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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Development of Thermal Barriers for Solid Rocket Motor Nozzle Joints

The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the downstream Viton 0-ring temperature limit of 600 F. Carbon-6 performed extremely well in subscale rocket "char" motor tests when subjected to hot gas at 3200 F for an 11 second rocket firing, simulating the maximum downstream joint cavity fill time. The thermal barrier reduced the incoming hot gas temperature by 2200 F in an intentionally oversized gap defect, spread the incoming jet flow, and blocked hot slag, thereby offering protection to the downstream 0-rings.

Steinetz, Bruce M.↗
NASA NTRS2003

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗
NASA NTRS2013

Integrated High-Speed Torque Control System for a Robotic Joint

A control system for achieving high-speed torque for a joint of a robot includes a printed circuit board assembly (PCBA) having a collocated joint processor and high-speed communication bus. The PCBA may also include a power inverter module (PIM) and local sensor conditioning electronics (SCE) for processing sensor data from one or more motor position sensors. Torque control of a motor of the joint is provided via the PCBA as a high-speed torque loop. Each joint processor may be embedded within or collocated with the robotic joint being controlled. Collocation of the joint processor, PIM, and high-speed bus may increase noise immunity of the control system, and the localized processing of sensor data from the joint motor at the joint level may minimize bus cabling to and from each control node. The joint processor may include a field programmable gate array (FPGA).

Davis, Donald R.↗
NASA NTRS2017

Development of Stable, Low Resistance Solder Joints for a Space-Flight HTS Lead Assemblies

The solder joints in spaceflight high temperature superconductor (HTS) lead assemblies for certain astrophysics missions have strict constraints on size and power dissipation. In addition, the joints must tolerate years of storage at room temperature, many thermal cycles, and several vibration tests between their manufacture and their final operation on orbit. As reported previously, solder joints between REBCO coated conductors and normal metal traces for the Astro-H mission showed low temperature joint resistance that grew approximately as log time over the course of months. Although the assemblies worked without issue in orbit, for the upcoming X-ray Astrophysics Recovery Mission we are attempting to improve our solder process to give lower, more stable, and more consistent joint resistance. We produce numerous sample joints and measure time- and thermal cycle-dependent resistance, and characterize the joints using x-ray and other analysis tools. For a subset of the joints, we use SEMEDS to try to understand the physical and chemical processes that effect joint behavior.

high temperature superconductivity↗
NASA NTRSDate not supplied

Testing and Analysis Correlation of a Large-Scale Composite Sandwich Longitudinal Bonded Joint for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. This paper reports on the large-scale longitudinal bonded joint test articles that were fabricated and tested under axial compressive loading conditions to test the capability of the bonded joint design for buckling and joint failure. Test and analysis correlation of an as-manufactured undamaged longitudinal bonded joint panel are presented in the paper for tests to the onset of buckling and panel failure. Analysis predictions for buckling initiation and panel failure were both within 10% of the longitudinal bonded joint panel test results. This testing and analysis provide confidence in the potential use of composite bonded joints for future launch vehicle structures.

David W Sleight↗
NASA NTRSDate not supplied

Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) Hinge Joint Structural Performance

The Tendon Actuated Lightweight In-Space MANipulator (TALISMAN), invented and initially developed under the Space Technology Mission Directorate Human Robotics Systems program, is a tendon-actuated robot that established a new structural architecture for long-reach space manipulators. The TALISMAN is designed to have significant stiffness and strength in the plane of the tendons or cables, and operations are designed such that all primary loads are applied in that same plane. However, during normal operations it is possible for out-of-plane forces to be applied on the TALISMAN when secondary loads are imparted by a tool or action at the wrist. These secondary loading conditions will induce out-of-plane bending loads in the TALISMAN hinge joints. The TALISMAN hinge joints must be designed for these out-of-plane loads, to ensure no failure of the joint occurs during operations. A series hinge joint out-of-plane stiffness tests were conducted at five different joint angles; at three cable pre-loads from 25-lbf to 100-lbf; up to an equivalent out-of-plane tip load of 27.28-lbf at the end of a 51-in. long distal link. The objective of the tests was to provide an initial set of deflection, cable load, and strain data to inform accurate modeling of the hinge joint out-of-plane stiffness. The test objective was achieved by developing an FEM of the hinge joint able to predict tip displacement to within 10% of values measured in tests. The hinge joint FEM may now be implemented into a full-scale analysis model of the TALISMAN V2.0 to provide predictions of out-of-plane displacement under different load and joint angle conditions.

