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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Testing Dacron parachute components and assemblies by exposure to ethylene oxide sterilization, simulated package loading, and heat cycle
Parametric solid and surface models of the crew exploration vehicle (CEV) command module (CM) structure concepts are developed for rapid finite element analyses, structural sizing and estimation of optimal structural mass. The effects of the structural configuration and critical design parameters on the stress distribution are visualized, examined to arrive at an efficient design. The CM structural components consisted of the outer heat shield, inner pressurized crew cabin, ring bulkhead and spars. For this study only the internal cabin pressure load case is considered. Component stress, deflection, margins of safety and mass are used as design goodness criteria. The design scenario is explored by changing the component thickness parameters and materials until an acceptable design is achieved. Aluminum alloy, titanium alloy and an advanced composite material properties are considered for the stress analysis and the results are compared as a part of lessons learned and to build up a structural component sizing knowledge base for the future CEV technology support. This independent structural analysis and the design scenario based optimization process may also facilitate better CM structural definition and rapid prototyping.
Mesh adaption is a powerful tool for efficient unstructured- grid computations but causes load imbalance among processors on a parallel machine. We present a novel method to dynamically balance the processor workloads with a global view. This paper presents, for the first time, the implementation and integration of all major components within our dynamic load balancing strategy for adaptive grid calculations. Mesh adaption, repartitioning, processor assignment, and remapping are critical components of the framework that must be accomplished rapidly and efficiently so as not to cause a significant overhead to the numerical simulation. Previous results indicated that mesh repartitioning and data remapping are potential bottlenecks for performing large-scale scientific calculations. We resolve these issues and demonstrate that our framework remains viable on a large number of processors.
Methods for predicting erosion resulting from repeated localized impulsive loadings, such a impacts from droplets or in cavitation flow from microjets and bubbles, are examined. The parameters which determine the adequacy of a component to resist the loads put upon it are identified. The development of erosion rate models is discussed. The expected accuracy of the prediction and the sources of error are analyzed.
Minimizing the weight of structural components of the space station launched into orbit in a space shuttle can save cost, reduce the number of space shuttle missions, and facilitate on-orbit fabrication. Traditional manual design of such components, although feasible, cannot represent a minimum weight condition. At NASA Lewis Research Center, a design capability called CometBoards (Comparative Evaluation Test Bed of Optimization and Analysis Routines for the Design of Structures) has been developed especially for the design optimization of such flight components. Two components of the space station - a spacer structure and a support system - illustrate the capability of CometBoards. These components are designed for loads and behavior constraints that arise from a variety of flight accelerations and maneuvers. The optimization process using CometBoards reduced the weights of the components by one third from those obtained with traditional manual design. This paper presents a brief overview of the design code CometBoards and a description of the space station components, their design environments, behavior limitations, and attributes of their optimum designs.
Inconsistent citations in the literature and questions about convergence prompt reexamination of Hencky's classic solution for the large deflections of a clamped, circular isotropic membrane under uniform pressure. This classic solution is observed actually to be for uniform lateral loading because the radial component of the pressure acting on the deformed membrane is neglected. An algebraic error in Hencky's solution is corrected, additional terms are retained in the power series to assess convergence, and results are obtained for two additional values of Poisson's ratio. To evaluate the importance of the neglected radial component of the applied pressure, the problem is reformulated with this component included and is solved, with escalating algebraic complexity, by a similar power-series approach. The two solutions agree quite closely for lightly loaded membranes and diverge slowly as the load intensifies. Differences in maximum stresses and deflections are substantial only when stresses are very high. The more nearly spherical deflection shape of the membrane under true pressure loading suggests that a near-parabolic membrane reflector designed on the basis of the more convenient Hencky theory would not perform as well as expected. In addition, both theories are found to yield closed-form, nonuniform membrane-thickness distributions that produce parabolic middle-surface deflections under loading. Both distributions require that the circular boundary expand radially in amounts that depend on material and loading parameters.
Thermal protection systems (TPS) insulate planetary probes and Earth re-entry vehicles from the aerothermal heating experienced during hypersonic deceleration to the planet s surface. The systems are typically designed with some additional capability to compensate for both variations in the TPS material and for uncertainties in the heating environment. This additional capability, or robustness, also provides a surge capability for operating under abnormal severe conditions for a short period of time, and for unexpected events, such as meteoroid impact damage, that would detract from the nominal performance. Strategies and approaches to developing robust designs must also minimize mass because an extra kilogram of TPS displaces one kilogram of payload. Because aircraft structures must be optimized for minimum mass, reliability-based design approaches for mechanical components exist that minimize mass. Adapting these existing approaches to TPS component design takes advantage of the extensive work, knowledge, and experience from nearly fifty years of reliability-based design of mechanical components. A Non-Dimensional Load Interference (NDLI) method for calculating the thermal reliability of TPS components is presented in this lecture and applied to several examples. A sensitivity analysis from an existing numerical simulation of a carbon phenolic TPS provides insight into the effects of the various design parameters, and is used to demonstrate how sensitivity analysis may be used with NDLI to develop reliability-based designs of TPS components.
