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NASA NTRS2010

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Formed Domes

Simulated service testing (SST) development was required to help qualify a new 2195 aluminum lithium (Al-Li) alloy spin forming dome fabrication process for the National Aeronautics and Space Administration (NASA) Exploration Development Technology Program. The application for the technology is to produce high strength low weight tank components for NASA s next generation launch vehicles. Since plate material is not currently manufactured large enough to fabricate these domes, two plates are joined by means of friction stir welding. The plates are then pre-contour machined to near final thicknesses allowing for a thicker weld land and anticipating the level of stretch induced by the spin forming process. The welded plates are then placed in a spin forming tool and hot stretched using a trace method producing incremental contours. Finally the dome receives a room temperature contour stretch to final dimensions, heat treatment, quenching, and artificial aging to emulate a T-8 condition of temper. Stress corrosion cracking (SCC) tests were also performed by alternate immersion in a sodium chloride (NaCl) solution using the typical double beam assembly and with 4-point loaded specimens and use of bent-beam stress-corrosion test specimens under alternate immersion conditions. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K(sub ISCC)) which to our knowledge has not been determined previously for Al-Li 2195 alloy. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication

Stewart, Thomas J.↗

NASA NTRS2009

Damage Tolerance Testing of a NASA TransHab Derivative Woven Inflatable Module

Current options for Lunar habitat architecture include inflatable habitats and airlocks. Inflatable structures can have mass and volume advantages over conventional structures. However, inflatable structures carry different inherent risks and are at a lower Technical Readiness Level (TRL) than more conventional metallic structures. One of the risks associated with inflatable structures is in understanding the tolerance to induced damage. The Damage Tolerance Test (DTT) is designed to study the structural integrity of an expandable structure. TransHab (Figure 1) was an experimental inflatable module developed at the NASA/Johnson Space Center in the 1990 s. The TransHab design was originally envisioned for use in Mars Transits but was also studied as a potential habitat for the International Space Station (ISS). The design of the TransHab module was based on a woven design using an Aramid fabric. Testing of this design demonstrated a high level of predictability and repeatability with analytical predictions of stresses and deflections. Based on JSC s experience with the design and analysis of woven inflatable structures, the Damage Tolerance Test article was designed and fabricated using a woven design. The DTT article was inflated to 45 psig, representing 25% of the ultimate burst pressure, and one of the one-inch wide longitudinal structural members was severed by initiating a Linear Shaped Charge (LSC). Strain gage measurements, at the interface between the expandable elements (straps) and the nonexpandable metallic elements for pre-selected longitudinal straps, were taken throughout pressurization of the module and strap separation. Strain gage measurements show no change in longitudinal strap loading at the bulkhead interface after strap separation indicating loads in the restraint layer were re-distributed local to the damaged area due to the effects of friction under high internal pressure loading. The test completed all primary objectives with better than expected results. This paper will discuss space inflatable structures, damage tolerance analysis, test results, and applicability to the Lunar architecture.

Edgecombe, John↗

NASA NTRS1982

A study of the vent pipe for the gravity probe-B

The Gravity Probe B experiment to test Einstein's relativity theory is a possible Space Shuttle project. Cooling of the gyroscopes and thrusting of the Probe into a zero-drag environment is accomplished by vaporizing liquid helium and venting the gas from the Probe through a nozzle system. In order to avoid malfunctioning of this cooling-thruster system, the pressure difference across the vent pipe-thruster system must be maintained to be less than the vapor pressure of liquid helium at the given temperature. This study investigated helium gas flow through the vent pipe for various configurations, mass flow rates, and pipe diameters. In addition, pertinent properties of both liquid and gaseous helium were investigated. It was observed that helical coiling of the pipe about the Dewar caused less frictional drag and less pressure change than did sharp pipe bending. Also, for various flow rates and nozzle throat area sizes, the system would malfunction for a given bath temperature.

