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At least 631 records · Page 35

Initiation and Propagation of Skin/Stiffener Separation in Postbuckled Structures Subjected to Cyclic Loads

A methodology is proposed to evaluate experimentally and numerically the initiation and propagation of skin/stiffener separation in postbuckled panels subjected to cyclic loads. The response mechanisms that characterize skin/stiffener separation were investigated using a three point bend (3PB) test specimen, which is a simple specimen consisting of a laminate representing the skin and a doubler representing the stiffener flange. The 3PB tests were performed under quasi-static and cyclic loads. A fatigue cohesive model was used to analyze the initiation and propagation of skin/stiffener separation in the 3PB. The results indicate that the fatigue cohesive model with model parameters obtained from quasi-static fracture tests can provide accurate predictions of initiation from a pristine state, and the rate of fatigue crack propagation for a variety of mode mixities, load levels, and stress ratios.

Carlos G Davila↗

Initiation and Propagation of Skin/Stiffener Separation in Postbuckled Structures

A methodology is proposed to experimentally and numerically evaluate the initiation and propagation of skin/stiffener separation in postbuckled panels subjected to cyclic loads. The response mechanisms that characterize skin/stiffener separation were investigated using a three point bend (3PB) test specimen, which is a simple specimen consisting of a laminate representing the skin and a doubler representing the stiffener flange. The 3PB tests were performed under quasi-static and cyclic loads. A fatigue cohesive model was used to analyze the initiation and propagation of skin/stiffener separation in the 3PB specimen. The results indicate that the fatigue cohesive model with model parameters obtained from quasi-static fracture tests can provide accurate predictions of initiation from a pristine state, and the rate of fatigue crack propagation for a variety of mode mixities, load levels, and stress ratios.

Carlos G. Dávila↗

On the Representation of Through-The-Thickness Reinforcements in Finite Element Analysis of Stitched, Blade Stiffened Panels

Modern aircraft employ laminated composites for their tailorable in-plane properties, high specific strengths, and high specific stiffnesses. However, laminated composites exhibit relatively poor interlaminar properties without through-the-thickness reinforcements. Quantifying the necessary amount of through-the-thickness reinforcements is necessary to reduce cost and meet damage tolerance certification requirements. In this study, a discrete superposed cohesive element (DSCE) approach is applied to represent the mixed-mode delamination behavior of stitched stiffened panels subjected to seven-point bending. This approach is compared to a one-dimensional embedded spring element (ESE) method. The DSCE approach uses two superposed bilinear traction-separation laws to obtain a representative load-displacement response determined from interlaminar tensile and shear tests. Additionally, several stitch configurations (unstitched, stitched, and overstitched) are evaluated in terms of their load-displacement response and crack-arrestment capability. Results indicate that the DSCE and ESE approaches show good agreement with respect to the predicted load-displacement response, but the ESE method tends to overpredict the crack growth behavior by approximately 13%. Stitches were not observed to fail during skin-stringer separation. Using an overstitched laminate with stitches near the flange edge provides the greatest crack-arrestment capability. Furthermore, the skin retains 92% of its stiffness after skin-stringer separation occurs.

composites↗

On the Representation of Through-The-Thickness Reinforcements in Finite Element Analysis of Stitched, Blade Stiffened Panels

Modern aircraft employ laminated composites for their tailorable in-plane properties, high specific strengths, and high specific stiffnesses. However, laminated composites exhibit relatively poor interlaminar properties without through-the-thickness reinforcements. Quantifying the necessary amount of through-the-thickness reinforcements is necessary to reduce cost and meet damage tolerance certification requirements. In this study, a discrete superposed cohesive element (DSCE) approach is applied to represent the mixed-mode delamination behavior of stitched stiffened panels subjected to seven-point bending. This approach is compared to a one-dimensional embedded spring element (ESE) method. The DSCE approach uses two superposed bilinear traction-separation laws to obtain a representative load-displacement response determined from interlaminar tensile and shear tests. Additionally, several stitch configurations (unstitched, stitched, and overstitched) are evaluated in terms of their load-displacement response and crack-arrestment capability. Results indicate that the DSCE and ESE approaches show good agreement with respect to the predicted load-displacement response, but the ESE method tends to overpredict the crack growth behavior by approximately 13%. Stitches were not observed to fail during skin-stringer separation. Using an overstitched laminate with stitches near the flange edge provides the greatest crack-arrestment capability. Furthermore, the skin retains 92% of its stiffness after skin-stringer separation occurs.

