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NASA NTRS2019

Combined Qualification Vibration Testing and Fixed Base Modal Testing Utilizing a Fixed Based Correction Method

Vibration testing spaceflight hardware is a vital, but time consuming and expensive endeavor. Traditionally modal tests are performed at the component, subassembly, or system level, preferably free-free with mass loaded interfaces or fixed base on a seismic mass to identify the fundamental structural dynamic (modal) characteristics. Vibration tests are then traditionally performed on single-axis slip tables at qualification levels that envelope the maximum predicted flight environment and workmanship in order to verify the spaceflight hardware can survive its flight environment. These two tests currently require two significantly different test setups, facilities, and ultimately reconfiguration of the spaceflight hardware. The vision of this research is to show how traditional fixed-base modal testing can be accomplished using vibration qualification testing facilities, which not only streamlines testing and reduces test costs, but also opens up the possibility of performing modal testing to untraditionally high excitation levels that provide for test-correlated finite element models to be more representative of the spaceflight hardware's response in a flight environment. This paper documents the first steps towards this vision, which is the comparison of modal parameters identified from a traditional fixed-based modal test performed on a modal floor and those obtained by utilizing a fixed based correction method with a large single-axis electrodynamic shaker driving a slip table supplemented with additional small portable shakers driving on the slip table and test article. To show robustness of this approach, the test article chosen is a simple linear weldment, whose mass, size, and modal parameters couple well with the dynamics of the shaker/slip table. This paper will show that all dynamics due to the shaker/slip table were successfully removed resulting in true fixed-base modal parameters, including modal damping, being successfully extracted from a traditional style base-shake vibration test setup.

Base-Shake↗

NASA NTRS2019

High-fidelity Multidisciplinary Sensitivity Analysis and Design Optimization for Rotorcraft Applications

A multidisciplinary sensitivity analysis of rotorcraft simulations involving tightly coupled high-fidelity computational fluid dynamics and comprehensive analysis solvers is presented and evaluated. A sensitivity-enabled fluid dynamics solver and a nonlinear flexible multibody dynamics solver are coupled to predict aerodynamic loads and structural responses of helicopter rotor blades. A discretely consistent adjoint-based sensitivity analysis available in the fluid dynamics solver provides sensitivities arising from unsteady turbulent flows and unstructured dynamic overset meshes, while a complex-variable approach is used to compute structural sensitivities with respect to aerodynamic loads. The multidisciplinary sensitivity analysis is conducted through integrating the sensitivity components from each discipline of the coupled system. Accuracy of the coupled system is validated by conducting simulations for a benchmark rotorcraft model and comparing solutions with established analyses and experimental data. Sensitivities of lift computed by the multidisciplinary sensitivity analysis are verified by comparison with the sensitivities obtained by complex-variable simulations. Finally the multidisciplinary sensitivity analysis is applied to a constrained gradient-based design optimization for a HART-II rotorcraft configuration.

Wang, Li↗

NASA NTRSDate not supplied

An Application of Flexible Multibody Simulations to Space Launch Systems Liftoff Pad Separation and Umbilical Disconnect

A flexible multibody dynamics approach is applied to the Space Launch System (SLS) liftoff Coupled Loads Analysis (CLA), enabling the inclusion of a large array of component nonlinearities with extreme computational efficiency. The nonlinearities include the cryogenic induced preloads due to the large rotations of the aft struts connecting the Core Stage (CS) to the boosters, the contact/separation and potential re-contact at the booster aft skirt to Mobile Launcher(ML) interface, contact/separation and potential re-contact at the ML/extensible columns interfaces, secondary disconnect of the CS umbilicals including the LOX and LH2 Tail Service Mast Umbilicals (TSMUs), and the disconnect of the upper stage umbilical, the Interim Cryogenic Propulsion Stage Umbilical (ICPSU). The ICPSU disconnect involves algorithms simulating the winch motors reeling lanyard ropes, the nonlinear modeling of ropes and hoses, the disconnect and capture of multiple umbilical ground plates by catch-nets (geometrically nonlinear models), and the large rotations of the ML gantry in order to track clearances between the lifting SLS vehicle and umbilicals rotating out of the way. The flexible multibody dynamics framework utilized for these simulations provided a systematic and efficient framework for adding complex nonlinearities at the system level which would have otherwise not been possible in standard CLAs or would have to be treated by separate local analyses thereby not accounting for the coupled system behavior.

