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NASA NTRS2011

Use of Flexible Body Coupled Loads in Assessment of Day of Launch Flight Loads

A Day of Launch flight loads assessment technique that determines running loads calculated from flexible body coupled loads was developed for the Ares I-X Flight Test Vehicle. The technique was developed to quantify DOL flight loads in terms of structural load components rather than the typically used q-alpha metric to provide more insight into the DOL loads. In this technique, running loads in the primary structure are determined from the combination of quasi-static aerodynamic loads and dynamic loads. The aerodynamic loads are calculated as a function of time using trajectory parameters passed from the DOL trajectory simulation and are combined with precalculated dynamic loads using a load combination equation. The potential change in aerodynamic load due to wind variability during the countdown is included in the load combination. In the event of a load limit exceedance, the technique allows the identification of what load component is exceeded, a quantification of how much the load limit is exceeded, and where on the vehicle the exceedance occurs. This technique was used to clear the Ares I-X FTV for launch on October 28, 2009. This paper describes the use of coupled loads in the Ares I-X flight loads assessment and summarizes the Ares I-X load assessment results.

Starr, Brett R.↗

NASA NTRS2012

Reducing Undue Conservatism in "Higher Frequency" Structural Design Loads in Aerospace Components

This study is intended to investigate the frequency dependency of significant strain due to vibratory loads in aerospace vehicle components. The notion that "higher frequency" dynamic loads applied as static loads is inherently conservative is perceived as widely accepted. This effort is focused on demonstrating that principle and attempting to evolve methods to capitalize on it to mitigate undue conservatism. It has been suggested that observations of higher frequency modes that resulted in very low corresponding strain did so due to those modes not being significant. Two avionics boxes, one with its first significant mode at 341 Hz and the other at 857 Hz, were attached to a flat panel installed on a curved orthogrid panel which was driven acoustically in tests performed at NASA/MSFC. Strain and acceleration were measured at select locations on each of the boxes. When possible, strain gage rosettes and accelerometers were installed on either side of a given structural member so that measured strain and acceleration data would directly correspond to one another. Ultimately, a frequency above which vibratory loads can be disregarded for purposes of static structural analyses and sizing of typical robust aerospace components is sought.

Knight, J. Brent↗

NASA NTRS2018

SpiderFab: Process for On-Orbit Construction of Kilometer-Scale Apertures

The SpiderFab effort has investigated the value proposition and feasibility of radically changing the way we build and deploy spacecraft by enabling space systems to fabricate and integrate key components on-orbit. In this Phase II effort, we have focused on developing and demonstrating tools and processes to enable robotic systems to manufacture and assemble high performance structural elements that will serve as the support structures for components such as antennas and solar arrays. Through testing of these technologies in the laboratory environment,these efforts have established the technical feasibility of the key capabilities required for in-space manufacture of large apertures such as antennas, solar arrays, and optical systems,maturing prototype technical solutions for these capabilities to TRL-4. The SpiderFab effort has resulted in successful post-NIAC transition of the technology, first to SBIR-funded development of a technology for in-space manufacture (ISM) of truss structures, and then to a NASA/STMD Tipping Point Technologies funded effort to prepare a flight demonstration of ISM of a structure for a GEO communications satellite.

Manufacturing↗

NASA NTRS2002

Monitoring of Structural Integrity of Composite Structures by Embedded Optical Fiber Sensors

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Maintenance yearly costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Albert J. Osei↗

NASA NTRS2003

Investigation of Structural Properties of Carbon-Epoxy Composites Using Embedded Fiber-Optic Bragg Gratings

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Annual maintenance costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). This is a periodic perturbation in the refractive index of the fiber core. When a broadband light is coupled into the optical fiber sensor, a reflection peak will be obtained centered around a wavelength called Bragg-wavelength. The Bragg-wavelength depends on the refractive index and the period of the grating, which both change due to mechanical and thermal strain applied to the sensor. The shift in the Bragg-wavelength is directly proportional to the strain. Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Osei, Albert J.↗

NASA NTRS2003

Defect Clustering and Nano-Phase Structure Characterization of Multi-Component Rare Earth Oxide Doped Zirconia-Yttria Thermal Barrier Coatings

