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NASA NTRS1991

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.↗

NASA NTRS1993

De-Dopplerization of aircraft acoustic signals

A de-Dopplerization scheme is devised and applied to both a tonal noise source, a XV-15 aircraft, and a broadband noise source, a F-18 aircraft. The procedure is developed from the conservation equations of fluid mechanics and is described in the paper. The corrected time history is constructed by using linear interpolation in the measured time history. This was made possible by knowing the position history of the aircraft provided by radar and/or laser tracking. The XV-15 data established that the scheme can accurately account for Doppler frequency shifts. The F-18 data confirms what has been noted in prediction models and static tests pertaining to broadband shock associated noise. That is, the peak frequency increases and the peaks broaden toward the jet axis. Another issue addressed in the study is the influence of correcting for spherical spreading and Doppler amplitude on the spectral shape and overall sound pressure levels of the source. Results from this investigation confirm that the dominant noise source in high-speed jets is due to turbulent mixing.

Kelly, Jeffrey J.↗

NASA NTRS1993

Nonlinear response of graphite-epoxy wide columns subject to eccentric load

It is shown that including the effects of bend-twist coupling and material nonlinearity on the large displacement flexural response of graphite-epoxy wide columns is necessary to adequately model their response. Results from static tests on 0(30)T and (30/0/-30 sub 5)s laminated specimens under eccentric axial compression are compared to a nonlinear analysis. The analysis is based on a Kantrovich expansion of the displacements in the width coordinate and a finite element representation in the axial coordinate. An incremental, updated Lagrangian formulation and element corotational coordinates are employed. Nonlinear elastic material behavior was measured in a separate set of material characterization tests, and these data are used to compute tangent stillnesses in the updated configuration.

Griffin, O. H., Jr.↗

NASA NTRS1993

Applying and validating the RANS-3D flow-solver for evaluating a subsonic serpentine diffuser geometry

Subsonic inlet ducts for advanced, high-performance aircraft are evolving towards complex three-dimensional shapes for reasons of overall integration and weight. These factors lead to diffuser geometries that may sacrifice inlet performance, unless careful attention to design details and boundary layer management techniques are employed. The ability of viscous computational fluid dynamic (CFD) analysis of such geometries to aid the aircraft configurator in this complex design problem is herein examined. The RANS-3D Reynolds-Averaged Navier-Stokes solver is applied to model the complex flowfield occurring in a representative diffuser geometry and the solutions are compared to experimental results from a static test of the inlet duct. The computational results are shown to compare very favorably with experimental results over a range of mass flow rates, including those involving large amounts of separation in the diffuser. In addition, a novel grid topology is presented, and two turbulence models are evaluated in this study as part of the RANS-3D code.

Fletcher, Michael J.↗

NASA NTRS1957

Material compatibility with gaseous fluorine

Static tests on the compatibility of fluorine with non-metals at atmospheric temperature eliminated many materials from further consideration for use in fluorine systems. Several materials were found compatible at atmospheric pressures. Only Teflon and ruby (aluminum oxide) were compatible at 1500 pounds per square inch gage.

Price, Harold G , Jr↗

NASA NTRS1928

Choice of profile for the wings of an airplane. Part I

The choice of the profile for the wings of an airplane is a problem which should be solved by a scientific method based on data obtained by systematic experimentation. The problem, in its present form, may be stated as follows: "To find a profile which has certain required aerodynamic characteristics and which encloses the spars, whose number, dimensions and separating distance are likewise determined by structural considerations." At present, the static test, corresponding to the case of accelerated flight at limited speed, requires the knowledge of the moment of the aerodynamic resultant at the angle of zero lift, and the possibility of controlling the magnitude of the corresponding absolute coefficient within more or less extensive limits.

