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NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

NASA NTRS2010

Vibration Response Predictions for Heavy Panel Mounted Components from Panel Acreage Environment Specifications

The development of new launch vehicles in the Aerospace industry often relies on response measurements taken from previously developed vehicles during various stages of liftoff and ascent, and from wind tunnel models. These measurements include sound pressure levels, dynamic pressures in turbulent boundary layers and accelerations. Rigorous statistical scaling methods are applied to the data to derive new environments and estimate the performance of new skin panel structures. Scaling methods have proven to be reliable, particularly for designs similar to the vehicles used as the basis for scaling, and especially in regions of smooth acreage without exterior protuberances or heavy components mounted to the panel. To account for response attenuation of a panel-mounted component due to its apparent mass at higher frequencies, the vibroacoustics engineer often reduces the acreage vibration according to a weight ratio first suggested by Barrett. The accuracy of the reduction is reduced with increased weight of the panel-mounted component, and does not account for low-frequency amplification of the component/panel response as a system. A method is proposed that combines acreage vibration from scaling methods with finite element analysis to account for the frequency-dependent dynamics of heavy panel-mounted components. Since the acreage and mass-loaded skins respond to the same dynamic input pressure, such pressure may be eliminated in favor of a frequency-dependent scaling function applied to the acreage vibration to predict the mass-loaded panel response. The scaling function replaces the Barrett weight ratio, and contains all of the dynamic character of the loaded and unloaded skin panels. The solution simplifies for spatially uncorrelated and fully correlated input pressures. Since the prediction uses finite element models of the loaded and unloaded skins, a rich suite of response data are available to the design engineer, including interface forces, stress and strain, as well as acceleration and displacement. An extension of the method is also developed to incorporate the effect of a local protuberance near a heavy component. Acreage environments from traditional scaling methods with and without protuberance effects serve as the basis for the extension. Authors:

Harrison, Phillip↗

NASA NTRS1990

Electrochemical incineration of wastes

The novel technology of waste removal in space vehicles by electrochemical methods is presented to convert wastes into chemicals that can be eventually recycled. The important consideration for waste oxidation is to select a right kind of electrode (anode) material that should be stable under anodic conditions and also a poor electrocatalyst for oxygen and chlorine evolution. On the basis of long term electrolysis experiments on seven different electrodes and on the basis of total organic carbon reduced, two best electrodes were identified. The effect of redox ions on the electrolyte was studied. Though most of the experiments were done in mixtures of urine and waste, the experiments with redox couples involved 2.5 M sulfuric acid in order to avoid the precipitation of redox ions by urea. Two methods for long term electrolysis of waste were investigated: (1) the oxidation on Pt and lead dioxide electrodes using the galvanostatic methods; and (2) potentiostatic method on other electrodes. The advantage of the first method is the faster rate of oxidation. The chlorine evolution in the second method is ten times less then in the first. The accomplished research has shown that urine/feces mixtures can be oxidized to carbon dioxide and water, but current densities are low and must be improved. The perovskite and Ti4O7 coated with RuO2 are the best electrode materials found. Recent experiment with the redox agent improves the current density, however, sulphuric acid is required to keep the redox agent in solution to enhance oxidation effectively. It is desirable to reduce the use of acid and/or find substitutes.

Bhardwaj, R. C.↗

NASA NTRS1980

A mixed-mode crack analysis of rectilinear anisotropic solids using conservation laws of elasticity

A very simple and convenient method of analysis for studying two-dimensional mixed-mode crack problems in rectilinear anisotropic solids is presented. The analysis is formulated on the basis of conservation laws of anisotropic elasticity and of fundamental relationships in anisotropic fracture mechanics. The problem is reduced to a system of linear algebraic equations in mixed-mode stress intensity factors. One of the salient features of the present approach is that it can determine directly the mixed-mode stress intensity solutions from the conservation integrals evaluated along a path removed from the crack-tip region without the need of solving the corresponding complex near-field boundary value problem. Several examples with solutions available in the literature are solved to ensure the accuracy of the current analysis. This method is further demonstrated to be superior to other approaches in its numerical simplicity and computational efficiency. Solutions of more complicated and practical engineering problems dealing with the crack emanating from a circular hole in composites are presented also to illustrate the capacity of this method.