Application↗

NASA NTRSDate not supplied

Fabrication and Mechanical Testing of Heat Exchanger Tubes for Nuclear Propulsion and Other Applications from Continuous Carbon Nanotube Yarns and Tapes

As NASA and other agencies are looking to conduct sustained operations in space, nuclear engines have been receiving increased focus. The high specific impulse and high fuel efficiency at high thrust output of these engines can halve the transit time for human missions to Mars, or enable missions requiring multiple orbital parameter adjustments. In both Nuclear Thermal Propulsion (NTP) and Nuclear Electric Propulsion (NEP) systems, heat exchangers play a critical role in transferring energy from the reactor to a working fluid, hydrogen in the case of NTP and a molten salt or other fluid for electricity generation in NEP. Heat exchangers are also required in other parts of the spacecraft. Various manufacturing methods and materials are being considered for the heat exchangers. In this presentation the fabrication and testing of heat exchangers made from continuous carbon nanotube (CNT) yarns and tapes are discussed. The fabrication workflow is compared and contrasted, as well as performance of prototype heat exchanger tubes fabricated using the various CNT formats. The failure loads and mechanisms of the tubes under tensile, compression, and bending loads are assessed. A further comparison of the CNT materials to components fabricated from carbon fiber is made. The presented work will contribute to the selection of approaches for heat exchanger fabrication methods for nuclear propulsion and other applications.

Heat Exchanger↗

NASA NTRS1986

On 3-D inelastic analysis methods for hot section components

The objective of this program is to produce a series of new computer codes that permit more accurate and efficient three-dimensional inelastic structural analysis of combustor liners, turbine blades, and turbine vanes. Each code embodies a progression of mathematical models for increasingly comprehensive representation of the geometrical features, loading conditions, and forms of nonlinear material response that distinguish these three groups of hot section components.

Todd, E. S.↗

NASA NTRS1987

Three-dimensional inelastic analysis methods for hot section components

Todd, E. S.↗

NASA NTRS1986

On 3-D inelastic analysis methods for hot section components (base program)

A 3-D Inelastic Analysis Method program is described. This program consists of a series of new computer codes embodying a progression of mathematical models (mechanics of materials, special finite element, boundary element) for streamlined analysis of: (1) combustor liners, (2) turbine blades, and (3) turbine vanes. These models address the effects of high temperatures and thermal/mechanical loadings on the local (stress/strain)and global (dynamics, buckling) structural behavior of the three selected components. Three computer codes, referred to as MOMM (Mechanics of Materials Model), MHOST (Marc-Hot Section Technology), and BEST (Boundary Element Stress Technology), have been developed and are briefly described in this report.

Wilson, R. B.↗

NASA NTRS2016

Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m-Class System

Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. Therefore, the HIAD projects experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m-class system will introduce many new structural and logistical challenges to an already complicated manufacturing process.Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to ac-count for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs.There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m HIAD.In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current 12m aeroshell manufacturing and testing that is addressing these challenges

Infatables↗

NASA NTRS1990

Definition of large components assembled on-orbit and robot compatible mechanical joints

One of four major areas of project Pathfinder is in-space assembly and construction. The task of in-space assembly and construction is to develop the requirements and the technology needed to build elements in space. A 120-ft diameter tetrahedral aerobrake truss is identified as the focus element. A heavily loaded mechanical joint is designed to robotically assemble the defined aerobrake element. Also, typical large components such as habitation modules, storage tanks, etc., are defined, and attachment concepts of these components to the tetrahedral truss are developed.

Williamsen, J.↗

NASA NTRS2016

Manufacturing Challenges and Benefits When Scaling the HIAD Stacked-Torus Aeroshell to a 15 Meter Class System

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6 meters, with cone angles of 60 and 70 degrees. To meet NASA and commercial near-term objectives, the HIAD team must scale the current technology up to 12-15 meters in diameter. Therefore, the HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6-meter to a 15-meter class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15-meter-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6-meter aeroshell (the largest HIAD built to date), a 12-meter aeroshell has four times the cross-sectional area, and a 15-meter one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15-meter HIAD. In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current manufacturing and testing that addressing these challenges.