Knoshaug, R. N.↗

NASA NTRS1995

Solid film lubricants and thermal control coatings flown aboard the EOIM-3 MDA sub-experiment

Additional experimental data were desired to support the selection of candidate thermal control coatings and solid film lubricants for the McDonnell Douglas Aerospace (MDA) Space Station hardware. The third Evaluation of Oxygen Interactions With Materials Mission (EOIM-3) flight experiment presented an opportunity to study the effects of the low Earth orbit environment on thermal control coatings and solid film lubricants. MDA provided five solid film lubricants and two anodic thermal control coatings for EOIM-3. The lubricant sample set consisted of three solid film lubricants with organic binders one solid film lubricant with an inorganic binder, and one solid film lubricant with no binder. The anodize coating sample set consisted of undyed sulfuric acid anodize and cobalt sulfide dyed sulfuric acid anodize, each on two different substrate aluminum alloys. The organic and inorganic binders in the solid film lubricants experienced erosion, and the lubricating pigments experienced oxidation. MDA is continuing to assess the effect of exposure to the low Earth orbit environment on the life and friction properties of the lubricants. Results to date support the design practice of shielding solid film lubricants from the low Earth orbit environment. Post-flight optical property analysis of the anodized specimens indicated that there were limited contamination effects and some atomic oxygen and ultraviolet radiation effects. These effects appeared to be within the values predicted by simulated ground testing and analysis of these materials, and they were different for each coating and substrate.

Murphy, Taylor J.↗

NASA NTRS1994

Investigation of a Laminar Flow Leading Edge

The recent resurgence of interest in utilizing laminar flow on aircraft surfaces for reduction in skin friction drag has generated a considerable amount of research in natural laminar flow (NLF) and hybrid laminar flow control (HLFC) on transonic aircraft wings. This research has focused primarily on airfoil design and understanding transition behavior with little concern for the surface imperfections and manufacturing variations inherent to most production aircraft. In order for laminar flow to find wide-spread use on production aircraft, techniques for constructing the wings must be found such that the large surface imperfections present in the leading edge region of current aircraft do not occur. Toward this end, a modification to existing leading edge construction techniques was devised such that the resulting surface did not contain large gaps and steps as are common on current production aircraft of this class. A lowspeed experiment was first conducted on a simulation of the surface that would result from this construction technique. Preston tube measurements of the boundary layer downstream of the simulated joint and flow visualization using sublimation chemicals validated the literature on the effects of steps on a laminar boundary layer. These results also indicated that the construction technique was indeed compatible with laminar flow. In order to fully validate the compatibility of this construction technique with laminar flow, thus proving that it is possible to build wings that are smooth enough to be used on business jets and light transports in a manner compatible with laminar flow, a flight experiment is being conducted. In this experiment Mach number and Reynolds number will be matched in a real flight environment. The experiment is being conducted using the NASA Dryden F-104 Flight Test Fixture (FTF). The FTF is a low aspect ratio ventral fin mounted beneath an F-104G research aircraft. A new nose shape was designed and constructed for this experiment. This nose shape provides an accelerating pressure gradient in the leading edge region. By flying the aircraft at appropriate Mach numbers and altitudes, this nose shape simulates the leading edge region of a laminar flow wing for a business jet or light transport. Manufactured into the nose shape is a spanwise slot located approximately four inches downstream of the leading edge. The slot, which is an inch wide and one-eighth of an inch deep allows the simulation of surface imperfections, such as gaps and steps at skin joints, which will occur on aircraft using this new construction technique. By placing strips of aluminum of various sizes and shapes in the slot, the effect on the boundary layer of different sizes and shapes of steps and gaps will be examined. It is planned to use five different configurations, differing primarily in the size and number of gaps. Downstream of the slot, the state of the boundary layer is determined using hot film gages and Stanton gages. Agreement between these two very different techniques of measuring boundary layer properties is considered important to being able to state with confidence the effects on the boundary layer of the simulated manufacturing imperfections. To date, the aircraft has not flown. First flights of the aircraft are on schedule to begin October 4, 1993. Low-speed, preliminary experiments at matching Reynolds numbers have been completed.

