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At least 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Evaluation of Separation Mechanism Design for the Orion/Ares Launch Vehicle

As a part of the preliminary design work being performed for the Orion vehicle, the Orion to Spacecraft Adaptor (SA) separation mechanism was analyzed and sized, with findings presented here. Sizing is based on worst case abort condition as a result of an anomaly driving the launch vehicle engine thrust vector control hard-over causing a severe vehicle pitch over. This worst case scenario occurs just before Upper Stage Main Engine Cut-Off (MECO) when the vehicle is the lightest and the damping effect due to propellant slosh has been reduced to a minimum. To address this scenario and others, two modeling approaches were invoked. The first approach was a detailed 2-D (Simulink) model to quickly assess the Service Module Engine nozzle to SA clearance for a given separation mechanism. The second approach involved the generation of an Automatic Dynamic Analysis of Mechanical Systems (ADAMS) model to assess secondary effects due to mass centers of gravity that were slightly off the vehicle centerline. It also captured any interference between the Solar Arrays and the Spacecraft Adapter. A comparison of modeling results and accuracy are discussed. Most notably, incorporating a larger SA flange diameter allowed for a natural separation of the Orion and its engine nozzle even at relatively large pitch rates minimizing the kickoff force. Advantages and disadvantages of the 2-D model vs. a full 3-D (ADAMS) model are discussed as well.

Konno, Kevin E.↗
NASA NTRS2009

Improved Joining of Metal Components to Composite Structures

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Semmes, Edmund↗
NASA NTRS2009

Submillimeter-Wave Amplifier Module with Integrated Waveguide Transitions

To increase the usefulness of monolithic millimeter-wave integrated circuit (MMIC) components at submillimeter-wave frequencies, a chip has been designed that incorporates two integrated, radial E-plane probes with an MMIC amplifier in between, thus creating a fully integrated waveguide module. The integrated amplifier chip has been fabricated in 35-nm gate length InP high-electron-mobility-transistor (HEMT) technology. The radial probes were mated to grounded coplanar waveguide input and output lines in the internal amplifier. The total length of the internal HEMT amplifier is 550 m, while the total integrated chip length is 1,085 m. The chip thickness is 50 m with the chip width being 320 m. The internal MMIC amplifier is biased through wire-bond connections to the gates and drains of the chip. The chip has 3 stages, employing 35-nm gate length transistors in each stage. Wire bonds from the DC drain and gate pads are connected to off-chip shunt 51-pF capacitors, and additional off-chip capacitors and resistors are added to the gate and drain bias lines for low-frequency stability of the amplifier. Additionally, bond wires to the grounded coplanar waveguide pads at the RF input and output of the internal amplifier are added to ensure good ground connections to the waveguide package. The S-parameters of the module, not corrected for input or output waveguide loss, are measured at the waveguide flange edges. The amplifier module has over 10 dB of gain from 290 to 330 GHz, with a peak gain of over 14 dB at 307 GHz. The WR2.2 waveguide cutoff is again observed at 268 GHz. The module is biased at a drain current of 27 mA, a drain voltage of 1.24 V, and a gate voltage of +0.21 V. Return loss of the module is very good between 5 to 25 dB. This result illustrates the usefulness of the integrated radial probe transition, and the wide (over 10-percent) bandwidth that one can expect for amplifier modules with integrated radial probes in the submillimeter-regime (>300 GHz).

Samoska, Lorene↗
NASA NTRS1940

The Effect of Initial Displacement of the Center Support on the Buckling of a Column Continuous over Three Supports

The test indicate that "an indiscriminate single application of the Southwell method (for analyzing Exp. Observations in problems of elastic stability)--can result in definite and measurable errors" The test also indicate "that the effect of curvature due to bending on the critical load for the compression flange material of a box beam is probably small and can be neglected." We have not found this to be true in our tests. It is believed that the effect of curvature, together with a small amount of fixity at the ribs, tends to force the stiffeners to bow in each bay thus effectively increasing their end fixity and thereby raising their allowable loads.

