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NASA NTRS2017

Space Launch System, Core Stage, Structural Test Design and Implementation

As part of the National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program, engineers at NASA's Marshall Space Flight Center (MSFC) in Huntsville, Alabama are working to design, develop and implement the SLS Core Stage structural testing. The SLS will have the capability to return humans to the Moon and beyond and its first launch is scheduled for December of 2017. The SLS Core Stage consist of five major elements; Forward Skirt, Liquid Oxygen (LOX) tank, Intertank (IT), Liquid Hydrogen (LH2) tank and the Engine Section (ES). Structural Test Articles (STA) for each of these elements are being designed and produced by Boeing at Michoud Assembly Facility located in New Orleans, La. The structural test for the Core Stage STAs (LH2, LOX, IT and ES) are to be conducted by the MSFC Test Laboratory. Additionally, the MSFC Test Laboratory manages the Structural Test Equipment (STE) design and development to support the STAs. It was decided early (April 2012) in the project life that the LH2 and LOX tank STAs would require new test stands and the Engine Section and Intertank would be tested in existing facilities. This decision impacted schedules immediately because the new facilities would require Construction of Facilities (C of F) funds that require congressional approval and long lead times. The Engine Section and Intertank structural test are to be conducted in existing facilities which will limit lead times required to support the first launch of SLS. With a SLS launch date of December, 2017 Boeing had a need date for testing to be complete by September of 2017 to support flight certification requirements. The test facilities were required to be ready by October of 2016 to support test article delivery. The race was on to get the stands ready before Test Article delivery and meet the test complete date of September 2017. This paper documents the past and current design and development phases and the supporting processes, tools, and methodology for supporting the SLS Core Stage STA test stands and related STE. The paper will address key requirements, system development activities and project challenges. Additionally, the interrelationships as well as interdependencies within the SLS project will be discussed.

Shaughnessy, Ray↗

NASA NTRS1978

Low density bismaleimide-carbon microballoon composites

A process is described for constructing for a composite laminate structure which exhibits a high resistance to heat and flame provides safer interior structures for aircraft and submarine compartments. Composite laminate structures are prepared by the bismaleimide resin preimpregnation of a fiberglass cloth to form a face sheet which is bonded with a bismaleimide hot melt adhesive to a porous core structure selected from the group consisting of polyamide paper and bismaleimide-glass fabric which is filled with carbon microballoons. The carbon microballoons are prepared by pyrolyzing phenolic micro-balloons in the presence of nitrogen. A slurry of the carbon microballoons is prepared to fill the porous core structure. The porous core structure and face sheet are bonded to provide panel structures exhibiting increased mechanical capacities and lower oxygen limit values and smoke density values.

Kourtides, D. A.↗

NASA NTRS2013

Characterizing Facesheet/Core Disbonding in Honeycomb Core Sandwich Structure

Results are presented from an experimental investigation into facesheet core disbonding in carbon fiber reinforced plastic/Nomex honeycomb sandwich structures using a Single Cantilever Beam test. Specimens with three, six and twelve-ply facesheets were tested. Specimens with different honeycomb cores consisting of four different cell sizes were also tested, in addition to specimens with three different widths. Three different data reduction methods were employed for computing apparent fracture toughness values from the test data, namely an area method, a compliance calibration technique and a modified beam theory method. The compliance calibration and modified beam theory approaches yielded comparable apparent fracture toughness values, which were generally lower than those computed using the area method. Disbonding in the three-ply facesheet specimens took place at the facesheet/core interface and yielded the lowest apparent fracture toughness values. Disbonding in the six and twelve-ply facesheet specimens took place within the core, near to the facesheet/core interface. Specimen width was not found to have a significant effect on apparent fracture toughness. The amount of scatter in the apparent fracture toughness data was found to increase with honeycomb core cell size.

