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At least 577 records · Page 32

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NASA NTRS2007

Reliability Considerations for Composite Overwrapped Pressure Vessels on Spacecraft

Composite Overwrapped Pressure Vessels (COPVs) are used to store gases under high pressure onboard spacecraft. These are used for a variety of purposes such as propelling liquid fuel etc, Kevlar, glass, Carbon and other more recent fibers have all been in use to overwrap the vessels. COPVs usually have a thin metallic liner with the primary purpose of containing the gases and prevent any leakage. The liner is overwrapped with filament wound composite such as Kevlar, Carbon or Glass fiber. Although the liner is required to perform in the leak before break mode making the failure a relatively benign mode, the overwrap can fail catastrophically under sustained load due to stress rupture. It is this failure mode that is of major concern as the stored energy of such vessels is often great enough ta cause loss of crew and vehicle. The present paper addresses some of the reliability concerns associated specifically with Kevlar Composite Overwrapped Pressure Vessels. The primary focus of the paper is on how reliability of COPV's are established for the purpose of deciding in general their flight worthiness and continued use. Analytical models based on existing design data will be presented showing how to achieve the required reliability metric to the end of a specific period of performance. Uncertainties in the design parameters and how they affect reliability and confidence intervals will be addressed as well. Some trade studies showing how reliability changes with time during a program period will be presented.

Murthy, Pappu L. N.↗

NASA NTRS2007

Polymer-Layered Silicate Nanocomposites for Cryotank Applications

Previous composite cryotank designs have relied on the use of conventional composite materials to reduce microcracking and permeability. However, revolutionary advances in nanotechnology derived materials may enable the production of ultra-lightweight cryotanks with significantly enhanced durability and damage tolerance, as well as reduced propellant permeability. Layered silicate nanocomposites are especially attractive in cryogenic storage tanks based on results that have been reported for epoxy nanocomposite systems. These materials often exhibit an order of magnitude reduction in gas permeability when compared to the base resin. In addition, polymer-silicate nanocomposites have been shown to yield improved dimensional stability, strength, and toughness. The enhancement in material performance of these systems occurs without property trade-offs which are often observed in conventionally filled polymer composites. Research efforts at NASA Glenn Research Center have led to the development of epoxy-clay nanocomposites with 70% lower hydrogen permeability than the base epoxy resin. Filament wound carbon fiber reinforced tanks made with this nanocomposite had a five-fold lower helium leak rate than the corresponding tanks made without clay. The pronounced reduction observed with the tank may be due to flow induced alignment of the clay layers during processing. Additionally, the nanocomposites showed CTE reductions of up to 30%, as well as a 100% increase in toughness.

Miller, Sandi G.↗

NASA NTRS2007

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifing Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle's Kevlar-49 fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed non-conservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic-plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23% lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗

NASA NTRS1994

Yarn carrier with clutch

A yarn carrier apparatus particularly suited for use in braiding machinery or the like due to its capability of continuous yarn feeding and retraction of long lengths of yarn. The yarn carrier apparatus comprises a yarn supply spool which is rotatably mounted within the housing, a spring motor also mounted within the housing and operatively connected to the yarn supply spool through a mechanical transmission assembly which is adapted to multiply rotational movement between the first element of the gear assembly operatively connected to the spring motor and the final element of the gear assembly operatively connected to the yarn supply spool. The spring motor is adapted to tension the yarn during both feeding and retraction thereof, and it is further adapted to periodically rotatably slip within the housing and partially unwind so as to allow for continuous withdrawal of a long length of yarn without the spring motor becoming fully wound and preventing further yarn retraction.

Doyne, Richard A.↗

NASA NTRS1994

Waste gas storage

Method for storing a waste gas mixture comprised of nitrogen, oxygen, carbon dioxide, and inert gases, the gas mixture containing corrosive contaminants including inorganic acids and bases and organic solvents, and derived from space station operations. The gas mixture is stored under pressure in a vessel formed of a filament wound composite overwrap on a metal liner, the metal liner being pre-stressed in compression by the overwrap, thereby avoiding any tensile stress in the liner, and preventing stress corrosion cracking of the liner during gas mixture storage.

Vickers, Brian D.↗

NASA NTRS2000

Helical scan recording with a self-acting negative air bearing

A flat head and a tape transport arrangement impart a wrap angle to the tape at the upstream corner of the head. The wrap angle, corner sharpness and tape stiffness are sufficient to cause a moving tape to form a hollow bump at the upstream corner, thereby creating a hollow into which entrained air can expand, causing a subambient pressure within and downstream of the bump. This pressure keeps the tape in contact with the head. It is created without the need for a groove or complex pressure relief slot(s). No contact pressure arises at the signal exchange site due to media wrap. The highest contact pressures are developed at a wrapped upstream corner. For a tape drive, traveling in both forward and reverse, the wrap can be at both the upstream and downstream (which is the reverse upstream) corners. Heads that are not flat can also be used, if the wrap angle relative to a main surface is sufficient and not too large. The wrapped head can also be used with rotating media, such as disks (floppy and hard) and rotating heads, such as helical wound heads for video recording. Multiple flat tape bearing surfaces can be separated by grooves and/or angles. Each flat can carry heads along one or more gap lines. Multiple adjacent narrow tracks can thus be written for extreme high track density recording.