Lunquist, Eugene E.↗
NASA NTRS2009

Residual Stresses and Critical Initial Flaw Size Analyses of Welds

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). A series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on the fatigue life. The purpose of the weld analyses was to model the weld process using a variety of sequences to determine the 'best' sequence in terms of weld residual stresses and distortions. The many factors examined in this study include weld design (single-V, double-V groove), weld sequence, boundary conditions, and material properties, among others. The results of this weld analysis are included with service loads to perform a fatigue and critical initial flaw size evaluation.

Brust, Frederick W.↗
NASA NTRS2008

Split-Block Waveguide Polarization Twist for 220 to 325 GHz

A split-block waveguide circuit that rotates polarization by 90 has been designed with WR-3 input and output waveguides, which are rectangular waveguides used for a nominal frequency range of 220 to 325 GHz. Heretofore, twisted rectangular waveguides equipped with flanges at the input and output have been the standard means of rotating the polarizations of guided microwave signals. However, the fabrication and assembly of such components become difficult at high frequency due to decreasing wavelength, such that twisted rectangular waveguides become impractical at frequencies above a few hundred gigahertz. Conventional twisted rectangular waveguides are also not amenable to integration into highly miniaturized subassemblies of advanced millimeter- and submillimeter-wave detector arrays now undergoing development. In contrast, the present polarization- rotating waveguide can readily be incorporated into complex integrated waveguide circuits such as miniaturized detector arrays fabricated by either conventional end milling of metal blocks or by deep reactive ion etching of silicon blocks. Moreover, the present split-block design can be scaled up in frequency to at least 5 THz. The main step in fabricating a splitblock polarization-rotating waveguide of the present design is to cut channels having special asymmetrically shaped steps into mating upper and lower blocks (see Figure 1). The dimensions of the steps are chosen to be consistent with the WR-3 waveguide cross section, which is 0.864 by 0.432 mm. The channels are characterized by varying widths with constant depths of 0.432, 0.324, and 0.216 mm and by relatively large corner radii to facilitate fabrication. The steps effect both a geometric transition and the corresponding impedance-matched electromagnetic-polarization transition between (1) a WR-3 rectangular waveguide oriented with the electric field vector normal to the block mating surfaces and (2) a corresponding WR-3 waveguide oriented with its electric field vector parallel to the mating surfaces of the blocks. A prototype has been built and tested. Figure 2 presents test results indicative of good performance over nearly the entire WR-3 waveguide frequency band.

Ward, John↗
NASA NTRS2008

Measurements by a Vector Network Analyzer at 325 to 508 GHz

Recent experiments were performed in which return loss and insertion loss of waveguide test assemblies in the frequency range from 325 to 508 GHz were measured by use of a swept-frequency two-port vector network analyzer (VNA) test set. The experiments were part of a continuing effort to develop means of characterizing passive and active electronic components and systems operating at ever increasing frequencies. The waveguide test assemblies comprised WR-2.2 end sections collinear with WR-3.3 middle sections. The test set, assembled from commercially available components, included a 50-GHz VNA scattering- parameter test set and external signal synthesizers, augmented with recently developed frequency extenders, and further augmented with attenuators and amplifiers as needed to adjust radiofrequency and intermediate-frequency power levels between the aforementioned components. The tests included line-reflect-line calibration procedures, using WR-2.2 waveguide shims as the "line" standards and waveguide flange short circuits as the "reflect" standards. Calibrated dynamic ranges somewhat greater than about 20 dB for return loss and 35 dB for insertion loss were achieved. The measurement data of the test assemblies were found to substantially agree with results of computational simulations.

