the static firing of the Titan 34D solid rocket motor (SRM) in the vertical nozzle down orientation. The main load restraint structure was designed and built to secure the SRM from lifting off during the firing. In addition, the structure provided weather protection, temperature conditioning of the SRM, and positioning of the measurement and recording equipment. The structure was also used for stacking/de-stacking of SRM segments and other technological processes. The existing stand, its foundation and anchorage were thoroughly examined and reanalyzed. Necessary stand modifications were carried out to comply with the requirements of the Titan 34D SRM static firing.
Oxygen-barrier coating for titanium developed to provide effective and low-cost means for protecting titanium alloys from oxygen in environment when alloys used in high-temperature mechanical or structural applications. Provides protective surface layer, which reduces extent of surface oxidation of alloy and forms barrier to diffusion of oxygen, limiting contamination of substrate alloy by oxygen. Consists of submicron layer of aluminum deposited on surface of titanium by electron-beam evaporation, with submicron layer of dioxide sputtered onto aluminum to form coat.
Metallic material systems play a key role in meeting the stringent weight and durability requirements for reusable launch vehicle (RLV) airframe hot structures. Gamma titanium aluminides (gamma-TiAl) have been identified as high-payoff materials for high-temperature applications. The low density and good elevated temperature mechanical properties of gamma-TiAl alloys make them attractive candidates for durable lightweight hot structure and thermal protection systems at temperatures as high as 871 C. However, oxidation significantly degrades gamma-TiAl alloys under the high-temperature service conditions associated with the RLV operating environment. This paper discusses ongoing efforts at NASA Langley Research Center to develop durable ultrathin coatings for protecting gamma-TiAl alloys from high-temperature oxidation environments. In addition to offering oxidation protection, these multifunctional coatings are being engineered to provide thermal control features to help minimize heat input into the hot structures. This paper describes the coating development effort and discusses the effects of long-term high-temperature exposures on the microstructure of coated and uncoated gamma-TiAl alloys. The alloy of primary consideration was the Plansee alloy gamma-Met, but limited studies of the newer alloy gamma-Met-PX were also included. The oxidation behavior of the uncoated materials was evaluated over the temperature range of 704 C to 871 C. Sol-gel-based coatings were applied to the gamma-TiAl samples by dipping and spraying, and the performance evaluated at 871 C. Results showed that the coatings improve the oxidation resistance, but that further development is necessary.
The materials, production processes, testing procedures, and repair techniques for composite structures on the Orbiter are reviewed. The Orbiter currently features graphite/epoxy payload bay doors, as well as graphite/polyimide elevons, vertical tail, and aft body flap, which can withstand up to 600 F temperatures. Graphite/polyimide is also being considered for areas of the baseline aluminum structure and the thermal protection system in order to achieve a 20-30% weight reduction, i.e., over 7.5 tons. An analysis of the allowable stresses on FRC imide thermal protection system tiles bonded directly to the structure has shown satisfactory performances in high temperature and cryogenic conditions, although failure modes are yet to be determined. Ultrasonic emissions have been used for defect detection in nondestructive evaluations, together with tension, notch, shear, and compression tests. Field repairs have not been perfected, and require the evolution of high temperature adhesives that are curable under vacuum pressure and heat blankets.
The design of Space Station Freedom's external structure must not only protect the spacecraft from the hazardous environment, but also must be compatible with the extra vehicular activity system for assembly and maintenance. The external procedures for module support are utility connections, external orbital replaceable unit changeout, and maintenance of the meteoroid/debris shields and multilayer insulation. All of these interfaces require proper man-machine engineering to be compatible with the extra vehicular activity and manipulator systems. This paper discusses design solutions, including those provided for human interface, to the Space Station Freedom meteoroid/debris protection system. The system advantages and current access capabilities are illustrated through analysis of its configuration over the Space Station Freedom resource nodes and common modules, with emphasis on the cylindrical sections and endcones.
Flexible multi-shock shield system and method are disclosed for defending against hypervelocity particles. The flexible multi-shock shield system and method may include a number of flexible bumpers or shield layers spaced apart by one or more resilient support layers, all of which may be encapsulated in a protective cover. Fasteners associated with the protective cover allow the flexible multi-shock shield to be secured to the surface of a structure to be protected.
