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NASA NTRS1993

Precision of the calibration of the AXAF Engineering Test Article (VETA) mirrors

Measurements of the VETA encircled energies have been performed at 5 energies within 16 radii ranging from 0.05 to 200 arcseconds. We report here on the analysis of the accuracy of those measurements. A common 'error tree' structure applies, and we present representative numbers for the larger terms. At 0.277, 1.5, and 2.07 keV, and for radii of 3 arcsec and larger, our measurements have estimated 1 sigma errors of 0.6 to 1.5 percent. Effects of measurement statistics and of the VETA test mount limit the accuracy at smaller angles, and modulation by the counter window support structure together with the imperfect position repeatability limit the accuracy for the 0.93 and 2.3 keV energies. We expect to mitigate these limitations when calibrating the complete AXAF flight mirror assembly.

Schwartz, D. A.↗

NASA NTRS2007

Conceptual Design of the TPF-O SC Buses

The Terrestrial Planet Finder - Occulter (TPF-O) mission has two Spacecraft (SC) buses, one for a space telescope and the other for a formation-flying occulter. SC buses typically supply the utilities (support structures, propulsion, attitude control, power, communications, etc) required by the payloads. Unique requirements for the occulter SC bus are to provide the large delta V required for the slewing maneuvers of the occulter, and comunications for formation flying. The TPF-O telescope SC bus shares some key features of the one for the Hubble Space Telescope (HST): both support space telescopes designed to observe in the visible to near infrared range of wavelengths with comparable primary mirror apertures (2.4 m for HST, 2.4 - 4.0 m for TPF-O). However, TPF-O is expected to have a Wide Field Camera (WFC) with a Field of View (FOV) much larger than that of HST. Ths WFC is also expected to provide fine guidance. TPF-O is designed to operate in an orbit around the Sun-Earth Lagrange 2 (SEL2) point. The longer communications range to SEL2 and the large science FOV require higher performance communications than HST. Maintaining a SEL2 orbit requires TPF-O, unlike HST, to have a propulsion system. The velocity required for reachng SEL2 and the limited capabilities of affordable launch vehicles require both TPF-O elements to have compact, low-mass designs. Finally, it is possible that TPF-O may utilize a modular design derived fiom that of HST to allow servicing in the SEL2 orbit.

Purves, Lloyd R.↗

NASA NTRS1983

Modeling of flexible structures for active control

If a flexible structure has a plane of symmetry, the equations of motion can be split into two uncoupled sets, one for symmetrical motions and one for anti-symmetric motions. If there are m controls, it is often convenient to assign the linear combinations of controls that enter into the m lowest frequency modes and new controls. As an example the feed-support structure of a spacecraft antenna is considered. It is modeled as a tetrahedron made up of flexible bars and connected to the spacecraft by six short flexible legs containing force actuators and displacement sensors. Due to the three-sided symmetry of this structure, both the symmetric and the anti-symmetric equations of motion can be decoupled into two subsystems. The resulting four subsystems are: (1) pitch/fore-aft motions with four degrees of freedom (DOF), two controls, and one output (the fore-aft motion of the feed); (2) vertical motions with three DOF, one control, and one output (the vertical motion of the feed); (3) roll/lateral motions with four DOF, two controls, and one output (the lateral motions of the feed); and (4) yaw motion with one DOF, one control, and no output (the feed does not move during yaw motion).

Bryson, A. E., Jr.↗

NASA NTRS1986

An evaluation of candidate oxidation resistant materials for space applications in LEO

Ground based testing of materials considered for polyimide (Kapton) solar array blanket protection and graphite-epoxy stroctural member protection was performed in an RF plasma asher. Protective coatings on Kapton from various commercial sources and from NASA Lewis Research Center were exposed to the air plasma; and mass loss per unit area was measured for each sample. All samples evaluated provided some protection to the underlying surface, but metal-oxide-fluoropolymer coatings provided the best protection by exhibiting very little degradation after 47 hr of asher exposure. Mica paint was evaluated as a protective coating for graphite-epoxy structural members. Mica appeared to be resistant to attack by atomic oxygen, but only offered limited protection as a paint. this is believed to be due to the paint vehicle ashing underneath the mica leaving unattached mica flakes lying on the surface. The protective coatings on Kapton evaluated so far are promising but further research on protection of graphite-epoxy support structures is needed.

