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NASA NTRS1943

A Method for Removal of Bakelite-Impregnated Wire Strain Gages

An increasing interest is being shown in the use of wire-type strain gages to measure static and dynamic stresses in aircraft-engine parts. Bakelite cement has been found satisfactory as a bonding agent for attaching the strain gages to machine parts that must operate at elevated temperatures. On many occasions, it is desired to remove Bakelite-cemented gages from the test parts for the purpose of replacing faulty gages or of returning the parts to service after strain measurements have been completed. Removal of the gages by means of scraping without prior treatment is very unsatisfactory because it is tedious and almost invariably damages the finished surface. Various solvents have been tried, but all attempts in this direction have been unsuccessful inasmuch as Bakelite cement, when properly baked, forms a polymer of very high molecular weight that resists the action of solvents. This report presents a gas-flame method of removal that is rapid and does not inure the structural part.

Kemp, Richard H.↗

NASA NTRS2015

Strain Gage Loads Calibration Testing with Airbag Support for the Gulfstream III SubsoniC Research Aircraft Testbed (SCRAT)

This paper describes the design and conduct of the strain-gage load calibration ground test of the SubsoniC Research Aircraft Testbed, Gulfstream III aircraft, and the subsequent data analysis and results. The goal of this effort was to create and validate multi-gage load equations for shear force, bending moment, and torque for two wing measurement stations. For some of the testing the aircraft was supported by three airbags in order to isolate the wing structure from extraneous load inputs through the main landing gear. Thirty-two strain gage bridges were installed on the left wing. Hydraulic loads were applied to the wing lower surface through a total of 16 load zones. Some dead-weight load cases were applied to the upper wing surface using shot bags. Maximum applied loads reached 54,000 lb. Twenty-six load cases were applied with the aircraft resting on its landing gear, and 16 load cases were performed with the aircraft supported by the nose gear and three airbags around the center of gravity. Maximum wing tip deflection reached 17 inches. An assortment of 2, 3, 4, and 5 strain-gage load equations were derived and evaluated against independent check cases. The better load equations had root mean square errors less than 1 percent. Test techniques and lessons learned are discussed.

flight tests↗

NASA NTRS2019

Comparison of Electrical Output Format Options for the Analysis of Strain-Gage Balance Calibration Data

Fundamental characteristics of three gage output formats are discussed that may be used to both interpret and analyze wind tunnel strain-gage balance data. The first output format uses raw outputs, i.e., absolute voltage measurements, for the analysis. This choice requires an intercept term in the regression model of the outputs if the Iterative Method is chosen for the load prediction. Raw outputs can be used for the analysis of all known output characteristics as long as the Iterative Method is applied. However, raw outputs cannot be used to analyze data of a balance with bi-directional outputs if the Non-Iterative Method is chosen for the analysis. The second output format, i.e., difference type 1, uses the difference between raw outputs and the natural zeros of the balance gages for the analysis. In this case, the use of the intercept term becomes optional. Analysis results for difference type 1 will exactly match analysis results obtained by using raw outputs as long as identical math models are used for the regression analysis. In addition, difference type 1 may be used to analyze data of a balance with bi directional outputs if an analyst prefers to process data using the Non-Iterative Method. The third output format, i.e., difference type 2, uses the difference between raw outputs and the outputs of the zero load point of a load series for the data analysis. The application of this format is only recommended if the maximum magnitude of all tare loads of a given balance calibration data set is less than two percent of capacity. Data from the calibration of a force balance is used to illustrate the application of the three gage output formats.

