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NASA NTRSDate not supplied

Orion Artemis I As Flown MMOD Analysis

Introduction The Lockheed Martin Orion spacecraft conducted the Artemis I flight around the Moon from November 16 through December 11, 2022. After the flight, an engineer from the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group performed a Micrometeoroid and Orbital Debris MMOD analysis using the Bumper 3 risk assessment tool to predict the number of small impacts that would likely have occurred during the mission. Separately, a team from the same group inspected the Orion capsule for hypervelocity impact damage features. The results of the inspection were compared to those of the analysis to aid in improving the analysis, including the environment models. Scope of Work The spacecraft geometry model was created by Lockheed Martin during construction of the Artemis I Orion vehicle based on Computer Aided Design (CAD) models of the vehicle. New hypervelocity impact testing was performed to verify Ballistic Limit Equations (BLEs) used in the analysis to link impactor size and damage to the Thermal Protection System (TPS). The exact trajectory flown was recorded during the flight, including vehicle attitude. This data was used in conjunction with the ORDEM 3.2 and MEM 3 environment modeling tools to create models of particle flux impacting the spacecraft throughout the mission. Meteoroid shower forecast information was also included to account for additional particle flux associated with meteoroid showers. Inspection of the Orion capsule included the Backshell thermal tiles and the tape covering it, windows, fabric thermal materials, and small areas of other materials. Potential MMOD damage found was characterized using various techniques, including optical microscopy, computed tomography scanning, and X-ray spectroscopy. Findings The number of craters found in the Backshell tile, and their size distribution, matches well with the Bumper analysis prediction. Tape, window, and other material impacts recorded similarly align to Bumper analysis predictions. Conclusions and Recommendations This comparison of analysis with inspection of the hardware provides valuable insight into the MMOD environment and how accurately analysis tools assess the impact risk to spacecraft. As this was the first large, non-ablative returned surface from a lunar mission, this analysis extends the MMOD community’s insight beyond low Earth orbit into cis-lunar space.

MMOD↗

NASA NTRS1984

Quantitative non-destructive evaluation of composite materials based on ultrasonic wave propagation

The size, shape, and orientation of damage correlates well between the polar backscatter technique and the deply technique. There is good quantitative correlation between the areas of damage indicated by the two techniques. These results suggest that the polar backscatter technique is sensitive to specific orientations of damage. The polar backscatter technique provides a good qualitative image of the size and shape of the largest zone of damage in each of the principal orientations. A quantitative estimate of the extent of these largest damage zones is obtained from the polar backscatter technique. The selective sensitivity of polar backscatter provides a useful tool for further studies of the mechanisms of impact damage in graphite fiber reinforced composite laminates.

Miller, J. G.↗

NASA NTRS1985

Tough composite materials: Recent developments

The present volume broadly considers topics in composite fracture toughness and impact behavior characterization, composite system constituent properties and their interrelationships, and matrix systems' synthesis and characterization. Attention is given to the characterization of interlaminar crack growth in composites by means of the double cantilever beam specimen, the characterization of delamination resistance in toughened resin composites, the effect of impact damage and open holes on the compressive strength of tough resin/high strain fiber laminates, the effect of matrix and fiber properties on compression failure mechanisms and impact resistance, the relation of toughened neat resin properties to advanced composite mechanical properties, and constituent and composite properties' relationships in thermosetting matrices. Also treated are the effect of cross-link density on the toughening mechanism of elastomer-modified epoxies, the chemistry of fiber/resin interfaces, novel carbon fibers and their properties, the development of a heterogeneous laminating resin, solvent-resistant thermoplastics, NASA Lewis research in advanced composites, and opportunities for the application of composites in commercial aircraft transport structures.

