Systems design experience from three manned space programs.
Systems design experience derived from Mercury, Gemini and Apollo projects, discussing thermal protection, launch propulsion, life support, etc
Boynton, J. H.↗
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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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Systems design experience from three manned space programs
Systems design experience derived from Mercury Gemini and Apollo projects, discussing thermal protection, launch propulsion, life support, etc
Boynton, J. H.↗
Wind Tunnel Database Development using Modern Experiment Design and Multivariate Orthogonal Functions
A wind tunnel experiment for characterizing the aerodynamic and propulsion forces and moments acting on a research model airplane is described. The model airplane called the Free-flying Airplane for Sub-scale Experimental Research (FASER), is a modified off-the-shelf radio-controlled model airplane, with 7 ft wingspan, a tractor propeller driven by an electric motor, and aerobatic capability. FASER was tested in the NASA Langley 12-foot Low-Speed Wind Tunnel, using a combination of traditional sweeps and modern experiment design. Power level was included as an independent variable in the wind tunnel test, to allow characterization of power effects on aerodynamic forces and moments. A modeling technique that employs multivariate orthogonal functions was used to develop accurate analytic models for the aerodynamic and propulsion force and moment coefficient dependencies from the wind tunnel data. Efficient methods for generating orthogonal modeling functions, expanding the orthogonal modeling functions in terms of ordinary polynomial functions, and analytical orthogonal blocking were developed and discussed. The resulting models comprise a set of smooth, differentiable functions for the non-dimensional aerodynamic force and moment coefficients in terms of ordinary polynomials in the independent variables, suitable for nonlinear aircraft simulation.
Morelli, Eugene A.↗
NASA battery testbed: A designed experiment for the optimization of LEO battery operational parameters
Simulation of spacecraft battery operation is implemented. Robust design experiment to obtain optimum battery operational parameters is performed. It is found that short term tests using robust design of experiments can provide guidelines for optimum battery operation. It is decided to use robust design approach to provide guidelines for battery operation on current spacecraft in orbit as batteries age (GRO, UARS, EUVE, TOPEX).
Deligiannis, F.↗
Link GAT-1/PWI Overall Simulation Experiment Design
Link general aviation trainer/pilot warning indicator overall simulation experiment design
Copps, E. M.↗
Designed Experiment Results for Constituent Effects on NBR Based Solid Rocket Motor Insulation Performance
Solid rocket motor internal insulations are facing serious issues with obsolescence of constituents and the need for improved performance. The design community is at a unique point with a large number of rocket motors requiring reformulation of insulation or design upgrades at the same time. Unfortunately, performance data related to component choice is not generally available to aid development. A study of insulation component materials, conducted at Marshall Space Flight Center over the last four years, used designed experiments to understand the contribution of each material to the performance of a formulation. This report covers work with Nitrile Butadiene Rubber (NBR) based formulations. In-house compounding provided modified formulations allowing for isolation of both individual and synergistic effects. All formulas were tested for mechanical, thermal and producibility properties to evaluate performance. This presentation will describe the methodology for, and results from, identifying the individual and combined effects of components used in our formulations. Specific properties investigated include, rheology, cure characteristics, density, tensile strength, along with erosion/ablation under various heat loads and flame chemistries. Scale up of several formulas from lab to production size batches was accomplished. We will discuss troubleshooting problems of scale and the new set of designed experiments with Ethylene Propylene Diene Monomer (EPDM) based formulations.
Insulation↗
The use of designed experiments in the process development of continuous propellant mixing
A continuous mix pilot plant was constructed at Aerojet Propulsion Division in Sacramento, California to develop a robust propellant mixing process for the full scale plant that was to be built at the NASA Advanced Solid Rocket Motor facility Yellow Creek, Mississippi. The plant was used to conduct dozens of subsystem and full system mixing tests for evaluation of equipment, processing methods, and control schemes for later use at the production plant. As a culmination to this work, a series of designed experiments were conducted using an eight run Taguchi analysis with four factors at two levels each to determine the primary effect of processing parameters on propellant ballistic and mechanical properties. The factors examined in these runs included the propellant production rate (454 (1000) and 622 kg/hr (1371 Ib/hr)), the product temperature out of the mixer (49 (120) and 63 deg C (145 deg F)), mixer screw speed (75 and 90 rpm), and the deaerator excess capacity (20 and 80 percent). Measured response variables included the uncured and cured density, Crawford Bomb liquid strand burning rates, and selected mechanical properties. The experiment revealed that several of the response variables displayed significant changes from run-to-run with the product temperature being the single most important factor. After concluding this experiment, a twenty-six hour confirmation run was conducted to verify the conclusions reached in the designed experiment. The extended run produced over 12,250 kgs (27,000 lbs) of propellant meeting all of the pre-run targeted properties including density (1.803 g/cc (0.065 lb/in(exp 3)) with a 0.12 percent coefficient of variation (CV) at 25 deg C (77 deg F)), liquid strand burn rate (0.889 cm/s (0.350 in/s) with a 0.69 percent CV at 4210 KPa (610 psig), 15.6 deg C (60 deg F)), nominal maximum stress (828 KPa (120 psig) with a 2.84 percent CV, S&E at 25 deg C (77 deg F), 5.08 cm/min (2 in/min)), strain at nominal maximum (47.4 percent with a 3.96 percent CV), and initial tangent modulus (5349 KPa (775 psig) with a 7.26 percent CV).
