Results for “STRUCTURAL DESIGN” — Page 49

DOE OSTI2024

Fractal Nanostructured Solar Selective Surfaces for Next Gen Concentrating Solar Power (Final Report)

This project reports a novel coating with enhanced solar absorptance and reduced thermal emittance with high efficiency at elevated temperature for next-generation concentrated solar power (CSP) plants, with targeted operating temperatures around 750°C. Highly textured single and multimetallic oxide coatings were electrodeposited onto Inconel substrate by systematically varying the composition and process parameters. The optimized coating exhibited micro-to-nano structures designed to match the wavelengths in the visible region of the solar spectrum. These structures facilitate resonant absorption of solar radiation, significantly boosting solar absorption and accommodating thermal stress during high temperature exposure. A high solar absorptance exceeding 0.985 and a low thermal emittance below 0.5, yielding a thermal efficiency near 95%, was achieved for the optimized coatings without any anti-reflective overcoat, that remained robust after 750 h of isothermal exposure to 750°C in air. The coatings are also robust to severe mechanical and environmental stressors. The innovative approach presented in this study demonstrates the potential for tailoring air-stable solar absorber coatings to achieve high absorption, low emittance, and excellent high-temperature endurance, meeting the rigorous demands of next-generation CSP systems. A technoeconomic analysis reveals the economic advantage of the coatings for Gen3 CSP installations in different geographical zones globally.

14 SOLAR ENERGY↗

NASA NTRS1977

Probabilistic Fracture Mechanics and Optimum Fracture Control Analytical Procedures for a Reusable Solid Rocket Motor Case

A methodology for the reliability analysis of a reusable solid rocket motor case is discussed. The analysis is based on probabilistic fracture mechanics and probability distribution for initial flaw sizes. The developed reliability analysis is used to select the structural design variables of the solid rocket motor case on the basis of minimum expected cost and specified reliability bounds during the projected design life of the case. Effects of failure prevention plans such as nondestructive inspection and the material erosion between missions are also considered in the developed procedure for selection of design variables. The reliability-based procedure can be modified to consider other similar structures of reusable space vehicle systems with different failure prevention plans.

Hanagud, S.↗

NASA NTRS1985

Software Design Analyzer System

CRISP80 software design analyzer system a set of programs that supports top-down, hierarchic, modular structured design, and programing methodologies. CRISP80 allows for expression of design as picture of program.

Tausworthe, R. C.↗

NASA NTRS1982

A formulation of rotor-airframe coupling for design analysis of vibrations of helicopter airframes

A linear formulation of rotor airframe coupling intended for vibration analysis in airframe structural design is presented. The airframe is represented by a finite element analysis model; the rotor is represented by a general set of linear differential equations with periodic coefficients; and the connections between the rotor and airframe are specified through general linear equations of constraint. Coupling equations are applied to the rotor and airframe equations to produce one set of linear differential equations governing vibrations of the combined rotor airframe system. These equations are solved by the harmonic balance method for the system steady state vibrations. A feature of the solution process is the representation of the airframe in terms of forced responses calculated at the rotor harmonics of interest. A method based on matrix partitioning is worked out for quick recalculations of vibrations in design studies when only relatively few airframe members are varied. All relations are presented in forms suitable for direct computer implementation.

Kvaternik, R. G.↗

NASA NTRS1984

Sensitivity analysis of discrete structural systems: A survey

Methods for calculating sensitivity derivatives for discrete structural systems are surveyed, primarily covering literature published during the past two decades. Methods are described for calculating derivatives of static displacements and stresses, eigenvalues and eigenvectors, transient structural response, and derivatives of optimum structural designs with respect to problem parameters. The survey is focused on publications addressed to structural analysis, but also includes a number of methods developed in nonstructural fields such as electronics, controls, and physical chemistry which are directly applicable to structural problems. Most notable among the nonstructural-based methods are the adjoint variable technique from control theory, and the Green's function and FAST methods from physical chemistry.

