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NASA NTRS2009

A Refined Zigzag Beam Theory for Composite and Sandwich Beams

A new refined theory for laminated composite and sandwich beams that contains the kinematics of the Timoshenko Beam Theory as a proper baseline subset is presented. This variationally consistent theory is derived from the virtual work principle and employs a novel piecewise linear zigzag function that provides a more realistic representation of the deformation states of transverse-shear flexible beams than other similar theories. This new zigzag function is unique in that it vanishes at the top and bottom bounding surfaces of a beam. The formulation does not enforce continuity of the transverse shear stress across the beam s cross-section, yet is robust. Two major shortcomings that are inherent in the previous zigzag theories, shear-force inconsistency and difficulties in simulating clamped boundary conditions, and that have greatly limited the utility of these previous theories are discussed in detail. An approach that has successfully resolved these shortcomings is presented herein. Exact solutions for simply supported and cantilevered beams subjected to static loads are derived and the improved modelling capability of the new zigzag beam theory is demonstrated. In particular, extensive results for thick beams with highly heterogeneous material lay-ups are discussed and compared with corresponding results obtained from elasticity solutions, two other zigzag theories, and high-fidelity finite element analyses. Comparisons with the baseline Timoshenko Beam Theory are also presented. The comparisons clearly show the improved accuracy of the new, refined zigzag theory presented herein over similar existing theories. This new theory can be readily extended to plate and shell structures, and should be useful for obtaining relatively low-cost, accurate estimates of structural response needed to design an important class of high-performance aerospace structures.

Tessler, Alexander↗

NASA NTRSDate not supplied

A Procedure to Quantify Interlaminar Damage in Refractory Composites by In-Situ Micro-X-Ray Computed Tomography

Refractory composites are relevant for hot-structure applications on re-entry vehicles. To develop optimized high-performance hot structures, accurate material property data is required. Material properties that often limit design in two-dimensional (2-D) composites are interlaminar strengths. A better understanding of the failure mechanisms for interlaminar shear (ILS), interlaminar tension (ILT), and curved-beam interlaminar tension (CB-ILT) tests can provide insight on improving the design and fabrication of refractory composites. In-situ tests were performed to capture the progressive failure in American Society for Testing and Materials (ASTM) sized ILS (ASTM D3846), ILT (ASTM D7291), and CB-ILT (ASTM D6415) specimens. Before measuring internal damage of refractory composites specimens, the methodology of the test setup warrants a complete and thorough discussion. Detail on the test procedure, test stand design, micro-x-ray computed tomography (CT) configuration, data processing, and CT system uncertainty is discussed. Through keeping the many parameters of the CT system consistent, the uncertainty of the CT system was minimized, optimizing the quality of measurements. The overall quality of a CT scan can be quantified by three metrics: voxel resolution, minimal voxel resolution feature detection, and directional variability. A better understanding of the progressive failure mechanisms of refractory composites is provided by the results of both the present discussion and the one found in the accompanying paper titled “Analysis of Interlaminar Damage in Refractory Composites by In-Situ Micro-X-Ray Computed Tomography”.

In-situ micro-x-ray CT↗

NASA NTRSDate not supplied

Analysis of Interlaminar Damage in Refractory Composites by In-Situ Micro-X-Ray Computed Tomography

In-situ Damage Characterization↗

NASA NTRS1984

Simultaneous analysis and design

Optimization techniques are increasingly being used for performing nonlinear structural analysis. The development of element by element (EBE) preconditioned conjugate gradient (CG) techniques is expected to extend this trend to linear analysis. Under these circumstances the structural design problem can be viewed as a nested optimization problem. There are computational benefits to treating this nested problem as a large single optimization problem. The response variables (such as displacements) and the structural parameters are all treated as design variables in a unified formulation which performs simultaneously the design and analysis. Two examples are used for demonstration. A seventy-two bar truss is optimized subject to linear stress constraints and a wing box structure is optimized subject to nonlinear collapse constraints. Both examples show substantial computational savings with the unified approach as compared to the traditional nested approach.