Rutledge, Sharon↗

NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗

NASA NTRS1984

Rapid adhesive bonding concepts for specimen and panel fabrication and field repair

The NASA Langley Research Center has developed bonding concepts for aerospace composite materials which employ induction heating to directly apply heat to the bond line and/or adherends without simultaneously heating the entire structure, supports, and fixtures of a bonding assembly. These methods have demonstrated bonding process time reductions of two to three orders of magnitude, by comparison with conventional press molding. Attention is presently given to rapid adhesive bonding for lap shear specimens for aerospace panel bonding or field repair, as well as for the field repair requirements of metallic and advanced polymeric matrix composite structures.

Stein, B. A.↗

NASA NTRS2016

Flat H Redundant Frangible Joint Development

Orion and Commercial Crew Program (CCP) Partners have chosen to use frangible joints for certain separation events. The joints currently available are zero failure tolerant and will be used in mission safety applications. The goal is to further develop a NASA designed redundant frangible joint that will lower flight risk and increase reliability. FY16 testing revealed a successful design in subscale straight test specimens that gained efficiency and supports Orion load requirements. Approach / Innovation A design constraint is that the redundant joint must fit within the current Orion architecture, without the need for additional vehicle modification. This limitation required a design that changed the orientation of the expanding tube assemblies (XTAs), by rotating them 90deg from the standard joint configuration. The change is not trivial and affects the fracture mechanism and structural load paths. To address these changes, the design incorporates cantilevered arms on the break plate. The shock transmission and expansion of the XTA applies force to these arms and creates a prying motion to push the plate walls outward to the point of structural failure at the notched section. The 2014 test design revealed that parts could slip during functioning wasting valuable energy needed to separate the structure with only a single XTA functioning. Dual XTA functioning fully separated the assembly showing a discrepancy can be backed up with redundancy. Work on other fully redundant systems outside NASA is limited to a few patents that have not been subjected to functionality testing Design changes to prevent unwanted slippage (with ICA funding in 2015) showed success with a single XTA. The main goal for FY 2016 was to send the new Flat H RFJ to WSTF where single XTA test failures occurred back in 2014. The plan was to gain efficiency in this design by separating the Flat H RFJ with thicker ligaments with dimensions baselined in 2014. Other modifications included geometry changes to better disperse loads paths and to minimize air gaps. The design additionally added more structural strength to enhance the structural limits in static loads testing. The design also implemented a smoother load line through the assembly. Results / Knowledge Gained The new Flat H RFJ successfully fractured at WSTF with thicker ligaments and lower cord size. Where failure to separate occurred earlier, there is now excessive energy available for structural separation. The new challenge to provide some structural support to prevent secondary fracturing of the break plate remains to be completed. This future work is being funded by the JSC Engineering Directorate in 2017 to elevate the TRL on curved Flat H RFJs that configure with the Orion Service Panel Separation. Additional funding from JSC Engineering will provide new design testing to avoid secondary fracturing.

Brown, Chris↗

NASA NTRS1985

Rapid adhesive bonding and field repair of aerospace materials

Adhesive bonding in the aerospace industry typically utilizes autoclaves or presses which have considerable thermal mass. As a consequence, the rates of heatup and cooldown of the bonded parts are limited and the total time and cost of the bonding process are often relatively high. Many of the adhesives themselves do not inherently require long processing times. Bonding could be performed rapidly if the heat was concentrated in the bond lines or at least in the adherends. Rapid Adhesive Bonding concepts are developed to utilize induction heating techniques to provide heat directly to the bond line and/or adherends without heating the entire structure, supports, and fixtures of a bonding assembly. Bonding times for specimens can be cut by a factor of 10 to 100 compared to standard press or autoclave bonding. The development of Rapid Adhesive Bonding for lap shear specimens (per ASTM D1002 and D3163), for aerospace panel or component bonding, and for field repair needs of metallic and advanced fiber reinforced polymeric-matrix composite structures is reviewed. Equipment and procedures are described for bonding and repairing thin sheets, simple geometries, and honeycomb core panels.

Stein, B. A.↗

NASA NTRS1989

Scattering from thin dielectric straps surrounding a perfectly conducting structure

A method to calculate the electromagnetic scattered fields from a dielectric strap wrapped around convex, conducting structure is presented. A moment method technique is used to find the current excited within the strap by the incident plane wave. Then, Uniform Geometrical Theory of Diffraction (UTD) is used to compute the fields scattered by the strap. Reasonable agreement was obtained between the computed and the measured results. The results found in this study are useful in evaluating straps as a target support structure for scattering measurements.