Rinker, Martin↗

NASA NTRS2019

Hypervelocity Impact Performance of 3D Printed Aluminum Panels

With the continued development of additive manufacturing methods, control over the shape of ligaments, cell regularity, and macroscopic shape can all be easily tuned. This capability allows for tailoring of component architecture and promotes potential mass savings in a space vehicle structure. Additionally, it allows one the flexibility of combining structural elements such as MMOD protection and vehicle stiffness for launch loads for an overall mass reduction. At NASA JSC this technology is being explored in many different ways with the goal being a multifunctional structural component. For this study, four different types of aluminum panels have been 3D printed for testing, three being of a body centric cubic (BCC) lattice structure core and one being kelvin cell structure core. All samples have a 5.33 cm (0.05”) nominally thick aluminum face sheet printed on the front and back side of each panel, with all core materials having a 5.08 cm (2.0”) nominal thickness (see Table 1 for test sample summary and Figures 1 – 2 for sample illustrations). These tests will evaluate the performance of 3D printed aluminum panels under hypervelocity impact (HVI) conditions. The hypervelocity impact tests are being conducted at the JSC White Sands Test Facility (WSTF) Remote Hypervelocity Test Laboratory (RHTL), located in Las Cruces, New Mexico. All tests will be conducted with a 3.4mm Al 2017-T4 sphere at 6.8 km/s impacting at 0° to surface normal (i.e., impacting with no obliquity). Each sample will be trapped between two metal frames, with gasket material residing between the sample and frame, which will be the shipping and testing configuration for all tests. There will be an Al 2017-T4 witness plate staged 5.08 cm (2.0”) from each sample to capture signature of debris, if the rear face sheet of the sample were to perforate from the HVI test event.

Davis, B. A.↗

NASA NTRS2009

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗

NASA NTRS2012

An Efficient Analysis Methodology for Fluted-Core Composite Structures

The primary loading condition in launch-vehicle barrel sections is axial compression, and it is therefore important to understand the compression behavior of any structures, structural concepts, and materials considered in launch-vehicle designs. This understanding will necessarily come from a combination of test and analysis. However, certain potentially beneficial structures and structural concepts do not lend themselves to commonly used simplified analysis methods, and therefore innovative analysis methodologies must be developed if these structures and structural concepts are to be considered. This paper discusses such an analysis technique for the fluted-core sandwich composite structural concept. The presented technique is based on commercially available finite-element codes, and uses shell elements to capture behavior that would normally require solid elements to capture the detailed mechanical response of the structure. The shell thicknesses and offsets using this analysis technique are parameterized, and the parameters are adjusted through a heuristic procedure until this model matches the mechanical behavior of a more detailed shell-and-solid model. Additionally, the detailed shell-and-solid model can be strategically placed in a larger, global shell-only model to capture important local behavior. Comparisons between shell-only models, experiments, and more detailed shell-and-solid models show excellent agreement. The discussed analysis methodology, though only discussed in the context of fluted-core composites, is widely applicable to other concepts.

Oremont, Leonard↗

NASA NTRS2003

The Structural Changes of Tropical Cyclones Upon Interaction with Vertical Wind Shear

The Fourth Convection and Moisture Experiment (CAMEX-4) provided a unique opportunity to observe the distributions and document the roles of important atmospheric factors that impact the development of the core asymmetries and core structural changes of tropical cyclones embedded in vertical wind shear. The state-of-the-art instruments flown on the NASA DC-8 and ER-2, in addition to those on the NOAA aircraft, provided a unique set of observations that documented the core structure throughout the depth of the tropical cyclone. These data have been used to conduct a combined observational and modeling study using a state-of-the-art, high- resolution mesoscale model to examine the role of the environmental vertical wind shear in producing tropical cyclone core asymmetries, and the effects on the structure and intensity of tropical cyclones.The scientific objectives of this study were to obtain in situ measurements that would allow documentation of the physical mechanisms that influence the development of the asymmetric convection and its effect on the core structure of the tropical cyclone.

Ritchie, Elizabeth A.↗

NASA NTRS1995

Composite Cocured Modular Eggcrate-Core Sandwich Structure

Lightweight composite-material (e.g., graphite fiber/epoxy matrix) cocured sandwich panels with eggcratelike cores developed for use as principal components of optical benches and other structures that support precise optical instruments. Structures offer greater thermal and mechanical stability. Advantages include easier fabrication and better mechanical properties.