Using the striking distance theory that lightning leaders will strike the nearest grounded point on their last jump to earth corresponding to the striking distance, the probability of striking a point on a structure in the presence of other points can be estimated. The lightning strokes are divided into deciles having an average peak current and striking distance. The striking distances are used as radii from the points to generate windows of approach through which the leader must pass to reach a designated point. The projections of the windows on a horizontal plane as they are rotated through all possible angles of approach define an area that can be multiplied by the decile stroke density to arrive at the probability of strokes with the window average striking distance. The sum of all decile probabilities gives the cumulative probability for all strokes. The techniques can be applied to NASA-Kennedy launch pad structures to estimate the lightning protection effectiveness for the crane, gaseous oxygen vent arm, and other points. Streamers from sharp points on the structure provide protection for surfaces having large radii of curvature. The effects of nearby structures can also be estimated.
The technologies required to design, fabricate, and utilize an inflatable module for space applications has been demonstrated and proven by the TransHab team during the development phase of the program. Through testing and hands-on development several issues about inflatable space structures have been addressed , such as: ease of manufacturing, structural integrity, micrometeorite protection, folding , and vacuum deployment. The TransHab inflatable technology development program has proven that not only are inflatable structures a viable option, but they also offer significant advantages over conventional metallic structures.
This 2014 summer internship assignment at John F. Kennedy Space Center (K.S.C) was conducted with the National Aeronautics and Space Administration (NASA) Engineering and Technology (NE) group in support of the Control and Data Systems Division (NE-C) within the Test, Operations & Support Software Engineering Branch (NE-C2). The primary focus of this project was to assist Branch Chief Laurie B. Griffin, to support NASA's Small Payload Launch Integrated Testing Services (SPLITS) mission, by mastering the capabilities of 3-D modeling software called SketchUp. I used SketchUp to create a virtual environment for different laboratories of the NE-00 Division. My mission was to have these models uploaded into a K.S.C Partnerships Website and be used as a visual aid to viewers who browsed the site. The leads of this project were Kay L. Craig, Business and Industry Specialist (AD-A) and Steven E. Cain, (FA-C). I teamed with fellow intern Tait Sorenson of the Flight Structures and Thermal Protection Systems Branch (NE-M5) and met with many K.S.C lab managers willing to display their lab's structure and capabilities. The information collected during these lab tours was vital to the building of the K.S.C Partnerships Website. To accomplish this goal Sorenson and I later teamed with fellow Marketing intern Marlee Pereda-Ramos, of the Spaceport Planning Office In Center Planning And Development (AD-A) Along with Ramos, Tait and I toured an array of laboratories and got first hand exposure to their functions and capabilities.
The Navy A-6E aircraft is presently being modified with a new wing which uses graphite/epoxy structures and substructures around a titanium load-bearing structure. The ability of composites to conduct electricity is less than that of aluminum. This is cause for concern when the wing may be required to conduct large lightning currents. The manufacturer attempted to solve lightning protection issues by performing a risk assessment based on a statistical approach which allows relaxation of the wing lightning protection design levels over certain locations of the composite wing. A sensitivity study is presented designed to define the total risk of relaxation of the design levels.
The vision vehicle for the Hypersonics Project of the Fundamental Aeronautics Program at NASA is a two-stage-to-orbit re-useable system consisting of an air-breathing booster and rocket-based Orbiter. Systems level studies and design were based upon the use of a structurally integrated thermal protection system (SITPS) for both vehicles. The presentation details key features of SITPS and presents results from high-fidelity structural and thermal sizing of an SITPS concept on the Orbiter. The high fidelity sizing results show that the mass estimating relationships used to design the Orbiter subsystems provide reasonable approximations.
Tantalum-based ceramics are suitable for use in thermal protection systems. These composite structures have high efficiency surfaces (low catalytic efficiency and high emittance), thereby reducing heat flux to a spacecraft during planetary re-entry. These ceramics contain tantalum disilicide, molybdenum disilicide and borosilicate glass. The components are milled, along with a processing aid, then applied to a surface of a porous substrate, such as a fibrous silica or carbon substrate. Following application, the coating is then sintered on the substrate. The composite structure is substantially impervious to hot gas penetration and capable of surviving high heat fluxes at temperatures approaching 3000.degree. F. and above.