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NASA NTRSDate not supplied

Design, Instrumentation, and Data Analysis for the SLS Core Stage Green Run Test Series

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The actuators are powered by a Shuttle-derived hydraulic Core Auxiliary Power Unit (CAPU), and integrated with an all-new Core Stage thrust structure. The actuators are interfaced to the SLS Vehicle Management (VM) software via an all-new TVC Actuator Control (TAC) avionics subsystem. Despite the significant test and flight experience of the Shuttle hardware, the SLS Green Run ambient and hot fire test activities revealed a number of new findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC system did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. This paper is the fifth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the design of the TVC analyses conducted during the Core Stage Green Run test series are discussed in detail. Throughout the course of the test activities, the SLS flight control team worked diligently with the Core Stage contractor to revise test command profiles and ensure sufficient instrumentation was available to collect data. Post-test analysis combined the Green Run modal, ambient, and hot fire test data, MSFC 2- axis Core Stage TVC Inertial Load Simulator (ILS) data, Hardware-In-the-Loop (HWIL) Systems Integration Lab (SIL) results, and actuator Acceptance Testing Procedure (ATP) responses. These data were used to characterize the response, validate critical math models of the TVC subsystem, and isolate the probable cause of the unexpected responses. Through comprehensive analysis of the available test data sources, the integrated team identified the dominant contributors to the observed response and developed test-correlated rationale for vehicle flight control system performance, ultimately leading to a confident posture for the Artemis I mission.

John H. Wall↗

NASA NTRSDate not supplied

Impact of Thermochromic Coatings on Thermal Management for Human Spacecraft Applications

Thermochromic variable emittance coatings (VECs) allow for passive, dynamic thermal management of space vehicles due to their temperature dependent optical properties. Ideally, a thermochromic material should exhibit low mid-IR emissivity for lower temperatures and switch to high mid-IR emissivity for higher temperatures; one promising material that demonstrates these characteristics is Lanthanum Strontium Manganite (LSM). The transition temperatures of LSM are dependent on the Lanthanum-to-Strontium ratio x, La1-xSrxMnO3. La0.8Sr0.2MnO3, which has an emittance of 0.5 for < 270 K, then a linear increase in emittance to 0.8 over an increase of 70 K where it will saturate at ~340K, is commonly utilized but this is tunable by changing the Sr concentration. The tunability of the transition temperature range of LSM motivates a need to understand the optimal thermal transition range for human spacecraft. Additionally, LSM has high solar absorptance and to combat this issue the VEC will be micropatterned on top of a highly solar reflective layer of Barium Sulfate (BaSO4). Consequently, this work will elucidate the tradeoffs between solar absorptance and variable emittance for this technology since the micropattern adversely couples the solar absorptance to the mid-IR emittance. This work develops a computational model using Thermal Desktop to study the utility of VECs on human spacecraft, such as Orion, subjected to mission phases such as lunar transit and Gateway docking. The model considers both external heat loads, from solar irradiation and planetary IR, as well as vehicle heat loads, from avionics and crew, as an input into the body mounted thermochromic radiators. There are several design targets for VECs, i.e. achieving the largest change in emittance, finding the optimal temperature range for the transition, and achieving the highest emittance in the high temperature phase. This work prioritizes these design targets for LSM to achieve the optimal heat rejection for a human spacecraft. The VECs are compared with static emittance coatings and the efficiency gains are quantified. Thermochromic VECs will ultimately lead to simplifications of active cooling systems which synergistically correlates to mass reduction and less energy consumption for space vehicles.

Joseph Peoples↗

NASA NTRS1976

Stress-strain and failure properties of graphite/epoxy laminates

The results of a series of tensile tests on graphite/epoxy laminates at rates varying from 0.002 in/min to 2 in/min are reported. The loads are applied at various angles to the fiber directions in each case. The rate dependent behavior of the stress-strain response is assessed. Evidence is presented to indicate that failure first occurs on inner piles. Also, evidence is presented to indicate that, in some cases, moduli increase with increased stress or strain level. The lamination theory is used to predict moduli and comparisons with experiment are given. Also, the lamination theory is used in conjunction with three failure theories to predict ultimate strengths with varying degrees of success.

Yeow, Y. T.↗

NASA NTRS2015

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.