Vosteen, L. F.↗

NASA NTRS2017

Simulated Space Environment Effects on a Candidate Solar Sail Material

For long duration missions of solar sail vehicles, the sail material needs to survive the harsh space environment as the degradation of the sail material determines its operational lifetime. Therefore, understanding the effects of the space environment on the sail membrane is essential for mission success. In this study, the effect of simulated space environments of ionizing radiation and thermal aging were investigated. In order to assess some of the potential damage effects on the mechanical, thermal and optical properties of a commercial off the shelf (COTS) polyester solar sail membrane. The solar sail membrane was exposed to high energy electrons [about 70 keV and 10 nA/cm(exp. 2)], and the physical properties were characterized. After about 8.3 Grad dose, the tensile modulus, tensile strength and failure strain of the sail membrane decreased by 20 to 95%. The aluminum reflective layer was damaged and partially delaminated but it did not show any significant change in solar absorbance or thermal emittance. The mechanical properties of a precracked sample, simulating potential impact damage of the sail membrane, as well as thermal aging effects on metallized PEN (polyethylene naphthalate) film, will be discussed.

Kang, Jin Ho↗

NASA NTRS1980

Graphite-epoxy panel compression strength reduction due to local impact

The effects of low velocity impact on the compressive strength of graphite/epoxy structures are reviewed. Extensive tests were conducted on sandwich beams, laminated plates and stiffened panels. Conditions for failures were investigated by impact tests on statically loaded test specimens. Lightly loaded graphite structures (such as aircraft secondary structure) were insensitive to impact damage. In more heavily loaded structures, (such as wing panels), appreciable reductions in compressive strength occurred. The implications of the tests for structural design are discussed by comparing panel masses for designs where ultimate strains were reduced due to impact considerations with the masses of designs with higher ultimate strains. Preliminary test data are presented to show the possibility of improvements in damage to tolerance achievable by using an alternate matrix material.

Card, M. F.↗

NASA NTRS1980

Graphite-epoxy panel compression strength reduction due to local impact

A review of results from on-going research to investigate the effects of low-velocity impact on the compressive strength of graphite-epoxy structures is presented. Extensive tests have been conducted on sandwich beams, laminated plates and stiffened panels. Conditions for failures were investigated by impact tests on statically loaded test specimens. The effects of compression load intensity were such that lightly loaded graphite structures (such as aircraft secondary structure) were insensitive to impact damage. In more heavily loaded structures, (such as wing panels), however, appreciable reductions in compressive strength occurred. The implications of the tests for structural design are discussed by comparing panel masses for designs where ultimate strains have been reduced due to impact considerations with the masses of designs with higher ultimate strains. Finally, preliminary test data is presented to show the possibility of improvements in damage tolerance achievable by using an alternate matrix material.

Card, M. P.↗

NASA NTRS2017

Simulated Space Environment Effects on a Candidate Solar Sail Material

For long duration missions of solar sails, the sail material needs to survive harsh space environments and the degradation of the sail material controls operational lifetime. Therefore, understanding the effects of the space environment on the sail membrane is essential for mission success. In this study, we investigated the effect of simulated space environment effects of ionizing radiation, thermal aging and simulated potential damage on mechanical, thermal and optical properties of a commercial off the shelf (COTS) polyester solar sail membrane to assess the degradation mechanisms on a feasible solar sail. The solar sail membrane was exposed to high energy electrons (about 70 keV and 10 nA/cm2), and the physical properties were characterized. After about 8.3 Grad dose, the tensile modulus, tensile strength and failure strain of the sail membrane decreased by about 20 ~ 95%. The aluminum reflective layer was damaged and partially delaminated but it did not show any significant change in solar absorbance or thermal emittance. The effect on mechanical properties of a pre-cracked sample, simulating potential impact damage of the sail membrane, as well as thermal aging effects on metallized PEN (polyethylene naphthalate) film will be discussed.

