The structure and performance of the aerospace industry.
Book on structure and performance of aerospace industry and governmental relations
AIRCRAFT INDUSTRY↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Modeling Framework to Analyze Performance and Structural Reliability of Solid Oxide Electrolysis Cells
Solid oxide electrolysis cells (SOEC) have been receiving significant attention recently because of their high energy efficiency and fast hydrogen production. In this study a multi-physics model to simulate the SOEC performance and structural reliability of a state-of-the-art planar SOEC design was developed. The electrochemical reactions, fluid dynamics, species transport, electron transfer, and heat transfer were modeled in the commercial computational fluid dynamics (CFD) software STAR-CCM+. The thermomechanical analysis and the associated structural reliability evaluations were conducted using the commercial finite element analysis software ANSYS. The electrochemistry model was validated by using the experimentally obtained current-voltage (I-V) characteristics of the electrode-supported SOECs. The reliability analysis using a risk-of-rupture approach showed low failure probabilities under standard operating conditions considered in this study. For cells operated at voltages well above a thermoneutral voltage, the reliability evaluations indicated a potential risk of cell failure, but the damage was concentrated locally in specific areas of the cell which typically do not lead to total loss of cell function. The presented approach provides insights for evaluating representative cell and stack performances and structural reliability without intensive testing and for developing optimally performing and structurally reliable SOECs for efficient hydrogen generation.
25 ENERGY STORAGE↗
Insulation commonality assessment (phase 1). Volume 2: Section 7.0 through 16.0
The heat transfer characteristics of various materials used for the thermal insulation of spacecraft are discussed. Techniques for conducting thermal performance analysis, structural performance analysis, and dynamic analysis are described. Processes for producing and finishing the materials are explained. The methods for determining reliability, system safety, materials tests, and design effectiveness are explained.
Source record↗
Composite transport wing technology development: Design development tests and advanced structural concepts
Numerous design concepts, materials, and manufacturing methods were investigated for the covers and spars of a transport box wing. Cover panels and spar segments were fabricated and tested to verify the structural integrity of design concepts and fabrication techniques. Compression tests on stiffened panels demonstrated the ability of graphite/epoxy wing upper cover designs to achieve a 35 percent weight savings compared to the aluminum baseline. The impact damage tolerance of the designs and materials used for these panels limits the allowable compression strain and therefore the maximum achievable weight savings. Bending and shear tests on various spar designs verified an average weight savings of 37 percent compared to the aluminum baseline. Impact damage to spar webs did not significantly degrade structural performance. Predictions of spar web shear instability correlated well with measured performance. The structural integrity of spars manufactured by filament winding equalled or exceeded those fabricated by hand lay-up. The information obtained will be applied to the design, fabrication, and test of a full-scale section of a wing box. When completed, the tests on the technology integration box beam will demonstrate the structural integrity of an advanced composite wing design which is 25 percent lighter than the metal baseline.
Griffin, Charles F.↗
Compressive testing of filament-wound cylinders
An experimental investigation has been conducted on the compressive buckling and failure of filament-wound circular cylinders. This investigation identifies one of the relationships between structural performance and scale, as well as some of the causes of reduced structural performance in large-scale structures. It is hypothesized that this effect is related to two conditions: first, the number of fiber tow undulations; and second, the percentage of weak interfaces within the structure. The effect of winding pattern and the resulting location of the fiber undulations were studied by varying the winding parameters. Three types of cylinders were manufactured from Amoco T650-35/1908 graphite/epoxy preimpregnated tow with different winding sequences (0/+/-60)s, (+/-30/90)s, and (90/+/-30)s. The (90/+/-30)s cylinders were manufactured with two different winding patterns (distributed and classical) and radius-to-thickness ratios (15 and 55). All cylinders were loaded in compression to failure. Comparisons of the compressive strength and failure modes demonstrate the relationship between the winding parameters, scale, and structural performance of filament-wound composite cylinders.