Campbell, J. A.↗
Optimal experiment design for on-orbit identification
An optimal on-orbit experiment is designed to extract the most information from an on-orbit test, subject to the constraints of the testing environment. However, simply jumping in and optimizing standard measures of information with respect to the experiment design can cause severe problems if attention is not paid to the specific needs and properties of the problem at hand. The actual criteria to be optimized depends on (among other things) the particular ID algorithm and parametrization being used. Two parametric techniques are the focus of this presentation: recursive prediction error method (RPEM) and maximum likelihood estimation (MLE).
Bayard, David S.↗
Determination of Significant Composite Processing Factors by Designed Experiment (MSFC Center Director's Discretionary Fund)
To determie composite material properties' effects from porcessing variables, a 3 factorial designed experiment with two replicates was conducted. The factors were cure method (oven versus autoclave), layup (hand versus tape-laying machine), and thickness (8 versus 52 ply). Four material systems were tested: AS4/3501-6, IM7/8551-7, IM7/F655 bismaleimide (BMI), and shear tests on IM7/F584. Material properties were G(sub 12), v(sub 12), E(sub 1c) and E(sub 2c). Since the samples were necessarily nonstandard, strengths, though recorded, cannot be considered valid. Void content was also compared. Autoclave curing helped material properties for the low modulus fiber material but showed little benefit for higher stiffness fibers. The number of plies was very important for epoxy composites but not for the BMI. E(sub 1) was generally unaffected by any factor. Particularly high void content did correlate to reduced properties. Autoclave curing reduced void content over oven curiing but a moderate amount of voids, less than 1 percent void content, didnot correlate with material properties. Oven cures and hand layups can produce high-quality parts. Part thickness of epoxy composites is important, though cure optimization may improve performance. Significant variations can be caused by processing and it is important that test coupons always reflect the layup and processes of the final part.
Finckenor, J. L.↗
Fractional Factorial Experiment Designs to Minimize Configuration Changes in Wind Tunnel Testing
This paper serves as a tutorial to introduce the wind tunnel research community to configuration experiment designs that can satisfy resource constraints in a configuration study involving several variables, without arbitrarily eliminating any of them from the experiment initially. The special case of a configuration study featuring variables at two levels is examined in detail. This is the type of study in which each configuration variable has two natural states - 'on or off', 'deployed or not deployed', 'low or high', and so forth. The basic principles are illustrated by results obtained in configuration studies conducted in the Langley National Transonic Facility and in the ViGYAN Low Speed Tunnel in Hampton, Virginia. The crucial role of interactions among configuration variables is highlighted with an illustration of difficulties that can be encountered when they are not properly taken into account.
DeLoach, Richard↗
On a fractional representation approach to closed-loop experiment design
A plant model, based on a fractional representation of the loop, which is uniquely suited to the closed-loop experiment design problem, is proposed. The advantage of this model is that it substitutes an open-loop problem (for which there has been extensive work) for the original-closed loop problem. The results of Monte Carlo simulations which support the utility of this approach are included.
Hansen, Fred R.↗
Structural Assembly Demonstration Experiment (SADE) experiment design
The Structural Assembly Demonstration Experiment concept is to erect a hybrid deployed/assembled structure as an early space experiment in large space structures technology. The basic objectives can be broken down into three generic areas: (1) by performing assembly tasks both in space and in neutral buoyancy simulation, a mathematical basis will be found for the validity conditions of neutral buoyancy, thus enhancing the utility of water as a medium for simulation of weightlessness; (2) a data base will be established describing the capabilities and limitations of EVA crewmembers, including effects of such things as hardware size and crew restraints; and (3) experience of the M.I.T. Space Systems Lab in neutral buoyancy simulation of large space structures assembly indicates that the assembly procedure may create the largest loads that a structure will experience during its lifetime. Data obtained from the experiment will help establish an accurate loading model to aid designers of future space structures.