Wang, S. S.↗

NASA NTRS2001

Finite Element Methods for real-time Haptic Feedback of Soft-Tissue Models in Virtual Reality Simulators

We have applied the linear elastic finite element method to compute haptic force feedback and domain deformations of soft tissue models for use in virtual reality simulators. Our results show that, for virtual object models of high-resolution 3D data (>10,000 nodes), haptic real time computations (>500 Hz) are not currently possible using traditional methods. Current research efforts are focused in the following areas: 1) efficient implementation of fully adaptive multi-resolution methods and 2) multi-resolution methods with specialized basis functions to capture the singularity at the haptic interface (point loading). To achieve real time computations, we propose parallel processing of a Jacobi preconditioned conjugate gradient method applied to a reduced system of equations resulting from surface domain decomposition. This can effectively be achieved using reconfigurable computing systems such as field programmable gate arrays (FPGA), thereby providing a flexible solution that allows for new FPGA implementations as improved algorithms become available. The resulting soft tissue simulation system would meet NASA Virtual Glovebox requirements and, at the same time, provide a generalized simulation engine for any immersive environment application, such as biomedical/surgical procedures or interactive scientific applications.

Frank, Andreas O.↗

NASA NTRS2023

Progressive Damage and Failure Analysis of Thermoplastic Composites in Low Velocity Impact Using MAT299

As part of the NASA Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project, state-of-the-art progressive damage and failure analysis (PDFA) tools developed for use with thermosets are being evaluated for use in modeling alternative material systems, like thermoplastics. Experimental low-velocity impact data of a thermoplastic material system, AS4D/PEKK-FC, is presented and includes characterization of the impact damage mechanisms as well as associated load and displacement data. Following the presentation of experimental results, two simulation approaches using the PDFA tool MAT299 in the commercial off-the-shelf finite element software LS-DYNA are employed to predict damage area and force-displacement responses of thermoplastic panels subjected to various impact energies. The first modeling method uses solid elements with a high-density mesh and a ply-by-ply modeling approach similar to previously published work for thermosets. This method has the capability of capturing individual crack development, progression, and delamination on a per ply basis. The second modeling method uses TSHELL elements that have in-plane dimensions that are an order of magnitude larger than the elements used in the solid element approach and reduces the number of elements through the thickness of the laminate. The second method produces a lower-fidelity model with reduced run times that is incapable of monitoring every delamination plane and damage within each ply. Results from both simulation methods are compared to experiment, and limitations of the methods are discussed.

Composite material↗

NASA NTRS2023

Progressive Damage and Failure Analysis of Thermoplastic Composites in Low Velocity Impact Using MAT299

Composite material↗

NASA NTRS1953

Drag Measurements on Equivalent Bodies of Revolution of Six Configurations of the Convair MX-1964 (Originally MX-1626) Proposed Supersonic Bomber

Tests on equivalent bodies of revolution of six configurations of the Consolidated Vultee Aircraft Corporation proposed supersonic bomber (Convair MX-1964) have indicated that it is possible to reduce the drag of the configuration by designing it to have a favorable area distribution. The method of NACA RM L53I22c to predict the peak pressure drag of a configuration on the basis of its area distribution gave generally good agreement with the subject models.

Hall, James Rudyard↗

NASA NTRS1982

Electrophoresis tests on STS-3 and ground control experiments - A basis for future biological sample selections

Static zone electrophoresis is an electrokinetic method of separating macromolecules and small particles. However, its application for the isolation of biological cells and concentrated protein solutions is limited by sedimentation and convection. Microgravity eliminates or reduces sedimentation, floatation, and density-driven convection arising from either Joule heating or concentration differences. The advantages of such an environment were first demonstrated in space during the Apollo 14 and 16 missions. In 1975 the Electrophoresis Technology Experiment (MA-011) was conducted during the Apollo-Soyuz Test Project flight. In 1979 a project was initiated to repeat the separations of human kidney cells. One of the major objectives of the Electrophoresis Equipment Verification Tests (EEVT) on STS-3 was to repeat and thereby validate the first successful electrophoretic separation of human kidney cells. Attention is given to the EEVT apparatus, the preflight electrophoresis, and inflight operational results.

Morrison, D. R.↗

NASA NTRS1992

Star trackers, star catalogs, and attitude determination - Probabilistic aspects of system design

Optimizing spacecraft attitude determination systems that use onboard star trackers requires analysis and evaluation of some probabilistic aspects of system design. This paper discusses methods of constructing or compiling optimum star catalogs, which are defined as uniform distributions on a sphere. Both local and global measures of uniformity on a sphere are defined. Application of these methods and measures to a specific problem is also discussed. In addition, Poisson models of star tracker acquisition probabilities are formulated to provide a useful analytical basis for designing and optimizing attitude determination systems. These analytical models and methods lead to rapid and realistic quantitative results, and should therefore facilitate making system performance trades. Use of such methods should also reduce the need for performing tedious computer simulations to obtain analogous results.