WINGS - DESIGN & THEORY↗

NASA NTRS1993

Static internal performance of a single expansion ramp nozzle with multiaxis thrust vectoring capability

An investigation was conducted at static conditions in order to determine the internal performance characteristics of a multiaxis thrust vectoring single expansion ramp nozzle. Yaw vectoring was achieved by deflecting yaw flaps in the nozzle sidewall into the nozzle exhaust flow. In order to eliminate any physical interference between the variable angle yaw flap deflected into the exhaust flow and the nozzle upper ramp and lower flap which were deflected for pitch vectoring, the downstream corners of both the nozzle ramp and lower flap were cut off to allow for up to 30 deg of yaw vectoring. The effects of nozzle upper ramp and lower flap cutout, yaw flap hinge line location and hinge inclination angle, sidewall containment, geometric pitch vector angle, and geometric yaw vector angle were studied. This investigation was conducted in the static-test facility of the Langley 16-Foot Transonic Tunnel at nozzle pressure ratios up to 8.0.

Capone, Francis J.↗

NASA NTRS1993

Effects of internal yaw-vectoring devices on the static performance of a pitch-vectoring nonaxisymmetric convergent-divergent nozzle

An investigation was conducted in the static test facility of the Langley 16-Foot Transonic Tunnel to evaluate the internal performance of a nonaxisymmetric convergent divergent nozzle designed to have simultaneous pitch and yaw thrust vectoring capability. This concept utilized divergent flap deflection for thrust vectoring in the pitch plane and flow-turning deflectors installed within the divergent flaps for yaw thrust vectoring. Modifications consisting of reducing the sidewall length and deflecting the sidewall outboard were investigated as means to increase yaw-vectoring performance. This investigation studied the effects of multiaxis (pitch and yaw) thrust vectoring on nozzle internal performance characteristics. All tests were conducted with no external flow, and nozzle pressure ratio was varied from 2.0 to approximately 13.0. The results indicate that this nozzle concept can successfully generate multiaxis thrust vectoring. Deflection of the divergent flaps produced resultant pitch vector angles that, although dependent on nozzle pressure ratio, were nearly equal to the geometric pitch vector angle. Losses in resultant thrust due to pitch vectoring were small or negligible. The yaw deflectors produced resultant yaw vector angles up to 21 degrees that were controllable by varying yaw deflector rotation. However, yaw deflector rotation resulted in significant losses in thrust ratios and, in some cases, nozzle discharge coefficient. Either of the sidewall modifications generally reduced these losses and increased maximum resultant yaw vector angle. During multiaxis (simultaneous pitch and yaw) thrust vectoring, little or no cross coupling between the thrust vectoring processes was observed.

Asbury, Scott C.↗

NASA NTRS1993

Summary of Lift and Lift/Cruise Fan Powered Lift Concept Technology

A summary is presented of some of the lift and lift/cruise fan technology including fan performance, fan stall, ground effects, ingestion and thrust loss, design tradeoffs and integration, control effectiveness and several other areas related to vertical short takeoff and landing (V/STOL) aircraft conceptual design. The various subjects addressed, while not necessarily pertinent to specific short takeoff/vertical landing (STOVL) supersonic designs being considered, are of interest to the general field of lift and lift/cruise fan aircraft designs and may be of importance in the future. The various wind tunnel and static tests reviewed are: (1) the Doak VZ-4 ducted fan, (2) the 0.57 scale model of the Bell X-22 ducted fan aircraft, (3) the Avrocar, (4) the General Electric lift/cruise fan, (5) the vertical short takeoff and landing (V/STOL) lift engine configurations related to ingestion and consequent thrust loss, (6) the XV-5 and other fan-in-wing stall consideration, (7) hybrid configurations such as lift fan and lift/cruise fan or engines, and (8) the various conceptual design studies by air-frame contractors. Other design integration problems related to small and large V/STOL transport aircraft are summarized including lessons learned during more recent conceptual design studies related to a small executive V/STOL transport aircraft.

