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All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Shape and Stress Sensing of Multilayered Composite and Sandwich Structures Using an Inverse Finite Element Method

The marked increase in the use of composite and sandwich material systems in aerospace, civil, and marine structures leads to the need for integrated Structural Health Management systems. A key capability to enable such systems is the real-time reconstruction of structural deformations, stresses, and failure criteria that are inferred from in-situ, discrete-location strain measurements. This technology is commonly referred to as shape- and stress-sensing. Presented herein is a computationally efficient shape- and stress-sensing methodology that is ideally suited for applications to laminated composite and sandwich structures. The new approach employs the inverse Finite Element Method (iFEM) as a general framework and the Refined Zigzag Theory (RZT) as the underlying plate theory. A three-node inverse plate finite element is formulated. The element formulation enables robust and efficient modeling of plate structures instrumented with strain sensors that have arbitrary positions. The methodology leads to a set of linear algebraic equations that are solved efficiently for the unknown nodal displacements. These displacements are then used at the finite element level to compute full-field strains, stresses, and failure criteria that are in turn used to assess structural integrity. Numerical results for multilayered, highly heterogeneous laminates demonstrate the unique capability of this new formulation for shape- and stress-sensing.

Cerracchio, Priscilla↗
NASA NTRS2014

Simulations of DSB Yields and Radiation-induced Chromosomal Aberrations in Human Cells Based on the Stochastic Track Structure Induced by HZE Particles

The formation of double‐strand breaks (DSBs) and chromosomal aberrations (CAs) is of great importance in radiation research and, specifically, in space applications. We are presenting a new particle track and DNA damage model, in which the particle stochastic track structure is combined with the random walk (RW) structure of chromosomes in a cell nucleus. The motivation for this effort stems from the fact that the model with the RW chromosomes, NASARTI (NASA radiation track image) previously relied on amorphous track structure, while the stochastic track structure model RITRACKS (Relativistic Ion Tracks) was focused on more microscopic targets than the entire genome. We have combined chromosomes simulated by RWs with stochastic track structure, which uses nanoscopic dose calculations performed with the Monte‐Carlo simulation by RITRACKS in a voxelized space. The new simulations produce the number of DSBs as function of dose and particle fluence for high‐energy particles, including iron, carbon and protons, using voxels of 20 nm dimension. The combined model also calculates yields of radiation‐induced CAs and unrejoined chromosome breaks in normal and repair deficient cells. The joined computational model is calibrated using the relative frequencies and distributions of chromosomal aberrations reported in the literature. The model considers fractionated deposition of energy to approximate dose rates of the space flight environment. The joined model also predicts of the yields and sizes of translocations, dicentrics, rings, and more complex‐type aberrations formed in the G0/G1 cell cycle phase during the first cell division after irradiation. We found that the main advantage of the joined model is our ability to simulate small doses: 0.05‐0.5 Gy. At such low doses, the stochastic track structure proved to be indispensable, as the action of individual delta‐rays becomes more important.

Ponomarev, Artem↗
NASA NTRS2014

Coupled Fluid-Structure Interaction Analysis of Solid Rocket Motor with Flexible Inhibitors