Jensen, David W.↗
Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency
Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedstock materials for thermoforming, with flexural and tensile testing performed both along the primary fiber direction and in the off-axis orientation to establish baseline stiffness, strength, and anisotropy. As expected, short carbon fiber PETG exhibited the highest stiffness and strength in the primary fiber direction, while all systems showed reduced performance in the off-axis direction. This off-axis performance reduction provides clear justification for the use of additive reinforcement when such thermoformed sheets are intended for structural applications. The intended manufacturing sequence involves thermoforming the reinforced sheet first, followed by the application of additively manufactured lattice reinforcement; therefore, the reinforcement strategy does not impose limitations on sheet formability during thermoforming. Post-forming lattice reinforcement significantly reduced load-normalized displacement by approximately 95–99% relative to non-reinforced sheets and improved weight-normalized stiffness by ~70%. These findings demonstrate that geometry-driven additive reinforcement can effectively compensate for off-axis property reductions in thermoformed PETG composites, enabling enhanced multidirectional structural performance without compromising manufacturability.
Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
Robust Damage-Mitigating Control of Aircraft for High Performance and Structural Durability
This paper presents the concept and a design methodology for robust damage-mitigating control (DMC) of aircraft. The goal of DMC is to simultaneously achieve high performance and structural durability. The controller design procedure involves consideration of damage at critical points of the structure, as well as the performance requirements of the aircraft. An aeroelastic model of the wings has been formulated and is incorporated into a nonlinear rigid-body model of aircraft flight-dynamics. Robust damage-mitigating controllers are then designed using the H(infinity)-based structured singular value (mu) synthesis method based on a linearized model of the aircraft. In addition to penalizing the error between the ideal performance and the actual performance of the aircraft, frequency-dependent weights are placed on the strain amplitude at the root of each wing. Using each controller in turn, the control system is put through an identical sequence of maneuvers, and the resulting (varying amplitude cyclic) stress profiles are analyzed using a fatigue crack growth model that incorporates the effects of stress overload. Comparisons are made to determine the impact of different weights on the resulting fatigue crack damage in the wings. The results of simulation experiments show significant savings in fatigue life of the wings while retaining the dynamic performance of the aircraft.
Caplin, Jeffrey↗
Effects of Ink Formulation on the Structure and Performance of PGM-Free Catalyst Layer in PEMFCs
Platinum group metal (PGM) catalysts are the major electrocatalysts for oxygen reduction reaction (ORR) in the polymer electrolyte membrane fuel cells (PEMFCs). The cost becomes unaffordable if the PEMFC is in massive application. The PGM-Free catalyst shows very promising activity in rotation disk electrode (RDE) testing. The half-wave potential could reach 0.91 V versus standard hydrogen electrode (SHE). However, in a membrane electrode assembly (MEA), the performance of PGM-Free catalysts is not good enough to replace the PGM catalysts. Since the PGM-free catalysts are so different from the PGM catalysts in terms of catalytic activity, stability, surface conditions, particle size, etc., the fabrication of PGM-Free catalyst MEA cannot simply copy the method of making PGM MEA. Here we proposed a novel method of fabricating PGM-Free catalyst MEA, so that the intrinsic catalyst activity from RDE can be translated into MEA performance. The method is based on the catalyst coated membrane (CCM) method using optimized ionomer to carbon (I/C) ratio and solvent mixture of catalyst ink. Using this method, the PGM-free catalyst MEA achieved the current density 44.9 mA cm -2 at 0.9 V iR-free in H 2 /O 2 and 150 mA cm -2 at 0.8 V in H 2 /air, which surpassed the performance targets of US Department of Energy (DOE)for PGM-Free catalyst MEA. The property (solvent composition, dispersion of catalyst and ionomer in an ink), structure (pore structure) and the MEA performance have been characterized using, mercury intrusion porosimetry (MIP), MEA testing. A property-structure-performance relationship has been established.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Performance and structural tests of hot-air solar collectors
Report describes program to determine thermal performance and structural characteristics of selected hot-air collectors in both real and simulated environmental conditions.
Shih, K.↗
On-orbit structural dynamic performance of a low-frequency microwave radiometer for Mission to Planet Earth applications
The present paper addresses the on-orbit dynamic performance of a low-frequency microwave radiometer for earth science applications. The radiometer is one of the earth-observing instruments aboard a geostationary platform proposed as part of the Mission to Planet Earth. The paper includes establishing the structural requirements of the antenna, developing the structural and disturbance models, performing modal and forced response analyses, and evaluating the resulting distortions in terms of the antenna's ability to meet stringent structural performance requirements. Two antenna configurations are discussed: free-flying and platform-mounted. These configurations are analyzed for a representative disturbance function which simulates rotation of the subreflector in order to perform a raster-type scan of the earth disk. Results show that the scanning maneuver modeled did not induce antenna performance errors which were outside their estimated limits.
