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At least 271 records · Page 15

New Tool Creates a Big Stir

A new self-adjusting, retractable pin tool for friction stir welding is now used in the manufacturing of components for NASA Space Shuttles. Friction stir welding is a process that makes straight-line welds without bringing the parent material to a liquid state. This is accomplished through high-speed rotation, which generates frictional heat between the welding tool and the piece being welded. This heat causes the material to soften to the point of plasticity without allowing it to melt. The plasticized material is then transferred from the front edge of the welding tool to the trail edge, where it joins the pieces being welded. However, a major flaw of this method is its reliance on a single-piece pin tool. The weld is left unfinished and a hole remains where the pin was inserted. The hole must be covered with a rivet in order to preserve the integrity of the weld. The NASA-developed pin tool, however, eliminates the need for this finishing step, as its retraction allows continuous rewelding at lesser depths, until the hole is completely closed. With this NASA technology, welding of higher strength alloys, as well as non-planer and variable thickness structures can be achieved.

Source record↗

Composite Materials

Composites are lighter and stronger than metals. Aramid fibers like Kevlar and Nomex were developed by DuPont Corporation and can be combined in a honeycomb structure which can give an airplane a light, tough structure. Composites can be molded into many aerodynamic shapes eliminating rivets and fasteners. Langley Research Center has tested composites for both aerospace and non-aerospace applications. They are also used in boat hulls, military shelters, etc.

Source record↗

Advances in Structural Integrity Analysis Methods for Aging Metallic Airframe Structures with Local Damage

Analysis methodologies for predicting fatigue-crack growth from rivet holes in panels subjected to cyclic loads and for predicting the residual strength of aluminum fuselage structures with cracks and subjected to combined internal pressure and mechanical loads are described. The fatigue-crack growth analysis methodology is based on small-crack theory and a plasticity induced crack-closure model, and the effect of a corrosive environment on crack-growth rate is included. The residual strength analysis methodology is based on the critical crack-tip-opening-angle fracture criterion that characterizes the fracture behavior of a material of interest, and a geometric and material nonlinear finite element shell analysis code that performs the structural analysis of the fuselage structure of interest. The methodologies have been verified experimentally for structures ranging from laboratory coupons to full-scale structural components. Analytical and experimental results based on these methodologies are described and compared for laboratory coupons and flat panels, small-scale pressurized shells, and full-scale curved stiffened panels. The residual strength analysis methodology is sufficiently general to include the effects of multiple-site damage on structural behavior.

fatigue-crack growth↗

Residual Static Strength of ALuminum-Alloy Beams Containing Fatigue Cracks in the Tension Covers

Static tests were performed on 31 box beams containing fatigue cracks in order to determine their residual static strengths. The beams were constructed of 7075 and 2024 aluminum alloy according to several designs and employed stringers that were either bonded, riveted, or an integral part of the skin. skin (both aaterials) had the highest residual static strengths, whereas 7075 beams with integrally stiffened covers had the lowest residual static strengths. Except for the integrally stiffened beams, the skin material did not contribute to the residual static strength of the beams because the crack propagated across the skin before maximum load was reached. For the integrally stiffened beams, crack propagation and failure were synonymous. The test results are compared with predictions of the residual static strength. Fair agreement between predicted strength and actual strength was obtained for all beams tested.

Leybold, Herbert A.↗

Low Temperature SQUID for NDE Applications

We have developed a low temperature SuperConducting Quantum Interference Device - SQUID measurement system for detection of defects deep under the surface of aluminum structures using eddy current techniques. The system uses a two dimensional planar inducer with two different excitation frequencies to induce a current in the sample. We have developed a data analysis software program that enabled us to distinguish between round defects (holes), straight defects (slots) and slots close to holes simulating cracks starting from rivets in aluminum structures. We were able to detect defects that are 8mm below the surface. We have also measured the change in phase of the detected signal as a function of depth of the defect. This relationship can be used to determine the depth of hidden flaws. Using this analysis software with the high temperature SQUID system at NASA Langley we were able to detect slots close to holes in layered aluminum sample.

