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NASA NTRS2014

Simulation for Prediction of Entry Article Demise (SPEAD): an Analysis Tool for Spacecraft Safety Analysis and Ascent/Reentry Risk Assessment

For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of

Ling, Lisa↗

NASA NTRS1985

Critical assessment of precracked specimen configuration and experimental test variables for stress corrosion testing of 7075-T6 aluminum alloy plate

A research program was conducted to critically assess the effects of precracked specimen configuration, stress intensity solutions, compliance relationships and other experimental test variables for stress corrosion testing of 7075-T6 aluminum alloy plate. Modified compact and double beam wedge-loaded specimens were tested and analyzed to determine the threshold stress intensity factor and stress corrosion crack growth rate. Stress intensity solutions and experimentally determined compliance relationships were developed and compared with other solutions available in the literature. Crack growth data suggests that more effective crack length measurement techniques are necessary to better characterize stress corrosion crack growth. Final load determined by specimen reloading and by compliance did not correlate well, and was considered a major source of interlaboratory variability. Test duration must be determined systematically, accounting for crack length measurement resolution, time for crack arrest, and experimental interferences. This work was conducted as part of a round robin program sponsored by ASTM committees G1.06 and E24.04 to develop a standard test method for stress corrosion testing using precracked specimens.

Domack, M. S.↗

NASA NTRS1996

Effect of Cyclic Thermo-Mechanical Loads on Fatigue Reliability in Polymer Matrix Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multi-factor interaction relationship developed at NASA Lewis Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability- based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)(sub s) graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Shah, A. R.↗

NASA NTRS1998

Stressed-Oxidation Lifetime of Different SiC Fiber, CVI Matrix SiC Minicomposites in Air

The stressed-oxidation lifetime properties of several minicomposites composed of single fiber tows with a CVI SiC matrix were compared. The minicomposites were made up of Nicalon(Tm) and Hi-Nicalon(Tm) SiC fibers with carbon or BN interphases. Constant load stress-rupture tests were performed between 600 and 13000 C in air for all of the minicomposite systems. Cyclic load testing was performed on the Hi-Nicalon minicomposite systems. The factors controlling the different lifetime behaviors: fiber rupture properties, interphase oxidation, fiber degradation, and fiber-matrix bonding, are discussed in light of different minicomposite constituents. All of the systems were subject to intermediate temperature embrittlement. The Hi-Nicalon fiber, BN interphase system, performed the best for constant load conditions. For cyclic load conditions, both the BN- interphase and C-interphase minicomposites displayed poor, but different failure behavior.