Kang, Jin Ho↗

NASA NTRS1988

Hypervelocity impact testing of tethers

An experimental test program has been conducted to ascertain the strength losses to which representative space tether materials may be prone upon impact by hypervelocity particles of known size, density, and velocity, when the tether is under tensile loading typical of flight design loads. Twelve hypervelocity impacts were followed by tensile tests to failure to determine residual strength; relationships are established between particle velocity and strength loss due to impact damage, as well as between tether strength loss and the relationship between particle and tether diameters. Tentative design criteria are formulated in terms of a design factor allowing for strength degradation by impact.

Woodis, William R.↗

NASA NTRS1988

Fractography of composite delamination

Studies were made of the fractography of mode 2 delamination and the impact damage of carbon fiber reinforced polymer composites. Laminates fractured under mode 2 loading were potted in a clear epoxy polymer, sectioned and polished and examined using transmission and reflection light microscopy. There were only occasional fibers bridging the mode 2 cracks. These cracks were not always visible probably because the crack opening displacement was too small as to be resolved using light microscopy. A study was made of the effect of repetitive impacts on laminates of AS4/3501-6 and IM6/3501-6. Plots of cumulative impact energy vs cumulative absorbed energy exhibited a sharp change in slope which corresponded to the damage area reaching the edges of the specimen. The initial slope was highly reproducible for both composite materials. On the other hand, the intersection point between the two slopes, where the damage area reaches the specimen edges, was highly variable between specimens. This variability is tentatively ascribed to differences in laminate quality.

Source record↗

NASA NTRS1993

A fresh look at crater scaling laws for normal and oblique hypervelocity impacts

With the concomitant increase in the amount of man-made debris and an ever increasing use of space satellites, the issue of accidental collisions with particles becomes more severe. While the natural micrometeoroid population is unavoidable and assumed constant, continued launches increase the debris population at a steady rate. Debris currently includes items ranging in size from microns to meters which originated from spent satellites and rocket cases. To understand and model these environments, impact damage in the form of craters and perforations must be analyzed. Returned spacecraft materials such as those from LDEF and Solar Max have provided such a testbed. From these space-aged samples various impact parameters (i.e., particle size, particle and target material, particle shape, relative impact speed, etc.) may be determined. These types of analyses require the use of generic analytic scaling laws which can adequately describe the impact effects. Currently, most existing analytic scaling laws are little more than curve-fits to limited data and are not based on physics, and thus are not generically applicable over a wide range of impact parameters. During this study, a series of physics-based scaling laws for normal and oblique crater and perforation formation has been generated into two types of materials: aluminum and Teflon.

Watts, A. J.↗

NASA NTRS1992

Properties of five toughened matrix composite materials

The use of toughened matrix composite materials offers an attractive solution to the problem of poor damage tolerance associated with advanced composite materials. In this study, the unidirectional laminate strengths and moduli, notched (open-hole) and unnotched tension and compression properties of quasi-isotropic laminates, and compression-after-impact strengths of five carbon fiber/toughened matrix composites, IM7/E7T1-2, IM7/X1845, G40-800X/5255-3, IM7/5255-3, and IM7/5260 have been evaluated. The compression-after-impact (CAI) strengths were determined primarily by impacting quasi-isotropic laminates with the NASA Langley air gun. A few CAI tests were also made with a drop-weight impactor. For a given impact energy, compression after impact strengths were determined to be dependent on impactor velocity. Properties and strengths for the five materials tested are compared with NASA data on other toughened matrix materials (IM7/8551-7, IM6/1808I, IM7/F655, and T800/F3900). This investigation found that all five materials were stronger and more impact damage tolerant than more brittle carbon/epoxy composite materials currently used in aircraft structures.

