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NASA NTRS2010

A Coupled Aeroelastic Model for Launch Vehicle Stability Analysis

A technique for incorporating distributed aerodynamic normal forces and aeroelastic coupling effects into a stability analysis model of a launch vehicle is presented. The formulation augments the linear state-space launch vehicle plant dynamics that are compactly derived as a system of coupled linear differential equations representing small angular and translational perturbations of the rigid body, nozzle, and sloshing propellant coupled with normal vibration of a set of orthogonal modes. The interaction of generalized forces due to aeroelastic coupling and thrust can be expressed as a set of augmenting non-diagonal stiffness and damping matrices in modal coordinates with no penalty on system order. While the eigenvalues of the structural response in the presence of thrust and aeroelastic forcing can be predicted at a given flight condition independent of the remaining degrees of freedom, the coupled model provides confidence in closed-loop stability in the presence of rigid-body, slosh, and actuator dynamics. Simulation results are presented that characterize the coupled dynamic response of the Ares I launch vehicle and the impact of aeroelasticity on control system stability margins.

Orr, Jeb S.↗

NASA NTRS2010

SAW Sensor for Fastener Failure Detection

The proof of concept for using surface acoustic wave (SAW) strain sensors in the detection of aircraft fastener failures is demonstrated. SAW sensors were investigated because they have the potential for the development of passive wireless systems. The SAW devices employed four orthogonal frequency coding (OFC) spread spectrum reflectors in two banks on a high temperature piezoelectric substrate. Three SAW devices were attached to a cantilever panel with removable side stiffeners. Damage in the form of fastener failure was simulated by removal of bolts from the side stiffeners. During testing, three different force conditions were used to simulate static aircraft structural response under loads. The design of the sensor, the panel arrangement and the panel testing results are reported. The results show that the sensors successfully detected single fastener failure at distances up to 54.6 cm from the failure site under loaded conditions.

Wilson, W. C.↗

NASA NTRS2010

Experimental Creep Life Assessment for the Advanced Stirling Convertor Heater Head

The United States Department of Energy is planning to develop the Advanced Stirling Radioisotope Generator (ASRG) for the National Aeronautics and Space Administration (NASA) for potential use on future space missions. The ASRG provides substantial efficiency and specific power improvements over radioisotope power systems of heritage designs. The ASRG would use General Purpose Heat Source modules as energy sources and the free-piston Advanced Stirling Convertor (ASC) to convert heat into electrical energy. Lockheed Martin Corporation of Valley Forge, Pennsylvania, is integrating the ASRG systems, and Sunpower, Inc., of Athens, Ohio, is designing and building the ASC. NASA Glenn Research Center of Cleveland, Ohio, manages the Sunpower contract and provides technology development in several areas for the ASC. One area is reliability assessment for the ASC heater head, a critical pressure vessel within which heat is converted into mechanical oscillation of a displacer piston. For high system efficiency, the ASC heater head operates at very high temperature (850 C) and therefore is fabricated from an advanced heat-resistant nickel-based superalloy Microcast MarM-247. Since use of MarM-247 in a thin-walled pressure vessel is atypical, much effort is required to assure that the system will operate reliably for its design life of 17 years. One life-limiting structural response for this application is creep; creep deformation is the accumulation of time-dependent inelastic strain under sustained loading over time. If allowed to progress, the deformation eventually results in creep rupture. Since creep material properties are not available in the open literature, a detailed creep life assessment of the ASC heater head effort is underway. This paper presents an overview of that creep life assessment approach, including the reliability-based creep criteria developed from coupon testing, and the associated heater head deterministic and probabilistic analyses. The approach also includes direct benchmark experimental creep assessment. This element provides high-fidelity creep testing of prototypical heater head test articles to investigate the relevant material issues and multiaxial stress state. Benchmark testing provides required data to evaluate the complex life assessment methodology and to validate that analysis. Results from current benchmark heater head tests and newly developed experimental methods are presented. In the concluding remarks, the test results are shown to compare favorably with the creep strain predictions and are the first experimental evidence for a robust ASC heater head creep life.

Krause, David L.↗

NASA NTRS2011

Highly Loaded Composite Strut Test Development

Highly loaded composite struts, representative of structural elements of a proposed truss-based lunar lander descent stage concept, were selected for design, development, fabrication and testing under NASA s Advanced Composites Technology program. The focus of this paper is the development of a capability for experimental evaluation of the structural performance of these struts. Strut lengths range from 60 to over 120 inches, and compressive launch and ascent loads can exceed -100,000 lbs, or approximately two times the corresponding tensile loads. Allowing all possible compressive structural responses, including elastic buckling, were primary considerations for designing the test hardware.

