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At least 505 records · Page 28

Rocket combustion chamber life-enhancing design concepts

NASA continues to pursue technologies which can lead to an increase in life and reduce the costs of fabrication of the Space Shuttle Main Engine. The joint NASA/Air Force Advanced Launch System Program has set its prime objectives to be high reliability and low cost for their new advanced booster engine. In order to meet these objectives, NASA will utilize the results of several ongoing programs to provide the required technologies. An overview is presented of those programs which address life enhancing design concepts for the combustion chamber. Seven different design concepts, which reduce the thermal strain and/or increase the material strength of the combustion chamber liner wall are discussed. Subscale rocket test results are presented, where available, for life enhancing design concepts. Two techniques for reducing chamber fabrication costs are discussed, as well as issues relating to hydrocarbon fuels/combustion chamber liner materials compatibility.

Quentmeyer, Richard J.↗

Rocket combustion chamber life-enhancing design concepts

NASA continues to pursue technologies which can lead to an increase in life and reduce the costs of fabrication of the Space Shuttle Main Engine. The joint NASA/Air Force Advanced Launch System Program has set its prime objectives to be high reliability and low cost for their new advanced booster engine. In order to meet these objectives, NASA will utilize the results of several ongoing programs to provide the required technologies. An overview is presented of those programs which address life enhancing design concepts for the combustion chamber. Seven different design concepts, which reduce the thermal strain and/or increase the material strength of the combustion chamber liner wall are discussed. Subscale rocket test results are presented, where available, for life enhancing design concepts. Two techniques for reducing chamber fabrication costs are discussed, as well as issues relating to hydrocarbon fuels/combustion chamber liner materials compatibility.

Quentmeyer, R. J.↗

TPSAS-NF1676L-25778-DND

Testing required to design and certify aircraft structures has increased dramatically with the growth in use of composite materials, and the development time and cost have become an issue as industry looks towards the next generation of aircraft. To help address this challenge, NASA has formed an industry-spanning consortium with the goal of cutting by 30% today's 10-year timeline for developing and certifying composite aircraft structures. This goal is to be achieved by infusing leading edge, physics-based tools to improve the prediction of the response and failure of composite aerospace structures. The plan for the public-private partnership of NASA, the FAA, airframe manufacturers, aircraft engine manufacturers, and several universities is to conduct joint research under the five-year Advanced Composites Program (ACP). The emphasis of the ACP project is the development of damage prediction and non-destructive inspection methods capabilities that are sufficiently reliable to enable a reduction in the element and subcomponent testing necessary for design and certification. ACP also is expected to create rapid design tools to speed preliminary design and improve safety and performance. A critical element of this research concerns the residual strength of postbuckled stiffened panels with impact damage. This presentation will discuss different aspects of ongoing research on the prediction of structural collapse due to skin/stiffener separation. In particular, the presentation will examine issues that must be addressed in the analysis, such as R-curve toughening, delamination migration, bridging, as well as some unexpected effects of ply orientation.

Carlos G Davila↗

Design and Analysis of Outer Mold Line Close-outs for the Max Launch Abort System (MLAS) Flight Experiment

In 2007, the NASA Exploration Systems Mission Directorate (ESMD) chartered the NASA Engineering Safety Center (NESC) to demonstrate an alternate launch abort concept as risk mitigation for the Orion project's baseline "tower" design. On July 8, 2009, a full scale, passive aerodynamically stabilized Max Launch Abort System (MLAS) pad abort demonstrator was successfully launched from NASA Goddard Space Flight Center's Wallops Flight Facility. Aerodynamic close-outs were required to cover openings on the MLAS fairing to prevent aerodynamic flow-through and to maintain the MLAS OML surface shape. Two-ply duct tape covers were designed to meet these needs. The duct tape used was a high strength fiber reinforced duct tape with a rubberized adhesive that demonstrated 4.6 lb/in adhesion strength to the unpainted fiberglass fairing. Adhesion strength was observed to increase as a function of time. The covers were analyzed and experimentally tested to demonstrate their ability to maintain integrity under anticipated vehicle ascent pressure loads and to not impede firing of the drogue chute mortars. Testing included vacuum testing and a mortar fire test. Tape covers were layed-up on thin Teflon sheets to facilitate installation on the vehicle. Custom cut foam insulation board was used to fill mortar hole and separation joint cavities and provide support to the applied tape covers. Flight test results showed that the tape covers remained adhered during flight.