Cano, Roberto J.↗

DOE OSTI2025

Damage modeling of power tower receiver tubes using the SRLIFE tool

Concentrating Solar Power (CSP) molten-salt central receivers are subject to high, transient incident flux during daily operation. The resulting creep-fatigue damage impacts the receiver’s reliability and restricts the permissible incident flux distribution for a given receiver. This paper aims to reduce CSP plants’ levelized cost of electricity by developing a methodology to predict lifetime and identifies the primary damage mechanism (creep vs fatigue) for any given fluid temperature and temperature gradient. Results are presented in the form of a damage map that serves as a valuable operation guide and design tool. Damage maps can be used to reduce maintenance costs by improving reliability and reduce receiver capital costs by better utilizing the receiver area. FEA simulation and damage modeling of tubes subject to asymmetrical flux conditions is performed in the open-source receiver design tool srlife. Parametric studies are performed over a range of inner tube temperatures and thermal gradients for A230, 316H, 740H, A282, A617, and 800H high temperature alloys. Damage maps are presented for each alloy. A parametric, FEA-based methodology is presented for comparison of fatigue-creep ratios and prediction of tube lifetime based on the critical thermal operating conditions. Fatigue is found to be negligible compared to creep for almost every case. Here, this finding suggests that fatigue effects associated with cloud events are insignificant compared to creep at these high temperature operating conditions. Additionally, lifetime predictions identify thermal conditions where small changes in operating conditions can result in large changes in predicted lifetime.

14 SOLAR ENERGY↗

NASA NTRS2016

Ultrasonic Nondestructive Evaluation of Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) During Large-Scale Load Testing and Rod Push-Out Testing

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept developed by the Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration. The HWB has long been a focus of NASA's environmentally responsible aviation (ERA) project, following a building block approach to structures development, culminating with the testing of a nearly full-scale multi-bay box (MBB), representing a segment of the pressurized, non-circular fuselage portion of the HWB. PRSEUS is an integral structural concept wherein skins, frames, stringers and tear straps made of variable number of layers of dry warp-knit carbon-fiber stacks are stitched together, then resin-infused and cured in an out-of-autoclave process. The PRSEUS concept has the potential for reducing the weight and cost and increasing the structural efficiency of transport aircraft structures. A key feature of PRSEUS is the damage-arresting nature of the stitches, which enables the use of fail-safe design principles. During the load testing of the MBB, ultrasonic nondestructive evaluation (NDE) was used to monitor several sites of intentional barely-visible impact damage (BVID) as well as to survey the areas surrounding the failure cracks after final loading to catastrophic failure. The damage-arresting ability of PRSEUS was confirmed by the results of NDE. In parallel with the large-scale structural testing of the MBB, mechanical tests were conducted of the PRSEUS rod-to-overwrap bonds, as measured by pushing the rod axially from a short length of stringer.

Johnston, Patrick H.↗

NASA NTRS2019

Modeling of the Influence of a Damaged Thermally Grown Oxide (TGO) Layer in an Environmental Barrier Coating System

Environmental barrier coatings (EBC) are an enabling technology for the successful application of ceramic matrix composites (CMCs) in air-breathing gas turbine engines. EBCs are susceptible to a number of failure modes including oxidation/delamination, recessions, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object impact damage in a combustion environment. Spallation of environmental barrier coating (EBC), induced by a thermally grown oxide (TGO) layer, is a key EBC failure mode. The TGO layer, resulting from steam oxidation, grows either from a silicon bond coat layer (if present) or from a silicon carbide (SiC) based substrate itself. The TGO layer evolves (i.e., thickness increases with time) as water vapor and oxygen gradually diffuse through the EBC, and the EBC spalls off once the TGO layer reaches some critical thickness. The critical thickness of the TGO layer for failure is in the range of 20-30 microns, but it can vary due to exposure temperature, microstructure etc. Current work at NASA Glenn Research Center, under the Revolutionary Tools and Methods (RTM) subproject is aimed at addressing associated failure modes in EBC systems and developing robust analysis tools to aid in the design/analysis of these systems. The objective of the current work is to conduct a sensitivity study to examine the influence of uniformly and non-uniformly grown oxide layers on the associated driving forces leading to spallation of the EBC when subjected to isothermal loading. The effect of damage in the TGO layer on the resulting stress states is also assessed both in uniform and non-uniform TGO layers.