Drake, Aaron↗

NASA NTRS1994

Backward-facing step measurements at low Reynolds number, Re(sub h)=5000

An experimental study of the flow over a backward-facing step at low Reynolds number was performed for the purpose of validating a direct numerical simulation (DNS) which was performed by the Stanford/NASA Center for Turbulence Research. Previous experimental data on back step flows were conducted at Reynolds numbers and/or expansion ratios which were significantly different from that of the DNS. The geometry of the experiment and the simulation were duplicated precisely, in an effort to perform a rigorous validation of the DNS. The Reynolds number used in the DNS was Re(sub h)=5100 based on step height, h. This was the maximum possible Reynolds number that could be economically simulated. The boundary layer thickness, d, was approximately 1.0 h in the simulation and the expansion ratio was 1.2. The Reynolds number based on the momentum thickness, Re(sub theta), upstream of the step was 610. All of these parameters were matched experimentally. Experimental results are presented in the form of tables, graphs and a floppy disk (for easy access to the data). An LDV instrument was used to measure mean velocity components and three Reynolds stresses components. In addition, surface pressure and skin friction coefficients were measured. LDV measurements were acquired in a measuring domain which included the recirculating flow region.

Jovic, Srba↗

NASA NTRS1988

Automated seed manipulation and planting

Activities for the Fall Semester, 1987 focused on investigating the mechanical/electrical properties of wheat seeds and forming various Seed Planting System (SPS) concepts based on those properties. The Electrical Division of the design group was formed to devise an SPS using electrostatic charge fields for seeding operations. Experiments concerning seed separation using electrical induction (rearranging of the charges within the seed) were conducted with promising results. The seeds, when exposed to the high voltage and low current field produced by a Van de Graff generator, were observed to move back and forth between two electrodes. An SPS concept has been developed based on this phenomena, and will be developed throughout the Spring Semester, 1988. The Mechanical Division centered on SPS concepts involving valves, pumps, and fluids to separate and deliver seeds. An SPS idea utilizing the pressure difference caused by air as it rushes out of holes drilled in the wall of a closed container has been formulated and will be considered for future development. Also, a system of seed separation and delivery employing a combination of centrifugal force, friction, and air flow was considered.

Garcia, Ray↗

NASA NTRS1983

Dynamic crystallization experiments as constraints on chondrule genesis

The effectiveness of dynamic recrystallization experiments to reconstruct chondrule textures is evaluated. Consideration is given to the results of several experimental simulations of the silicate spheres of pyroxene-olivine chondrules, Si-rich chondrules, chondrites, droplet chondrules, and microporphyritic chondrules. It is shown that many chondrules have textures consistent with heating to 1400-1600 C, and cooling rates from a few degrees to several thousands of degrees per hour. It is shown that this physical constraint effectively rules out mechanisms for chondrule genesis which do not require instantaneous or very slow cooling. Analysis of the available textural, chemical, and isotopic data suggest that chondrules were generated from primordial particles, and several mechanisms might have assisted in chondrule heating as they settled down toward the median plane of the nebula. The most important of these mechanisms appear to be friction with the nebular gas and heating by flares.

Hewins, R. H.↗

NASA NTRS1984

Synoptic scale wind field properties from the SEASAT SASS

Dealiased SEASAT SEASAT A Scatterometer System SASS vector winds obtained during the Gulf Of Alaska SEASAT Experiment GOASEX program are processed to obtain superobservations centered on a one degree by one degree grid. The grid. The results provide values for the combined effects of mesoscale variability and communication noise on the individual SASS winds. These superobservations winds are then processed further to obtain estimates of synoptic scale vector winds stress fields, the horizontal divergence of the wind, the curl of the wind stress and the vertical velocity at 200 m above the sea surface, each with appropriate standard deviations of the estimates for each grid point value. They also explain the concentration of water vapor, liquid water and precipitation found by means of the SMMR Scanning Multichannel Microwave Radiometer at fronts and occlusions in terms of strong warm, moist air advection in the warm air sector accompanied by convergence in the friction layer. Their quality is far superior to that of analyses based on conventional data, which are shown to yield many inconsistencies.

Pierson, W. J., Jr.↗

NASA NTRS1999

Combination Space Station Handrail Clamp and Pointing Device

A device for attaching an experiment carrier to a space station handrail is provided. The device has two major components, a clamping mechanism for attachment to a space station handrail, and a pointing carrier on which an experiment package can be mounted and oriented. The handrail clamp uses an overcenter mechanism and the carrier mechanism uses an adjustable preload ball and socket for carrier positioning. The handrail clamp uses a stack of disk springs to provide a spring loaded button. This configuration provides consistent clamping force over a range of possible handrail thicknesses. Three load points are incorporated in the clamping mechanism thereby spreading the clamping load onto three separate points on the handrail. A four bar linkage is used to provide for a single actuation lever for all three load points. For additional safety, a secondary lock consisting of a capture plate and push lock keeps the clamp attached to the handrail in the event of main clamp failure. For the carrier positioning mechanism, a ball in a spring loaded socket uses friction to provide locking torque; however. the ball and socket are torque limited so that the ball ran slip under kick loads (125 pounds or greater). A lead screw attached to disk spring stacks is used to provide an adjustable spring force on the socket. A locking knob is attached to the lead screw to allow for hand manipulation of the lead screw.

