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At least 649 records · Page 36

Some Remaining Challenges in Aerospace Structures

The science behind analyzing and building structures was laid out by legendary scientists such as Euler, Bernoulli, Gauss, Timoshenko and many others. The 20thcentury saw the birth of aviation and space travel, which required more advances in understanding structural behavior. The constraints on aerospace structures relative to weight, durability, performance, and damage tolerance are enormous and in many instances, in competition with each other. Performance requirements driven by other disciplines: aerodynamics, thermal behavior, pressure containment, extreme stability, are now the norm in high performance aerospace structures

Kenneth R Hamm↗

Aerodynamic Synthesis of a Centrifugal Impeller Using CFD and Measurements

The performance and flow structure in an unshrouded impeller of approximately 4:1 pressure ratio is synthesized on the basis of a detailed analysis of 3D viscous CFD results and aerodynamic measurements. A good data match was obtained between CFD and measurements using laser anemometry and pneumatic probes. This solidified the role of the CFD model as a reliable representation of the impeller internal flow structure and integrated performance. Results are presented showing the loss production and secondary flow structure in the impeller. The results indicate that while the overall impeller efficiency is high, the impeller shroud static pressure recovery potential is underdeveloped leading to a performance degradation in the downstream diffusing element. Thus, a case is made for a follow-on impeller parametric design study to improve the flow quality. A strategy for aerodynamic performance enhancement is outlined and an estimate of the gain in overall impeller efficiency that might be realized through improvements to the relative diffusion process is provided.

Larosiliere, L. M.↗

Engineering Overview of a Multidisciplinary HSCT Design Framework Using Medium-Fidelity Analysis Codes

An objective of the HPCC Program at NASA Langley has been to promote the use of advanced computing techniques to more rapidly solve the problem of multidisciplinary optimization of a supersonic transport configuration. As a result, a software system has been designed and is being implemented to integrate a set of existing discipline analysis codes, some of them CPU-intensive, into a distributed computational framework for the design of a High Speed Civil Transport (HSCT) configuration. The proposed paper will describe the engineering aspects of integrating these analysis codes and additional interface codes into an automated design system. The objective of the design problem is to optimize the aircraft weight for given mission conditions, range, and payload requirements, subject to aerodynamic, structural, and performance constraints. The design variables include both thicknesses of structural elements and geometric parameters that define the external aircraft shape. An optimization model has been adopted that uses the multidisciplinary analysis results and the derivatives of the solution with respect to the design variables to formulate a linearized model that provides input to the CONMIN optimization code, which outputs new values for the design variables. The analysis process begins by deriving the updated geometries and grids from the baseline geometries and grids using the new values for the design variables. This free-form deformation approach provides internal FEM (finite element method) grids that are consistent with aerodynamic surface grids. The next step involves using the derived FEM and section properties in a weights process to calculate detailed weights and the center of gravity location for specified flight conditions. The weights process computes the as-built weight, weight distribution, and weight sensitivities for given aircraft configurations at various mass cases. Currently, two mass cases are considered: cruise and gross take-off weight (GTOW). Weights information is obtained from correlations of data from three sources: 1) as-built initial structural and non-structural weights from an existing database, 2) theoretical FEM structural weights and sensitivities from Genesis, and 3) empirical as-built weight increments, non-structural weights, and weight sensitivities from FLOPS. For the aeroelastic analysis, a variable-fidelity aerodynamic analysis has been adopted. This approach uses infrequent CPU-intensive non-linear CFD to calculate a non-linear correction relative to a linear aero calculation for the same aerodynamic surface at an angle of attack that results in the same configuration lift. For efficiency, this nonlinear correction is applied after each subsequent linear aero solution during the iterations between the aerodynamic and structural analyses. Convergence is achieved when the vehicle shape being used for the aerodynamic calculations is consistent with the structural deformations caused by the aerodynamic loads. To make the structural analyses more efficient, a linearized structural deformation model has been adopted, in which a single stiffness matrix can be used to solve for the deformations under all the load conditions. Using the converged aerodynamic loads, a final set of structural analyses are performed to determine the stress distributions and the buckling conditions for constraint calculation. Performance constraints are obtained by running FLOPS using drag polars that are computed using results from non-linear corrections to the linear aero code plus several codes to provide drag increments due to skin friction, wave drag, and other miscellaneous drag contributions. The status of the integration effort will be presented in the proposed paper, and results will be provided that illustrate the degree of accuracy in the linearizations that have been employed.