Cook, Woodrow L.↗

NASA NTRS1993

Numerical and experimental investigation of the bending response of thin-walled composite cylinders

A numerical and experimental investigation of the bending behavior of six eight-ply graphite-epoxy circular cylinders is presented. Bending is induced by applying a known end-rotation to each end of the cylinders, analogous to a beam in bending. The cylinders have a nominal radius of 6 inches, a length-to-radius ratio of 2 and 5, and a radius-to-thickness ratio of approximately 160. A (+/- 45/0/90)S quasi-isotropic layup and two orthotropic layups, (+/- 45/0 sub 2)S and (+/- 45/90 sub 2)S, are studied. A geometrically nonlinear special-purpose analysis, based on Donnell's nonlinear shell equations, is developed to study the prebuckling responses and gain insight into the effects of non-ideal boundary conditions and initial geometric imperfections. A geometrically nonlinear finite element analysis is utilized to compare with the prebuckling solutions of the special-purpose analysis and to study the buckling and post buckling responses of both geometrically perfect and imperfect cylinders. The imperfect cylinder geometries are represented by an analytical approximation of the measured shape imperfections. Extensive experimental data are obtained from quasi-static tests of the cylinders using a test fixture specifically designed for the present investigation. A description of the test fixture is included. The experimental data are compared to predictions for both perfect and imperfect cylinder geometries. Prebuckling results are presented in the form of displacement and strain profiles. Buckling end-rotations, moments, and strains are reported, and predicted mode shapes are presented. Observed and predicted moment vs. end-rotation relations, deflection patterns, and strain profiles are illustrated for the post buckling responses. It is found that a geometrically nonlinear boundary layer behavior characterizes the prebuckling responses. The boundary layer behavior is sensitive to laminate orthotropy, cylinder geometry, initial geometric imperfections, applied end-rotation, and non-ideal boundary conditions. Buckling end-rotations, strains, and moments are influenced by laminate orthotropy and initial geometric imperfections. Measured buckling results correlate well with predictions for the geometrically imperfect specimens. The postbuckling analyses predict equilibrium paths with a number of scallop-shaped branches that correspond to unique deflection patterns. The observed postbuckling deflection patterns and measured strain profiles show striking similarities to the predictions in some cases. Ultimate failure of the cylinders is attributed to an interlaminar shear failure mode along the nodal lines of the postbuckling deflection patterns.

Fuchs, J. P.↗

NASA NTRS1994

Static performance investigation of a skewed-throat multiaxis thrust-vectoring nozzle concept

The static performance of a jet exhaust nozzle which achieves multiaxis thrust vectoring by physically skewing the geometric throat has been characterized in the static test facility of the 16-Foot Transonic Tunnel at NASA Langley Research Center. The nozzle has an asymmetric internal geometry defined by four surfaces: a convergent-divergent upper surface with its ridge perpendicular to the nozzle centerline, a convergent-divergent lower surface with its ridge skewed relative to the nozzle centerline, an outwardly deflected sidewall, and a straight sidewall. The primary goal of the concept is to provide efficient yaw thrust vectoring by forcing the sonic plane (nozzle throat) to form at a yaw angle defined by the skewed ridge of the lower surface contour. A secondary goal is to provide multiaxis thrust vectoring by combining the skewed-throat yaw-vectoring concept with upper and lower pitch flap deflections. The geometric parameters varied in this investigation included lower surface ridge skew angle, nozzle expansion ratio (divergence angle), aspect ratio, pitch flap deflection angle, and sidewall deflection angle. Nozzle pressure ratio was varied from 2 to a high of 11.5 for some configurations. The results of the investigation indicate that efficient, substantial multiaxis thrust vectoring was achieved by the skewed-throat nozzle concept. However, certain control surface deflections destabilized the internal flow field, which resulted in substantial shifts in the position and orientation of the sonic plane and had an adverse effect on thrust-vectoring and weight flow characteristics. By increasing the expansion ratio, the location of the sonic plane was stabilized. The asymmetric design resulted in interdependent pitch and yaw thrust vectoring as well as nonzero thrust-vector angles with undeflected control surfaces. By skewing the ridges of both the upper and lower surface contours, the interdependency between pitch and yaw thrust vectoring may be eliminated and the location of the sonic plane may be further stabilized.

