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NASA NTRS2003

Thermal-Structural Analysis of Sunshield Membranes

Future large infrared space telescopes, such as the James Webb Space Telescope (JWST), will require deployable sunshields to provide passive cooling for optics and instruments. Deployable sunshield structures for such applications typically consist of multiple thin-film membrane layers supported by deployable booms. The mechanical design of the sunshield must accommodate thermal strains due to layer-to-layer temperature differences as well as potentially large in-plane temperature gradients within individual film layers. This paper describes a thermal-structural analysis for predicting the stress state in a thin-film membrane subject to both mechanical thermal loads that could aid in the mechanical design of future sunshield structures. First the temperature field predicted by a thermal analysis is mapped to a structural finite element model, and then the structural response is predicted using a nonlinear static analysis. The structural model uses membrane elements in conjunction with a tension field material model to predict the response of the thin-film membrane layer. The tension field material model accounts for no-compression behavior associated with wrinkling and slackness. This approach was used to study the problem of a single membrane layer from the NASA reference concept for the JWST sunshield. Results from the analysis show that the membrane can experience a loss of tensile preload due to the presence of an in-plane temperature gradient representative of the cold-side layer temperature distribution predicted for the reference concept JWST.

Johnston, John↗

NASA NTRS2003

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

Hebsur, Mohan G.↗

NASA NTRS2003

Load Diffusion in Composite and Smart Structures

The research carried out here builds on our previous NASA supported research on the general topic of edge effects and load diffusion in composite structures. Further fundamental solid mechanics studies were carried out to provide a basis for assessing the complicated modeling necessary for the multi-functional large scale structures used by NASA. An understanding of the fundamental mechanisms of load diffusion in composite subcomponents is essential in developing primary composite structures. Some specific problems recently considered were those of end effects in smart materials and structures, study of the stress response of pressurized linear piezoelectric cylinders for both static and steady rotating configurations, an analysis of the effect of pre-stressing and pre-polarization on the decay of end effects in piezoelectric solids and investigation of constitutive models for hardening rubber-like materials. Our goal in the study of load diffusion is the development of readily applicable results for the decay lengths in terms of non-dimensional material and geometric parameters. Analytical models of load diffusion behavior are extremely valuable in building an intuitive base for developing refined modeling strategies and assessing results from finite element analyses. The decay behavior of stresses and other field quantities provides a significant aid towards this process. The analysis is also amenable to parameter study with a large parameter space and should be useful in structural tailoring studies. Special purpose analytical models of load diffusion behavior are extremely valuable in building an intuitive base for developing refined modeling strategies and in assessing results from general purpose finite element analyses. For example, a rational basis is needed in choosing where to use three-dimensional to two-dimensional transition finite elements in analyzing stiffened plates and shells. The decay behavior of stresses and other field quantities furnished by this research provides a significant aid towards this element transition issue. A priori knowledge of the extent of boundary-layers induced by edge effects is also useful in determination of the instrumentation location in structural verification tests or in material characterization tests.

Horgan, C. O.↗

NASA NTRS1996

Numerical Comparison of Active Acoustic and Structural Noise Control in a Stiffened Double Wall Cylinder

The active acoustic and structural noise control characteristics of a double wall cylinder with and without ring stiffeners were numerically evaluated. An exterior monopole was assumed to acoustically excite the outside of the double wall cylinder at an acoustic cavity resonance frequency. Structural modal vibration properties of the inner and outer shells were analyzed by post-processing the results from a finite element analysis. A boundary element approach was used to calculate the acoustic cavity response and the coupled structural-acoustic interaction. In the frequency region of interest, below 500 Hz, all structural resonant modes were found to be acoustically slow and the nonresonant modal response to be dominant. Active sound transmission control was achieved by control forces applied to the inner or outer shell, or acoustic control monopoles placed just outside the inner or outer shell. A least mean square technique was used to minimize the interior sound pressures at the nodes of a data recovery mesh. Results showed that single acoustic control monopoles placed just outside the inner or outer shells resulted in better sound transmission control than six distributed point forces applied to either one of the shells. Adding stiffeners to the double wall structure constrained the modal vibrations of the shells, making the double wall stiffer with associated higher modal frequencies. Active noise control obtained for the stiffened double wall configurations was less than for the unstiffened cylinder. In all cases, the acoustic control monopoles controlled the sound transmission into the interior better than the structural control forces.

