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At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Design/Analysis of Metal/Composite Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISM structure is the metal/composite bonded joints that will be required to survive down to an operational ultra-low temperature of 30K (-405 F). The initial and current baseline design for the plug-type joint consists of a titanium thin walled fitting (1-3mm thick) bonded to the interior surface of an M555/954-6 composite truss square tube with an axially stiff biased lay-up. Metallic fittings are required at various nodes of the truss structure to accommodate instrument and lift-point bolted interfaces. Analytical experience and design work done on metal/composite bonded joints at temperatures below liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are virtually nonexistent. Increasing the challenge is the difficulty in testing for these required tools and parameters at 30K. A preliminary finite element analysis shows that failure due to CTE mismatch between the biased composite and titanium or aluminum is likely. Failure is less likely with Invar, however an initial mass estimate of Invar fittings demonstrates that Invar is not an automatic alternative. In order to gain confidence in analyzing and designing the ISM joints, a comprehensive joint development testing program has been planned and is currently running. The test program is designed for the correlation of the analysis methodology, including tuning finite element model parameters, and developing a composite failure criterion for the effect of multi-axial composite stresses on the strength of a bonded joint at 30K. The testing program will also consider stress mitigation using compliant composite layers and potential strength degradation due to multiple thermal cycles. Not only will the finite element analysis be correlated to the test data, but the FEA will be used to guide the design of the test. The first phase of the test program has been completed and the preliminary analysis has been revisited based on the test data In this work, we present an overview of the test plan, results today, and resulting design improvements.

Bartoszyk, Andrew E.↗
DOE OSTI2021

Predictive Data Analytics Framework Using Advanced Test Reactor Acoustic Data

Although a nuclear reactor is a hostile environment for sensing and electrical communications, the reactor core is amenable to acoustic communication. An acoustic measurement infrastructure (AMI) has been installed at the Advanced Test Reactor (ATR) nozzle trench area to record acoustic signals that has the ability to capture different operating regime of the reactor. This AMI includes ATR in-pile structural components, coolant, acoustic receivers, primary coolant pumps (PCP) as signal sources, a data acquisition system, and signal-processing algorithms, enabling real-time. This report will discusses development of recursive Fast Fourier Transform approach to process in real-time acoustic signals, application of short time Fast Fourier Transform to the ATR brush data to understand the vibration level and to develop spectrograms for different primary coolant pump combinations. The combination of primary coolant pumps for normal and power axial locator mechanism of ATR are different and generates different signatures. These acoustic signatures were used to develop machine learning approaches to automatically classify different operating regimes. This lay the foundation for predictive analytic framework that can be leverage by ATR to optimize their operation and maintenance. The path forward involves continued engagement with ATR and expanded implementation of AMI and predictive framework at ATR and other facilities within INL and at other experimental reactors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2007

Probabilistic Analysis of Space Shuttle Body Flap Actuator Ball Bearings

A probabilistic analysis, using the 2-parameter Weibull-Johnson method, was performed on experimental life test data from space shuttle actuator bearings. Experiments were performed on a test rig under simulated conditions to determine the life and failure mechanism of the grease lubricated bearings that support the input shaft of the space shuttle body flap actuators. The failure mechanism was wear that can cause loss of bearing preload. These tests established life and reliability data for both shuttle flight and ground operation. Test data were used to estimate the failure rate and reliability as a function of the number of shuttle missions flown. The Weibull analysis of the test data for a 2-bearing shaft assembly in each body flap actuator established a reliability level of 99.6 percent for a life of 12 missions. A probabilistic system analysis for four shuttles, each of which has four actuators, predicts a single bearing failure in one actuator of one shuttle after 22 missions (a total of 88 missions for a 4-shuttle fleet). This prediction is comparable with actual shuttle flight history in which a single actuator bearing was found to have failed by wear at 20 missions.

