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NASA NTRS2010

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

NASA NTRS2011

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

Chamis, Christos C.↗

NASA NTRSDate not supplied

Space Launch System: SLS Real Time Rollout Monitoring for MPCV

The NASA Space Launch System (SLS) rocket, Orion spacecraft, and Mobile Launcher (ML) are transported to Pad 39B from the Vehicle Assembly Building on a large, tracked vehicle known as the Crawler Transporter (CT). The CT is a holdover from the Apollo and Space Shuttle programs but has been extensively upgraded to accommodate the SLS. The Dynamic Rollout Test (DRT) on March 17, 2022 marked the first full rollout of the SLS and ML. Analysis indicated that loads and vibrations would be well below design limits, but out of an abundance of caution it was decided to monitor the response in real time during the rollout to assure that loads remained within predicted limits. This first rollout was outfitted with extensive test instrumentation such as accelerometers, pressure sensors, and strain gauges. This instrumentation remained in place following the integrated vehicle modal test and was being used for additional Operational Modal Analysis (OMA) during the rollout in addition to the real-time monitoring. This presentation discusses the specific loads and accelerations monitored during the rollout, how and why those responses were chosen, and how the system was implemented. Finally, a post-rollout loads reconstruction is used to assess the process and the analysis tools used for the rollout analysis.

SLS↗

NASA NTRS1991

Determination of cytoplasmic calcium concentration in Dryopteris spores: a developmentally non-disruptive technique for loading of the calcium indicator fura-2

Germination of Dryopteris spores is mediated by the physiologically active, far-red-absorbing form of phytochrome, Pfr, and external Ca2+ is necessary for the transduction of the light signal. Because knowledge about the cytoplasmic calcium ion concentration, [Ca2+]i, is of great importance for understanding the role of calcium during signal transduction, this value was measured using fura-2 in fern spores undergoing the normal developmental progression into germination. Fura-2 was loaded into the spores by electroporation, which does not disrupt the normal process of germination. The intensity of the fluorescence emission of the loaded fura-2 was analysed by a microspectrophotometric assay of single spores, and successful loading could be obtained by the application of ten electrical pulses (field strength 7.5 kV cm-1, half-life (time constant) 230 microseconds). Fura-2 was alternately excited by light of wavelengths 355 and 385 nm through an inverted fluorescence microscope, and the emitted fura-2 fluorescence was collected by a silicon-intensified video camera. The cytoplasmic calcium ion concentration was calculated from the ratio of the camera output obtained for both wavelengths and displayed by a pseudo-color technique. Spores responded to changes of the extracellular Ca2+ concentration, and this observation is considered as evidence that fura-2 is loaded into the cytoplasm. The substitution of a low external [Ca2+] (1 mM ethyleneglycol-bis(2-aminoethylether)-N,N,N',N'-tetraacetic acid (EGTA)) by 1 mM CaCl2 caused a fast increase of [Ca2+]i from approx. 50 nM to above 500 nM. In contrast, the subsequent substitution of CaCl2 by EGTA decreased [Ca2+]i again below 100 nM within 0.5 h. Furthermore, the application of ionomycin could initiate a change in [Ca2+]i according to the Ca2+ gradient established between the extracellular medium and cytoplasm. In spores sown on a Ca(2+) -free medium, [Ca2+]i, analysed in a buffer containing EGTA, was found to be around 50 nM during the first days of cultivation, independent of the irradiation protocol. However, if spores were grown in darkness on a Ca(2+) -containing medium and analysed in EGTA, [Ca2+]i was significantly higher (> or = 500 nM). In red-light-irradiated spores, [Ca2+]i was found to decrease with increasing time after irradiation, and was determined to be less than 100 nM when analysis was done 44 h after germination was initiated by the light treatment.