composites↗

Simulating Ordinary Chondrite (Tamdakht) Ablation at the Hypersonic Materials Environmental Test System (HyMETS) Facility.

NASA’s Science Mission Directorate (SMD) created the Asteroid Threat Assessment Project (ATAP) to inform decision-makers of risks associated with Potentially Hazardous Objects (PHOs), which may pose an existential threat to human civilization. ATAP assesses risk, in part, by developing analytical physics-based damage models which draw upon data collected during material property characterization efforts, entry simulations, hazard simulations, and ground-based arc-jet testing. Therefore, a pathfinder test campaign was con-ducted at the Hypersonic Materials Environmental Test System (HyMETS) at the NASA Langley Re-search Center to investigate the ablation mechanisms of an ordinary chondrite (Tamdakht H5) and a terrestrial analog (basalt). The HyMETS facility is a 400 kW constricted arc heater used to screen material performance under simulated aerothermal conditions of hypersonic flow.1 Facility conditions were chosen to simulate Earth entry conditions be-tween the upper-mesosphere and the lower thermo-sphere. The ablation mechanisms of Tamdakht and bas-alt are illustrated with still images collected from high-speed video cameras (fig. 1, Tamdakht). Tamdakht produces a relatively stable melt flow, as evidenced by the perpetual growth of a flange at the sidewall and the exiguous detachment of molten material into the flow. Furthermore, an inspection of high-speed video and chemical analysis of the post-test melt layer suggests that the dominant mode of mass loss for Tamdakht, at these test conditions, is expressed through the vaporization of volatiles (e.g., iron, potassium, sodium, phosphorus, and sulfur). The vaporization rates of Tamdakht are greater than basalt under the most extreme test conditions, which leads to an enhanced blowing layer, in-creased thermal shielding, and reduced recession. The ablation mechanisms of basalt are markedly different from Tamdakht and are attributed to the presence of hydrated minerals dispersed at irregular intervals throughout the silicate matrix. Rapid de-composition of secondary minerals and the subsequent formation of water lead to the ejection of the subsurface and overlying melt layer. Furthermore, the presence of water is suspected of lowering the viscosity of the melt layer resulting in increased mass loss near the edge of the test article where drag forces overcome rheological properties (fig. 1, bas-alt). Finally, the results will be discussed in the broader context of meteorite-based material response model development and the potential impact on the Asteroid Threat Assessment Project (ATAP).

Brody K. Bessire↗

Flex-Capsules for the Roman Space Telescope High Gain Antenna Gimbal

The Cable Wrap mechanism has been traditionally used for feeding power and telemetry through each gimbal actuator exiting at the gimbal output flange. Such a mechanism had often utilized round wire bundles or a multitude of single insulated conductors woven together flatwise to handle the angular rotation. Though flexible printed circuit board (PCB) is not a new technology, it was decided to implement it for the Roman Space Telescope (RST) High Gain Antenna Gimbal in an effort to improve reliability with consistency of manufacture and to save mass and minimize required volume. This paper provides a description of what we term Flex-Capsule (a similar vendor flight development is termed Twist Capsule), discusses the reasoning behind choosing a new engineering development over maintaining heritage, and includes commentary pertaining to life cycle analysis, electrical performance, and flexible PCB lubrication. Lessons learned from the design, analysis, and test campaign are also included. The conclusion is that benefits of pursuing the Flex-Capsule over heritage Cable Wrap have been realized.