Adelman, H. M.↗

NASA NTRSDate not supplied

Core Stage TVC Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗

NASA NTRSDate not supplied

Space Launch System: Core Stage Thrust Vector Control Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗

NASA NTRSDate not supplied

X-57 Static Structural Requirements and Airworthiness Approach

The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California, U.S.A.) has been flying various types of aircraft, including experimental ones requiring structural modifications. Many of these aircraft aren’t typically certified by the Federal Aviation Administration (FAA) or the Department of Defense (DoD), but NASA can provide its own airworthiness certification utilizing a riskbased approach. The AFRC has established review processes and procedures to identify hazards, manage risks associated with flight programs, ensure safe flight operations, and satisfy programmatic requirements. The Aerostructures Branch at AFRC developed guidelines for the structural safety of flight, covering experimental aircraft, new components, payloads, and modifications. These guidelines detail structural design, analysis, instrumentation, ground testing, and flight-test operational aspects. The guidelines are followed for defining the airworthiness plan throughout the life cycle of a project. The guidelines can be tailored to the risk posture of each individual project. This paper documents the details of the structural airworthiness plan for the X-57 aircraft, including existing, modified, and newly developed structures. Additionally, it covers the design requirements and load cases specific to the X-57 aircraft.

Wesley W. Li↗

NASA NTRS2013

Next-Generation MKIII Lightweight HUT/Hatch Assembly

The MK III (H-1) carbon-graphite/ epoxy Hard Upper Torso (HUT)/Hatch assembly was designed, fabricated, and tested in the early 1990s. The spacesuit represented an 8.3 psi (≈58 kPa) technology demonstrator model of a zero prebreathe suit. The basic torso shell, brief, and hip areas of the suit were composed of a carbon-graphite/epoxy composite lay-up. In its current configuration, the suit weighs approximately 120 lb (≈54 kg). However, since future planetary suits will be designed to operate at 0.26 bar (≈26 kPa), it was felt that the suit's re-designed weight could be reduced to 79 lb (≈35 kg) with the incorporation of lightweight structural materials. Many robust, lightweight structures based on the technologies of advanced honeycomb materials, revolutionary new composite laminates, metal matrix composites, and recent breakthroughs in fullerene fillers and nanotechnology lend themselves well to applications requiring materials that are both light and strong. The major problem involves the reduction in weight of the HUT/ Hatch assembly for use in lunar and/or planetary applications, while at the same time maintaining a robust structural design. The technical objective is to research, design, and develop manufacturing methods that support fa b rica - tion of a lightweight HUT/Hatch assembly using advanced material and geometric redesign as necessary. Additionally, the lightweight HUT/Hatch assembly will interface directly with current MK III hardware. Using the new operating pressure and current MK III (H-1) interfaces as a starting block, it is planned to maximize HUT/Hatch assembly weight reduction through material selection and geometric redesign. A hard upper torso shell structure with rear-entry closure and corresponding hatch will be fabricated. The lightweight HUT/Hatch assembly will retrofit and interface with existing MK III (H-1) hardware elements, providing NASA with immediate "plug-andplay" capability. NASA crewmembers will have a lightweight, robust, life-support system that will minimize fatigue during extraterrestrial surface sojourns. Its unique feature is the utilization of a new and innovative family of materials used by the aerospace industry, which at the time of this reporting has not been used for the proposed application.