Wind Tunnel Strain-Gage Balance↗

NASA NTRSDate not supplied

An Improved Weighted Least Squares Algorithm for the Analysis of Strain-Gage Balance Calibration Data

An improved version of an algorithm is presented that uses a weighted least squares fit of balance calibration data for the generation of the balance load prediction equations. The weighted least squares fit assigns a weighting factor between zero and one to each calibration data point that depends on a simple count of the number of intentionally loaded balance gages. The greater the number of the loaded gages is, the smaller a data point's weighting factor becomes. This strategy has two advantages. First, single-component loads become more influential during the regression analysis of the calibration data. In addition, the negative influence of load schedule asymmetries on the regression analysis results can more effectively be controlled. The original algorithm of 2017 was improved in 2020. Now, gage output differences relative to the natural zeros are exclusively used as input for the determination of the number of intentionally loaded gages. The improved weighted least squares fit can be applied with both the Non-Iterative Method and the Iterative Method that are used for the balance load prediction in the aerospace testing community. Machine calibration data of a force balance is used to illustrate benefits of the application of the improved weighted least squares fit of balance calibration data.

strain-gage balance↗

NASA NTRS2024

Evaluation, Analysis, and Application of Internal Strain-Gage Balance Data

Experimental processes, analytical methods, and numerical algorithms are described that may be used to predict the forces and moments of an internal strain–gage balance during a wind tunnel test. First, the control volume model of a strain–gage balance and the concepts of load state, load space, and output space are introduced. These important abstractions provide a better understanding of fundamental characteristics of different balance load prediction approaches. Then, the description of strain–gage balance data and the definition of the primary bridge sensitivity are discussed. Afterwards, basic elements of the calibration of a typical six–component balance are reviewed. Two fundamentally different balance load prediction methods, the processing of check loads, and related topics are also discussed. Three real–world balance data examples are reviewed in great detail to illustrate typical analysis results for a variety of strain–gage balance designs. Finally, important observations are summarized and recommendations are provided. – Additional information and detailed mathematical derivations can be found in the appendices of the document. They include the following topics: balance terminology, definitions of important statistical metrics, balance axis system conventions, balance load transformations, the combined load diagram, electrical output format options, bi–directional output characteristics, determination of the natural zeros, derivation of two balance load prediction methods, description of two tare load iteration algorithms, modeling of balance temperature effects, basics of three–component moment balances, definition of the percent contribution, detection of linear and near–linear dependencies in balance calibration data, a regression model search algorithm, balance interactions, and other related information.

strain-gage balance↗

NASA NTRS1969

Ratio matching of half-bridge weldable strain gages, computer program

Computer program reduces the unbalance of weldable half-bridge strain gage installations. The program calculates the two resistance ratios of each half-bridge gage, outputting a table of gages ranked according to resistance ratio. The tabulation forms a convenient record of gage characteristics.

Anderson, K. F.↗

NASA NTRS1973

Experiments to study strain gage load calibrations on a wing structure at elevated temperatures

Laboratory experiments were performed to study changes in strain-gage bridge load calibrations on a wing structure heated to temperatures of 200 F, 400 F, and 600 F. Data were also obtained to define the experimental repeatability of strain-gage bridge outputs. Experiments were conducted to establish the validity of the superposition of bridge outputs due to thermal and mechanical loads during a heating simulation of Mach 3 flight. The strain-gage bridge outputs due to load cycle at each of the above temperature levels were very repeatable. A number of bridge calibrations were found to change significantly as a function of temperature. The sum of strain-gage bridge outputs due to individually applied thermal and mechanical loads compared well with that due to combined or superimposed loads. The validity of superposition was, therefore, established.

Monaghan, R. C.↗

NASA NTRS1973

Impact gages for detecting meteoroid and other orbital debris impacts on space vehicles.

Impacts on space vehicles have been simulated using the McDonnell Douglas Aerophysics Laboratory (MDAL) Light-Gas Guns to launch particles at hypervelocity speeds into scaled space structures. Using impact gages and a triangulation technique, these impacts have been detected and accurately located. This paper describes in detail the various types of impact gages (piezoelectric PZT-5A, quartz, electret, and off-the-shelf plastics) used. This description includes gage design and experimental results for gages installed on single-walled scaled payload carriers, multiple-walled satellites and space stations, and single-walled full-scale Delta tank structures. A brief description of the triangulation technique, the impact simulation, and the data acquisition system are also included.