Matthew K Mahlin↗
NASA NTRSDate not supplied

Material Variability Effects on Damage Development Within Composite Adhesively Bonded Joints

Use of composite adhesively bonded joints (ABJ) is of critical importance to the adoption of composite materials in the automotive industry, as ABJ enable lower stress concentrations as compared to conventional mechanically fastened joints. ABJ are better suited for joining composite materials as compared to fastened joints because fastened joints require drilling of holes which locally affect composite material structure. Composite materials and adhesives are subject to unavoidable stochastic local material variations which make different failure scenarios possible. An experimentally tested ABJ configuration is simulated using finite element analysis (FEA). Experimentally, under tension, the joints failed by three major failure modes, with peak loads ranging from 13.0-16.1 kips. Progressive failure analysis tools are used to simulate damage development within each material within the joint. The simulation agreed well with the average experimental peak load. Stochastically occurring adhesive porosity and matrix-fiber micro-disbonding were numerically simulated. The simulations revealed a similar trend as observed experimentally: joints which failed at higher peak loads had lower levels of damage within the face-sheets of the composite panels which were adhesively bonded; these joints which failed at higher peak loads also had greater damage in the doubler of the experimentally tested double lap joint configuration.

Richard Larson↗
DOE OSTI2026

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturing approach to fabricate π-joints using an integrated Additive Manufacturing and Compression Molding (AMCM) process. The joints were manufactured using unidirectional aerospace-grade LMPAEK/CF at 60% fiber loading for the stiffeners/skin and LM-PAEK/GF as the adhesive and characterized to evaluate their microstructure and strength. While the results indicate void formation at the joint caused by inadequate pressure, the peak tensile load of 600N recorded is akin to injection-autoclave molded π-joints, which validates the potential of this high-rate integrated approach to eliminate time-consuming and labour-intensive processes of making π-joints to reduce cost and produce high-quality joints.

Marathe, Umesh [ORNL]↗
NASA NTRS1976

Bolted joints in graphite-epoxy composites

All-graphite/epoxy laminates and hybrid graphite-glass/epoxy laminates were tested. The tests encompassed a range of geometries for each laminate pattern to cover the three basic failure modes - net section tension failure through the bolt hole, bearing and shearout. Static tensile and compressive loads were applied. A constant bolt diameter of 6.35 mm (0.25 in.) was used in the tests. The interaction of stress concentrations associated with multi-row bolted joints was investigated by testing single- and double-row bolted joints and open-hole specimens in tension. For tension loading, linear interaction was found to exist between the bearing stress reacted at a given bolt hole and the remaining tension stress running by that hole to be reacted elsewhere. The interaction under compressive loading was found to be non-linear. Comparative tests were run using single-lap bolted joints and double-lap joints with pin connection. Both of these joint types exhibited lower strengths than were demonstrated by the corresponding double-lap joints. The analysis methods developed here for single bolt joints are shown to be capable of predicting the behavior of multi-row joints.

Hart-Smith, L. J.↗
NASA NTRS1978

Spacesuit mobility joints

Joints for use in interconnecting adjacent segments of an hermetically sealed spacesuit which have low torques, low leakage and a high degree of reliability are described. Each of the joints is a special purpose joint characterized by substantially constant volume and low torque characteristics. Linkages which restrain the joint from longitudinal distension and a flexible, substantially impermeable diaphragm of tubular configuration spanning the distance between pivotally supported annuli are featured. The diaphragms of selected joints include rolling convolutions for balancing the joints, while various joints include wedge-shaped sections which enhance the range of motion for the joints.