Woods-Vedeler, Jessica A.↗

TOPEX/Poseidon Precision Orbit Determination Using Combined GPS, SLR, and DORIS

TOPEX/Poseidon (T/P) is a joint spaceborne oceanographic mission of U.W. NASA and France CNES design launched August 10, 1992. The satellite has a variety tracking systems for both operational and precision orbit determination. Three precise tracking systems: Satellite Laser Ranging (SLR), Doppler Orbitography and Radiopositioning Integrated by Satellite (DORIS), and Global Positioning System (GPS) provide high quality measurements essential for reconstructing the T/P orbital height with centimeter precision. This paper presents results of simultaneously processing all three data types to exploit the inherent strength of each in a combined solution. SLR and DORIS are routinely combined to provide orbit solutions for the T/P science team. GPS orbit solutions are produced as part of the first demonstration flight of a high quality spaceborne GPS receiver. Coordinate frame and software system differences between the combined SLR/DORIS orbits and the GPS orbits induce orbital height differences of 2 to 3 centimeters. Combining the three data types within a single software system permits removal of software system differences while obtaining coordinate frame calibration information. These calibrations will aid future spaceborne GPS missions that are not complemented with SLR and/or DORIS.

TOPEX/Poseidon↗

Damage Tolerance Assessment of Friction Pull Plug Welds

Friction stir welding is a solid state welding process developed and patented by The Welding Institute in Cambridge, England. Friction stir welding has been implemented in the aerospace industry in the fabrication of longitudinal welds in pressurized cryogenic propellant tanks. As the industry looks to implement friction stir welding in circumferential welds in pressurized cryogenic propellant tanks, techniques to close out the termination hole associated with retracting the pin tool are being evaluated. Friction pull plug welding is under development as a one means of closing out the termination hole. A friction pull plug weld placed in a friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite, plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size in the test or service environments. Test data relating residual strength capability to flaw size in two aluminum alloy friction plug weld configurations is presented.

McGill, Preston↗

The X-beam as a deployable boom for the space station

Extension of antennas and thrust modules from the primary structure of the space station will require deployable beams of high stiffness and strength, as well as low mass and package volume. A square boom cross section is desirable for interface reasons. These requirements and others are satisfied by the X-beam. The X-beam folds by simple geometry, using single-degree-of-freedom hinges at simple angles, with no strain during deployment. Strut members are of large diameter with unidirectional graphite fibers for maximum beam performance. Fittings are aluminum with phosphor bronze bushings so that compliance is low and joint lifetime is high. The several beam types required for different applications on the space station will use the same basic design, with changes in strut cross section where necessary. Deployment is by a BI-STEM which pushes the beam out; retraction is by cables which cause initial folding and pull the beam in.

Adams, Louis R.↗

The Relationship Between Solar Radio and Hard X-Ray Emission

This review discusses the complementary relationship between radio and hard Xray observations of the Sun using primarily results from the era of the Reuven Ramaty High Energy Solar Spectroscopic Imager satellite. A primary focus of joint radio and hard X-ray studies of solar flares uses observations of nonthermal gyrosynchrotron emission at radio wavelengths and bremsstrahlung hard X-rays to study the properties of electrons accelerated in the main flare site, since it is well established that these two emissions show very similar temporal behavior. A quantitative prescription is given for comparing the electron energy distributions derived separately from the two wavelength ranges: this is an important application with the potential for measuring the magnetic field strength in the flaring region, and reveals significant differences between the electrons in different energy ranges. Examples of the use of simultaneous data from the two wavelength ranges to derive physical conditions are then discussed, including the case of microflares, and the comparison of images at radio and hard X-ray wavelengths is presented. There have been puzzling results obtained from observations of solar flares at millimeter and submillimeter wavelengths, and the comparison of these results with corresponding hard X-ray data is presented. Finally, the review discusses the association of hard X-ray releases with radio emission at decimeter and meter wavelengths, which is dominated by plasma emission (at lower frequencies) and electron cyclotron maser emission (at higher frequencies), both coherent emission mechanisms that require small numbers of energetic electrons. These comparisons show broad general associations but detailed correspondence remains more elusive.