Morscher, Gregory N.↗

NASA NTRS2021

Power Operations of the Mars Exploration Rovers

The rovers of the National Aeronautics and Space Administration’s (NASA) Mars Exploration Rovers (MER) project, Spirit (MER-A) and Opportunity (MER-B), safely landed on the surface of Mars three weeks apart during January 2004. Spirit and Opportunity were built and operated by the Jet Propulsion Laboratory (JPL), which is managed by the California Institute of Technology (Caltech) for NASA. Spirit landed at Gusev Crater, 14.8 degrees south of the equator, and operated continuously on the surface of Mars from January 4, 2004 until last contact from Spirit on March 22, 2010. Opportunity landed at Meridiani Planum, a location 2.5 degrees south of the Martian equator. Opportunity operated continuously on the Martian surface from January 25, 2004 until the last received transmission from Opportunity on June 10, 2018. The goal of the MER project was to determine if Mars ever had a habitable environment, in particular, if it ever had water. During their missions, both Spirit and Opportunity found evidence that liquid water once flowed on the surface of Mars. Both Spirit and Opportunity used a 1.33 m2 triple-junction solar array as their power sources. Based on observations of the original Mars rover, the Sojourner rover of the Mars Pathfinder mission that landed on Mars on July 4, 1997, the expectation was that the Martian dust would rapidly accumulate on the solar arrays of Spirit and Opportunity, and that the rovers would not have enough energy to continue operations after 90 Martian days (sols). Instead, due in part to lower dust accumulation rates than expected and numerous dust cleaning events, the Spirit and Opportunity rovers continued to operate on the Martian surface for over 2000 sols (MER-A) and 5000 sols (MER-B), respectively. During this time, the rovers experienced multiple Martian winters and several dust storms. Because the sources of solar array energy loss were known, the solar array energy output offered a method to scientifically estimate the loading and aeolian removal of dust from the solar arrays each sol. The MER Power operations team called this value that they calculated the solar array Dust Factor (DF). Dust Factor was defined as the fraction of sunlight that penetrates the accumulated dust on the surface of the solar array. A Dust Factor of 1.0 would indicate that the solar array was perfectly clean. A Dust Factor of 0.6 would indicate that only 60% of the available sunlight was able to penetrate the accumulated dust on the solar arrays. The MER Power subsystem operations team used the Multi-Mission Power Analysis Tool (MMPAT) to perform these Dust Factor calculations. The MMPAT software tool modeled the behavior of the solar arrays and the batteries as they interacted with the spacecraft power loads over the mission timeline. MMPAT also had knowledge (through telemetry and user inputs) of telemetered Power subsystem voltages and currents, atmospheric opacity (Tau), rover surface location, rover attitude, the planetary tilt and distance of Mars from the sun based on day of year, the instantaneous elevation of the sun based on time of day, temperatures (internal and external), terrain masking, and shadowing (due to the camera mast and antennas). Once all of the known sources of array energy loss are accounted, the remaining difference between the expected array energy and the actual array energy determines the solar array Dust Factor. The assumptions made while determining the Dust Factor are 1) that the single measured atmospheric opacity value (Tau) is constant over the course of the entire sol, 2) there is no measurable solar cell degradation, 3) there are no shorted strings and therefore, 4) all unexpected solar array energy losses are due to accumulated dust on the solar array. Although it cannot provide an absolute measure of dust loading, the determination of solar array Dust Factor provides a useful way of tracking dust accumulation and aeolian dust removal trends on Martian spacecraft. Any spacecraft on the Martian surface is vulnerable to dust, especially solar-powered spacecraft. The Spirit and Opportunity rovers were operational on the Martian surface for much longer than expected due in part to aeolian removal of dust from their solar arrays. The first few dust removal events were a pleasant surprise to the MER operations teams; however, over time a pattern began to arise. In over three Mars Years on the surface, the Power operations team tracked the solar array Dust Factor at Gusev Crater (location of MER-A) and observed that there were several significant dust removal and deposition events in Mars Year (MY) 27, even in the absence of a large dust storm. In MY 28 at Gusev Crater, the large atmospheric opacity (Tau) increase lagged significant dust removal events. Overall at Gusev Crater, there was a pattern of steady dust accumulation on the solar arrays, with a small number of significant dust cleaning events. At Meridiani Planum, where Opportunity rover operated for over seven Mars Years (late MY 26 to mid MY 34), a clear and consistent pattern of dust movement emerged. Meridiani Planum had a predictable, seasonally dependent pattern of gradual and continuous dust accumulation and removal. In summary, this paper explains the reasons for the development of the solar array Dust Factor and how it was used in mission operations. In particular, this paper describes the MMPAT software package, how it models array energy, including the important assumptions, model inputs and sources of error. And finally, this paper will show how the calculated solar array Dust Factor was used at Gusev Crater and Meridiani Planum to predict dust accumulation rates and weather patterns, and the importance of this generated data set for current and future solar- powered missions to Mars, such as the InSight lander and the planned Mars Sample Return rover.