Akin, D. L.↗
Gender Consideration in Experiment Design for Airbrake in Prebreathe
If gender is a confounder of the decompression sickness (DCS) or venous gas emboli (VGE) outcomes of a proposed air break in oxygen prebreathe (PB) project, then decisions about the final experiment design must be made. We evaluated if the incidence of DCS and VGE from tests in altitude chambers over 20 years were different between men and women after resting and exercise prebreathe protocols. Nitrogen washout during PB is our primary risk mitigation strategy to prevent subsequent DCS and VGE in subjects. Bubbles in the pulmonary artery (venous blood) were detected from the precordial position using Doppler ultrasound bubble detectors. The subjects were monitored for VGE for four min at about 15 min intervals for the duration of the altitude exposure, with maximum bubble grade assigned a Spencer Grade of IV. There was no difference in DCS incidence between men and women in either PB protocol. The incidence of VGE and Grade IV VGE is statistically lower in women compared to men after resting PB. Even when 10 tests were compared with Mantel-Haenszel 2 where both men (n = 168) and women (n = 92) appeared, the p-value for VGE incidence was still significant at 0.03. The incidence of VGE and Grade IV VGE is not statistically lower in women compared to men after exercise PB. Even when six tests were compared with Mantel-Haenszel x2 where both men (n = 165) and women (n = 49) appeared, the p-value for VGE incidence was still not significant at 0.90. Our goal is to understand the risk of brief air breaks during PB without other confounding variables invalidating our conclusions. The cost to additionally account for the confounding role of gender on VGE outcome after resting PB is judged excessive. Our decision is to only evaluate air breaks in the exercise PB protocol. So there is no restriction to recruiting women as test subjects.
Conkin, Johnny↗
Gender Consideration in Experiment Design for Air Break in Prebreathe
If gender is a confounder of the decompression sickness (DCS) or venous gas emboli (VGE) outcomes of a proposed air break in oxygen prebreathe (PB) project, then decisions about the final experiment design must be made. We evaluated if the incidence of DCS and VGE from tests in altitude chambers over 20 years were different between men and women after resting and exercise PB protocols. Nitrogen washout during PB is our primary risk mitigation strategy to prevent subsequent DCS and VGE in subjects. Bubbles in the pulmonary artery (venous blood) were detected from the precordial position using Doppler ultrasound bubble detectors. The subjects were monitored for VGE for four min at about 15 min intervals for the duration of the altitude exposure, with maximum bubble grade assigned a Spencer Grade of IV.
Conkin, Johnny↗
The application of statistically designed experiments to resistance spot welding
State-of-the-art Resistance Spot Welding (RSW) equipment has the potential to permit realtime monitoring of operations through advances in computerized process control. In order to realize adaptive feedback capabilities, it is necessary to establish correlations among process variables, welder outputs, and weldment properties. The initial step toward achieving this goal must involve assessment of the effect of specific process inputs and the interactions among these variables on spot weld characteristics. This investigation evaluated these effects through the application of a statistically designed experiment to the RSW process. A half-factorial, Taguchi L sub 16 design was used to understand and refine a RSW schedule developed for welding dissimilar aluminum-lithium alloys of different thickness. The baseline schedule had been established previously by traditional trial and error methods based on engineering judgment and one-factor-at-a-time studies. A hierarchy of inputs with respect to each other was established, and the significance of these inputs with respect to experimental noise was determined. Useful insight was gained into the effect of interactions among process variables, particularly with respect to weldment defects. The effects of equipment related changes associated with disassembly and recalibration were also identified. In spite of an apparent decrease in equipment performance, a significant improvement in the maximum strength for defect-free welds compared to the baseline schedule was achieved.
Hafley, Robert A.↗
A designed experiment in stitched/RTM composites
The damage tolerance of composite laminates can be significantly improved by the addition of through-the-thickness fibrous reinforcement such as stitching. However, there are numerous stitching parameters which can be independently varied, and their separate and combined effects on mechanical properties need to be determined. A statistically designed experiment (a 2(sup 5-1) fractional factorial, also known as a Taguchi L16 test matrix) used to evaluate five important parameters is described. The effects and interactions of stitch thread material, stitch thread strength, stitch row spacing and stitch pitch are examined for both thick (48 ply) and thin (16 ply) carbon/epoxy (AS4/E905L) composites. Tension, compression and compression after impact tests are described. Preliminary results of completed tension testing are discussed. Larger threads decreased tensile strength. Panel thickness was found not to be an important stitching parameter for tensile properties. Tensile modulus was unaffected by stitching.
Dickinson, Larry C.↗
Inverse problems and optimal experiment design in unsteady heat transfer processes identification
Experimental-computational methods for estimating characteristics of unsteady heat transfer processes are analyzed. The methods are based on the principles of distributed parameter system identification. The theoretical basis of such methods is the numerical solution of nonlinear ill-posed inverse heat transfer problems and optimal experiment design problems. Numerical techniques for solving problems are briefly reviewed. The results of the practical application of identification methods are demonstrated when estimating effective thermophysical characteristics of composite materials and thermal contact resistance in two-layer systems.
Artyukhin, Eugene A.↗
Experiment Design Considerations for Longitudinal Community Noise Surveys
NASA is planning community noise surveys in the coming years to collect data that might enable the return of overland supersonic flight. Community noise surveys are typically cross-sectional, with only a single response per respondent. However, to determine community response to individual supersonic overflights, longitudinal surveys with repeated responses per respondent are more practical. The downside of repeated responses is the potential for response bias, such as a carryover effect in which previous test conditions affect current behavior. Subjective sonic boom listening test data collected at NASA Langley Research Center were reanalyzed to look for evidence of carryover effects. Initial results do not suggest strong carryover effects. This presentation will provide results and suggestions for experiment design of future community surveys.
X-59↗