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NASA NTRS2003

Neural-Net Based Optical NDE Method for Structural Health Monitoring

This paper answers some performance and calibration questions about a non-destructive-evaluation (NDE) procedure that uses artificial neural networks to detect structural damage or other changes from sub-sampled characteristic patterns. The method shows increasing sensitivity as the number of sub-samples increases from 108 to 6912. The sensitivity of this robust NDE method is not affected by noisy excitations of the first vibration mode. A calibration procedure is proposed and demonstrated where the output of a trained net can be correlated with the outputs of the point sensors used for vibration testing. The calibration procedure is based on controlled changes of fastener torques. A heterodyne interferometer is used as a displacement sensor for a demonstration of the challenges to be handled in using standard point sensors for calibration.

Decker, Arthur J.↗

NASA NTRS2003

Sensitivity and Calibration of Non-Destructive Evaluation Method That Uses Neural-Net Processing of Characteristic Fringe Patterns

Decker, Arthur J.↗

NASA NTRS2004

Fully Suspended, Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig With Forced Excitation

The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig, a significant advancement in the Dynamic Spin Rig (DSR), is used to perform vibration tests of turbomachinery blades and components under rotating and nonrotating conditions in a vacuum. The rig has as its critical components three magnetic bearings: two heteropolar radial active magnetic bearings and a magnetic thrust bearing. The bearing configuration allows full vertical rotor magnetic suspension along with a feed-forward control feature, which will enable the excitation of various natural blade modes in bladed disk test articles. The theoretical, mechanical, electrical, and electronic aspects of the rig are discussed. Also presented are the forced-excitation results of a fully levitated, rotating and nonrotating, unbladed rotor and a fully levitated, rotating and nonrotating, bladed rotor in which a pair of blades was arranged 180 degrees apart from each other. These tests include the bounce mode excitation of the rotor in which the rotor was excited at the blade natural frequency of 144 Hz. The rotor natural mode frequency of 355 Hz was discerned from the plot of acceleration versus frequency. For nonrotating blades, a blade-tip excitation amplitude of approximately 100 g/A was achieved at the first-bending critical (approximately 144 Hz) and at the first-torsional and second-bending blade modes. A blade-tip displacement of 70 mils was achieved at the first-bending critical by exciting the blades at a forced-excitation phase angle of 908 relative to the vertical plane containing the blades while simultaneously rotating the shaft at 3000 rpm.

Morrison, Carlos R.↗

NASA NTRS2004

International Space Station (ISS) Low Pressure Intramodule Quick Disconnect Failures

A failure of an ISS intermodule Quick Disconnect (QD) during protoflight vibration testing of ISS regenerative Environmental Control and Life Support (ECLS) hardware led to the discovery of QD design, manufacturing, and test flaws which can yield the male QD susceptible to failure of the secondary housing seal and inadequate housing assembly locking mechanisms. Discovery of this failure had large implications when considering that currently there are 399 similar units on orbit and approximately 1100 units on the ground integrated into flight hardware. Discovery of the nature of the failure required testing and analysis and implementation of a recovery plan requiring part screening and review of element level and project hazard analysis to determine if secondary seals are required. Implementation also involves coordination with the Nodes and MPLM project offices, Regenerative ECLS Project, ISS Payloads, JAXA, ESA, and ISS Logistics and Maintenance.

Lewis, John F.↗

NASA NTRS2007

Measuring a Precise Ultra-Lightweight Spaceflight Mirror on Earth: The Analysis of the SHARPI PM Mirror Figure Data during Mirror Processing at GSFC

The SHARPI (Solar High Angular Resolution Photometric Imager) primary mirror is a 5kg, 0.5m paraboloid, diffraction limited at FUV wavelengths when placed in a 0-G environment. The ULE sandwich honeycomb mirror and the attached mount pads were delivered by ITT (then Kodak) in 2003 to NASA s Goddard Space Flight Center (GSFC). At GSFC, we accepted, coated, mounted, and vibration tested this mirror in preparation for flight on the PICTURES (Planet Imaging Concept Testbed Using a Rocket Experiment) mission. At each step, the integrated analysis of interferometer data and FEA models was essential to quantify the 0-G mirror figure. This task required separating nanometer sized variations from hundreds of nanometers of gravity induced distortion. The ability to isolate such features allowed in-situ monitoring of mirror figure, diagnosis of perturbations, and remediation of process errors. In this paper, we describe the technical approach used to achieve these measurements and overcome the various difficulties maintaining UV diffraction-limited performance with this aggressively lightweighted mirror.