Flexible inhibitors are generally used in solid rocket motors (SRMs) as a means to control the burning of propellant. Vortices generated by the flow of propellant around the flexible inhibitors have been identified as a driving source of instabilities that can lead to thrust oscillations in launch vehicles. Potential coupling between the SRM thrust oscillations and structural vibration modes is an important risk factor in launch vehicle design. As a means to predict and better understand these phenomena, a multidisciplinary simulation capability that couples the NASA production CFD code, Loci/CHEM, with CFDRC's structural finite element code, CoBi, has been developed. This capability is crucial to the development of NASA's new space launch system (SLS). This paper summarizes the efforts in applying the coupled software to demonstrate and investigate fluid-structure interaction (FSI) phenomena between pressure waves and flexible inhibitors inside reusable solid rocket motors (RSRMs). The features of the fluid and structural solvers are described in detail, and the coupling methodology and interfacial continuity requirements are then presented in a general Eulerian-Lagrangian framework. The simulations presented herein utilize production level CFD with hybrid RANS/LES turbulence modeling and grid resolution in excess of 80 million cells. The fluid domain in the SRM is discretized using a general mixed polyhedral unstructured mesh, while full 3D shell elements are utilized in the structural domain for the flexible inhibitors. Verifications against analytical solutions for a structural model under a steady uniform pressure condition and under dynamic modal analysis show excellent agreement in terms of displacement distribution and eigenmode frequencies. The preliminary coupled results indicate that due to acoustic coupling, the dynamics of one of the more flexible inhibitors shift from its first modal frequency to the first acoustic frequency of the solid rocket motor. This insight could have profound implications for SRM and flexible inhibitor designs for current and future launch vehicles including SLS.

Yang, H. Q.↗
NASA NTRS2014

Simulations of DSB Yields and Radiation-induced Chromosomal Aberrations in Human Cells Based on the Stochastic Track Structure iIduced by HZE Particles

The formation of double‐strand breaks (DSBs) and chromosomal aberrations (CAs) is of great importance in radiation research and, specifically, in space applications. We are presenting a new particle track and DNA damage model, in which the particle stochastic track structure is combined with the random walk (RW) structure of chromosomes in a cell nucleus. The motivation for this effort stems from the fact that the model with the RW chromosomes, NASARTI (NASA radiation track image) previously relied on amorphous track structure, while the stochastic track structure model RITRACKS (Relativistic Ion Tracks) was focused on more microscopic targets than the entire genome. We have combined chromosomes simulated by RWs with stochastic track structure, which uses nanoscopic dose calculations performed with the Monte‐Carlo simulation by RITRACKS in a voxelized space. The new simulations produce the number of DSBs as function of dose and particle fluence for high‐energy particles, including iron, carbon and protons, using voxels of 20 nm dimension. The combined model also calculates yields of radiation‐induced CAs and unrejoined chromosome breaks in normal and repair deficient cells. The joined computational model is calibrated using the relative frequencies and distributions of chromosomal aberrations reported in the literature. The model considers fractionated deposition of energy to approximate dose rates of the space flight environment. The joined model also predicts of the yields and sizes of translocations, dicentrics, rings, and more complex‐type aberrations formed in the G0/G1 cell cycle phase during the first cell division after irradiation. We found that the main advantage of the joined model is our ability to simulate small doses: 0.05‐0.5 Gy. At such low doses, the stochastic track structure proved to be indispensable, as the action of individual delta‐rays becomes more important.

Ponomarev, Artem↗
NASA NTRS2012

Vlasov Simulation of Electrostatic Solitary Structures in Multi-Component Plasmas

Electrostatic solitary structures have been observed in the Earth's magnetosheath by the Cluster spacecraft. Recent theoretical work has suggested that these solitary structures are modeled by electron acoustic solitary waves existing in a four-component plasma system consisting of core electrons, two counter-streaming electron beams, and one species of background ions. In this paper, the excitation of electron acoustic waves and the formation of solitary structures are studied by means of a one-dimensional electrostatic Vlasov simulation. The present result first shows that either electron acoustic solitary waves with negative potential or electron phase-space holes with positive potential are excited in four-component plasma systems. However, these electrostatic solitary structures have longer duration times and higher wave amplitudes than the solitary structures observed in the magnetosheath. The result indicates that a high-speed and small free energy source may be needed as a fifth component. An additional simulation of a five-component plasma consisting of a stable four-component plasma and a weak electron beam shows the generation of small and fast electron phase-space holes by the bump-on-tail instability. The physical properties of the small and fast electron phase-space holes are very similar to those obtained by the previous theoretical analysis. The amplitude and duration time of solitary structures in the simulation are also in agreement with the Cluster observation.

