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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Preload Loss in a Spacecraft Fastener via Vibration-Induced Unwinding

Sound engineering practice requires that fasteners and bolted joints maintain preload in service. NASA recently concluded a series of vibration tests of a multicomponent structure intended to simulate an upper stage section of a launch vehicle. The stacked components were joined through six circumferentially placed bolted cup-cone-style pyrotechnic joint mechanisms designed to share spacecraft structural loads and then enable separation during ascent. Over the course of the vibration test campaign, all six bolted cup-cone mechanisms experienced some degree of preload loss with two mechanisms losing half of their original bolt preload. A subsequent forensic anomaly investigation concluded that vibration-induced unwinding of the preload nut-and-bolt assemblies occurred despite the use of safety wire and high levels of thread friction. A series of experiments were done to better understand how large, heavily preloaded fasteners could unwind. Additionally, thread friction torque was measured and the fastener locking capability of safety wire was evaluated. The friction coefficient between the clamped cup-cone components was characterized and finally a highly instrumented mechanism-level vibration test was done to reproduce the unwinding phenomenon to better understand the mechanism's behavior. The conclusion drawn was that vibration and structural forces led to relative motion (sliding) of the clamped components, resulting in self-loosening and unwinding effects on the nut-and-bolt assembly. To counter this phenomenon, more effective fastener locking methodologies were recommended and a follow-on effort was initiated to quantify the relationship between preload, component motion, and resulting unwinding forces. It is hoped that elucidation of these effects can be used to design more effective fastener locking features.

fasteners↗
NASA NTRS2018

High Speed Bearing Wear Rate Measurements for Spacecraft Active Thermal Control Fluid Pumps with a Novel Pin on Disk Apparatus

A novel pin on disc tribometer was designed and constructed to generate a high-speed, wear coefficient database for hydrodynamic bearings that are typically used in canned motors found in the active thermal control circuits of robotic and inhabited spacecraft. The primary motivation for this work was the premature failure of the active external thermal control pump on the International Space Station in 2010. During the failure investigation of this incident, the root cause was postulated to be high speed wear of the bearings. Although a detailed forensic analysis gave credibility to this theory, the lack of wear coefficient data at relevant conditions prevented validation of this finding. The database generated from the new Extreme Environment Tribometer (EET) enabled a closure calculation within 5% of the observed wear from inspections of the failed hardware. Testing in anhydrous ammonia and surrogate fluid was performed to provide a means for simplified testing in the future and to populate a preliminary database for the design of future active thermal control systems on spacecraft. The EET and test techniques developed for the measurement of high-speed wear coefficients are available to future system designers.

thermal control↗
NASA NTRS2021

Chemical Reactivity of In-Situ Lunar Dust for Biotoxicity Assessment

How does the chemical reactivity of in-situ lunar dust compare to Apollo samples currently stored in curation facilities here on Earth? Essential investigations of this question will help us to further mitigate exploration risks for future human explorers on the Moon and will also provide critical information for astrobiologists and space biologists using the Moon for scientific inquiry. Apollo 14 dust biotoxicity studies, carried out by the NASA Lunar Airborne Dust Toxicity Assessment Group (LADTAG), included numerous cellular and animal experiments. Intratracheal instillation and inhalation studies in rats both showed Apollo 14 dust to be intermediate in toxicity compared to low-tox titanium dusts and high-tox quartz dusts of similar particle sizes. The collective results were used in models to establish a safe exposure limit for astronauts. Although LADTAG took extensive steps to preserve what chemical reactivity may still have existed in the samples, it is simply unknown if they possessed true in-situ chemical reactivity or if that reactivity has decayed. Initial gas loss on collection and other alterations, and even intermittent exposure to Earth-normal conditions during subsequent decades of handling, obscure a forensic reconstruction of the initial state. Because a mineral dust’s chemical reactivity influences its biotoxicity, researchers have developed methods to “activate” lunar dust and simulants. Past studies that modeled impact processes and radiation in the lunar environment suggest that in-situ lunar dust is likely to be more chemically reactive than Earth-exposed samples. Because of these results, in-situ measurements are warranted. Since the lunar surface is heterogeneous, dust biotoxicity is expected to vary from site to site due to particle size, mineralogy, physical characteristics, degree of space weathering, and chemical reactivity. This circumstance dictates dust assessments at a suite of lunar sites enabled by CLPS opportunities. Dose, location, and duration of particle exposure will also affect biological responses. In-situ chemical reactivity measurements can inform cross-cutting collaborative research campaigns such as astrobiology studies examining regolith interactions with organisms and its ability to preserve chemical and structural biomarkers, as well as space biology investigations that examine regolith-microbe interactions relating to life support systems, plant growth, biomining, and development of regolith biocomposites.