Weston, R. P.↗

Performance Evaluation of Engineered Structured Sorbents for Atmosphere Revitalization Systems On Board Crewed Space Vehicles and Habitats

Engineered structured (ES) sorbents are being developed to meet the technical challenges of future crewed space exploration missions. ES sorbents offer the inherent performance and safety attributes of zeolite and other physical adsorbents but with greater structural integrity and process control to improve durability and efficiency over packed beds. ES sorbent techniques that are explored include thermally linked and pressure-swing adsorption beds for water-save dehumidification and sorbent-coated metal meshes for residual drying, trace contaminant control, and carbon dioxide control. Results from sub-scale performance evaluations of a thermally linked pressure-swing adsorbent bed and an integrated sub-scale ES sorbent system are discussed.

Howard, David F.↗

Hypervelocity Impact Performance of Open Cell Foam Core Sandwich Panel Structures

Open cell metallic foam core sandwich panel structures are of interest for application in spacecraft micrometeoroid and orbital debris shields due to their novel form and advantageous structural and thermal performance. Repeated shocking as a result of secondary impacts upon individual foam ligaments during the penetration process acts to raise the thermal state of impacting projectiles ; resulting in fragmentation, melting, and vaporization at lower velocities than with traditional shielding configurations (e.g. Whipple shield). In order to characterize the protective capability of these structures, an extensive experimental campaign was performed by the Johnson Space Center Hypervelocity Impact Technology Facility, the results of which are reported in this paper. Although not capable of competing against the protection levels achievable with leading heavy shields in use on modern high-risk vehicles (i.e. International Space Station modules), metallic foam core sandwich panels are shown to provide a substantial improvement over comparable structural panels and traditional low weight shielding alternatives such as honeycomb sandwich panels and metallic Whipple shields. A ballistic limit equation, generalized in terms of panel geometry, is derived and presented in a form suitable for application in risk assessment codes.

Ryan, S.↗

Harnessing the surface structure to enable high-performance cathode materials for lithium-ion batteries

The ever-increasing demand for high-performance batteries have been driving the fundamental understanding of the crystal/surface structural and electrochemical properties of intercalation cathode materials, among which the olivine-type, spinel and layered lithium transition metal oxide materials have received particular attention in the past decade due to their successful commercialization. While the most current studies focus on the macroscopic and bulk crystal structure of these materials, our previous work suggests that, as a confined region where charge transfer takes place, the interfacial structures of cathode materials largely dictate their electrochemical performances due to the structural symmetry breaking from 3D (bulk) to 2D (surface), which leads to reconstructions under the different chemical/electrochemical conditions. By summarizing works in this subject and offering our perspectives, this tutorial review will reveal for the first time the correlation between surface structure and interface reconstruction at atomic/molecular scales and their direct impact on corresponding electrochemical performances. More importantly, by extending the knowledge obtained from these three well-studied system, we believe that the same principles established could universally apply to other cathode materials that have been the frontiers of new battery chemistries.

25 ENERGY STORAGE↗

Probabilistic Multi-Hazard Performance Assessment of Concrete Structures in Nuclear Installations

