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NASA NTRS2011

Inflatable nested toroid structure

An inflatable structure comprises at least two generally toroidal, inflatable modules. When in a deployed mode, the first, inner module has a major diameter less than that of a second, outer module and is positioned within the inner circumference of the outer module such that the first module is nested circumferentially alongside the second module. The inflatable structure, in a non-deployed, non-inflated mode, is of compact configuration and adapted to be transported to a site of deployment. When deployed, the inflatable structure is of substantially increased interior volume. In one embodiment, access between the interior of the first module and the second module is provided by at least one port or structural pass-through. In another embodiment, the inflatable structure includes at least one additional generally toroidal module external of and circumferentially surrounding the second module.

Johnson, Christopher J.↗

NASA NTRS2009

Damage Tolerance Testing of a NASA TransHab Derivative Woven Inflatable Module

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

Edgecombe, John↗

NASA NTRS2009

Hatch Integration Testing of a NASA TransHab Derivative Woven Inflatable Module

Edgecombe, John↗

NASA NTRS2015

Hypersonic Inflatable Aerodynamic Decelerator Ground Test Development

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology readiness levels have been incrementally matured by NASA over the last thirteen years, with most recent support from NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). Recently STMD GCDP has authorized funding and support through fiscal year 2015 (FY15) for continued HIAD ground developments which support a Mars Entry, Descent, and Landing (EDL) study. The Mars study will assess the viability of various EDL architectures to enable a Mars human architecture pathfinder mission planned for mid-2020. At its conclusion in November 2014, NASA's first HIAD ground development effort had demonstrated success with fabricating a 50 W/cm2 modular thermal protection system, a 400 C capable inflatable structure, a 10-meter scale aeroshell manufacturing capability, together with calibrated thermal and structural models. Despite the unquestionable success of the first HIAD ground development effort, it was recognized that additional investment was needed in order to realize the full potential of the HIAD technology capability to enable future flight opportunities. The second HIAD ground development effort will focus on extending performance capability in key technology areas that include thermal protection system, lifting-body structures, inflation systems, flight control, stage transitions, and 15-meter aeroshell scalability. This paper presents an overview of the accomplishments under the baseline HIAD development effort and current plans for a follow-on development effort focused on extending those critical technologies needed to enable a Mars Pathfinder mission.

Del Corso, Jospeh A.↗

NASA NTRS2018

Demonstration of Probabilistic Sensitivity Analyses Tools on the Structural Response of a Representative Inflatable Space Structure

This work provides an initial step toward demonstrating a probabilistic numerical simulation capability to support trade studies and the development of a certification plan for inflatable space habitats. This study concentrates on interpreting the results from probabilistic analysis and numerical simulation tools to identify parameter sensitivities for a novel inflatable airlock concept, specifically the Non‐Axisymmetric Inflatable Pressure Structure (NAIPS) that was designed and tested under NASA's Minimalistic Advanced Softgoods Hatch (MASH) Program. A brief overview of the finite element model is provided along with the probabilistic sensitivity analysis approach. The sensitivity studies required a model that was numerically stable and efficient enough that hundreds of simulations could be completed in the allotted time. Therefore, the existing full model was simplified by: extracting a quarter symmetry section of the dome; focusing on a single inflation pressure; and replacing the non‐linear material stress‐strain curves with linear, isotropic materials defined by elastic moduli. Responses of interest include the sensitivity of various structural component loads to material properties, cord lengths, inflation pressure and friction. Multiple sensitivity studies were completed and three are reported here. The first study focused on utilizing wide input parameter ranges to provide an opportunity to assess numerical robustness. The next two studies narrowed the parameter ranges to enable focus on understanding uncertainty at a fixed operating condition. The completion of the sensitivity studies improved understanding of the interdependence of multiple inputs on the responses. In addition, numerical stability of the simulations over wide parameter ranges, shows the feasibility of incorporating uncertainty‐based methods in the design and certification of inflatable space habitats. With the experience and trust gained, it is anticipated that these same methods will be applied to nonlinear, orthotropic models in the future.