Muftu , Sinan↗

NASA NTRS2000

Contact sheet recording with a self-acting negative air bearing

Muftu , Sinan↗

NASA NTRS1982

Quasi-bipolar battery construction and method of fabricating

A lightweight, battery construction for lead acid batteries in which biplates are formed from a continuous strip of thermoplastic material, one face of the strip being provided with a plurality of electrically isolated lead strip arrays, each having a transverse axis about which the strip is folded or pleated to provide pleated biplate walls. The pleated continuous strip is sealed along edge longitudinal portions to provide chambers for receiving a plurality of non-conductive thermoplastic separator-plates and to contain electrolyte liquid. Separator-plates support resilient yieldable porous glass mats and scrim fabric in which active material is carried. The assembly of pleated biplates and separator-plates is maintained in pressure relation by exterior resilient means. A method of making such a continuous pleated biplate construction and of assembling one or more battery modules which may be connected in series or in parallel. A biplate construction having continuously wound lead stripes attached to a substrate.

Rippel, Wally E.↗

NASA NTRS1992

Yarn carrier apparatus for braiding machines and the like

El-Shiekh, Aly↗

NASA NTRS2005

Pressure vessel with impact and fire resistant coating and method of making same

An impact and fire resistant coating laminate is provided which serves as an outer protective coating for a pressure vessel such as a composite overwrapped vessel with a metal lining. The laminate comprises a plurality of fibers (e.g., jute twine or other, stronger fibers) which are wound around the pressure vessel and an epoxy matrix resin for the fibers. The epoxy matrix resin including a plurality of microspheres containing a temperature responsive phase change material which changes phase in response to exposure thereof to a predetermined temperature increase so as to afford increased insulation and heat absorption.

DeLay, Thomas K.↗

NASA NTRS1985

High cycle life secondary lithium battery

A secondary battery (10) of high energy density and long cycle is achieved by coating the separator (18) with a film (21) of cationic polymer such as polyvinyl-imidazoline. The binder of the positive electrode (14) such as an ethylene-propylene elastomer binder (26) containing particles (28) of TiS.sub.2 chalcogenide can also be modified to contain sulfone functional groups by incorporating liquid or solid sulfone materials such as 0.1 to 5 percent by weight of sulfolane into the binder. The negative lithium electrode (14), separator (18) and positive electrode (16) are preferably spirally wound and disposed within a sealed casing (17) containing terminals (32, 34). The modified separator and positive electrode are more wettable by the electrolytes in which a salt is dissolved in a polar solvent such as sulfolane.

Yen, Shiao-Ping S.↗

NASA NTRS1985

Trace water sensor

A solid electrolytic type hygrometer is described, which operates with high reliability while providing rapid and sensitive response. A gold foil electrode (16) is wrapped about a hollow glass cylinder (18), a sheet (12) of hygroscopic-electrolytic material is wrapped about the foil, and a wire (14) is wound around the outside of the electrolytic sheet. Moisture passing between wire turns can be absorbed by the electrolytic material (12), and then dissociated by current passed by the electrodes (14, 16) through the electrolytic material. The cylinder has a slit (20) extending along its length, to allow resilient expansion to press the sheet of electrolytic material firmly against the electrodes. The wire turns lie against one another to cause rapid dissociation of moisture throughout the electrolytic material. Additional guard wires (42,44, FIG. 2) lie at opposite ends of the electrolytic sheet, and currents pass through them to avoid moisture buildup at the ends of the main wire coil. The electrical current through the sheet or membrane is proportional to the partial pressure of the water-vapor.

Stephens, James B.↗

NASA NTRS1987

Helical spring holder assembly

A helically-threaded spring holder on which a helically wound spring is mounted has a groove formed in one side of the thread at the end where the spring engages the spring holder. The groove relieves the portion of the side in which it is formed from restricting the spring against axial movement during deflection of the spring. The circumferential length of this groove is chosen to establish the number of spring coils which can be deflected without contacting the side of the thread. The end of the thread is also made rigid to prevent flexing thereof during maximal elongation of the spring.

Newman, Wyatt S.↗

NASA NTRS2003

Drive system for the retraction/extension of variable diameter rotor systems

A drive system for a variable diameter rotor (VDR) system includes a plurality of rotor blade assemblies with inner and outer rotor blade segments. The outer blade segment being telescopically mounted to the inner blade segment. The VDR retraction/extension system includes a drive housing mounted at the root of each blade. The housing supports a spool assembly, a harmonic gear set and an electric motor. The spool assembly includes a pair of counter rotating spools each of which drive a respective cable which extends through the interior of the inboard rotor blade section and around a pulley mounted to the outboard rotor blade section. In operation, the electric motor drives the harmonic gear set which rotates the counter rotating spools. Rotation of the spools causes the cables to be wound onto or off their respective spool consequently effecting retraction/extension of the pulley and the attached outboard rotor blade section relative the inboard rotor blade section. As each blade drive system is independently driven by a separate electrical motor, each independent VDR blade assembly is independently positionable.