McCarthy, Mike↗

NASA NTRS1991

NASA advanced aeronautics design solar powered remotely piloted vehicle

Environmental problems such as the depletion of the ozone layer and air pollution demand a change in traditional means of propulsion that is sensitive to the ecology. Solar powered propulsion is a favorable alternative that is both ecologically harmless as well as cost effective. Integration of solar energy into designs ranging from futuristic vehicles to heating is beneficial to society. The design and construction of a Multi-Purpose Remotely Piloted Vehicle (MPRPV) seeks to verify the feasibility of utilizing solar propulsion as a primary fuel source. This task has been a year long effort by a group of ten students, divided into five teams, each dealing with different aspects of the design. The aircraft was designed to take-off, climb to the design altitude, fly in a sustained figure-eight flight path, and cruise for approximately one hour. This mission requires flight at Reynolds numbers between 150,000 and 200,000 and demands special considerations in the aerodynamic design in order to achieve flight in this regime. Optimal performance requires a light weight configuration with both structural integrity and maximum power availability. The structure design and choice of solar cells for the propulsion was governed by the weight, efficiency, and cost considerations. The final design is a MPRPV weighting 35 N which cruises 7 m/s at the design altitude of 50 m. The configuration includes a wing composed of balsa and foam NACA 6409 airfoil sections and carbon fiber spars, a tail of similar construction, and a truss structure fuselage. The propulsion system consists of 98 10 percent efficient solar cells donated by Mobil Solar, a NiCad battery for energy storage, and a folding propeller regulated by a lightweight and efficient control system. The airfoils and propeller chosen for the design were research and tested during the design process.

Elario, David S.↗

NASA NTRS1980

FAME, a microprocessor based front-end analysis and modeling environment

Higher order software (HOS) is a methodology for the specification and verification of large scale, complex, real time systems. The HOS methodology was implemented as FAME (front end analysis and modeling environment), a microprocessor based system for interactively developing, analyzing, and displaying system models in a low cost user-friendly environment. The nature of the model is such that when completed it can be the basis for projection to a variety of forms such as structured design diagrams, Petri-nets, data flow diagrams, and PSL/PSA source code. The user's interface with the analyzer is easily recognized by any current user of a structured modeling approach; therefore extensive training is unnecessary. Furthermore, when all the system capabilities are used one can check on proper usage of data types, functions, and control structures thereby adding a new dimension to the design process that will lead to better and more easily verified software designs.

Rosenbaum, J. D.↗

DOE OSTI2026

Next-generation anodes for high-energy and low-cost sodium-ion batteries

Sodium-ion batteries (NIBs) are increasingly becoming commercially viable alternatives to lithium-ion batteries (LIBs), driven by sodium’s lower cost and greater resource availability. However, current NIB technology still falls short of established LIB systems, such as those based on LiFePO 4 , in both cost efficiency and energy density. Although since the early 2020s, industrial advances have raised NIB energy densities to around 175 Wh kg −1 , performance remains limited by the relatively low specific capacity (typically 200–350 mAh g −1 ) and low tap density (0.3–1.0 g cm −3 ) of the prevailing hard carbon anodes. This Review analyses emerging anode materials that could unlock higher-energy and lower-cost NIBs, with a focus on high-capacity hard carbon and alloy-based systems. We discuss the latest progress, fundamental challenges and future directions in these anode materials across the key themes of electrode design, structure–property engineering and characterization. Here, by offering forward-looking insights into the rational design and optimization of anode materials, this Review aims to accelerate the research and development of commercially viable NIBs and support the broader advancement of energy storage technologies.

Batteries↗

NASA NTRS1982

Extensional collapse modes of structural members

Attenuation of the load transmitted to a vehicle occupant by the structure, either by modifying structural assembly, changing geometry of its elements, or adding specific load limiting devices to help dissipate kinetic energy was studied. General aviation aircraft have fuselage subfloors of a built up structure which are generally very stiff perpendicular to the floor of the cabin. The subfloor structure, designed to crush at an appropriate force level, can be used to advantage in a crash by dissipating energy through plastic buckling of the floor beams and frames. Simple closed form solutions to predict the mean crushing force levels of subfloor designs is useful in engineering practice. The crushing process of thin walled, plate formed, open structures with particular emphasis on L and cruciform shapes was analyzed. Lower and upper bound solutions for the mean crushing strength of cruciforms are obtained by considering modes of deformation which account for both bending and extensional deformation. It is the importance of extensional deformation to the energy absorption process, representing at least one third of the dissipated energy is shown.