Wu, K. Chauncey↗

NASA NTRS2011

Advances in Ceramic Matrix Composite Blade Damping Characteristics for Aerospace Turbomachinery Applications

For advanced aerospace propulsion systems, development of ceramic matrix composite integrally-bladed turbine disk technology is attractive for a number of reasons. The high strength-to-weight ratio of ceramic composites helps to reduce engine weight and the one-piece construction of a blisk will result in fewer parts count, which should translate into reduced operational costs. One shortcoming with blisk construction, however, is that blisks may be prone to high cycle fatigue due to their structural response to high vibration environments. Use of ceramic composites is expected to provide some internal damping to reduce the vibratory stresses encountered due to unsteady flow loads through the bladed turbine regions. A goal of our research was to characterize the vibration viscous damping behavior of C/SiC composites. The vibration damping properties were measured and calculated. Damping appeared to decrease with an increase in the natural frequency. While the critical damping amount of approximately 2% is required for typical aerospace turbomachinery engines, the C/SiC damping at high frequencies was less than 0.2% from our study. The advanced high-performance aerospace propulsion systems almost certainly will require even more damping than what current vehicles require. A purpose of this paper is to review some work on C/SiC vibration damping by the authors for the NASA CMC turbine blisk development program and address an importance of the further investigation of the blade vibration damping characteristics on candidate CMC materials for the NASA s advanced aerospace turbomachinery engine systems.

Min, James B.↗

NASA NTRS2011

A Data System for a Rapid Evaluation Class of Subscale Aerial Vehicle

A low cost, rapid evaluation, test aircraft is used to develop and test airframe damage diagnosis algorithms at Langley Research Center as part of NASA's Aviation Safety Program. The remotely operated subscale aircraft is instrumented with sensors to monitor structural response during flight. Data is collected for good and compromised airframe configurations to develop data driven models for diagnosing airframe state. This paper describes the data acquisition system (DAS) of the rapid evaluation test aircraft. A PC/104 form factor DAS was developed to allow use of Matlab, Simulink simulation code in Langley's existing subscale aircraft flight test infrastructure. The small scale of the test aircraft permitted laboratory testing of the actual flight article under controlled conditions. The low cost and modularity of the DAS permitted adaptation to various flight experiment requirements.

Hogge, Edward F.↗

NASA NTRS2012

The Influence of Boundary Layer Parameters on Interior Noise

Predictions of the wall pressure in the turbulent boundary of an aerospace vehicle can differ substantially from measurement due to phenomena that are not well understood. Characterizing the phenomena will require additional testing at considerable cost. Before expending scarce resources, it is desired to quantify the effect of the uncertainty in wall pressure predictions and measurements on structural response and acoustic radiation. A sensitivity analysis is performed on four parameters of the Corcos cross spectrum model: power spectrum, streamwise and cross stream coherence lengths and Mach number. It is found that at lower frequencies where high power levels and long coherence lengths exist, the radiated sound power prediction has up to 7 dB of uncertainty in power spectrum levels with streamwise and cross stream coherence lengths contributing equally to the total.

Palumbo, Daniel L.↗

NASA NTRS2012

Loads Correlation of a Full-Scale UH-60A Airloads Rotor in a Wind Tunnel

Wind tunnel measurements of the rotor trim, blade airloads, and structural loads of a full-scale UH-60A Black Hawk main rotor are compared with calculations obtained using the comprehensive rotorcraft analysis CAMRAD II and a coupled CAMRAD II/OVERFLOW 2 analysis. A speed sweep at constant lift up to an advance ratio of 0.4 and a thrust sweep at constant speed into deep stall are investigated. The coupled analysis shows significant improvement over comprehensive analysis. Normal force phase is better captured and pitching moment magnitudes are better predicted including the magnitude and phase of the two stall events in the fourth quadrant at the deeply stalled condition. Structural loads are, in general, improved with the coupled analysis, but the magnitude of chord bending moment is still significantly underpredicted. As there are three modes around 4 and 5/rev frequencies, the structural responses to the 5/rev airloads due to dynamic stall are magnified and thus care must be taken in the analysis of the deeply stalled condition.

Yeo, Hyeonsoo↗

NASA NTRS2012

Composite Pressure Vessel Variability in Geometry and Filament Winding Model

Composite pressure vessels (CPVs) are used in a variety of applications ranging from carbon dioxide canisters for paintball guns to life support and pressurant storage on the International Space Station. With widespread use, it is important to be able to evaluate the effect of variability on structural performance. Data analysis was completed on CPVs to determine the amount of variation that occurs among the same type of CPV, and a filament winding routine was developed to facilitate study of the effect of manufacturing variation on structural response.