Gmirya, Yuriy↗

NASA NTRS1987

Brushless DC motor control system responsive to control signals generated by a computer or the like

A control system for a brushless DC motor responsive to digital control signals is disclosed. The motor includes a multiphase wound stator and a permanent magnet rotor. The rotor is arranged so that each phase winding, when energized from a DC source, will drive the rotor through a predetermined angular position or step. A commutation signal generator responsive to the shaft position provides a commutation signal for each winding. A programmable control signal generator such as a computer or microprocessor produces individual digital control signals for each phase winding. The control signals and commutation signals associated with each winding are applied to an AND gate for that phase winding. Each gate controls a switch connected in series with the associated phase winding and the DC source so that each phase winding is energized only when the commutation signal and the control signal associated with that phase winding are present. The motor shaft may be advanced one step at a time to a desired position by applying a predetermined number of control signals in the proper sequence to the AND gates and the torque generated by the motor may be regulated by applying a separate control signal to each AND gate which is pulse width modulated to control the total time that each switch connects its associated winding to the DC source during each commutation period.

Packard, Douglas T.↗

NASA NTRS2008

Validation of Procedures for Monitoring Crewmember Immune Function

There is ample evidence to suggest that space flight leads to immune system dysregulation. This may be a result of microgravity, confinement, physiological stress, radiation, environment or other mission-associated factors. The clinical risk (if any) from prolonged immune dysregulation during exploration-class space flight has not yet been determined, but may include increased incidence of infection, allergy, hypersensitivity, hematological malignancy or altered wound healing. Each of the clinical events resulting from immune dysfunction has the potential to impact mission critical objectives during exploration-class missions. To date, precious little in-flight immune data has been generated to assess this phenomenon. The majority of recent flight immune studies have been post-flight assessments, which may not accurately reflect the in-flight status of immunity as it resolves over prolonged flight. There are no procedures currently in place to monitor immune function or its effect on crew health. The objective of this Supplemental Medical Objective (SMO) is to develop and validate an immune monitoring strategy consistent with operational flight requirements and constraints. This SMO will assess immunity, latent viral reactivation and physiological stress during both short and long duration flights. Upon completion, it is expected that any clinical risks resulting from the adverse effects of space flight on the human immune system will have been determined. In addition, a flight-compatible immune monitoring strategy will have been developed with which countermeasures validation could be performed. This study will determine, to the best level allowed by current technology, the in-flight status of crewmembers' immune systems. The in-flight samples will allow a distinction between legitimate in-flight alterations and the physiological stresses of landing and readaptation which are believed to alter R+0 assessments. The overall status of the immune system during flight (activation, deficiency, dysregulation) and the response of the immune system to specific latent virus reactivation (known to occur during space flight) will be thoroughly assessed. The first in-flight activity for integrated immunity very recently occurred during the STS-120 Space Shuttle mission. The protocols functioned well from a technical perspective, and accurate in-flight data was obtained from 1 Shuttle and 2 ISS crewmembers. Crew participation rates for the study continue to be robust.

Crucian, Brian↗

NASA NTRS2007

Neural Network Burst Pressure Prediction in Composite Overwrapped Pressure Vessels

Acoustic emission data were collected during the hydroburst testing of eleven 15 inch diameter filament wound composite overwrapped pressure vessels. A neural network burst pressure prediction was generated from the resulting AE amplitude data. The bottles shared commonality of graphite fiber, epoxy resin, and cure time. Individual bottles varied by cure mode (rotisserie versus static oven curing), types of inflicted damage, temperature of the pressurant, and pressurization scheme. Three categorical variables were selected to represent undamaged bottles, impact damaged bottles, and bottles with lacerated hoop fibers. This categorization along with the removal of the AE data from the disbonding noise between the aluminum liner and the composite overwrap allowed the prediction of burst pressures in all three sets of bottles using a single backpropagation neural network. Here the worst case error was 3.38 percent.

Hill, Eric v. K.↗

NASA NTRS2008

Vibroacoustic Response Data of Stiffened Panels and Cylinders

NASA has collected vibroacoustic response data on a variety of complex, aerospace structures to support research into numerical modeling of such structures. This data is being made available to the modeling community to promote the development and validation of analysis methods for these types of structures. Existing data from two structures is described, as well as plans for a data set from a third structure. The first structure is a 1.22 m by 1.22 m stiffened aluminum panel, typical of a commercial aircraft sidewall section. The second is an enclosed, stiffened aluminum cylinder, approximately 3.66 m long and 1.22 m in diameter, constructed to resemble a small aircraft fuselage with no windows and a periodic structure. The third structure is a filament-wound composite cylinder with composite stiffeners. Numerous combinations of excitation and response variables were measured on the structures, including: shaker excitation; diffuse acoustic field; velocity response from a laser vibrometer; intensity scans; and point acceleration.

Cabell, Randolph↗