Vykukal, H. C.↗
NASA NTRS1979

Spacesuit mobility knee joints

Pressure suit mobility joints are for use in interconnecting adjacent segments of an hermetically sealed spacesuit in which low torques, low leakage and a high degree of reliability are required. Each of the joints is a special purpose joint characterized by substantially constant volume and low torque characteristics and includes linkages which restrain the joint from longitudinal distension and includes a flexible, substantially impermeable diaphragm of tubular configuration spanning the distance between pivotally supported annuli. The diaphragms of selected joints include rolling convolutions for balancing the joints, while various joints include wedge-shaped sections which enhance the range of motion for the joints.

Vykukal, H. C.↗
NASA NTRS1986

Measuring Hole Elongation in Bolted Joints

Measurement does not affect joint parameters. Verification of analytical and strength-prediction methods for bolted composite joints based generally on data obtained experimentally from double-lap-joint specimens. In mechanically fastened joints, stresses maximal at fastener holes. Ability to measure accurately hole elongations without affecting joint parameters provides better understanding of elastic and plastic behavior of joint material leading to failure mechanisms in mechanically fastened joints required for design of more-efficient, lightweight composite joints.

Wichorek, G. R.↗
NASA NTRS1989

Simplified procedures for designing adhesively bonded composite joints

Procedures for the preliminary design of composite adhesive joints are described. Typical joints, their respective free body diagrams, and approximate equations for estimating the stresses in each of these typical joints are summarized. Equations are also presented to check the critical conditions of the joint such as minimum length, maximum adhesive shear stress, and peel-off stress. To illustrate the procedure, sample designs are described in step-by-step fashion for a butt joint with single doubler subjected to static loads, cyclic loads, and environmental effects. The results show that unsymmetric adhesive joints are inefficient and should be avoided, and hygrothermal environments and cyclic loads dramatically reduce the structural integrity of the joint and require several joint lengths compared with those for static load with no environmental effects.

Chamis, C. C.↗
NASA NTRS1988

Adaptive independent joint control of manipulators - Theory and experiment

The author presents a simple decentralized adaptive control scheme for multijoint robot manipulators based on the independent joint control concept. The proposed control scheme for each joint consists of a PID (proportional integral and differential) feedback controller and a position-velocity-acceleration feedforward controller, both with adjustable gains. The static and dynamic couplings that exist between the joint motions are compensated by the adaptive independent joint controllers while ensuring trajectory tracking. The proposed scheme is implemented on a MicroVAX II computer for motion control of the first three joints of a PUMA 560 arm. Experimental results are presented to demonstrate that trajectory tracking is achieved despite strongly coupled, highly nonlinear joint dynamics. The results confirm that the proposed decentralized adaptive control of manipulators is feasible, in spite of strong interactions between joint motions. The control scheme presented is computationally very fast and is amenable to parallel processing implementation within a distributed computing architecture, where each joint is controlled independently by a simple algorithm on a dedicated microprocessor.

Seraji, H.↗
NASA NTRS1991

Simplified procedures for designing adhesively bonded composite joints

Procedures for the preliminary design for composite adhesive joints are described. Typical joints, their respective free body diagrams, and approximate equations for estimating the stresses in each of these typical joints are summarized. Equations are also presented to check the critical conditions of the joint such as minimum length, maximum adhesive shear stress, and peel-off stress. To illustrate the procedure, sample designs are described in step-by-step fashion for a butt joint with single doubler subjected to static loads, cyclic loads, and environmental effects. The results show that unsymmetric adhesive joints are inefficient and should be avoided, and hygrothermal environments and cyclic loads dramatically reduce the structural integrity of the joint and require several joint lengths compared with those for static load with no environmental effects.