Grosveld, Ferdinand W.↗

NASA NTRS2004

Structural Design for a Neptune Aerocapture Mission

A multi-center study was conducted in 2003 to assess the feasibility of and technology requirements for using aerocapture to insert a scientific platform into orbit around Neptune. The aerocapture technique offers a potential method of greatly reducing orbiter mass and thus total spacecraft launch mass by minimizing the required propulsion system mass. This study involved the collaborative efforts of personnel from Langley Research Center (LaRC), Johnson Space Flight Center (JSFC), Marshall Space Flight Center (MSFC), Ames Research Center (ARC), and the Jet Propulsion Laboratory (JPL). One aspect of this effort was the structural design of the full spacecraft configuration, including the ellipsled aerocapture orbiter and the in-space solar electric propulsion (SEP) module/cruise stage. This paper will discuss the functional and structural requirements for each of these components, some of the design trades leading to the final configuration, the loading environments, and the analysis methods used to ensure structural integrity. It will also highlight the design and structural challenges faced while trying to integrate all the mission requirements. Component sizes, materials, construction methods and analytical results, including masses and natural frequencies, will be presented, showing the feasibility of the resulting design for use in a Neptune aerocapture mission. Lastly, results of a post-study structural mass optimization effort on the ellipsled will be discussed, showing potential mass savings and their influence on structural strength and stiffness

Dyke, R. Eric↗

NASA NTRS2001

Impact of dilution on microbial community structure and functional potential: comparison of numerical simulations and batch culture experiments

A series of microcosm experiments was performed using serial dilutions of a sewage microbial community to inoculate a set of batch cultures in sterile sewage. After inoculation, the dilution-defined communities were allowed to regrow for several days and a number of community attributes were measured in the regrown assemblages. Based upon a set of numerical simulations, community structure was expected to differ along the dilution gradient; the greatest differences in structure were anticipated between the undiluted-low-dilution communities and the communities regrown from the very dilute (more than 10(-4)) inocula. Furthermore, some differences were expected among the lower-dilution treatments (e.g., between undiluted and 10(-1)) depending upon the evenness of the original community. In general, each of the procedures used to examine the experimental community structures separated the communities into at least two, often three, distinct groups. The groupings were consistent with the simulated dilution of a mixture of organisms with a very uneven distribution. Significant differences in community structure were detected with genetic (amplified fragment length polymorphism and terminal restriction fragment length polymorphism), physiological (community level physiological profiling), and culture-based (colony morphology on R2A agar) measurements. Along with differences in community structure, differences in community size (acridine orange direct counting), composition (ratio of sewage medium counts to R2A counts, monitoring of each colony morphology across the treatments), and metabolic redundancy (i.e., generalist versus specialist) were also observed, suggesting that the differences in structure and diversity of communities maintained in the same environment can be manifested as differences in community organization and function.

Non-NASA Center↗

NASA NTRS2004

Inflatable Space Structures Technology Development for Large Radar Antennas

There has been recent interest in inflatable space-structures technology for possible applications on U.S. Department of Defense (DOD) missions because of the technology's potential for high mechanical-packaging efficiency, variable stowed geometry, and deployment reliability. In recent years, the DOD sponsored Large Radar Antenna (LRA) Program applied this new technology to a baseline concept: a rigidizable/inflatable (RI) perimeter-truss structure supporting a mesh/net parabolic reflector antenna. The program addressed: (a) truss concept development, (b) regidizable materials concepts assessment, (c) mesh/net concept selection and integration, and (d) developed potential mechanical-system performance estimates. Critical and enabling technologies were validated, most notably the orbital radiation durable regidized materials and the high modulus, inflatable-deployable truss members. These results in conjunction with conclusions from previous mechanical-packaging studies by the U.S. Defense Advanced Research Projects Agency (DARPA) Special Program Office (SPO) were the impetus for the initiation of the DARPA/SPO Innovative Space-based Antenna Technology (ISAT) Program. The sponsor's baseline concept consisted of an inflatable-deployable truss structure for support of a large number of rigid, active radar panels. The program's goal was to determine the risk associated with the application of these new RI structures to the latest in radar technologies. The approach used to define the technology maturity level of critical structural elements was to: (a) develop truss concept baseline configurations (s), (b) assess specific inflatable-rigidizable materials technologies, and (c) estimate potential mechanical performance. The results of the structures portion of the program indicated there was high risk without the essential materials technology flight experiments, but only moderate risk if the appropriate on-orbit demonstrations were performed. This paper covers both programs (LRA and ISAT) in two sections, Parts 1 and 2 respectively. Please note that the terms strut, tube, and column are all used interchangeably and refer to the basic strut element of a truss. Also, the paper contains a mix of English and metric dimensional descriptions that reflect prevailing technical discipline conventions and common usage.

