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NASA NTRS1986

Development of Space Station strut design

Candidate Space Station struts exhibiting high stiffness (38-40 msi modulus of elasticity) were manufactured and experimentally evaluated. One and two inch diameter aluminum-clad evaluation specimens were manufactured using a unique dry fiber resin injection process. Preliminary tests were performed on strut elements having 80 percent high-modulus graphite epoxy and 20 percent aluminum. Performed tests included modulus of elasticity, thermal cycling, and coefficient of thermal expansion. The paper describes the design approach, including an analytical assessment of strut thermal deformation behavior. The major thrust of this paper is the manufacturing process which produces aluminum-clad struts with precisely controlled properties which can be fine-tuned after fabrication. An impact test and evaluation procedure for evaluating toughness is described.

Johnson, R. R.↗

NASA NTRS2015

Orbital Debris Assesment Tesing in the AEDC Range G

The space environment presents many hazards for satellites and spacecraft. One of the major hazards is hypervelocity impacts from uncontrolled man-made space debris. Arnold Engineering Development Complex (AEDC), The National Aeronautics and Space Administration (NASA), The United States Air Force Space and Missile Systems Center (SMC), the University of Florida, and The Aerospace Corporation configured a large ballistic range to perform a series of hypervelocity destructive impact tests in order to better understand the effects of space collisions. The test utilized AEDC's Range G light gas launcher, which is capable of firing projectiles up to 7 km/s. A non-functional full-scale representation of a modern satellite called the DebriSat was destroyed in the enclosed range enviroment. Several modifications to the range facility were made to ensure quality data was obtained from the impact events. The facility modifcations were intended to provide a high impact energy to target mass ratio (>200 J/g), a non-damaging method of debris collection, and an instrumentation suite capable of providing information on the physics of the entire imapct event.

Polk, Marshall↗

NASA NTRS2017

Development of an Input Suite for an Orthotropic Composite Material Model

An orthotropic three-dimensional material model suitable for use in modeling impact tests has been developed that has three major components elastic and inelastic deformations, damage and failure. The material model has been implemented as MAT213 into a special version of LS-DYNA and uses tabulated data obtained from experiments. The prominent features of the constitutive model are illustrated using a widely-used aerospace composite the T800S3900-2B[P2352W-19] BMS8-276 Rev-H-Unitape fiber resin unidirectional composite. The input for the deformation model consists of experimental data from 12 distinct experiments at a known temperature and strain rate: tension and compression along all three principal directions, shear in all three principal planes, and off axis tension or compression tests in all three principal planes, along with other material constants. There are additional input associated with the damage and failure models. The steps in using this model are illustrated composite characterization tests, verification tests and a validation test. The results show that the developed and implemented model is stable and yields acceptably accurate results.

finite element method↗

NASA NTRS2011

Prediction of Weather Impacted Airport Capacity using Ensemble Learning

Ensemble learning with the Bagging Decision Tree (BDT) model was used to assess the impact of weather on airport capacities at selected high-demand airports in the United States. The ensemble bagging decision tree models were developed and validated using the Federal Aviation Administration (FAA) Aviation System Performance Metrics (ASPM) data and weather forecast at these airports. The study examines the performance of BDT, along with traditional single Support Vector Machines (SVM), for airport runway configuration selection and airport arrival rates (AAR) prediction during weather impacts. Testing of these models was accomplished using observed weather, weather forecast, and airport operation information at the chosen airports. The experimental results show that ensemble methods are more accurate than a single SVM classifier. The airport capacity ensemble method presented here can be used as a decision support model that supports air traffic flow management to meet the weather impacted airport capacity in order to reduce costs and increase safety.

Weather impact↗

NASA NTRS2019

Heat-Cleaned Nextel in MMOD Shielding

Meteoroid and orbital debris (MMOD) shielding can include NextelTM ceramic cloth in the outer layers of the shielding to enhance MMOD breakup. The Nextel fabric can contain size (or sizing) which aids in manufacture of the fabric. Sizing is a starch, oil or waxy material that is added to the rovings and yarns to protect the fibers from being cut or broken during the fabric manufacturing process and by later handling. For spacecraft applications, sizing is removed by heat-cleaning to reduce/eliminate off-gassing during vacuum operations. After the sizing is removed, the fibers in the woven fabric are prone to breakage during handling which reduces fabric strength. Because heat-cleaned Nextel tends to shed fibers that can be irritating to workers, the usual practice for hypervelocity impact tests is to use Nextel with sizing. The reduced strength of heat-cleaned Nextel does not typically effect the performance of MMOD shields with Nextel used in outer layers of the shield, because the density and areal density of the ceramic fibers in the fabric control MMOD breakup (not fabric strength). This paper provides data demonstrating that hypervelocity impact protection performance is not adversely altered for shields containing heat-cleaned Nextel compared to Nextel with sizing.