Vedder, John D.↗

NASA NTRS2002

Life-Extending Control for Aircraft Engines Studied

Current aircraft engine controllers are designed and operated to provide both performance and stability margins. However, the standard method of operation results in significant wear and tear on the engine and negatively affects the on-wing life--the time between cycles when the engine must be physically removed from the aircraft for maintenance. The NASA Glenn Research Center and its industrial and academic partners have been working together toward a new control concept that will include engine life usage as part of the control function. The resulting controller will be able to significantly extend the engine's on-wing life with little or no impact on engine performance and operability. The new controller design will utilize damage models to estimate and mitigate the rate and overall accumulation of damage to critical engine parts. The control methods will also provide a means to assess tradeoffs between performance and structural durability on the basis of mission requirements and remaining engine life. Two life-extending control methodologies were studied to reduce the overall life-cycle cost of aircraft engines. The first methodology is to modify the baseline control logic to reduce the thermomechanical fatigue (TMF) damage of cooled stators during acceleration. To accomplish this, an innovative algorithm limits the low-speed rotor acceleration command when the engine has reached a threshold close to the requested thrust. This algorithm allows a significant reduction in TMF damage with only a very small increase in the rise time to reach the commanded rotor speed. The second methodology is to reduce stress rupture/creep damage to turbine blades and uncooled stators by incorporating an engine damage model into the flight mission. Overall operation cost is reduced by an optimization among the flight time, fuel consumption, and component damages. Recent efforts have focused on applying life-extending control technology to an existing commercial turbine engine, and doing so without modifying the hardware or adding sensors. This approach makes it possible to retrofit existing engines with life-extending control technology by changing only the control software in the full-authority digital engine controller (FADEC). The significant results include demonstrating a 20- to 30-percent reduction in TMF damage to the hot section by developing and implementing smart acceleration logic during takeoff. The tradeoff is an increase, from 5.0 to 5.2 sec, in the time required to reach maximum power from ground idle. On a typical flight profile of a cruise at Mach 0.8 at an altitude of 41,000 ft, and cruise time of 104 min, the optimized system showed that a reduction in cruise speed from Mach 0.8 to 0.79 can achieve an estimated 25-to 35-percent creep/rupture damage reduction in the engine's hot section and a fuel savings of 2.1 percent. The tradeoff is an increase in flight time of 1.3 percent (1.4 min).

Guo, Te-Huei↗

NASA NTRS2022

Computing Sensitivities in Evolutionary Systems: A Real-time Reduced Order Modeling Strategy

We present a new methodology for computing sensitivities in evolutionary systems using a model-driven low-rank approximation. To this end, we formulate a variational principle that seeks to minimize the distance between the time derivative of the reduced approximation and sensitivity dynamics. The first order optimality condition of the variational principle leads to a system of closed form evolution equations for an orthonormal basis and corresponding sensitivity coefficients. This approach allows for the computation of sensitivities with respect to a large number of parameters in an accurate and tractable manner by extracting correlations between different sensitivities on the fly. The presented method requires solving forward evolution equations, sidestepping the restrictions imposed by the forward/backward workflow of adjoint sensitivities. For example, the presented method, unlike the adjoint equation, does not impose any input/output load and can be used in applications in which real-time sensitivities are of interest. We demonstrate the utility of the method for three test cases: (1) computing sensitivity with respect to model parameters in the Rössler system, (2) computing sensitivity with respect to an infinite-dimensional forcing parameter in the chaotic Kuramoto--Sivashinsky equation, and (3) computing sensitivity with respect to reaction parameters for species transport in a turbulent reacting flow.

Reduced order model↗

NASA NTRS1995

Two-dimensional mesh embedding for Galerkin B-spline methods

A number of advantages result from using B-splines as basis functions in a Galerkin method for solving partial differential equations. Among them are arbitrary order of accuracy and high resolution similar to that of compact schemes but without the aliasing error. This work develops another property, namely, the ability to treat semi-structured embedded or zonal meshes for two-dimensional geometries. This can drastically reduce the number of grid points in many applications. Both integer and non-integer refinement ratios are allowed. The report begins by developing an algorithm for choosing basis functions that yield the desired mesh resolution. These functions are suitable products of one-dimensional B-splines. Finally, test cases for linear scalar equations such as the Poisson and advection equation are presented. The scheme is conservative and has uniformly high order of accuracy throughout the domain.

Shariff, Karim↗

NASA NTRS2010

Alternative Modal Basis Selection Procedures for Nonlinear Random Response Simulation

Three procedures to guide selection of an efficient modal basis in a nonlinear random response analysis are examined. One method is based only on proper orthogonal decomposition, while the other two additionally involve smooth orthogonal decomposition. Acoustic random response problems are employed to assess the performance of the three modal basis selection approaches. A thermally post-buckled beam exhibiting snap-through behavior, a shallowly curved arch in the auto-parametric response regime and a plate structure are used as numerical test articles. The results of the three reduced-order analyses are compared with the results of the computationally taxing simulation in the physical degrees of freedom. For the cases considered, all three methods are shown to produce modal bases resulting in accurate and computationally efficient reduced-order nonlinear simulations.