Antonille, Scott↗

NASA NTRS2008

Design of an Indoor Sonic Boom Simulator at NASA Langley Research Center

Construction of a simulator to recreate the soundscape inside residential buildings exposed to sonic booms is scheduled to start during the summer of 2008 at NASA Langley Research Center. The new facility should be complete by the end of the year. The design of the simulator allows independent control of several factors that create the indoor soundscape. Variables that will be isolated include such factors as boom duration, overpressure, rise time, spectral shape, level of rattle, level of squeak, source of rattle and squeak, level of vibration and source of vibration. Test subjects inside the simulator will be asked to judge the simulated soundscape, which will represent realistic indoor boom exposure. Ultimately, this simulator will be used to develop a functional relationship between human response and the sound characteristics creating the indoor soundscape. A conceptual design has been developed by NASA personnel, and is currently being vetted through small-scale risk reduction tests that are being performed in-house. The purpose of this document is to introduce the conceptual design, identify how the indoor response will be simulated, briefly outline some of the risk reduction tests that have been completed to vet the design, and discuss the impact of these tests on the simulator design.

Klos, Jacob↗

NASA NTRS2008

Rotor Airloads Prediction Using Unstructured Meshes and Loose CFD/CSD Coupling

The FUN3D unsteady Reynolds-averaged Navier-Stokes solver for unstructured grids has been modified to allow prediction of trimmed rotorcraft airloads. The trim of the rotorcraft and the aeroelastic deformation of the rotor blades are accounted for via loose coupling with the CAMRAD II rotorcraft computational structural dynamics code. The set of codes is used to analyze the HART-II Baseline, Minimum Noise and Minimum Vibration test conditions. The loose coupling approach is found to be stable and convergent for the cases considered. Comparison of the resulting airloads and structural deformations with experimentally measured data is presented. The effect of grid resolution and temporal accuracy is examined. Rotorcraft airloads prediction presents a very substantial challenge for Computational Fluid Dynamics (CFD). Not only must the unsteady nature of the flow be accurately modeled, but since most rotorcraft blades are not structurally stiff, an accurate simulation must account for the blade structural dynamics. In addition, trim of the rotorcraft to desired thrust and moment targets depends on both aerodynamic loads and structural deformation, and vice versa. Further, interaction of the fuselage with the rotor flow field can be important, so that relative motion between the blades and the fuselage must be accommodated. Thus a complete simulation requires coupled aerodynamics, structures and trim, with the ability to model geometrically complex configurations. NASA has recently initiated a Subsonic Rotary Wing (SRW) Project under the overall Fundamental Aeronautics Program. Within the context of SRW are efforts aimed at furthering the state of the art of high-fidelity rotorcraft flow simulations, using both structured and unstructured meshes. Structured-mesh solvers have an advantage in computation speed, but even though remarkably complex configurations may be accommodated using the overset grid approach, generation of complex structured-mesh systems can require months to set up. As a result, many rotorcraft simulations using structured-grid CFD neglect the fuselage. On the other hand, unstructured-mesh solvers are easily able to handle complex geometries, but suffer from slower execution speed. However, advances in both computer hardware and CFD algorithms have made previously state-of-the-art computations routine for unstructured-mesh solvers, so that rotorcraft simulations using unstructured grids are now viable. The aim of the present work is to develop a first principles rotorcraft simulation tool based on an unstructured CFD solver.

Biedron, Robert T.↗

NASA NTRS2008

Vibration Performance Comparison Study on Current Fiber Optic Connector Technologies

Fiber optic cables are increasingly being used in harsh environments where they are subjected to vibration. Understanding the degradation in performance under these conditions is essential for integration of the fibers into the given application. System constraints oftentimes require fiber optic connectors so subsystems can be removed or assembled as needed. In the present work, various types of fiber optic connectors were monitored in-situ during vibration testing to examine the transient change in optical transmission and the steady-state variation following the event. Inspection of the fiber endfaces and connectors was performed at chosen intervals throughout the testing.