Jon C Rask↗
NASA NTRSDate not supplied

Chemical Reactivity of In-Situ Lunar Dust for Biotoxicity Assessment

Introduction: How does the chemical reactivity of in-situ lunar dust compare to Apollo samples currently stored in curation facilities here on Earth? Essential investigations of this question will help us to further mitigate exploration risks for future human explorers on the Moon and will also provide critical information for astrobiologists and space biologists using the Moon for scientific inquiry. Discussion: Apollo 14 dust biotoxicity studies, carried out by the NASA Lunar Airborne Dust Toxici-ty Assessment Group (LADTAG), included numerous physiochemical studies[1] and cellular and animal ex-periments. Intratracheal instillation [2] and inhalation studies [3] in rats both showed Apollo 14 dust to be intermediate in toxicity compared to low-tox titanium dusts and high-tox quartz dusts of similar particle siz-es. The collective results were used in models [4] to establish a safe exposure limit for astronauts [5]. Alt-hough LADTAG took extensive steps to preserve what chemical reactivity may still have existed in the sam-ples, it is simply unknown if they possessed true in-situ chemical reactivity or if that reactivity has de-cayed. Initial gas loss on collection and other altera-tions, and even intermittent exposure to Earth-normal conditions during subsequent decades of handling, obscure a forensic reconstruction of the initial state. Because a mineral dust’s chemical reactivity influ-ences its biotoxicity [6], researchers have developed methods to “activate” lunar dust and simulants [7][8]. Past studies that modeled impact processes and radia-tion [9] in the lunar environment suggest that in-situ lunar dust is likely to be more chemically reactive than Earth-exposed samples. Because of these results, in-situ measurements are warranted [10]. Other studies have examined the hydroxyl generating capability of iron bearing mineral phases [11][12] and further em-phasize the role iron plays in chemical reactivity of lunar material, as well as decay of chemical reactivity in mineral dusts [12]. Recent observations of the lunar surface reveal the presence of hematite [13], a finding that further supports the hypothesis that in-situ lunar dust is reactive. Since the lunar surface is heterogene-ous, dust biotoxicity is expected to vary from site to site [14] due to particle size, mineralogy, physical characteristics, degree of space weathering, and chemi-cal reactivity (Figure 1). This circumstance dictates dust assessments at a suite of lunar sites enabled by upcoming NASA and commercial lunar payload ser-vices (CLPS) opportunities. Dose, location, and dura-tion of particle exposure will also affect biological responses. In-situ chemical reactivity measurements can inform cross-cutting collaborative research cam-paigns such as astrobiology studies examining regolith interactions with organisms and its ability to preserve chemical and structural biomarkers, as well as space biology investigations that examine regolith-microbe interactions relating to life support systems, plant growth, biomining, and development of regolith bio-composites. Figure 1: Environment conditions on the lunar surface that may alter regolith reactivity. Summary A series of in-situ measurements of lu-nar dust free radical chemistry at future Artemis and CLPS landing sites, combined with LADTAG-like studies of freshly collected lunar dust specimens, will reveal the true chemical reactivity of in-situ lunar dust and generate scientific data that can be compared to the chemical reactivity and biotoxicity of samples from Apollo landing sites. Furthermore, results from in situ measurements and biotoxicity studies of freshly col-lected specimens can also be used to validate, or re-quire revision of, the current astronaut permissible exposure limit [15]. References: [1] McKay D et al (2015), Acta As-tronaut 107:163–176. [2] Rask J et al (2013), LPSC, p 3062. [3] Lam CW et al (2013), Inhal Toxicol 25:661–678. [4] James JT, et. al. (2013) , Inhal Toxicol 25:243–256. [5] Scully RR, et.al. (2013), Inhal Toxi-col 25:785–793. [6] Porter, D. W., et.al., (2002), Tox-icology 175, 63–71. [7] Wallace WT, et.al., (2009), Meteorit Planet Sci 44:961–970. [8] Wallace WT, et.al., (2010), Earth Planet Sci Lett 295:571–577. [9] Loftus D, Rask J, et.al., (2010), Earth Moon Planet 107:95–105. [10] Rask J, et.al., (2009) LEAG p 57. [11] Turci F, et.a., (2015), Astrobiology. 2015;15(5):371-380. [12] Hendrix DA, et.al., (2019), Geohealth. 2019;3(1):28-42. [13] Li, S., et.al., (2020), Science advances, 6(36), p.eaba1940. [14] Rask J. (2018), In: Cudnik B. (eds) Encyclopedia of Lunar Science. Springer, Cham. [15] Rask, J, (2020), LPI, Artemis III Sci. def. paper 2120.