Feldman, Jay D.↗

NASA NTRS2001

Temperature Humidity and Sea Level Pressure Increments Induced by 1DVAR Analysis of GPS Refractivity

The Global Positioning System (GPS) transmitted signals are affected by the atmosphere. Using the radio occultation technique, where a receiver is placed on a low-Earth-orbiting platform. it is possible to perform soundings. by measuring the bending angles of the rays. The information can be converted into atmospheric refractivity. We have developed a one dimensional variational (1DVAR) analysis that uses GPS/MET 1995 refractivity and 6-hour FVDAS (Finite Volume Data Assimilation System) forecasts as background information to constrain the retrievals. The analysis increments are defined as 1DVAR minus background temperature, humidity and sea level pressure. Before assimilating the 1DVAR profiles into the FVDAS. the increments need to be understood. First, some bias could be induced in the retrievals when confronted with actual biased data: second. bias in the back-round could create undesired bias in the retrievals. Anv bias in the analyses will ultimately change the climatology of the model the retrievals will be assimilated into. We relate the increments to the reduction of the difference between observed minus computed refractivity profiles. We also point out the difference in the mean increments using backgrounds which have assimilated either NESDIS TIROS Operational Vertical Sounder (TOVS) operational retrievals or Data Assimilation Office (DAO) TOVS interactive retrievals. The climatology of the model in terms of refractivity is significantly different and this impacts the GPS 1DVAR increments. This testifies that changing the basic load of assimilated data has an influence on the impact the GPS data may have in a DAS.

Poli, Paul↗

NASA NTRSDate not supplied

Artificial Generation of 2-D Fiber Reinforced Composite Microstructures with Statistically Equivalent Features

Fiber reinforced composites are used widely for their high strength and low weight advantages in various aerospace and automotive applications. While their use may be sought after, modeling of these material requires increasing fidelity at the lower scales to capture accurate material behavior under loading. The first steps in creating statistically equivalent models to real life cases is developing a method of rapid evaluation and artificial microstructure generation. The outlined work is capable of tracking microscale fiber positions and determining regions of localized volume fraction extrema (high and low end). Groupings of high and low volume fraction regions are called clusters and their geometry is used to characterize the microstructure. These cluster features can be evaluated for both artificial models and actual scans, allowing correlation to be established which can ultimately be used to regenerate statistically equivalent models. The results of this work show that if one feature is to be correlated, a model can be generated which matches almost exactly. But once more features are equally taken into account, the regeneration loses accuracy.

micromechanics↗

NASA NTRS2014

G2 Autonomous Control for Cryogenic Delivery Systems

The Independent System Health Management-Autonomous Control (ISHM-AC) application development for cryogenic delivery systems is intended to create an expert system that will require minimal operator involvement and ultimately allow for complete autonomy when fueling a space vehicle in the time prior to launch. The G2-Autonomous Control project is the development of a model, simulation, and ultimately a working application that will control and monitor the cryogenic fluid delivery to a rocket for testing purposes. To develop this application, the project is using the programming language/environment Gensym G2. The environment is an all-inclusive application that allows development, testing, modeling, and finally operation of the unique application through graphical and programmatic methods. We have learned G2 through training classes and subsequent application development, and are now in the process of building the application that will soon be used to test on cryogenic loading equipment here at the Kennedy Space Center Cryogenics Test Laboratory (CTL). The G2 ISHM-AC application will bring with it a safer and more efficient propellant loading system for the future launches at Kennedy Space Center and eventually mobile launches from all over the world.

cryogenic fluids↗

NASA NTRS1981

Room temperature shear properties of the strain isolator pad for the shuttle thermal protection system

Tests were conducted at room temperature to determine the shear properties of the strain isolator pad (SIP) material used in the thermal protection system of the space shuttle. Tests were conducted on both the .23 cm and .41 cm thick SIP material in the virgin state and after fifty fully reversed shear cycles. The shear stress displacement relationships are highly nonlinear, exhibit large hysteresis effects, are dependent on material orientation, and have a large low modulus region near the zero stress level where small changes in stress can result in large displacements. The values at the higher stress levels generally increase with normal and shear force load conditioning. Normal forces applied during the shear tests reduces the low modulus region for the material. Shear test techniques which restrict the normal movement of the material give erroneous stress displacement results. However, small normal forces do not significantly effect the shear modulus for a given shear stress. Poisson's ratio values for the material are within the range of values for many common materials. The values are not constant but vary as a function of the stress level and the previous stress history of the material. Ultimate shear strengths of the .23 cm thick SIP are significantly higher than those obtained for the .41 cm thick SIP.

Sawyer, J. W.↗

NASA NTRS1991

Plate and butt-weld stresses beyond elastic limit, material and structural modeling

Ultimate safety factors of high performance structures depend on stress behavior beyond the elastic limit, a region not too well understood. An analytical modeling approach was developed to gain fundamental insights into inelastic responses of simple structural elements. Nonlinear material properties were expressed in engineering stresses and strains variables and combined with strength of material stress and strain equations similar to numerical piece-wise linear method. Integrations are continuous which allows for more detailed solutions. Included with interesting results are the classical combined axial tension and bending load model and the strain gauge conversion to stress beyond the elastic limit. Material discontinuity stress factors in butt-welds were derived. This is a working-type document with analytical methods and results applicable to all industries of high reliability structures.