Al-Hekail, Zeyad↗

NASA NTRS1991

The effect of atomic oxygen on polysiloxane-polyimide for spacecraft applications in low Earth orbit

Polysiloxane-polyimide films are of interest as a replacement for polyimide Kapton in the Space Station Freedom solar array blanket. The blanket provides the structural support for the solar cells as well as providing transport of heat away from the back of the cells. Polyimide Kapton would be an ideal material to use; however, its high rate of degradation due to attack by atomic oxygen in low Earth orbit, at the altitudes Space Station Freedom will fly, is of such magnitude that if left unprotected, the blanket will undergo structural failure in much less than the desired 15 year operating life. Polysiloxane-polyimide is of interest as a replacement material because it should from its own protective silicon dioxide coating upon exposure to atomic oxygen. Mass, optical, and photomicrographic data obtained in the evaluation of the durability of polysiloxane-polyimide to an atomic oxygen environment are presented.

Rutledge, Sharon K.↗

NASA NTRS1975

Mated aerodynamic characteristics investigation for 0.04-scale model Boeing 747 CAM/external tank (model AX1284 E-5) combination in the University of Washington Aeronautical Laboratory F. K. Kirsten Wind Tunnel (CA11)

Experimental investigations of the aerodynamic characteristics of a 0.04-scale external tank (ET) force model in combination with a 0.04-scale Boeing 747 force model were conducted. Test purposes were: (1) to determine ET airloads for selected configurations and (2) to determine the effectiveness of ET position, incidence, and support structure and 747 vertical stabilizing surfaces on stability, control, and performance of 747/ET combinations. The 747 was tested alone to establish baseline data and to verify test results. Six-component aerodynamic force and moment data were recorded for the 747 CAM and ET combination. Six-component force and moment data were also recorded for the ET, which was mounted on an internal balance supported by the 747. Data were recorded for angles of attack from -4 deg to +24 deg in 2 deg increments and angles of sideslip of - deg to + or - 20 deg. Testing was conducted at Mach 0.15 with dynamic pressure deg at 36 psf and unit Reynolds number of 1.3 million per foot. Photographs of test configurations are shown.

Source record↗

NASA NTRS2001

Modular electronics packaging system

A modular electronics packaging system includes multiple packaging slices that are mounted horizontally to a base structure. The slices interlock to provide added structural support. Each packaging slice includes a rigid and thermally conductive housing having four side walls that together form a cavity to house an electronic circuit. The chamber is enclosed on one end by an end wall, or web, that isolates the electronic circuit from a circuit in an adjacent packaging slice. The web also provides a thermal path between the electronic circuit and the base structure. Each slice also includes a mounting bracket that connects the packaging slice to the base structure. Four guide pins protrude from the slice into four corresponding receptacles in an adjacent slice. A locking element, such as a set screw, protrudes into each receptacle and interlocks with the corresponding guide pin. A conduit is formed in the slice to allow electrical connection to the electronic circuit.

Hunter, Don J.↗

NASA NTRS2002

Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance

The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.

DellaCorte, Christopher↗

NASA NTRS1991

A self-reconfigurable manipulator system with dextrous bracing structure

The authors present a dextrous bracing structure of a dual-arm system as a means of implementing a self-reconfigurable manipulator system. The dextrous bracing structure allows a dual-arm system to relocate the bracing point between two arms, select the type of contact as the bracing point, and lock or release the joints of individual arms. The self-reconfigurable dual-arm system is now capable of reconfiguring its topology through serial, parallel and bracing structures, supporting general types of contact, rigid or sliding, as well as locking or releasing some of its joints as needed. The focus is on an analysis of the effects of the dextrous bracing on the performance of a dual-arm system in terms of dual-arm manipulabilities and resistivities. The analysis shows that a self-reconfigurable dual-arm system with a dextrous bracing structure gives continuously varying performance characteristics ranging from serial to parallel structures.