Mital, Subodh K.↗

NASA NTRS1985

Damage tolerant composite wing panels for transport aircraft

Commercial aircraft advanced composite wing surface panels were tested for durability and damage tolerance. The wing of a fuel-efficient, 200-passenger airplane for 1990 delivery was sized using grahite-epoxy materials. The damage tolerance program was structured to allow a systematic progression from material evaluations to the optimized large panel verification tests. The program included coupon testing to evaluate toughened material systems, static and fatigue tests of compression coupons with varying amounts of impact damage, element tests of three-stiffener panels to evaluate upper wing panel design concepts, and the wing structure damage environment was studied. A series of technology demonstration tests of large compression panels is performed. A repair investigation is included in the final large panel test.

Smith, Peter J.↗

NASA NTRSDate not supplied

Testing of a Multi-Stringer Post-Buckled Panel with Incremental Damage Detection

A multi-stringer panel was designed and tested to produce a failure mode of skin-stiffener delamination due to compression loading of a post-buckled skin to support the validation of high-fidelity progressive damage failure analysis modeling. The test procedure included multiple methods of data acquisition ranging from multiple strain gages, front and back digital image correlation, passive thermography, acoustic emission, and ultrasonic inspection to capture key events and damage progression prior to catastrophic failure. Detailed data showing the initial stiffness, onset of skin buckling, buckled mode shape, damage initiation load, damage propagation morphology, and peak load was captured. Two panel configurations were tested. The first had a Teflon insert placed in the interface between the skin and the stiffener flanges adjacent to the center skin bay. The second was subjected to impact damage to the skin-stiffener flange. In each case, continuously-loaded-to-failure tests were conducted first with passive thermography being used exclusively to determine key damage events. Then, incrementally loaded tests were completed where ultrasonic inspections were conducted between each increment. The amount of load applied between each increment was determined based on the in-situ damage detection provided by the passive thermography system. The results of the testing showed a complex delamination growth pattern which migrated between ply interfaces through matrix splits in the upper skin ply of the panel. The result of the testing produced very detailed data which will prove to be useful for validation of delamination growth and migration predictions from progressive damage failure analysis methods.

Jason Action↗

NASA NTRS1985

Fuel containment, lightning protection and damage tolerance in large composite primary aircraft structures

The damage-tolerance characteristics of high strain-to-failure graphite fibers and toughened resins were evaluated. Test results show that conventional fuel tank sealing techniques are applicable to composite structures. Techniques were developed to prevent fuel leaks due to low-energy impact damage. For wing panels subjected to swept stroke lightning strikes, a surface protection of graphite/aluminum wire fabric and a fastener treatment proved effective in eliminating internal sparking and reducing structural damage. The technology features developed were incorporated and demonstrated in a test panel designed to meet the strength, stiffness, and damage tolerance requirements of a large commercial transport aircraft. The panel test results exceeded design requirements for all test conditions. Wing surfaces constructed with composites offer large weight savings if design allowable strains for compression can be increased from current levels.

Griffin, Charles F.↗

NASA NTRS2009

Orbital Debris Quarterly News, Vol. 13, No. 2

Topics include: debris clouds left by satellite collision; debris flyby near the International Space Station; and break-up of an ullage motor from a Russian Proton launch vehicle. Findings from the analysis of the STS-126 Shuttle Endeavour window impact damage are provided. Abstracts from the NASA Orbital Debris program office are presented and address a variety of topics including: Reflectance Spectra Comparison of Orbital Debris, Intact Spacecraft, and Intact Rocket Bodies in the GEO Regime; Shape Distribution of Fragments From Microsatellite Impact Tests; Micrometeoroid and Orbital Debris Threat Mitigation Techniques for the Space Shuttle Orbiter; Space Debris Environment Remediation Concepts; and, In Situ Measurement Activities at the NASA Orbital Debris Program Office. Additionally, a Meeting Report is provided for the 12 meeting of the NASA/DoD Orbital Debris Working Group.

Liou, J.-C.↗