Wahls, Deborah M.↗
Verifying the structure-property-performance relationship of Y6-based small molecule acceptors by alkoxy-side chain isomerization and conjugated skeleton asymmetry
Non-fullerene small molecule acceptors (NF-SMAs) such as Y6 derivatives were the current working horse for the top performing polymer solar cells (PSCs). For this reason, numerous chemical modifications have been explored for establishing structure–property-performance relationship for Y6-based NF-SMAs. In this work, we explored the isomerization on asymmetrical Y6 derivatives by varying the position of alkoxy side chain on the thiophene linkage between the core and one of the end groups of Y6. The isomers with differences in conformational restriction raised by noncovalent interactions as well as steric hindrance revealed distinctive behavior in crystallization and polymorphism, which led to a significant contrast in PSC performances. Here the X-TO1 molecule with alkoxy side chain facing the end group (outward) displayed preferred molecular configuration and polymorph, delivering power conversion efficiency (PCE) of 15.63%, while its isomer X-TO2 showed coexisted polymorphs significantly increased the charge recombination in the PSC devices led to a low PCE around 3%. This structure–property-performance relationship not only highlighted the elegancy of isomerization in tuning the photovoltaic performances but also identified polymorphism as one of the causes for impairing photovoltaic performances of PSCs.
36 MATERIALS SCIENCE↗
High-performance deployable structures for the support of high-concentration ratio solar array modules
A study conducted on high-performance deployable structures for the support of high-concentration ratio solar array modules is discussed. Serious consideration is being given to the use of high-concentration ratio solar array modules or applications such as space stations. These concentrator solar array designs offer the potential of reduced cost, reduced electrical complexity, higher power per unit area, and improved survivability. Arrays of concentrators, such as the miniaturized Cassegrainian concentrator modules, present a serious challenge to the structural design because their mass per unit area (5.7 kg/square meters) is higher than that of flexible solar array blankets, and the requirement for accurate orientation towards the Sun (plus or minus 0.5 degree) requires structures with improved accuracy potentials. In addition, use on a space station requires relatively high structural natural frequencies to avoid deleterious interactions with control systems and other large structural components. The objective here is to identify and evaluate conceptual designs of structures suitable for deploying and accurately supporting high-concentration ratio solar array modules.
Mobrem, M.↗
Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing
Computer vision and deep learning tools that advance the ability to establish processing-structure-property-performance (PSPP) relations are presented. The Bayesian binning method for image segmentation enables quantitative analysis of microstructural features in an automated way, while the analysis of shapes and relative orientation of these features reveals local deformation maps indicative of both, material flow and residual stresses due to materials processing. The deep learning method leads to the previous knowledge agnostic mapping of empirically observed microstructural zones in friction stir welding (FSW) process and synthetic microstructure generation capability that is statistically equivalent to experimentally collected data.
97 MATHEMATICS AND COMPUTING↗
Advanced Lightweight Metallic Fuselage Project Manufacturing Trade Study
Recent advances in large-scale flow forming of integrally stiffened cylinders (ISCs) have motivated evaluation of available technologies for rapid manufacturing of metallic fuselages. The current state-of-the-art in flow forming of ISCs produces 10-ft. diameter, 5-ft. long barrels with integral longitudinal blade stiffeners, and these single-piece ISCs are produced in approximately 1.5 hours. While other manufacturing processes are required to incorporate additional structural elements (ASE) such as circumferential ring frames, reinforcements around window and door cut-outs, and floors to the ISCs to complete the fuselage structure, flow forming technology may assist the aerospace industry in meeting manufacturing rate demands. In order to evaluate this technology, a fuselage manufacturing demonstration article (MDA) fabricated from two ISCs is scheduled for fabrication and delivery to NASA Langley Research Center (LaRC) by the end of 2022. In this study, eight manufacturing technologies were assessed to downselect candidate manufacturing processes for adding ASE to complete the MDA. A literature review and evaluation of contractor-produced panels covering a spectrum of welding and additive manufacturing (AM) processes were conducted at NASA LaRC. The analytical hierarchy process (AHP) was used to evaluate figures of merit (FOMs) for selecting manufacturing process(es) to integrate ASE with the ISCs to form a fuselage MDA. The AHP results revealed that scalability, structural performance, and distortion control were the most valued criteria for downselecting the manufacturing process to construct the internal stiffening structures. Based on the FOMs, this study concluded that a welding process is best suited for integrating the majority of the ASE, namely the circumferential ring frames. All of the welding processes received higher scores than AM processes due to higher maturity, higher structural performance, fewer post-processing requirements in machining and heat treating, and faster deposition rates. Among the welding processes, cold metal transfer (CMT) welding was ranked the most favorable process for assembling the MDA, with the other welding processes (laser welding (LW), friction stir welding (FSW), and refill friction stir spot welding (RFSSW)) scoring slightly lower. This was a consequence of the perceived maturity of the CMT welding process and its relatively high structural performance and low distortion resulting from the low heat input. Among the AM processes, CMT AM showed the greatest promise due to benefits derived from its scalability, lower 1st order process complexity, and low distortion. The AM processes may have potential for select applications, such as adding structural reinforcements around window and door cut-outs, but are not considered optimal for integrating the entire MDA.