Analytical studies were conducted to investigate in detail the heat balance characteristics of the nuclear light bulb engine. Distributions of energy deposition to all engine components from the fission process, conduction and convection, and thermal radiation were considered. Where uncertainties in basic data or heat transfer characteristics were encountered, ranges of heat loads were calculated and reference values were selected. The influence of these heat loads on engine performance, space radiator requirements, and cooling sequence and cooling circuit designs was determined. The analyses resulted in revisions to the previously reported reference engine characteristics, principally in the heat loads to some engine components and in the cooling sequence. These revisions were incorporated in the engine dynamics digital computer simulation program. No significant changes occurred in the dynamic response of the engine to perturbations in fuel injection rate, reactivity or exhaust nozzle area.
A technique for calculating the effects of on-orbit loads on the structural dynamics of the International Space Station is developed on the basis of MSC/NASTRAN superelement solution sequences. The complexity of the Space Station program with its multiple configurations, international partners, and contractors is stressed, and the impact of this complexity on the dynamic-load analysis process is indicated. The MSC/NASTRAN-based approach is outlined, and its application to two versions of the Permanent Manned Capability configuration is described in detail, including component mode synthesis, GFSC/FLAME coupled-loads analysis (with components from the system FEM model or from the Work Package), and ISI/MATRIX-X generation of closed-loop forcing functions. The results of these sample analyses are presented in extensive tables and graphs and briefly characterized.
Aerodynamic experiments were performed on an oscillating NACA 0012 airfoil utilizing a tunnel-spanning wing in both unswept and 30 degree swept configurations. The airfoil was tested in steady state and in oscillatory pitch about the quarter chord. The unsteady aerodynamic loading was measured using pressure transducers along the chord. Numerical integrations of the unsteady pressure transducer responses were used to compute the normal force, chord force, and moment components of the induced loading. The effects of sweep on the induced aerodynamic load response was examined. For the range of parameters tested, it was found that sweeping the airfoil tends to delay the onset of dynamic stall. Sweeping was also found to reduce the magnitude of the unsteady load variation about the mean response. It was determined that at mean incidence angles greater than 9 degrees, sweep tends to reduce the stability margin of the NACA 0012 airfoil; however, for all cases tested, the airfoil was found to be stable in pure pitch. Turbulent eddies were found to convect downstream above the upper surface and generate forward-moving acoustic waves at the trailing edge which move upstream along the lower surface.
The goal of this research effort was to study methods of video image correlation and electronic shearography for nondestructive evaluation of aerospace components. Methods of physical load application must be developed before interrogations with these methods may be used to qualify hardware. To that end, inspection procedures were developed for a variety of aerospace components and material systems. Experiments were also conducted from which the relationship between the control settings of the electronic shearography apparatus may be related to flaw detectability. A short feasibility study was conducted to determine the applicability of electronic shearography to the determination of the stress intensity factor of a Mode 1 crack tip by measurement of the localized zone of three dimensional plasticity
The HD 220 program was created as part of the space shuttle solid rocket booster recovery system definition. The model was generated to investigate the damage to SRB components under water impact loads. The random nature of environmental parameters, such as ocean waves and wind conditions, necessitates estimation of the relative frequency of occurrence for these parameters. The nondeterministic nature of component strengths also lends itself to probabilistic simulation. The Monte Carlo technique allows the simultaneous perturbation of multiple independent parameters and provides outputs describing the probability distribution functions of the dependent parameters. This allows the user to determine the required statistics for each output parameter.
NASA’s Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology was selected for a Technology Demonstration Mission under the Space Technology Mission Directorate in 2017. HIAD is an enabling technology that can facilitate atmospheric entry of heavy payloads to planets such as Earth and Mars using a deployable aeroshell. The deployable nature of the HIAD technology allows it to avoid the size constraints imposed on current rigid aeroshell entry systems. This enables use of larger aeroshells resulting in increased entry system performance (e.g. higher pay-load mass and/or volume, higher landing altitude at Mars). The Low Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) is currently scheduled for late-2021. LOFTID will be launched out of Vandenberg Air Force Base as a secondary payload on an Atlas V rocket. The flight test features a 6m diameter, 70-deg sphere-cone aeroshell and will provide invaluable high-energy orbital re-entry flight data. This data will be essential in supporting the HIAD team to mature the technology to diameters of 10m and greater. Aeroshells of this scale are applicable to potential near-term commercial applications and future NASA missions. Currently the LOFTID project has completed fabrication of the engineering design unit (EDU) inflatable structure (IS) and the flexible thermal protection system (F-TPS). These two components along with the rigid nose and center body comprise the HIAD aeroshell system. This EDU aeroshell is the precursor to the LOFTID aeroshell that will be used for flight. The EDU was built to verify the design given the subtle differences between the LOFTID aeroshell and past aeroshell designs that have been fabricated under the NASA HIAD project. To characterize the structural performance of the LOFTID aeroshell design, three structural tests will be performed. The first test to be conducted is static load testing, which will induce a uniform load across the forward surface of the aeroshell to simulate the expected pressure forces during atmospheric entry. The IS integrated with the rigid center body will first be tested alone to provide data for analytical model correlation, and then the F-TPS will be integrated for a second series of static load testing of the full aeroshell system. Instrumentation will be employed during the test series to measure component loads during testing, and a laser scanner will be used to generate a 3D map of the aeroshell surface to verify that the shape of the structure is acceptable at the simulated flight loads. After static load testing, pack and deployment testing will be conducted multiple times on the integrated system to demonstrate the aeroshell’s ability to fit within the required packed volume for the LOFTID mission without experiencing significant damage. Finally, the aeroshell will undergo modal testing to characterize its structural response. This presentation will discuss the setup and execution of each of the three tests that the EDU aeroshell will undergo. In addition, initial results of the testing will be presented outlining key findings as LOFTID moves for-ward with fabrication of the flight aeroshell.