Wincheski, Buzz↗

Flexible Cryogenic Temperature and Liquid-Level Probes

Lightweight, flexible probes have been developed for measuring temperatures at multiple locations in tanks that contain possibly pressurized cryogenic fluids. If the fluid in a given tank is subcritical (that is, if it consists of a liquid and its vapor), then in one of two modes of operation, the temperature measurements made by a probe of this type can be used to deduce the approximate level of the liquid. The temperature sensors are silicon diodes located at intervals along a probe. If the probe is to be used to measure a temperature gradient along a given axis in the tank, then the probe must be mounted along that axis. In the non-liquid-level-sensing temperature-measurement mode, a constant small electric current is applied to each diode and the voltage across the diode . a known function of the current and temperature . is measured as an indication of its temperature. For the purpose of this measurement, "small electric current" signifies a current that is not large enough to cause a significant increase in the measured temperature. More specifically, the probe design calls for a current of 10 A, which, in the cryogenic temperature range of interest, generates heat at a rate of only about 0.01 mW per diode. In the liquid-level-sensing mode, one applies a larger current (30 mA) to each diode so as to heat each diode appreciably (with a power of about 36 mW in the temperature range of interest). Because the liquid cools the diode faster than does the vapor, the temperature of the diode is less when diode is immersed in the liquid than when it is above the surface of the liquid. Thus, the temperature (voltage) reading from each diode can be used to determine whether the liquid level is above or below the diode, and one can deduce that the liquid level lies between two adjacent diodes, the lower one of which reads a significantly lower temperature. The aforementioned techniques for measuring temperature and deducing liquid level are not new. What is new here are the designs of the probes and of associated external electronic circuitry. In each probe, the diodes and the lead wires are embedded in a strong, lightweight, flexible polyimide strip. Each probe is constructed as an integral unit that includes a multipin input/output plug or socket for solderless connection of the lead wires to the external circuitry. The polyimide strip includes mounting tabs with holes that can accommodate rivets, screws, or other fasteners. Alternatively, a probe can be mounted by use of an epoxy. A probe can be manufactured to almost any length or width, and the diodes can be embedded at almost any desired locations along and across the polyimide strip. In designing a probe for a specific application, one seeks a compromise between (1) minimizing the number of diodes in order to minimize the complexity of input/output connections and external electronic circuitry while (2) using enough diodes to obtain the required precision. Optionally, to minimize spurious heating of the cryogenic fluid, the external circuitry can be designed to apply power to the probe only during brief measurement intervals. Assuming that the external circuitry is maintained at a steady temperature, a power-on interval of only a few seconds is sufficient to obtain accurate data on temperatures and/or the height of the liquid/vapor interface.

Haberbusch, Mark↗

Finite Element Model Development For Aircraft Fuselage Structures

The ability to extend the valid frequency range for finite element based structural dynamic predictions using detailed models of the structural components and attachment interfaces is examined for several stiffened aircraft fuselage structures. This extended dynamic prediction capability is needed for the integration of mid-frequency noise control technology. Beam, plate and solid element models of the stiffener components are evaluated. Attachment models between the stiffener and panel skin range from a line along the rivets of the physical structure to a constraint over the entire contact surface. The finite element models are validated using experimental modal analysis results.

Buehrle, Ralph D.↗

Finite Element Model Development and Validation for Aircraft Fuselage Structures

The ability to extend the valid frequency range for finite element based structural dynamic predictions using detailed models of the structural components and attachment interfaces is examined for several stiffened aircraft fuselage structures. This extended dynamic prediction capability is needed for the integration of mid-frequency noise control technology. Beam, plate and solid element models of the stiffener components are evaluated. Attachment models between the stiffener and panel skin range from a line along the rivets of the physical structure to a constraint over the entire contact surface. The finite element models are validated using experimental modal analysis results. The increased frequency range results in a corresponding increase in the number of modes, modal density and spatial resolution requirements. In this study, conventional modal tests using accelerometers are complemented with Scanning Laser Doppler Velocimetry and Electro-Optic Holography measurements to further resolve the spatial response characteristics. Whenever possible, component and subassembly modal tests are used to validate the finite element models at lower levels of assembly. Normal mode predictions for different finite element representations of components and assemblies are compared with experimental results to assess the most accurate techniques for modeling aircraft fuselage type structures.