Concrete structures in nuclear installations are subject to time-dependent degradation mechanisms that can deteriorate their physical and mechanical properties, potentially exacerbating the risk of structural failure under external forces such as a seismic event. Previous research has extensively investigated the seismic response of nuclear concrete structures and the associated risk, as well as their effect on structural components safety margins. However, substantial work is still necessary to incorporate concrete aging effects into such evaluations. In fact, most models in the literature assume pristine concrete conditions and do not account for the impact of aging on the structural components’ fragility curves. This work identifies relevant time-dependent degradation mechanisms and provides simplified models to predict the the evolution of key material properties based on data from the literature. Namely, this work focuses on the aging effects of corrosion, alkali–silica reaction (ASR), and irradiation on reinforced concrete within US Department of Energy (DOE) nuclear facilities and nuclear power plants (NPP) structures. Furthermore, degradation models based on literature data are presented that define the relationship between probabilistic material properties and the concrete’s age. In this work, sampled material properties served as input for a simplified finite element model (FEM) of a critical nuclear structural system, with the output of the FEM being the seismic response for a given ground motion. The results of the FEM were then used within a probabilistic performance assessment with a statistically significant number of samples. The research presented herein addresses the detrimental effects of hazards caused by natural phenomena on deteriorated concrete elements of nuclear installations. This work directly benefits the safety analysis performed on US DOE/ National Nuclear Security Administration (NNSA) nuclear facilities located in areas prone to seismic activity. The results presented herein could aid in the improvement of DOE-STD-1020, the DOE Standard that addresses seismic risk analysis and capacity evaluation in DOE facilities. DOE-STD-1020 refers to the requirements in American Society of Civil Engineers (ASCE) 4-98, now superseded by ASCE 4-16, that shall be met in performing dynamic response analyses and generating in-structure response spectra, provided that such requirements are consistent with the requirements of ASCE/Structural Engineering Institute (SEI) 43-05. Moreover, the results presented herein could also aid in the updating of section C3.1.1. of ASCE 4-16 to account for the effects of aging on the stiffness of reinforced elements and American Concrete Institute (ACI) 349.3R-18, “Report on Evaluation and Repair of Existing Nuclear Safety-Related Concrete Structures.” Ultimately, this work can assist the risk assessment of potential lifetime extension of the existing US commercial nuclear fleet (light water reactors) and the safety analysis of the emerging advanced nuclear reactors. The proposed proof-of-concept methodology employs open-source DOE computational tools and is transferable to commercial software commonly used by engineering firms.

42 ENGINEERING↗

Use of Smart Structures for Control and Performance Improvement of Hypersonic Vehicles

The objective of this presentation was to point out the fact that there are many promising applications for smart structures technology on hypersonic vehicles. This is not inherently obvious due to the real and perceived operating environments of hypersonic vehicles. The idea behind this project was to talk to hypersonic vehicle designers and academics to find out what sort of problems could be solved with smart structures. Two main conclusions can be drawn: One is that the actual environment inside a hypersonic vehicle is not always as severe as it appears. The second is that the hypersonic community needs a different type of research done on a faster timetable in order to use smart structures technology. Vehicle design cycle times are such that a technology must be proven before the vehicle is designed.

August, James A.↗

Tropical Cyclone Wind Shear-Relative Asymmetry in Reanalyses

Abstract While tropical cyclones (TCs) are axisymmetric vortices to the first order, they often exhibit noteworthy structural asymmetries. These often result from environmental vertical wind shear, which tilts the vortex and induces a wavenumber 1 pattern in the circulation and precipitation fields. Reanalyses and climate models have improved in representing the TC structure and climatology, but their relatively coarse resolution and dependence on parameterized physics cast doubt on their ability to capture the asymmetric TC structure. We perform the most comprehensive process-oriented assessment of TC asymmetry to date in reanalyses. Specifically, we analyze the composite shear-relative TC structure in ERA5 and Climate Forecast System Reanalysis (CFSR), which vary in their resolutions, physical parameterization suites, and data assimilation techniques. These structures are compared with aircraft reconnaissance radar observations. In agreement with the observations, the strongest tangential winds are usually found left-of-shear, while inner core rainfall, ascent, vortex tilt, and low-level inflow are favored directly downshear or in the downshear-left quadrant. Outer rainband convection generally peaks in the downshear-right quadrant. Thermodynamic asymmetries are also apparent, with anomalous low-level moisture right-of-shear, midlevel warmth in the upshear-right quadrant (uptilt), and cloud properties suggestive of a realistic precipitation life cycle from growth to fallout. We also decompose rainfall contributions from the convective parameterization and large-scale cloud schemes and highlight the roles of vorticity advection, buoyancy advection, and diabatic processes in driving asymmetric vertical motions in the inner core and outer rainband regions. Our results suggest that process-level studies of TC asymmetry and TC–wind shear interaction under future warming are viable using climate models. Significance Statement Asymmetries are common in tropical cyclones (TCs), influencing their intensity, track, and hazards. Vertical wind shear often plays a leading-order role in causing these asymmetries. It is uncertain how well asymmetric structures and processes are captured in reanalyses and global climate models (GCMs) with grid spacings of 0.25° and coarser. In this study, we first evaluate TC asymmetry in reanalyses, which have the benefit of being forced by observations. This helps to assess whether the resolutions associated with GCMs sufficiently capture asymmetric structures and processes and motivates upcoming work with free-running GCMs to study how TC asymmetry may change in a warming climate.