chemical reactivity↗
NASA NTRS2021

Arecibo Observatory Auxiliary M4N Socket Termination Failure Investigation

The NASA Engineering and Safety Center (NESC) was requested to support the Arecibo Observatory failure investigation in determining the root cause of the Auxiliary M4N cable failure. The NESC and Kennedy Space Center led an integrated NASA investigation with support from Marshall Space Flight Center and The Aerospace Corporation that included forensic investigation of failed hardware, finite element modeling, materials characterization, and root cause analysis. This document contains the outcome of the NESC Assessment.

Zinc Spelter Sockets↗
NASA NTRS2021

NASA Engineering and Safety Center Technical Bulletin No. 21-05: Industry Recommendations from Arecibo Observatory Zinc Spelter Socket Joint Failure Analysis

A structural analysis and forensic investigation concluded that the Arecibo Observatory M4N socket joint failure in August 2020 was primarily due to cumulative damage caused by initially low structural design margins and a high percentage of sustained load, resulting in zinc creep deformation, progressive internal socket wire damage, and eventual loss of joint capacity. Open spelter sockets of this type are used throughout industry in stay cables. Recommendations are proposed to prevent failures of similar socket joints, including verification of positive stress margins in socket joint wires for all failure modes, periodic visual inspections with pass/fail criteria for zinc extrusion that are tied to structural qualification, and revisiting codes/ industry standards to capture lessons learned.

Arecibo Observatory↗
NASA NTRSDate not supplied

Digital Twins and Living Models at NASA

The idea of a “digital twin” was born at NASA in the 1960s as a “living model” of the Apollo mission. In response to Apollo 13’s oxygen tank explosion and subsequent damage to the main engine, NASA employed multiple simulators to evaluate the failure and extended a physical model of the vehicle to include digital components. This “digital twin” was the first of its kind, allowing for a continuous ingestion of data to model the events leading to up to the accident for forensic analysis and exploration of next steps. Fast forward half a century and NASA, along with others in the aerospace community, continues to develop and utilize high-fidelity digital models of physical systems and components as well as the extreme environments in which they operate. NASA aims to travel further and stay longer in space as we realize the Artemis program, taking us from the moon to Mars by establishing a sustainable presence on the Moon to prepare for missions to Mars. We will no longer be able to rely on constant connectivity with an asset nor be in-the-loop for on-demand human intervention in the event of an anomaly. Further, the importance of digital twins is increasing as we seek alternatives for certification of structures so large that they cannot be fully evaluated in existing test facilities and autonomous systems that are not deterministic. The idea of a digital twin is not a new one. What is new is the scale, ordinality, and non-deterministic nature of the models that are critical to achieving NASA’s goals. Their number and autonomy from each other as well as the reference system is suggestive of a changing ecosystem, returning us the idea of a living model.

Digital Twin↗
NASA NTRS2021

Latent Cure Epoxy Resins for Reliable Joints in Secondary-Bonded Composite Structures

In high-performance polymer matrix composite assemblies, adhesive bonding is generally superior to mechanical fastening in structural performance and manufacturing efficiency. However, adhesive bonds are susceptible to minute levels of contamination accumulated during assembly that can lead to unpredictable, weak bonds. Current methods of measuring bond strength are all destructive mechanical tests. To overcome these challenges, redundant load paths (e.g., mechanical fasteners) are often implemented in secondary-bonded, primary-structures, which can greatly reduce structural performance. This study investigated reformulated aerospace epoxy matrix resins with stoichiometric offset to inhibit cure of the matrix resin prior to assembly. Inhibited resins can reflow and mix across the joint interface, which eliminates the material discontinuity and forms a homogenous joint with reliable fracture properties. The goal of this study was to develop and demonstrate secondary composite assemblies that are mechanically and microscopically indistinguishable from a co-cured composite joint. This article describes the development of latent epoxy resins, the fabrication of test articles, and the mechanical properties measured from experimental joints compared with conventional, co-cured laminates. Methods of in-line quality control using and infrared spectroscopy and post-assembly forensics are also described. The final mode-II fracture toughness measured from precracked AERoBOND specimens was similar to that measured from co-cured laminates indicating that later cure epoxy materials could be a suitable replacement for secondary bonding.

