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NASA NTRS2015

Superelastic Ball Bearings: Materials and Design to Avoid Mounting and Dismounting Brinell Damage in an Inaccessible Press-Fit Application-: Design Approach - I

Ball bearings require proper fit and installation into machinery structures (onto shafts and into bearing housings) to ensure optimal performance. For some applications, both the inner and outer race must be mounted with an interference fit and care must be taken during assembly and disassembly to avoid placing heavy static loads between the balls and races otherwise Brinell dent type damage can occur. In this paper, a highly dent resistant superelastic alloy, 60NiTi, is considered for rolling element bearing applications that encounter excessive static axial loading during assembly or disassembly. A small (R8) ball bearing is designed for an application in which access to the bearing races to apply disassembly tools is precluded. First Principles analyses show that by careful selection of materials, raceway curvature and land geometry, a bearing can be designed that allows blind assembly and disassembly without incurring raceway damage due to ball denting. Though such blind assembly applications are uncommon, the availability of bearings with unusually high static load capability may enable more such applications with additional benefits, especially for miniature bearings.

tribology↗

NASA NTRS2024

Development of a Data Fusion Methodology for Lineload Aerodynamic Databases for a Launch Vehicle during Liftoff and Transition

The need for databases for the distributed loading on launch vehicles during the early portion of flight necessitates the use of expensive computational flows in regimes where wake effects dominate. While also being expensive, this is a regime that computational tools tend to historically have problems simulating accurately. To help tackle this problem, a method of data fusion to combine computational results to wind tunnel derived force and moment data is developed. Using this method, significant reduction in computational costs and increases in confidence of the final product is possible and has been used to generate several databases for the Space Launch System (SLS) at NASA. While the full details of database generation are not part of this work, the crucial method at its core is developed here. Two SLS geometries are used throughout the work to demonstrate the techniques. These are two of the larger geometries and represent both planned crewed missions to the Moon as well as potential cargo missions to deep space. The method uses principal component analysis (PCA) to generate a reduced ordered model (ROM) to help fill in the full parameter space. Other similar techniques are explored, but were not found to have a significant result on the predictions of the ROM. Because the full number of components are kept to generate the model, this lack of difference is expected. This method is then extended to ensure that predicted surfaces match trusted force and moment data derived from wind tunnel testing. This extension is done by setting up a constrained optimization problem in order to minimize the deviation from the surface resolved computational data while still integrating to the desired values. When generating the constrained optimization problem, a weighting factor to balance these competing needs is introduced. The work compares previously introduced weighting terms from similar work to the proposed terms and shows that the previously used terms do not have as desirable behavior in this flow regime. This method is then expanded by developing a technique to incorporate uncertainty quantification into the developed data fusion methodology. This expansion takes a two pronged approach. One examines transferring the uncertainties in the force and moment database and characterizes how those adjustments change the predicted lineloads. The second looks at model form error and looks how rebuilding the model using slightly different data changes the predictions. These two terms are then combined in order to create an uncertainty model that takes both effects into account. The limitations of the proposed methods is then discussed as well as possible techniques to address these shortcomings.

Launch Vehicles↗

NASA NTRS1993

Impact damage resistance of composite fuselage structure, part 2

The strength of laminated composite materials may be significantly reduced by foreign object impact induced damage. An understanding of the damage state is required in order to predict the behavior of structure under operational loads or to optimize the structural configuration. Types of damage typically induced in laminated materials during an impact event include transverse matrix cracking, delamination, and/or fiber breakage. The details of the damage state and its influence on structural behavior depend on the location of the impact. Damage in the skin may act as a soft inclusion or affect panel stability, while damage occurring over a stiffener may include debonding of the stiffener flange from the skin. An experiment to characterize impact damage resistance of fuselage structure as a function of structural configuration and impact threat was performed. A wide range of variables associated with aircraft fuselage structure such as material type and stiffener geometry (termed, intrinsic variables) and variables related to the operating environment such as impactor mass and diameter (termed, extrinsic variables) were studied using a statistically based design-of-experiments technique. The experimental design resulted in thirty-two different 3-stiffener panels. These configured panels were impacted in various locations with a number of impactor configurations, weights, and energies. The results obtained from an examination of impacts in the skin midbay and hail simulation impacts are documented. The current discussion is a continuation of that work with a focus on nondiscrete characterization of the midbay hail simulation impacts and discrete characterization of impact damage for impacts over the stiffener.