Haftka, R. T.↗

NASA NTRS1985

Simultaneous analysis and design

Haftka, R. T.↗

NASA NTRS1990

Integrated controls-structures design methodology development for a class of flexible spacecraft

Future utilization of space will require large space structures in low-Earth and geostationary orbits. Example missions include: Earth observation systems, personal communication systems, space science missions, space processing facilities, etc., requiring large antennas, platforms, and solar arrays. The dimensions of such structures will range from a few meters to possibly hundreds of meters. For reducing the cost of construction, launching, and operating (e.g., energy required for reboosting and control), it will be necessary to make the structure as light as possible. However, reducing structural mass tends to increase the flexibility which would make it more difficult to control with the specified precision in attitude and shape. Therefore, there is a need to develop a methodology for designing space structures which are optimal with respect to both structural design and control design. In the current spacecraft design practice, it is customary to first perform the structural design and then the controller design. However, the structural design and the control design problems are substantially coupled and must be considered concurrently in order to obtain a truly optimal spacecraft design. For example, let C denote the set of the 'control' design variables (e.g., controller gains), and L the set of the 'structural' design variables (e.g., member sizes). If a structural member thickness is changed, the dynamics would change which would then change the control law and the actuator mass. That would, in turn, change the structural model. Thus, the sets C and L depend on each other. Future space structures can be roughly divided into four mission classes. Class 1 missions include flexible spacecraft with no articulated appendages which require fine attitude pointing and vibration suppression (e.g., large space antennas). Class 2 missions consist of flexible spacecraft with articulated multiple payloads, where the requirement is to fine-point the spacecraft and each individual payload while suppressing the elastic motion. Class 3 missions include rapid slewing of spacecraft without appendages, while Class 4 missions include general nonlinear motion of a flexible spacecraft with articulated appendages and robot arms. Class 1 and 2 missions represent linear mathematical modeling and control system design problems (except for actuator and sensor nonlinearities), while Class 3 and 4 missions represent nonlinear problems. The development of an integrated controls/structures design approach for Class 1 missions is addressed. The performance for these missions is usually specified in terms of (1) root mean square (RMS) pointing errors at different locations on the structure, and (2) the rate of decay of the transient response. Both of these performance measures include the contributions of rigid as well as elastic motion.

Maghami, P. G.↗

NASA NTRS1973

Design and analysis of the radiator structure for space power systems

The design, analysis, fabrication, and development of the 5-kWe radiator structure are shown. Thermal performance, meteoroid protection, structural capability during launch, development testing and space operation, material evaluation, and the configuration selection are described. The fin-tube development program depends on the relative values of the thermal coefficients of expansion. The initial selection of aluminum fins and Type 316 stainless-steel tubes was based on previous experience; however, the large differential in their expansion rates showed that an alternate, more compatible, combination was needed. Copper, stainless-steel-clad copper, boron-impregnated aluminum, and an independent radiator with a titanium structure were all considered as alternate materials. The final selection was Lockalloy fins with Type 304 stainless-steel D tubes.

Dauterman, W. H.↗

NASA NTRS1981

Structural analysis of cylindrical thrust chambers, volume 3

A system of three computer programs is described for use in conjunction with the BOPAGE finite element program. The programs are demonstrated by analyzing cumulative plastic deformation in a regeneratively cooled rocket thrust chamber. The codes provide the capability to predict geometric and material nonlinear behavior of cyclically loaded structures without performing a cycle-by-cycle analysis over the life of the structure. The program set consists of a BOPACE restart tape reader routine, and extrapolation program and a plot package.

Pearson, M. L.↗

NASA NTRS1988

Parameter identification for vibration control of SCOLE

A least-squares identification method has been used to derive an empirical model of the vibrational dynamics of the Spacecraft Control Laboratory Experiment, an apparatus for testing parameter identification and control schemes for large flexible space structures. Testing is performed by exciting the structure with torque wheels. Linear least-squares analysis is employed to obtain the parameters that best fit the output of an autoregressive model to the data, and to determine the control effectiveness of the torque wheels using the excitation portion of the test data.

Sparks, D. W., Jr.↗

NASA NTRS1992

Design for cyclic loading endurance of composites

The present paper describes the application of the computer code IPACS (Integrated Probabilistic Assessment of Composite Structures) to air craft wing type structures. The code performs a complete probabilistic structural analysis for composites taking into account the uncertainties in geometry, boundary conditions, material properties, laminate lay-ups and loads. Results of the analysis are presented in terms of cumulative distribution functions (CDF) and probability density function (PDF) of life of a wing type composite structure under different hygrothermal environments subjected to random pressure. The sensitivity of fatigue life to a number of critical structural/material variables is also computed from the analysis.

Shiao, Michael C.↗

NASA NTRS1994

Acoustic method of damage sensing in composite materials

The use of acoustic emission and acousto-ultrasonics to characterize impact damage in composite structures is being performed on both graphite epoxy and kevlar bottles. Further development of the acoustic emission methodology to include neural net analysis and/or other multivariate techniques will enhance the capability of the technique to identify failure mechanisms during fracture. The acousto-ultrasonics technique will be investigated to determine its ability to predict regions prone to failure prior to the burst tests. The combination of the two methods will allow for simple nondestructive tests to be capable of predicting the performance of a composite structure prior to being placed in service and during service.