Advanced oxide thermal barrier coatings have been developed by incorporating multi-component rare earth oxide dopants into zirconia-yttria to effectively promote the creation of the thermodynamically stable, immobile oxide defect clusters and/or nano-scale phases within the coating systems. The presence of these nano-sized defect clusters has found to significantly reduce the coating intrinsic thermal conductivity, improve sintering resistance, and maintain long-term high temperature stability. In this paper, the defect clusters and nano-structured phases, which were created by the addition of multi-component rare earth dopants to the plasma-sprayed and electron-beam physical vapor deposited thermal barrier coatings, were characterized by high-resolution transmission electron microscopy (TEM). The defect cluster size, distribution, crystallographic and compositional information were investigated using high-resolution TEM lattice imaging, selected area diffraction (SAD), electron energy-loss spectroscopy (EELS) and energy dispersive spectroscopy (EDS) analysis techniques. The results showed that substantial defect clusters were formed in the advanced multi-component rare earth oxide doped zirconia- yttria systems. The size of the oxide defect clusters and the cluster dopant segregation was typically ranging from 5 to 50 nm. These multi-component dopant induced defect clusters are an important factor for the coating long-term high temperature stability and excellent performance.

Zhu, Dongming↗

NASA NTRS1990

Defect Clustering and Nano-Phase Structure Characterization of Multi-Component Rare Earth Oxide Doped Zirconia-Yttria Thermal Barrier Coatings

Advanced oxide thermal barrier coatings have been developed by incorporating multi- component rare earth oxide dopants into zirconia-yttria to effectively promote the creation of the thermodynamically stable, immobile oxide defect clusters and/or nano-scale phases within the coating systems. The presence of these nano-sized defect clusters has found to significantly reduce the coating intrinsic thermal conductivity, improve sintering resistance, and maintain long-term high temperature stability. In this paper, the defect clusters and nano-structured phases, which were created by the addition of multi-component rare earth dopants to the plasma- sprayed and electron-beam physical vapor deposited thermal barrier coatings, were characterized by high-resolution transmission electron microscopy (TEM). The defect cluster size, distribution, crystallographic and compositional information were investigated using high-resolution TEM lattice imaging, selected area diffraction (SAD), and energy dispersive spectroscopy (EDS) analysis techniques. The results showed that substantial defect clusters were formed in the advanced multi-component rare earth oxide doped zirconia-yttria systems. The size of the oxide defect clusters and the cluster dopant segregation was typically ranging fiom 5 to 50 nm. These multi-component dopant induced defect clusters are an important factor for the coating long-term high temperature stability and excellent performance.

Zhu, Dongming↗

NASA NTRS1986

Propeller-induced structure-borne noise - Laboratory-based test apparatus

A potentially important source of structure-borne interior noise transmission in advanced turboprop aircraft is the impingement of the propeller wake/vortex on downstream aerodynamic surfaces. The expected levels of propeller wake/vortex-induced structure-borne noise transmission are not known nor can they be determined with present-day technology. A test apparatus has been designed, built and calibrated for the purposes of studying propeller-induced, structure-borne noise transmission in prototypical aircraft structures. The principal approach to the test apparatus design was to provide a physical means of separating the airborne and structure-borne noise components so that the structure-borne noise transmission response could be studied directly without airborne noise contamination. This was accomplished by housing the receiving fuselage structure in an acoustic shield fitted with a wing-to-fuselage acoustic seal. Initial evaluation of the wing-to-fuselage acoustic seal indicates adequate airborne noise isolation to allow direct study of structure-borne noise transmission.

Unruh, J. F.↗

NASA NTRS1991

Nondestructive Structural Damage Detection in Flexible Space Structures Using Vibration Characterization

Spacecraft are susceptible to structural damage over their operating life from impact, environmental loads, and fatigue. Structural damage that is not detected and not corrected may potentially cause more damage and eventually catastrophic structural failure. NASA's current fleet of reusable spacecraft, namely the Space Shuttle, has been flown on several missions. In addition, configurations of future NASA space structures, e.g. Space Station Freedom, are larger and more complex than current structures, making them more susceptible to damage as well as being more difficult to inspect. Consequently, a reliable structural damage detection capability is essential to maintain the flight safety of these structures. Visual inspections alone can not locate impending material failure (fatigue cracks, yielding); it can only observe post-failure situations. An alternative approach is to develop an inspection and monitoring system based on vibration characterization that assesses the integrity of structural and mechanical components. A methodology for detecting structural damage is presented. This methodology is based on utilizing modal test data in conjunction with a correlated analytical model of the structure to: (1) identify the structural dynamic characteristics (resonant frequencies and mode shapes) from measurements of ambient motions and/or force excitation; (2) calculate modal residual force vectors to identify the location of structural damage; and (3) conduct a weighted sensitivity analysis in order to assess the extent of mass and stiffness variations, where structural damage is characterized by stiffness reductions. The approach is unique from other existing approaches in that varying system mass and stiffness, mass center locations, the perturbation of both the natural frequencies and mode shapes, and statistical confidence factors for structural parameters and experimental instrumentation are all accounted for directly.