Verderaime, V.↗

NASA NTRS2000

New Alloys for Electroformed Replicated X-Ray Optics

The process of electroforming x-ray mirror shells off a superpolished mandrel has been widely used. The recently launched XMM mission is a good example of this, containing 174 such mirror shells of diameters ranging from 0.3-0.7 m and thicknesses of 0.47-1.07 mm. To continue to utilize this technique for the next generation of x-ray observatories, where ever-larger collecting areas will be required within the constraints of tight weight budgets, demands that new alloys be developed that can withstand the large stresses imposed on very thin shells by the replication and handling processes. Towards this end, we began a development program in late 1997 to produce a high-strength alloy suitable for electroforming very thin high-resolution x-ray optics. The requirements for this task are quite severe; not only must the electroformed deposit be very strong, it must also have extremely low residual stresses to prevent serious figure distortions in large thin-walled shells. Further, the electroforming must be performed at near room temperature, as large temperature changes will modify the figure of the mandrel, in an environment that is not corrosive for the mandrel. The figure of merit for the strength of the electroformed deposit is its Precision Elastic Limit (PEL). This is a measure of permanent strain, at the few parts per million level, under applied stress. Pure nickel is very ductile and will permanently deform, at the parts-per-million level under loads of a few x 10(exp 7) Pa. These stresses are easily exceeded when thin-walled shells (150 micron thick) are replicated. Our goal was to develop an alloy an order of magnitude stronger than this. We will present the results of our development program, showing the evolution of our plating baths through to our present 'glassy' nickel alloy that satisfies the goals above. For each we will show the electroforming characteristics of the bath and the PEL measurements for the resulting alloys. We estimate the ultimate limit on shell thickness and mass for x-ray mirrors produced in these baths.

Engelhaupt, D.↗

NASA NTRS2015

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

Crycooling↗

NASA NTRS2016

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heaters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

cryocooling↗

NASA NTRSDate not supplied

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗

NASA NTRS1995

Hindlimb suspension diminishes femoral cross-sectional growth in the rat

Growth, functional adaptation, and torsional strength were examined in the femora of 39-day-old male Sprague-Dawley rats subjected to hindlimb suspension for 0, 1, 2, 3, or 4 weeks and were compared with measurements for age-matched control animals. Our goal was to understand the effect of reduced loading on the normal age-related changes in femoral properties during growth. The control animals exhibited growth-related increases in all geometric and torsional properties of the femur. The mean body mass and femoral length of the hindlimb-suspended rats were similar to those of the controls throughout the experiment. Over 4 weeks, the femoral cross-sectional and torsional measurements from the hindlimb-suspended rats demonstrated increases in comparison with the basal values (+33% cross-sectional area, +64% polar moment of inertia, +67% ultimate torque, and +181% torsional rigidity), but the age-matched controls showed significantly greater growth-related increases (+71% cross-sectional area, +136% polar moment of inertia, +127% ultimate torque, and +367% torsional rigidity). The differences in femoral structural strength between the hindlimb-suspended animals and the age-matched controls were attributable to differences in altered cross-sectional geometry.

NASA Discipline Musculoskeletal↗

NASA NTRS2014

Time and Frequency-Domain Cross-Verification of SLS 6DOF Trajectory Simulations

The SLS GNC team and its partners have developed several time- and frequency-based simulations for development and analysis of the proposed SLS launch vehicle. The simulations differ in fidelity and some have unique functionality that allows them to perform specific analyses. Some examples of the purposes of the various models are: trajectory simulation, multi-body separation, Monte Carlo, hardware in the loop, loads, and frequency domain stability analyses. While no two simulations are identical, many of the models are essentially six degree-of-freedom (6DOF) representations of the SLS plant dynamics, hardware implementation, and flight software. Thus at a high level all of those models should be in agreement. Comparison of outputs from several SLS trajectory and stability analysis tools are ongoing as part of the program's current verification effort. The purpose of these comparisons is to highlight modeling and analysis differences, verify simulation data sources, identify inconsistencies and minor errors, and ultimately to verify output data as being a good representation of the vehicle and subsystem dynamics. This paper will show selected verification work in both the time and frequency domain from the current design analysis cycle of the SLS for several of the design and analysis simulations. In the time domain, the tools that will be compared are MAVERIC, CLVTOPS, SAVANT, STARS, ARTEMIS, and POST 2. For the frequency domain analysis, the tools to be compared are FRACTAL, SAVANT, and STARS. The paper will include discussion of these tools including their capabilities, configurations, and the uses to which they are put in the SLS program. Determination of the criteria by which the simulations are compared (matching criteria) requires thoughtful consideration, and there are several pitfalls that may occur that can severely punish a simulation if not considered carefully. The paper will discuss these considerations and will present a framework for responding to these issues when they arise. For example, small event timing differences can lead to large differences in mass properties if the criteria are to measure those properties at the same time, or large differences in altitude if the criteria are to measure those properties when the simulation experiences a staging event. Similarly, a tiny difference in phase can lead to large gain margin differences for frequency-domain comparisons of gain margins.