Christiansen, Eric L.↗

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 NTRSDate not supplied

Orion Artemis I As Flown MMOD Analysis

MMOD↗

NASA NTRS1997

Assessment and Management of the Risks of Debris Hits During Space Station EVAs

The risk of EVAs is critical to the decision of whether or not to automate a large part of the construction of the International Space Station (ISS). Furthermore, the choice of the technologies of the space suit and the life support system will determine (1) the immediate safety of these operations, and (2) the long-run costs and risks of human presence in space, not only in lower orbit (as is the case of the ISS) but also perhaps, outside these orbits, or on the surface of other planets. The problem is therefore both an immediate one and a long-term one. The fundamental question is how and when to shift from the existing EMU system (suit, helmet, gloves and life support system) to another type (e.g. a hard suit), given the potential trade-offs among life-cycle costs, risks to the astronauts, performance of tasks, and uncertainties about new systems' safety inherent to such a shift in technology. A more immediate issue is how to manage the risks of EVAs during the construction and operation of the ISS in order to make the astronauts (in the words of the NASA Administrator) "as safe outside as inside". For the moment (June 1997), the plan is to construct the Space Station using the low-pressure space suits that have been developed for the space shuttle. In the following, we will refer to this suit assembly as EMU (External Maneuvering Unit). It is the product of a long evolution, starting from the U.S. Air Force pilot suits through the various versions and changes that occurred for the purpose of NASA space exploration, in particular during the Gemini and the Apollo programs. The Shuttle EMU is composed of both soft fabrics and hard plates. As an alternative to the shuttle suit, at least two hard suits were developed by NASA: the AX5 and the MRKIII. The problem of producing hard suits for space exploration is very similar to that of producing deep-sea diving suits. There was thus an opportunity to develop a suit that could be manufactured for both purposes with the economies of scale that could be gained from a two-branch manufacturing line (space and deep sea). Of course, the space suit would need to be space qualified. Some of the problems in adopting one of the hard suits were first that the testing had to be completed, and second that it required additional storage space. The decision was made not to develop a hard suit in time for the construction and operation of the ISS. Instead, to improve the safety of the current suit, it was decided to reinforce the soft parts of the shuttle EMU with KEVLAR linings to strengthen it against debris impacts. Test results, however, show that this advanced suit design has little effect on the penetration characteristics.

Pate-Cornell, Elisabeth↗

NASA NTRS2003

Mechanical Properties of Triaxial Braided Carbon/Epoxy Composites

In an on-going effort to increase the safety and efficiency of turbine engines, the National Aeronautics and Space Administration is exploring lightweight alternatives to the metal containment structures that currently encase commercial jet engines. Epoxy reinforced with braided carbon fibers is a candidate structural material which may be suitable for an engine case. This paper reports flat-coupon mechanical-property experiments performed to compliment previously reported subcomponent impact testing and analytical simulation of containment structures. Triaxial-braid T700/5208 epoxy and triaxial-braid T700h436 toughened epoxy composites were evaluated. Also, two triaxial-braid architectures (0 degrees plus or minus 60 degrees, and 0 degrees plus or minus 45 degrees) with the M36 resin were evaluated through tension, compression, and shear testing. Tensile behavior was compared between standard straight-sided specimens (ASTM D3039) and bow-tie specimens. Both double-notch shear (ASTM D3846) and Iosepescu (ASTM D5379) tests were performed as well. The M36/O degrees plus or minus 45 degrees configuration yield the best response when measurements were made parallel to the axial tows. Conversely, the M36/0 degrees plus or minus 60 degrees configuration was best when measurements were made perpendicular to the axial tows. The results were used to identify critical properties and to augment the analysis of impact experiments.