Mastandrea, J. R.↗

NASA NTRS1973

Evaluation of submarine strain-gage systems for monitoring coastal sediment migration

Single and multiple strain-gage systems were respectively evaluated as in situ point and areal sensors for monitoring sand-height variations in coastal environments. Static loading tests indicate that gage response pressure is linear for sand heights up to 24 inches. Response pressures are a function of both sand height and aggregate density, with density being influenced by both sediment texture and degree of compaction. Poorer sediment sorting and greater compaction result in higher response pressures. Field tests in a beach foreshore environment indicate that the gage systems are effective qualitative instruments for monitoring long-period migration trends of beach sediments; whereas, short-period responses are not sufficiently reliable. The durability and compactness of the gage systems must be substantially increased for effective field operations. It is recommended that the systems' qualitative potentials be further developed, whereas their development as quantitative instruments be terminated. Further development should emphasize the construction of remote recording systems designed for semipermanent installation.

Shideler, G. L.↗

NASA NTRS1975

A hot-wire surface gage for skin friction and separation detection measurements

A heated-element, skin-friction gage employing a very low thermal conductivity support is described. It is shown that the effective dimension of the gage in the stream direction in only 0.06 mm, including the effects of heat conduction in the supporting material. Because of its small size, the calibration of the gage is independent of the kind of boundary-layer flow (whether laminar or turbulent) and is insensitive to pressure gradients. Construction tolerances can be maintained so that a single universal calibration can be applied. Multiple gages, sufficiently closely spaced so as to interfere with each other, are shown to provide accurate determinations of the locations of the points of boundary-layer separation and reattachment.

Rubesin, M. W.↗

NASA NTRS1975

The Shuttle Orbital Maneuvering System P-V-T Propellant Quantity Gaging Accuracy and Leak Detection Allowance for Four Instrumentation Conditions

The shuttle orbital maneuvering system (OMS) pressure-volume-temperature (P-V-T) propellant gaging module computes the quantity of usable OMS propellant remaining based on the real gas P-V-T relationship for the propellant tank pressurant, helium. The OMS P-V-T propellant quantity gaging error was determined for four sets of instrumentation configurations and accuracies with the propellant tank operating in the normal constant pressure mode and in the blowdown mode. The instrumentation inaccuracy allowance for propellant leak detection was also computed for these same four sets of instrumentation. These gaging errors and leak detection allowances are presented in tables designed to permit a direct comparison of the effectiveness of the four instrumentation sets. The results show the magnitudes of the improvements in propellant quantity gaging accuracies and propellant leak detection allowances which can be achieved by employing more accurate pressure and temperature instrumentation.

Duhon, D. D.↗

NASA NTRS1976

The effects of incomplete annealing on the temperature dependence of sheet resistance and gage factor in aluminum and phosphorus implanted silicon on sapphire

Partial annealing of damage to the crystal lattice during ion implantation reduces the temperature coefficient of resistivity of ion-implanted silicon, while facilitating controlled doping. Reliance on this method for temperature compensation of the resistivity and strain-gage factor is discussed. Implantation conditions and annealing conditions are detailed. The gage factor and its temperature variation are not drastically affected by crystal damage for some crystal orientations. A model is proposed to account for the effects of electron damage on the temperature dependence of resistivity and on silicon piezoresistance. The results are applicable to the design of silicon-on-sapphire strain gages with high gage factors.

