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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Motion Magnification to Visualize the Modes of Space Structures

Traditional structural testing involves using accelerometers and strain gages to measure the motion. While this traditional instrumentation suite has proven accurate, it is limited to capture data only in the discrete locations where the transducers are placed. Additionally, applying the instrumentation can be a difficult and labor intensive task. By using video cameras, the motion of the test article – such as a launch vehicle or launch vehicle payload – can be easily captured at any location in the field of view and easily visualized using a post-processing technique called Motion Magnification. It is also much easier to place video cameras to measure motion rather than having to place contact sensors, especially when placement locations can be limited on final flight hardware. Recently, a team of MIT Lincoln Laboratory (MITLL) and NASA Marshall Space Flight Center (MSFC) have been collaborating to use Motion Magnification to measure the dynamics of large space structures. This presentation will detail some of the results of this collaboration.

Eric Colby Stewart↗
NASA NTRS2022

Detecting Flow-Induced Vibration in Bellows

The NESC performed testing to determine if high-speed video techniques can be used to predict the onset of flow-induced vibrations (FIV) in bellows. A comprehensive test matrix was established to determine if Motion Magnification (MM) and Digital Image Correlation (DIC) can be used to determine the onset of FIV in straight and gimbaled bellows. Several of the tests were intended to determine if MM and DIC can establish the resonant frequencies of the bellows with no a priori knowledge. The results of the MM and DIC were compared with data from strain gages and microphones. Although the testing was limited to one single-ply unshielded bellows, this effort provided the proof-of-concept that MM and DIC are feasible methods for determining the onset of FIV in bellows.

Flow-induced vibration↗
NASA NTRSDate not supplied

Local Analysis-Test Correlation Of Tow-Steered Composite Shells With Small Cutouts

The prebuckling and postbuckling behavior of two composite tow-steered shells with small cutouts is assessed using nonlinear dynamic finite element analyses and compared in detail with experimental measurements. The cylindrical shells were manufactured without cutouts using an automated fiber placement system, where the shells’ fiber orientation angles vary continuously around the shell circumference from ±10 degrees on the axially stiff crown and keel, to ±45 degrees on the shear-stiff sides. The first shell with overlaps has laminate thickness variations on the crown and keel that result from application of all 24 tows during each pass of the fiber placement system. The second shell without overlaps uses the fiber placement system’s tow drop/add capability to achieve a more uniform shell wall thickness. An unreinforced cutout representing a passenger door on a commercial aircraft fuselage is machined into the side of each of the two shells. These shells with cutouts were tested in axial compression and buckled elastically in previous work. Detailed nonlinear finite element analysis results are compared with their corresponding measured local load-displacement and load-strain responses in prebuckling, at global buckling, and into a stable postbuckled state. Test data from displacement transducers, strain gages, and digital image correlation are extracted at the centers of the crown and keel, and at the middles of the top and left edges of the cutout. The overall agreement between these measured and analytical responses is excellent in prebuckling through global buckling, and very good from global buckling through postbuckling. As such, the excellent correlation observed here increases confidence in applying tow-steered composites in operational vehicles.

Composites↗
NASA NTRSDate not supplied

Local Analysis-Test Correlation Of Tow-Steered Composite Shells With Small Cutouts

The prebuckling and postbuckling behavior of two composite tow-steered shells with small cutouts is assessed using nonlinear dynamic finite element analyses and compared in detail with experimental measurements. The cylindrical shells were manufactured without cutouts using an automated fiber placement system, where the shells’ fiber orientation angles vary continuously around the shell circumference from ±10 degrees on the axially stiff crown and keel, to ±45 degrees on the shear-stiff sides. The first shell with overlaps has laminate thickness variations on the crown and keel that result from application of all 24 tows during each pass of the fiber placement system. The second shell without overlaps uses the fiber placement system’s tow drop/add capability to achieve a more uniform shell wall thickness. An unreinforced cutout representing a passenger door on a commercial aircraft fuselage is machined into the side of each of the two shells. These shells with cutouts were tested in axial compression and buckled elastically in previous work. Detailed nonlinear finite element analysis results are compared with their corresponding measured local load-displacement and load-strain responses in prebuckling, at global buckling, and into a stable postbuckled state. Test data from displacement transducers, strain gages, and digital image correlation are extracted at the centers of the crown and keel, and at the middles of the top and left edges of the cutout. The overall agreement between these measured and analytical responses is excellent in prebuckling through global buckling, and very good from global buckling through postbuckling. As such, the excellent correlation observed here increases confidence in applying tow-steered composites in operational vehicles.