Bowman, C. L.↗

NASA NTRS1975

Experimental transient and permanent deformation studies of steel-sphere-impacted or impulsively-loaded aluminum beams with clamped ends

The sheet explosive loading technique (SELT) was employed to obtain elastic-plastic, large-deflection transient and/or permanent strain data on simple well-defined structural specimens and materials: initially-flat 6061-T651 aluminum beams with both ends ideally clamped via integral construction. The SELT loading technique was chosen since it is both convenient and provides forcing function information of small uncertainty. These data will be useful for evaluating pertinent structural response prediction methods. A second objective was to obtain high-quality transient-strain data for a well-defined structural/material model subjected to impact by a rigid body of known mass, impact velocity, and geometry; large-deflection, elastic-plastic transient response conditions are of primary interest. The beam with both ends clamped and a steel sphere as the impacting body were chosen. The steel sphere was launched vertically by explosive propulsion to achieve various desired impact velocities. The sphere/beam impact tests resulted in producing a wide range of structural responses and permanent deformations, including rupture of the beam from excessive structural response in two cases. The transient and permanent strain data as well as the permanent deflection data obtained are of high quality and should be useful for checking and evaluating methods for predicting the responses of simple 2-d structures to fragment (sphere) impact. Transient strain data very close to the point of impact were not obtained over as long a time as desirable because the gage(s) in that region became detached during the transient response.

Witmer, E. A.↗

NASA NTRS1975

Improving the toughness of refractory compounds

Composition and processing studies were conducted on silicon nitride and silicon carbide materials. Charpy mode impact testing to 2415 F established the effectiveness of higher purity silicon nitride powder sources in reducing the scatter of measurements and in improving short time bend strengths as well as bend stress rupture properties. Stabilized zirconia additions in particular were observed to dramatically enhance low and high temperature bend strengths and stress rupture properties for all grades of silicon nitride powder. Silicon carbide samples showed relatively poor impact resistance, although the maxima in stress rupture behavior was exhibited by this material.

Vasilos, T.↗

NASA NTRS2011

Investigation of Hygro-Thermal Aging on Carbon/Epoxy Materials for Jet Engine Fan Sections

This poster summarizes 2 years of aging on E862 epoxy and E862 epoxy with triaxial braided T700s carbon fiber composite. Several test methods were used to characterize chemical, physical, and mechanical properties of both the resin and composite materials. The aging cycle that was used included varying temperature and humidity exposure. The goal was to evaluate the environmental effects on a potential jet engine fan section material. Some changes were noted in the resin which resulted in increased brittleness, though this did not significantly affect the tensile and impact test results. A potential decrease in compression strength requires additional investigation.

Kohlman, Lee W.↗

NASA NTRS1988

Development and properties of aluminum-clad graphite/epoxy tubes for space structures

This paper presents the development and properties of seamless aluminum-clad P75/Epoxy tubes and the unique manufacturing method used in their production. Thermo-mechanical properties of the tubes were determined analytically and verified by tests. These properties were shown to be suitable for space structures that require high stiffness, low weight and thermal expansion, and dimensional stability during operational life. A special feature of the tubes is the ability to tune the tube for thermal expansion after fabrication by a chemical milling process. The tubes are also resistant to atomic oxygen and handling damage. The toughness of the tubes was demonstrated by impact testing. Cyclic thermal testing showed no adverse effects on the expansion and stiffness behavior of the tubes. The paper also includes a discussion of a joining method that uses aluminum end fittings and an efficient scarf joint configuration. Additional studies considered various adhesives and fitting materials. Joint allowables were higher for titanium and B4C particulate magnesium fittings. The effect of different adhesives under static loading conditions favored the high-strength adhesives.

Johnson, R. R.↗

NASA NTRS2008

Material Density Distribution of Small Debris in Earth Orbit

Over 200 spacecraft and rocket body breakups in Earth orbit have populated that regime with debris fragments in the sub-micron through meter size range. Though the largest debris fragments can cause significant collisional damage to active (operational) spacecraft, these are few and trackable by radar. Fragments on the order of a millimeter to a centimeter in size are as yet untrackable. But this smaller debris can result in damage to critical spacecraft systems and, under the worst conditions, fragmenting collision events. Ongoing research at the NASA Orbital Debris Program Office on the sources of these small fragments has focused on the material components of spacecraft and rocket bodies and on breakup event morphology. This has led to fragment material density estimates, and also the beginnings of shape categorizations. To date the NASA Standard Breakup Model has not considered specific material density distinctions of small debris. The basis of small debris in that model is the fourth hypervelocity impact event of the Satellite Orbital Debris Characterization Impact Test (SOCIT) series. This test targeted a flight-ready, U.S. Transit navigation satellite with a solid aluminum sphere impactor. Results in this event yield characteristic length (size) and area-to-mass distributions of fragments smaller than 10 cm in the NASA model. Recent re-analysis of the SOCIT4 small fragment dataset highlighted the material-specific characteristics of metals and non-metals. Concurrent analysis of Space Shuttle in-situ impact data showed a high percentage of aluminum debris in shuttle orbit regions. Both analyses led to the definition of three main on-orbit debris material density categories -low density (< 2 g/cc), medium density (2 to 6 g/cc), and high density (> 6 g/cc). This report considers the above studies in an explicit extension of the NASA Standard Breakup Model where separate material densities for debris are generated and these debris fragments are propagated in Earth orbit. The near Earth environment is thus parameterized by debris density percentages within subsections of that environment. This model version is used in the upgraded NASA Orbital Debris Engineering Model (ORDEM).

