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NASA NTRS2018

Design and Development of a Laboratory-Scale Ice Adhesion Testing Device

When an aircraft traverses through clouds containing supercooled water droplets, in-flight icing can occur that negatively affects vehicle performance by increasing weight and drag leading to loss of lift. Super-cooled water droplets present in clouds that impact vehicle surfaces can lead to inflight icing any time during the year.1 Most events occur at temperatures ranging from 0 to -20degC. Ice generated on the aircraft can vary between clear/glaze, rime, and mixed (Fig. 1) depending on air temperature (-5 to -20degC), liquid water content (0.3-0.6 g/m3), and droplet size (median volumetric diameter of 15-40 μm). Current strategies to remove ice are based on active technologies such as pneumatic boots, heated surfaces, and deicing agents (i.e., ethylene- and propylene-based glycols). The latter have potential environmental concerns. A passive approach to mitigate accreting ice that is actively being investigated are protective coatings. An ice mitigating coating could potentially be used as a stand-alone material, but more likely in combination with an active approach. In the latter scenario, potential reduction in power consumption by the active approach may be realized. To determine the ice adhesion strength of impact ice that is representative of the aircraft environment is not a trivial matter. Test methods utilizing slowly formed ice (i.e., freezer ice) do not accurately simulate this environment. Likewise, some testing methodologies involve sample relocation from the icing environment to the test chamber that can result in thermal shock to the sample, thus affecting the results. The Adverse Environment Rotor Test Stand (AERTS) located at Pennsylvania State University (PSU) has been demonstrated to simulate impact icing conditions within the icing envelope for the determination of ice adhesion shear strength (IASS) without removal/relocation of the sample.2 Due to the confidence in results obtained from AERTS, this instrument is in high demand and requires a significant amount of lead time and capital investment to obtain IASS results. As a solution for quickly and economically screening coatings in a controlled manner under impact icing conditions, a laboratory-scale ice adhesion test and dead blades were then removed from the rotor/blade assembly to obtain the final mass. The IASS of the live blade was determined from the difference in mass (before and after testing) of the live and dead blades, the ice shed area, and the rpm of the shed event. The same live blade sample was tested in triplicate at all three test temperatures. Surface roughness was determined using a Bruker Dektak XT Stylus Profilometer. Measurements were conducted using a 12.5 μm tip at a vertical range of 65.5 μm with an applied force of 3 mg. Data were collected over a 1.0 mm length at a resolution of 0.056 μm/point. Five single line scans at different locations were collected and processed using a two-point leveling subtraction. The resultant Ra (arithmetic roughness) and Rq (root mean square roughness) average values were calculated.

Smith, Joseph G., Jr.↗

NASA NTRS2020

Robotics System Process and Concept for On-orbit Assembly for Potential Mars Sample Return

Proposed Mars Sample Return (MSR) missions would require on-orbit assembly of containment vessels to meet backward Planetary Protection requirements and transfer of the sample container through various stations and positions. Some operations would have to be performed autonomously, and others would require ground-in-loop decision-making stages and verification processes. One concept design for an Earth Return Orbiter (ERO) Capture, Contain, and Return System (CCRS) Transfer Mechanism (TM) is a multi-Degree of Freedom (DOF) manipulator that utilizes a passive End Effector (EE) to assist in containment vessel assembly. To converge on a feasible design, a robotic system process has been instantiated. This process is composed of three main phases: robotic problem definition (operating environment, operations/functions, system goals), robotic solution selection (trade studies on the number of degrees of freedom, number of mechanisms, types of mechanisms), robotic solution design, implementation, and verification and validation (kinematic configuration, robotic and kinematic analysis and topology optimization of components). As a final product of this process, a half-scale functional prototype of the TM was developed to demonstrate the end-to-end operation capability.