Composites↗
NASA NTRS2023

Reduced-Order Modeling and Parameter Identification of Wind Tunnel Measurement Systems

We present a method to develop a physics-based, reduced-order model of a wind tunnel measurement system (including a sting, strain gage force balance, and test article) that can be used to predict the dynamics of the system. This reduced-order model is combined with a simple finite element beam model of a sting to estimate the dynamics of the full assembly. We make comparisons between a full finite element model and the hybrid reduced-order model to show that this hybrid reduced-order model is capable of predicting the first six natural frequencies to within 10% error. This technique could be used to identify reduced-order parameters for a large number of balances and stings, which could then be used to estimate the dynamics of different measurement assemblies.

Reduced-order Modeling↗
NASA NTRSDate not supplied

Reduced-Order Modeling and Parameter Identification of Wind Tunnel Measurement Systems

We present a method to develop a physics-based, reduced-order model of a wind tunnel measurement system (including a sting, strain gage force balance, and test article) that can be used to predict the dynamics of the system. This reduced-order model is combined with a simple finite element beam model of a sting to estimate the dynamics of the full assembly. We make comparisons between a full finite element model and the hybrid reduced-order model to show that this hybrid reduced-order model is capable of predicting the first six natural frequencies to within 10% error. This technique could be used to identify reduced-order parameters for a large number of balances and stings, which could then be used to estimate the dynamics of different measurement assemblies.

Reduced-order Modeling↗
NASA NTRSDate not supplied

Finite Element Contact Analysis and Redesign of Rotorcraft Planetary Gear Sets With Asymmetric Profiles

This article explores the use of asymmetric gear teeth for rotorcraft main rotor planetary gearsets. Two baseline designs having symmetric gear teeth were selected for redesign studies. Finite element-based contact analyses were used to compare designs. Bending stress predictions for the two existing baseline designs were compared to strain gage measurements to confirm the suitability of the modeling. The same modeling method is then used to assess design changes to improve the bending stress and contact pressure magnitudes using asymmetric tooth profiles. For the first redesign study, the selected gearset is mildly asymmetric, with a 4° difference in pressure angles between the two sides of a tooth. For the second redesign study, the selected gearset is strongly asymmetric with a 18° difference in pressure angles. The results demonstrate that the asymmetric tooth approach provides additional design flexibility toward balancing the contact stresses and bending stresses of the sun, planet, and ring members.

gear↗
NASA NTRSDate not supplied

Force Measurement for Wind Tunnel Facilities - Current Practices and Research Investments

This presentation will provide an introduction to strain gage balances (force transducers) used in NASA’s wind tunnel facilities. It will cover the breadth of wind tunnel applications using balances ranging from cryogenic facilities to facilities with aero heating affects. Specific areas of expertise including six-component balance design and calibration will also be discussed. Moreover, research areas including additive manufacturing of wind tunnel balances, the development of topology optimization tools to produce novel force transducer geometries, and dynamic force measurement will also be highlighted.

Wind tunnel balance↗
DOE OSTI2022

2.2.2.405 - Verdant/NREL Research Measurement Campaign

The marine renewable energy industry primarily uses thermoset composite materials for blades and other hydrodynamic components, which can have up to 50% reduction in strength when exposed to seawater and are not recyclable. Thermoplastic composite materials have been shown at a coupon-scale to have improved seawater saturated properties but have not been validated at full scale. The primary goal of the project is to demonstrate the structural properties of thermoplastic-fiberglass composite blades compared to epoxy-fiberglass composite blades in seawater at a tidal energy site on an operational turbine. Through this work, NREL manufactured, tested and deployed thermoplastic blades and a data acquisition system on Verdant Power's turbine TriFrame in the East River, NYC. The thermoplastic blades and DAQ were retrieved after a 6-month deployment with no signs of degradation and all cable connections, structural supports and strain gages had a 100% survival rate. The blades are currently undergoing post-deployment structural validation to compare their performance to traditional epoxy blades that were deployed for the same amount of time. This will increase confidence in thermoplastic materials and move it closer to commercial adoption, as well as increase confidence in the design of a DAQ and instrumentation method for a tidal turbine. However, due to an error in the DAQ software that was introduced after the DAQ and software were validated, there was no loads data collected during the deployment.

blade testing↗
NASA NTRS1998

Thin Film Sensors for Minimally-Intrusive Measurements in Harsh High Temperature Environment

Advanced thin film sensors are being developed to provide accurate surface temperature, heat flux and strain measurements for components used in hostile propulsion environments. These sensors are sputter deposited and microfabricated directly onto the test articles with no additional bonding agent. The thickness of the sensors is only a few micrometers which creates minimal disturbance of the gas flow over the test surface. Thus thin film sensors have the advantage over conventional wire- based sensors by providing minimally intrusive measurement and having a faster response. These thin film sensors are being developed for characterization of advanced materials and structures in hostile, high-temperature environments, and for validation of design codes. This paper presents the advances of three high temperature thin film sensor technologies developed at NASA Lewis Research Center: thermocouples, heat-flux gages and strain gages. The fabrication techniques of these thin film sensors which include physical vapor deposition, photolithography patterning and lead Wire attachment are described. Sensors demonstrations on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are presented. The advantages and limitations of thin film sensor technology are also discussed.