Infatables↗

NASA NTRS2013

Hidden Connections between Regression Models of Strain-Gage Balance Calibration Data

Hidden connections between regression models of wind tunnel strain-gage balance calibration data are investigated. These connections become visible whenever balance calibration data is supplied in its design format and both the Iterative and Non-Iterative Method are used to process the data. First, it is shown how the regression coefficients of the fitted balance loads of a force balance can be approximated by using the corresponding regression coefficients of the fitted strain-gage outputs. Then, data from the manual calibration of the Ames MK40 six-component force balance is chosen to illustrate how estimates of the regression coefficients of the fitted balance loads can be obtained from the regression coefficients of the fitted strain-gage outputs. The study illustrates that load predictions obtained by applying the Iterative or the Non-Iterative Method originate from two related regression solutions of the balance calibration data as long as balance loads are given in the design format of the balance, gage outputs behave highly linear, strict statistical quality metrics are used to assess regression models of the data, and regression model term combinations of the fitted loads and gage outputs can be obtained by a simple variable exchange.

Ulbrich, Norbert↗

NASA NTRS1996

Load-Following Power Timeline Analyses for the International Space Station

Spacecraft are typically complex assemblies of interconnected systems and components that have highly time-varying thermal communications, and power requirements. It is essential that systems designers be able to assess the capability of the spacecraft to meet these requirements which should represent a realistic projection of demand for these resources once the vehicle is on-orbit. To accomplish the assessment from the power standpoint, a computer code called ECAPS has been developed at NASA Lewis Research Center that performs a load-driven analysis of a spacecraft power system given time-varying distributed loading and other mission data. This program is uniquely capable of synthesizing all of the changing spacecraft conditions into a single, seamless analysis for a complete mission. This paper presents example power load timelines with which numerous data are integrated to provide a realistic assessment of the load-following capabilities of the power system. Results of analyses show how well the power system can meet the time-varying power resource demand.

Fincannon, James↗

NASA NTRS1998

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗

NASA NTRS1987

Random loading fatigue crack growth: Crack closure considerations

The prediction of fatigue crack growth is an important element of effective fracture control for metallic structures and mechanical components, especially in the aerospace industry. The prediction techniques available and applied today are mostly based on fatigue crack growth measurements determined in constant amplitude testing. However, while many service loadings are constant amplitude, many more loadings are random amplitude. An investigation to determine which statistics of random loadings are relevant to fatigue crack closure was conducted. The fundamentals of random processes and crack closure are briefly reviewed, then the relevance of certain random process parameters to the crack closure calculation are discussed qualitatively. A course for further research is outlined.

Ortiz, Keith↗

NASA NTRS2013

The Effect of Pre-Stressing on the Static Indentation Load Capacity of the Superelastic 60NiTi

Superelastic nickel-titanium alloys, such as 60NiTi (60Ni-40Ti by wt.%), are under development for use in mechanical components like rolling element bearings and gears. Compared to traditional bearing steels, these intermetallic alloys, when properly heat-treated, are hard but exhibit much lower elastic modulus (approx.100 GPa) and a much broader elastic deformation range (approx.3 percent or more). These material characteristics lead to high indentation static load capacity, which is important for certain applications especially space mechanisms. To ensure the maximum degree of elastic behavior, superelastic materials must be pre-stressed, a process referred to as "training" in shape memory effect (SME) terminology, at loads and stresses beyond expected use conditions. In this paper, static indentation load capacity tests are employed to assess the effects of pre-stressing on elastic response behavior of 60NiTi. The static load capacity is measured by pressing 12.7 mm diameter ceramic Si3N4 balls into highly polished, hardened 60NiTi flat plates that have previously been exposed to varying levels of pre-stress (up to 2.7 GPa) to determine the load that results in shallow but measurable (0.6 m, 25 in. deep) permanent dents. Hertz stress calculations are used to estimate contact stress. Without exposure to pre-stress, the 60NiTi surface can withstand an approximately 3400 kN load before significant denting (>0.4 m deep) occurs. When pre-stressed to 2.7 GPa, a static load of 4900 kN is required to achieve a comparable dent, a 30 percent increase. These results suggest that stressing contact surfaces prior to use enhances the static indentation load capacity of the superelastic 60NiTi. This approach may be adaptable to the engineering and manufacture of highly resilient mechanical components such as rolling element bearings.