Lyle, Karen H.↗

NASA NTRS2018

Probabilistic Sensitivity Analyses Incorporating Surrogate Models for the Structural Response of a Representative Inflatable Space Structure

This study concentrates on results from probabilistic analysis and numerical simulation tools to identify parameter sensitivities and assess surrogate model suitability for a novel inflatable airlock concept, specifically the Non-Axisymmetric Inflatable Pressure Structure (NAIPS) under NASA's Minimalistic Advanced Softgoods Hatch (MASH) Program. The current studies extended the demonstration of probabilistic analysis tools to identify parameter sensitivities by: incorporating nonlinear material load-strain property curves and orthotropic representation of the fabric; and exploring the use of surrogate models to facilitate rapid evaluations as new information becomes available, as well as enable optimizations. The airlock model has been simplified to focus on the end dome section. Brief overviews of the finite element model and associated surrogate models are provided along with the probabilistic sensitivity analysis approaches. Responses of interest include the sensitivities of various loads in the structural elements of the NAIPS to material properties, cord lengths, inflation pressure and friction between softgoods components. The use of surrogate models was explored to facilitate rapid sensitivity evaluations as parameter ranges change. The completion of the sensitivity studies improved understanding of the dependence of load responses to several uncertain parameters and confidence in the ability to use surrogate models to represent the finite element simulations.

Lyle, Karen H.↗

NASA NTRS2018

Structural Certification of Human-Rated Inflatable Space Structures

This paper details the results of an initial study to develop a certification plan for human-rated inflatable space structures, including guidelines for qualification testing. Habitable softgoods inflatables are multi-layered shell structures that use high-strength webbing, cordage and broadcloth fabric to carry the skin loads of a variety of volumetric shapes and structural architectures. The primary objectives of this study are to define the key parameters that affect these structures and propose a statistically robust approach to defining safety and knockdown factors based on test and analysis. Current NASA standards for habitable inflatable space structures use a factor of safety of 4, which was inherited from airship design criteria. An updated approach to defining a design factor, taking into account material strength variability, load variability in the article, number of test samples, and damage and degradation effects is specified. Accurate analytical modeling of these structures is hindered by the difficulty of obtaining accurate and consistent material data due to load-history- dependent, nonlinear load versus strain behavior. A building block approach to certification is detailed that uses stochastic modeling and statistical test design and analysis to address the unique challenges these high-strength softgoods structures present. Human-rated inflatable modules are a transformative capability for launching much larger habitable volumes into space than is possible with rigid shell structures. This research aims to provide the framework for certifying these structures for future human space exploration missions.

Jones, Thomas C.↗

NASA NTRS2010

Inflatable Tubular Structures Rigidized with Foams

Inflatable tubular structures that have annular cross sections rigidized with foams, and the means of erecting such structures in the field, are undergoing development. Although the development effort has focused on lightweight structural booms to be transported in compact form and deployed in outer space, the principles of design and fabrication are also potentially applicable to terrestrial structures, including components of ultralightweight aircraft, lightweight storage buildings and shelters, lightweight insulation, and sales displays. The use of foams to deploy and harden inflatable structures was first proposed as early as the 1960s, and has been investigated in recent years by NASA, the U.S. Air Force Research Laboratory, industry, and academia. In cases of deployable booms, most of the investigation in recent years has focused on solid cross sections, because they can be constructed relatively easily. However, solid-section foam-filled booms can be much too heavy for some applications. In contrast, booms with annular cross sections according to the present innovation can be tailored to obtain desired combinations of stiffness and weight through choice of diameters, wall thicknesses, and foam densities. By far the most compelling advantage afforded by this innovation is the possibility of drastically reducing weights while retaining or increasing the stiffnesses, relative to comparable booms that have solid foamfilled cross sections. A typical boom according to this innovation includes inner and outer polyimide film sleeves to contain foam that is injected between them during deployment.

Tinker, Michael L.↗

NASA NTRS1960

Structural Considerations of Inflatable Reentry Vehicles

The state of the design art for inflated structures applicable to reentry vehicles is discussed. Included are material properties, calculations of buckling and collapse loads, and calculations of deflections and vibration frequencies. A new theory for the analysis of inflated plates is presented and compared with experiment.