Ricles, James M.↗

NASA NTRS1992

Assigning Damping Parameters To Component Dynamical Modes

Damping parameters found by solving nonlinear optimization problem. Paper discusses assignment of matrices of damping parameters to mathematical models of vibrations and rotations of interconnected flexible components of large, flexible structure. Such models truncated at component level to reduce amount of computation necessary to simulate dynamics of structure numerically at both component and system levels.

Lee, Allan Y.↗

NASA NTRS1992

Damage-mitigating control of aerospace systems for high performance and extended life

The concept of damage-mitigating control is to minimize fatigue (as well as creep and corrosion) damage of critical components of mechanical structures while simultaneously maximizing the system dynamic performance. Given a dynamic model of the plant and the specifications for performance and stability robustness, the task is to synthesize a control law that would meet the system requirements and, at the same time, satisfy the constraints that are imposed by the material and structural properties of the critical components. The authors present the concept of damage-mitigating control systems design with the following objectives: (1) to achieve high performance with a prolonged life span; and (2) to systematically update the controller as the new technology of advanced materials evolves. The major challenge is to extract the information from the material properties and then utilize this information in a mathematical form so that it can be directly applied to robust control synthesis for mechanical systems. The basic concept of damage-mitigating control is illustrated using a relatively simplified model of a space shuttle main engine.

Ray, Asok↗

NASA NTRS2004

Scatter in Carbon/Silicon Carbide (C/SiC) Composites Quantified

Carbon-fiber-reinforced silicon carbide matrix (C/SiC) composites processed by chemical vapor infiltration are candidate materials for aerospace thermal structures. Carbon fibers can retain properties at very high temperatures, but they are known to have poor oxidation resistance in adverse, high-temperature environments. Nevertheless, the combination of CVI-SiC matrix with higher stiffness and oxidation resistance, the interfacial coating, and additional surface-seal coating provides the necessary protection to the carbon fibers, and makes the material viable for high-temperature space applications operating under harsh environments. Furthermore, C/SiC composites, like other ceramic matrix composites (CMCs), exhibit graceful non-catastrophic failure because of various inherent energy dissipating mechanisms. The material exhibits nonlinearity in deformation even at very low stress levels. This is the result of the severe matrix microcracking present in the as processed composite because of large differences between the coefficients of thermal expansion of the fiber and the matrix. Utilization of these advanced composites in next generation space vehicles will require innovative structural configurations, updated materials, and refined analyses. Structural safety issues for these vehicles are in direct competition with performance and cost. One would have to quantify the uncertainties associated with the design using formal probabilistic methods. Specifically four fundamental aspects on which analyses are based-- (1) loading conditions, (2) material behavior, (3) geometrical configurations, and (4) structural connections between the composite components and baseline structure--are stochastic in nature. A direct way to formally account for uncertainties is to develop probabilistic structural analysis methods where all participating variables are described by appropriate probability density functions. The present work, however, focuses on analyzing the stochastic material behavior of these advanced composites using formal probabilistic analysis methods. Often, some of the desirable property characteristics that allow composites to offer advantages over conventional structural materials (like tailoring of composite properties) and the complexity are in fact responsible for their greater statistical variability and the requirements for more characterization tests. Composite properties are anisotropic as well, having different properties in different directions. This means that characterization of a property such as stiffness--which will vary greatly depending on the orientation of the fiber relative to the direction of the testing--must be repeated for several different directions and loading conditions. The fabrication process for composites also introduces statistical variations in properties and geometry. A composite part is produced in a number of steps, each of which introduces statistical variability. The matrix is usually produced from a combination of raw materials; and the fiber, which has its own set of properties, is often coated or surface treated, introducing yet another source of variability.

Murthy, Pappu L. N.↗

NASA NTRS2005

LC Circuits for Diagnosing Embedded Piezoelectric Devices

A recently invented method of nonintrusively detecting faults in piezoelectric devices involves measurement of the resonance frequencies of inductor capacitor (LC) resonant circuits. The method is intended especially to enable diagnosis of piezoelectric sensors, actuators, and sensor/actuators that are embedded in structures and/or are components of multilayer composite material structures.