Hayduk, R. J.↗

NASA NTRS1983

Simultaneous control and optimization for elastic systems

Studies are conducted to determine the dynamic response of beams and plates to loads which are extreme within a certain class of admissible loads. Two approaches to this problem are suggested. In approach one, Pontryagin's maximality principle is regarded as an additional constraint. The optimality of design is then determined by standard numerical techniques. The "adjoint variable approach' to sensitivity of structural design is applied for a given inhomogeneous term. The inhomogeneous term is an extremal element of admissible load vectors, which constitute a closed subspace of a Sobolev space. Again, the maximality principle is invoked. While only beam and plate theory problems are used as examples, generalizations are easy to perceive.

Komkov, V.↗

NASA NTRS1984

Extensional collapse modes of structural members

Attenuation of the load transmitted to a vehicle occupant by the structure, either by modifying structural assembly, changing geometry of its elements, or adding specific load limiting devices to help dissipate kinetic energy was studied. General aviation aircraft have fuselage subfloors of a built up structure which are generally very stiff perpendicular to the floor of the cabin. The subfloor structure, designed to crush at an appropriate force level, can be used to advantage in a crash by dissipating energy through plastic buckling of the floor beams and frames. Simple closed form solutions to predict the mean crushing force levels of subfloor designs is useful in engineering practice. The crushing process of thin walled, plate formed, open structures with particular emphasis on L and cruciform shapes was analyzed. Lower and upper bound solutions for the mean crushing strength of cruciforms are obtained by considering modes of deformation which account for both bending and extensional deformation. It is the importance of extensional deformation to the energy absorption process, representing at least one third of the dissipated energy is shown. Previously announced in STAR as N82-33765

Hayduk, R. J.↗

NASA NTRS1988

Lunar landing and launch facilities and operations

A preliminary design of a lunar landing and launch facility for a Phase 3 lunar base is formulated. A single multipurpose vehicle for the lunar module is assumed. Three traffic levels are envisioned: 6, 12, and 24 landings/launches per year. The facility is broken down into nine major design items. A conceptual description of each of these items is included. Preliminary sizes, capacities, and/or other relevant design data for some of these items are obtained. A quonset hut tent-like structure constructed of aluminum rods and aluminized mylar panels is proposed. This structure is used to provide a constant thermal environment for the lunar modules. A structural design and thermal analysis is presented. Two independent designs for a bridge crane to unload/load heavy cargo from the lunar module are included. Preliminary investigations into cryogenic propellant storage and handling, landing/launch guidance and control, and lunar module maintenance requirements are performed. Also, an initial study into advanced concepts for application to Phase 4 or 5 lunar bases has been completed in a report on capturing, condensing, and recycling the exhaust plume from a lunar launch.

Source record↗

NASA NTRS1989

Minimum weight design of helicopter rotor blades with frequency constraints

The minimum weight design of helicopter rotor blades subject to constraints on fundamental coupled flap-lag natural frequencies has been studied in this paper. A constraint has also been imposed on the minimum value of the blade autorotational inertia to ensure that the blade has sufficient inertia to autorotate in case of an engine failure. The program CAMRAD has been used for the blade modal analysis and the program CONMIN has been used for the optimization. In addition, a linear approximation analysis involving Taylor series expansion has been used to reduce the analysis effort. The procedure contains a sensitivity analysis which consists of analytical derivatives of the objective function and the autorotational inertia constraint and central finite difference derivatives of the frequency constraints. Optimum designs have been obtained for blades in vacuum with both rectangular and tapered box beam structures. Design variables include taper ratio, nonstructural segment weights and box beam dimensions. The paper shows that even when starting with an acceptable baseline design, a significant amount of weight reduction is possible while satisfying all the constraints for blades with rectangular and tapered box beams.

Chattopadhyay, Aditi↗

NASA NTRS1998

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Jones, Clyde S., III↗