Buehrle, Ralph D.↗

Advances in Fatigue and Fracture Mechanics Analyses for Aircraft Structures

This paper reviews some of the advances that have been made in stress analyses of cracked aircraft components, in the understanding of the fatigue and fatigue-crack growth process, and in the prediction of residual strength of complex aircraft structures with widespread fatigue damage. Finite-element analyses of cracked structures are now used to determine accurate stress-intensity factors for cracks at structural details. Observations of small-crack behavior at open and rivet-loaded holes and the development of small-crack theory has lead to the prediction of stress-life behavior for components with stress concentrations under aircraft spectrum loading. Fatigue-crack growth under simulated aircraft spectra can now be predicted with the crack-closure concept. Residual strength of cracked panels with severe out-of-plane deformations (buckling) in the presence of stiffeners and multiple-site damage can be predicted with advanced elastic-plastic finite-element analyses and the critical crack-tip-opening angle (CTOA) fracture criterion. These advances are helping to assure continued safety of aircraft structures.

Newman, J. C., Jr.↗

Residual Strength Analysis Methodology: Laboratory Coupons to Structural Components

The NASA Aircraft Structural Integrity (NASIP) and Airframe Airworthiness Assurance/Aging Aircraft (AAA/AA) Programs have developed a residual strength prediction methodology for aircraft fuselage structures. This methodology has been experimentally verified for structures ranging from laboratory coupons up to full-scale structural components. The methodology uses the critical crack tip opening angle (CTOA) fracture criterion to characterize the fracture behavior and a material and a geometric nonlinear finite element shell analysis code to perform the structural analyses. The present paper presents the results of a study to evaluate the fracture behavior of 2024-T3 aluminum alloys with thickness of 0.04 inches to 0.09 inches. The critical CTOA and the corresponding plane strain core height necessary to simulate through-the-thickness effects at the crack tip in an otherwise plane stress analysis, were determined from small laboratory specimens. Using these parameters, the CTOA fracture criterion was used to predict the behavior of middle crack tension specimens that were up to 40 inches wide, flat panels with riveted stiffeners and multiple-site damage cracks, 18-inch diameter pressurized cylinders, and full scale curved stiffened panels subjected to internal pressure and mechanical loads.

Dawicke, D. S.↗

The Effect of Surface Irregularities on Wing Drag. II - Lap Joints: Lap Joints - 2

Tests have been made in the NACA 8-foot high-speed wind tunnel of the drag caused by four types of lap joint. The tests were made on an airfoil of NACA 23012 section and 5-foot chord and covered in a range of speeds from 80 to 500 miles per hour and lift coefficients from 0 to 0.30. The increases in profile drag caused by representative arrangements of laps varied from 4 to 9%. When there were protruding rivet heads on the surface, the addition of laps increased the drag only slightly. Laps on the forward part of a wing increased the drag considerably more than those farther back.

Hood, Manley J.↗

Preliminary Test Results of a Non-Contacting Finger Seal on a Herringbone-Grooved Rotor

The baseline non-contacting finger seal is a NASA patented design. The primary difference between it and Gul Aroras design patented by AlliedSignal is that there are no lift pads on the high pressure fingers. The baseline non-contacting finger seal is comprised of a back plate, aft spacer, aft (or low pressure) finger element, forward (or high pressure) finger element, forward spacer, and front plate. The components are held together with 20 flat head screws. A typical seal would have a back plate of approximately the same thickness as the front plate and would be riveted together. The thicker back plate allows use of threaded fasteners so that different finger elements can be tested without having to replace all the individual seal components. The finger elements are essentially washers made of thin sheet stock with multiple curved slots machined around the inner diameter to form the fingers. They are clocked so that the fingers of one cover the slots of the other. The aft finger element fingers have axial extensions or "lift pads" at the seal id that are concentric to the rotor. The fingers act as cantilever beams and flex in response to rotor dynamic motion and radial growth of the rotor due to centrifugal or thermal forces.