DellaCorte, Christopher↗

NASA NTRS2003

Deformation and Flexibility Equations for Idealized ARIS Umbilicals, Under Planar End-Loading Conditions

The International Space Station (ISS) relies on the Active Rack Isolation System (ARIS) as the central component of an integrated, station-wide strategy to isolate microgravity space-science experiments. ARIS uses electromechanical actuators to isolate an International Standard Payload Rack (ISPR) from disturbances due to the motion of the ISS. Disturbances to microgravity experiments on ARIS-isolated racks are primarily transmitted via the ARTS power and vacuum umbilicals. Recent experimental tests indicate that these umbilicals resonate at frequencies outside the ARIS controller's bandwidth, at levels of potential concern for certain microgravity experiments. Reduction in the umbilical resonant frequencies could help to address this issue. This report develops equations for the in-plane deflections and flexibilities of an idealized umbilical (thin, flexible, cantilever beam) under end-point, in-plane loading (inclined-force and moment). The effect of gravity is neglected due to the on-orbit application. The analysis assumes an initially straight, cantilevered umbilical with uniform cross-section, which undergoes large deflections with no plastic deformation, such that the umbilical terminus remains in a single quadrant and the umbilical slope changes monotonically. The analysis is applicable to the ARIS power and vacuum umbilicals, under the indicated assumptions.

Hampton, R. David↗

NASA NTRS2000

Deformation and Flexibility Equations for Idealized ARIS Umbilicals, Under Planar End-Loading Conditions

The International Space Station (ISS) relies on the Active Rack Isolation System (ARIS) as the central component of an integrated, station-wide strategy to isolate microgravity space-science experiments. ARIS uses electromechanical actuators to isolate an International Standard Payload Rack (ISPR) from disturbances due to the motion of the ISS. Disturbances to microgravity experiments on ARIS-isolated racks are primarily transmitted via the ARIS power and vacuum umbilicals. Recent experimental tests indicate that these umbilicals resonate at frequencies outside the ARIS controller's bandwidth. at levels of potential concern for certain microgravity experiments. Reduction in the umbilical resonant frequencies could help to address this issue. This paper develops equations for the in-plane deflections and flexibilities of an idealized umbilical (thin, flexible, cantilever beam) under end-point, in-plane loading (inclined-force and moment). The effect of gravity is neglected due to the on:orbit application. The analysis assumes an initially straight. cantilevered umbilical with uniform cross-section. which undergoes large deflections with no plastic deformation, such that the umbilical terminus remains in a single quadrant and the umbilical slope changes monotonically. The analysis is applicable to the ARIS power and vacuum umbilicals. under the indicated assumptions.

Hampton, R. David↗

NASA NTRS2014

Design Environment for Multifidelity and Multidisciplinary Components

One of the greatest challenges when developing propulsion systems is predicting the interacting effects between the fluid loads, thermal loads, and structural deflection. The interactions between technical disciplines often are not fully analyzed, and the analysis in one discipline often uses a simplified representation of other disciplines as an input or boundary condition. For example, the fluid forces in an engine generate static and dynamic rotor deflection, but the forces themselves are dependent on the rotor position and its orbit. It is important to consider the interaction between the physical phenomena where the outcome of each analysis is heavily dependent on the inputs (e.g., changes in flow due to deflection, changes in deflection due to fluid forces). A rigid design process also lacks the flexibility to employ multiple levels of fidelity in the analysis of each of the components. This project developed and validated an innovative design environment that has the flexibility to simultaneously analyze multiple disciplines and multiple components with multiple levels of model fidelity. Using NASA's open-source multidisciplinary design analysis and optimization (OpenMDAO) framework, this multifaceted system will provide substantially superior capabilities to current design tools.

Platt, Michael↗