In most high-temperature engineering applications, components are subjected to complex combinations of thermal and mechanical loading during service. A number of viscoplastic constitutive models were proposed which potentially can provide mathematical descriptions of material response under such conditions. Implementation of these models into large finite element codes such as MARC has already resulted in much improved inelastic analysis capability for hot-section aircraft engine components. However, a number of questions remain regarding the validity of methods adopted in characterizing these constitutive models for particular high-temperature materials. One area of concern is that the majority of experimental data available for this purpose are determined under isothermal conditions. This is in contrast to service conditions which, as noted above, almost always involve some form of thermal cycling. The obvious question arises as to whether a constitutive model characterized using an isothermal data base can adequately predict material response under thermomechanical conditions. An experimental program was initiated within the HOST program to address this particular concern. The results of the most recent isothermal and thermomechanical experiments are described.
Brittle materials are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts. thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The CARES/Life code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. For this presentation an interview of the CARES/Life program will be provided. Emphasis will be placed on describing the latest enhancements to the code for reliability analysis with time varying loads and temperatures (fully transient reliability analysis). Also, early efforts in investigating the validity of using Weibull statistics, the basis of the CARES/Life program, to characterize the strength of MEMS structures will be described as as well as the version of CARES/Life for MEMS (CARES/MEMS) being prepared which incorporates single crystal and edge flaw reliability analysis capability. It is hoped this talk will open a dialog for potential collaboration in the area of MEMS testing and life prediction.
Composite materials have become ubiquitous in the aerospace industry due to their exceptionally light weight and high strength characteristics, as well as their unique ability to be engineered and tailored to meet specific loading conditions and performance requirements. These advanced materials offer superior strength-to-weight ratios compared to traditional metallic materials, making them particularly valuable in weight-critical aerospace applications where every pound saved translates to improved efficiency and performance. In currently operating fleets of commercial and military aircraft, composite materials have been successfully applied to critical structural components, including primary load-bearing elements such as the fuselage sections and flooring structures, which must withstand significant in-flight loads and provide passenger safety. Additionally, these materials have been specifically tailored and optimized for aerodynamic components such as wings and tail assemblies, where their ability to be molded into complex shapes while maintaining structural integrity is particularly advantageous. The application of composite materials extends beyond primary structural elements into the realm of internal cabin components, most notably in innovative seat designs where weight reduction and structural integration are paramount concerns. Modern composite seat structures can be designed to integrate multiple functions, including structural support, comfort features, and safety systems, all while maintaining the lightweight characteristics essential for aircraft performance.
Online detection techniques to monitor the health of rotating engine components are becoming increasingly attractive to aircraft engine manufacturers in order to increase safety of operation and lower maintenance costs. Health monitoring remains a challenge to easily implement, especially in the presence of scattered loading conditions, crack size, component geometry, and materials properties. The current trend, however, is to utilize noninvasive types of health monitoring or nondestructive techniques to detect hidden flaws and mini-cracks before any catastrophic event occurs. These techniques go further to evaluate material discontinuities and other anomalies that have grown to the level of critical defects that can lead to failure. Generally, health monitoring is highly dependent on sensor systems capable of performing in various engine environmental conditions and able to transmit a signal upon a predetermined crack length, while acting in a neutral form upon the overall performance of the engine system.
The 10- by 10-Foot Abe Silverstein Supersonic Wind Tunnel (10×10) is the largest and fastest wind tunnel facility at NASA’s Glenn Research Center(GRC) and is specifically designed to test supersonic propulsion components from inlets and nozzles to full-scale jet and rocket engines[1]. Recently, a critical part of the wind tunnel failed and required a redesign before reintegrating into the facility. The design requirements of this new component required that clearances between large metallic components exist, which have the potential for undesirable nonlinear dynamics to occur, in particular rattling. Rattling is feared to occur when the wind tunnel is being operated in certain flow regimes that induce cyclic aero loads on the new component near its natural frequencies. This paper describes the approach taken to better understand and resolve this vibration problem using modal testing. A modal test was developed and executed by GRC’s Structural Dynamics Lab to quantify the modal parameters of the structure, namely which specific excitation frequencies caused the structure to rattle. These results were shared with facility operators as frequency ranges that should be avoided to ensure maximum lifespan of the new structure. Additional means of structural health monitoring (SHM) as well as Vortex shedding are briefly discussed in this paper.