Oswald, Fred B.↗
NASA NTRS2008

Probabilistic Analysis of Space Shuttle Body Flap Actuator Ball Bearings

A probabilistic analysis, using the 2-parameter Weibull-Johnson method, was performed on experimental life test data from space shuttle actuator bearings. Experiments were performed on a test rig under simulated conditions to determine the life and failure mechanism of the grease lubricated bearings that support the input shaft of the space shuttle body flap actuators. The failure mechanism was wear that can cause loss of bearing preload. These tests established life and reliability data for both shuttle flight and ground operation. Test data were used to estimate the failure rate and reliability as a function of the number of shuttle missions flown. The Weibull analysis of the test data for the four actuators on one shuttle, each with a 2-bearing shaft assembly, established a reliability level of 96.9 percent for a life of 12 missions. A probabilistic system analysis for four shuttles, each of which has four actuators, predicts a single bearing failure in one actuator of one shuttle after 22 missions (a total of 88 missions for a 4-shuttle fleet). This prediction is comparable with actual shuttle flight history in which a single actuator bearing was found to have failed by wear at 20 missions.

Oswald, Fred B.↗
NASA NTRS1979

Relationship of physiography and snow area to stream discharge

The author has identified the following significant results. A comparison of snowmelt runoff models shows that the accuracy of the Tangborn model and regression models is greater if the test data falls within the range of calibration than if the test data lies outside the range of calibration data. The regression models are significantly more accurate for forecasts of 60 days or more than for shorter prediction periods. The Tangborn model is more accurate for forecasts of 90 days or more than for shorter prediction periods. The Martinec model is more accurate for forecasts of one or two days than for periods of 3,5,10, or 15 days. Accuracy of the long-term models seems to be independent of forecast data. The sufficiency of the calibration data base is a function not only of the number of years of record but also of the accuracy with which the calibration years represent the total population of data years. Twelve years appears to be a sufficient length of record for each of the models considered, as long as the twelve years are representative of the population.

Mccuen, R. H.↗
NASA NTRS1993

Topex Microwave Radiometer thermal control - Post-system-test modifications and on-orbit performance

The Topex Microwave Radiometer has had an excellent thermal performance since launch. The instrument, however, went through a hardware modification right before launch to correct for a thermal design inadequacy that was uncovered during the spacecraft thermal vacuum test. This paper reports on how the initially obscure problem was tracked down, and how the thermal models were revised, validated, and utilized to investigate the solution options and guide the hardware modification decisions. Details related to test data interpretation, analytical uncertainties, and model-prediction vs. test-data correlation, are documented. Instrument/spacecraft interface issues, where the problem originated and where in general pitfalls abound, are dealt with specifically. Finally, on-orbit thermal performance data are presented, which exhibit good agreement with flight predictions, and lessons learned are discussed.

Lin, Edward I.↗
NASA NTRS1995

Fracture analysis of stiffened panels under biaxial loading with widespread cracking

An elastic-plastic finite-element analysis with a critical crack-tip opening angle (CTOA) fracture criterion was used to model stable crack growth and fracture of 2024-T3 aluminum alloy (bare and clad) panels for several thicknesses. The panels had either single or multiple-site damage (MSD) cracks subjected to uniaxial or biaxial loading. Analyses were also conducted on cracked stiffened panels with single or MSD cracks. The critical CTOA value for each thickness was determined by matching the failure load on a middle-crack tension specimen. Comparisons were made between the critical angles determined from the finite-element analyses and those measured with photographic methods. Predicted load-against-crack extension and failure loads for panels under biaxial loading, panels with MSD cracks, and panels with various numbers of stiffeners were compared with test data whenever possible. The predicted results agreed well with the test data even for large-scale plastic deformations. The analyses were also able to predict stable tearing behavior of a large lead crack in the presence of MSD cracks. The analyses were then used to study the influence of stiffeners on residual strength in the presence of widespread fatigue cracking. Small MSD cracks were found to greatly reduce the residual strength for large lead cracks even for stiffened panels.