Freeland, R. E.↗

NASA NTRS2004

Validation of Design and Analysis Techniques of Tailored Composite Structures

Aeroelasticity is the relationship between the elasticity of an aircraft structure and its aerodynamics. This relationship can cause instabilities such as flutter in a wing. Engineers have long studied aeroelasticity to ensure such instabilities do not become a problem within normal operating conditions. In recent decades structural tailoring has been used to take advantage of aeroelasticity. It is possible to tailor an aircraft structure to respond favorably to multiple different flight regimes such as takeoff, landing, cruise, 2-g pull up, etc. Structures can be designed so that these responses provide an aerodynamic advantage. This research investigates the ability to design and analyze tailored structures made from filamentary composites. Specifically the accuracy of tailored composite analysis must be verified if this design technique is to become feasible. To pursue this idea, a validation experiment has been performed on a small-scale filamentary composite wing box. The box is tailored such that its cover panels induce a global bend-twist coupling under an applied load. Two types of analysis were chosen for the experiment. The first is a closed form analysis based on a theoretical model of a single cell tailored box beam and the second is a finite element analysis. The predicted results are compared with the measured data to validate the analyses. The comparison of results show that the finite element analysis is capable of predicting displacements and strains to within 10% on the small-scale structure. The closed form code is consistently able to predict the wing box bending to 25% of the measured value. This error is expected due to simplifying assumptions in the closed form analysis. Differences between the closed form code representation and the wing box specimen caused large errors in the twist prediction. The closed form analysis prediction of twist has not been validated from this test.

Jegley, Dawn C.↗

NASA NTRS2005

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The new U.S. National Vision for Space Exploration requires many new enabling technologies to accomplish the goals of space commercialization and returning humans to the moon and extraterrestrial environments. Traditionally, flight elements are complete subsystems requiring humans to complete the integration and assembly. These bulky structures also require the use of heavy launch vehicles to send the units to a desired location. This philosophy necessitates a high degree of safety, numerous space walks at a significant cost. Future space mission costs must be reduced and safety increased to reasonably achieve exploration goals. One proposed concept is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly. Assembly is autonomously performed when two components join after determining that specifications are correct. Local sensors continue monitor joint integrity post assembly, which is critical for safety and structural reliability. Achieving this concept requires a change in space structure design philosophy and the development of innovative technologies to perform autonomous assembly. Assembly of large space structures will require significant numbers of integrity sensors. Thus simple, low-cost sensors are integral to the success of this concept. This paper addresses these issues and proposes a novel concept for assembling space structures autonomously. Core technologies required to achieve in space assembly are presented. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Additionally, these novel technologies can be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

NASA NTRS2005

Automatic Aircraft Structural Topology Generation for Multidisciplinary Optimization and Weight Estimation

An approach is proposed for the application of rapid generation of moderate-fidelity structural finite element models of air vehicle structures to allow more accurate weight estimation earlier in the vehicle design process. This should help to rapidly assess many structural layouts before the start of the preliminary design phase and eliminate weight penalties imposed when actual structure weights exceed those estimated during conceptual design. By defining the structural topology in a fully parametric manner, the structure can be mapped to arbitrary vehicle configurations being considered during conceptual design optimization. A demonstration of this process is shown for two sample aircraft wing designs.

Sensmeier, Mark D.↗

NASA NTRS2005

Persistent Structures in the Turbulent Boundary Layer

Persistent structures in the turbulent boundary layer are located and analyzed. The data are taken from flight experiments on large commercial aircraft. An interval correlation technique is introduced which is able to locate the structures. The Morlet continuous wavelet is shown to not only locates persistent structures but has the added benefit that the pressure data are decomposed in time and frequency. To better understand how power is apportioned among these structures, a discrete Coiflet wavelet is used to decompose the pressure data into orthogonal frequency bands. Results indicate that some structures persist a great deal longer in the TBL than would be expected. These structure contain significant power and may be a primary source of vibration energy in the airframe.

Palumbo, Dan↗

NASA NTRS2004

Self Assembled Structures by Directional Solidification of Eutectics

Interest in ordered porous structures has grown because of there unique properties such as photonic bandgaps, high backing packing density and high surface to volume ratio. Inspired by nature, biometric strategies using self assembled organic molecules dominate the development of hierarchical inorganic structures. Directional solidification of eutectics (DSE) also exhibit self assembly characteristics to form hierarchical metallic and inorganic structures. Crystallization of diphasic materials by DSE can produce two dimensional ordered structures consisting of rods or lamella. By selective removal of phases, DSE is capable to fabricate ordered pore arrays or ordered pin arrays. Criteria and limitations to fabricate hierarchical structures will be presented. Porous structures in silicon base alloys and ceramic systems will be reported.