NASA Discipline Plant Biology↗

NASA NTRS1996

Effect of Cyclic Thermo-Mechanical Loads on Fatigue Reliability in Polymer Matrix Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multi-factor interaction relationship developed at NASA Lewis Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability- based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)(sub s) graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Shah, A. R.↗

NASA NTRSDate not supplied

Evaluation of Preliminary Buffet Forcing Function Development based on Wind-Tunnel Tests of Geometrically-similar Models

The current state-of-the-art for launch vehicle buffet load estimation involves wind tunnel testing of highly instrumented rigid models and data processing of experimental unsteady pressure measurements to estimate the fluctuating aerodynamic loads. The model and instrumentation requirements to accomplish this type of testing are significant. The rigid model, in particular, must be built with relatively high geometric fidelity to approximate similar aerodynamic phenomena that will occur during the full-scale vehicle flight. Due to this requirement, several iterative wind tunnel tests are often required during the design maturation of the vehicle. For preliminary buffet load estimation, however, data from previous launch vehicle wind tunnel tests of geometrically similar models can be used to provide initial buffet environment estimates before a high geometric fidelity wind tunnel test has been conducted. In this paper, two components of this preliminary buffet estimation process are described: (1) assembly of buffet forcing functions from multiple data sources and (2) scaling of these buffet forcing functions to geometrically-similar components of a target vehicle configuration. The impacts of these estimation methods on the full-vehicle buffet forcing functions, including their longitudinal distribution along the vehicle, frequency-content at individual stations, and station-to-station coherence, are investigated. Considerations for using these methods to extrapolate wind tunnel data to geometrically similar models are also discussed.

Patrick S Heaney↗

NASA NTRS2011

Space Shuttle Day-of-Launch Trajectory Design Operations

A top priority of any launch vehicle is to insert as much mass into the desired orbit as possible. This requirement must be traded against vehicle capability in terms of dynamic control, thermal constraints, and structural margins. The vehicle is certified to specific structural limits which will yield certain performance characteristics of mass to orbit. Some limits cannot be certified generically and must be checked with each mission design. The most sensitive limits require an assessment on the day-of-launch. To further minimize vehicle loads while maximizing vehicle performance, a day-of-launch trajectory can be designed. This design is optimized according to that day s wind and atmospheric conditions, which increase the probability of launch. The day-of-launch trajectory design and verification process is critical to the vehicle s safety. The Day-Of-Launch I-Load Update (DOLILU) is the process by which the National Aeronautics and Space Administration's (NASA) Space Shuttle Program tailors the vehicle steering commands to fit that day s environmental conditions and then rigorously verifies the integrated vehicle trajectory s loads, controls, and performance. This process has been successfully used for almost twenty years and shares many of the same elements with other launch vehicles that execute a day-of-launch trajectory design or day-of-launch trajectory verification. Weather balloon data is gathered at the launch site and transmitted to the Johnson Space Center s Mission Control. The vehicle s first stage trajectory is then adjusted to the measured wind and atmosphere data. The resultant trajectory must satisfy loads and controls constraints. Additionally, these assessments statistically protect for non-observed dispersions. One such dispersion is the change in the wind from the last measured balloon to launch time. This process is started in the hours before launch and is repeated several times as the launch count proceeds. Should the trajectory design not meet all constraint criteria, Shuttle would be No-Go for launch. This Shuttle methodology is very similar to other unmanned launch vehicles. By extension, this method would likely be employed for any future NASA launch vehicle. This paper will review the Shuttle s day-of-launch trajectory optimization and verification operations as an example of a more generic application of day-of-launch design and validation. With Shuttle s retirement, it is fitting to document the current state of this critical process and capture lessons learned to benefit current and future launch vehicle endeavors.