Ott, Melanie N.↗

NASA NTRS2007

Build-Up Approach to Updating the Mock Quiet Spike Beam Model

When a new aircraft is designed or a modification is done to an existing aircraft, the aeroelastic properties of the aircraft should be examined to ensure the aircraft is flight worthy. Evaluating the aeroelastic properties of a new or modified aircraft can include performing a variety of analyses, such as modal and flutter analyses. In order to produce accurate results from these analyses, it is imperative to work with finite element models (FEM) that have been validated by or correlated to ground vibration test (GVT) data, Updating an analytical model using measured data is a challenge in the area of structural dynamics. The analytical model update process encompasses a series of optimizations that match analytical frequencies and mode shapes to the measured modal characteristics of structure. In the past, the method used to update a model to test data was "trial and error." This is an inefficient method - running a modal analysis, comparing the analytical results to the GVT data, manually modifying one or more structural parameters (mass, CG, inertia, area, etc.), rerunning the analysis, and comparing the new analytical modal characteristics to the GVT modal data. If the match is close enough (close enough defined by analyst's updating requirements), then the updating process is completed. If the match does not meet updating-requirements, then the parameters are changed again and the process is repeated. Clearly, this manual optimization process is highly inefficient for large FEM's and/or a large number of structural parameters. NASA Dryden Flight Research Center (DFRC) has developed, in-house, a Mode Matching Code that automates the above-mentioned optimization process, DFRC's in-house Mode Matching Code reads mode shapes and frequencies acquired from GVT to create the target model. It also reads the current analytical model, as we11 as the design variables and their upper and lower limits. It performs a modal analysis on this model and modifies it to create an updated model that has similar mode shapes and frequencies as those of the target model. The Mode Matching Code output frequencies and modal assurance criteria (MAC) values that allow for the quantified comparison of the updated model versus the target model. A recent application of this code is the F453 supersonic flight testing platform, NASA DFRC possesses a modified F-15B that is used as a test bed aircraft for supersonic flight experiments. Traditionally, the finite element model of the test article is generated. A GVT is done on the test article ta validate and update its FEM. This FEM is then mated to the F-15B model, which was correlated to GVT data in fall of 2004, A GVT is conducted with the test article mated to the aircraft, and this mated F-15B/ test article FEM is correlated to this final GVT.

Herrera, Claudia Y.↗

NASA NTRS2009

Prediction of Spacecraft Vibration using Acceleration and Force Envelopes

The base forces in the GLAST X- and Z-axis sine vibration tests were similar to those derived using generic inputs (from users guide and handbook), but the base forces in the sine test were generally greater than the flight data. Basedrive analyses using envelopes of flight acceleration data provided more accurate predictions of the base force than generic inputs, and as expected, using envelopes of both the flight acceleration and force provided even more accurate predictions The GLAST spacecraft interface accelerations and forces measured during the MECO transient were relatively low in the 60 to 150 Hz regime. One may expect the flight forces measured at the base of various spacecraft to be more dependent on the mass, frequencies, etc. of the spacecraft than are the corresponding interface acceleration data, which may depend more on the launch vehicle configuration.

Gordon, Scott↗

NASA NTRS2009

The Fiber Optic Subsystem Components on Express Logistics Carrier for International Space Station

ISS SSP 50184 HRDL optical fiber communication subsystem, has system level requirements that were changed to accommodate large loss optical fiber links previously installed. SSQ22680 design is difficult to implement, no metal shell over socket/pin combination to protect the weak part of the pin. Additions to ISS are planned for the future. AVIM still used for interconnection in space flight applications without incident. Thermal cycling resulted in less than 0.25 dB max change in Insertion Loss for all types during cycling, nominal as compared to the AVIM. Vibration testing results conclusion; no significant changes, nominal as compared to AVIM.

Ott, Melanie N.↗

NASA NTRS2009

Got Mercury?