magnetohydrodynamics (MHD)↗
NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

In this paper, a unique system level spacecraft design optimization will be presented. A Genetic Algorithm is used to design the global pattern of the reinforcing structure, while a gradient routine is used to adequately stiffen the sub-structure. The system level structural design includes determining the optimal physical location (and number) of reinforcing beams of a lunar pallet lander deck structure. Design of the substructure includes determining placement of secondary stiffeners and the number of rivets required for assembly.. In this optimization, several considerations are taken into account. The primary objective was to raise the primary natural frequencies of the structure such that the Pallet Lander primary structure does not significantly couple with the launch vehicle. A secondary objective is to determine how to properly stiffen the reinforcing beams so that the beam web resists the shear buckling load imparted by the spacecraft components mounted to the pallet lander deck during launch and landing. A third objective is that the calculated stress does not exceed the allowable strength of the material. These design requirements must be met while, minimizing the overall mass of the spacecraft. The final paper will discuss how the optimization was implemented as well as the results. While driven by optimization algorithms, the primary purpose of this effort was to demonstrate the capability of genetic algorithms to enable design automation in the preliminary design cycle. By developing a routine that can automatically generate designs through the use of Finite Element Analysis, considerable design efficiencies, both in time and overall product, can be obtained over more traditional brute force design methods.

Burt, Adam↗
NASA NTRS2014

Structural Pain Compensating Flight Control

The problem of control command and maneuver induced structural loads is an important aspect of any control system design. Designers must design the aircraft structure and the control architecture to achieve desired piloted control responses while limiting the imparted structural loads. The classical approach is to build the structure with high margins, restrict control surface commands to known good combinations, and train pilots to follow procedural maneuvering limitations. With recent advances in structural sensing and the continued desire to improve safety and vehicle fuel efficiency, it is both possible and desirable to develop control architectures that enable lighter vehicle weights while maintaining and improving protection against structural damage.

advanced autonomy↗
NASA NTRS2014

Constraining the Structure of the Transition Disk HD 135344B (SAO 206462) by Simultaneous Modeling of Multiwavelength Gas and Dust Observations

Context: Constraining the gas and dust disk structure of transition disks, particularly in the inner dust cavity, is a crucial step toward understanding the link between them and planet formation. HD 135344B is an accreting (pre-)transition disk that displays the CO 4.7 micrometer emission extending tens of AU inside its 30 AU dust cavity. Aims: We constrain HD 135344B's disk structure from multi-instrument gas and dust observations. Methods: We used the dust radiative transfer code MCFOST and the thermochemical code ProDiMo to derive the disk structure from the simultaneous modeling of the spectral energy distribution (SED), VLT/CRIRES CO P(10) 4.75 Micrometers, Herschel/PACS [O(sub I)] 63 Micrometers, Spitzer/IRS, and JCMT CO-12 J = 3−2 spectra, VLTI/PIONIER H-band visibilities, and constraints from (sub-)mm continuum interferometry and near-IR imaging. Results: We found a disk model able to describe the current gas and dust observations simultaneously. This disk has the following structure. (1) To simultaneously reproduce the SED, the near-IR interferometry data, and the CO ro-vibrational emission, refractory grains (we suggest carbon) are present inside the silicate sublimation radius (0.08 is less than R less than 0.2 AU). (2) The dust cavity (R is less than 30 AU) is filled with gas, the surface density of the gas inside the cavity must increase with radius to fit the CO ro-vibrational line profile, a small gap of a few AU in the gas distribution is compatible with current data, and a large gap of tens of AU in the gas does not appear likely. (4) The gas-to-dust ratio inside the cavity is >100 to account for the 870 Micrometers continuum upper limit and the CO P(10) line flux. (5) The gas-to-dust ratio in the outer disk (30 is less than R less than 200 AU) is less than 10 to simultaneously describe the [O(sub I)] 63 Micrometers line flux and the CO P(10) line profile. (6) In the outer disk, most of the gas and dust mass should be located in the midplane, and a significant fraction of the dust should be in large grains. Conclusions: Simultaneous modeling of the gas and dust is required to break the model degeneracies and constrain the disk structure. An increasing gas surface density with radius in the inner cavity echoes the effect of a migrating Jovian planet in the disk structure. The low gas mass (a few Jupiter masses) throughout the HD 135344B disk supports the idea that it is an evolved disk that has already lost a large portion of its mass.