Workman, Gary L.↗

NASA NTRS1996

An acoustic emission and acousto-ultrasonic analysis of impact damaged composite pressure vessels

The use of acoustic emission to characterize impact damage in composite structures is being performed on composite bottles wrapped with graphite epoxy and kevlar bottles. Further development of the acoustic emission methodology will include neural net analysis and/or other multivariate techniques to enhance the capability of the technique to identify dominant failure mechanisms during fracture. The acousto-ultrasonics technique will also continue to be investigated to determine its ability to predict regions prone to failure prior to the burst tests. Characterization of the stress wave factor before, and after impact damage will be useful for inspection purposes in manufacturing processes. The combination of the two methods will also allow for simple nondestructive tests capable of predicting the performance of a composite structure prior to its being placed in service and during service.

Workman, Gary L.↗

NASA NTRS2011

Next Generation X-Ray Optics: High-Resolution, Light-Weight, and Low-Cost

X-ray telescopes are essential to the future of x-ray astronomy. This paper describes a comprehensive program to advance the technology for x-ray telescopes well beyond the state of the art represented by the three currently operating missions: Chandra, XMM-Newton , and Suzaku . This program will address the three key issues in making an x-ray telescope: (I) angular resolution, (2) effective area per unit mass, and (3) cost per unit effective area. The objectives of this technology program are (1) in the near term, to enable Explorer-class x-ray missions and an IXO type mission, and (2) in the long term, to enable a flagship x-ray mission with sub-arcsecond angular resolution and multi-square-meter effective area, at an affordable cost. We pursue two approaches concurrently, emphasizing the first approach in the near term (2-5 years) and the second in the long term (4-10 years). The first approach is precision slumping of borosilicate glass sheets. By design and choice at the outset, this technique makes lightweight and low-cost mirrors. The development program will continue to improve angular resolution, to enable the production of 5-arcsecond x-ray telescopes, to support Explorer-class missions and one or more missions to supersede the original IXO mission. The second approach is precision polishing and light-weighting of single-crystal silicon mirrors. This approach benefits from two recent commercial developments: (1) the inexpensive and abundant availability of large blocks of mono crystalline silicon, and (2) revolutionary advances in deterministic, precision polishing of mirrors. By design and choice at the outset, this technique is capable of producing lightweight mirrors with sub-arcsecond angular resolution. The development program will increase the efficiency and reduce the cost of the polishing and the lightweighting processes, to enable the production of lightweight sub-arcsecond x-ray telescopes. Concurrent with the fabrication of lightweight mirror segments is the continued development and perfection of alignment and integration techniques, for incorporating individual mirror segments into a precision mirror assembly. Recently, we have been developing a technique called edge-bonding, which has achieved an accuracy to enable 10- arcsecond x-ray telescopes. Currently, we are investigating and improving the long-term alignment stability of so-bonded mirrors. Next, we shall refine this process to enable 5-arsecond x-ray telescopes. This technology development program includes all elements to demonstrate progress toward TRL-6: metrology; x-ray performance tests; coupled structural, thermal, and optical performance analysis, and environmental testing.

Zhang, William W.↗

NASA NTRS2012

Next Generation X-Ray Optics: High-Resolution, Light-Weight, and Low-Cost

X-ray telescopes are essential to the future of x-ray astronomy. In this talk I will describe a comprehensive program to advance the technology for x-ray telescopes well beyond the state of the art represented by the three currently operating missions: Chandra, XMM-Newton, and Suzaku. This program will address the three key issues in making an x-ray telescope: (1) angular resolution, (2) effective area per unit mass, and (3) cost per unit effective area. The objectives of this technology program are (1) in the near term, to enable Explorer-class x-ray missions and an IXO-type mission, and (2) in the long term, to enable a flagship x-ray mission with sub-arcsecond angular resolution and multi-square-meter effective area, at an affordable cost. We pursue two approaches concurrently, emphasizing the first approach in the near term (2-5 years) and the second in the long term (4-10 years). The first approach is precision slumping of borosilicate glass sheets. By design and choice at the outset, this technique makes lightweight and low-cost mirrors. The development program will continue to improve angular resolution, to enable the production of 5-arcsecond x-ray telescopes, to support Explorer-class missions and one or more missions to supersede the original IXO mission. The second approach is precision polishing and light-weighting of single-crystal silicon mirrors. This approach benefits from two recent commercial developments: (1) the inexpensive and abundant availability of large blocks of monocrystalline silicon, and (2) revolutionary advances in deterministic, precision polishing of mirrors. By design and choice at the outset, this technique is capable of producing lightweight mirrors with sub-arcsecond angular resolution. The development program will increase the efficiency and reduce the cost of the polishing and the light-weighting processes, to enable the production of lightweight sub-arcsecond x-ray telescopes. Concurrent with the fabrication of lightweight mirror segments is the continued development and perfection of alignment and integration techniques, for incorporating individual mirror segments into a precision mirror assembly. Recently, we have been developing a technique called edge-bonding, which has achieved an accuracy to enable 10-arcsecond x-ray telescopes. Currently, we are investigating and improving the long-term alignment stability of so-bonded mirrors. Next, we shall refine this process to enable 5-arsecond x-ray telescopes. This technology development program includes all elements to demonstrate progress toward TRL-6: metrology; x-ray performance tests; coupled structural, thermal, and optical performance analysis, and environmental testing.