Fung, King Man↗
NASA NTRS2008

Balanced Flow Meters without Moving Parts

Balanced flow meters are recent additions to an established class of simple, rugged flow meters that contain no moving parts in contact with flow and are based on measurement of pressure drops across objects placed in flow paths. These flow meters are highly accurate, minimally intrusive, easily manufacturable, and reliable. A balanced flow meter can be easily mounted in a flow path by bolting it between conventional pipe flanges. A balanced flow meter can be used to measure the flow of any of a variety of liquids or gases, provided that it has been properly calibrated. Relative to the standard orifice-plate flow meter, the balanced flow meter introduces less turbulence and two times less permanent pressure loss and is therefore capable of offering 10 times greater accuracy and repeatability with less dissipation of energy. A secondary benefit of the reduction of turbulence is the reduction of vibration and up to 15 times less acoustic noise generation. Both the balanced flow meter and the standard orifice-plate flow meter are basically disks that contain holes and are instrumented with pressure transducers on their upstream and downstream faces. The most obvious difference between them is that the standard orifice plate contains a single, central hole while the balanced flow meter contains multiple holes. The term 'balanced' signifies that in designing the meter, the sizes and locations of the holes are determined in an optimization procedure that involves balancing of numerous factors, including volumetric flow, mass flow, dynamic pressure, kinetic energy, all in an effort to minimize such undesired effects as turbulence, pressure loss, dissipation of kinetic energy, and non-repeatability and nonlinearity of response over the anticipated range of flow conditions. Due to proper balancing of these factors, recent testing demonstrated that the balanced flow-meter performance was similar to a Venturi tube in both accuracy and pressure recovery, but featured reduced cost and pipe-length requirements.

Kelley, Anthony R.↗
NASA NTRS2008

Fire Chemistry Testing of Spray-On Foam Insulation (SOFI)

An experimental study was initiated that included the long-term testing of the following SOFI materials, which make up the majority of the Thermal Protection System of the Shuttle External Tank: NCFI 24-124 (acreage foam) and BX-265 (close-out foam, including the intertank flange and bipod areas). A potential alternate material, NCFI 27-68 (acreage foam with flame retardant removed), was also tested. Fire chemistry testing was completed on samples that were retrieved after aging/weathering at intervals of 3, 6, and 12 months. The testing included three standard test methods: limiting oxygen index (ASTM G125), radiant panel (ASTM E162), and cone calorimeter (ASTM E1354).

Source record↗
NASA NTRS2008

Thermal Performance of Aged and Weathered Spray-On Foam Insulation (SOFI) Materials Under Cryogenic Vacuum Conditions (Cryostat-4)

The NASA Cryogenics Test Laboratory at Kennedy Space Center conducted long-term testing of SOFI materials under actual-use cryogenic conditions with Cryostat-4. The materials included in the testing were NCFI 24-124 (acreage foam), BX-265 (close-out foam, including intertank flange and bipod areas), and a potential alternate material, NCFI 27-68, (acreage foam with the flame retardant removed). Specimens of these materials were placed at two locations: a site that simulated aging (the Vehicle Assembly Building [VAB]) and a site that simulated weathering (the Atmospheric Exposure Test Site [beach site]). After aging/weathering intervals of 3, 6, and 12 months, the samples were retrieved and tested for their thermal performance under cryogenic vacuum conditions with test apparatus Cryostat-4.

Source record↗
NASA NTRS2008

Cryogenic Moisture Analysis of Spray-On Foam Insulation (SOFI)

The NASA Cryogenics Test Laboratory at Kennedy Space Center conducted long-term testing of SOFI materials under actual-use cryogenic conditions. The lab tested NCFI 24-124 (acreage foam), BX-265 (close-out foam, including intertank flange and bipod areas), and a potential alternate material, NCFI 27-68 (acreage foam with the flame retardant removed). Specimens of all three materials were placed at a site that simulated aging (the Vehicle Assembly Building [VAB]) and a site that simulated weathering (Atmospheric Exposure Test Site [beach site]). After aging/ weathering intervals of 3, 6, and 12 months, the samples were retrieved and tested for their ability to absorb moisture under conditions similar to those experienced by the Space Shuttle External Tank (ET) during the loading of cryogenic propellants.