Proctor, Margaret P.↗

Flexible Cryogenic Temperature and Liquid-Level Probes

Lightweight, flexible probes have been developed for measuring temperatures at multiple locations in tanks that contain possibly pressurized cryogenic fluids. If the fluid in a given tank is subcritical (that is, if it consists of a liquid and its vapor), then in one of two modes of operation, the temperature measurements made by a probe of this type can be used to deduce the approximate level of the liquid. The temperature sensors are silicon diodes located at intervals along a probe. If the probe is to be used to measure a temperature gradient along a given axis in the tank, then the probe must be mounted along that axis. In the temperature-measurement mode, a constant small electric current is applied to each diode and the voltage across the diode a known function of the current and temperature is measured as an indication of its temperature. For the purpose of this measurement, small electric current signifies a current that is not large enough to cause a significant increase in the measured temperature. More specifically, the probe design calls for a current of 10 A, which, in the cryogenic temperature range of interest, generates heat at a rate of only about 0.01 mW per diode. In the liquid-level-sensing mode, one applies a larger current (30 mA) to each diode so as to heat each diode appreciably (with a power of about 36 mW in the temperature range of interest). Because the liquid cools the diode faster than does the vapor, the temperature of the diode is less when the diode is immersed in the liquid than when it is above the surface of the liquid. Thus, the temperature (voltage) reading from each diode can be used to determine whether the liquid level is above or below the diode, and one can deduce that the liquid level lies between two adjacent diodes, the lower one of which reads a significantly lower temperature. The aforementioned techniques for measuring temperature and deducing liquid level are not new. What is new here are the designs of the probes and of associated external electronic circuitry. In each probe, the diodes and the lead wires are embedded in a strong, lightweight, flexible polyimide strip. Each probe is constructed as an integral unit that includes a multipin input/output plug or socket for solderless connection of the lead wires to the external circuitry. The polyimide strip includes mounting tabs with holes that can accommodate rivets, screws, or other fasteners. Alternatively, a probe can be mounted by use of an epoxy. A probe can be manufactured to almost any length or width, and the diodes can be embedded at almost any desired location along and across the polyimide strip. In designing a probe for a specific application, one seeks a compromise between (1) minimizing the number of diodes in order to minimize the complexity of input/output connections and external electronic circuitry while (2) using enough diodes to obtain the required precision. Optionally, to minimize spurious heating of the cryogenic fluid, the external circuitry can be designed to apply power to the probe only during brief measurement intervals. Assuming that the external circuitry is maintained at a steady temperature, a power-on interval of only a few seconds is sufficient to obtain accurate data on temperatures and/or the height of the liquid/vapor interface.

Haberbusch, Mark↗

Fastener Design Course [Workbook]

Richard T. Barrett, Senior Aerospace Engineer of NASA Lewis Research Center presents a comprehensive course on fastener design. A recognized expert in the field of fastener technology Mr. Barrett combines lecture, charts, illustrations with real-world experiences. Topics covered include: materials, plantings and coatings, locking methods threads, joint stiffness, rivets, inserts, nut plates, thread lubricants, design criteria, etc. These presentation slides accompany the DVD.