Magurany, Charles J.↗

NASA NTRS1998

Evaluation of the Transient Liquid Phase (TLP) Bonding Process for Ti3Al-Based Honeycomb Core Sandwich Structure

The suitability of using transient liquid phase (TLP) bonding to fabricate honeycomb core sandwich panels with Ti-14Al-21Nb (wt%) titanium aluminide (T3Al) face sheets for high-temperature hypersonic vehicle applications was evaluated. Three titanium alloy honeycomb cores and one Ti3Al alloy honeycomb core were investigated. Edgewise compression (EWC) and flatwise tension (FWT) tests on honeycomb core sandwich specimens and tensile tests of the face sheet material were conducted at temperatures ranging from room temperature to 1500 F. EWC tests indicated that the honeycomb cores and diffusion bonded joints were able to stabilize the face sheets up to and beyond the face sheet compressive yield strength for all temperatures investigated. The specimens with the T3Al honeycomb core produced the highest FWT strengths at temperatures above 1000 F. Tensile tests indicated that TLP processing conditions resulted in decreases in ductility of the Ti-14Al-21Nb face sheets. Microstructural examination showed that the side of the face sheets to which the filler metals had been applied was transformed from equiaxed alpha2 grains to coarse plates of alpha2 with intergranular Beta. Fractographic examination of the tensile specimens showed that this transformed region was dominated by brittle fracture.

Bird, R. Keith↗

NASA NTRS2016

The Formation of Nucleobases from the Irradiation of Purine in Astophysical Ices and Comparisons with Meteorites.

N-heterocycles have been identified in meteorites and their extraterrestrial origins are suggested by isotopic ratio measurements. Although small N- heterocycles have not been detected in the interstellar medium (ISM), recent experiments in our lab have shown that the irradiation of the aromatic molecules like benzene (C6H6) and naphthalene (C10H8) in mixed molecular ices leads to the formation of O- and N-heterocyclic molecules. Among the class of N-heterocycles are the nucleobases, which are of astrobiological interest because they are the information bearing units of DNA and RNA. Nucleobases have been detected in meteorites [3-5], with isotopic signatures that are also consistent with an extraterrestrial origin. Three of the biologically relevant nucleobases (uracil, cytosine, and guanine) have a pyrimidine core structure while the remaining two (adenine and guanine) possess a purine core. Previous experiments in our lab have demonstrated that all of the bio-logical nucleobases (and numerous other molecules) with a pyrimidine core structure can be produced by irradiating pyrimidine in mixed molecular ices of several compositions [6-8]. In this work, we study the formation of purine-based molecules, including the nucleobases adenine, and guanine, from the ultraviolet (UV) irradiation of purine in ices consisting mixtures of H2O and NH3 at low temperature. The experiments are designed to simulate the astrophysical conditions under which these species may be formed in dense molecular clouds, protoplanetary disks, or on the surfaces of icy bodies in planetary systems.

Astrochemistry↗

NASA NTRS1999

MESSENGER, MErcury: Surface, Space ENvironment, GEochemistry, and Ranging; A Mission to Orbit and Explore the Planet Mercury

MESSENGER is a scientific mission to Mercury. Understanding this extraordinary planet and the forces that have shaped it is fundamental to understanding the processes that have governed the formation, evolution, and dynamics of the terrestrial planets. MESSENGER is a MErcury Surface, Space ENvironment, GEochemistry and Ranging mission to orbit Mercury for one Earth year after completing two flybys of that planet following two flybys of Venus. The necessary flybys return significant new data early in the mission, while the orbital phase, guided by the flyby data, enables a focused scientific investigation of this least-studied terrestrial planet. Answers to key questions about Mercury's high density, crustal composition and structure, volcanic history, core structure, magnetic field generation, polar deposits, exosphere, overall volatile inventory, and magnetosphere are provided by an optimized set of miniaturized space instruments. Our goal is to gain new insight into the formation and evolution of the solar system, including Earth. By traveling to the inner edge of the solar system and exploring a poorly known world, MESSENGER fulfills this quest.