Newman, J. C., Jr.↗
NASA NTRS1995

Fracture analysis of stiffened panels under biaxial loading with widespread cracking

An elastic-plastic finite-element analysis with a critical crack-tip-opening angle (CTOA) fracture criterion was used to model stable crack growth and fracture of 2024-T3 aluminum alloy (bare and clad) panels for several thicknesses. The panels had either single or multiple-site damage (MSD) cracks subjected to uniaxial or biaxial loading. Analyses were also conducted on cracked stiffened panels with single or MSD cracks. The critical CTOA value for each thickness was determined by matching the failure load on a middle-crack tension specimen. Comparisons were made between the critical angles determined from the finite-element analyses and those measured with photographic methods. Predicted load-against-crack extension and failure loads for panels under biaxial loading, panels with MSD cracks, and panels with various number of stiffeners were compared with test data, whenever possible. The predicted results agreed well with the test data even for large-scale plastic deformations. The analyses were also able to predict stable tearing behavior of a large lead crack in the presence of MSD cracks. The analyses were then used to study the influence of stiffeners on residual strength in the presence of widespread fatigue cracking. Small MSD cracks were found to greatly reduce the residual strength for large lead cracks even for stiffened panels.

Newman, J. C., Jr.↗
NASA NTRS1996

US/Russian Joint Film Test

A joint U.S./Russian film test was conducted during MIR Mission 18 to evaluate the effects of radiation on photographic film during long-duration space flights. Two duplicate sets of film were flown on this MIR mission: one set was processed and evaluated by the NASA/JSC Photographic Laboratory, and the other by the RKK Energia's Photographic Laboratory in Moscow. This preliminary report includes only the results of the JSC evaluation (excluding the SN-10 film which was not available for evaluation at the time this report was written). The final report will include an evaluation by JSC of the SN-10 film and an evaluation of the test data by the RKK Energia. ISC's evaluation of the test data showed the positive film flown was damaged very little when exposed to approximately 8 rads of radiation. Two of the three negative films were significantly damaged and the third film was damaged only moderately.

Slater, Richard↗
NASA NTRS1997

Substructure System Identification for Finite Element Model Updating

This report summarizes research conducted under a NASA grant on the topic 'Substructure System Identification for Finite Element Model Updating.' The research concerns ongoing development of the Substructure System Identification Algorithm (SSID Algorithm), a system identification algorithm that can be used to obtain mathematical models of substructures, like Space Shuttle payloads. In the present study, particular attention was given to the following topics: making the algorithm robust to noisy test data, extending the algorithm to accept experimental FRF data that covers a broad frequency bandwidth, and developing a test analytical model (TAM) for use in relating test data to reduced-order finite element models.

Craig, Roy R., Jr.↗
NASA NTRS2001

Safe Affordable Fission Engine (SAFE 30) Module Conductivity Test Thermal Model Correlation

Two SAFE 30 modules were tested to determinate the thermal conductivity efficiency of the tri-cusps filled between the heat pipe and the heater cores. The modules consisted of four one-inch diameter tubes with heaters joined to an empty 1 inch diam. tube. The test was conducted on a vacuum chamber with 4 configurations: tri-cusps filled with and without radiation shielding and non-filled tri-cusps with and without radiation shielding. The tri-cusps material helps the bonding of the heat pipe to the four electric heater cores, filling the gap between the pipes. The baseline configuration is a brazed joint between the pipe. The test consisted of controlling the power applied to the heaters until a set surface temperature is reach. The temperatures varied between a max. of 800 C to 500 C. Test data, input energy and chamber surface temperature from each individual test, was used as boundary conditions for the model. Nodes located on the same location as the test thermocouples were plotted again test data to determinate the accuracy of the analysis. The unknown n variables on the analysis are the radiation emissivity of the pipe and chamber and the radiation view factor between the module and the chamber. A correlation was determined using a parametric analysis varying the surface emissivity and view factor until a good match was reach.

Roman, Jose↗
NASA NTRS1993

TOPEX Microwave Radiometer Thermal Control: Post-System-Test Modifications and On-Orbit Performance

The Topex Microwave Radiometer has had an excellent thermal performance since launch. The instrument, however, went through a hardware modification right before launch to correct for athermal design inadequacy that was uncovered during the spacecraft thermal vacuum test. This paper reports on how the initially obscure problem was tracked down, and how the thermal models were revised, validated, and utilized to investigate the solution options and guide the hardware modification decisions. Details related to test data interpretation, analytical uncertainties, and model-prediction vs. test-data correlation, are documented. Instrument/spacecraft interface issues, where the problem originated and where in general pitfalls abound, are dealt with specifically. Finally, on-orbit thermal performance data are presented, which exhibit good agreement with flight predictions, and lessons learned are discussed.