Przekop, Adam↗

NASA NTRS1992

Computational studies of metal-metal and metal-ligand interactions

The geometric structure of Cr(CO)6 is optimized at the modified coupled-pair functional (MCPF), single and double excitation coupled-cluster (CCSD) and CCSD(T) levels of theory (including a perturbational estimate for connected triple excitations), and the force constants for the totally symmetric representation are determined. The geometry of Cr(CO)5 is partially optimized at the MCPF, CCSD and CCSD(T) levels of theory. Comparison with experimental data shows that the CCSD(T) method gives the best results for the structures and force constants, and that remaining errors are probably due to deficiencies in the one-particle basis sets used for CO. A detailed comparison of the properties of free CO is therefore given, at both the MCPF and CCSD/CCSD(T) levels of treatment, using a variety of basis sets. With very large one-particle basis sets, the SSCD(T) method gives excellent results for the bond distance, dipole moment and harmonic frequency of free CO. The total binding energies of Cr(CO)6 and Cr(CO)5 are also determined at the MCPF, CCSD and CCSD(T) levels of theory. The CCSD(T) method gives a much larger total binding energy than either the MCPF or CCSD methods. An analysis of the basis set superposition error (BSSE) at the MCPF level of treatment points out limitations in the one-particle basis used here and in a previous study. Calculations using larger basis sets reduced the BSSE, but the total binding energy of Cr(CO)6 is still significantly smaller than the experimental value, although the first CO bond dissociation energy of Cr(CO)6 is well described. An investigation of 3s3p correlation reveals only a small effect. The remaining discrepancy between the experimental and theoretical total binding energy of Cr(CO)6 is probably due to limitations in the one-particle basis, rather than limitations in the correlation treatment. In particular an additional d function and an f function on each C and O are needed to obtain quantitative results. This is underscored by the fact that even using a very large primitive se (1042 primitive functions contracted to 300 basis functions), the superposition error for the total binding energy of Cr(CO)6 is 22 kcal/mol at the MCPF level of treatment.

Barnes, Leslie A.↗

NASA NTRS1998

The Dissociation Energies of He2, HeH, and ArH; A Bond Function Study

The bond energies and bond lengths are determined for He2, HeH, and ArH at the CCSD(T) level using both atom-centered basis sets and those that include bond functions. The addition of bond functions dramatically improves the rate of convergence of the results with respect to the size of the atom-centered basis set; with bond functions, triple zeta atom-centered basis set, outperform quintuple zeta basis sets without bond functions. The addition of bond functions also reduces the number of diffuse functions that must be added to the atom-centered sets. Employing bond functions appear to offer a very cost effective method of computing the interaction between weakly bound systems, especially for He.

Bauschlicher, Charles W., Jr.↗

NASA NTRS1990

Reduced and simplified chemical kinetics for air dissociation using Computational Singular Perturbation

The Computational Singular Perturbation CSP methods is employed (1) in the modeling of a homogeneous isothermal reacting system and (2) in the numerical simulation of the chemical reactions in a hypersonic flowfield. Reduced and simplified mechanisms are constructed. The solutions obtained on the basis of these approximate mechanisms are shown to be in very good agreement with the exact solution based on the full mechanism. Physically meaningful approximations are derived. It is demonstrated that the deduction of these approximations from CSP is independent of the complexity of the problem and requires no intuition or experience in chemical kinetics.

Goussis, D. A.↗

NASA NTRS1993

Technical support for digital systems technology development. Task order 1: ISP contention analysis and control

Alternatives for realizing a packet-based network switch for use on a frequency division multiple access/time division multiplexed (FDMA/TDM) geostationary communication satellite were investigated. Each of the eight downlink beams supports eight directed dwells. The design needed to accommodate multicast packets with very low probability of loss due to contention. Three switch architectures were designed and analyzed. An output-queued, shared bus system yielded a functionally simple system, utilizing a first-in, first-out (FIFO) memory per downlink dwell, but at the expense of a large total memory requirement. A shared memory architecture offered the most efficiency in memory requirements, requiring about half the memory of the shared bus design. The processing requirement for the shared-memory system adds system complexity that may offset the benefits of the smaller memory. An alternative design using a shared memory buffer per downlink beam decreases circuit complexity through a distributed design, and requires at most 1000 packets of memory more than the completely shared memory design. Modifications to the basic packet switch designs were proposed to accommodate circuit-switched traffic, which must be served on a periodic basis with minimal delay. Methods for dynamically controlling the downlink dwell lengths were developed and analyzed. These methods adapt quickly to changing traffic demands, and do not add significant complexity or cost to the satellite and ground station designs. Methods for reducing the memory requirement by not requiring the satellite to store full packets were also proposed and analyzed. In addition, optimal packet and dwell lengths were computed as functions of memory size for the three switch architectures.

Stehle, Roy H.↗