Pisciotta, B. P.↗

NASA NTRS1975

Flush-mounted hot-wire gage for skin friction and separation detection measurements

A heated-element skin-friction gage employing a very low thermal-conductivity support is described. It is shown that the effective dimension of the gage in the stream direction is only 0.06 mm, including the effects of heat conduction in the supporting material. Because of its small size, the calibration of the gage is independent of the kind of boundary-layer flow (whether laminar or turbulent) and is insensitive to pressure gradients. Construction tolerances can be maintained so that a single universal calibration can be applied. Multiple gages, sufficiently closely spaced so as to interfere with each other, are shown to provide accurate determinations of the location of the points of boundary-layer separation and reattachment.

Rubesin, M. W.↗

NASA NTRS1977

Problems Associated with Attaching Strain Gages to Titanium Alloy Ti-61-4V

Weldable strain gages have shown excellent high temperature characteristics for supersonic cruise aircraft application. The spotwelding attachment method, however, has resulted in serious reductions in the fatigue life of titanium alloy (Ti-6Al-4V) fatigue specimens. The reduction is so severe that the use of weldable strain gages on operational aircraft must be prohibited. The cause of the fatigue problem is thought to be a combination of the microstructure changes in the material caused by spotwelding and the presence of the flange of the stain gage. Brazing, plating, and plasma spraying were investigated as substitutes for spotwelding. The attachment of a flangeless gage by plasma spraying provided the most improvement in the fatigue life of the titanium.

Jenkins, J. M.↗

NASA NTRS1977

A study of the effect of radical load distributions on calibrated strain gage load equations

For several decades, calibrated strain gages have been used to measure loads on airplanes. The accuracy of the equations used to relate the strain gage measurements to the applied loads has been based primarily on the results of the load calibration. An approach is presented for studying the effect of widely varying load distributions on strain gage load equations. The computational procedure provides a link between the load calibration and the load to be measured in flight. A matrix approach to equation selection is presented, which is based on equation standard error, load distribution, and influence coefficient plots of the strain gage equations, and is applied to a complex, delta-wing structure.

Jenkins, J. M.↗

NASA NTRS1977

Strain gage calibration of a complex wing

Modern complex structural arrangements have complicated the task of measuring flight loads with calibrated strain gages. This paper examines the use of a relatively simple structural model to characterize the load responses of strain gages located on various spars of a delta wing. Strains measured during a laboratory load calibration of a wing structure are compared with calculations obtained from a simplified NASA structural analysis (NASTRAN) model. Calculated and measured influence coefficient plots that show the shear, bending, and torsion characteristics of typical strain-gage bridges are presented. Typical influence coefficient plots are given for several load equations to illustrate the derivation of the equations from the component strain-gage bridges. A relatively simple structural model was found to be effective in predicting the general nature of strain distributions and influence coefficient plots. The analytical processes are shown to be useful in obtaining a good load calibration. The analytical processes cannot, however, be used in lieu of an actual load calibration of an aircraft wing.

Jenkins, J. M.↗

NASA NTRS1978

Buried wire gage for wall shear stress measurements

A buried wire gage for measuring wall shear stress in fluid flow was studied and further developed. Several methods of making this relatively new type of gage were examined to arrive at a successful technique that is well-suited for wind-tunnel testing. A series of measurements was made to demonstrate the adequacy of a two-point calibration procedure for these gages. The buried wire gage is also demonstrated to be ideally suited for quantitative measurement of wall shear stress in wind-tunnel testing.

Murthy, V. S.↗

NASA NTRS1978

Bi-directional, buried-wire skin-friction gage

A compact, nonobtrusive, bi-directional, skin-friction gage was developed to measure the mean shear stress beneath a three-dimensional boundary layer. The gage works by measuring the heat flux from two orthogonal wires embedded in the surface. Such a gage was constructed and its characteristics were determined for different angles of yaw in a calibration experiment in subsonic flow with a Preston tube used as a standard. Sample gages were then used in a fully three-dimensional turbulent boundary layer on a circular cone at high relative incidence, where there were regimes of favorable and adverse pressure gradients and three-dimensional separation. Both the direction and magnitude of skin friction were then obtained on the cone surface.

Higuchi, H.↗