Carstens, Jacob D.↗

Analysis of Advanced Rotorcraft Configurations

Advanced rotorcraft configurations are being investigated with the objectives of identifying vehicles that are larger, quieter, and faster than current-generation rotorcraft. A large rotorcraft, carrying perhaps 150 passengers, could do much to alleviate airport capacity limitations, and a quiet rotorcraft is essential for community acceptance of the benefits of VTOL operations. A fast, long-range, long-endurance rotorcraft, notably the tilt-rotor configuration, will improve rotorcraft economics through productivity increases. A major part of the investigation of advanced rotorcraft configurations consists of conducting comprehensive analyses of vehicle behavior for the purpose of assessing vehicle potential and feasibility, as well as to establish the analytical models required to support the vehicle development. The analytical work of FY99 included applications to tilt-rotor aircraft. Tilt Rotor Aeroacoustic Model (TRAM) wind tunnel measurements are being compared with calculations performed by using the comprehensive analysis tool (Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD 11)). The objective is to establish the wing and wake aerodynamic models that are required for tilt-rotor analysis and design. The TRAM test in the German-Dutch Wind Tunnel (DNW) produced extensive measurements. This is the first test to encompass air loads, performance, and structural load measurements on tilt rotors, as well as acoustic and flow visualization data. The correlation of measurements and calculations includes helicopter-mode operation (performance, air loads, and blade structural loads), hover (performance and air loads), and airplane-mode operation (performance).

Johnson, Wayne↗

High performance silicon solar arrays employing advanced structures

Specific design features to reduce cell mass, lower panel operating temperatures, and improve power to mass ratios for silicon solar cell arrays in space applications are presented. Because mass constraints limit payload capacity for launch into GEO, graphite/epoxy structures combined with high performance Si cells are needed to deliver a power/mass ratio of 265 W/kg, notably for Solar Electric Propulsion systems, compared with existing level of 65 W/kg. Shallow diffusion and back surface field cell technology have raised cell efficiencies to 15%, with a back emissivity of 1.64. Structural design requirements comprise Shuttle interface compatibility, full ground test capability, low mass, and high stiffness. Three array alternatives are discussed, and the STACBEAM configuration, which consists of a triangular truss and a piston deployer with folding accomplished on simple hinges, provides 0.2 Hz stiffness and achieves the design power/mass goals.

Rockey, D. E.↗

Experimental flight test vibration measurements and nondestructive inspection on a USCG HC-130H aircraft

This paper presents results of experimental flight test vibration measurements and structural inspections performed by the Federal Aviation Administration's Airworthiness Assurance NDI Validation Center (AANC) at Sandia National Laboratories and the US Coast Guard Aircraft Repair and Supply Center (ARSC). Structural and aerodynamic changes induced by mounting a Forward Looking Infrared (FLIR) system on a USCG HC-130H aircraft are described. The FLIR adversely affected the air flow characteristics and structural vibration on the external skin of the aircraft's right main wheel well fairing. Upon initial discovery of skin cracking and visual observation of skin vibration in flight by the FLIR, a baseline flight without the FLIR was conducted and compared to other measurements with the FLIR installed. Nondestructive inspection procedures were developed to detect cracks in the skin and supporting structural elements and document the initial structural condition of the aircraft. Inspection results and flight test vibration data revealed that the FLIR created higher than expected flight loading and was the possible source of the skin cracking. The Coast Guard performed significant structural repair and enhancement on this aircraft, and additional in-flight vibration measurements were collected on the strengthened area both with and without the FLIR installed. After three months of further operational FLIR usage, the new aircraft skin with the enhanced structural modification was reinspected and found to be free of flaws. Additional US Coast Guard HC-130H aircraft are now being similarly modified to accommodate this FLIR system. Measurements of in- flight vibration levels with and without the FLIR installed, and both before and after the structural enhancement and repair were conducted on the skin and supporting structure in the aircraft's right main wheel fairing. Inspection results and techniques developed to verify the aircraft's structural integrity are discussed.