Many of the operational and payload lighting units used in various spacecraft contain elemental mercury. If these devices were damaged on-orbit, elemental mercury could be released into the cabin. Although there are plans to replace operational units with alternate light sources, such as LEDs, that do not contain mercury, mercury-containing lamps efficiently produce high quality illumination and may never be completely replaced on orbit. Therefore, exposure to elemental mercury during spaceflight will remain possible and represents a toxicological hazard. Elemental mercury is a liquid metal that vaporizes slowly at room temperature. However, it may be completely vaporized at the elevated operating temperatures of lamps. Although liquid mercury is not readily absorbed through the skin or digestive tract, mercury vapors are efficiently absorbed through the respiratory tract. Therefore, the amount of mercury in the vapor form must be estimated. For mercury releases from lamps that are not being operated, we utilized a study conducted by the New Jersey Department of Environmental Quality to calculate the amount of mercury vapor expected to form over a 2-week period. For longer missions and for mercury releases occurring when lamps are operating, we conservatively assumed complete volatilization of the available mercury. Because current spacecraft environmental control systems are unable to remove mercury vapors, both short-term and long-term exposures to mercury vapors are possible. Acute exposure to high concentrations of mercury vapors can cause irritation of the respiratory tract and behavioral symptoms, such as irritability and hyperactivity. Chronic exposure can result in damage to the nervous system (tremors, memory loss, insomnia, etc.) and kidneys (proteinurea). Therefore, the JSC Toxicology Group recommends that stringent safety controls and verifications (vibrational testing, etc.) be applied to any hardware that contains elemental mercury that could yield airborne mercury vapor concentrations greater than 0.1 mg/cu m in the total spacecraft atmosphere for exposures lasting 30 days or less or 0.01 mg/cu m mercury vapor for exposures lasting more than 30 days. We also encourage the use of alternative devices that do not contain mercury.

Meyers, Valerie E.↗

NASA NTRS2011

Safe, Advanced, Adaptable Isolation System Eliminates the Need for Critical Lifts

The Starr Soft Support isolation system incorporates an automatically reconfigurable aircraft jack into NASA's existing 1-Hertz isolators. This enables an aircraft to float in mid-air without the need for a critical lift during ground vibration testing (GVT), significantly reducing testing risk, time, and costs. Currently incorporating the most advanced technology available, the 60,000-poundcapacity (27-metric-ton) isolation system is used for weight and measurement tests, control-surface free-play tests, and structural mode interaction tests without the need for any major reconfiguration, often saving days of time and significantly reducing labor costs. The Starr Soft Support isolation system consists of an aircraft-jacking device with three jacking points, each of which has an individual motor and accommodates up to 20,000 pounds (9 metric tons) for a total 60,000-pound (27-metric-ton) capacity. The system can be transported to the aircraft by forklift and placed at its jacking points using a pallet jack. The motors power the electric actuators, raising the aircraft above the ground until the landing gear can retract. Inflatable isolators then deploy, enabling the aircraft to float in mid-air, simulating a 1-Hertz free-free boundary condition. Inflatable isolators have been in use at NASA for years, enabling aircraft to literally float unsupported for highly accurate GVT. These isolators must be placed underneath the aircraft for this to occur. Traditionally, this is achieved by a critical lift a high-risk procedure in which a crane and flexible cord system are used to lift the aircraft. In contrast, the Starr Soft Support isolation system eliminates the need for critical lift by integrating the inflatable isolators into an aircraft jacking system. The system maintains vertical and horizontal isolating capabilities. The aircraft can be rolled onto the system, jacked up, and then the isolators can be inflated and positioned without any personnel needing to work underneath the aircraft. Also, the system accommodates changes in aircraft configuration, automatically adapting to changes in mass, and it can adjust the height of the isolators in one basic setup. Dryden personnel used the Starr Soft Support system to successfully perform a GVT on an F-15 being structurally modified by Gulfstream, Dryden's Gulfstream III used for science research and the crew exploration module and adaptor cone assembly.

Ginn, Starr↗

NASA NTRS2005

Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig

The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig is an apparatus for vibration testing of turbomachine blades in a vacuum at rotational speeds from 0 to 40,000 rpm. This rig includes (1) a vertically oriented shaft on which is mounted an assembly comprising a rotor holding the blades to be tested, (2) two actively controlled heteropolar radial magnetic bearings at opposite ends of the shaft, and (3) an actively controlled magnetic thrust bearing at the upper end of the shaft. This rig is a more capable successor to a prior apparatus, denoted the Dynamic Spin Rig (DSR), that included a vertically oriented shaft with a mechanical thrust bearing at the upper end and a single actively controlled heteropolar radial magnetic bearing at the lower end.

