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Combining the quasi-static loads, workmanship verification, and model validation tests of aerospace hardware into a single vibration test sequence can considerably reduce schedule and cost.
Crack propagation was studied in a full-scale wing structure under different simulated flight conditions. Omission of low-amplitude gust cycles had a small effect on the crack rate. Truncation of the infrequently occurring high-amplitude gust cycles to a lower level had a noticeably accelerating effect on crack growth. The application of fail-safe load (100 percent limit load) effectively stopped subsequent crack growth under resumed flight-simulation loading. In another flight-simulation test series on sheet specimens, the variables studied are the design stress level and the cyclic frequency of the random gust loading. Inflight mean stresses vary from 5.5 to 10.0 kg/sq mm. The effect of the stress level is larger for the 2024 alloy than for the 7075 alloy. Three frequencies were employed: namely, 10 cps, 1 cps, and 0.1 cps. The frequency effect was small. The advantages and limitations of flight-simulation tests are compared with those of alternative test procedures such as constant-amplitude tests, program tests, and random-load tests. Various testing purposes are considered. The variables of flight-simulation tests are listed and their effects are discussed. A proposal is made for performing systematic flight-simulation tests in such a way that the compiled data may be used as a source of reference.
Sliding friction tests at ultrahigh load of eight greases and 18 dry lubricants and various base materials
Sliding friction tests at ultrahigh load of eight greases and 18 dry lubricants and various base materials
Wind tunnel tests for load and pressure distributions on flat-top cylinders with thick boundary layer
Performance tests of water-lubricated, Rayleigh step, hydrodynamic journal bearings under no load conditions to determine stability
In tests conducted at the NASA Langley Research Center Helicopter Rotor Test Facility, simultaneous measurements of the high-frequency fluctuating aerodynamic blade loads and far-field radiated noise were made on a full-scale, nontranslating rotor system. After their characteristics were determined, the measured blade loads were used in an existing theory to predict the far-field rotational noise. A comparison of the calculated and measured rotational noise is presented with specific attention given to the effect of blade loading coefficients, chordwise loading distributions, blade loading phases, and observer azimuthal position on the predictions.
In ground testing prior to launch the static loads portion of the launch profile may be simulated by either applying static loads directly to the spacecraft through an appropriate loading facility or by subjecting the spacecraft to acceleration loads on a centrifuge. The factors to be considered in selecting one of the two simulation methods are discussed, giving attention to the relative advantages of the two methods in each case.
A GLARE fuselage panel, representative of the crown section of the Fokker 100 fuselage in front of the wing, was tested. The panels were loaded by air pressure resulting in tangential stress in the panel by axial loading, representative of both the cabin pressure and the fuselage bending due to taxiing and gust loading. A fatigue test, simulating 180000 flights, followed by static tests were performed. The panel was loaded to failure at 1.32 ultimate load. The test set-up, the uniform strain distribution of the panel, and the fatigue loads applied at high test frequency are described. The use of GLARE leads to a substantial weight reduction without affecting the fatigue static strength.
The magnitude of yield and flow stresses in aged Inconel 718 are observed to be different in tension and compression. This phenomenon, called the Strength differential (SD), contradicts the metal plasticity axiom that the second deviatoric stress invariant alone is sufficient for representing yield and flow. Apparently, at least one of the other two stress invariants is also significant. A unified viscoplastic model was developed that is able to account for the SD effect in aged Inconel 718. Building this model involved both theory and experiments. First, a general threshold function was proposed that depends on all three stress invariants and then the flow and evolution laws were developed using a potential-based thermodynamic framework. Judiciously chosen shear and axial tests were conducted to characterize the material. Shear tests involved monotonic loading, relaxation, and creep tests with different loading rates and load levels. The axial tests were tension and compression tests that resulted in sufficiently large inelastic strains. All tests were performed at 650 C. The viscoplastic material parameters were determined by optimizing the fit to the shear tests, during which the first and the third stress invariants remained zero. The threshold surface parameters were then fit to the tension and compression test data. An experimental procedure was established to quantify the effect of each stress invariant on inelastic deformation. This requires conducting tests with nonproportional three-dimensional load paths. Validation of the model was done using biaxial tests on tubular specimens of aged Inconel 718 using proportional and nonproportional axial-torsion loading. These biaxial tests also helped to determine the most appropriate form of the threshold function; that is, how to combine the stress invariants. Of the set of trial threshold functions, the ones that incorporated the third stress invariant give the best predictions. However, inclusion of the first stress invariant does not significantly improve the model predictions. The model shows excellent predictive capability for nonproportional load paths. Additionally, it reduces to the well-known models of Mises Drucker and Drucker-Prager. The requisite experiments involve reasonably simple load paths in the axial-shear stress plane and hence can be performed on a variety of different materials: be they metallic, geological. polymeric, ceramic or granular. The general form of the threshold function allows representation of inelastic deformation in a range of materials.
We test through simulation the influence of lock-off time on the aggregated flexibility of thermostatically controllable loads (TCLs), which is modeled by virtual battery (VB) models. The VB model provides a simple but effective way to quantify the aggregated flexibility of TCLs, but its efficacy is not clear when there is lock-off time for TCLs. TCLs cannot be turned on during the lock-off period, and so lock-off time imposes inevitable restrictions on not only the flexibility of individual TCLs but also the aggregated flexibility of a group of TCLs. We first test the influence of lock-off time on the efficacy of VB models with two artificial signals. One of the signal is of low frequency while the other is of high frequency. We then use real-world data to test the influence. One set of data is from a duck curve from CAISO while the other set of data is from AGC signals from PJM. The duck curve changes slowly while the AGC signals change rapidly over time. From both the artificial signals and real-word data, we find that lock-off time has a more significant impact on rapid signals than on slow signals.