Manufacturing↗
Evaluation of the impact performance of realistic space structures
Impact performance of composite spacecraft structures
IMPACT DAMAGE↗
Acoustic and Thermal Testing of an Integrated Multilayer Insulation and Broad Area Cooling Shield System
A Multilayer Insulation (MLI) and Broad Area Cooling (BAC) shield thermal control system shows promise for long-duration storage of cryogenic propellant. The NASA Cryogenic Propellant Storage and Transfer (CPST) project is investigating the thermal and structural performance of this tank-applied integrated system. The MLI/BAC Shield Acoustic and Thermal Test was performed to evaluate the MLI/BAC shield's structural performance by subjecting it to worst-case launch acoustic loads. Identical thermal tests using Liquid Nitrogen (LN2) were performed before and after the acoustic test. The data from these tests was compared to determine if any degradation occurred in the thermal performance of the system as a result of exposure to the acoustic loads. The thermal test series consisted of two primary components: a passive boil-off test to evaluate the MLI performance and an active cooling test to evaluate the integrated MLI/BAC shield system with chilled vapor circulating through the BAC shield tubes. The acoustic test used loads closely matching the worst-case envelope of all launch vehicles currently under consideration for CPST. Acoustic test results yielded reasonable responses for the given load. The thermal test matrix was completed prior to the acoustic test and successfully repeated after the acoustic test. Data was compared and yielded near identical results, indicating that the MLI/BAC shield configuration tested in this series is an option for structurally implementing this thermal control system concept.
Wood, J. J.↗
Acoustic and Thermal Testing of an Integrated Multilayer Insulation and Broad Area Cooling Shield System
A Multilayer Insulation (MLI) and Broad Area Cooling (BAC) shield thermal control system shows promise for long-duration storage of cryogenic propellant. The NASA Cryogenic Propellant Storage and Transfer (CPST) project is investigating the thermal and structural performance of this tank-applied integrated system. The MLI/BAC Shield Acoustic and Thermal Test was performed to evaluate the MLI/BAC shield's structural performance by subjecting it to worst-case launch acoustic loads. Identical thermal tests using Liquid Nitrogen (LN2) were performed before and after the acoustic test. The data from these tests was compared to determine if any degradation occurred in the thermal performance of the system as a result of exposure to the acoustic loads. The thermal test series consisted of two primary components: a passive boil-off test to evaluate the MLI performance and an active cooling test to evaluate the integrated MLI/BAC shield system with chilled vapor circulating through the BAC shield tubes. The acoustic test used loads closely matching the worst-case envelope of all launch vehicles currently under consideration for CPST. Acoustic test results yielded reasonable responses for the given load. The thermal test matrix was completed prior to the acoustic test and successfully repeated after the acoustic test. Data was compared and yielded near identical results, indicating that the MLI/BAC shield configuration tested in this series is an option for structurally implementing this thermal control system concept.
Wood, Jessica J.↗
Parametric studies of advanced turboprops
The effects of geometric variables (sweep and twist) on the structural performance of advanced turboprops are investigated. The investigation is limited to aerodynamically efficient turboprops using an acceptable design configuration as a baseline. The baseline configuration is modified using a seven by seven array of independently varying sweep and twist parameters while maintaining acceptable aerodynamic efficiency. The turboprop structural performance is evaluated in terms of critical speeds, tip displacements, and vibration frequencies where geometric nonlinearities are included. The results obtained are presented in such a manner as to highlight the effects of sweep and twist on the structural performance of aerodynamically efficient turboprop configurations.
Fertis, D. G.↗