Leonard, Robert W.↗

NASA NTRS2015

Structural Testing of a 6m Hypersonic Inflatable Aerodynamic Decelerator System

NASA is developing low ballistic coefficient technologies to support the Nations long-term goal of landing humans on Mars. Current entry, decent, and landing technologies are not practical for this class of payloads due to geometric constraints dictated by current and future launch vehicle fairing limitations. Hypersonic Inflatable Aerodynamic Decelerators (HIADs) are being developed to circumvent this limitation and are now considered a leading technology to enable landing of heavy payloads on Mars. At the beginning of 2014, a 6m diameter HIAD inflatable structure with an integrated flexible thermal protection system (TPS) was subjected to a static load test series to verify its structural performance under flight-relevant loads. The inflatable structure was constructed into a 60 degree sphere-cone configuration using nine inflatable torus segments composed of fiber-reinforced thin films. The inflatable tori were joined together using adhesives and high-strength textile woven structural straps. These straps help distribute the load throughout the inflatable structure. The 6m flexible TPS was constructed using multiple layers of high performance materials that are designed to protect the inflatable structure from heat loads that would be seen in flight during atmospheric entry. A custom test fixture was constructed to perform the static load test series. The fixture consisted of a round structural tub with enough height and width to allow for displacement of the HIAD test article as loads were applied. The bottom of the tub rim had an airtight seal with the floor. The rigid centerbody of the HIAD was mounted to a pedestal in the center of the structural tub. Using an impermeable membrane draped over the HIAD test article, an airtight seal was created with the top rim of the static load tub. This seal allowed partial vacuum to be pulled beneath the HIAD resulting in a uniform static pressure load applied to the outer surface. Using this technique, the test article was subjected to loads of up to 50,000lbs. During the test series an extensive amount of instrumentation was used to provide a rich data set, including deflected shape, structural strap loads, torus cord loads, inflation pressures, and applied static load. In this paper the 2014 6m HIAD static load test series will be discussed in detail, including the design of the 6m HIAD test article, the test setup, and test execution. Analysis results will be described supporting the conclusions that were drawn from the test series..

Hypersonic↗

NASA NTRS2001

Structural Dynamics Experimental Activities in Ultra-Lightweight and Inflatable Space Structures

This paper reports recently completed structural dynamics experimental activities with new ultralightweight and inflatable space structures (a.k.a., "Gossamer" spacecraft) at NASA Langley Research Center, NASA Marshall Space Flight Center, and NASA Goddard Space Flight Center. Nine aspects of this work are covered, as follows: 1) inflated, rigidized tubes, 2) active control experiments, 3) photogrammetry, 4) laser vibrometry, 5) modal tests of inflatable structures, 6) in-vacuum modal tests, 7) tensioned membranes, 8) deployment tests, and 9) flight experiment support. Structural dynamics will play a major role in the design and eventual in-space deployment and performance of Gossamer spacecraft, and experimental R&D work such as this is required now to validate new analytical prediction methods. The activities discussed in the paper are pathfinder accomplishments, conducted on unique components and prototypes of future spacecraft systems.

Pappa, Richard S.↗

NASA NTRS2001

Structural Dynamics Experimental Activities in Ultra-Lightweight and Inflatable Space Structures

This paper reports recently completed structural dynamics experimental activities with new ultra-lightweight and inflatable space structures (a.k.a., "Gossamer" spacecraft) at NASA Langley Research Center, NASA Marshall Space Flight Center, and NASA Goddard Space Flight Center. Nine aspects of this work are covered: 1) inflated, rigidized tubes, 2) active control experiments, 3) photogrammetry, 4) laser vibrometry, 5) modal tests of inflatable structures, 6) in-vacuum modal tests, 7) tensioned membranes, 8) deployment tests, and 9) flight experiment support. Structural dynamics will play a major role in the design and eventually in-space deployment and performance of Gossamer spacecraft. Experimental research and development such as this is required to validate new analysis methods. The activities discussed in the paper are pathfinder accomplishments. conducted on unique components and prototypes of future spacecraft systems.

Pappa, Richard S.↗

NASA NTRS2019

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↗

NASA NTRS2019

Calibration of a Structural Finite Element Model for a Representative Inflatable Space Structure Utilizing Probabilistic Methods and Surrogate Models

A structural finite element model representing a novel inflatable airlock concept has been calibrated using full‐scale test data. The concept, denoted as the Non‐Axisymmetric Inflatable Pressure Structure (NAIPS), was developed under NASA’s Minimalistic Advanced Softgoods Hatch (MASH) Program. The current studies extended previous numerical efforts by incorporating the midbody section of the NAIPS to the dome section and calibrating the model with test data using a process that included surrogate models. Brief overviews of the finite element model and calibration process are provided. The completion of the calibration process provided a model that adequately replicated the test data. The successful demonstration of calibration of a finite element model representing an inflatable habitat provides confidence in the ability to use numerical simulations and associated surrogate models to support design and certification of inflatable space habitats.