Lee, Sukhan↗

NASA NTRS2012

Quasi-Monolithic Structures for Spaceflight Using Hydroxide-Catalysis Bonding

Future space-based missions will take measurements of the universe with unprecedented results. To do this, these missions will require materials and bonding techniques with ever-increasing stability in order to make their measurements. As an example, the Laser Interferometer Space Antenna (LISA) will detect and observe gravitational waves in the 0.1 mHz to 1 Hz frequency range with strain sensitivities on the order of 10(exp -21) at its most sensitive frequency. To make these measurements, critical components such as the optical bench or telescope support structure, will need to have path-length stabilities of better than 1 pm/(square root)Hz. The baseline construction method for the LISA optical bench is to affix fused silica optical components to a Zerodur baseplate using hydroxide-catalysis bonding (HCB). HCB is a recently developed technique that allows the bonding of glasses, some metals, and silicon carbide with significant strength and stability with a bond thickness of less than a few micrometers. In addition, a wide range of surface profiles can be bonded using only a small amount of hydroxide solution. These characteristics make HCB ideal for adhering optical components in complex optical systems. In addition to being used to construct the LISA optical bench, the HCB technique shows great promise for constructing other structures such as hollow retroreflectors to be used for lunar laser ranging, or a visible nulling coronograph to be used for exo-planet detection. Here we present construction techniques that could be used to make an optical bench, hollow retroreflector, nulling coronograph, or other quasi-monolithic structures using HCB. In addition, we present dimensional stability results of an optical bench that was made using HCB, as well as HCB strength measurements.

Preston, Alix↗

NASA NTRS2006

Novel In-Space Manufacturing Concepts for the Development of Large Space Telescopes

There is a continuous demand for larger, lighter, and higher quality telescopes. Over the past several decades, we have seen the evolution from launchable 2 meter-class telescopes (such as Hubble), to today s demand for deployable 6 meter-class telescopes (such as JWST), to tomorrow s need for up to 150 meter-class telescopes. As the apertures continue to grow, it will become much more difficult and expensive to launch assembled telescope structures. To address this issue, we are seeing the emergence of new novel structural concepts, such as inflatable structures and membrane optics. While these structural concepts do show promise, it is very difficult to achieve and maintain high surface figure quality. Another potential solution to develop large space telescopes is to move the fabrication facility into space and launch the raw materials. In this paper we present initial in-space manufacturing concepts to enable the development of large telescopes. This includes novel approaches for the fabrication of both the optical elements and the telescope support structure. We will also discuss potential optical designs for large space telescopes and describe their relation to the fabrication methods. These concepts are being developed to meet the demanding requirements of DARPA s LASSO (Large Aperture Space Surveillance Optic) program which currently requires a 150 meter optical aperture with a 17 degree field of view.

Mooney, James T.↗

NASA NTRS2014

Loads and Structural Dynamics Requirements for Spaceflight Hardware

The purpose of this document is to establish requirements relating to the loads and structural dynamics technical discipline for NASA and commercial spaceflight launch vehicle and spacecraft hardware. Requirements are defined for the development of structural design loads and recommendations regarding methodologies and practices for the conduct of load analyses are provided. As such, this document represents an implementation of NASA STD-5002. Requirements are also defined for structural mathematical model development and verification to ensure sufficient accuracy of predicted responses. Finally, requirements for model/data delivery and exchange are specified to facilitate interactions between Launch Vehicle Providers (LVPs), Spacecraft Providers (SCPs), and the NASA Technical Authority (TA) providing insight/oversight and serving in the Independent Verification and Validation role. In addition to the analysis-related requirements described above, a set of requirements are established concerning coupling phenomena or other interaction between structural dynamics and aerodynamic environments or control or propulsion system elements. Such requirements may reasonably be considered structure or control system design criteria, since good engineering practice dictates consideration of and/or elimination of the identified conditions in the development of those subsystems. The requirements are included here, however, to ensure that such considerations are captured in the design space for launch vehicles (LV), spacecraft (SC) and the Launch Abort Vehicle (LAV). The requirements in this document are focused on analyses to be performed to develop data needed to support structural verification. As described in JSC 65828, Structural Design Requirements and Factors of Safety for Spaceflight Hardware, implementation of the structural verification requirements is expected to be described in a Structural Verification Plan (SVP), which should describe the verification of each structural item for the applicable requirements. The requirement for and expected contents of the SVP are defined in JSC 65828. The SVP may also document unique verifications that meet or exceed these requirements with Technical Authority approval.

George James↗

NASA NTRS1981

Static and dynamic characteristics of large deployable space reflectors

A linear numerical model of the structural characteristics of deployable reflectors was developed. Due to cyclic symmetry of the reflector structure about its axis, only one of many segments is modeled using finite elements. The succeeding segments satisfy continuity of displacement and slope at the interface between consecutive segments. This process leads to (N/2+1) static or dynamic problems of smaller order and bandwidth where N is the number of segments. The solution of each reduced problem leads to motions having a distinct circumferential wave number. The dynamic coupling to the feed support structure is studied adopting modal synthesis.

El-Raheb, M.↗