Zhang, William W.↗

NASA NTRS2015

Composite Cryotank Technologies and Development 2.4 and 5.5M out of Autoclave Tank Test Results

The Composite Cryotank Technologies and Demonstration (CCTD) project substantially matured composite, cryogenic propellant tank technology. The project involved the design, analysis, fabrication, and testing of large-scale (2.4-m-diameter precursor and 5.5-m-diameter) composite cryotanks. Design features included a one-piece wall design that minimized tank weight, a Y-joint that incorporated an engineered material to alleviate stress concentration under combined loading, and a fluted core cylindrical section that inherently allows for venting and purging. The tanks used out-of-autoclave (OoA) cured graphite/epoxy material and processes to enable large (up to 10-m-diameter) cryotank fabrication, and thin-ply prepreg to minimize hydrogen permeation through tank walls. Both tanks were fabricated at Boeing using automated fiber placement on breakdown tooling. A fluted core skirt that efficiently carried axial loads and enabled hydrogen purging was included on the 5.5-m-diameter tank. Ultrasonic inspection was performed, and a structural health monitoring system was installed to identify any impact damage during ground processing. The precursor and 5.5-m-diameter tanks were tested in custom test fixtures at the National Aeronautics and Space Administration Marshall Space Flight Center. The testing, which consisted of a sequence of pressure and thermal cycles using liquid hydrogen, was successfully concluded and obtained valuable structural, thermal, and permeation performance data. This technology can be applied to a variety of aircraft and spacecraft applications that would benefit from 30 to 40% weight savings and substantial cost savings compared to aluminum lithium tanks.

Jackson, Justin R.↗

NASA NTRS1992

Structural and aerodynamic considerations for an oblique all-wing aircraft

A key design issue for the Oblique All-Wing aircraft is the packaging of the payload compartment, the fuel tanks, and the other internal components within the airfoil. The internal arrangement of such vehicles is strongly coupled to the exterior vehicle geometry. For example, the height requirements of a passenger cabin directly influence the aircraft thickness and span. As a result, the internal arrangement strongly affects aerodynamic performance and structural weight. Configuration criteria are defined and/or discussed, and a baseline aircraft is developed. Also, some of the major tradeoffs that affect structural weight and aerodynamic performance are presented.

Waters, M. H.↗

NASA NTRS1994

Structural/aerodynamic Blade Analyzer (SAB) User's Guide, Version 1.0

The structural/aerodynamic blade (SAB) analyzer provides an automated tool for the static-deflection analysis of turbomachinery blades with aerodynamic and rotational loads. A structural code calculates a deflected blade shape using aerodynamic loads input. An aerodynamic solver computes aerodynamic loads using deflected blade shape input. The two programs are iterated automatically until deflections converge. Currently, SAB version 1.0 is interfaced with MSC/NASTRAN to perform the structural analysis and PROP3D to perform the aerodynamic analysis. This document serves as a guide for the operation of the SAB system with specific emphasis on its use at NASA Lewis Research Center (LeRC). This guide consists of six chapters: an introduction which gives a summary of SAB; SAB's methodology, component files, links, and interfaces; input/output file structure; setup and execution of the SAB files on the Cray computers; hints and tips to advise the user; and an example problem demonstrating the SAB process. In addition, four appendices are presented to define the different computer programs used within the SAB analyzer and describe the required input decks.

Morel, M. R.↗

NASA NTRS2019

Overview of Heatshield for Extreme Entry Environment Technology (HEEET)

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes > 3500 W/cm2 and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufacturing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high-density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature to sub-component level testing such as 4pt bend testing at sub-ambient and elevated temperature and culminates in testing of the ETU results from which will validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are being utilized to establish the systems structural capability during entry.A broad range of aerothermal tests (arcjet tests) were performed to develop material response models for predicting the required TPS thickness to meet a missions needs and to evaluate failure modes and establish the capability of the system. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview for each of these areas and argue that HEEET has successfully achieved TRL 6.

HEEET↗