twist capsule↗

Flex-Capsule for the Roman Space Telescope High Gain Antenna Gimbal

The Cable Wrap mechanism has been traditionally used for feeding power and telemetry through each gimbal actuator exiting at the Gimbal output flange. Such a mechanism had often utilized round wire bundles, or a multitude of single insulated conductors woven together flatwise to handle the angular rotation. Though flexible printed circuit board (PCB) is not a new technology, it was decided to implement it for the Roman Space Telescope (RST) High Gain Antenna Gimbal in an effort to improve reliability with consistency of manufacture and to save mass and minimize required volume. This paper provides a description of what we term Flex-Capsule (a similar vendor flight development is termed Twist Capsule), discusses the reasoning behind choosing a new engineering development over maintaining heritage, and includes commentary pertaining to life cycle analysis, electrical performance, and flexible PCB lubrication. Lessons learned from the design, analysis, and test campaign are also included. The conclusion is that benefits of pursuing the Flex-Capsule over heritage Cable Wrap have been realized.

twist capsule↗

History of Structural Stitching Development for Aerospace Applications

Layered composite structures are a commonly used, lightweight option for aerospace vehicles today. However, these structures are prone to delamination between plies as well as separation between co-cured sections such as skins and flanges. In addition, delamination can easily be induced by impact damage from events such as tool drops and hailstones. Since such delaminations are often not visible from the external surface of the structure, additional material or fasteners must be included in the design to ensure the structure will maintain the required load-carrying ability through its lifetime. However, adding extra material increases weight and reduces structural efficiency and adding fasteners and their associated holes reduces manufacturing efficiency and adds the requirement to inspect the holes since they could become crack initiation points. Alternate means to reduce delaminations could be beneficial. An alternative to these options is to build the structure with through-thickness reinforcement, such as using stitching threads, to limit delamination, increase out-of-plane strength, and provide a method to join structural elements together without fasteners. The history of through-thickness stitching as it could be applied to aerospace vehicles is described in this paper.

carbon-epoxy↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

Welding of Crack Sensitive Aluminum Alloys for Liquid Rocket Propulsion Applications

In this welding test campaign, electron beam welding (EBW) and manual gas tungsten arc welding (GTAW) processes were utilized to join an additively manufactured aluminum alloy nozzle to a wrought aluminum flange. Both aluminum alloys were 6061, which in their conventional form are susceptible to solidification cracking issues. The AM nozzle utilized a novel high-performance modified version of 6061 which exhibits crack resistant properties during the AM process and during welding. When manually conducting GTAWs a filler wire with the same modified version of 6061 was utilized to weld different combinations of 6061 coupons (either modified or unmodified). Due to the grain refinement technology in the modified 6061, either as filler material or base material, there was complete elimination of weld solidification cracking. During EBW development a combination of wrought 6061 with a modified and additively manufactured 6061 was investigated. The EBWs developed exhibited no crack like defects. Each weld development program utilized non-destructive evaluation, metallography, and mechanical testing to determine the final weld acceptance. Mechanical testing involved hardness evaluation and tension testing on welded coupons. Both welding techniques were successfully developed and exhibited adequate properties for the final test articles and met all requirements of the development campaign. These welds were ultimately developed to be utilized on a set of all-aluminum liquid rocket nozzles to demonstrate additively manufactured aluminum alloys for propulsion applications. These aluminum nozzles were tested at NASA Marshall Space Flight Center’s hot fire test facility and subsequently underwent a test campaign involving a variety of chamber pressures and liquid propellant combinations. Following the hot fire test campaign each weldment was investigated for post operation performance and any defects that may have evolved during testing.