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NASA NTRS2004

Hybrid Inflatable Pressure Vessel

Figure 1 shows a prototype of a large pressure vessel under development for eventual use as a habitable module for long spaceflight (e.g., for transporting humans to Mars). The vessel is a hybrid that comprises an inflatable shell attached to a rigid central structural core. The inflatable shell is, itself, a hybrid that comprises (1) a pressure bladder restrained against expansion by (2) a web of straps made from high-strength polymeric fabrics. On Earth, pressure vessels like this could be used, for example, as portable habitats that could be set up quickly in remote locations, portable hyperbaric chambers for treatment of decompression sickness, or flotation devices for offshore platforms. In addition, some aspects of the design of the fabric straps could be adapted to such other items as lifting straps, parachute straps, and automotive safety belts. Figure 2 depicts selected aspects of the design of a vessel of this type with a toroidal configuration. The bladder serves as an impermeable layer to keep air within the pressure vessel and, for this purpose, is sealed to the central structural core. The web includes longitudinal and circumferential straps. To help maintain the proper shape upon inflation after storage, longitudinal and circumferential straps are indexed together at several of their intersections. Because the web is not required to provide a pressure seal and the bladder is not required to sustain structural loads, the bladder and the web can be optimized for their respective functions. Thus, the bladder can be sealed directly to the rigid core without having to include the web in the seal substructure, and the web can be designed for strength. The ends of the longitudinal straps are attached to the ends of the rigid structural core by means of clevises. Each clevis pin is surrounded by a roller, around which a longitudinal strap is wrapped to form a lap seam with itself. The roller is of a large diameter chosen to reduce bending of the fibers in the strap. The roller also serves to equalize the load in the portions of the strap on both sides of the clevis pin. The lap seam is formed near the clevis by use of a tapered diamond stitch: This stitch is designed specifically to allow fibers in the stitch and strap to relax under load in such a manner that the load becomes more nearly evenly distributed among all fibers in the stitch region. Thus, the tapered diamond stitch prevents load concentrations that could cause premature failure of the strap and thereby increases the strength of the strap/structural-core joint. The lap seam can be rated at >90 percent of the strength of the strap material.

Raboin, Jasen↗

NASA NTRS1988

Experimental studies in vortex pair motion coincident with a liquid reaction

An experimental examination of the coincidence of a liquid reaction (acid/base) with the formation of a vortex pair structure is described in which emphasis is placed on the evolution of the strained diffusion layer and reacted core structures. Flow visualization of the reaction process is achieved via the technique of chemically sensitive LIF. The observed growth of reacted core structures associated with each vortex is compared with theoretically predicted behavior (Marble, 1983; Karagozian and Marble, 1986). Vortex pair separation is also compared with theoretical correlations, and the relevance of the analogy between a fast liquid reaction and a gaseous reaction is discussed.

Karagozian, A. R.↗

NASA NTRS2004

[Relationship Between Core Convective Structure and Intensity Change in Tropical Cyclones]

Tropical Storm Chantal during August 2001 was a storm that failed to intensify over the few days prior to making landfall on the Yucatan Peninsula. An observational study of Tropical Storm Chantal is presented using a diverse data set including remote and in situ measurements from the NASA ER-2 and DC-8 and the NOAA WP-3D N42RF aircraft and satellite data. The authors discuss the storm structure from the larger scale environment down to the convective scale. Large vertical shear (850-200 hPa shear magnitude range 8-15 m/s) plays a very important role in preventing Chantal from intensifying. The storm had a poorly defined vortex that only extended up to 5-6 km altitude, and an adjacent intense convective region that comprised an Mesoscale Convective System (MCS). The entire low-level circulation center was in the rain-free western side of the storm, about 80 km to the west-southwest of the MCS. The MCS appears to have been primarily the result of intense convergence between large scale, low-level easterly flow with embedded downdrafts, and the cyclonic vortex flow. The individual cells in the MCS such as Cell 2 during the period of the observations, were extremely intense with reflectivity core diameters of 10 km and peak updrafts exceeding 20 m/s. Associated with this MCS were two broad subsidence (warm) regions both of which had portions over the vortex. The first layer near 700 hPa was directly above the vortex and covered most of it. The second layer near 500 hPa was along the forward and right flanks of Cell 2 and undercut the anvil divergence region above. There was not much resemblance of these subsidence layers to typical upper level warm cores in hurricanes that are necessary to support strong surface winds and a low central pressure. The observations are compared to previous studies of weakly sheared storms and modeling studies of shear effects and intensification. The configuration of the convective updrafts, low-level circulation, and lack of vertical coherence between the upper and low level warming regions, likely inhibited intensification of Chantal. This configuration is consistent with modeling of vortices in sheared environments, which suggest strongest convection and rain in the downshear left quadrant of the storm, and subsidence in the upshear right quadrant. The vertical shear profile is however different from what was assumed in previous modeling in that the winds are strongest in the lowest levels and the deep tropospheric vertical shear is on the order of 10-12 m/s.

