Results for “bolts” — Page 3

NASA NTRS1989

Ultrasonic pulsed phase locked loop interferometer for bolt load measurements

The pulsed phase-locked-loop bolt monitor (P2L2) that uses ultrasonic waves to measure bolt preload with accuracies ranging from 1 to 3 percent (depending on the specific bolt) is described. To remeasure bolt load after installation, a thermal calibration factor compensates for bolt temperature changes, and a standard reference block allows correction for acoustic phase errors due to measurement equipment configuration such as utilization of a different transducer, couplant, or cable. Some examples of critical applications including Space Shuttle landing-gear wheels and NASA wind-tunnel fan blades are discussed.

Allison, S. G.↗

NASA NTRS1992

Torque, Tension, And Friction In Bolts

Improved equations predict relationships among tension in bolt, torque applied to bolt during installation, effective coefficient of friction, and number of times bolt has been installed. Bolted joints designed with new equations, use fewer and/or smaller bolts to carry same loads, reducing weights.

Morawski, Julian↗

NASA NTRS1994

Instrumented Bolts Would Measure Shear Forces In Joints

Bolts instrumented with strain gauges used to measure shear forces. Bolts installed in multiple-bolt lap joints to obtain data on distribution of stresses and deformations in and around joints. Strain gauges indicate share of applied load borne by each individual bolt. In original application, bolted panels made of advanced refractory composite materials designed to withstand use at temperatures up to 4,000 degrees F. Also applicable to other joint materials and measurement of shear loads in other connections such as, shear loads on shafts in pulleys or gears.

Sawyer, James Wayne↗

NASA NTRS1995

Instrumented Bolt Measures Load In Two Ways

Bolt instrumented to allow both ultrasonic and strain-gauge measurements of tensile load in bolt during installation and use of bolt in structure. Bolt head design allows interface for ultrasonic transducer installed, while shallow chamfered circumferential groove on bolt shank contains four strain gauges at equal angular intervals wired as a full-bridge transducer.

Smith, D. E.↗

NASA NTRS1995

Experiments On Vibration-Induced Loosening Of Bolts

Report describes experimental study of loosening of bolts in presence of vibrations. Eleven design parameters considered likely to affect tendency to loosen evaluated for relative importance. Parameters were bolt diameter, lubrication on bolt, lubrication on mating materials, bolt-hole tolerance, preload, nut-locking device, grip length, thread pitch, class of fit, joint configuration, and mass of configuration. Bolts tested in vibration for two values of each design parameter.

Ramey, G. ED↗

NASA NTRS2008

Simulating the Structural Response of a Preloaded Bolted Joint

The present paper describes the structural analyses performed on a preloaded bolted-joint configuration. The joint modeled was comprised of two L-shaped structures connected together using a single bolt. Each L-shaped structure involved a vertical flat segment (or shell wall) welded to a horizontal segment (or flange). Parametric studies were performed using elasto-plastic, large-deformation nonlinear finite element analyses to determine the influence of several factors on the bolted-joint response. The factors considered included bolt preload, washer-surface-bearing size, edge boundary conditions, joint segment length, and loading history. Joint response is reported in terms of displacements, gap opening, and surface strains. Most of the factors studied were determined to have minimal effect on the bolted-joint response; however, the washer-bearing-surface size affected the response significantly.

Knight, Norman F., Jr.↗

NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism (CBM). The mechanism that effects the structural connection of the CBM halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per CBM. The CBM has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface; see Figure 1. The Powered Bolt Assemblies are preloaded to approximately 19 kilo pounds (KIPs) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes which create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗

NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism. The mechanism that effects the structural connection of the Common Berthing Mechanism halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per Common Berthing Mechanism. The Common Berthing Mechanism has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface (Figure 1). The Powered Bolt Assemblies are preloaded to approximately 84.5 kN (19000 lb) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes that create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗

NASA NTRS2014

Ultrasonic Method for Deployment Mechanism Bolt Element Preload Verification

Deployment mechanisms play a pivotal role in mission success. These mechanisms often incorporate bolt elements for which a preload within a specified range is essential for proper operation. A common practice is to torque these bolt elements to a specified value during installation. The resulting preload, however, can vary significantly with applied torque for a number of reasons. The goal of this effort was to investigate ultrasonic methods as an alternative for bolt preload verification in such deployment mechanisms. A family of non-explosive release mechanisms widely used by satellite manufacturers was chosen for the work. A willing contractor permitted measurements on a sampling of bolt elements for these release mechanisms that were installed by a technician following a standard practice. A variation of approximately 50% (+/- 25%) in the resultant preloads was observed. An alternative ultrasonic method to set the preloads was then developed and calibration data was accumulated. The method was demonstrated on bolt elements installed in a fixture instrumented with a calibrated load cell and designed to mimic production practice. The ultrasonic method yielded results within +/- 3% of the load cell reading. The contractor has since adopted the alternative method for its future production. Introduction

Johnson, Eric C.↗

NASA NTRS2021

Wake Instability Behind Isolated Trip Near the Leading Edge of the BOLT-II Configuration