Hughes, Stephen J.↗

NASA NTRSDate not supplied

Simulation and Modeling of Hypersonic Turbulent Boundary Layers Subject to Favorable Pressure Gradients due to Streamline Curvature

Direct numerical simulations (DNS) of favorable-pressure-gradient turbulent boundary layers are presented for a nominal freestream Mach number of 5, with the objective of assessing the limitations of the currently available Reynolds-averaged Navier-Stokes (RANS) models. The favorable pressure gradient is induced by the streamwise curvature of the two-dimensional, planar, convex measurement surface used during experiments at the Texas A&M University. The DNS data shows good comparison with the measured velocity profiles, strain rates, and some, but not all, of the Reynolds-stress components. The discrepancies between the predicted and the measured wall-normal as well as shear stress components are primarily attributed to the lower than actual values inferred from typical PIV measurements of turbulent boundary layers. The DNS data shows a zero or slightly negative Reynolds shear stress in the outer part of the boundary-layer, which is indicative of the decaying turbulent motion under a strong favorable pressure gradient. The DNS data is also compared with the results of RANS computations based on commonly used zero, one, and two equation eddy-viscosity models. The RANS models yield reasonable comparisons with the DNS-based skin friction under zero and weak pressure gradients, but significant discrepancies under a strong pressure gradient. The k-w SST model provided the best overall predictions of skin friction, except in the region where the flow transitions from a favorable to an adverse pressure gradient. While the RANS models examined herein also give good predictions of the Reynolds shear stress under a sufficiently weak pressure gradient, none of those models are able to appropriately capture the reduction in the Reynolds stresses when the flow was subjected to a strong pressure gradient. An a priori assessment of the turbulent heat-flux prediction based on the assumption of a constant turbulent Prandtl number with the DNS data shows that while the constant turbulent Prandtl number model is effective in predicting the wall-normal component of turbulent heat flux, it does not capture the turbulent heat transfer in the streamwise direction for all the pressure gradient cases. The failure of the constant turbulent Prandtl number model highlights a requirement for more advanced models of the turbulent heat flux.

turbulent boundary layers↗

NASA NTRS2014

Direct Numerical Simulations of High-Speed Turbulent Boundary Layers over Riblets

Direct numerical simulations (DNS) of spatially developing turbulent boundary layers over riblets with a broad range of riblet spacings are conducted to investigate the effects of riblets on skin friction at high speeds. Zero-pressure gradient boundary layers under two flow conditions (Mach 2:5 with T(sub w)/T(sub r) = 1 and Mach 7:2 with T(sub w)/T(sub r) = 0:5) are considered. The DNS results show that the drag-reduction curve (delta C(sub f)/C(sub f) vs l(sup +)(sub g )) at both supersonic speeds follows the trend of low-speed data and consists of a `viscous' regime for small riblet size, a `breakdown' regime with optimal drag reduction, and a `drag-increasing' regime for larger riblet sizes. At l l(sup +)(sub g) approx. 10 (corresponding to s+ approx 20 for the current triangular riblets), drag reduction of approximately 7% is achieved at both Mach numbers, and con rms the observations of the few existing experiments under supersonic conditions. The Mach- number dependence of the drag-reduction curve occurs for riblet sizes that are larger than the optimal size, with smaller slopes of (delta C(sub f)/C(sub f) for larger freestream Mach numbers. The Reynolds analogy holds with 2(C(sub h)=C(sub f) approximately equal to that of at plates for both drag-reducing and drag-increasing configurations.