inner dust cavity↗
NASA NTRS2014

GRAIL Refinements to Lunar Seismic Structure

Gravity field measurements are perhaps the most numerous of the indirect observations relevant to the Moon's internal structure. Multiple recent missions have mapped the global lunar gravity field, each one improving upon the resolution of the last. The details of the Moon's deepest structure, including the parameters that define the lunar core, however, were still largely unaddressed by pre-GRAIL gravity measurements, which were not high enough resolution to resolve the tidal coefficients at a sufficient degree of accuracy. Current constraints on core size and state arise from other indirect measurements, including lunar laser ranging, magnetic induction studies, and analyses of elemental abundances in depth-derived mare basalts. These inferences vary widely, but when considered together with structure models derived from the seismic data gathered during the Apollo missions, a schematic of the lunar interior containing a partially molten deepest mantle layer overlying molten outer and solid inner core layers was obtained. Seismology provides the most direct constraints on the variables that govern the dynamic properties of the body. However, the GRAIL mission's high-resolution measurements of the lunar gravity field are being used to constrain the interior structure of the Moon using a "crust to core" approach. GRAIL's constraints on crustal thickness, mantle structure, core radius and stratification, and core state (solid vs. molten) therefore complement seismic investigations. This work focuses on expanding our knowledge of the Moon's internal structure using joint gravity and seismic analyses, which will improve constraints on the deep lunar mantle and core.

Weber, Renee C.↗
NASA NTRS2015

A Flexible and Non-instrusive Approach for Computing Complex Structural Coverage Metrics

Software analysis tools and techniques often leverage structural code coverage information to reason about the dynamic behavior of software. Existing techniques instrument the code with the required structural obligations and then monitor the execution of the compiled code to report coverage. Instrumentation based approaches often incur considerable runtime overhead for complex structural coverage metrics such as Modified Condition/Decision (MC/DC). Code instrumentation, in general, has to be approached with great care to ensure it does not modify the behavior of the original code. Furthermore, instrumented code cannot be used in conjunction with other analyses that reason about the structure and semantics of the code under test. In this work, we introduce a non-intrusive preprocessing approach for computing structural coverage information. It uses a static partial evaluation of the decisions in the source code and a source-to-bytecode mapping to generate the information necessary to efficiently track structural coverage metrics during execution. Our technique is flexible; the results of the preprocessing can be used by a variety of coverage-driven software analysis tasks, including automated analyses that are not possible for instrumented code. Experimental results in the context of symbolic execution show the efficiency and flexibility of our nonintrusive approach for computing code coverage information

DO-178C↗
NASA NTRS2016

Effects of Zoledronate and Mechanical Loading during Simulated Weightlessness on Bone Structure and Mechanical Properties