Strahle, Jackson W↗

NASA NTRS2001

Delta L: An Apparatus for Measuring Macromolecule Crystal Growth Rates in Microgravity

Strongly diffracting high quality macromolecule crystals of suitable volume are keenly sought for X-ray diffraction analysis so that high-resolution molecular structure data can be obtained. Such data is of tremendous value to medical research, agriculture and commercial biotechnology. In previous studies by many investigators microgravity has been reported in some instances to improve biological macromolecule X-ray crystal quality while little or no improvement was observed in other cases. A better understanding of processes effecting crystal quality improvement in microgravity will therefore be of great benefit in optimizing crystallization success in microgravity. In ground based research with the protein lysozyme we have previously shown that a population of crystals grown under the same solution conditions, exhibit a variation in X-ray diffraction properties (Judge et al., 1999). We have also observed that under the same solution conditions, individual crystals will grow at slightly different growth rates. This phenomenon is called growth rate dispersion. For small molecule materials growth rate dispersion has been directly related to crystal quality (Cunningham et al., 1991; Ristic et al., 1991). We therefore postulate that microgravity may act to improve crystal quality by reducing growth rate dispersion. If this is the case then as different, Materials exhibit different degrees of growth rate dispersion on the ground then growth rate dispersion could be used to screen which materials may benefit the most from microgravity crystallization. In order to assess this theory the Delta L hardware is being developed so that macromolecule crystal growth rates can be measured in microgravity. Crystal growth rate is defined as the change or delta in crystal size (defined as a characteristic length, L) over time; hence the name of the hardware. Delta L will consist of an optics, a fluids, and a data acquisition sub-assemblies. The optics assembly will consist of a video microscope camera mounted on three axis computer controlled translation stages. The fluids assembly consists of macromolecule and precipitant reservoirs, a temperature controlled growth cell and waste container, The data acquisition is achieved by using a frame-gabber, with images being stored on a hard drive. In operation, macromolecule and precipitant solution will be injected into the temperature controlled growth cell. As macromolecule crystals grow, the video microscope camera controlled by the translation stages, will be used to locate and record images of individual crystals, returning to the same crystals at specific time intervals. The images will be stored on the hard drive and used to calculate the crystal growth rate. To prevent vibrations interfering in the crystal growth rate measurements (Snell et al., 1997) Delta L will be used in connection with the Glovebox Integrated Microgravity Isolation Technology (g-LIMIT) inside the Microgravity Science Glovebox (MSG), onboard the International Space Station (ISS).

Judge, Russell A.↗

NASA NTRS1977

Comparison of DOD tape automated bonding programs

Tape automated bonding (TAB) shows promise of being the predominant assembly and interconnect technique for microcircuit devices in the 1980's. After briefly reviewing the evolution of TAB, consideration was given to factors influencing and motivating TAB, including current major problem areas. Solutions to these problems are being investigated under five Department of Defense programs. These complementary efforts are discussed and compared. The findings are contrasted against recent improvements and advancements in automated wire bonding.

Unger, R. F.↗

NASA NTRS1987

Use of MSC/NASTRAN for the thermal analysis of the Space Shuttle Orbiter braking system

A description is given of the thermal modeling and analysis effort being conducted to investigate the transient temperature and thermal stress characteristics of the Space Shuttle Orbiter brake components and subsystems. Models are constructed of the brake stator as well as of the entire brake assembly to analyze the temperature distribution and thermal stress during the landing and braking process. These investigations are carried out on a UNIVAC computer system with MSC/NASTRAN Version 63. Analytical results and solution methods are presented and comparisons are made with SINDA results.

Shu, James↗

NASA NTRS1990

Theoretical models of gas dynamics and star formation in interacting ring galaxies

A series of one and two dimensional hydrodynamic simulations of a ring wave in interstellar gas disks was completed. These calculations included nonlinear source terms to model the effects of interstellar interactions and star formation, as well as the spatial-temporal gas flow. Toomre's kinematical model was merged with the Arnold, Shandarin, and Zeldovich 'pancake' theory of caustics in galaxy formation. The resulting theory can describe almost all the structure in restricted three-body simulations of single-pass collisions, even with multi-component potentials. Off-center galactic collisions were studied to understand the dynamics involved. Multi-color optical and near-infrared observations of faint tidal features were performed in about two dozen interacting galaxies selected from the Arp atlas. This sample provided evidence for ongoing star formation in tidal structures, and even enhancements of star formation in some cases. The task of assembling the data for gas-rich, late-type galaxies, was undertaken to see if a more coherent picture of the gas distribution would emerge from the more complete data. Analytic solutions of the equations with subsonic flows to balance gas consumption for expulsion form a galactic fountain were also derived.