White, S. M.↗

The Strength of One-Piece Solid, Build-Up and Laminated Wood Airplane Wing Beams

The purpose of this report is to summarize the results of all wood airplane wing beams tested to date in the Bureau of Standards Laboratory in order that the various kinds of wood and methods of construction may be compared. All beams tested were of an I section and the majority were somewhat similar in size and cross section to the front wing beam of the Curtiss JN-4 machine. Construction methods may be classed as (1) solid beams cut from solid stock; (2) three-piece beams, built up of three pieces, web and flanges glued together by a tongue-and-groove joint and (3) laminated beams built up of thin laminations of wood glued together.

Nelson, John H↗

On the design and development of a miniature ceramic gimbal bearing

A review is made of a program to develop ceramic gimbal bearings for a miniaturized missile guidance system requiring nonmagnetic properties and higher load capacity than possible with conventional AISI 440C stainless steel bearings. A new gimbal design concept is described which utilizes the compressive strength and nonmagnetic properties of silicon nitride (Si3N4) ceramics for the gimbal bearing. Considerable manufacturing development has occurred in the last 5 years making ceramic bearings a viable option in the gimbal design phase. A preliminary study into the feasibility of the proposed design is summarized. Finite element analysis of the brittle ceramic bearing components under thermal stress and high acceleration loading were conducted to ensure the components will not fail catastrophically in service. Finite element analysis was also used to optimize the adhesive joint design. Bearing torque tests run at various axial loads indicate that the average running torque of ceramic bearings varies with load similarly to that of conventional steel bearings.

Hanson, Robert A.↗

Evaluation of boron-epoxy-reinforced titanium tubular truss for application to a space shuttle booster thrust structure

Results of a study to demonstrate the applicability of boron-epoxy-composite-reinforced titanium tubular members to a space shuttle booster thrust structure are presented and discussed. The experimental results include local buckling of all-composite and composite-reinforced-metal cylinders with low values of diameter-thickness ratio, static tests on composite-to-metal bonded step joints, and a test to failure of a boron-epoxy-reinforced titanium demonstration truss. The demonstration truss failed at 118 percent of design ultimate load. Test results and analysis for all specimens and the truss are compared. Comparing an all-titanium design and a boron-epoxy-reinforced-titanium (75 percent B-E and 25 percent Ti) design for application to the space shuttle booster thrust structure indicates that the latter would weigh approximately 24 percent less. Experimental data on the local buckling strength of cylinders with a diameter-thickness ratio of approximately 50 are needed to insure that undue conservatism is not used in future designs.

Corvelli, N.↗

The Wallops Flight Facility Model for an Integrated Federal/Commercial Launch Range