Dost, Ernest F.↗

NASA NTRS2014

Design, Analysis, and On-Sun Evaluation of Reflective Strips Under Controlled Buckling

Solar concentrators are envisioned for use in a variety of space-based applications, including applications involving in situ resource utilization. Identifying solar concentrators that minimize mass and cost are of great interest, especially since launch cost is driven in part by the mass of the payload. Concentrators must also be able to survive the wide temperature excursions on the lunar surface. Identifying smart structures which compensate for changes in concentrator geometry brought about by temperature extremes are of interest. Some applications may benefit from the ability to change the concentrators focal pattern at will. This paper addresses a method of designing a single reflective strip to produce a desired focal pattern through the use of controlled buckling. Small variations in the cross section over the length of the reflective strip influence the distribution of light in the focal region. A finite element method of analysis is utilized here which calculates the curve produced for a given strip cross section and axial load. Varying axial force and strip cross section over the length of the reflective strip provide a means of optimizing ray convergence in the focal region. Careful selection of a tapered cross section yields a reflective strip that approximates a parabola. An array of reflective strips under controlled buckling produces a light weight concentrator and adjustments in the compression of individual strips provide a means of compensating for temperature excursions or changing the focal pattern at will.

solar collectors↗

NASA NTRS2014

Design, Analysis, and On-Sun Evaluation of Reflective Strips Under Controlled Buckling

Solar concentrators are envisioned for use in a variety of space-based applications, including applications involving in situ resource utilization. Identifying solar concentrators that minimize mass and cost are of great interest, especially since launch cost is driven in part by the mass of the payload. Concentrators must also be able to survive the wide temperature excursions on the lunar surface. Identifying smart structures which compensate for changes in concentrator geometry brought about by temperature extremes are of interest. Some applications may benefit from the ability to change the concentrator's focal pattern at will. This paper addresses a method of designing a single reflective strip to produce a desired focal pattern through the use of controlled buckling. Small variations in the cross section over the length of the reflective strip influence the distribution of light in the focal region. A finite element method of analysis is utilized here which calculates the curve produced for a given strip cross section and axial load. Varying axial force and strip cross section over the length of the reflective strip provide a means of optimizing ray convergence in the focal region. Careful selection of a tapered cross section yields a reflective strip that approximates a parabola. An array of reflective strips under controlled buckling produces a light weight concentrator and adjustments in the compression of individual strips provide a means of compensating for temperature excursions or changing the focal pattern at will.

buckling↗

NASA NTRS1987

Potential benefits of magnetic suspension and balance systems

The potential of Magnetic Suspension and Balance Systems (MSBS) to improve conventional wind tunnel testing techniques is discussed. Topics include: elimination of model geometry distortion and support interference to improve the measurement accuracy of aerodynamic coefficients; removal of testing restrictions due to supports; improved dynamic stability data; and stores separation testing. Substantial increases in wind tunnel productivity are anticipated due to the coalescence of these improvements. Specific improvements in testing methods for missiles, helicopters, fighter aircraft, twin fuselage transports and bombers, state separation, water tunnels, and automobiles are also forecast. In a more speculative vein, new wind tunnel test techniques are envisioned as a result of applying MSBS, including free-flight computer trajectories in the test section, pilot-in-the-loop and designer-in-the-loop testing, shipboard missile launch simulation, and optimization of hybrid hypersonic configurations. Also addressed are potential applications of MSBS to such diverse technologies as medical research and practice, industrial robotics, space weaponry, and ore processing in space.