Harrington, Brian E.↗

NASA NTRS2005

Space Shuttle Transportation (Roll-Out) Loads Diagnostics

The Space Transportation System (STS) consists of three primary components; an Orbiter Vehicle, an External Fuel Tank, and two Solid Rocket Boosters. The Orbiter Vehicle and Solid Rocket Boosters are reusable components, and as such, they are susceptible to durability issues. Recently, the fatigue load spectra for these components have been updated to include load histories acquired during the rollout phase of the STS processing for flight. Using traditional program life assessment techniques, the incorporation of these "rollout" loads produced unacceptable life estimates for certain Orbiter structural members. As a result, the Space Shuttle System Engineering and Integration Office has initiated a program to re-assess the method used for developing the "rollout" loads and performing the life assessments. In the fall of 2003 a set of tests were preformed to provide information to either validate existing load spectra estimation techniques or generate new load spectra estimation methods. Acceleration and strain data were collected from two rollouts of a partial-stack configuration of the Space Shuttle. The partial stack configuration consists of two Solid Rocket Boosters tied together at the upper External Tank attachment locations mounted on the Mobile Launch Platform carried by a Crawler Transporter (CT). In the current analysis, the data collected from this test is examined for consistency in speed, surface condition effects, and the characterization of the forcing function. It is observed that the speed of the CT is relatively stable. The dynamic response acceleration of the partial-stack is slightly sensitive to the surface condition of the road used for transport, and the dynamic response acceleration of the partial-stack generally increases as the transport speed increases. However, the speed sensitivity is dependent on the measurement location. Finally, the character of the forcing function is narrow-banded with the primary drivers being harmonics of two CT speed dependent excitations. One source is an excitation due to the CT treads striking the road surface, and the second is unknown.

Elliott, Kenny B.↗

NASA NTRS1993

Establishment of computerized numerical databases on thermophysical and other properties of molten as well as solid materials and data evaluation and validation for generating recommended reliable reference data

The Center for Information and Numerical Data Analysis and Synthesis, (CINDAS), measures and maintains databases on thermophysical, thermoradiative, mechanical, optical, electronic, ablation, and physical properties of materials. Emphasis is on aerospace structural materials especially composites and on infrared detector/sensor materials. Within CINDAS, the Department of Defense sponsors at Purdue several centers: the High Temperature Material Information Analysis Center (HTMIAC), the Ceramics Information Analysis Center (CIAC) and the Metals Information Analysis Center (MIAC). The responsibilities of CINDAS are extremely broad encompassing basic and applied research, measurement of the properties of thin wires and thin foils as well as bulk materials, acquisition and search of world-wide literature, critical evaluation of data, generation of estimated values to fill data voids, investigation of constitutive, structural, processing, environmental, and rapid heating and loading effects, and dissemination of data. Liquids, gases, molten materials and solids are all considered. The responsibility of maintaining widely used databases includes data evaluation, analysis, correlation, and synthesis. Material property data recorded on the literature are often conflicting, diverging, and subject to large uncertainties. It is admittedly difficult to accurately measure materials properties. Systematic and random errors both enter. Some errors result from lack of characterization of the material itself (impurity effects). In some cases assumed boundary conditions corresponding to a theoretical model are not obtained in the experiments. Stray heat flows and losses must be accounted for. Some experimental methods are inappropriate and in other cases appropriate methods are carried out with poor technique. Conflicts in data may be resolved by curve fitting of the data to theoretical or empirical models or correlation in terms of various affecting parameters. Reasons (e.g. phase transitions) must be found for unusual dependence or any anomaly. Such critical evaluation involves knowledge of theory, experience in measurement, familiarity with metallurgy (microstructural behavior) and not inconsiderable judgment. An examination of typical data compiled and analyzed by CINDAS shows that the thermal conductivity of a material reported in the literature may vary by a factor of two of more; the range of reported values increases as temperature increases reflecting the difficulty of high temperature measurements. Often only estimates of melt behavior are available, despite the importance of melt properties in modeling, welding, or other solidification processes. There may be only a few measurements available for properties such as kinematic viscosity, even for widely used materials such as stainless steel. In the face of such a paucity of existing data and in a national environment where too few new data are being generated it is nonetheless the responsibility of CINDAS to select and disseminate recommended values of a wide variety of thermophysical properties.