Wing, David J.↗

NASA NTRS1992

Transonic propulsion aerodynamics research at NASA Langley Research Center

The Propulsion Aerodynamics Branch (and its predecessors) at the NASA Langley Research Center has been conducting propulsion aerodynamics research since 1941. During that time, branch research has had an impact on almost every aircraft flown. Before 1982, the primary contribution was in the form of experimental data obtained in the 16-Foot Transonic Tunnel and an associated static test facility. During the last decade, computational fluid dynamics research has played an increasing role in branch contributions. This paper provides an overview of the propulsion/airframe integration activities conducted in the branch during the last several years and some indication of the direction of future research.

Leavitt, Laurence D.↗

NASA NTRS1994

Static investigation of two fluidic thrust-vectoring concepts on a two-dimensional convergent-divergent nozzle

A static investigation was conducted in the static test facility of the Langley 16-Foot Transonic Tunnel of two thrust-vectoring concepts which utilize fluidic mechanisms for deflecting the jet of a two-dimensional convergent-divergent nozzle. One concept involved using the Coanda effect to turn a sheet of injected secondary air along a curved sidewall flap and, through entrainment, draw the primary jet in the same direction to produce yaw thrust vectoring. The other concept involved deflecting the primary jet to produce pitch thrust vectoring by injecting secondary air through a transverse slot in the divergent flap, creating an oblique shock in the divergent channel. Utilizing the Coanda effect to produce yaw thrust vectoring was largely unsuccessful. Small vector angles were produced at low primary nozzle pressure ratios, probably because the momentum of the primary jet was low. Significant pitch thrust vector angles were produced by injecting secondary flow through a slot in the divergent flap. Thrust vector angle decreased with increasing nozzle pressure ratio but moderate levels were maintained at the highest nozzle pressure ratio tested. Thrust performance generally increased at low nozzle pressure ratios and decreased near the design pressure ratio with the addition of secondary flow.

Wing, David J.↗

NASA NTRS1993

Time-Accurate Unsteady Flow Simulations Supporting the SRM T+68-Second Pressure Spike Anomaly Investigation (STS-54B)

Time-accurate unsteady flow simulations are being performed supporting the SRM T+68sec pressure 'spike' anomaly investigation. The anomaly occurred in the RH SRM during the STS-54 flight (STS-54B) but not in the LH SRM (STS-54A) causing a momentary thrust mismatch approaching the allowable limit at that time into the flight. Full-motor internal flow simulations using the USA-2D axisymmetric code are in progress for the nominal propellant burn-back geometry and flow conditions at T+68-sec--Pc = 630 psi, gamma = 1.1381, T(sub c) = 6200 R, perfect gas without aluminum particulate. In a cooperative effort with other investigation team members, CFD-derived pressure loading on the NBR and castable inhibitors was used iteratively to obtain nominal deformed geometry of each inhibitor, and the deformed (bent back) inhibitor geometry was entered into this model. Deformed geometry was computed using structural finite-element models. A solution for the unsteady flow has been obtained for the nominal flow conditions (existing prior to the occurrence of the anomaly) showing sustained standing pressure oscillations at nominally 14.5 Hz in the motor IL acoustic mode that flight and static test data confirm to be normally present at this time. Average mass flow discharged from the nozzle was confirmed to be the nominal expected (9550 lbm/sec). The local inlet boundary condition is being perturbed at the location of the presumed reconstructed anomaly as identified by interior ballistics performance specialist team members. A time variation in local mass flow is used to simulate sudden increase in burning area due to localized propellant grain cracks. The solution will proceed to develop a pressure rise (proportional to total mass flow rate change squared). The volume-filling time constant (equivalent to 0.5 Hz) comes into play in shaping the rise rate of the developing pressure 'spike' as it propagates at the speed of sound in both directions to the motor head end and nozzle. The objectives of the present analysis are to: (1) capture the dynamic responses of the motor combustion gas flow to correlate with available low-frequency (less than 12.5 sample/sec) data and (2) observe the high-frequency (up to 50 Hz) characteristics of the response to determine any potentials for dynamic coupling.