Welding↗

Analysis of Triangular Rollable and Collapsible Composite Booms Under the Effects of Gravity and Twist

Finite element analysis is used to investigate Triangular Rollable and Collapsible (TRAC) composite booms. The TRAC booms are subjected to a suite of loading conditions, including in-plane bending, out-of-plane bending, and axial compression. Simulations containing as-designed boom geometry are performed, as are simulations with geometric deviations associated with the as-built conditions of a sample TRAC boom. Namely, a cross-sectional twist along the length of the boom is incorporated into the analysis to study the effect of the twist on the deformation characteristics of the boom. Twisting in the sample boom was observed after short-term storage in a rolled configuration and may be attributed to differential creep deformation between the inner and outer flanges of the TRAC boom. Simulations are conducted with and without the effects of gravity to understand the significance of gravity on testing conditions. Booms of three lengths are evaluated: 3 meters, 7.5 meters and 30 meters. The mechanical responses of the TRAC booms are discussed with reference to the effects of gravity, boom length and cross-sectional twisting. Gravity is found to have a more significant effect on boom mechanical response as boom length is increased. Cross-sectional twisting is found to have a more significant effect on boom mechanical response in the shorter booms.

High-strain composites↗

Analysis of Triangular Rollable and Collapsible (TRAC) Composite Booms under the Effects of Gravity and Twist

Finite element analysis is used to investigate Triangular Rollable and Collapsible (TRAC) composite booms. The TRAC booms are subjected to a suite of loading conditions, including in-plane bending, out-of-plane bending, and axial compression. Simulations containing as-designed boom geometry are performed, as are simulations with geometric deviations associated with the as-built conditions of a sample TRAC boom. Namely, a cross-sectional twist along the length of the boom is incorporated into the analysis to study the effect of the twist on the deformation characteristics of the boom. Twisting in the sample boom was observed after short-term storage in a rolled configuration and may be attributed to differential creep deformation between the inner and outer flanges of the TRAC boom. Simulations are conducted with and without the effects of gravity to understand the significance of gravity on testing conditions. Booms of three lengths are evaluated: 3 meters, 7.5 meters and 30 meters. The mechanical responses of the TRAC booms are discussed with reference to the effects of gravity, boom length and cross-sectional twisting. Gravity is found to have a more significant effect on boom mechanical response as boom length is increased. Cross-sectional twisting is found to have a more significant effect on boom mechanical response in the shorter booms.

High-strain composites↗

Effect of Barely Visible Impact Damage on Thermoplastic Welded Structure

Spirit Aerosystems recently conducted screening tests on thermoplastic skin/stringer panels manufactured with Automated Fiber Placement (AFP) and stamp forming which were joined using Spirit’s Co-Fusion process. Skin and stringer gauge were both set to 0.168 cm. The resulting panel design is 48 cm tall, 49 cm wide, and has 3 stringers welded at a 21.5 cm pitch. Barely Visible Impact Damage (BVID) and Residual Compressive Strength were chosen to conduct a damage tolerance study. Zee stringers, made with IM8/PEKK-FC material, were Co-Fusion welded to a T1100/TC1225 skin. Out of these 5 panels, 1 was chosen to be a BVID survey panel, 1 for pristine compressive strength determination, and 3 to be impacted to create BVID followed by testing for residual compressive strength. On the survey panel, impacts ranged in energy from 40J – 65J and dent depth measurements were conducted at 24 hours, 48 hours, and two weeks after impacting. The residual compressive strength panel failed near the predicted load of 214 MPa. For the residual compressive strength panels, BVID was created at two different mid-bay locations: 1) striking the OML coincident with the stringer and 2) striking the skin IML 2.5 cm away from the stringer flange. Pulse Echo Ultrasonic Testing was used to inspect the panels before and after creating BVID.

HiCAM↗

Review of HAYNES® 282® alloy for supercritical CO2 structural applications

In this paper, HAYNES® 282® alloy (282® alloy) properties, microstructure, high temperature oxidation resistance, weldability, and American Society of Mechanical Engineers (ASME) code case highlights are reviewed. The long term performance of high temperature, high strength, creep resistant alloys is critical to the success of supercritical carbon dioxide equipment. Several modern power generation technologies require alloys that can operate continuously at or above 700oC. 282® alloy is a precipitation strengthened nickel based super alloy that meets these requirements. The results of 282® alloy research reviewed in this paper include longterm cyclic oxidation behavior in air and sCO2, independent research and validation of 100k hour creep life, and successful welding of the alloy in the age hardened condition. The latter is critical for joining of hardened components (flanges, piping, heat exchanger internal, etc.) and field repair. Several highlights from the code case for this ASMEapproved material are also presented.