Space flight modulates bone remodeling to favor bone resorption. Current countermeasures include an anti-resorptive drug class, bisphosphonates (BP), and high-force loading regimens. Does the combination of anti-resorptives and high-force exercise during weightlessness have negative effects on the mechanical and structural properties of bone? In this study, we implemented an integrated model to mimic mechanical strain of exercise via cyclical loading (CL) in mice treated with the BP Zoledronate (ZOL) combined with hindlimb unloading (HU). Our working hypothesis is that CL combined with ZOL in the HU model induces additive structural and mechanical changes. Thirty-two C57BL6 mice (male,16 weeks old, n8group) were exposed to 3 weeks of either HU or normal ambulation (NA). Cohorts of mice received one subcutaneous injection of ZOL (45gkg), or saline vehicle, prior to experiment. The right tibia was axially loaded in vivo, 60xday to 9N in compression, repeated 3xweek during HU. During the application of compression, secant stiffness (SEC), a linear estimate of slope of the force displacement curve from rest (0.5N) to max load (9.0N), was calculated for each cycle once per week. Ex vivo CT was conducted on all subjects. For ex vivo mechanical properties, non-CL left femurs underwent 3-point bending. In the proximal tibial metaphysis, HU decreased, CL increased, and ZOL increased the cancellous bone volume to total volume ratio by -26, +21, and +33, respectively. Similar trends held for trabecular thickness and number. Ex vivo left femur mechanical properties revealed HU decreased stiffness (-37),and ZOL mitigated the HU stiffness losses (+78). Data on the ex vivo Ultimate Force followed similar trends. After 3 weeks, HU decreased in vivo SEC (-16). The combination of CL+HU appeared additive in bone structure and mechanical properties. However, when HU + CL + ZOL were combined, ZOL had no additional effect (p0.05) on in vivo SEC. Structural data followed this trend with ZOL not modulating trabecular thickness in CL + NAHU mice. In summary, our integrated model simulates the combination of weightlessness, exercise-induced mechanical strain, and anti-resorptive treatment that astronauts experience during space missions. Based on these results, we conclude that, at the structural and stiffness level, zoledronate treatment during simulated spaceflight does not impede the skeletal response to axial compression. In contrast to our hypothesis, our data show that zoledronate confers no additional mechanical or structural benefit beyond those gained from cyclical loading.

Mechanical Loading↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗
NASA NTRS2015

Lightning Protection and Structural Bonding for the B2 Test Stand

With the privatization of the space industry, NASA has entered a new era. To explore deeper parts of the solar system, NASA is developing a new spacecraft, the Space Launch System (SLS), capable of reaching these destinations, such as an asteroid or Mars. However, the test stand that is capable of testing the stage has been unused for many years. In addition to the updating/repair of the stand, more steel is being added to fully support the SLS. With all these modifications, the lightning protection system must be brought up to code to assure the protection of all personnel and assets. Structural bonding is a part of the lightning protection system. The focus of this project was to assure proper structural bonding. To begin, all relevant technical standards and the construction specifications were reviewed. This included both the specifications for the lightning protection and for general construction. The drawings were reviewed as well. From the drawings, bolted structural joints were reviewed to determine whether bonding was necessary. Several bolted joints were determined to need bonding according to the notes in the drawings. This exceeds the industry standards. The bolted joints are an electrically continuous joint. During tests, the stand experiences heavy vibration that may weaken the continuity of the bolted joint. Therefore, the secondary bonding is implemented to ensure that the structural joint has low resistance. If the structural joint has a high resistance because of corrosion, a potential gradient can occur that can cause a side flash. Damage, injury, or death can occur from a side flash so they are to be prevented. A list of the identified structural joints was compiled and sent to the contractor to be bonded. That covers the scope of this project.

Kinard, Brandon↗
NASA NTRS2016

Optimization of a Hot Structure Aeroshell and Nose Cap for Mars Atmospheric Entry

