Investigation of fatigue-crack growth under simple variable-amplitude loading
Fatigue crack growth tests on Al alloy sheets under variable amplitude loading
Hudson, C. M.↗
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Autonomous Cryogenic Load Operations: Knowledge-Based Autonomous Test Engineer
The Knowledge-Based Autonomous Test Engineer (KATE) program has a long history at KSC. Now a part of the Autonomous Cryogenic Load Operations (ACLO) mission, this software system has been sporadically developed over the past 20 years. Originally designed to provide health and status monitoring for a simple water-based fluid system, it was proven to be a capable autonomous test engineer for determining sources of failure in the system. As part of a new goal to provide this same anomaly-detection capability for a complicated cryogenic fluid system, software engineers, physicists, interns and KATE experts are working to upgrade the software capabilities and graphical user interface. Much progress was made during this effort to improve KATE. A display of the entire cryogenic system's graph, with nodes for components and edges for their connections, was added to the KATE software. A searching functionality was added to the new graph display, so that users could easily center their screen on specific components. The GUI was also modified so that it displayed information relevant to the new project goals. In addition, work began on adding new pneumatic and electronic subsystems into the KATE knowledge base, so that it could provide health and status monitoring for those systems. Finally, many fixes for bugs, memory leaks, and memory errors were implemented and the system was moved into a state in which it could be presented to stakeholders. Overall, the KATE system was improved and necessary additional features were added so that a presentation of the program and its functionality in the next few months would be a success.
Schrading, J. Nicolas↗
Integrated Vehicle Ground Vibration Testing in Support of Launch Vehicle Loads and Controls Analysis
All structural systems possess a basic set of physical characteristics unique to that system. These unique physical characteristics include items such as mass distribution and damping. When specified, they allow engineers to understand and predict how a structural system behaves under given loading conditions and different methods of control. These physical properties of launch vehicles may be predicted by analysis or measured by certain types of tests. Generally, these properties are predicted by analysis during the design phase of a launch vehicle and then verified by testing before the vehicle becomes operational. A ground vibration test (GVT) is intended to measure by test the fundamental dynamic characteristics of launch vehicles during various phases of flight. During the series of tests, properties such as natural frequencies, mode shapes, and transfer functions are measured directly. These data will then be used to calibrate loads and control systems analysis models for verifying analyses of the launch vehicle. NASA manned launch vehicles have undergone ground vibration testing leading to the development of successful launch vehicles. A GVT was not performed on the inaugural launch of the unmanned Delta III which was lost during launch. Subsequent analyses indicated had a GVT been performed, it would have identified instability issues avoiding loss of the vehicle. This discussion will address GVT planning, set-up, execution and analyses, for the Saturn and Shuttle programs, and will also focus on the current and on-going planning for the Ares I and V Integrated Vehicle Ground Vibration Test (IVGVT).
Askins, Bruce R.↗
Improved Regression Analysis of Temperature-Dependent Strain-Gage Balance Calibration Data
An improved approach is discussed that may be used to directly include first and second order temperature effects in the load prediction algorithm of a wind tunnel strain-gage balance. The improved approach was designed for the Iterative Method that fits strain-gage outputs as a function of calibration loads and uses a load iteration scheme during the wind tunnel test to predict loads from measured gage outputs. The improved approach assumes that the strain-gage balance is at a constant uniform temperature when it is calibrated and used. First, the method introduces a new independent variable for the regression analysis of the balance calibration data. The new variable is designed as the difference between the uniform temperature of the balance and a global reference temperature. This reference temperature should be the primary calibration temperature of the balance so that, if needed, a tare load iteration can be performed. Then, two temperature{dependent terms are included in the regression models of the gage outputs. They are the temperature difference itself and the square of the temperature difference. Simulated temperature{dependent data obtained from Triumph Aerospace's 2013 calibration of NASA's ARC-30K five component semi{span balance is used to illustrate the application of the improved approach.
wind tunnel testing↗
Opening Loads Analyses for Various Disk-Gap-Band Parachutes
Detailed opening loads data is presented for 18 tests of Disk-Gap-Band (DGB) parachutes of varying geometry with nominal diameters ranging from 43.2 to 50.1 ft. All of the test parachutes were deployed from a mortar. Six of these tests were conducted via drop testing with drop test vehicles weighing approximately 3,000 or 8,000 lb. Twelve tests were conducted in the National Full-Scale Aerodynamics Complex 80- by 120-foot wind tunnel at the NASA Ames Research Center. The purpose of these tests was to structurally qualify the parachute for the Mars Exploration Rover mission. A key requirement of all tests was that peak parachute load had to be reached at full inflation to more closely simulate the load profile encountered during operation at Mars. Peak loads measured during the tests were in the range from 12,889 to 30,027 lb. Of the two test methods, the wind tunnel tests yielded more accurate and repeatable data. Application of an apparent mass model to the opening loads data yielded insights into the nature of these loads. Although the apparent mass model could reconstruct specific tests with reasonable accuracy, the use of this model for predictive analyses was not accurate enough to set test conditions for either the drop or wind tunnel tests. A simpler empirical model was found to be suitable for predicting opening loads for the wind tunnel tests to a satisfactory level of accuracy. However, this simple empirical model is not applicable to the drop tests.