Tossey, Brett↗

High Power Radiofrequency Operation of the Radiofrequency Quadrupoles in the Spallation Neutron Source

The Spallation Neutron Source (SNS) recently took delivery of a third Radiofrequency Quadrupole (RFQ03) that will ultimately be installed on the front-end (FE) of the SNS Linac. The first RFQ (RFQ01) operated in the SNS FE for more than a decade before being replaced with the second RFQ (RFQ02). RFQ01 was relocated to the Beam Test Facility (BTF) where it operated for five more years. The RFQ02 was initially installed in the BTF for high power testing and used with H- beam for BTF operation. It replaced RFQ01 in the SNS FE in 2017 and has been operating for beam production since then. There are some differences between the three RFQs. RFQ01 has a square cross-section with pi-mode stabilizing loops (PISLs) with the structure being fabricated using two layers of materials, GlidCop outside and OFHC inside. RFQ02 and RFQ03 has an octagonal cross-section with end-wall stabilizer rods and was fabricated using OFHC only. RFQ01 suffered some field flatness distortion incidents that resulted in degradation in beam transmission efficiency and required RF tuning. RFQ02 has performed well but had a melted RF seal in the high energy end wall, that was ultimately mitigated by a redesign of the end flange seals. The SNS decided to order RFQ03 that has a design that followed that of RFQ02 closely, but end-wall contacts were modified to prevent RF seal failure. This report presents the testing, installation, high power RF operation, and design improvements of the RFQ03.

Ren, Haitao↗

Internal combustion engine with dual-channel cylinder liner cooling

A cylinder liner is provided that includes a cylinder bore capable of housing a piston, a top end having an annular flange, a first cylindrical section, a second cylindrical section, and an annular ridge that separates the first cylindrical section and the second cylindrical section. When employed in an a liner bore of an engine bock, the cylinder liner provides for two channels that allow for coolant to be supplied to the cylinder liner.

Chen, Allen Yao↗

SULI Internship Deliverables (Flow Orifice Design: Measuring Degas Flow of Experiment Loops at the Advanced Test Reactor)

These deliverables present a design for a new orifice flow meter to be installed in three experiment loops at the Advanced Test Reactor. The current configuration of the experiment loop system has an orifice that is not properly sized to the low flow rates of the degas line of the pressurizer system, causing inaccurate flow measurements. Under consideration of flow conditions and system constraints, an iterative procedure was utilized to determine the optimal sizing for a new orifice. This orifice is designed to accurately and precisely measure the flow rate of the degas line, which will consequently improve control of the pressure and chemistry of the loop pressurizer system. The scope of this project includes recommendations for orifice sizing, material, flange type, face type, and installation location on the loop piping spools. The design is suitable for experiment loops 1D-N, 2B-SE, and 2D-SW and meets all necessary standards.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Initial PIP-II Beam Current Monitor Fault Case Analyses & Beam Position Monitor Linearity Studies in CST Studio Suite

The use of non-invasive sensors & systems to measure particle beam characteristics is a crucial part of modern accelerator control systems due to their ability to return real time beam data while minimizing negative effects on beam quality. To ensure that one can be reasonably confident these sensors will behave as desired upon be-ing implemented within the beamline, simulations pre-dicting the performance of these sensors under beamline conditions can be used as a valuable tool for checking sensor functionality without a physical test bench. This paper details the design, testing, and results of two sensor models developed using CST Studio Suite soft-ware designed to mimic two sensors to be implemented within the PIP-III beamline: an elliptical, large-aperture beam position monitor (BPM) for which vertical & hori-zontal position signal linearity was analyzed, and an AC current transformer (ACCT) beam current monitor (BCM) used to search for potential fault cases within the BCM and beam pipe flange gaps. Special focus is given to the discovery of linearity variations within the BPM and the use of frequency domain techniques in the BCM fault case analyses.

Rouzky, A. R.↗