Struck-Marcell, Curtis↗

NASA NTRS2003

Dry Process for Manufacturing Hybridized Boron Fiber/Carbon Fiber Thermoplastic Composite Materials from a Solution Coated Precursor

An apparatus for producing a hybrid boron reinforced polymer matrix composite from precursor tape and a linear array of boron fibers. The boron fibers are applied onto the precursor tapes and the precursor tape processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the precursor tape with the boron fibers becomes a hybrid boron reinforced polymer matrix composite. A driving mechanism is used to pulled the precursor tape through the method and a take-up spool is used to collect the formed hybrid boron reinforced polymer matrix composite.

Harry L Belvin↗

NASA NTRS2014

SLS-Derived Lab: Precursor to Deep Space Human Exploration

Plans to send humans to Mars are in work and the launch system is being built. Are we ready? Robotic missions have successfully demonstrated transportation, entry, landing and surface operations but for human missions there are significant, potentially show-stopping issues. These issues, called Strategic Knowledge Gaps (SKGs) are the unanswered questions concerning long-duration exploration beyond low-earth-orbit. The gaps represent a risk of loss of life or mission and because they require extended exposure to the weightless environment outside earth's protective geo-magnetic field they cannot be resolved on the earth or on the International Space Station (ISS). Placing a laboratory at the relatively close and stable lunar Distant Retrograde Orbit (DRO) provides an accessible location with the requisite environmental conditions for conducting SKG research and testing mitigation solutions. Configurations comprised of multiple 3 meter and 4.3 meter diameter modules have been studied but the most attractive solution uses elements of the human Mars launch vehicle or Space Launch System (SLS) for a Mars proving ground laboratory. A shortened version of an SLS hydrogen propellant tank creates a Skylab-like pressure vessel that flies fully outfitted on a single launch. This not only offers significant savings by incorporating SLS pressure vessel development costs but avoids the expensive ISS approach using many launches with substantial on-orbit assembly before becoming operational. One of the most challenging SKGs is crew radiation protection; this is why SKG laboratory research is combined with Mars transit Habitat systems development. Fundamentally, the two cannot be divorced because using the habitat systems for protection requires actual hardware geometry and material properties intended to contribute to shielding effectiveness. The SKGs are difficult problems, solutions are not obvious, and require integrated, iterative, and multi-disciplinary development. A lunar DRO lab built from the launch system elements enables an early and representative transit habitat test bed necessary for closing gaps before sending humans on a 1000 day Mars mission.

Griffin, Brand↗

NASA NTRS2015

SLS-Derived Lab- Precursor to Deep Space Human Exploration

Plans to send humans to Mars are in the works and the launch system is being built. Are we ready? Transportation, entry, landing, and surface operations have been successfully demonstrated for robotic missions. However, for human missions, there are significant, potentially show-stopping issues. These issues, called Strategic Knowledge Gaps (SKGs), are the unanswered questions concerning long duration exploration Beyond low Earth Orbit (BEO). The gaps represent a risk of loss of life or mission and because they require extended exposure to the weightless environment outside of earth's protective geo-magnetic field, they cannot be resolved on Earth or on the International Space Station (ISS). Placing a laboratory at a relatively close and stable lunar Distant Retrograde Orbit (DRO) provides an accessible location with the requisite environmental conditions for conducting SKG research and testing mitigation solutions. Configurations comprised of multiple 3 m and 4.3 m diameter modules have been studied but the most attractive solution uses elements of the human Mars launch vehicle or Space Launch System (SLS) for a Mars proving ground laboratory. A shortened version of an SLS hydrogen propellant tank creates a Skylab-like pressure vessel that flies fully outfitted on a single launch. This not only offers significant savings by incorporating SLS pressure vessel development costs but avoids the expensive ISS approach using many launches with substantial on-orbit assembly before becoming operational. One of the most challenging SKGs is crew radiation protection; this is why SKG laboratory research is combined with Mars transit habitat systems development. Fundamentally, the two cannot be divorced because using the habitat systems for protection requires actual hardware geometry and material properties intended to contribute to shielding effectiveness. The SKGs are difficult problems. The solutions to these problems are not obvious; they require integrated, iterative, and multi-disciplinary development. A lunar DRO lab built from SLS elements enables an early and representative transit habitat test bed necessary for closing gaps before sending humans on a 1,000-day Mars mission.