Ho, C. Y.↗

NASA NTRS2007

System and method of designing a load bearing layer of an inflatable vessel

A computer-implemented method is provided for designing a restraint layer of an inflatable vessel. The restraint layer is inflatable from an initial uninflated configuration to an inflated configuration and is constructed from a plurality of interfacing longitudinal straps and hoop straps. The method involves providing computer processing means (e.g., to receive user inputs, perform calculations, and output results) and utilizing this computer processing means to implement a plurality of subsequent design steps. The computer processing means is utilized to input the load requirements of the inflated restraint layer and to specify an inflated configuration of the restraint layer. This includes specifying a desired design gap between pairs of adjacent longitudinal or hoop straps, whereby the adjacent straps interface with a plurality of transversely extending hoop or longitudinal straps at a plurality of intersections. Furthermore, an initial uninflated configuration of the restraint layer that is inflatable to achieve the specified inflated configuration is determined. This includes calculating a manufacturing gap between pairs of adjacent longitudinal or hoop straps that correspond to the specified desired gap in the inflated configuration of the restraint layer.

Spexarth, Gary R.↗

NASA NTRS1992

Environmental fatigue of an Al-Li-Cu alloy. Part 3: Modeling of crack tip hydrogen damage

Environmental fatigue crack propagation rates and microscopic damage modes in Al-Li-Cu alloy 2090 (Parts 1 and 2) are described by a crack tip process zone model based on hydrogen embrittlement. Da/dN sub ENV equates to discontinuous crack advance over a distance, delta a, determined by dislocation transport of dissolved hydrogen at plastic strains above a critical value; and to the number of load cycles, delta N, required to hydrogenate process zone trap sites that fracture according to a local hydrogen concentration-tensile stress criterion. Transgranular (100) cracking occurs for process zones smaller than the subgrain size, and due to lattice decohesion or hydride formation. Intersubgranular cracking dominates when the process zone encompasses one or more subgrains so that dislocation transport provides hydrogen to strong boundary trapping sites. Multi-sloped log da/dN-log delta K behavior is produced by process zone plastic strain-hydrogen-microstructure interactions, and is determined by the DK dependent rates and proportions of each parallel cracking mode. Absolute values of the exponents and the preexponential coefficients are not predictable; however, fractographic measurements theta sub i coupled with fatigue crack propagation data for alloy 2090 established that the process zone model correctly describes fatigue crack propagation kinetics. Crack surface films hinder hydrogen uptake and reduce da/dN and alter the proportions of each fatigue crack propagation mode.

Piascik, Robert S.↗

NASA NTRS1972

Stress and buckling analysis of a double-bubble tank structure

An analytical study of a two-lobed circular arc pressure vessel (double-bubble tank) with a local perturbation from the cylindrical shape was made. It can be concluded that NASTRAN provides a good linear buckling analysis capability for structures that cannot be handled by other analysis techniques. However, solutions are relatively expensive from a computational standpoint. Two worthwhile additions to the NASTRAN program would be the inclusion of a new beam element that adequately represents the shear transfer when modeling stiffeners on a shell and the capability, in a rigid format, to keep certain prescribed loads constant during the eigenvalue extraction process.

Robinson, J. C.↗

NASA NTRS1975

Growth of surface and corner cracks in beta-processed and mill-annealed Ti-6Al-4V

Empirical stress-intensity expressions were developed to relate the growth of cracks from corner flaws to the growth of cracks from surface flaws. An experimental program using beta-processed Ti-6Al-4V verified these expressions for stress ratios, R greater than or equal to 0. An empirical crack growth-rate expression which included stress-ratio and stress-level effects was also developed. Cracks grew approximately 10 percent faster in transverse-grain material than in longitudinal-grain material and at approximately the same rate in longitudinal-grain mill-annealed Ti-6Al-4V. Specimens having surface and corner cracks and made of longitudinal-grain, beta-processed material were tested with block loads, and increasing the stresses in a block did not significantly change the crack growth rates. Truncation of the basic ascending stress sequence within a block caused more rapid crack growth, whereas both the descending and low-to-high stress sequences slowed crack growth.