Chattin, Richard L.↗

NASA NTRS2013

Aquarius' Object-Oriented, Plug and Play Component-Based Flight Software

The Aquarius mission involves a combined radiometer and radar instrument in low-Earth orbit, providing monthly global maps of Sea Surface Salinity. Operating successfully in orbit since June, 2011, the spacecraft bus was furnished by the Argentine space agency, Comision Nacional de Actividades Espaciales (CONAE). The instrument, built jointly by NASA's Caltech/JPL and Goddard Space Flight Center, has been successfully producing expectation-exceeding data since it was powered on in August of 2011. In addition to the radiometer and scatterometer, the instrument contains an command & data-handling subsystem with a computer and flight software (FSW) that is responsible for managing the instrument, its operation, and its data. Aquarius' FSW is conceived and architected as a Component-based system, in which the running software consists of a set of Components, each playing a distinctive role in the subsystem, instantiated and connected together at runtime. Component architectures feature a well-defined set of interfaces between the Components, visible and analyzable at the architectural level (see [1]). As we will describe, this kind of an architecture offers significant advantages over more traditional FSW architectures, which often feature a monolithic runtime structure. Component-based software is enabled by Object-Oriented (OO) techniques and languages, the use of which again is not typical in space mission FSW. We will argue in this paper that the use of OO design methods and tools (especially the Unified Modeling Language), as well as the judicious usage of C++, are very well suited to FSW applications, and we will present Aquarius FSW, describing our methods, processes, and design, as a successful case in point.

Component Architecture↗

NASA NTRS1985

Polymer, metal and ceramic matrix composites for advanced aircraft engine applications

Advanced aircraft engine research within NASA Lewis is being focused on propulsion systems for subsonic, supersonic, and hypersonic aircraft. Each of these flight regimes requires different types of engines, but all require advanced materials to meet their goals of performance, thrust-to-weight ratio, and fuel efficiency. The high strength/weight and stiffness/weight properties of resin, metal, and ceramic matrix composites will play an increasingly key role in meeting these performance requirements. At NASA Lewis, research is ongoing to apply graphite/polyimide composites to engine components and to develop polymer matrices with higher operating temperature capabilities. Metal matrix composites, using magnesium, aluminum, titanium, and superalloy matrices, are being developed for application to static and rotating engine components, as well as for space applications, over a broad temperature range. Ceramic matrix composites are also being examined to increase the toughness and reliability of ceramics for application to high-temperature engine structures and components.

Mcdanels, D. L.↗

NASA NTRS1986

Polymer, metal, and ceramic matrix composites for advanced aircraft engine applications

Mcdanels, D. L.↗

NASA NTRS2016

Development and Implementation of a Generic Analysis Template for Structural-Thermal-Optical-Performance Modeling

Performance-related effects of system level temperature changes can be a key consideration in the design of many types of optical instruments. This is especially true for space-based imagers, which may require complex thermal control systems to maintain alignment of the optical components. Structural-Thermal-Optical-Performance (STOP) analysis is a multi-disciplinary process that can be used to assess the performance of these optical systems when subjected to the expected design environment. This type of analysis can be very time consuming, which makes it difficult to use as a trade study tool early in the project life cycle. In many cases, only one or two iterations can be performed over the course of a project. This limits the design space to best practices since it may be too difficult, or take too long, to test new concepts analytically. In order to overcome this challenge, automation, and a standard procedure for performing these studies is essential. A methodology was developed within the framework of the Comet software tool that captures the basic inputs, outputs, and processes used in most STOP analyses. This resulted in a generic, reusable analysis template that can be used for design trades for a variety of optical systems. The template captures much of the upfront setup such as meshing, boundary conditions, data transfer, naming conventions, and post-processing, and therefore saves time for each subsequent project. A description of the methodology and the analysis template is presented, and results are described for a simple telescope optical system.

Scola, Salvatore↗

NASA NTRS1997

Computation of LFT Uncertainty Bounds with Repeated Parametric Uncertainties

A new methodology in which linear fractional transformation uncertainty bounds are directly constructed for use in robust control design and analysis is proposed. Existence conditions for model validating solutions with or without repeated scalar uncertainty are given. The approach is based on minimax formulation to deal with multiple non-repeated structured uncertainty components subject to fixed levels of repeated scalar uncertainties. Input directional dependence and variations with different experiments are addressed by maximizing uncertainty levels over multiple experimental data sets. Preliminary results show that reasonable uncertainty bounds on structured non-repeated uncertainties can be identified directly from measurement data by assuming reasonable levels of repeated scalar uncertainties.

Lim, K. B.↗