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NASA NTRS2004

[Relationship Between Core Convective Structure and Intensity Change in Tropical Cyclones]

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NASA NTRS2005

[Summary of Research on Relationship Between Core Convective Structure and Intensity Change in Tropical Cyclones]

The downshear reformation of Tropical Storm Gabrielle (2001) was investigated using radar reflectivity and lightning data that were nearly continuous in time, as well as frequent aircraft reconnaissance flights. Initially the storm was a marginal tropical storm in an environment with strong 850-200 hPa vertical wind shear of 12-13 meters per second and an approaching upper tropospheric trough. Both the observed outflow and an adiabatic balance model calculation showed that the radial-vertical circulation increased with time as the trough approached. Convection was highly asymmetric, with almost all radar return located in one quadrant left of downshear in the storm. Reconnaissance data show that an intense mesovortex formed downshear of the original center. This vortex was located just south of, rather than within, a strong downshear left lightning outbreak, consistent with tilting of the horizontal vorticity associated with the vertical wind shear. The downshear mesovortex contained a 972 hPa minimum central pressure, 20 hPa lower than minimum pressure in the original vortex just three hours earlier. The mesovortex became the new center of the storm, but weakened somewhat prior to landfall. It is argued that dry air carried around the storm from the region of upshear subsidence, as well as the direct effects of the shear, prevented the reformed vortex from continuing to intensify. Despite the subsequent weakening of the reformed center, it reached land with greater intensity than the original center. It is argued that this intensification process was set into motion by the vertical wind shear in the presence of an environment with upward motion forced by the upper tropospheric trough. In addition, the new center formed much closer to the coast and made landfall much earlier than predicted. Such vertical shear-induced intensity and track fluctuations are important to understand, especially in storms approaching the coast. The structures of the highly sheared tropical storm Chantal During CAMEX-4 is also discussed.

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NASA NTRSDate not supplied

In Situ Observations and Pressure Measurements for Autoclave Co-Cure of Honeycomb Core Sandwich Structures

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Mark Anders↗

NASA NTRS2010

Hypervelocity Impact Performance of Open Cell Foam Core Sandwich Panel Structures

Open cell metallic foam core sandwich panel structures are of interest for application in spacecraft micrometeoroid and orbital debris shields due to their novel form and advantageous structural and thermal performance. Repeated shocking as a result of secondary impacts upon individual foam ligaments during the penetration process acts to raise the thermal state of impacting projectiles ; resulting in fragmentation, melting, and vaporization at lower velocities than with traditional shielding configurations (e.g. Whipple shield). In order to characterize the protective capability of these structures, an extensive experimental campaign was performed by the Johnson Space Center Hypervelocity Impact Technology Facility, the results of which are reported in this paper. Although not capable of competing against the protection levels achievable with leading heavy shields in use on modern high-risk vehicles (i.e. International Space Station modules), metallic foam core sandwich panels are shown to provide a substantial improvement over comparable structural panels and traditional low weight shielding alternatives such as honeycomb sandwich panels and metallic Whipple shields. A ballistic limit equation, generalized in terms of panel geometry, is derived and presented in a form suitable for application in risk assessment codes.

Ryan, S.↗