Polymer-matrix composites (PMCs)↗
NASA NTRSDate not supplied

Tribology Induced Water Pump Bearing Failure

NASA’s In-Space Propulsion facility experienced two infant mortality water pump bearing failures during a recent refurbishment campaign, the cause or causes of which were unclear. A forensic failure study was undertaken that included site visits, collection and examination of physical evidence and a bearing and pump design review. The pumps are large (2000 hp) vertical turbine design machines that utilize metallic sleeve bearings cooled and lubricated by the pumped fluid (water). Though initial possible root cause for the failures were attributed to improper fabrication and debris contamination, detailed examination of failure surfaces combined with bearing design revealed that the failure mode was thermal seizure brought on by inadequate cooling flow. An unusual contributing factor was that the use of grease as an assembly lubricant, as opposed to a fluid like oil, appears to have exacerbated the rather than alleviated the thermal runaway by blocking water flow. Resolution of the problem was achieved through the design and installation of dedicated bearing lubrication water feed system.

bearings↗
NASA NTRSDate not supplied

Recent Results from Dragonfly Testing/Analysis as we head to PDR

Dragonfly is a relocatable lander mission to Saturn's moon Titan4, which as well as being a target of out-standing astrobiological interest as an organic-rich Ocean World, has the combination of low gravity (1/7 that of Earth) and a thick atmosphere (4x the density of Earth), making it an environment uniquely suitable for flight. Thus, the Dragonfly lander (similar in size to the Curiosity Mars rover) can take off using lift from a set of eight rotors and fly to a new landing site several kilometers away. The ability to perform such flights, lasting approximately 30 minutes, every month or so on Titan brings unprecedented mobility to planetary exploration, on a world known to have a diverse land-scape of dunes, craters and other features. Dragonfly is planned to launch in 2027, and following a nearly seven year interplanetary cruise would arrive at Titan by 2034. Due to the large scale height of the Titan atmosphere, Entry, Descent, and Landing (EDL) will be prolonged affair, taking nearly two hours to reach the surface. The ballistic entry environments that Dragonfly will be subjected to are fairly similar to that experienced by recent Mars missions; peak heating on the aeroshell will be about 300 W/sq.cm and peak deceleration is about 10g’s. Following the five minute entry segment, much of the remaining time is spent descending on the drogue and main para-chutes, which carry the dual role of decelerating the spacecraft and stabilizing the system during the long descent. While on one hand, this leisurely EDL sequence affords a relaxed timeline and plenty of time for event staging, it also provides ample opportunity for small disturbances to grow into potential flight safety risks, adding emphasis to the need for careful modeling, simulation and testing of key dynamic events. About two hours after entering the atmosphere, the nearly one metric ton rotocraft will be lowered approximately one meter out of the backshell (the ‘pose’ maneuver) to expose all eight rotors. The rotors will then be used to arrest any residual spin rate and prepare the system for transition to powered flight. Once despin is complete and the lander reaches a target altitude of 1.2 km above the surface (as verified by on-board lidar), the lander will be released and free fall for approximately one second before beginning controlled free flight. This entire “preparation for powered flight” process takes place over several minutes while the system is subject to the dynamic environment produced by so-called “wrist-mode” oscillations as the lander and backshell swing on the main parachute. Once in free flight, the lander will engage on-board terrain relative navigation to locate and navigate to a safe landing zone in the Shangri-La dune field south of Selk crater. Communication during this sequence will be limited to a series of direct-to-Earth X-band tones signalling key events and providing forensic information. Once on the ground, the lander will begin to send additional information, including data collected during this EDL sequence by the on-board Dragonfly Entry Aerosciences Measurements (DrEAM) instrumentation suite. This presentation will walk through the entry to first landing timeline in more detail, with a focus on recent analysis and testing results that inform system performance, margins and residual risk estimation.

Dragonfly↗