Source record↗
NASA NTRS2009

Meteoroid and Orbital Debris Threats to NASA's Docking Seals: Initial Assessment and Methodology

The Crew Exploration Vehicle (CEV) will be exposed to the Micrometeoroid Orbital Debris (MMOD) environment in Low Earth Orbit (LEO) during missions to the International Space Station (ISS) and to the micrometeoroid environment during lunar missions. The CEV will be equipped with a docking system which enables it to connect to ISS and the lunar module known as Altair; this docking system includes a hatch that opens so crew and supplies can pass between the spacecrafts. This docking system is known as the Low Impact Docking System (LIDS) and uses a silicone rubber seal to seal in cabin air. The rubber seal on LIDS presses against a metal flange on ISS (or Altair). All of these mating surfaces are exposed to the space environment prior to docking. The effects of atomic oxygen, ultraviolet and ionizing radiation, and MMOD have been estimated using ground based facilities. This work presents an initial methodology to predict meteoroid and orbital debris threats to candidate docking seals being considered for LIDS. The methodology integrates the results of ground based hypervelocity impacts on silicone rubber seals and aluminum sheets, risk assessments of the MMOD environment for a variety of mission scenarios, and candidate failure criteria. The experimental effort that addressed the effects of projectile incidence angle, speed, mass, and density, relations between projectile size and resulting crater size, and relations between crater size and the leak rate of candidate seals has culminated in a definition of the seal/flange failure criteria. The risk assessment performed with the BUMPER code used the failure criteria to determine the probability of failure of the seal/flange system and compared the risk to the allotted risk dictated by NASA's program requirements.

deGroh, Henry C., III↗
NASA NTRS2009

Effects of Hypervelocity Impacts on Silicone Elastomer Seals and Mating Aluminum Surfaces

While in space silicone based elastomer seals planned for use on NASA's Crew Exploration Vehicle (CEV) are exposed to threats from micrometeoroids and orbital debris (MMOD). An understanding of these threats is required to assess risks to the crew, the CEV orbiter, and missions. An Earth based campaign of hypervelocity impacts on small scale seal rings has been done to help estimate MMOD threats to the primary docking seal being developed for the Low Impact Docking System (LIDS). LIDS is being developed to enable the CEV to dock to the ISS (International Space Station) or to Altair (NASA's next lunar lander). The silicone seal on LIDS seals against aluminum alloy flanges on ISS or Altair. Since the integrity of a seal depends on both sealing surfaces, aluminum targets were also impacted. The variables considered in this study included projectile mass, density, speed, incidence angle, seal materials, and target surface treatments and coatings. Most of the impacts used a velocity near 8 km/s and spherical aluminum projectiles (density = 2.7 g/cubic centimeter), however, a few tests were done near 5.6 km/s. Tests were also performed using projectile densities of 7.7, 2.79, 2.5 or 1.14 g/cubic centimeter. Projectile incidence angles examined included 0 degrees, 45 degrees , and 60 degrees from normal to the plane of the target. Elastomer compounds impacted include Parker's S0383-70 and Esterline's ELA-SA-401 in the as received condition, or after an atomic oxygen treatment. Bare, anodized and nickel coated aluminum targets were tested simulating the candidate mating seal surface materials. After impact, seals and aluminum plates were leak tested: damaged seals were tested against an undamaged aluminum plate; and undamaged seals were placed at various locations over craters in aluminum plates. It has been shown that silicone elastomer seals can withstand an impressive level of damage before leaking beyond allowable limits. In general on the tests performed to date, the diameter of the crater in either the elastomer, or the aluminum, must be at least as big as 80% to 90% of width of the bulb of the seal before significant leakage occurs.

deGroh, Henry C., III↗
NASA NTRS2009

Coupled Thermo-Electro-Magneto-Elastic Response of Smart Stiffened Panels

This report documents the procedures developed for incorporating smart laminate and panel analysis capabilities within the HyperSizer aerospace structural sizing software package. HyperSizer analyzes stiffened panels composed of arbitrary composite laminates through stiffener homogenization, or "smearing " techniques. The result is an effective constitutive equation for the stiffened panel that is suitable for use in a full vehicle-scale finite element analysis via MSC/NASTRAN. The existing thermo-elastic capabilities of HyperSizer have herein been extended to include coupled thermo-electro-magneto-elastic analysis capabilities. This represents a significant step toward realization of design tools capable of guiding the development of the next generation of smart aerospace structures. Verification results are presented that compare the developed smart HyperSizer capability with an ABAQUS piezoelectric finite element solution for a facesheet-flange combination. These results show good agreement between HyperSizer and ABAQUS, but highlight a limitation of the HyperSizer formulation in that constant electric field components are assumed.