Lin, Edward I.↗
NASA NTRS2001

Reusable Solid Rocket Motor Nozzle Joint-4 Thermal Analysis

This study provides for development and test verification of a thermal model used for prediction of joint heating environments, structural temperatures and seal erosions in the Space Shuttle Reusable Solid Rocket Motor (RSRM) Nozzle Joint-4. The heating environments are a result of rapid pressurization of the joint free volume assuming a leak path has occurred in the filler material used for assembly gap close out. Combustion gases flow along the leak path from nozzle environment to joint O-ring gland resulting in local heating to the metal housing and erosion of seal materials. Analysis of this condition was based on usage of the NASA Joint Pressurization Routine (JPR) for environment determination and the Systems Improved Numerical Differencing Analyzer (SINDA) for structural temperature prediction. Model generated temperatures, pressures and seal erosions are compared to hot fire test data for several different leak path situations. Investigated in the hot fire test program were nozzle joint-4 O-ring erosion sensitivities to leak path width in both open and confined joint geometries. Model predictions were in generally good agreement with the test data for the confined leak path cases. Worst case flight predictions are provided using the test-calibrated model. Analysis issues are discussed based on model calibration procedures.

Clayton, J. Louie↗
NASA NTRS2002

Program of Research in Flight Dynamics in the JIAFS, George Washington University at NASA Langley Research Center

The program objectives are fully defined in the original proposal entitled 'Program of Research in Flight Dynamics in GW at NASA Langley Research Center,' which was originated March 20, 1975, and in the renewals of the research program from December 1, 2000 to November 30, 2001. The program in its present form includes three major topics: 1) the improvement of existing methods and development of new methods for wind tunnel and flight test data analysis, 2) the application of these methods to wind tunnel and flight test data obtained from advanced airplanes, 3) the correlation of flight results with wind tunnel measurements, and theoretical predictions. The Principal Investigator of the program is Dr. Vladislav Klein. Three Graduate Research Scholar Assistants (K. G. Mas, M. M. Eissa and N. M. Szyba) also participated in the program. Specific developments in the program during the period Dec. 1, 2001 through Nov. 30, 2002 included: 1) Data analysis of highly swept delta wing aircraft from wind and water tunnel data, and 2) Aerodynamic characteristics of the radio control aircraft from flight test.

Klein, Vladislav↗
NASA NTRS2010

Northrop Grumman TR202 LOX/LH2 Deep Throttling Engine Project Status

NASA's Propulsion and Cryogenic Advanced Development (PCAD) project is currently developing enabling propulsion technologies in support of the Exploration Initiative, with a particular focus on the needs of the Altair Project. To meet Altair requirements, several technical challenges need to be overcome, one of which is the ability for the lunar descent engine(s) to operate over a deep throttle range with cryogenic propellants. To address this need, PCAD has enlisted Northrop Grumman Aerospace Systems (NGAS) in a technology development effort associated with the TR202, a LOX/LH2 expander cycle engine driven by independent turbopump assemblies and featuring a variable area pintle injector similar to the injector used on the TR200 Apollo Lunar Module Descent Engine (LMDE). Since the Apollo missions, NGAS has continued to mature deep throttling pintle injector technology. The TR202 program has completed two phases of pintle injector testing. The first phase of testing used ablative thrust chambers and demonstrated igniter operation as well as stable performance at several power levels across the designed 10:1 throttle range. The second phase of testing was performed on a calorimeter chamber and demonstrated injector performance at various power levels (75%, 50%, 25%, 10%, and 7.5%) across the throttle range as well as chamber heat flux to show that the engine can close an expander cycle design across the throttle range. This paper provides an overview of the TR202 program. It describes the different phases of the program with the key milestones of each phase. It then shows when those milestones were met. Next, it describes how the test data was used to update the conceptual design and how the test data has created a database for deep throttling cryogenic pintle technology that is readily scaleable and can be used to again update the design once the Altair program's requirements are firm. The final section of the paper describes the path forward, which includes demonstrating continuously throttling with an actuator and pursuing a path towards integrated engine sea-level test-bed testing.