Chin, Keith B.↗

NASA NTRS1971

Organizational stress and individual strain: A social-psychological study of risk factors in coronary heart disease among administrators, engineers, and scientists

It is hypothesized that organizational stresses, such as high quantitative work load, responsibility for persons, poor relations with role senders, and contact with alien organizational territories, may be associated with high levels of psychological and physiological strain which are risk factors in coronary heart disease. It is further hypothesized that persons with coronary-prone Type A personality characteristics are most likely to exhibit strain under conditions of organizational stress. Measures of these stresses, personality traits, and strains were obtained from 205 male NASA administrators, engineers, and scientists. Type A personality measures included sense of time urgency, persistence, involved striving, leadership, and preference for competitive and environmentally overburdening situations.

Caplan, R. D.↗

NASA NTRS2005

Heat Load Sharing in a Capillary Pumped Loop with Multiple Evaporators and Multiple Condensers

This paper describes the heat load sharing function among multiple parallel evaporators in a capillary pumped loop (CPL). In the normal mode of operation, the evaporators cool the instruments by absorbing the waste heat. When an instruments is turned off, the attached evaporator can keep it warm by receiving heat from other evaporators serving the operating instruments. This is referred to as heat load sharing. A theoretical basis of heat load sharing is given first. The fact that the wicks in the powered evaporators will develop capillary pressure to force the generated vapor to flow to cold locations where the pressure is lower leads to the conclusion that heat load sharing is an inherent function of a CPL with multiple evaporators. Heat load sharing has been verified with many CPLs in ground tests. Experimental results of the Capillary Pumped Loop 3 (CAPL 3) Flight Experiment are presented in this paper. Factors that affect the amount of heat being shared are discussed. Some constraints of heat load sharing are also addressed.

Ku, Jentung↗

NASA NTRS2002

Skeletal Adaptation to Daily Activity: A Biochemical Perspective

Musculoskeletal forces generated by normal daily activity on Earth maintain the functional and structural properties of muscle and bone throughout most of one's adult life. A reduction in the level of cumulative daily loading caused by space flight, bed rest or spinal cord injury induces rapid muscle atrophy, functional changes in muscle, and bone resorption in regions subjected to the reduced loading. Bone cells in culture and bone tissue reportedly respond to a wide variety of non-mechanical and mechanical stimuli ranging, from electromagnetic fields, and hormones to small amplitude, high frequency vibrations, fluid flow, strain rate, and stress/strain magnitude. However, neither the transduction mechanism that transforms the mechanical input into a muscle or bone metabolic response nor the characteristics, of the loading history that directly or indirectly stimulates the cell is known. Identifying the factors contributing to the input stimulus will have a major impact on the design of effective countermeasures for long duration space flight. This talk will present a brief overview of current theories of bone remodeling and functional adaptation to mechanical loading. Work from our lab will be presented from the perspective of daily cumulative loading on Earth and its relationship to bone density and structure. Our objective is to use the tibia and calcaneus as model bone sites of cortical and cancellous bone adaptation, loaded daily by musculoskeletal forces in equilibrium with the ground reaction force. All materials that will be discussed are in the open scientific literature.

Whalen, Robert T.↗

NASA NTRS2014

Time-Dependent Behavior of High-Strength Kevlar and Vectran Webbing

High-strength Kevlar and Vectran webbings are currently being used by both NASA and industry as the primary load-bearing structure in inflatable space habitation modules. The time-dependent behavior of high-strength webbing architectures is a vital area of research that is providing critical material data to guide a more robust design process for this class of structures. This paper details the results of a series of time-dependent tests on 1-inch wide webbing including an initial set of comparative tests between specimens that underwent realtime and accelerated creep at 65 and 70% of their ultimate tensile strength. Variability in the ultimate tensile strength of the webbings is investigated and compared with variability in the creep life response. Additional testing studied the effects of load and displacement rate, specimen length and the time-dependent effects of preconditioning the webbings. The creep test facilities, instrumentation and test procedures are also detailed. The accelerated creep tests display consistently longer times to failure than their real-time counterparts; however, several factors were identified that may contribute to the observed disparity. Test setup and instrumentation, grip type, loading scheme, thermal environment and accelerated test postprocessing along with material variability are among these factors. Their effects are discussed and future work is detailed for the exploration and elimination of some of these factors in order to achieve a higher fidelity comparison.