Lawing, Pierce L.↗

NASA NTRS2002

Process Cost Modeling for Multi-Disciplinary Design Optimization

For early design concepts, the conventional approach to cost is normally some kind of parametric weight-based cost model. There is now ample evidence that this approach can be misleading and inaccurate. By the nature of its development, a parametric cost model requires historical data and is valid only if the new design is analogous to those for which the model was derived. Advanced aerospace vehicles have no historical production data and are nowhere near the vehicles of the past. Using an existing weight-based cost model would only lead to errors and distortions of the true production cost. This report outlines the development of a process-based cost model in which the physical elements of the vehicle are costed according to a first-order dynamics model. This theoretical cost model, first advocated by early work at MIT, has been expanded to cover the basic structures of an advanced aerospace vehicle. Elemental costs based on the geometry of the design can be summed up to provide an overall estimation of the total production cost for a design configuration. This capability to directly link any design configuration to realistic cost estimation is a key requirement for high payoff MDO problems. Another important consideration in this report is the handling of part or product complexity. Here the concept of cost modulus is introduced to take into account variability due to different materials, sizes, shapes, precision of fabrication, and equipment requirements. The most important implication of the development of the proposed process-based cost model is that different design configurations can now be quickly related to their cost estimates in a seamless calculation process easily implemented on any spreadsheet tool. In successive sections, the report addresses the issues of cost modeling as follows. First, an introduction is presented to provide the background for the research work. Next, a quick review of cost estimation techniques is made with the intention to highlight their inappropriateness for what is really needed at the conceptual phase of the design process. The First-Order Process Velocity Cost Model (FOPV) is discussed at length in the next section. This is followed by an application of the FOPV cost model to a generic wing. For designs that have no precedence as far as acquisition costs are concerned, cost data derived from the FOPV cost model may not be accurate enough because of new requirements for shape complexity, material, equipment and precision/tolerance. The concept of Cost Modulus is introduced at this point to compensate for these new burdens on the basic processes. This is treated in section 5. The cost of a design must be conveniently linked to its CAD representation. The interfacing of CAD models and spreadsheets containing the cost equations is the subject of the next section, section 6. The last section of the report is a summary of the progress made so far, and the anticipated research work to be achieved in the future.

Bao, Han P.↗

NASA NTRS2019

An Analytic Model for Estimating the First Contact Resistance Needed to Avoid Damaging ESD During Spacecraft Docking in GEO

NASA’s Gateway program will involve spacecraft (s/c) docking in the outer radiation belt in order to transfer Gateway elements between s/c for transport to lunar orbit. The charging of these s/c to different potentials prior to docking raises the possibility of a damaging electrostatic discharge (ESD) at the time of first contact between the s/c. A proposed mitigation strategy is for first contact to occur prior to docking through a resistor with resistance R that would lower the potential difference at an optimal rate to a sufficiently low value to prevent ESD damage. The coupling of s/c by a resistor can be modeled by SPIS, but for realistic two s/c models SPIS can take hours to simulate the evolution of the s/c surface charges and potentials to an equilibrium state. Our objective is to develop a simpler model of s/c resistive coupling that runs orders of magnitude faster while providing useful first design estimates of the time variation of the s/c potentials, current through the resistor, and how these vary with R and s/c configuration This configuration is defined by the relative separation and orientation of the s/c, and their solar illumination. The configuration and geometry of the s/c determine their capacitive coupling. The s/c capacitances are computed using Nascap-2K. This poster presents the first version of such a model, and initial tests.

Goodman, Michael L.↗

NASA NTRSDate not supplied

Mars Sample Return Earth Entry System Helicopter Drop Test Reconstruction

The Mars Sample Return campaign conducted four successful helicopter drop tests of the Earth Entry System at the Utah Test and Training Range on October, 2023. The tests acquired data for the 52.5 deg sphere cone geometry that can be used to develop models for the terminal descent aerodynamics and flight dynamics used to model ground impact conditions. The acquired test data included both sensor data outputs from an on-board inertial measurement unit, global positioning system, and video cameras as well as atmospheric measurements from weather balloons. This data was processed using a Kalman filter/smoother to reconstruct the capsule’s trajectory and aerodynamics. An equation-error method was used to reconcile the aerodynamics by solving for a set of dispersions in the aerodynamic database that form a best-fit to the reconstructed aerodynamics. The reconstructed trajectories were compared with flight simulations generated using Program to Optimize Simulated Trajectories II. The results indicate that the simulation underpredicted the vehicle oscillation amplitudes. The reconstruction exhibits a persistent low-amplitude oscillation that does not damp out as predicted.