Dynys, Frederick W.↗

NASA NTRS2003

Structural Anomalies Detected in Ceramic Matrix Composites Using Combined Nondestructive Evaluation and Finite Element Analysis (NDE and FEA)

Most reverse engineering approaches involve imaging or digitizing an object and then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. The rapid prototyping technique builds high-quality physical prototypes directly from computer-aided design files. This fundamental technique for interpreting and interacting with large data sets is being used here via Velocity2 (an integrated image-processing software, ref. 1) using computed tomography (CT) data to produce a prototype three-dimensional test specimen model for analyses. A study at the NASA Glenn Research Center proposes to use these capabilities to conduct a combined nondestructive evaluation (NDE) and finite element analysis (FEA) to screen pretest and posttest structural anomalies in structural components. A tensile specimen made of silicon nitrite (Si3N4) ceramic matrix composite was considered to evaluate structural durability and deformity. Ceramic matrix composites are being sought as candidate materials to replace nickel-base superalloys for turbine engine applications. They have the unique characteristics of being able to withstand higher operating temperatures and harsh combustion environments. In addition, their low densities relative to metals help reduce component mass (ref. 2). Detailed three-dimensional volume rendering of the tensile test specimen was successfully carried out with Velocity2 (ref. 1) using two-dimensional images that were generated via computed tomography. Subsequent, three-dimensional finite element analyses were performed, and the results obtained were compared with those predicted by NDE-based calculations and experimental tests. It was shown that Velocity2 software can be used to render a three-dimensional object from a series of CT scan images with a minimum level of complexity. The analytical results (ref. 3) show that the high-stress regions correlated well with the damage sites identified by the CT scans and the experimental data. Furthermore, modeling of the voids collected via NDE offered an analytical advantage that resulted in more accurate assessments of the material s structural strength. The top figure shows a CT scan image of the specimen test section illustrating various hidden structural entities in the material and an optical image of the test specimen considered in this study. The bottom figure represents the stress response predicted from the finite element analyses (ref .3 ) for a selected CT slice where it clearly illustrates the correspondence of the high stress risers due to voids in the material with those predicted by the NDE. This study is continuing, and efforts are concentrated on improving the modeling capabilities to imitate the structural anomalies as detected.

Abdul-Aziz, Ali↗

NASA NTRS2005

Analysis of Piezoelectric Structural Sensors with Emergent Computing Techniques

The purpose of this project was to try to interpret the results of some tests that were performed earlier this year and to demonstrate a possible use of emergence in computing to solve IVHM problems. The test data used was collected with piezoelectric sensors to detect mechanical changes in structures. This project team was included of Dr. Doug Ramers and Dr. Abdul Jallob of the Summer Faculty Fellowship Program, Arnaldo Colon-Lopez - a student intern from the University of Puerto Rico of Turabo, and John Lassister and Bob Engberg of the Structural and Dynamics Test Group. The tests were performed by Bob Engberg to compare the performance two types of piezoelectric (piezo) sensors, Pb(Zr(sub 1-1)Ti(sub x))O3, which we will label PZT, and Pb(Zn(sub 1/3)Nb(sub 2/3))O3-PbTiO, which we will label SCP. The tests were conducted under varying temperature and pressure conditions. One set of tests was done by varying water pressure inside an aluminum liner covered with carbon-fiber composite layers (a cylindrical "bottle" with domed ends) and the other by varying temperatures down to cryogenic levels on some specially prepared composite panels. This report discusses the data from the pressure study. The study of the temperature results was not completed in time for this report. The particular sensing done with these piezo sensors is accomplished by the sensor generating an controlled vibration that is transmitted into the structure to which the sensor is attached, and the same sensor then responding to the induced vibration of the structure. There is a relationship between the mechanical impedance of the structure and the resulting electrical impedance produced in the in the piezo sensor. The impedance is also a function of the excitation frequency. Changes in the real part of impendance signature relative to an original reference signature indicate a change in the coupled structure that could be the results of damage or strain. The water pressure tests were conducted by pressurizing the bottle on a test stand, and running sweeps of excitations frequencies for each of the piezo sensors and recording the resulting impedance. The sweeps were limited to 401 points by the available analyzer, and it was decided to perform individual sweeps at five different excitation frequency ranges. The frequency ranges used for the PZTs were different in two of the five ranges from the ranges used for the SCP. The bottles were pressurized to empty (no water), 0psig, 77 psig, 155 psig, 227 psig in nearly uniform increments of about 77psi. One of each of the two types of piezo sensors was fastened on to the bottle surface at two locations: about midway between the ends on cylindrical portion of the bottle and at the very edge of one of the end domes. The data was collected in files by sensor type (2 cases), by location (2 cases), by frequency range (5 cases), and pressure (5cases) to produce 100 data sets of 401 impedances. After familiarization with the piezo sensing technology and obtaining the data, the team developed a set of questions to try to answer regarding the data and made assignments of responsibilities. The next section lists the questions, and the remainder of the report describes the data analysis work performed by Dr. Ramers. This includes a discussion of the data, the approach to answering the question using statistical techniques, the use of an emergent system to investigate the data where statistical techniques were not usable, conclusions regarding the data, and recommendations.