The National Aeronautics and Space Administration (NASA) is preparing to send humans beyond Low Earth Orbit and eventually to the surface of Mars. As part of the Evolvable Mars Campaign, different vehicle configurations are being designed and considered for delivering large payloads to the surface of Mars. Weight and packing volume are driving factors in the vehicle design, and the thermal protection system (TPS) for planetary entry is a technology area which can offer potential weight and volume savings. The feasibility and potential benefits of a ceramic matrix composite hot structure concept for different vehicle configurations are explored in this paper, including the nose cap for a Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and an aeroshell for a mid lift-to-drag (Mid L/D) concept. The TPS of a planetary entry vehicle is a critical component required to survive the severe aerodynamic heating environment during atmospheric en- try. The current state-of-the-art is an ablative material to protect the vehicle from the heat load. The ablator is bonded to an underlying structure, which carries the mechanical loads associated with entry. The alternative hot structure design utilizes an advanced carbon-carbon material system on the outer surface of the vehicle, which is exposed to the severe heating and acts as a load carrying structure. The preliminary design using the hot structure concept and the ablative concept is determined for the spherical nose cap of the HIAD entry vehicle and the aeroshell of the Mid L/D entry vehicle. The results of the study indicate that the use of hot structures for both vehicle concepts leads to a feasible design with potential weight and volume savings benefits over current state-of-the-art TPS technology that could enable future missions.

Langston, Sarah L.↗
NASA NTRS2017

Parametric Study of an Ablative TPS and Hot Structure Heatshield for a Mars Entry Capsule Vehicle

The National Aeronautics and Space Administration is planning to send humans to Mars. As part of the Evolvable Mars Campaign, different en- try vehicle configurations are being designed and considered for delivering larger payloads than have been previously sent to the surface of Mars. Mass and packing volume are driving factors in the vehicle design, and the thermal protection for planetary entry is an area in which advances in technology can offer potential mass and volume savings. The feasibility and potential benefits of a carbon-carbon hot structure concept for a Mars entry vehicle is explored in this paper. The windward heat shield of a capsule design is assessed for the hot structure concept as well as an ablative thermal protection system (TPS) attached to a honeycomb sandwich structure. Independent thermal and structural analyses are performed to determine the minimum mass design. The analyses are repeated for a range of design parameters, which include the trajectory, vehicle size, and payload. Polynomial response functions are created from the analysis results to study the capsule mass with respect to the design parameters. Results from the polynomial response functions created from the thermal and structural analyses indicate that the mass of the capsule was higher for the hot structure concept as compared to the ablative TPS for the parameter space considered in this study.

Langston, Sarah L.↗
NASA NTRS2017

Systems and Methods for Designing and Fabricating Contact-Free Support Structures for Overhang Geometries of Parts in Powder-Bed Metal Additive Manufacturing

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step.

Chou, Yuag-Shan↗
NASA NTRS2018

Systems and Methods for Designing and Fabricating Support Structures for Overhang Geometries of Parts in Additive Manufacturing

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is minimally or not connected to the part, the support structure can be removed with minimal or no post-processing step.

Chou, Yuag-Shan↗
NASA NTRS2017

Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Abstract: NASA is currently investigating methods to reduce the boil-off rate on large cryogenic upper stages. Two such methods to reduce the total heat load on existing upper stages are vapor cooling of the cryogenic tank support structure and integration of thick multilayer insulation systems to the upper stage of a launch vehicle. Previous efforts have flown a 2-layer MLI blanket and shown an improved thermal performance, and other efforts have ground-tested blankets up to 70 layers thick on tanks with diameters between 2 3 meters. However, thick multilayer insulation installation and testing in both thermal and structural modes has not been completed on a large scale tank. Similarly, multiple vapor cooled shields are common place on science payload helium dewars; however, minimal effort has gone into using boil-off to intercept heat on large structural surfaces associated with rocket stages. A majority of the vapor cooling effort focuses on metallic cylinders called skirts, which are the most common structural components for launch vehicles. In order to provide test data for comparison with analytical models, a 4 meter diameter test tank and assembly is currently being designed to include skirt structural systems with integral vapor cooling. In order to give a more representative result for actual applications, the technologies will be designed for an 8.4 m and scaled down to a 4 meter tank. In order to prove that the insulation system and vapor cooling attachment methods are structurally sound, acoustic testing will also be performed on the system. The test tank with insulation and vapor cooled shield installed will be tested thermally in the B2 test facility at NASAs Plum Brook Station both before and after being vibration tested at Plum Brooks Space Power Facility.

Johnson, Wesley↗