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At least 649 records · Page 36

Unexpected Control Structure Interaction on International Space Station

On June 23, 2011, the International Space Station (ISS) was performing a routine 180 degree yaw maneuver in support of a Russian vehicle docking when the on board Russian Segment (RS) software unexpectedly declared two attitude thrusters failed and switched thruster configurations in response to unanticipated ISS dynamic motion. Flight data analysis after the maneuver indicated that higher than predicted structural loads had been induced at various locations on the United States (U.S.) segment of the ISS. Further analysis revealed that the attitude control system was firing thrusters in response to both structural flex and rigid body rates, which resonated the structure and caused high loads and fatigue cycles. It was later determined that the thruster themselves were healthy. The RS software logic, which was intended to react to thruster failures, had instead been heavily influenced by interaction between the control system and structural flex. This paper will discuss the technical aspects of the control structure interaction problem that led to the RS control system firing thrusters in response to structural flex, the factors that led to insufficient preflight analysis of the thruster firings, and the ramifications the event had on the ISS. An immediate consequence included limiting which thrusters could be used for attitude control. This complicated the planning of on-orbit thruster events and necessitated the use of suboptimal thruster configurations that increased propellant usage and caused thruster lifetime usage concerns. In addition to the technical aspects of the problem, the team dynamics and communication shortcomings that led to such an event happening in an environment where extensive analysis is performed in support of human space flight will also be examined. Finally, the technical solution will be presented, which required a multidisciplinary effort between the U.S. and Russian control system engineers and loads and dynamics structural engineers to develop and implement an extensive modification in the RS software logic for ISS attitude control thruster firings.

Gomez, Susan F.↗

Optimization of a Multifunctional Hot Structure Aeroshell for Mars Entry

Vehicle size and weight are driving cost factors in sending vehicles into space because the cost of launch is directly related to the payload mass being delivered. Vehicle size and weight have a larger impact on deep- space missions compared to sending a payload to low Earth orbit due to the extra fuel and supplies required to complete the longer duration mission. One area of study for possible vehicle volume or weight reduction is the thermal protection system (TPS) of a vehicle. Hot structures have been proposed as a TPS concept which can carry both primary structural loads and thermal loads. The use of hot structures on a Mars entry vehicle may be feasible and have potential volume and weight savings over the current state of the art ablative TPS technology. A preliminary trade study was performed on a mid lift-to-drag aeroshell Mars entry concept vehicle; comparing the weight and skin thickness of a vehicle using ablative TPS with a vehicle using hot structures. Independent thermal and structural analyses were performed to determine the minimum mass designs. The goal of this study was to determine if the use of hot structures was feasible and had potential for significant vehicle volume and weight savings over the current state of the art. This trade study found that use of a hot structures leads to a feasible alternative to ablative TPS technology, with potential 53% weight and 22% thickness (volume) saving benefits that could enable future missions.

Langston, Sarah L.↗

3D Printed Structural Core with MMOD Protection

Deep space exploration requires large habitats for both orbital and surface missions. The weight of a habitat is driven largely by its structure and future vehicles require lighter weight structures to minimize launch mass and cost. Unlike honeycomb core materials used in the past, a 3D printed core can be analyzed and optimized for specific load environments, further cutting down mass of the vehicle. Multi-functional structures can integrate features into the primary structure that are traditionally added mass. MMOD (Micro Meteor and Orbital Debris) protection, for example, can be integrated directly into the primary structure of a habitat. This minimizes the mass of the structure and eliminates the need for additional MMOD layers and attachment hardware. This project seeks to develop 3D printed structural core that can be optimized for flights loads and provide integrated MMOD protection.

Hagen, Richard↗

Design of Multifunctional Hierarchical Space Structures

We describe a system for the design of space structures with tunable structural properties based on the discrete assembly of modular lattice elements. These lattice elements can be constructed into larger beam-like elements, which can then be assembled into large scale truss structures. These discrete lattice elements are reversibly assembled with mechanical fasteners, which allows them to be arbitrarily reconfigured into various application-specific designs. In order to assess the validity of this approach, we design two space structures with similar geometry but widely different structural requirements: an aerobrake, driven by strength requirements, and a precision segmented reflector, driven by stiffness and accuracy requirements. We will show agreement between simplified numerical models based on hierarchical assembly and analytical solutions. We will also present an assessment of the error budget resulting from the assembly of discrete structures. Lastly, we will address launch vehicle packing efficiency issues for transporting these structures to lower earth orbit.