Historically, the federal government has been the predominant purchaser of space launches in the United States. The government met its needs through purchase of hardware and services. It also provided the infrastructure necessary to conduct launch operations through federal launch ranges, both military and NASA. Under this model, the government had the complete ownership, responsibility, liability, and expense for launch activities. As the commercial space sector grew, there emerged a corresponding growth in demand for launch range services. However, the expense and complexity of activities has thus far deterred a rapid rise in the establishment of purely commercial launch sites. In this context, purely commercial is defined as "without benefit of capabilities provided by the federal government." Consistent with the Commercial Space Launch Act, in recent years NASA and the Air Force have supported commercial launches from government launch ranges on a cost-reimbursable, non-interference basis. In this mode the commercial launch service providers contract with the government to provide services including use of facilities, tracking and data services, and range safety. As the commercial market projections began to show significant opportunities for economic development, several states established spaceports to provide the services necessary to meet these projected commercial needs. In 1997, NASA agreed to the establishment of the Virginia Space Flight Center (VSFC) at the Wallops Flight Facility. Under this arrangement, NASA agreed to allow Virginia Commercial Space Flight Authority (VCSFA) to construct facilities on NASA property and agreed to provide services in accordance with the Space Act of 1958 and the Commercial Space Launch Act of 1984 (as amended) to support VSFC launch customers. The relationship between NASA and VCSFA, however, has evolved beyond a customer supplier relationship. A partnership relationship has emerged which pairs the strengths of the established NASA test range and the state-sponsored, commercial launch facility provider, in an attempt to satisfy the needs for flexible, low-cost access to space. Furthermore, the future of the NASA/Wallops Test Range is closely linked with the success of VCSFA in promoting commercial launches from Wallops. This paper will describe the changing paradigm of the federal launch range and the unique aspects of the NASA/Wallops Facility relationship with VCSFA. Discussion will include institutional cost-sharing, business development and marketing, joint educational programs, and strategic planning.

Underwood, Bruce E.↗

Evaluation of The Performance of The Mars Environmental Compatibility Assessment Electrometer

The Mars Environmental Compatibility Assessment (MECA) electrometer is an instrument that was designed jointly by researchers at the Jet Propulsion Laboratory and the Kennedy Space Center, and is intended to fly on a future space exploration mission of the surface of Mars. The electrometer was designed primarily to study (1) the electrostatic interaction between the Martian soil and five different types of insulators, which are attached to the electrometer, as the electrometer is rubbed over the Martian soil. The MECA/Electrometer is also capable of measuring (2) the presence of charged particles in the Martian atmosphere, (3) the local electric field strength, and (4) the local temperature. The goal of the research project described in this report was to test and evaluate the measurement capabilities of the MECA/Electrometer under simulated Martian surface conditions using facilities located in the Labs and Testbeds Division at the Kennedy Space Center. The results of this study indicate that the Martian soil simulant can triboelectrically charge up the insulator surface. However, the maximum charge buildup did not exceed 18% of the electrometer's full-range sensitivity when rubbed vigorously, and is more likely to be as low as 1% of the maximum range when rubbed through soil. This indicates that the overall gain of the MECA/Electrometer could be increased by a factor of 50 if measurements at the 50% level of full-range sensitivity are desired. The ion gauge, which detects the presence of charged particles, was also evaluated over a pressure range from 10 to 400 Torr (13 to 533 mbar). The electric field sensor was also evaluated. Although the temperature sensor was not evaluated due to project time constraints, it was previously reported to work properly.

Mantovani, James G.↗

Evaluation of the Performance of the Mars Environmental Compatibility Assessment Electrometer

The Mars Environmental Compatibility Assessment (MECA) electrometer is an instrument that was designed jointly by researchers at the Jet Propulsion Laboratory and the Kennedy Space Center, and is intended to fly on a future space exploration mission of the surface of Mars. The electrometer was designed primarily to study (1) the electrostatic interaction between the Martian soil and five different types of insulators, which are attached to the electrometer, as the electrometer is rubbed over the Martian soil. The MECA/Electrometer is also capable of measuring (2) the presence of charged particles in the Martian atmosphere, (3) the local electric field strength, and (4) the local temperature. The goal of the research project described in this report was to test and evaluate the measurement capabilities of the MECA/Electrometer under simulated Martian surface conditions using facilities located in the Labs and Testbeds Division at the Kennedy Space Center. The results of this study indicate that the Martian soil simulant can triboelectrically charge up the insulator surface. However, the maximum charge buildup did not exceed 18% of the electrometer's full-range sensitivity when rubbed vigorously, and is more likely to be as low as 1% of the maximum range when rubbed through soil. This indicates that the overall gain of the MECA/Electrometer could be increased by a factor of 50 if measurements at the 50% level of full-range sensitivity are desired. The ion gauge, which detects the presence of charged particles, was also evaluated over a pressure range from 10 to 400 Torr (13 to 533 mbar). The electric field sensor was also evaluated. Although the temperature sensor was not evaluated due to project time constraints, it was previously reported to work properly.