Barrett, Richart T.↗

Leveraging Data Intensive Computing to Support Automated Event Services

A large portion of Earth Science investigations is phenomenon- or event-based, such as the studies of Rossby waves, mesoscale convective systems, and tropical cyclones. However, except for a few high-impact phenomena, e.g. tropical cyclones, comprehensive records are absent for the occurrences or events of these phenomena. Phenomenon-based studies therefore often focus on a few prominent cases while the lesser ones are overlooked. Without an automated means to gather the events, comprehensive investigation of a phenomenon is at least time-consuming if not impossible. An Earth Science event (ES event) is defined here as an episode of an Earth Science phenomenon. A cumulus cloud, a thunderstorm shower, a rogue wave, a tornado, an earthquake, a tsunami, a hurricane, or an EI Nino, is each an episode of a named ES phenomenon," and, from the small and insignificant to the large and potent, all are examples of ES events. An ES event has a finite duration and an associated geolocation as a function of time; its therefore an entity in four-dimensional . (4D) spatiotemporal space. The interests of Earth scientists typically rivet on Earth Science phenomena with potential to cause massive economic disruption or loss of life, but broader scientific curiosity also drives the study of phenomena that pose no immediate danger. We generally gain understanding of a given phenomenon by observing and studying individual events - usually beginning by identifying the occurrences of these events. Once representative events are identified or found, we must locate associated observed or simulated data prior to commencing analysis and concerted studies of the phenomenon. Knowledge concerning the phenomenon can accumulate only after analysis has started. However, except for a few high-impact phenomena. such as tropical cyclones and tornadoes, finding events and locating associated data currently may take a prohibitive amount of time and effort on the part of an individual investigator. And even for these high-impact phenomena, the availability of comprehensive records is still only a recent development. A major reason for the lack of comprehensive ,records for the majority of the ES phenomena is the perception that they do not pose immediate and/or severe threat to life and property and are thus not consistently tracked. monitored, and catalogued. Many phenomena even lack commonly accepted criteria for definitions. However. the lack of comprehensive records is also due to the increasingly prohibitive volume of observations and model data that must be examined. NASA Earth Observing System Data Information System (EOSDIS) alone archives several petabytes (PB) of satellite remote sensing data and steadily increases. All of these factors contribute to the difficulty of methodically identifying events corresponding to a given phenomenon and significantly impede systematic investigations. In the following we present a couple motivating scenarios, demonstrating the issues faced by Earth scientists studying ES phenomena.

Clune, Thomas L.↗

Test Analysis Correlation of the Single Stringer Bending Tests for the Space Shuttle ET-137 Intertank Stringer Crack Investigation

On November 5, 2010, Space Shuttle mission STS-133 was scrubbed due to a hydrogen leak at the Ground Umbilical Carrier Plate (GUCP). After the scrub, a crack in the foam thermal protection system (TPS) was observed on the External Tank (ET) near the interface between the liquid oxygen (LOX) tank and the Intertank. When the damaged foam was removed, two 9-in. long cracks were found on the feet of Intertank stringer S7-2, and the stringer failure was the cause of the TPS crack. An investigation was conducted to determine the root cause of the cracks, establish a remedy/repair for the stringers, and provide flight rationale for the damaged tank, ET-137. The Space Transportation System (STS) Super Lightweight ET (SLWT) is comprised of two propellant tanks (an aft liquid hydrogen (LH2) tank and a forward LOX tank) and an Intertank. The Intertank serves as the structural connection between the two propellant tanks and also functions to receive and distribute all thrust loads from the solid rocket boosters . The Intertank is a stiffened cylinder structure consisting of eight mechanically joined panels (two integrally-stiffened, machined thrust panels to react the booster loads and six stringer-stiffened skin panels). There are one main ring frame, four intermediate ring frames, and forward and aft flange chords that mate to the respective propellant tanks.. The skin/stringer panels utilize external hat-section stringers that are mechanically attached with rivets along most of their length and with specialty fasteners, such as GP Lockbolts and Hi-Loks, at the forward and aft ends where the stringers attach to the flange chords. During the STS-133 Intertank stringer crack investigation, cracks were found on a total of five stringers. All of the cracks were at the LOX end, in the feet of the stringers, and near the forward fasteners (GP Lockbolts). Video of tanking for the November 5 launch attempt was used to determine that the TPS failure, and thus the stringer failure, occurred as the LOX liquid level crossed the LOX tank / Intertank interface ring frame. Hence, cryogenically-induced displacements were suspected as a contributing cause of the stringer cracks. To study the behavior of Intertank stringers subjected to similar displacements, static load tests of individual stringers, colloquially known as "single stringer bending tests" were performed. Approximately thirty stringers were tested, many of which were cut from the partially completed Intertank for what would have been ET-139. In addition to the tests, finite element (FE) analyses of the test configuration were also performed. In this paper, the FE analyses and test-analysis correlation for stringer test S6-8 are presented. Stringer S6-8 is a "short chord" configuration with no doubler panels.