Chris D Karlgaard↗

NASA NTRSDate not supplied

Mars Sample Return Earth Entry System Helicopter Drop Test Reconstruction

Chris D Karlgaard↗

NASA NTRS1973

Adhesive-bonded scarf and stepped-lap joints

Continuum mechanics solutions are derived for the static load-carrying capacity of scarf and stepped-lap adhesive-bonded joints. The analyses account for adhesive plasticity and adherend stiffness imbalance and thermal mismatch. The scarf joint solutions include a simple algebraic formula which serves as a close lower bound, within a small fraction of a per cent of the true answer for most practical geometries and materials. Digital computer programs were developed and, for the stepped-lap joints, the critical adherend and adhesive stresses are computed for each step. The scarf joint solutions exhibit grossly different behavior from that for double-lap joints for long overlaps inasmuch as that the potential bond shear strength continues to increase with indefinitely long overlaps on the scarf joints. The stepped-lap joint solutions exhibit some characteristics of both the scarf and double-lap joints. The stepped-lap computer program handles arbitrary (different) step lengths and thickness and the solutions obtained have clarified potentially weak design details and the remedies. The program has been used effectively to optimize the joint proportions.

Hart-Smith, L. J.↗

NASA NTRS2000

Annual Research Briefs - 2000: Center for Turbulence Research

This report contains the 2000 annual progress reports of the postdoctoral Fellows and visiting scholars of the Center for Turbulence Research (CTR). It summarizes the research efforts undertaken under the core CTR program. Last year, CTR sponsored sixteen resident Postdoctoral Fellows, nine Research Associates, and two Senior Research Fellows, hosted seven short term visitors, and supported four doctoral students. The Research Associates are supported by the Departments of Defense and Energy. The reports in this volume are divided into five groups. The first group largely consists of the new areas of interest at CTR. It includes efficient algorithms for molecular dynamics, stability in protoplanetary disks, and experimental and numerical applications of evolutionary optimization algorithms for jet flow control. The next group of reports is in experimental, theoretical, and numerical modeling efforts in turbulent combustion. As more challenging computations are attempted, the need for additional theoretical and experimental studies in combustion has emerged. A pacing item for computation of nonpremixed combustion is the prediction of extinction and re-ignition phenomena, which is currently being addressed at CTR. The third group of reports is in the development of accurate and efficient numerical methods, which has always been an important part of CTR's work. This is the tool development part of the program which supports our high fidelity numerical simulations in such areas as turbulence in complex geometries, hypersonics, and acoustics. The final two groups of reports are concerned with LES and RANS prediction methods. There has been significant progress in wall modeling for LES of high Reynolds number turbulence and in validation of the v(exp 2) - f model for industrial applications.

Source record↗

NASA NTRS1999

Initial Study of Friction Pull Plug Welding

Pull plug friction welding is a new process being developed to conveniently eliminate defects from welded plate tank structures. The general idea is to drill a hole of precise, optimized dimensions and weld a plug into it, filling the hole perfectly. A conically-shaped plug is rotated at high angular velocity as it is brought into contact with the plate material in the hole. As the plug is pulled into the hole, friction rapidly raises the temperature to the point at which the plate material flows plastically. After a brief heating phase, the plug rotation is terminated. The plug is then pulled upon with a forging force, solidly welding the plug into the hole in the plate. Three aspects of this process were addressed in this study. The transient temperature distribution was analyzed based on slightly idealized boundary conditions for different plug geometries. Variations in hole geometry and ram speed were considered, and a program was created to calculate volumes of displaced material and empty space, as well as many other relevant dimensions. The relation between the axially applied forging force and the actual forging pressure between the plate and plug surfaces was determined for various configurations.