Lyle, Karen H.↗

NASA NTRS2002

Structural Modeling of a Five-Meter Thin Film Inflatable Antenna/Concentrator

Inflatable structures have been the subject of renewed interest in recent years for space applications such as communications antennas, solar thermal propulsion, and space solar power. A major advantage of using inflatable structures in space is their extremely light weight. An obvious second advantage is on-orbit deployability and related space savings in the launch configuration. A recent technology demonstrator flight for inflatable structures was the Inflatable Antenna Experiment (IAE) that was deployed on orbit from the Shuttle Orbiter. Although difficulty was encountered in the inflation/deployment phase, the flight was successful overall and provided valuable experience in the use of such structures. Several papers on static structural analysis of inflated cylinders have been written, describing different techniques such as linear shell theory, and nonlinear and variational methods, but very little work had been done in dynamics of inflatable structures until recent years. In 1988 Leonard indicated that elastic beam bending modes could be utilized in approximating lower-order frequencies of inflatable beams. Main, et al. wrote a very significant 1995 paper describing results of modal tests of inflated cantilever beams and the determination of effective material properties. Changes in material properties for different pressures were also discussed, and the beam model was used in a more complex structure. The paper demonstrated that conventional finite element analysis packages could be very useful in the analysis of complex inflatable structures. The purposes of this paper are to discuss the methodology for dynamically characterizing a large 5-meter thin film inflatable reflector, and to discuss the test arrangement and results. Nonlinear finite element modal results are compared to modal test data. The work is significant and of considerable interest to researchers because of 1) the large size of the structure, making it useful for scaling studies, and 2) application of commercially available finite element software for modeling pressurized thin-film structures.

Smalley, Kurt B.↗

NASA NTRS1993

Inflatable Habitat Structure

Report describes proposed inflatable habitat structure used during exploration of Moon or Mars. Provides living and working space for 12 crewmembers and includes horizontal cylindrical skin 8 m in diameter and 45 m long. Skin encloses floors and arch frame, supported by exostructure on foundations.

Kennedy, Kriss J.↗

NASA NTRS2015

Overview of the 2nd Gen 3.7m HIAD Static Load Test

To support NASAs long term goal of landing humans on Mars, technologies which enable the landing of heavy payloads are being developed. Current entry, decent, and landing technologies are not practical for human class payloads due to geometric constraints dictated by current launch vehicle fairing limitations. Therefore, past and present technologies are now being explored to provide a mass and volume efficient solution to atmospheric entry, including Hypersonic Inflatable Aerodynamic Decelerators (HIADs). In October of 2014, a 3.7m HIAD inflatable structure with an integrated flexible thermal protection sys-tem (F-TPS) was subjected to a static load test series to verify the designs structural performance. The 3.7m HIAD structure was constructed in a 70 deg sphere-cone stacked-toroid configuration using eight inflatable tori, which were joined together using adhesives and high strength textile webbing to help distribute the loads throughout the inflatable structure. The inflatable structure was fabricated using 2nd generation structural materials that permit an increase in use temperature to 400 C+ as compared to the 250 C limitation of the 1st generation materials. In addition to the temperature benefit, these materials also offer a 40 reduction in structure mass. The 3.7m F-TPS was fabricated using high performance materials to protect the inflatable structure from heat loads that would be seen during atmospheric entry. The F-TPS was constructed of 2nd generation TPS materials increasing its heating capability from 35W sq cm to over 100W sq cm. This test article is the first stacked-torus HIAD to be fabricated and tested with a 70 deg sphere-cone. All previous stacked-torus HIADs have employed a 60o sphere-cone. To perform the static load test series, a custom test fixture was constructed. The fixture consisted of a structural tub rim with enough height to allow for dis-placement of the inflatable structure as loads were applied. The tub rim was attached to the floor to provide an airtight seal. The center body of the inflatable structure was attached to a pedestal mount as seen in Figure 1. Using an impermeable membrane seal draped over the test article, partial vacuum was pulled beneath the HIAD, resulting in a uniform static pressure load applied to the outer surface. During the test series an extensive amount of instrumentation was used to characterize deformed shape, shoulder deflection, strap loads, and cord loads as a function of structural configuration and applied static load. In this overview, the 3.7m HIAD static load test series will be discussed in detail, including the 3.7m HIAD inflatable structure and flexible TPS design, test setup and execution, and finally results and conclusions from the test series.

HIAD↗

NASA NTRS2017

Non-Axisymmetric Inflatable Pressure Structure (NAIPS) Full-Scale Pressure Test

Inflatable space structures have the potential to significantly reduce the required launch volume for large pressure vessels required for exploration applications including habitats, airlocks and tankage. In addition, mass savings can be achieved via the use of high specific strength softgoods materials, and the reduced design penalty from launching the structure in a densely packaged state. Large inclusions however, such as hatches, induce a high mass penalty at the interfaces with the softgoods and in the added rigid structure while reducing the packaging efficiency. A novel, Non-Axisymmetric Inflatable Pressure Structure (NAIPS) was designed and recently tested at NASA Langley Research Center to demonstrate an elongated inflatable architecture that could provide areas of low stress along a principal axis in the surface. These low stress zones will allow the integration of a flexible linear seal that substantially reduces the added mass and volume of a heritage rigid hatch structure. This paper describes the test of the first full-scale engineering demonstration unit (EDU) of the NAIPS geometry and a comparison of the results to finite element analysis.

Jones, Thomas C.↗