Gromski, J.↗
NASA NTRS2019

UH-60A Airloads Flight Test Program: Data Counter 9017

Aeromechanics Branch interns at Ames Research Center have been directly contributing to the data quality analysis and reporting of the UH-60A Airloads Flight Test Program for many years. In chronological order (together with the semester and year): Caroline Edwards (Summer 2011); Joni DeGuzman and Carson Turner (Fall 2011); Eric Fritz (Spring 2012); Connor Beierle (Fall 2012); Christopher Olinger (Spring and Summer 2013); Needa Lin, Anatole Levkoff, Maxwell Loebig, Jose Orejel, Megan Prout, and Albert Sue (Summer 2014); Jared Archey (Fall 2014); Alexander Crone (Summer 2015); Jeffrey Diament, Austin Djang, and Jessica Swan (Summer 2016); Makenzie Allen (Summer 2017); Colin Lauzon (Fall 2017); Eric Gilkey (Spring 2018); and Nicholas Masso (Summer 2019). These interns have spent their internships reviewing flight logs, extracting the data out of TRENDS, formatting the data into spreadsheets, writing code to automate the process, and plotting results. Without their efforts, much of the work would be unfinished. The authors appreciate the achievements of the UH-60A Airloads Working Group during its 20-year lifetime, as well the contributions of Randy Peterson, Tom Norman, and William Warmbrodt to the data processing and assistance with the report preparation. Lastly, this report is dedicated to William Bousman for his efforts preceding, during, and subsequent to the UH-60A Airloads Flight Test Program.

Kufeld, Robert M.↗
NASA NTRS1990

Structural properties of laminated Douglas fir/epoxy composite material

This publication contains a compilation of static and fatigue strength data for laminated-wood material made from Douglas fir and epoxy. Results of tests conducted by several organizations are correlated to provide insight into the effects of variables such as moisture, size, lamina-to-lamina joint design, wood veneer grade, and the ratio of cyclic stress to steady stress during fatigue testing. These test data were originally obtained during development of wood rotor blades for large-scale wind turbines of the horizontal-axis (propeller) configuration. Most of the strength property data in this compilation are not found in the published literature. Test sections ranged from round cylinders 2.25 in. in diameter to rectangular slabs 6 by 24 in. in cross section and approximately 30 ft. long. All specimens were made from Douglas fir veneers 0.10 in. thick, bonded together with the WEST epoxy system developed for fabrication and repair of wood boats. Loading was usually parallel to the grain. Size effects (reduction in strength with increase in test volume) are observed in some of the test data, and a simple mathematical model is presented that includes the probability of failure. General characteristics of the wood/epoxy laminate are discussed, including features that make it useful for a wide variety of applications.

Spera, David A.↗
NASA NTRS2024

Spacecraft Priming Analysis and Research Test Apparatus: Number 1 (SPARTAN 1), Test and Analysis Results

Spacecraft with Earth-storable propellants are required by range safety to launch with propellant isolated from the thrusters for ground operations, which is often accomplished by placing a pyrotechnic, or a latching isolation valve between the tank and the thrusters. Once on-orbit, downstream lines are vented out to space through the thrusters and are left evacuated and at vacuum pressure. Propellant isolation valve then opens and floods the lines with high velocity propellant which can lead to a significant pressure surge upon filling. Replicating this event during ground testing using water as a propellant simulant has always been difficult and costly to accurately perform due to the low vacuum pressure targeted on the downstream side of the system. This report describes the Spacecraft Priming Analysis and Research Test Apparatus (SPARTA) at Marshall Space Flight Center’s (MSFC) Component Development Area (CDA) and the initial test series meant to be a pathfinder for construction methods and test procedures to reduce the cost of future testing. The test data collected are critical to analytical models as the details to replicate prior ground tests are often lacking in enough detail to adequately model the test that was conducted. This report also describes the Thermal Desktop/FloCAD analysis that was performed alongside the test series. The test methods defined for this campaign showed a dramatic improvement on heritage test procedures. Test pace increased due to faster drying and pulling vacuum more effectively. Results generated in this test matched analytical predictions very well and provide a releasable set of test data to be leveraged on future NASA and commercial partner spacecraft development programs.

spacecraft↗