Cruz, J. R.↗
Buckling behavior of Rene 41 tubular panels for a hypersonic aircraft wing
The buckling characteristics of Rene 41 tubular panels for a hypersonic aircraft wing were investigated. The panels were repeatedly tested for buckling characteristics using a hypersonic wing test structure and a universal tension/compression testing machine. The nondestructive buckling tests were carried out under different combined load conditions and in different temperature environments. The force/stiffness technique was used to determine the buckling loads of the panel. In spite of some data scattering, resulting from large extrapolations of the data fitting curve (because of the termination of applied loads at relatively low percentages of the buckling loads), the overall test data correlate fairly well with theoretically predicted buckling interaction curves. Also, the structural efficiency of the tubular panels was found to be slightly higher than that of beaded panels.
Ko, W. L.↗
Buckling behavior of Rene 41 tubular panels for a hypersonic aircraft wing
The buckling characteristics of Rene 41 tubular panels for a hypersonic aircraft wing were investigated. The panels were repeatedly tested for buckling characteristics using a hypersonic wing test structure and a universal tension/compression testing machine. The nondestructive buckling tests were carried out under different combined load conditions and in different temperature environments. The force/stiffness technique was used to determine the buckling loads of the panels. In spite of some data scattering resulting from large extrapolations of the data-fitting curve (because of the termination of applied loads at relatively low percentages of the buckling loads), the overall test data correlate fairly well with theoretically predicted buckling interaction curves. Also, the structural efficiency of the tubular panels was found to be slightly higher than that of beaded panels.
Ko, W. L.↗
Flight Test Identification and Simulation of a UH-60A Helicopter and Slung Load
Helicopter slung-load operations are common in both military and civil contexts. Helicopters and loads are often qualified for these operations by means of flight tests, which can be expensive and time consuming. There is significant potential to reduce such costs both through revisions in flight-test methods and by using validated simulation models. To these ends, flight tests were conducted at Moffett Field to demonstrate the identification of key dynamic parameters during flight tests (aircraft stability margins and handling-qualities parameters, and load pendulum stability), and to accumulate a data base for simulation development and validation. The test aircraft was a UH-60A Black Hawk, and the primary test load was an instrumented 8- by 6- by 6-ft cargo container. Tests were focused on the lateral and longitudinal axes, which are the axes most affected by the load pendulum modes in the frequency range of interest for handling qualities; tests were conducted at airspeeds from hover to 80 knots. Using telemetered data, the dynamic parameters were evaluated in near real time after each test airspeed and before clearing the aircraft to the next test point. These computations were completed in under 1 min. A simulation model was implemented by integrating an advanced model of the UH-60A aerodynamics, dynamic equations for the two-body slung-load system, and load static aerodynamics obtained from wind-tunnel measurements. Comparisons with flight data for the helicopter alone and with a slung load showed good overall agreement for all parameters and test points; however, unmodeled secondary dynamic losses around 2 Hz were found in the helicopter model and they resulted in conservative stability margin estimates.
Cicolani, Luigi S.↗
Hitts Law? A test of the relationship between information load and movement precision
Recent technological developments have made viable a man-machine interface heavily dependent on graphics and pointing devices. This has led to new interest in classical reaction and movement time work by Human Factors specialists. Two experiments were designed and run to test the dependence of target capture time on information load (Hitt's Law) and movement precision (Fitts' Law). The proposed model linearly combines Hitt's and Fitts' results into a combination law which then might be called Hitts' Law. Subjects were required to react to stimuli by manipulating a joystick so as to cause a cursor to capture a target on a CRT screen. Response entropy and the relative precision of the capture movement were crossed in a factorial design and data obtained that were found to support the model.