Ramers, Douglas L.↗

NASA NTRS2006

Rapid Assessment of Aircraft Structural Topologies for Multidisciplinary Optimization and Weight Estimation

Algorithms for rapid generation of moderate-fidelity structural finite element models of air vehicle structures to allow more accurate weight estimation earlier in the vehicle design process have been developed. Application of these algorithms should help to rapidly assess many structural layouts before the start of the preliminary design phase and eliminate weight penalties imposed when actual structure weights exceed those estimated during conceptual design. By defining the structural topology in a fully parametric manner, the structure can be mapped to arbitrary vehicle configurations being considered during conceptual design optimization. Recent enhancements to this approach include the porting of the algorithms to a platform-independent software language Python, and modifications to specifically consider morphing aircraft-type configurations. Two sample cases which illustrate these recent developments are presented.

Samareh, Jamshid A.↗

NASA NTRS2006

Structural Analysis and Testing of the Inflatable Re-entry Vehicle Experiment (IRVE)

The Inflatable Re-entry Vehicle Experiment (IRVE) is a 3.0 meter, 60 degree half-angle sphere cone, inflatable aeroshell experiment designed to demonstrate various aspects of inflatable technology during Earth re-entry. IRVE will be launched on a Terrier-Improved Orion sounding rocket from NASA s Wallops Flight Facility in the fall of 2006 to an altitude of approximately 164 kilometers and re-enter the Earth s atmosphere. The experiment will demonstrate exo-atmospheric inflation, inflatable structure leak performance throughout the flight regime, structural integrity under aerodynamic pressure and associated deceleration loads, thermal protection system performance, and aerodynamic stability. Structural integrity and dynamic response of the inflatable will be monitored with photogrammetric measurements of the leeward side of the aeroshell during flight. Aerodynamic stability and drag performance will be verified with on-board inertial measurements and radar tracking from multiple ground radar stations. In addition to demonstrating inflatable technology, IRVE will help validate structural, aerothermal, and trajectory modeling and analysis techniques for the inflatable aeroshell system. This paper discusses the structural analysis and testing of the IRVE inflatable structure. Equations are presented for calculating fabric loads in sphere cone aeroshells, and finite element results are presented which validate the equations. Fabric material properties and testing are discussed along with aeroshell fabrication techniques. Stiffness and dynamics tests conducted on a small-scale development unit and a full-scale prototype unit are presented along with correlated finite element models to predict the in-flight fundamental mod

Lindell, Michael C.↗

NASA NTRS2006

Structure Detection of Nonlinear Aeroelastic Systems with Application to Aeroelastic Flight Test Data

This viewgraph presentation reviews the applicability of NARMAX structure detection to aeroelastic systems. In conclusion, the simulation results demonstrate bootstrap approach for structure computation of aircraft structural stiffness provided a high rate of true model selection: 1. T-test and stepwise regression methods had difficulty providing accurate results 2. Work contributes to understanding of the use of structure detection for modelling and identification of aerospace systems. 3. Limitation of model complexity that can be studied with these structure computation techniques 4. Result of the large number of candidate terms, for a given model order, and the data length required to guarantee convergence 5. Another approach to structure computation problem uses a least absolute shrinkage and selection operator (LASSO)

Kukreja, Sunil L.↗

NASA NTRS2006

Probabilistic Design of Composite Structures

A formal procedure for the probabilistic design evaluation of a composite structure is described. The uncertainties in all aspects of a composite structure (constituent material properties, fabrication variables, structural geometry, and service environments, etc.), which result in the uncertain behavior in the composite structural responses, are included in the evaluation. The probabilistic evaluation consists of: (1) design criteria, (2) modeling of composite structures and uncertainties, (3) simulation methods, and (4) the decision-making process. A sample case is presented to illustrate the formal procedure and to demonstrate that composite structural designs can be probabilistically evaluated with accuracy and efficiency.

Chamis, Christos C.↗