Jones, Thomas C.↗

NASA NTRS1992

Shear joint capability versus bolt clearance

The results of a conservative analysis approach into the determination of shear joint strength capability for typical space-flight hardware as a function of the bolt-hole clearance specified in the design are presented. These joints are comprised of high-strength steel fasteners and abutments constructed of aluminum alloys familiar to the aerospace industry. A general analytical expression was first arrived at which relates bolt-hole clearance to the bolt shear load required to place all joint fasteners into a shear transferring position. Extension of this work allowed the analytical development of joint load capability as a function of the number of fasteners, shear strength of the bolt, bolt-hole clearance, and the desired factor of safety. Analysis results clearly indicate that a typical space-flight hardware joint can withstand significant loading when less than ideal bolt hole clearances are used in the design.

Lee, H. M.↗

NASA NTRS2016

The Ultimate Factor of Safety for Aircraft and Spacecraft Its History, Applications and Misconceptions

The ultimate factor of safety (FOSULT) concept used in aircraft and spacecraft has evolved over many decades. Currently an FOSULT 1.5 is the FAR‐mandated value for aircraft while an FOSULT of 1.4 has been used in various spacecraft. This paper was motivated by the desire to concisely explain the origins, proper interpretation and application of the ultimate factor of safety concept, since the authors have seen throughout their careers many misconceptions and incorrect applications of this concept. The history of the ultimate factor of safety concept is briefly summarized, the proper application of the factor of safety in aircraft design, structural analysis and operations is covered in detail, examples of limit load exceedance in aircraft and spacecraft are discussed, the evolution of the 1.4 FOSULT for spacecraft is described and some misconceptions regarding the ultimate factor of safety concept are addressed. It is hoped that this paper can be a summary resource for engineers to understand the origin, purpose and proper application of the ultimate factor of safety.

Zipay, John J.↗

NASA NTRS1976

A note on correlation description

The paper suggests some modifications to definitions of correlation functions made by Freeman and Bennett (1974) specifically for comparing measured quantities with those predicted by rotor theories, with reference to rotorcraft flight simulation. Special attention is paid to the quality of correlation, determined by a quality factor relating the measured and computed entities. Correlation criteria (mean load and rotor performance, overall amplitude and phase, harmonic altitude and harmonic phase) are examined, along with phase angle correlation criteria (harmonic phase defined by sine-cosine relation and harmonic phase defined by a first positive peak rotor azimuth position)

Mccloud, J. L., III↗

NASA NTRS1979

Dynamic response of damaged angleplied fiber composites

The effects of low level damage induced by monotonic load, cyclic load and/or residual stresses on the vibration frequencies and damping factors of fiber composite angleplied laminates were investigated. Two different composite systems were studied - low modulus fiber and ultra high modulus fiber composites. The results obtained show that the frequencies and damping factors of angleplied laminates made from low modulus fiber composites are sensitive to low level damage while those made from ultra high modulus composites are not. Vibration tests may not be sufficiently sensitive to assess concentrated local damage in angleplied laminates. Dynamic response determined from low-velocity impact coupled with the Fast Fourier Transform and packaged in a minicomputer can be a convenient procedure for assessing low-level damage.