Chamis, C. C.↗
NASA NTRS1991

Measurements of fuselage skin strains and displacements near a longitudinal lap joint in a pressurized aircraft

Strains and displacements in a small area near a longitudinal lap joint in the fuselage skin of a B737 aircraft were measured during a pressurization cycle to a differential pressure of 6.2 psi while the aircraft was on the ground. It was found that hoop strains were higher than longitudinal strains at each location; membrane strains in the unreinforced skin were higher than in the joint; membrane strains in the hoop direction, as well as radial displacements, tended to be highest at the mid-bay location between skin reinforcements; significant bending in the hoop direction occurred in the joint and in the skin near the joint, and the bending was unsymmetrically distributed about the stringer at the middle of the joint; and radial displacements were unsymmetrically distributed across the lap joint. The interpretation of the strain gage data for locations on the bonded and riveted lap joint assumed that the joint did not contain disbonded areas.

Phillips, Edward P.↗
NASA NTRS1995

Description of and preliminary tests results for the Joint Damping Experiment (JDX)

An effort is currently underway to develop an experiment titled joint Damping E_periment (JDX) to fly on the Space Shuttle as Get Away Special Payload G-726. This project is funded by NASA's IN-Space Technology Experiments Program and is scheduled to fly in July 1995 on STS-69. JDX will measure the influence of gravity on the structural damping of a three bay truss having clearance fit pinned joints. Structural damping is an important parameter in the dynamics of space structures. Future space structures will require more precise knowledge of structural damping than is currently available. The mission objectives are to develop a small-scale shuttle flight experiment that allows researchers to: (1) characterize the influence of gravity and joint gaps on structural damping and dynamic behavior of a small-scale truss model, and (2) evaluate the applicability of low-g aircraft test results for predicting on-orbit behavior. Completing the above objectives will allow a better understanding and/or prediction of structural damping occurring in a pin jointed truss. Predicting damping in joints is quite difficult. One of the important variables influencing joint damping is gravity. Previous work has shown that gravity loads can influence damping in a pin jointed truss structure. Flying this experiment as a GAS payload will allow testing in a microgravity environment. The on-orbit data (in micro-gravity) will be compared with ground test results. These data will be used to help develop improved models to predict damping due to pinned joints. Ground and low-g aircraft testing of this experiment has been completed. This paper describes the experiment and presents results of both ground and low-g aircraft tests which demonstrate that damping of the truss is dramatically influenced by gravity.

Bingham, Jeffrey G.↗
NASA NTRS2000

Wormhole Formation in RSRM Nozzle Joint Backfill

The RSRM nozzle uses a barrier of RTV rubber upstream of the nozzle O-ring seals. Post flight inspection of the RSRM nozzle continues to reveal occurrence of "wormholes" into the RTV backfill. The term "wormholes", sometimes called "gas paths", indicates a gas flow path not caused by pre-existing voids, but by a little-understood internal failure mode of the material during motor operation. Fundamental understanding of the mechanics of the RSRM nozzle joints during motor operation, nonlinear viscoelastic characterization of the RTV backfill material, identification of the conditions that predispose the RTV to form wormholes, and screening of candidate replacement materials is being pursued by a joint effort between Thiokol Propulsion, NASA, and the Army Propulsion & Structures Directorate at Redstone Arsenal. The performance of the RTV backfill in the joint is controlled by the joint environment. Joint movement, which applies a tension and shear load on the material, coupled with the introduction of high pressure gas in combination create an environment that exceeds the capability of the material to withstand the wormhole effect. Little data exists to evaluate why the material fails under the modeled joint conditions, so an effort to characterize and evaluate the material under these conditions was undertaken. Viscoelastic property data from characterization testing will anchor structural analysis models. Data over a range of temperatures, environmental pressures, and strain rates was used to develop a nonlinear viscoelastic model to predict material performance, develop criteria for replacement materials, and quantify material properties influencing wormhole growth. Three joint simulation analogs were developed to analyze and validate joint thermal barrier (backfill) material performance. Two exploratory tests focus on detection of wormhole failure under specific motor operating conditions. A "validation" test system provides data to "validate" computer models and predictions. Finally, two candidate replacement materials are being screened and "validated" using the developed test systems.

Stevens, J.↗