Green, Steven J.↗

NASA NTRS2013

Analysis of a Hybrid Wing Body Center Section Test Article

The hybrid wing body center section test article is an all-composite structure made of crown, floor, keel, bulkhead, and rib panels utilizing the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) design concept. The primary goal of this test article is to prove that PRSEUS components are capable of carrying combined loads that are representative of a hybrid wing body pressure cabin design regime. This paper summarizes the analytical approach, analysis results, and failure predictions of the test article. A global finite element model of composite panels, metallic fittings, mechanical fasteners, and the Combined Loads Test System (COLTS) test fixture was used to conduct linear structural strength and stability analyses to validate the specimen under the most critical combination of bending and pressure loading conditions found in the hybrid wing body pressure cabin. Local detail analyses were also performed at locations with high stress concentrations, at Tee-cap noodle interfaces with surrounding laminates, and at fastener locations with high bearing/bypass loads. Failure predictions for different composite and metallic failure modes were made, and nonlinear analyses were also performed to study the structural response of the test article under combined bending and pressure loading. This large-scale specimen test will be conducted at the COLTS facility at the NASA Langley Research Center.

Wu, Hsi-Yung T.↗

NASA NTRS2013

Analysis-Driven Design Optimization of a SMA-Based Slat-Cove Filler for Aeroacoustic Noise Reduction

Airframe noise is a significant component of environmental noise in the vicinity of airports. The noise associated with the leading-edge slat of typical transport aircraft is a prominent source of airframe noise. Previous work suggests that a slat-cove filler (SCF) may be an effective noise treatment. Hence, development and optimization of a practical slat-cove-filler structure is a priority. The objectives of this work are to optimize the design of a functioning SCF which incorporates superelastic shape memory alloy (SMA) materials as flexures that permit the deformations involved in the configuration change. The goal of the optimization is to minimize the actuation force needed to retract the slat-SCF assembly while satisfying constraints on the maximum SMA stress and on the SCF deflection under static aerodynamic pressure loads, while also satisfying the condition that the SCF self-deploy during slat extension. A finite element analysis model based on a physical bench-top model is created in Abaqus such that automated iterative analysis of the design could be performed. In order to achieve an optimized design, several design variables associated with the current SCF configuration are considered, such as the thicknesses of SMA flexures and the dimensions of various components, SMA and conventional. Designs of experiment (DOE) are performed to investigate structural response to an aerodynamic pressure load and to slat retraction and deployment. DOE results are then used to inform the optimization process, which determines a design minimizing actuator forces while satisfying the required constraints.

Scholten, William↗

NASA NTRS2015

Cohesive Laws for Analyzing Through-Crack Propagation in Cross Ply Laminates

The laminate cohesive approach (LCA) is a methodology for the experimental characterization of cohesive through-the-thickness damage propagation in fiber-reinforced polymer matrix composites. LCA has several advantages over other existing approaches for cohesive law characterization, including: visual measurements of crack length are not required, structural effects are accounted for, and LCA can be applied when the specimen is too small to achieve steady-state fracture. In this work, the applicability of this method is investigated for two material systems: IM7/8552, a conventional prepreg, and AS4/VRM34, a non-crimp fabric cured using an out-of-autoclave process. The compact tension specimen configuration is used to propagate stable Mode I damage. Trilinear cohesive laws are characterized using the fracture toughness and the notch tip opening displacement. Test results are compared for the IM7/8552 specimens with notches machined by waterjet and by wire slurry saw. It is shown that the test results are nearly identical for both notch tip preparations methods, indicating that significant specimen preparation time and cost savings can be realized by using the waterjet to notch the specimen instead of the wire slurry saw. The accuracy of the cohesive laws characterized herein are assessed by reproducing the structural response of the test specimens using computational methods. The applicability of the characterization procedure for inferring lamina fracture toughness is also discussed.