Bell, P. D.↗

NASA NTRS1975

Discrete time modelization of human pilot behavior

This modelization starts from the following hypotheses: pilot's behavior is a time discrete process, he can perform only one task at a time and his operating mode depends on the considered flight subphase. Pilot's behavior was observed using an electro oculometer and a simulator cockpit. A FORTRAN program has been elaborated using two strategies. The first one is a Markovian process in which the successive instrument readings are governed by a matrix of conditional probabilities. In the second one, strategy is an heuristic process and the concepts of mental load and performance are described. The results of the two aspects have been compared with simulation data.

Cavalli, D.↗

NASA NTRS1983

Designing for a new era of launch vehicle operational efficiency

It is pointed out that early recognition of operational requirements and assessment of their effects provides the best chance of designing an economically viable future space transportation system (FSTS). Operational factors which may influence configuration design include fleet size, operation mode, refurbishment, and the resource requirements. FTST has a simplified operational role compared to the Space Shuttle, which, in addition to transportation, must perform experiments, support payloads, and stay long on orbit. In the future a space station will perform many of these tasks. The FSTS comprises a two-stage fully reusable launch vehicle designed to carry 150,000 lb to a space station, off-load, and return. It would always be launched fully loaded, and its cargo would be processed and redistributed at the space station. Attention is given to ground servicing, flight operations, rendezvous-compatible orbits, launch windows, standard trajectories, entry windows, operational costs, the mission model, and resource requirements.

Talay, T. A.↗

NASA NTRS1984

Ceramic wear in indentation and sliding

The various wear mechanisms involved with single-crystal ceramic materials in indentation and in sliding contacts. Experiments simulating interfacial events have been conducted with hemispherical, conical and pyramidal indenters (riders). With spherical riders, under either abrasive or adhesive conditions, two types of fracture pits have been observed. First, spherical-shaped fracture pits and wear particles are found as a result of either indenting or sliding. These are shown to be due to a spherical-shaped fracture along the circular or spherical stress trajectories. Second, polyhedral fracture pits and debris, produced by anisotropic fracture, and also found both during indenting and sliding. These are primarily controlled by surface and subsurface cracking along cleavage planes. Several quantitative results have also been obtained from this work. For example, using a pyramidal diamond, crack length of Mn-Zn ferrite in the indentation process grows linearly with increasing normal load. Moreover, the critical load to fracture both in indentation and sliding is essentially isotropic and is found to be directly proportional to the indenter radius.

Miyoshi, K.↗

NASA NTRS1984

Method and apparatus for gripping uniaxial fibrous composite materials

A strip specimen is cut from a unidirectional strong, brittle fiber composite material, and the surfaces of both ends of the specimen are grit blasted. The specimen is then placed between metal load transfer members having grit blasted surfaces. Sufficient compressive stress is applied to the load transfer members to prevent slippage during testing at both elevated temperatures and room temperatures. The need for adhesives, load pads, and other secondary composite processing is eliminated. This gripping system was successful in tensile testing, creep rupture testing, and fatigue testing uniaxial composite materials at 316 C.

Whittenberger, J. D.↗

NASA NTRS1985

Large deflections of a cantilever beam under arbitrarily directed tip load

The nonlinear beam equation was integrated numerically in a direct fashion to obtain results for large deflections of cantilevers under tip loads of arbitrary direction. A short BASIC computer program for performing this integration is presented. Results for selected load cases are presented. The numerical process is performed rapidly on a modern microcomputer, and comparisons with results from closed form solutions show that the process is accurate.

Mccomb, H. E., Jr.↗