Rich, Brian S.↗

NASA NTRS2018

Transition Delay via Vortex Generators in a Hypersonic Boundary Layer at Flight Conditions

The potential of realizable, stationary streaks undergoing non-modal growth to stabilize a hypersonic boundary-layer flow and, subsequently, delay the laminar-turbulent transition onset, is studied via numerical computations. The geometry and flow conditions are selected to match a relevant trajectory location from the ascent phase of the HIFiRE-1 flight experiment, namely, a 7-degree half-angle cone with 2.5 mm nose radius, freestream Mach number of 5.30, freestream unit Reynolds number equal to 13.42 x 10(exp 6)/m, and wall-to-adiabatic temperature ratio of approximately 0.35 over most of the test article. This paper investigates flow modifications induced by wall-mounted vortex generators (VGs), followed by an analysis of the modal instability of the perturbed, streaky boundary-layer flow. Results are presented both for a single array of VGs that was designed on the basis of optimal growth theory and for a VG configuration involving two separate arrays with opposite orientations that ware designed to provide staged control of flow instabilities while simultaneously reducing the amplification of streak instabilities resulting from the control devices. Earlier research had shown that the onset of transition during the HIFiRE-1 flight experiment, which did not include any control devices, correlated with an amplification factor of N = 14.7 for the planar Mack modes. If one assumes that the transition N -factor is not affected by the introduction of the VGs, then the control configurations based on a single array of VGs and two separate arrays would result in a transition delay of 17% and 40%, respectively. These findings suggest a passive flow control s to induce streaks that would delay transition in hypersonic boundary dominated by Mack-mode instabilities.

Incompressible boundary layer↗

NASA NTRS2023

AI-3000K Infrared Line List for Hot CO 2

AI-3000K is a semi-empirical IR line list constructed for hot CO 2 spectra analysis and simulation up to 3000 – 4000 K. Compared to previously published Ames-1000K and UCL-4000, it represents a major upgrade, utilizing a new algorithm for optimization and including the latest improvements in potential energy surface (PES), dipole moment surface (DMS), and room temperature IR line list (Ames-2021 296K). To maximize the success of introducing experimental based accurate line positions, a new PES (X01d) was refined with respect to >800 selected CDSD2019 [Tashkun et al. JQSRT (2019) 228, 124] energy levels in the range of 0 – 24,000 cm -1 , with σ rms = 0.5 – 0.7 cm -1 . Most differences between the X01d PES based levels and CDSD2019 energies are within ± 2 cm -1 . A new DMS is fitted from extrapolated CCSD(T)/aug-cc-pV(T,Q,5)Z dipole calculations, with σ rms = 5.1 × 10 -6 au for 11,155 geometries up to 40,000 cm -1 , denoted Ames-2021–40K. Compared to the best available Ames-2021 DMS and room temperature IR line list [Huang et al J. Phys. Chem. A (2022) 126, 5940], the relative intensity differences are expected to be ∼ 1 ‰. The line position accuracy of ''X01d + Ames-2021–40K'' IR line list is significantly improved by adopting CDSD2019 energy levels up to 24,000 cm -1 (J ≤ 150). The Einstein A21 coefficients for E' < 15,000 cm -1 transitions are replaced by more accurate values from the Ames-2021 296K IR line list. In short, the AI-3000K is the X01d PES and Ames-2021–40K DMS based line list enhanced with the A 21 of Ames-2021 296K line list and CDSD energy levels. It provides continuous coverage from 0 to 20,000 cm -1 for the four most abundant isotopologues: 12 C 16 O 2 (626), 13 C 16 O 2 (636), 16 O 12 C 18 O (628), and 16 O 12 C 17 O (627). The impacts of isotopologue and E'/E'' cutoffs have been examined. Intensity convergence (not accuracy) of AI-3000K line list is quantitatively estimated in 1 cm -1 bins. It is better than 99% in the whole range of 0 – 20,000 (or 10,000) cm -1 at 1000 K (or 2000 K), or better than 90% in the whole range of 0 – 15,000 (or 9000) cm -1 at 2000 K (or 3000 K), respectively. Convergence beyond 3000 K will require a new PES and DMS for E' > 40,000 cm -1 . The AI-3000K and HITEMP based IR simulations are compared to high resolution shock tube experiments for CO 2 -Ar mixture up to 2000 K. With line position accuracy comparable to that of HITEMP, AI-3000K IR line list yields better agreements at more frequencies. Potential sources of discrepancies with experiment are discussed.