Lei, Jih-Fen↗
NASA NTRS1982

Benchmark notch test for life prediction

Aircraft gas turbine engine components are subjected to severe stress, temperature, and environmental conditions. Economic and reliabilty demands have prompted inordinate effort in development of analytic methods to predict stresses and strains in aircraft engines. There remains, however, the need to check or verify these analytical methodologies against actual experimental data measurements. The laser interferometric strain displacement gage was recognized as having the potential to accomplish this task and was employed in this program. The actual strains incurred at the root of a discontinuity in cyclically loaded test samples subjected to inelastic deformation at high temperature where creep deformation readily occur were measured. The steady-state, cyclic stress-strain response at the root of the discontinuity in the tested samples was analyzed for comparison with the measured results. A comprehensive set of local notch root strain measurements for a variety of load patterns in an Inconel 718 notch specimen at 649 C (1200 F) was obtained and documented using the laser interferometric strain displacement gage.

Domas, P. A.↗
NASA NTRS1982

Benchmark notch test for life prediction

The laser Interferometric Strain Displacement Gage (ISDG) was used to measure local strains in notched Inconel 718 test bars subjected to six different load histories at 649 C (1200 F) and including effects of tensile and compressive hold periods. The measurements were compared to simplified Neuber notch analysis predictions of notch root stress and strain. The actual strains incurred at the root of a discontinuity in cyclically loaded test samples subjected to inelastic deformation at high temperature where creep deformations readily occur were determined. The steady state cyclic, stress-strain response at the root of the discontinuity was analyzed. Flat, double notched uniaxially loaded fatigue specimens manufactured from the nickel base, superalloy Inconel 718 were used. The ISDG was used to obtain cycle by cycle recordings of notch root strain during continuous and hold time cycling at 649 C. Comparisons to Neuber and finite element model analyses were made. The results obtained provide a benchmark data set in high technology design where notch fatigue life is the predominant component service life limitation.

Domas, P. A.↗
NASA NTRS2019

Application of a Temperature-Dependent Load Prediction Method to a RUAG Six-Component Block-Type Balance

Temperature-dependent data of a RUAG six-component block-type balance was analyzed to assess the accuracy of two load prediction methods for temperature-dependent balance data. The supplied data was prepared for the analysis by splitting it into calibration and check load data subsets. The first calibration data subset was obtained at a temperature of 294 Kelvin. The second calibration data subset was obtained at a temperature of 315 Kelvin. A subset of 38 points was extracted from the second data set and used as check loads so that the accuracy of the two load prediction methods could be tested. First, the Iterative Method in combination with an extended independent and dependent variable set was used for the balance load prediction. This approach fits electrical outputs as a function of loads and the temperature and, afterwards, constructs a load iteration scheme from the regression coefficients so that loads can be predicted from outputs and the temperature during a wind tunnel test. The Non-Iterative Method was also used for the load prediction. This alternate method can more easily be implemented in a data system as loads are directly fitted as a function of electrical outputs and the temperature. Analysis results for the axial force are only discussed in the paper as similar results were obtained for the other five load components. Results for both methods clearly show that the cross-product term constructed from either a primary gage load or a primary gage output and the temperature explains the majority of the temperature-dependent part of the predicted balance load. This term models the temperature dependent nature of the gage sensitivity. Therefore, it is recommended to apply primary gage loadings at different temperatures during a balance calibration whenever temperature effects need to be described. These loadings will contain information about the temperature-dependent nature of the gage sensitivities that can be quantified by related cross-product terms in regression models of the data.

strain-gage balance↗
DOE OSTI2021

An Artificial-Intelligence and Machine-Learning-Based Methodology to Conduct Seemingly Strain-Controlled Fatigue Test in a Pressurized-Water-Reactor-Test-Loop-Autoclave, While Not Controlling the Strain