Duan, Lian↗

NASA NTRS1977

Influence of transverse surface waves on turbulent boundary layers

Wavy wall experiments using solid waves and progressive waves have been reported. For this paper, the major effects of waviness of the wall on the flow are identified as due to oscillatory curvature (convex-concavity) and oscillatory acceleration/deceleration of the flow, which imposes a highly nonequilibrium influence upon the turbulence structure. The theoretical analysis in this presentation takes into account proper turbulence modeling (including the nonequilibrium effects) for the wavy wall problem. The analysis proceeds in three stages: (1) inviscid solution for induced pressure due to the physical wall, (2) solution of a turbulent boundary layer with pressure gradients and curvature effects in the modeling from which the profile correction is computed, and (3) induced pressure computations for the corrected profile. The phase shift of pressure perturbations with respect to the physical wall can be predicted, and pressure drag and skin friction drag can be estimated, with nonlinear viscous effects included. Comparison of the theoretical estimates with experimental data are also presented.

Balasubramanian, R.↗

NASA NTRS2003

Experiments on the Flow of a Thin Liquid Film Over a Horizontal Stationary and Rotating Disk Surface

Experiments on characterization of thin liquid films flowing over stationary and rotating disk surfaces are described. The thin liquid film was created by introducing deionized water from a flow collar at the center of an aluminum disk with a known initial film thickness and uniform radial velocity. Radial film thickness distribution was measured using a non-intrusive laser light interface reflection technique that enabled the measurement of the instantaneous film thickness over a finite segment of the disk. Experiments were performed for a range of flow rates between 3.01pm and 15.01pm, corresponding to Reynolds numbers based on the liquid inlet gap height and velocity between 238 and 1,188. The angular speed of the disk was varied from 0 rpm to 300 rpm. When the disk was stationary, a circular hydraulic jump was present in the liquid film. The liquid-film thickness in the subcritical region (down-stream of the hydraulic jump) was an order of magnitude greater than that in the supercritical region (upstream of the hydraulic jump) which was of the order of 0.3 mm. As the Reynolds number increased, the hydraulic jump migrated toward the edge of the disk. In the case of rotation, the liquid-film thickness exhibited a maximum on the disk surface. The liquid-film inertia and friction influenced the inner region where the film thickness progressively increased. The outer region where the film thickness decreased was primarily affected by the centrifugal forces. A flow visualization study of the thin film was also performed to determine the characteristics of the waves on the free surface. At high rotational speeds, spiral waves were observed on the liquid film. It was also determined that the angle of the waves which form on the liquid surface was a function of the ratio of local radial to tangential velocity.

Ozar, B.↗

NASA NTRS1978

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold-rolling material and Ti-6Al-4V and INCONEL 718 were selected as typical hot-rolling and cold-rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape-rolling process were developed. These models utilize the upper-bound and the slab methods of analysis, and are capable of predicting the lateral spread, roll-separating force, roll torque and local stresses, strains and strain rates. This computer-aided design (CAD) system is also capable of simulating the actual rolling process and thereby designing roll-pass schedule in rolling of an airfoil or similar shape. The predictions from the CAD system were verified with respect to cold rolling of mild steel plates. The system is being applied to cold and hot isothermal rolling of an airfoil shape, and will be verified with respect to laboratory experiments under controlled conditions.

Lahoti, G. D.↗

NASA NTRS1976

Tornadoes and other atmospheric vortices

The growth of random vortices in an atmosphere with buoyant instability and vertical wind shear is studied along with the velocities in a single gravity-driven vortex; a frictionless adiabatic model which is supported by laboratory experiments is first considered. The effects of axial drag, heat transfer, and precipitation-induced downdrafts are then calculated. Heat transfer and axial drag tend to have stabilizing effects; they reduce the downdrafts of updrafts due to buoyancy. It is found that downdrafts or tornadic magnitude might occur in negatively-buoyant columns. The radial-inflow velocity required to maintain a given maximum tangential velocity in a tornado is determined by using a turbulent vortex model. Conditions under which radial-inflow velocities become sufficiently large to produce tangential velocities of tornadic magnitude are determined. The radial velocities in the outer regions, as well as the tangential velocities in the inner regions may be large enough to cause damage. The surface boundary layer, which is a region where large radial inflows can occur, is studied, and the thickness of the radial-inflow friction layer is estimated. A tornado model which involves a rotating parent cloud, as well as buoyancy and precipitation effects, is discussed.

Deissler, R. G.↗

NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar M Rao↗

NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

Prabhakar Rao↗