Single-ended notch design facilitates accurate measurements of crack progression. Novel test specimen and novel loading fixture and fracture testing of materials under Mode II, or sliding-mode, loading. Testing required for analysis of failures in structural materials, bearings, and the like.
Three test methods were employed to characterize the response of unidirectional Boron/Aluminum metal matrix composite material under monotonic and cyclic loading conditions, namely, losipescu shear, off-axis tension and compression. The characterization of the elastic and plastic response includes the elastic material properties, yielding and subsequent hardening of the unidirectional composite under different stress ratios in the material principal coordinate system. Yield loci generated for different stress ratios are compared for the three different test methods, taking into account residual stresses and specimen geometry. Subsequently, the yield locus for in-plane shear is compared with the prediction of an analytical, micromechanical model. The influence of the scatter in the experimental data on the predicted yield surface is also analyzed. Lastly, the experimental material strengths in tension and compression are correlated with the maximum stress and the Tsai-Wu failure criterion.
A test program was initiated by Marshall Space Flight Center and sponsored by the NASA Engineering and Safety Center to characterize the failure behavior of a typical high-strength aerospace threaded fastener under a range of shear to tension loading ratios for both a nut and an insert configuration where the shear plane passes through the body and threads, respectively. The testing was performed with a customized test fixture designed to test a bolt with a single shear plane at a discrete range of loading angles. The results provide data to compare against existing combined loading failure criteria and to quantify the bolt strength when the shear plane passes through the threads.
Cryogenic insulation designed to operate at various pressures from one atmosphere to vacuum, with high thermal performance and light weight, is needed for cryogenically fueled space launch vehicles and aircraft. Multilayer insulation (MLI) performs well in a high vacuum, but the required vacuum shell for use in the atmosphere is heavy. Spray-on foam insulation (SOFI) is often used in these systems because of its light weight, but can have a higher heat flux than desired. We report on the continued development of Load Responsive Multilayer Insulation (LRMLI), an advanced thermal insulation system that uses dynamic beam discrete spacers that provide high thermal performance both in atmosphere and vacuum. LRMLI consists of layers of thermal radiation barriers separated and supported by micromolded polymer spacers. The spacers have low thermal conductance, and self-support a thin, lightweight vacuum shell that provides internal high vacuum in the insulation. The dynamic load responsive spacers compress to support the external load of a vacuum shell in one atmosphere, and decompress under reduced atmospheric pressure for lower heat leak. Structural load testing was performed on the spacers with various configurations. LRMLI was installed on a 400 liter tank and boil off testing with liquid nitrogen performed at various chamber pressures from one atmosphere to high vacuum. Testing was also performed with an MLI blanket on the outside of the LRMLI.
A biaxial resonant test method was utilized to simultaneously fatigue test a wind turbine blade in the flap and edge (lead-lag) direction. Biaxial resonant blade fatigue testing is an accelerated life test method utilizing oscillating masses on the blade; each mass is independently oscillated at the respective flap and edge blade resonant frequency. The flap and edge resonant frequency were not controlled, nor were they constant for this demonstrated test method. This biaxial resonant test method presented surmountable challenges in test setup simulation, control and data processing. Biaxial resonant testing has the potential to complete test projects faster than single-axis testing. The load modulation during a biaxial resonant test may necessitate periodic load application above targets or higher applied test cycles.
The problem of control command and maneuver induced structural loads is an important aspect of any control system design. The aircraft structure and the control architecture must be designed to achieve desired piloted control responses while limiting the imparted structural loads. The classical approach is to utilize high structural margins, restrict control surface commands to a limited set of analyzed combinations, and train pilots to follow procedural maneuvering limitations. With recent advances in structural sensing and the continued desire to improve safety and vehicle fuel efficiency, it is both possible and desirable to develop control architectures that enable lighter vehicle weights while maintaining and improving protection against structural damage. An optimal control technique has been explored and shown to achieve desirable vehicle control performance while limiting sensed structural loads to specified values. This technique has been implemented and flown on the National Aeronautics and Space Administration Full-scale Advanced Systems Testbed aircraft. The flight tests illustrate that the approach achieves the desired performance and show promising potential benefits. The flights also uncovered some important issues that will need to be addressed for production application.
Acoustic emissions (AE) generated from Kevlar 49/epoxy composite pressure vessels subjected to sustained load-to-failure tests were studied. Data from two different transducer locations on the vessels were compared. It was found that AE from vessel wall-mounted transducers showed a wide variance from those for identical vessels subjected to the same pressure loading. Emissions from boss-mounted transducers did, however, yield values that were relatively consistent. It appears that the signals from the boss-mounted transducers represent an integrated average of the emissions generated by fibers fracturing during the vessel tests. The AE from boss-mounted transducers were also independent of time for vessel failure. This suggests that a similar number of fiber fractures must occur prior to initiation of vessel failure. These studies indicate a potential for developing an AE test procedure for predicting the residual service life or integrity of composite vessels.