Bergan, Andrew C.↗

NASA NTRS2016

HIAD on ULA (HULA) Orbital Reentry Flight Experiment Concept

This paper describes a proposed orbital velocity reentry flight test of a Hypersonic Inflatable Aerodynamic Decelerator (HIAD). The flight test builds upon ground development activities that continue to advance the materials, design, and manufacturing techniques for the inflatable structure and flexible thermal protection system (F-TPS) that comprise the inflatable heat shield. While certain aspects of material and system performance can be assessed using a variety of ground testing capabilities, only orbital velocity energy on a trajectory through the gradient density of the atmosphere can impart the combined aerodynamic and aeroheating design environments in real time. To achieve this at limited cost, the HIAD would be delivered to a spin-stabilized entry trajectory as a secondary payload on the Centaur stage of a United Launch Alliance (ULA) Atlas V launch vehicle. Initial trajectory studies indicate that the combination of launch vehicle capability and achievable reentry vehicle ballistic numbers make this a strategic opportunity for technology development. This 4 to 6 meter diameter scale aeroshell flight, referred to as HIAD on ULA (HULA), would also contribute to ULA asset recovery development. ULA has proposed that a HIAD be utilized as part of the Sensible, Modular, Autonomous Return Technology (SMART) initiative to enable recovery of the Vulcan launch vehicle booster main engines [1], including a Mid-Air Recovery (MAR) to gently return these assets for reuse. Whereas HULA will attain valuable aerothermal and structural response data toward advancing HIAD technology, it may also provide a largest-to-date scaled flight test of the MAR operation, which in turn would allow the examination of a nearly pristine post-entry aeroshell. By utilizing infrared camera imaging, HULA will also attain aft-side thermal response data, enhancing understanding of the aft side aerothermal environment, an area of high uncertainty. The aeroshell inflation will utilize a heritage design compressed gas system to minimize development costs. The data will be captured to both an onboard recorder and a recorder that is jettisoned and recovered separately from the reentry vehicle to mitigate risk. This paper provides an overview, including the architecture and flight concept of operations, for the proposed HULA flight experiment.

Dinonno, J. M.↗

NASA NTRS2016

Non-Invasive Tension Measurement Devices for Parachute Cordage

The need for lightweight and non-intrusive tension measurements has arisen alongside the development of high-fidelity computer models of textile and fluid dynamics. In order to validate these computer models, data must be gathered in the operational environment without altering the design, construction, or performance of the test article. Current measurement device designs rely on severing a cord and breaking the load path to introduce a load cell. These load cells are very reliable, but introduce an area of high stiffness in the load path, directly affecting the structural response, adding excessive weight, and possibly altering the dynamics of the parachute during a test. To capture the required data for analysis validation without affecting the response of the system, non-invasive measurement devices have been developed and tested by NASA. These tension measurement devices offer minimal impact to the mass, form, fit, and function of the test article, while providing reliable, axial tension measurements for parachute cordage.

Litteken, Douglas A.↗

NASA NTRS2018

Electric Motor Noise for Small Quadcopters: Part I - Acoustic Measurements

There is increased interest in using electric motors to drive propulsors across a range of small air vehicle classes. Applications include both vertical lift and conventional takeoff and landing systems for Small Unmanned Aircraft Systems. Mission profiles call for integrating these systems into urban airspaces exposing populated areas to new noise sources. In addition to the propulsor noise from rotors and propellers, electric motors are expected to contribute to the overall sound levels and possibly human annoyance. This work presents acoustic measurements of electric motors used for small quadcopters to characterize the sound and identify sources with and without a propeller. Free field microphone measurements were used to determine directivity and a phased microphone array was used to identify sound sources. A companion paper (Part II – Source Characteristics and Prediction) compares the far field results with current probe measurements of the signal driving the motor, the structural response of the motor case, and describes prediction methods of electric motor noise.

Aircraft Noise↗

NASA NTRS2018

Preliminary Design of the Superconducting Rotor for NASA's High-Efficiency Megawatt Motor

NASA Glenn Research Center is developing a 1.4~MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. The design of the superconducting rotor and the optimization of its electromagnetic and structural responses are analyzed in this paper. Candidate designs are evaluated in terms of absolute performance, specific performance, and performance per cost. It is found that optimizing the electromagnetic response for absolute or specific performance yields designs that are similar to each other, but opposite of the cost-optimized design. A method to define the thermal requirements of the superconducting coils and integrated cryocooler is also presented.

electric machines↗

NASA NTRS2018

Electric Motor Noise from Small Quadcopters: Part 1 - Acoustic Measurements

There is increased interest in using electric motors to drive propulsors across a range of small air vehicle classes. Applications include both vertical lift and conventional takeoff and landing systems for Small Unmanned Aircraft Systems. Mission profiles call for integrating these systems into urban airspaces exposing populated areas to new noise sources. In addition to the propulsor noise from rotors and propellers, electric motors are expected to contribute to the overall sound levels and possibly human annoyance. This work presents acoustic measurements of electric motors used for small quadcopters to characterize the sound and identify sources with and without a propeller. Free field microphone measurements were used to determine directivity and a phased microphone array was used to identify sound sources. A companion paper (Part II - Source Characteristics and Prediction) compares the far field results with current probe measurements of the signal driving the motor, the structural response of the motor case, and describes prediction methods of electric motor noise.

Electric Propulsion↗

NASA NTRS2018

Sensor Arrays for Aerospace Vehicles

Advances in highly scalable sensors, wireless networks, distributed computing and data fusion algorithms enable significant improvements in high-level information-centric state determination for adaptable and autonomous aerospace vehicles. The objective is to increase insight into structural response of space vehicles and insight into the aerodynamics of new aircraft.

Alena, Richard↗