VanZwieten, Tannen↗

NASA NTRS2017

Time and Frequency-Domain Cross-Verification of SLS 6DOF Trajectory Simulations

The Space Launch System (SLS) Guidance, Navigation, and Control (GNC) team and its partners have developed several time- and frequency-based simulations for development and analysis of the proposed SLS launch vehicle. The simulations differ in fidelity and some have unique functionality that allows them to perform specific analyses. Some examples of the purposes of the various models are: trajectory simulation, multi-body separation, Monte Carlo, hardware in the loop, loads, and frequency domain stability analyses. While no two simulations are identical, many of the models are essentially six degree-of-freedom (6DOF) representations of the SLS plant dynamics, hardware implementation, and flight software. Thus at a high level all of those models should be in agreement. Comparison of outputs from several SLS trajectory and stability analysis tools are ongoing as part of the program's current verification effort. The purpose of these comparisons is to highlight modeling and analysis differences, verify simulation data sources, identify inconsistencies and minor errors, and ultimately to verify output data as being a good representation of the vehicle and subsystem dynamics. This paper will show selected verification work in both the time and frequency domain from the current design analysis cycle of the SLS for several of the design and analysis simulations. In the time domain, the tools that will be compared are MAVERIC, CLVTOPS, SAVANT, STARS, ARTEMIS, and POST 2. For the frequency domain analysis, the tools to be compared are FRACTAL, SAVANT, and STARS. The paper will include discussion of these tools including their capabilities, configurations, and the uses to which they are put in the SLS program. Determination of the criteria by which the simulations are compared (matching criteria) requires thoughtful consideration, and there are several pitfalls that may occur that can severely punish a simulation if not considered carefully. The paper will discuss these considerations and will present a framework for responding to these issues when they arise. For example, small event timing differences can lead to large differences in mass properties if the criteria are to measure those properties at the same time, or large differences in altitude if the criteria are to measure those properties when the simulation experiences a staging event. Similarly, a tiny difference in phase can lead to large gain margin differences for frequency-domain comparisons of gain margins.

Johnson, Matthew↗

NASA NTRS2020

Fiber-Optic Strain-Based Deflection and Twist Sensing for a High-Aspect-Ratio Swept Wing

Designs of aircraft structures have been moving toward leaner, lightweight designs for increased fuel efficiency. The Passive Aeroelastic Tailored (PAT) wing developed under the NASA Advanced Air Transport Technology (AATT) project is an example of a swept-wing design with high aspect ratio that incorporates lightweight highly-flexible tailored composite construction. The passive aeroelastic tailored structural design has explored the design space to enable aeroelastically tailored wing structures to increase aspect ratios (from 9 to 14) and ultimately reduce weight by 20 percent to 25 percent without impacting aeroelastic performance. To further study the aeroelastic performance of such a wing, the NASA Armstrong Flight Research Center (AFRC) (Edwards, California) has developed efficient real-time structural algorithms that are used in conjunction with a fiber-optic measurement system for lightweight vehicle applications. The AFRC Fiber Optic Sensing System (FOSS) provides up to 8,000 distributed surface strain measurements at one-half-inch increments and can be used to estimate a variety of structural parameters such as shape and load. This report discusses the implementation of strain-based displacement and twist-sensing techniques applied to the PAT wing test article tested at the NASA AFRC Flight Loads Laboratory. Empirical FOSS strain data are collected under varying loading conditions. Strain data are processed with the displacement and twist-sensing algorithms and independently verified by comparison to conventional ground-based instrumentation.

Pena, Francisco↗

NASA NTRS1979

Evaluation of urethane for feasibility of use in wind turbine blade design

A preliminary evaluation was conducted of the use of cast urethane as a possible material for low-cost blades for wind turbines. Specimen test data are presented for ultimate tensile strength, elastic modulus, flexural strain, creep, and fatigue properties of a number of urethane formulations. Data are also included for a large-scale urethane blade section composed of cast symmetrical half-profiles tested as a cantilever beam. Based on these results, an analysis was conducted of a full-scale blade design of cast urethane that meets the design specifications of the rotor blades for the NASA/DOE experimental 100-kW MOD-0 wind turbine. Because of the low value of elastic modulus for urethane (around 457 000 psi), the design loads would have to be carried by metal reinforcement. Considerations for further evaluation are noted.

Lieblein, S.↗