Griffin, Brand M.↗

NASA NTRS1978

Design and fabrication of a radiative actively cooled honeycomb sandwich structural panel for a hypersonic aircraft

The panel assembly consisted of an external thermal protection system (metallic heat shields and insulation blankets) and an aluminum honeycomb structure. The structure was cooled to temperature 442K (300 F) by circulating a 60/40 mass solution of ethylene glycol and water through dee shaped coolant tubes nested in the honeycomb and adhesively bonded to the outer skin. Rene'41 heat shields were designed to sustain 5000 cycles of a uniform pressure of + or - 6.89kPa (+ or - 1.0 psi) and aerodynamic heating conditions equivalent to 136 kW sq m (12 Btu sq ft sec) to a 422K (300 F) surface temperature. High temperature flexible insulation blankets were encased in stainless steel foil to protect them from moisture and other potential contaminates. The aluminum actively cooled honeycomb sandwich structural panel was designed to sustain 5000 cycles of cyclic in-plane loading of + or - 210 kN/m (+ or - 1200 lbf/in.) combined with a uniform panel pressure of + or - 6.89 kPa (?1.0 psi).

Ellis, D. A.↗

NASA NTRS1985

A review of fracture mechanics life technology

Current lifetime prediction technology for structural components subjected to cyclic loads was reviewed. The central objectives of the project were to report the current state of and recommend future development of fracture mechanics-based analytical tools for modeling and forecasting subcritical fatigue crack growth in structures. Of special interest to NASA was the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. A survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology were conducted. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include: development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Thomas, J. M.↗

NASA NTRS1986

A review of fracture mechanics life technology

Lifetime prediction technology for structural components subjected to cyclic loads is examined. The central objectives of the project are: (1) to report the current state of the art, and (2) recommend future development of fracture mechanics-based analytical tools for modeling subcritical fatigue crack growth in structures. Of special interest is the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. The authors conducted a survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Besuner, P. M.↗

NASA NTRS1995

Flow simulations about steady-complex and unsteady moving configurations using structured-overlapped and unstructured grids

The limiting factor in simulating flows past realistic configurations of interest has been the discretization of the physical domain on which the governing equations of fluid flow may be solved. In an attempt to circumvent this problem, many Computational Fluid Dynamic (CFD) methodologies that are based on different grid generation and domain decomposition techniques have been developed. However, due to the costs involved and expertise required, very few comparative studies between these methods have been performed. In the present work, the two CFD methodologies which show the most promise for treating complex three-dimensional configurations as well as unsteady moving boundary problems are evaluated. These are namely the structured-overlapped and the unstructured grid schemes. Both methods use a cell centered, finite volume, upwind approach. The structured-overlapped algorithm uses an approximately factored, alternating direction implicit scheme to perform the time integration, whereas, the unstructured algorithm uses an explicit Runge-Kutta method. To examine the accuracy, efficiency, and limitations of each scheme, they are applied to the same steady complex multicomponent configurations and unsteady moving boundary problems. The steady complex cases consist of computing the subsonic flow about a two-dimensional high-lift multielement airfoil and the transonic flow about a three-dimensional wing/pylon/finned store assembly. The unsteady moving boundary problems are a forced pitching oscillation of an airfoil in a transonic freestream and a two-dimensional, subsonic airfoil/store separation sequence. Accuracy was accessed through the comparison of computed and experimentally measured pressure coefficient data on several of the wing/pylon/finned store assembly's components and at numerous angles-of-attack for the pitching airfoil. From this study, it was found that both the structured-overlapped and the unstructured grid schemes yielded flow solutions of comparable accuracy for these simulations. This study also indicated that, overall, the structured-overlapped scheme was slightly more CPU efficient than the unstructured approach.