Aeronautics↗

Geometry and Joint Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties, manufacturability of the components, and automated robotic constructability of a final system. Geometry choices considered include building block complexity, symmetry of the unit cell, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and structural performance of the joint, including proof load, shear load, mass, and loading area; as well as validation and verification opportunities. Manufacturability metrics include cost and time, manufacturing method (COTS versus custom), and tolerances required. Automated constructability metrics include local effects of loads imparted to the structure by the robot and assembly complexity, encompassing the ability of the robot to clamp and number of placement motions needed for assembly.

Ochalek, Megan E.↗

Improving Accuracy of Structural Dynamic Modification with Augmented Residual Vectors

It is often important to perform sensitivity analysis to determine how a structural model will be impacted by design changes. Often, the structural analysts will manually make changes to the finite element model (FEM) to determine the effects. But when dealing with a large FEM with millions of degrees of freedom these manual changes can be cumbersome and calculation of the effects can computationally expensive. Therefore, it is desirable to determine the effects of model changes through approximation methods. One common technique is to determine the analytical sensitivity of the FEM model with respect to the given change. These analytical sensitivities are valid when small changes are made to the structural model, but invalid if large changes need to be assessed. Another approach is to use Structural Dynamic Modification (SDM) to create a surrogate model to analyze model changes. SDM is a widely-used sensitivity method and is used in applications of model updating, uncertainty quantification, and model design studies. SMD is valid for moderate (10-20 percent) changes in the structural model, but model approximations are often needed for large parameter changes (greater than 20 percent). Structural Dynamic Modification can be improved by using residual vectors to augment the surrogate model formulation from SDM. Adding the residual modes increases the fidelity of the surrogate model while keeping the computational cost low. This paper discusses the application and limitations of the augmented residual modes method to two structures: the Integrated Spacecraft and Payload Element (ISPE) of the Space Launch System (SLS) and the full SLS as it is configured during its Integrated Modal Test (IMT).

Stewart, Eric C.↗

Tailored Wingbox Structures through Additive Manufacturing: A Summary of Ongoing Research at NASA LaRC

The use of wingbox structural design for improved performance (i.e., fuel burn reduction) of subsonic transports is driven by two trends: reduced structural weight and increased wingspan. These two trends are in direct competition, as the increased span will exacerbate the structural reaction to aerodynamic loading, and the reduced structural weight will nominally weaken the aircraft’s ability to handle this response. Novel structural configurations, enabled by recent improvements in manufacturing, may be critical toward bridging this gap.This paper summarizes pertinent activities at the NASA Langley Research Center in terms of additive manufacturing of metallic wing structures and substructures. Numerical design optimization activities are summarized as well, in order to understand where on a wingbox an additively-manufactured part may be useful and the way in which that part beneficially impacts the flight physics. The paper concludes with a discussion of how these two research paths may be better married in order to fully integrate both the benefits and realistic limitations of additive manufacturing and numerical structural design.

Stanford, Bret. K.↗

Wake Structure Induced by Seal Whisker: Effects of Angle of Incidence

Seal whiskers have been found to produce unique wake flow structures that minimize self-induced vibration and reduce drag. The cause of these wake features are due to the peculiar three-dimensional morphology of the whisker surface. The whisker can be defined as an elliptical cross section with variation in the major and minor axis of the ellipse along the length of the whisker as well as rotation of the elliptical plane with respect to the whisker axis, angle of incidence. While the effects of several dominant parameters of the whisker morphology have been studied, the effect of the rotation of the elliptical plane has not been well understood. This paper will examine the influence of the angle of incidence on the wake flow structure through series of water channel studies. Several models of whisker-like geometries will be tested which isolate the rotation angle as the only variation between models. The wake structure behind each seal whisker model will be measured through particle image velocimetry (PIV). The different models’ wake structures will be compared identifying the effect of angle of incidence on the wake structure. Angle of incidence was found to influence the wake structure through reorganization of velocity patterns, reduction of recovery length and modification of magnitude of Tu. These results help provide a more complete understanding of the seal whisker geometry relationship to wake structure and can provide insight into design practices for application of whisker geometery to various engineering problems.

vortex induced vibration↗

Instrumentation Needs of Inflatable Space Structures

NASA and industry are developing inflatable, crewed space structures for large-scale habitats for in-space and surface missions. Space certified inflatables are composed of high strength fabrics that carry the structural loads from internal pressure and replace traditional metallic primary structure. Inflatables can be packed for launch, fit inside a small launch shroud, and expand in orbit to create a large habitable volume for the crew. For safe operation of inflatable habitats, structural health monitoring (SHM) techniques are required to monitor and evaluate the structural loads in both ground and flight tests. Because of the nature of fabric structures, SHM techniques need to be soft, flexible, and be able to interface with softgoods. Litteken's presentation will introduce inflatable structures, their design, and their planned use for future NASA missions. He will discuss SHM needs for inflatables and their specific requirements for implementation with flight hardware.