Bednarcyk, Brett A.↗
NASA NTRS2010

Nondestructive Crack Detection in a Fuel System Component

The paper discusses development of various NDE techniques to detect cracks in A40 steel poppets used in a valve of the fuel system of the Space Shuttle Orbiter. The valve assembly experiences a severe high cycle fatigue environment during its operation. Cracks were discovered at the radius of the poppet flange. Experience shows that very small cracks or material anomalies do not cause failure in a single operation event. While the design is being modified to eliminate the issue, NDE has been used to screen the poppets for cracks before every use. Several surface flaw detection techniques were considered and a few NDE techniques were developed to provide NDE screening for the flaw detection. The primary method used was the eddy current testing. In the eddy current technique, the X-Y channel test data from the eddy current instrument was recorded as computer files. A Matlab data review and plotting application was developed to analyze the data files. The Matlab application provides much higher resolution than the eddy current instrument that was used to acquire the data. Other techniques that were used included ultrasonic surface wave and magnetic particle testing. A probability of detection (POD) study was undertaken to determine the 90/95 size for the eddy current technique. This study used specimens with same geometry and material as the poppet. Fatigue cracks were grown in these specimens. Information on results of the NDE techniques and results of the POD study are provided.

Koshti, Ajay↗
NASA NTRS2007

Improved High-Voltage Gas Isolator for Ion Thruster

A report describes an improved high-voltage isolator for preventing electrical discharge along the flow path of a propellant gas being fed from a supply at a spacecraft chassis electrical potential to an ion thruster at a potential as high as multiple kilovolts. The isolator must survive launch vibration and must remain electrically nonconductive for thousands of hours under conditions that, in the absence of proper design, would cause formation of electrically conductive sputtered metal, carbon, and/or decomposed hydrocarbons on its surfaces. The isolator includes an alumina cylinder containing a spiral channel filled with a porous medium made from alumina microbeads fired together with an alumina slurry. Connections to gas-transport tubes are made at both ends of the alumina cylinder by means of metal caps containing fine-mesh screens to prevent passage of loose alumina particles. The outer surface of the alumina cylinder is convoluted to lengthen the electrical path between the metal caps and to afford shadow shielding to minimize the probability of formation of a continuous deposit that would electrically connect the ends. A flanged cylindrical metal cap that surrounds the alumina cylinder without touching one of the ends provides additional shadow shielding.

Banks, Bruce↗
NASA NTRS2009

High Temperature Variable Conductance Heat Pipes for Radioisotope Stirling Systems

In a Stirling radioisotope system, heat must continually be removed from the GPHS modules, to maintain the GPHS modules and surrounding insulation at acceptable temperatures. Normally, the Stirling convertor provides this cooling. If the Stirling convertor stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, but also ending the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) is under development to allow multiple stops and restarts of the Stirling convertor. The status of the ongoing effort in developing this technology is presented in this paper. An earlier, preliminary design had a radiator outside the Advanced Stirling Radioisotope Generator (ASRG) casing, used NaK as the working fluid, and had the reservoir located on the cold side adapter flange. The revised design has an internal radiator inside the casing, with the reservoir embedded inside the insulation. A large set of advantages are offered by this new design. In addition to reducing the overall size and mass of the VCHP, simplicity, compactness and easiness in assembling the VCHP with the ASRG are significantly enhanced. Also, the permanently elevated temperatures of the entire VCHP allows the change of the working fluid from a binary compound (NaK) to single compound (Na). The latter, by its properties, allows higher performance and further mass reduction of the system. Preliminary design and analysis shows an acceptable peak temperature of the ASRG case of 140 C while the heat losses caused by the addition of the VCHP are 1.8 W.

Tarau, Calin↗