In general, low cycle fatigue analysis of pressurized water reactor (PWR) components, requires strain-controlled fatigue test data such as using strain versus life (ε–N) curves. Conducting strain-controlled fatigue tests under in-air conditions is not an issue. However, controlling strain in a PWR-test-loop-autoclave is a challenge, since an extensometer cannot be placed in a narrow autoclave (typically used in a high-temperature-pressure PWR-test-loop). This is due to lack of space inside an autoclave that houses the test specimen. In addition, installing a contact-type extensometer in the path of a high-pressure flow can be a challenge. These difficulties of using an extensometer inside an autoclave led us to use an outside-autoclave displacement sensor which measures the displacement of pull-rod-specimen assembly. However, in our study (based on in-air fatigue test data), we found that a pull-rod-controlled based fatigue test can lead to substantial cyclic hardening/softening resulting in substantially different cyclic strain amplitudes and their rates compared to the desired cyclic strain amplitudes and its rates. In this paper, we propose an Artificial-Intelligence and Machine-Learning based technique such as using k-means clustering technique to improve the pull-rod-control based fatigue test method, such that the gage-area strain amplitude and rates can reasonably be achieved. In support of this, we present the fatigue test results for both 316 SS base and 81/182 dissimilar-metal-weld specimens.

42 ENGINEERING↗
NASA NTRSDate not supplied

Evaluation of the Accuracy of the Load Prediction Equations of Low-Load Balance Calibration Data

Accuracy and reliability of the load prediction equations of a low-load calibration data set of a force balance were investigated. First, independent load prediction equations were generated from the data of a full-load and low-load machine calibration. Then, the low- load data set was processed as a set of precision check loads for the load prediction equations that were obtained from the full-load and low-load calibrations. Finally, the load prediction equations of the two calibrations were applied to four manual check load data sets that were recorded between 2009 and 2022. The residuals of the predicted calibration and check loads were compared in all cases. No systematic improvement of the load prediction accuracy was observed when the load prediction equations of the low-load calibration were applied to the check load data sets. Therefore, it is recommended to apply a full-load calibration to a six-component balance even if the balance is not used across its entire design envelope. This approach has the advantage that the resulting load prediction equations are less likely to be applied outside of the calibration load ranges. In addition, it is expected that the numerical estimates of the gage sensitivities are more reliable assuming that the uncertainties of the applied loads and measured outputs of the calibration data are more or less constant across the load range of the balance.

strain-gage balance↗
NASA NTRS2019

Calibration and Data Analysis Recommendations for Three-Component Moment Balances

Fundamental characteristics of design, calibration, and application of three-component moment balances are investigated in great detail. These balances are typically used to determine loads on control surfaces, canards, or other parts that are attached to a wind tunnel model. First, three different descriptions of the load state of a moment balance are reviewed. Then, load transformations between different load formats and the combined load diagram for two of the three load components are discussed. An error analysis showed that it is critical to maximize the product of the distance between the bending moment gages and their sensitivities in order to minimize the overall error in the normal force prediction. In addition, it is important to apply a sufficient number of calibration loadings near the first bending moment gage. Then, unwanted near-linear dependencies between the two bending moment gage outputs can be avoided. The error in the bending moment prediction is also investigated that results from the elastic deformation of the metric part of the balance under load. Finally, the application of the Non-Iterative Method to three-component moment balance calibration data is described in order to obtain regression models that can be used to predict loads from measured outputs during a wind tunnel test.

Strain-Gage Balance↗
NASA NTRS2017

Pre-Test Assessment of the Upper Bound of the Drag Coefficient Repeatability of a Wind Tunnel Model

A new method is presented that computes a pre{test estimate of the upper bound of the drag coefficient repeatability of a wind tunnel model. This upper bound is a conservative estimate of the precision error of the drag coefficient. For clarity, precision error contributions associated with the measurement of the dynamic pressure are analyzed separately from those that are associated with the measurement of the aerodynamic loads. The upper bound is computed by using information about the model, the tunnel conditions, and the balance in combination with an estimate of the expected output variations as input. The model information consists of the reference area and an assumed angle of attack. The tunnel conditions are described by the Mach number and the total pressure or unit Reynolds number. The balance inputs are the partial derivatives of the axial and normal force with respect to all balance outputs. Finally, an empirical output variation of 1.0 microV/V is used to relate both random instrumentation and angle measurement errors to the precision error of the drag coefficient. Results of the analysis are reported by plotting the upper bound of the precision error versus the tunnel conditions. The analysis shows that the influence of the dynamic pressure measurement error on the precision error of the drag coefficient is often small when compared with the influence of errors that are associated with the load measurements. Consequently, the sensitivities of the axial and normal force gages of the balance have a significant influence on the overall magnitude of the drag coefficient's precision error. Therefore, results of the error analysis can be used for balance selection purposes as the drag prediction characteristics of balances of similar size and capacities can objectively be compared. Data from two wind tunnel models and three balances are used to illustrate the assessment of the precision error of the drag coefficient.

drag coefficient measurement↗