AI-3000K↗

NASA NTRS1993

Aerodynamic control of NASP-type vehicles through Vortex manipulation. Volume 2: Static wind tunnel tests

Forebody Vortex Control (FVC) was explored in this research program for potential application to a NASP-type configuration. Wind tunnel tests were conducted to evaluate a number of jet blowing schemes. The configuration tested has a slender forebody and a 78 deg swept delta wing. Blowing jets were implemented on the leeward side of the forebody with small circular tubes tangential to the surface that could be directed aft, forward, or at angles in between. The effects of blowing are observed primarily in the yawing and rolling moments and are highly dependent on the jet configuration and the angle of attack. Results show that the baseline flow field, without blowing activated, is quite sensitive to the geometry differences of the various protruding jets, as well as being sensitive to the blowing, particularly in the angle of attack range where the forebody vortices are naturally asymmetric. The time lag of the flow field response to the initiation of blowing was also measured. The time response was very short, on the order of the time required for the flow disturbance to travel the distance from the nozzle to the specific airframe location of interest at the free stream velocity. Overall, results indicate that sizable yawing and rolling moments can be induced with modest blowing levels. However, direct application of this technique on a very slender forebody would require thorough wind tunnel testing to optimize the jet location and configuration.

Suarez, Carlos J.↗

NASA NTRS2007

Notch Fatigue Strength of a PM Disk Superalloy

New powder metallurgy (PM) disk superalloys, such as ME3, LSHR, and Alloy 10, have been developed in recent years which enable rim temperatures in turbine disk applications to approach 1300 F. Before these alloys can be utilized at 1300 F their long term durability must be ensured. One of the key requirements for disk rims is notch fatigue strength. This issue is extremely important and is a direct result of the blade attachment geometry employed at the disk rim. Further, the imposition of a dwell at maximum load, associated with take off and landing, can also affect notch fatigue strength. For these reasons a study has been undertaken to assess the notch dwell fatigue strength of a modern PM disk alloy through spin pit evaluation of a prototypical disk. The first element of this program involves screening potential heat treatments with respect to notch fatigue strength at 1300 F utilizing a conventional notch fatigue specimen with a stress concentration factor (K(sub t)) of 2 and a 90 sec dwell at peak load. The results of this effort are reported in this paper including the downselect of an optimal heat treatment, from a notch fatigue standpoint.

Gayda, John↗

NASA NTRS2004

A Sizing Methodology for the Conceptual Design of Blended-Wing-Body Transports

This paper describes the development of a methodology for sizing Blended-Wing-Body (BWB) transports and how the capabilities of the Flight Optimization System (FLOPS) have been expanded using that methodology. In this approach, BWB transports are sized based on the number of passengers in each class that must fit inside the centerbody or pressurized vessel. Weight estimation equations for this centerbody structure were developed using Finite Element Analysis (FEA). This paper shows how the sizing methodology has been incorporated into FLOPS to enable the design and analysis of BWB transports. Previous versions of FLOPS did not have the ability to accurately represent or analyze BWB configurations in any reliable, logical way. The expanded capabilities allow the design and analysis of a 200 to 450-passenger BWB transport or the analysis of a BWB transport for which the geometry is already known. The modifications to FLOPS resulted in differences of less than 4 percent for the ramp weight of a BWB transport in this range when compared to previous studies performed by NASA and Boeing.

Kimmel, William M.↗