Mantovani, James G.↗

Repair of Sandwich Structure in Support of the Payload Adapter Fitting

As part of a program examining a composite payload adaptor fitting (PAF) for NASA’s Space Launch System (SLS), a repair study of impact damage and misdrilled holes was undertaken. At the beginning of this repair study, the PAF was baselined as a honeycomb sandwich structure with eight-ply quasi-isotropic, carbon-fiber-reinforced epoxy facesheets. Although the baseline configuration could change, the repair program presented herein is generic enough in nature such that it will apply to most sandwich configurations. The vast majority of loads experienced by this structure will be in-plane compression; thus, this repair study concentrates on the in-plane compression strength of representative sandwich structure specimens. The PAF is a truncated cone with a minimum diameter of about 170 inches at the top and a maximum diameter of about 335 inches at the bottom. While the launch vehicle hardware should be protected throughout its life on the ground, rogue events (or misdrilled holes) are still a possibility. This study is not meant to address large scale damage or damage to the part other than in the acreage (the uniform portion of the structure that does not consist of joints or other detailed areas), but address the most probable type of damages (small impacts and misdrilled holes) in the vast majority of the structure (the acreage).

Nettles, A. T.↗

Comparative Study of 3-Dimensional Woven Joint Architectures for Composite Spacecraft Structures

The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology (ACT) Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite structural applications on Ares V inspired the evaluation of advanced joining technologies, specifically 3D woven composite joints, which could be applied to segmented barrel structures needed for autoclave cured barrel segments due to autoclave size constraints. Implementation of these 3D woven joint technologies may offer enhancements in damage tolerance without sacrificing weight. However, baseline mechanical performance data is needed to properly analyze the joint stresses and subsequently design/down-select a preform architecture. Six different configurations were designed and prepared for this study; each consisting of a different combination of warp/fill fiber volume ratio and preform interlocking method (Z-fiber, fully interlocked, or hybrid). Tensile testing was performed for this study with the enhancement of a dual camera Digital Image Correlation (DIC) system which provides the capability to measure full-field strains and three dimensional displacements of objects under load. As expected, the ratio of warp/fill fiber has a direct influence on strength and modulus, with higher values measured in the direction of higher fiber volume bias. When comparing the Z-fiber weave to a fully interlocked weave with comparable fiber bias, the Z-fiber weave demonstrated the best performance in two different comparisons. We report the measured tensile strengths and moduli for test coupons from the 6 different weave configurations under study.

Jones, Justin S.↗

Comparative Study of 3-Dimensional Woven Joint Architectures for Composite Spacecraft Structures

The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology (ACT) Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite structural applications on Ares V inspired the evaluation of advanced joining technologies, specifically 3D woven composite joints, which could be applied to traditionally manufactured barrel segments. Implementation of these 3D woven joint technologies may offer enhancements in damage tolerance without sacrificing weight. However, baseline mechanical performance data is needed to properly analyze the joint stresses and subsequently design/down-select a preform architecture. Six different configurations were designed and prepared for this study; each consisting of a different combination of warp/fill fiber volume ratio and preform interlocking method (z-fiber, fully interlocked, or hybrid). Tensile testing was performed for this study with the enhancement of a dual camera Digital Image Correlation (DIC) system which provides the capability to measure full-field strains and three dimensional displacements of objects under load. As expected, the ratio of warp/fill fiber has a direct influence on strength and modulus, with higher values measured in the direction of higher fiber volume bias. When comparing the z-fiber weave to a fully interlocked weave with comparable fiber bias, the z-fiber weave demonstrated the best performance in two different comparisons. We report the measured tensile strengths and moduli for test coupons from the 6 different weave configurations under study.

Jones, Justin S.↗

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.

Bjorkman, Gerry↗