Litteken, Doug↗

Fracture Control for Additively Manufactured Spacecraft Structures

This paper describes how the intent of current NASA fracture control requirements may be applied to “fracture critical” additively manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing NASA standards and is required on all human-rated space structures. As legacy spacecraft structures have been built using primarily metallic and composite materials manufactured using well established methods, guidance for application of fracture control to parts composed of these material types has been established and is documented in several NASA requirements. Additive manufactured structures offer advantages in design flexibility and manufacturing efficiency and as a result are expected to continue to be used more and more in the future. Recently, relevant guidance has been published by NASA to define materials and processes requirements for certain additive manufactured hardware, but procedures for fracture control are not addressed yet in any requirements or guidance document. While use of additive manufactured parts in non-critical scenarios may be of relatively low concern in current structural certification processes, there is a need for new fracture control guidance in order to use and certify additively manufacture hardware that is “fracture critical” where failure of the part may result in loss of life or loss of vehicle. Assurance of damage tolerance, i.e., that as-built flaws in a given part either do not exist or will not grow to become catastrophic, is of particular interest to the fracture control community. This poses a challenge due to the fact that damage tolerance behavior is not well understood in additive manufactured parts compared to legacy material types and manufacturing techniques. The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large. Different hardware types (e.g., pressure vessel, structural member) are described to highlight specific challenges and solutions for each. The discussion concludes with considering specific disciplines within fracture control (non-destructive evaluation, materials & processes, fracture mechanics, and structural certification) in a proposed extension of existing fracture control requirements to additive manufactured parts.

McElroy, Mark↗

Fracture Control for Additive Manufactured Spacecraft Structures

This paper describes how the intent of current NASA fracture control requirements may be applied to “fracture critical” additively manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing NASA standards and is required on all human-rated space structures. As legacy spacecraft structures have been built using primarily metallic and composite materials manufactured using well established methods, guidance for application of fracture control to parts composed of these material types has been established and is documented in several NASA requirements. Additive manufactured structures offer advantages in design flexibility and manufacturing efficiency and as a result are expected to continue to be used more and more in the future. Recently, relevant guidance has been published by NASA to define materials and processes requirements for certain additive manufactured hardware, but procedures for fracture control are not addressed yet in any requirements or guidance document. While use of additive manufactured parts in non-critical scenarios may be of relatively low concern in current structural certification processes, there is a need for new fracture control guidance in order to use and certify additively manufacture hardware that is “fracture critical” where failure of the part may result in loss of life or loss of vehicle. Assurance of damage tolerance, i.e., that as-built flaws in a given part either do not exist or will not grow to become catastrophic, is of particular interest to the fracture control community. This poses a challenge due to the fact that damage tolerance behavior is not well understood in additive manufactured parts compared to legacy material types and manufacturing techniques. The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large. Different hardware types (e.g., pressure vessel, structural member) are described to highlight specific challenges and solutions for each. The discussion concludes with considering specific disciplines within fracture control (non-destructive evaluation, materials & processes, fracture mechanics, and structural certification) in a proposed extension of existing fracture control requirements to additive manufactured parts.

McElroy, Mark↗

Fully-Coupled Fluid-Structure Interaction Simulations of a Supersonic Parachute

A validated computational fluid-structure interaction method for simulating the complex interaction between the large deformation of very thin, highly deformable structures and compressible flows is extended to consider large-scale problems in supersonic flows using parallel computing. The coupled fluid-structure interaction system is solved in a partitioned, or weakly-coupled, manner. The foundations of the applied fluid-structure interaction method are a higher-order, block-structured Cartesian, sharp immersed boundary method for the compressible Navier-Stokes equations and a computational structural dynamics solver employing a geometrically nonlinear 3-node shell element based on the mixed interpolation of tensorial components formulation. The method is applied to large deformation fluid-structure interaction validation cases before being applied to the inflation of a supersonic parachute in the upper Martian atmosphere where the goal is to demonstrate the capabilities of the solver when considering large-scale problems in supersonic flows.