Zaleski, M.↗
Autonomous Cryogenics Loading Operations Simulation Software: Knowledgebase Autonomous Test Engineer
The Simulation Software, KATE (Knowledgebase Autonomous Test Engineer), is used to demonstrate the automatic identification of faults in a system. The ACLO (Autonomous Cryogenics Loading Operation) project uses KATE to monitor and find faults in the loading of the cryogenics int o a vehicle fuel tank. The KATE software interfaces with the IHM (Integrated Health Management) systems bus to communicate with other systems that are part of ACLO. One system that KATE uses the IHM bus to communicate with is AIS (Advanced Inspection System). KATE will send messages to AIS when there is a detected anomaly. These messages include visual inspection of specific valves, pressure gauges and control messages to have AIS open or close manual valves. My goals include implementing the connection to the IHM bus within KATE and for the AIS project. I will also be working on implementing changes to KATE's Ul and implementing the physics objects in KATE that will model portions of the cryogenics loading operation.
Wehner, Walter S.↗
Residual Strength Predictions with Crack Buckling
Fracture tests were conducted on middle crack tension, M(T), and compact tension, C(T), specimens of varying widths, constructed from 0.063 inch thick sheets of 2024-T3 aluminum alloy. Guide plates were used to restrict out-of-plane displacements in about half of the tests. Analyses using the three-dimensional, elastic-plastic finite element code WARP3D simulated the tests with and without guide plates using a critical CTOA fracture criterion. The experimental results indicate that crack buckling reduced the failure loads by up to 40%. Using a critical CTOA value of 5.5 deg., the WARP3D analyses predicted the failure loads for the tests with guide plates within +/- 10% of the experimentally measured values. For the M(T) tests without guide plates, the WARP3D analyses predicted the failure loads for the 12 and 24 inch tests within 10%, while over predicting the failure loads for the 40 inch wide tests by about 20%.
Dawicke, D. S.↗
Development of an accelerated creep testing technique via multi-specimen loading
This report summarizes a research effort undertaken by Argonne National Laboratory to accelerate the development of creep data package for code qualification. The goal is to explore new creep testing techniques to shorten the overall time needed to generate high-quality data to support an ASME code case on laser powder bed fusion 316H stainless steel. Progresses on the design and implementation of a 3-specimen load train and an innovative strain measurement method with direct potential current drop (DCPD) technique are reported.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Effect of plasticity on the experimental characterization of the creep property of a cement paste: Spherical vs. conical microindentation
Microindentation is today a powerful tool for rapidly characterizing the elastic modulus and the logarithmic basic creep of a cement paste. However, a theoretical work proved that a microindentation test with a sharp indenter shape involves stress concentration and delayed plasticity which can cause an overestimation of the estimated creep property. This work aims at experimentally investigating the effect of the shape indenter on the identification of the visco-elastic property of a cement paste by microindentation. First, several microindentation grids were carried out on a cement paste with both a Berkovich indenter and a spherical indenter at different penetration depths or load levels for load control (creep) tests or displacement control (relaxation) tests, respectively. As for a visco-elastic material the duality principle between creep and relaxation holds, a numerical method was developed for predicting the relaxation response from the assumed logarithmic creep compliance. The present results show that only spherical microindentation satisfy the duality principle for which creep and relaxation response can be predicted by a unique logarithmic creep compliance function. Finally, spherical microindentation creep tests at low load as well as spherical microindentation relaxation tests provide a greater indentation modulus M and contact creep modulus C{sub v} as likely less affected by possible plasticity effects.
36 MATERIALS SCIENCE↗
Lightweight ZERODUR: Validation of Mirror Performance and Mirror Modeling Predictions
Upcoming spaceborne missions, both moderate and large in scale, require extreme dimensional stability while relying both upon established lightweight mirror materials, and also upon accurate modeling methods to predict performance under varying boundary conditions. We describe tests, recently performed at NASA's XRCF chambers and laboratories in Huntsville Alabama, during which a 1.2 m diameter, f/1.2988% lightweighted SCHOTT lightweighted ZERODUR(TradeMark) mirror was tested for thermal stability under static loads in steps down to 230K. Test results are compared to model predictions, based upon recently published data on ZERODUR(TradeMark). In addition to monitoring the mirror surface for thermal perturbations in XRCF Thermal Vacuum tests, static load gravity deformations have been measured and compared to model predictions. Also the Modal Response(dynamic disturbance) was measured and compared to model. We will discuss the fabrication approach and optomechanical design of the ZERODUR(TradeMark) mirror substrate by SCHOTT, its optical preparation for test by Arizona Optical Systems (AOS). Summarize the outcome of NASA's XRCF tests and model validations
technology↗
Space Shuttle Body Flap Actuator Bearing Testing for NASA Return to Flight