The BOLT-II (Holden Mission) configuration is an extended version of the BOLT flight article and depicts hypersonic boundary-layer transition in the presence of multiple and potentially interacting instability mechanisms. Several numerical studies of the boundary-layer instabilities over these configurations have been reported in the recent literature, including our previous studies of the modal instability characteristics of boundary-layer streaks adjacent to the minor-axis symmetry plane of the BOLT configuration and the wake instabilities behind a diamond planform (“pizza-box”) trip along the symmetry plane on the secondary side of the BOLT-II configuration. The present work extends the latter study to a scaled version of the same trip that is located in the region of nonzero crossflow in the vicinity of the leading edge at X/L = 0.5. Collectively, the trips along the symmetry plane and near the leading edge are the focus of the NASA roughness experiment on the secondary side of the BOLT-II configuration. The laminar basic state computation at the nominal flight design condition of Re ∞ = 5.44 x 10 6 /m and Re ∞ = 2.5 x 10 6 /m shows that the leading-edge trip with k/δ ≈ 0.70 and planform-side-length-to-height ratio of b/k = 3.0 induces multiple asymmetric, longitudinal streaks within the trip wake. The most prominent streak among these resembles a finite amplitude crossflow vortex, and it supports the amplification of multiple families of unstable modes. The application of multi-dimensional instability analysis to the wake flow reveals that the most amplified unstable mode can achieve a peak N-factor of up to 20 by X/L = 0.80, indicating that the onset of transition is more than likely to occur within eighty percent of the model length. To the best of our knowledge, the present study represents the first analysis including nonparallel and curvature effects on hypersonic tripwake instabilities in the presence of boundary-layer crossflow over a three-dimensional configuration.

Boundary layer transition↗

NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

Hypersonic↗

NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

hypersonic↗

NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗

NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗

DOE OSTI2025

Comparative analysis of thermal management systems in electric vehicles at extreme weather conditions: Case study on Nissan Leaf 2019 Plus, Chevrolet Bolt 2020 and Tesla Model 3 2020

With the surge in electric vehicle (EV) adoption and the need for extended driving ranges, optimizing energy efficiency, particularly through thermal management, is critical, especially in extreme weather. Managing the substantial energy needed for cabin climate control and battery temperature regulation can increase energy demands by over 50 %, severely limiting range. This study conducts a comparative analysis of thermal management systems (TMS) in three popular EV vehicles, 2020 Chevrolet Bolt, 2019 Nissan Leaf Plus, and 2020 Tesla Model 3, evaluating their distinct TMS configurations and performance under varied weather conditions. Using both numerical simulations and experimental data collected on a controlled test bench at Argonne National Laboratory, we assess how TMS architecture and operational modes influence energy consumption and range. A comprehensive TMS model was developed, integrating cabin and battery thermal sub-models in the Autonomie software platform, to simulate temperature fluctuations and range impacts. Cabin climate was modeled using a mono-zonal approach, while battery cell temperature distribution was estimated through a 2D nodal structure. Each vehicle's distinct TMS setup was evaluated: the Chevrolet Bolt and Tesla Model 3 use a dual evaporator vapor compression cycle with a PTC heater for the cabin and a coolant loop for battery thermal management; the Nissan Leaf Plus employs a heat pump with a PTC heater for the cabin and air-cooling for the battery. Tests conducted at ambient temperatures of 35°C, 22°C, -7°C, and -18°C reveal significant differences in energy use and range reduction across both configurations and conditions. At 35°C, the Tesla Model 3, Chevrolet Bolt, and Nissan Leaf Plus have a range reduction of 8%, 9%, and 13%, respectively, due to air conditioning. In winter, heating technology is paramount; at -7°C, the Nissan Leaf's heat pump configuration achieves a lower range reduction (19.3%) compared to the Tesla and Chevrolet Bolt PTC heaters, which reduce range by 28.3% and 31%, respectively. Further, this study provides valuable insights for automotive engineers, EV technology researchers, and thermal management system designers aiming to enhance electric vehicle performance by understanding how different weather conditions and TMS architectures impact energy consumption and driving range.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1966

Modified power tool rapidly drives series torque bolts

Feeder attachment, which fits on a standard power driver, drives a series of longitudinally attached torque bolts into place with great speed. It allows loading of a series of bolts and then positions individual bolts in the driving head for assembly. The attachment contains a socket gun which may be modified to accommodate different types and sizes of bolts.

Source record↗

NASA NTRS1966

Nondestructive test method accurately sorts mixed bolts

Neutron activation analysis method sorts copper plated steel bolts from nickel plated steel bolts. Copper and nickel plated steel bolt specimens of the same configuration are irradiated with thermal neutrons in a test reactor for a short time. After thermal neutron irradiation, the bolts are analyzed using scintillation energy readout equipment.

Dezeih, C. J.↗

NASA NTRS1970

Automatic, computerized testing of bolts

System for testing bolts with various platings, lubricants, nuts, and tightening procedures tests 200 fasteners, and processes and summarizes the results, within one month. System measures input torque, nut rotation, bolt clamping force, bolt shank twist, and bolt elongation, data is printed in report form. Test apparatus is described.

Carlucci, J., Jr.↗