US COAST GUARD↗

A Study on Recycled Polymers Recovered from Multilayer Plastic Packaging Films by Solvent–Targeted Recovery and Precipitation (STRAP)

Multilayer plastic film use increased in multiple packaging applications due to its versatility and overall increased performance over monolayer structures. However, the performance gains from multiple layers also make recycling difficult because they contain multiple polymers that can be immiscible and burdensome to traditional mechanical recycling operations. A possible solution is the solvent-targeted recovery and precipitation (STRAP) process, but the effect on the retrieved polymer is still unknown. Here, the STRAP process is applied to two different multilayer films and samples of recovered polymers are evaluated for physical, molecular, and thermal properties. Changes in the molecular weight are not significant, but differences in thermal properties are reported along with the coprecipitation of different polymers. Solvent retention in the polymer matrix from STRAP reduced the glass transition temperature of samples, but enhanced drying recovered it. Heavy metals, such as Cd, Cr, and Pb are not detected, indicating regulatory compliance for different applications.

36 MATERIALS SCIENCE↗

Cell invasion during competitive growth of polycrystalline solidification patterns

Abstract Spatially extended cellular and dendritic array structures forming during solidification processes such as casting, welding, or additive manufacturing are generally polycrystalline. Both the array structure within each grain and the larger scale grain structure determine the performance of many structural alloys. How those two structures coevolve during solidification remains poorly understood. By in situ observations of microgravity alloy solidification experiments onboard the International Space Station, we have discovered that individual cells from one grain can unexpectedly invade a nearby grain of different misorientation, either as a solitary cell or as rows of cells. This invasion process causes grains to interpenetrate each other and hence grain boundaries to adopt highly convoluted shapes. Those observations are reproduced by phase-field simulations further demonstrating that invasion occurs for a wide range of misorientations. Those results fundamentally change the traditional conceptualization of grains as distinct regions embedded in three-dimensional space.

36 MATERIALS SCIENCE↗

Compression strength of composite primary structural components

The geometrically nonlinear response and failure of thin-walled structural components made from advanced composite materials is discussed. The materials involved are structural components in flight vehicle structures that are laminated from graphite-epoxy unidirectional tape. The investigation involves the buckling, postbuckling, and failure of structures subject to axial compression. The structural analysis was performed using the Structural Analysis of General Shells (STAGS) computer code. Experimental and theoretical methods are used to study the fundamental mechanisms limiting the load-carrying capacity of these components.

Johnson, Eric R.↗

Global and Local Stress Analyses of McDonnell Douglas Stitched/RFI Composite Wing Stub Box

This report contains results of structural analyses performed in support of the NASA structural testing of an all-composite stitched/RFI (resin film infusion) wing stub box. McDonnell Douglas Aerospace Company designed and fabricated the wing stub box. The analyses used a global/local approach. The global model contains the entire test article. It includes the all-composite stub box, a metallic load-transition box and a metallic wing-tip extension box. The two metallic boxes are connected to the inboard and outboard ends of the composite wing stub box, respectively. The load-transition box was attached to a steel and concrete vertical reaction structure and a load was applied at the tip of the extension box to bend the wing stub box upward. The local model contains an upper cover region surrounding three stringer runouts. In that region, a large nonlinear deformation was identified by the global analyses. A more detailed mesh was used for the local model to obtain more accurate analysis results near stringer runouts. Numerous analysis results such as deformed shapes, displacements at selected locations, and strains at critical locations are included in this report.

Wang, John T.↗