Newman, James C., III↗

NASA NTRS2010

Conceptual Design of a Vertical Takeoff and Landing Unmanned Aerial Vehicle with 24-HR Endurance

This paper describes a conceptual design study for a vertical takeoff and landing (VTOL) unmanned aerial vehicle (UAV) that is able to carry a 25-lb science payload for 24 hr and is able to land and take off at elevations as high as 15,000 ft without human intervention. In addition to the science payload, this vehicle must be able to carry a satellite communication system, and the vehicle must be able to be transported in a standard full-size pickup truck and assembled by only two operators. This project started with a brainstorming phase to devise possible vehicle configurations that might satisfy the requirements. A down select was performed to select a near-term solution and two advanced vehicle concepts that are better suited to the intent of the mission. Sensitivity analyses were also performed on the requirements and the technology levels to obtain a better understanding of the design space. This study found that within the study assumptions the mission is feasible; the selected concepts are recommended for further development.

Fredericks, William J.↗

NASA NTRS2017

Preventing Precipitation in the ISS Urine Processor

The ISS Urine Processor Assembly (UPA) was initially designed to achieve 85% recovery of water from pretreated urine on ISS. Pretreated urine is comprised of crew urine treated with flush water, an oxidant (chromium trioxide), and an inorganic acid (sulfuric acid) to control microbial growth and inhibit precipitation. Unfortunately, initial operation of the UPA on ISS resulted in the precipitation of calcium sulfate at 85% recovery. This occurred because the calcium concentration in the crew urine was elevated in microgravity due to bone loss. The higher calcium concentration precipitated with sulfate from the pretreatment acid, resulting in a failure of the UPA due to the accumulation of solids in the Distillation Assembly. Since this failure, the UPA has been limited to a reduced recovery of water from urine to prevent calcium sulfate from reaching the solubility limit. NASA personnel have worked to identify a solution that would allow the UPA to return to a nominal recovery rate of 85%. This effort has culminated with the development of a pretreatment based on phosphoric acid instead of sulfuric acid. By eliminating the sulfate associated with the pretreatment, the brine can be concentrated to a much higher concentration before calcium sulfate reach the solubility limit. This paper summarizes the development of this pretreatment and the testing performed to verify its implementation on ISS.

Muirhead, Dean↗

NASA NTRS1993

Parallel processing for nonlinear dynamics simulations of structures including rotating bladed-disk assemblies

The principal objective of this research is to develop, test, and implement coarse-grained, parallel-processing strategies for nonlinear dynamic simulations of practical structural problems. There are contributions to four main areas: finite element modeling and analysis of rotational dynamics, numerical algorithms for parallel nonlinear solutions, automatic partitioning techniques to effect load-balancing among processors, and an integrated parallel analysis system.

Hsieh, Shang-Hsien↗

NASA NTRS1973

Shuttle cryogenic supply system. Optimization study. Volume 5 B-1: Programmers manual for math models

A computer program for rapid parametric evaluation of various types of cryogenics spacecraft systems is presented. The mathematical techniques of the program provide the capability for in-depth analysis combined with rapid problem solution for the production of a large quantity of soundly based trade-study data. The program requires a large data bank capable of providing characteristics performance data for a wide variety of component assemblies used in cryogenic systems. The program data requirements are divided into: (1) the semipermanent data tables and source data for performance characteristics and (2) the variable input data which contains input parameters which may be perturbated for parametric system studies.

Source record↗

NASA NTRS2000

Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs: Cost Assessment of Manufacturing/Design Concepts

The objective of the Integral Airframe Structures (IAS) program was to demonstrate, for an integrally stiffened structural concept, performance and weight equal to "built-up" structure with lower manufacturing cost. This report presents results of the cost assessment for several design configuration/manufacturing method combinations. The attributes of various cost analysis models were evaluated and COSTRAN selected for this study. A process/design cost evaluation matrix was developed based on material, forming, machining, and assembly of structural sub-elements and assembled structure. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current built-up technology baseline. This would correspond to a total cost reduction of $1.7 million per ship set for a 777-sized airplane. However, there are important outstanding issues with regard to the cost of capacity of high technology machinery, and the ability to cost-effectively provide surface finish acceptable to the commercial aircraft industry. The projected high raw material cost of large extrusions also played an important role in the trade-off between plate and extruded concepts.

Metschan, S.↗