The Space Shuttle body flap (BF) is located beneath the main engine nozzles and is required for proper aerodynamic control during orbital descent. The body flap is controlled by four actuators connected by a common shaft and driven by the hydraulic power drive unit. Inspection of the actuators during refurbishment revealed three shaft bearings with unexpected damage. One was coated with black oxide on the balls and race wear surfaces, a second contained a relatively deep wear scar, and the third with scratches and an aluminum particle in the wear track. A shaft bearing life test program was initiated to measure the wear life and explain the 5.08-micrometer wear scar. A tribological analysis was conducted to demonstrate that the black oxide coated wear surfaces did not damage the bearing, interfere with the lubrication, or cause severe bearing wear. Pre-damaged (equivalent of 30 missions), commercial equivalent bearings and previously flown shaft bearings were tested at axial loads, speeds, and temperatures seen during flight operations. These bearing were successfully life tested at 60 C for 24 hours or 90 flights. With a safety factor of 4X, the bearings were qualified for 22 flights when only a maximum of 12 flights are expected. Additional testing at 23 C was performed to determine the lubricant life and to further understand the mechanism that caused the blackened balls. Test results indicating bearing life was shortened at a lower temperature surprised the investigators. Start\Stop bearing testing that closely simulates mission profile was conducted at 23 C. Results of this testing showed lubricant life of 12 flights including a safety factor of four. Additional testing with bearings that have the equivalent of 30 missions of damage is being tested at 23 C. These tests are being performed over the Shuttle load profile to demonstrate the residual bearing life in the actuators exceeds 12 missions. Testing showed that the end of the shaft bearing life was characterized by bearing temperature rise, preload drop, and the onset of a severe wear bearing failure mechanism. The severe wear failure mechanism is characterized by rough wear scars, extensive bearing wear and steel transfer between the balls and the races.
Jet, Timothy R.↗
Experiments on the stability of water lubricated three lobe hydrodynamic journal bearings at zero load
Water-lubricated three-lobe hydrodynamic journal bearing stability tests at zero load with and without axial grooves
Schuller, F. T.↗
A New High-Speed, High-Cycle, Gear-Tooth Bending Fatigue Test Capability
A new high-speed test capability for determining the high cycle bending-fatigue characteristics of gear teeth has been developed. Experiments were performed in the test facility using a standard spur gear test specimens designed for use in NASA Glenn s drive system test facilities. These tests varied in load condition and cycle-rate. The cycle-rate varied from 50 to 1000 Hz. The loads varied from high-stress, low-cycle loads to near infinite life conditions. Over 100 tests were conducted using AISI 9310 steel spur gear specimen. These results were then compared to previous data in the literature for correlation. Additionally, a cycle-rate sensitivity analysis was conducted by grouping the results according to cycle-rate and comparing the data sets. Methods used to study and verify load-path and facility dynamics are also discussed.
Stringer, David B.↗
Fatigue and Damage Tolerance Analysis of a Hybrid Composite Tapered Flexbeam
The behavior of nonlinear tapered composite flexbeams under combined axial tension and cyclic bending loading was studied using coupon test specimens and finite element (FE) analyses. The flexbeams used a hybrid material system of graphite/epoxy and glass/epoxy and had internal dropped plies, dropped in an overlapping stepwise pattern. Two material configurations, differing only in the use of glass or graphite plies in the continuous plies near the midplane, were studied. Test specimens were cut from a full-size helicopter tail-rotor flexbeam and were tested in a hydraulic load frame under combined constant axialtension load and transverse cyclic bending loads. The first determination damage observed in the specimens occurred at the area around the tip of the outermost ply-drop group in the tapered region of the flexbeam, near the thick end. Delaminations grew slowly and stably, toward the thick end of the flexbeam, at the interfaces above and below the dropped-ply region. A 2D finite element model of the flexbeam was developed. The model was analyzed using a geometrically non-linear analysis with both the ANSYS and ABAQUS FE codes. The global responses of each analysis agreed well with the test results. The ANSYS model was used to calculate strain energy release rates (G) for delaminations initiating at two different ply-ending locations. The results showed that delaminations were more inclined to grow at the locations where they were observed in the test specimens. Both ANSYS and ABAQUS were used to calculate G values associated with delamination initiating at the observed location but growing in different interfaces, either above or below the ply-ending group toward the thick end, or toward the thin end from the tip of the resin pocket. The different analysis codes generated the same trends and comparable peak values, within 5-11 % for each delamination path. Both codes showed that delamination toward the thick region was largely mode II, and toward the thin region was predominantly mode I. The calculated peak G-values from either analysis predict delamination is most likely to occur along the same interface where it was observed in the test specimens. Calculated peak G values were used with material characterization data to calculate a curve relating the fatigue life of the specimens, N, to the applied transverse load, V, for a given constant axial load.
Murri, Gretchen B.↗