Phillips, Dawn R.↗

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

In this paper, a unique system level spacecraft design optimization will be presented. A Genetic Algorithm is used to design the global pattern of the reinforcing structure, while a gradient routine is used to adequately stiffen the sub-structure. The system level structural design includes determining the optimal physical location (and number) of reinforcing beams of a lunar pallet lander deck structure. Design of the substructure includes determining placement of secondary stiffeners and the number of rivets required for assembly.. In this optimization, several considerations are taken into account. The primary objective was to raise the primary natural frequencies of the structure such that the Pallet Lander primary structure does not significantly couple with the launch vehicle. A secondary objective is to determine how to properly stiffen the reinforcing beams so that the beam web resists the shear buckling load imparted by the spacecraft components mounted to the pallet lander deck during launch and landing. A third objective is that the calculated stress does not exceed the allowable strength of the material. These design requirements must be met while, minimizing the overall mass of the spacecraft. The final paper will discuss how the optimization was implemented as well as the results. While driven by optimization algorithms, the primary purpose of this effort was to demonstrate the capability of genetic algorithms to enable design automation in the preliminary design cycle. By developing a routine that can automatically generate designs through the use of Finite Element Analysis, considerable design efficiencies, both in time and overall product, can be obtained over more traditional brute force design methods.

Burt, Adam↗

ldentifying Episodes of Earth Science Phenomena Using a Big-Data Technology

A significant portion of Earth Science investigations is phenomenon- (or event-) based, such as the studies of Rossby waves, volcano eruptions, tsunamis, mesoscale convective systems, and tropical cyclones. However, except for a few high-impact phenomena, e.g. tropical cyclones, comprehensive records are absent for the occurrences or events of these phenomena. Phenomenon-based studies therefore often focus on a few prominent cases while the lesser ones are overlooked. Without an automated means to gather the events, comprehensive investigation of a phenomenon is at least time-consuming if not impossible. We have constructed a prototype Automated Event Service (AES) system that is used to methodically mine custom-defined events in the reanalysis data sets of atmospheric general circulation models. Our AES will enable researchers to specify their custom, numeric event criteria using a user-friendly web interface to search the reanalysis data sets. Moreover, we have included a social component to enable dynamic formation of collaboration groups for researchers to cooperate on event definitions of common interest and for the analysis of these events. An Earth Science event (ES event) is defined here as an episode of an Earth Science phenomenon (ES phenomenon). A cumulus cloud, a thunderstorm shower, a rogue wave, a tornado, an earthquake, a tsunami, a hurricane, or an El Nino, is each an episode of a named ES phenomenon, and, from the small and insignificant to the large and potent, all are examples of ES events. An ES event has a duration (often finite) and an associated geo-location as a function of time; it's therefore an entity embedded in four-dimensional (4D) spatiotemporal space. Earth Science phenomena with the potential to cause massive economic disruption or loss of life often rivet the attention of researchers. But, broader scientific curiosity also drives the study of phenomena that pose no immediate danger, such as land/sea breezes. Due to Earth System's intricate dynamics, we are continuously discovering novel ES phenomena. We generally gain understanding of a given phenomenon by observing and studying individual events. This process usually begins by identifying the occurrences of these events. Once representative events are identified or found, we must locate associated observed or simulated data prior to commencing analysis and concerted studies of the phenomenon. Knowledge concerning the phenomenon can accumulate only after analysis has started. However, as mentioned previously, comprehensive records only exist for a very limited set of high-impact phenomena; aside from these, finding events and locating associated data currently may take a prohibitive amount of time and effort on the part of an individual investigator. The reason for the lack of comprehensive records for most of the ES phenomena is mainly due to the perception that they do not pose immediate and/or severe threat to life and property. Thus they are not consistently tracked, monitored, and catalogued. Many phenomena even lack precise and/or commonly accepted criteria for definitions. Moreover, various Earth Science observations and data have accumulated to a previously unfathomable volume; NASA Earth Observing System Data Information System (EOSDIS) alone archives several petabytes (PB) of satellite remote sensing data, which are steadily increasing. All of these factors contribute to the difficulty of methodically identifying events corresponding to a given phenomenon and significantly impede systematic investigations. We have not only envisioned AES as an environment for identifying customdefined events but also aspired for it to be an interactive environment with quick turnaround time for revisions of query criteria and results, as well as a collaborative environment where geographically distributed experts may work together on the same phenomena. A Big Data technology is thus required for the realization of such a system. In the following, we first introduce the technology selected for AES in the next section. We then demonstrate the utility of AES using a use case, Blizzard, before we conclude.

Kuo, Kwo-Sen↗