Krisko, P. H.↗

NASA NTRS1992

Study of compression-loaded and impact-damaged structurally efficient graphite-thermoplastic trapezoidal-corrugation sandwich and semisandwich panels

The structural efficiency of compression-loaded trapezoidal-corrugation sandwich and semisandwich composite panels is studied to determine their weight savings potential. Sandwich panels with two identical face sheets and a trapezoidal corrugated core between them and semisandwich panels with a corrugation attached to a single skin are considered. An optimization code is used to find the minimum weight designs for critical compressive load levels ranging from 3000 to 24,000 lb/in. Graphite-thermoplastic panels based on the optimal minimum weight designs were fabricated and tested. A finite element analysis of several test specimens was also conducted. The results of the optimization study, the finite element analysis, and the experiments are presented. The results of testing impact damage panels are also discussed.

Jegley, Dawn C.↗

NASA NTRS2017

STEREO Superior Solar Conjunction Mission Phase

With its long duration and high gain antenna (HGA) feed thermal constraint; the NASA Solar-TErestrial RElations Observatory (STEREO) solar conjunction mission phase is quite unique to deep space operations. Originally designed for a two year heliocentric orbit mission to primarily study coronal mass ejection propagation, after 8 years of continuous science data collection, the twin STEREO observatories entered the solar conjunction mission phase, for which they were not designed. Nine months before entering conjunction, an unforeseen thermal constraint threatened to stop daily communications and science data collection for 15months. With a 3.5 month long communication blackout from the superior solar conjunction, without ground commands, each observatory will reset every 3 days, resulting in 35 system resets at an Earth range of 2 AU. As the observatories will be conjoined for the first time in 8 years, a unique opportunity for calibrating the same instruments on identical spacecraft will occur. As each observatory has lost redundancy, and with only a limited fidelity hardware simulator, how can the new observatory configuration be adequately and safely tested on each spacecraft? Without ground commands, how would a 3-axis stabilized spacecraft safely manage the ever accumulating system momentum without using propellant for thrusters? Could science data still be collected for the duration of the solar conjunction mission phase? Would the observatories survive? In its second extended mission, operational resources were limited at best. This paper discusses the solutions to the STEREO superior solar conjunction operational challenges, science data impact, testing, mission operations, results, and lessons learned while implementing.

STEREO↗

NASA NTRS2007

A One-Piece Lunar Regolith Bag Garage Prototype

Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. This Technical Memorandum details the design and construction of a prototype for a one-piece regolith bag unpressurized garage concept and a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. The conceptualization was that a lightweight fabric form be launched from Earth and landed on the lunar surface to be robotically filled with raw lunar regolith. Regolith bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and also performed under cold and elevated temperatures. In some cases, Johnson Space Center lunar simulant (JSC-1) was used in conjunction with testing. A series of preliminary structures was constructed during final prototype design based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite. The structure is free-standing, but has not yet been load tested. Future plans would be to construct higher fidelity prototypes and to conduct appropriate tests of the structure.

Smithers, G. A.↗

NASA NTRS1996

Finite-Element Vibration Analysis and Modal Testing of Graphite Epoxy Tubes and Correlation Between the Data

Structural materials in the form of graphite epoxy composites with embedded rubber layers are being used to reduce vibrations in rocket motor tubes. Four filament-wound, graphite epoxy tubes were studied to evaluate the effects of the rubber layer on the modal parameters (natural vibration frequencies, damping, and mode shapes). Tube 1 contained six alternating layers of 30-degree helical wraps and 90-degree hoop wraps. Tube 2 was identical to tube 1 with the addition of an embedded 0.030-inch-thick rubber layer. Tubes 3 and 4 were identical to tubes 1 and 2, respectively, with the addition of a Textron Kelpoxy elastomer. This report compares experimental modal parameters obtained by impact testing with analytical modal parameters obtained by NASTRAN finite-element analysis. Four test modes of tube 1 and five test modes of tube 3 correlate highly with corresponding analytical predictions. Unsatisfactory correlation of test and analysis results occurred for tubes 2 and 4 and these comparisons are not shown. Work is underway to improve the analytical models of these tubes. Test results clearly show that the embedded rubber layers significantly increase structural modal damping as well as decrease natural vibration frequencies.

Taleghani, Barmac K.↗