Chamis, C. C.↗

NASA NTRS1979

Dynamic response of damaged angleplied fiber composites

An investigation was conducted to determine the effects of low level damage induced by monotonic load, cyclic load and/or residual stresses on the vibration frequencies and damping factors of fiber composite angleplied laminates. Two different composite systems were studied - low modulus fiber and ultra high modulus fiber composites. The results obtained showed that the frequencies and damping factors of angleplied laminates made from low modulus fiber composites are sensitive to low level damage while those made from ultra high modulus composites are not. Also, vibration tests may not be sufficiently sensitive to assess concentrated local damage in angleplied laminates. And furthermore, dynamic response determined from low-velocity impact coupled with the Fast Fourier Transform and packaged in a minicomputer can be a convenient procedure for assessing low-level damage in fiber composite angleplied laminates.

Chamis, C. C.↗

NASA NTRS1980

An acoustic sensitivity study of general aviation propellers

This paper describes the results of a study in which a systematic approach has been taken in studying the effect of selected propeller parameters on the character and magnitude of propeller noise. Four general aviation aircraft were chosen, i.e., a Cessna 172, Cessna 210, Cessna 441, and a 19 passenger commuter concept, to provide a range in flight velocity, engine horsepower, and gross weight. The propeller parameters selected for examination consisted of number of blades, rpm reduction, thickness/chord reduction, activity factor reduction, proplets, airfoil improvement, sweep, position of maximum blade loading, and diameter reduction.

Korkan, K. D.↗

NASA NTRS1986

New methodology for shaft design based on life expectancy

The design of power transmission shafting for reliability has not historically received a great deal of attention. However, weight sensitive aerospace and vehicle applications and those where the penalties of shaft failure are great, require greater confidence in shaft design than earlier methods provided. This report summarizes a fatigue strength-based, design method for sizing shafts under variable amplitude loading histories for limited or nonlimited service life. Moreover, applications factors such as press-fitted collars, shaft size, residual stresses from shot peening or plating, corrosive environments can be readily accommodated into the framework of the analysis. Examples are given which illustrate the use of the method, pointing out the large life penalties due to occasional cyclic overloads.

Loewenthal, S. H.↗

NASA NTRS1991

HITCAN for actively cooled hot-composite thermostructural analysis

A computer code, high temperature composite analyzer (HITCAN), was developed to analyze/design hot metal matrix composite structures. HITCAN is a general purpose code for predicting the global structural and local stress-strain response of multilayered (arbitrarily oriented) metal matrix structures both at the constituent (fiber, matrix, and interphase) and the structural level, including the fabrication process effects. The thermomechanical properties of the constituents are considered to be nonlinearly dependent on several parameters, including temperature, stress, and stress rate. The computational procedure employs an incremental iterative nonlinear approach utilizing a multifactor-interaction material behavior model, i.e., the material properties are expressed in terms of a product of several factors that affect the properties. HITCAN structural analysis capabilities (static, load stepping - a multistep static analysis with material properties updated at each step, modal, and buckling) for cooled hot structures are demonstrated through a specific example problem.

Chamis, C. C.↗

NASA NTRS1991

Evaluation of the concept of pressure proof testing fuselage structures

The FAA and NASA have recently completed independent technical evaluations of the concept of pressure proof testing the fuselage of commercial transport airplanes. The results of these evaluations are summarized. The objectives of the evaluations were to establish the potential benefit of the pressure proof test, to quantify the most desirable proof test pressure, and to quantify the required proof test interval. The focus of the evaluations was on multiple-site cracks extending from adjacent rivet holes of a typical fuselage longitudinal lap splice joint. The FAA and NASA do not support pressure proof testing the fuselage of aging commercial transport aircraft. The argument against proof testing is as follows: (1) a single proof test does not insure an indefinite life; therefore, the proof test must be repeated at regular intervals; (2) for a proof factor of 1.33, the required proof test interval must be below 300 flights to account for uncertainties in the evaluation; (3) conducting the proof test at a proof factor of 1.5 would considerably exceed the fuselage design limit load; therefore, it is not consistent with accepted safe practices; and (4) better safety can be assured by implementing enhanced nondestructive inspection requirements, and adequate reliability can be achieved by an inspection interval several times longer than the proof test interval.

Harris, Charles E.↗