Morrison, Carlos R.↗

NASA NTRS2013

High Voltage Hall Accelerator Propulsion System Development for NASA Science Missions

NASA Science Mission Directorates In-Space Propulsion Technology Program is sponsoring the development of a 3.8 kW-class engineering development unit Hall thruster for implementation in NASA science and exploration missions. NASA Glenn Research Center and Aerojet are developing a high fidelity high voltage Hall accelerator (HiVHAc) thruster that can achieve specific impulse magnitudes greater than 2,700 seconds and xenon throughput capability in excess of 300 kilograms. Performance, plume mappings, thermal characterization, and vibration tests of the HiVHAc engineering development unit thruster have been performed. In addition, the HiVHAc project is also pursuing the development of a power processing unit (PPU) and xenon feed system (XFS) for integration with the HiVHAc engineering development unit thruster. Colorado Power Electronics and NASA Glenn Research Center have tested a brassboard PPU for more than 1,500 hours in a vacuum environment, and a new brassboard and engineering model PPU units are under development. VACCO Industries developed a xenon flow control module which has undergone qualification testing and will be integrated with the HiVHAc thruster extended duration tests. Finally, recent mission studies have shown that the HiVHAc propulsion system has sufficient performance for four Discovery- and two New Frontiers-class NASA design reference missions.

Kamhawi, Hani↗

NASA NTRS2013

Understanding How Kurtosis Is Transferred from Input Acceleration to Stress Response and Its Influence on Fatigue Llife

High cycle fatigue of metals typically occurs through long term exposure to time varying loads which, although modest in amplitude, give rise to microscopic cracks that can ultimately propagate to failure. The fatigue life of a component is primarily dependent on the stress amplitude response at critical failure locations. For most vibration tests, it is common to assume a Gaussian distribution of both the input acceleration and stress response. In real life, however, it is common to experience non-Gaussian acceleration input, and this can cause the response to be non-Gaussian. Examples of non-Gaussian loads include road irregularities such as potholes in the automotive world or turbulent boundary layer pressure fluctuations for the aerospace sector or more generally wind, wave or high amplitude acoustic loads. The paper first reviews some of the methods used to generate non-Gaussian excitation signals with a given power spectral density and kurtosis. The kurtosis of the response is examined once the signal is passed through a linear time invariant system. Finally an algorithm is presented that determines the output kurtosis based upon the input kurtosis, the input power spectral density and the frequency response function of the system. The algorithm is validated using numerical simulations. Direct applications of these results include improved fatigue life estimations and a method to accelerate shaker tests by generating high kurtosis, non-Gaussian drive signals.

Kihm, Frederic↗

NASA NTRS2014

The Effect of Drive Signal Limiting on High Cycle Fatigue Life Analysis

It is common practice to assume a Gaussian distribution of both the input acceleration and the response when modeling random vibration tests. In the laboratory, however, shaker controllers often limit the drive signal to prevent high amplitude peaks. The high amplitudes may either be truncated at a given level (socalled brick wall limiting or abrupt clipping), or compressed (soft limiting), resulting in drive signals which are no longer Gaussian. The paper first introduces several methods for limiting a drive signal, including brick wall limiting and compression. The limited signal is then passed through a linear time-invariant system representing a device under test. High cycle fatigue life predictions are subsequently made using spectral fatigue and rainflow cycle counting schemes. The life predictions are compared with those obtained from unclipped input signals. Some guidelines are provided to help the test engineer decide how clipping should be applied under different test scenarios.

Kihm, Frederic↗

NASA NTRS2015

Rapid State Space Modeling Tool for Rectangular Wing Aeroservoelastic Studies

This paper introduces a modeling and simulation tool for aeroservoelastic analysis of rectangular wings with trailing-edge control surfaces. The inputs to the code are planform design parameters such as wing span, aspect ratio, and number of control surfaces. Using this information, the generalized forces are computed using the doublet-lattice method. Using Roger's approximation, a rational function approximation is computed. The output, computed in a few seconds, is a state space aeroservoelastic model which can be used for analysis and control design. The tool is fully parameterized with default information so there is little required interaction with the model developer. All parameters can be easily modified if desired. The focus of this paper is on tool presentation, verification, and validation. These processes are carried out in stages throughout the paper. The rational function approximation is verified against computed generalized forces for a plate model. A model composed of finite element plates is compared to a modal analysis from commercial software and an independently conducted experimental ground vibration test analysis. Aeroservoelastic analysis is the ultimate goal of this tool, therefore, the flutter speed and frequency for a clamped plate are computed using damping-versus-velocity and frequency-versus-velocity analysis. The computational results are compared to a previously published computational analysis and wind-tunnel results for the same structure. A case study of a generic wing model with a single control surface is presented. Verification of the state space model is presented in comparison to damping-versus-velocity and frequency-versus-velocity analysis, including the analysis of the model in response to a 1-cos gust.

Modeling and Simulation↗