Dougherty, N. S.↗

NASA NTRS1995

AP reclamation and reuse in RSRM propellant

A solid propellant ingredient reclamation pilot plant has been evaluated at the Strategic Operations of Thiokol Corporation, located in Brigham City, Utah. The plant produces AP wet cake (95 percent AP, 5 percent water) for recycling at AP vendors. AP has been obtained from two standard propellant binder systems (PBAN and HTPB). Analytical work conducted at Thiokol indicates that the vendor-recrystallized AP meets Space Shuttle propellant specification requirements. Thiokol has processed 1-, 5-, and 600-gallon propellant mixes with the recrystallized AP. Processing, cast, cure, ballistic, mechanical, and safety properties have been evaluated. Phillips Laboratory static-test-fired 70-pound and 800-pound BATES motors. The data indicate that propellant processed with reclaimed AP has nominal properties.

Miks, Kathryn F.↗

NASA NTRS1995

Plume diagnostics of SRM static firings for pressure perturbation studies

During the shuttle launches, the solid rocket motors (SRM) occasionally experience pressure perturbations (8-13 psi) between 65 and 75 seconds into the motor burn time. The magnitudes of these perturbations are very small in comparison with the operating motor chamber pressure, which is over 600 psi during this time frame. These SRM pressure perturbations are believed to be caused primarily by the expulsion of slag (aluminum oxide). Two SRM static tests, TEM-11 and FSM-4, were instrumented extensive]y for the study of the phenomenon associated with pressure perturbations. The test instrumentation used included nonintrusive optical and infrared diagnostics of the plume, such as high-speed photography, radiometers, and thermal image cameras. Results from all these nonintrusive observations strongly support the scenario that the pressure perturbation event in the shuttle SRM is caused primarily by the expulsion of molten slag. The slag was also expelled preferentially near the bottom of the nozzle due to slag accumulation at the bottom of the aft end of the horizontally oriented motor.

Sambamurthi, J. K.↗

NASA NTRS1996

Static Internal Performance of a Two-Dimensional Convergent-Divergent Nozzle with External Shelf

An investigation was conducted in the static test facility of the Langley 16-Foot Transonic Tunnel to determine the internal performance of a two-dimensional convergent-divergent nozzle. The nozzle design was tested with dry and afterburning throat areas, which represent different power settings and three expansion ratios. For each of these configurations, three trailing-edge geometries were tested. The baseline geometry had a straight trailing edge. Two different shaping techniques were applied to the baseline nozzle design to reduce radar observables: the scarfed design and the sawtooth design. A flat plate extended downstream of the lower divergent flap trailing edge parallel to the model centerline to form a shelf-like expansion surface. This shelf was designed to shield the plume from ground observation (infrared radiation (IR) signature suppression). The shelf represents the part of the aircraft structure that might be present in an installed configuration. These configurations were tested at nozzle pressure ratios from 2.0 to 12.0.

Lamb, Milton↗

NASA NTRS1995

Effects of Slag Ejection on Solid Rocket Motor Performance

In past firings of the Reusable Solid Rocket Motor (RSRM) both static test and flight motors have shown small pressure perturbations occurring primarily between 65 and 80 seconds. A joint NASA/Thiokol team investigation concluded that the cause of the pressure perturbations was the periodic ingestion and ejection of molten aluminum oxide slag from the cavity around the submerged nozzle nose which tends to trap and collect individual aluminum oxide droplets from the approach flow. The conclusions of the team were supported by numerous data and observations from special tests including high speed photographic films, real time radiography, plume calorimeters, accelerometers, strain gauges, nozzle TVC system force gauges, and motor pressure and thrust data. A simplistic slag ballistics model was formulated to relate a given pressure perturbation to a required slag quantity. Also, a cold flow model using air and water was developed to provide data on the relationship between the slag flow rate and the chamber pressure increase. Both the motor and the cold flow model exhibited low frequency oscillations in conjunction with periods of slag ejection. Motor and model frequencies were related to scaling parameters. The data indicate that there is a periodicity to the slag entrainment and ejection phenomena which is possibly related to organized oscillations from instabilities in the dividing streamline shear layer which impinges on the underneath surface of the nozzle.

Whitesides, R. Harold↗