Boustani, Jonathan↗

Magnetic Gears and Their Structural Limitations

Magnetic gears present significant structural design challenges, because metallic/electrically conductive structures are highly undesirable as they would lead to significant efficiency reductions. Additionally, most non-electrically conductive structural materials have low thermal conductivity, which makes cooling the gear difficult. These limitations are of particular significant in magnetic gear's modulator structures. NASA Glenn has shown that pole pieces on the order of 1 to 2 mm thick optimize magnetic gears specific torque. These thin pole pieces however see very large magnetic forces and modulator structural limitations prevent the use of magnetically optimum pole pieces. The best solution to this issue to date has been the use of carbon fiber retaining rings on the external surface of the modulator, however this solution increases ring modulator airgap, resulting in a torque reduction from the optimum design. The pole pieces are also the largest sources of losses in magnetic gears. Because the modulator is nestled between the ring and sun gear extraction of this heat is a difficult problem and the modulator structure has to be designed to dissipate this heat load. In the presentation I will present the design of NASA Glenn's 4th magnetic gear's modulator in detail that uses a combination of 3D fiber reinforced nylon, IM7 carbon fiber, and pitch base cn80 fiber to close both structurally and thermally.

Tallerico, Thomas↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

Integration of Advanced Structures and Materials Technologies for a Robust Lunar Habitat

NASA’s Artemis program plans to have a sustainable lunar base deployed on the Moon by 2028. The base calls for a foundation surface habitat that can support a crew of four members for a minimum mission duration of 28-days. The lack of a magnetic field and significant lunar atmosphere extends the lifetime of secondary radiation emitted from metallic structures, which is a health hazard for exposed astronauts. Integration of non-metallic structural materials into surface habitat design may alleviate some of these concerns. Additionally, it is favorable for the structure to be collapsible for transportation to optimize payload volume, mass efficiency, and monetary constraints. As a result, inflatable structures are being investigated due to their improved packing efficiency at launch, optimal mass-to-volume ratio, and large surface area that can efficiently disperse structural loads and heat. Currently, only two inflatable airlocks have been deployed in space. Thus, there is a significant need to advance technologies associated with inflatable structures to provide greater options for future missions, i.e., Artemis and beyond. This study focused on the inflatable lunar habitat applications of emerging NASA Langley Research Center (LaRC) technologies and their required development steps to become space qualified. The Bowling Habitat architecture was generated from 13 of these NASA LaRC technologies, five of which were deemed critical, five determined as enhancing technologies, and three were classified as transformational technologies for the Artemis program. To address the payload constraints, the study also considered a tentative timeline that aligned with the current Artemis schedule for transporting the Bowling Habitat to the Moon. Ultimately, the Bowling Habitat mainly addressed the structural needs of an inflatable lunar habitat, meaning that major areas pertaining to the life-style aspects of the habitat must be improved. Areas include, but are not limited to, hard connection points, the monitoring of human health, and extra radiation protection for solar proton events.

Inflatable Habitat↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading. The structure is able to sustain design limit load (DLL). Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions.

Eric M. Roberts↗

Early Lessons on Combining Lidar and Multi‑baseline SAR Measurements for Forest Structure Characterization

The estimation and monitoring of 3D forest structure at large scales strongly rely on the use of remote sensing techniques. Today, two of them are able to provide 3D forest structure estimates: lidar and synthetic aperture radar (SAR) configurations. The differences in wavelength, imaging geometry, and technical implementation make the measurements pro-vided by the two configurations different and, when it comes to the sensitivity to individual 3D forest structure components, complementary. Accordingly, the potential of combining lidar and SAR measurements toward an improved 3D forest structure estimation has been recognised from the very beginning. However, until today there is no established frame-work for this combination. This paper attempts to review differences, commonalities, and complementarities of lidar and SAR measurements. First, vertical lidar reflectance and SAR reflectivity profiles at different wavelengths are compared in different forest types. Then, current perspectives on their combination for the generation of enhanced structure products are discussed. Two promising frameworks for combining lidar and SAR measurements are reviewed. The first one is a model-based framework where lidar-derived parameters are used to initialize SAR scattering models, and relies on both the validity of the models and on the physical equivalence of the used lidar and SAR parameters. The second one is a structure-based framework based on the ability of lidar and SAR measurements to express physical forest structure by means of appropriate indices. These indices can then be used to establish a link between the two kind of measurements. The review is supported by experimental results achieved using space- and airborne data acquired in recent relevant mission and campaigns.

Matteo Pardini↗

MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures

In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.

Robotics↗