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The facilities, testing techniques, and design methods are described for NASA Dryden Flight Research Center. High temperature strain gage technology, realistic flight hardware fabrication, and structural analysis are discussed. A considerable amount of experimental work on hot structure concepts for hypersonic vehicles was performed; all the work is not complete, and there are still problem areas that need to be resolved.
The test procedures and the results obtained during the evaluation test program on the Solaron Corporation air-type solar collector are presented. The tests were performed under simulated conditions, following long-term exposure to natural weathering conditions. The Solaron Model 2001, air-type solar collector has a gross area of 19 square feet and the weight is 160 pounds. The absorber plate is made of 24-gage steel, the coating is baked-on black paint, the cover consists of two sheets of 1/8-inch low-iron tempered glass, and the insulation is one thickness of 3 5/8-inch fiberglass batting.
Miniature semiconductor strain gage pressure transducers mounted in several arrangements were studied. Both surface mountings and recessed flush mountings were tested. Test parameters included mounting arrangement, blade material, temperature, local strain in the acceleration normal to the transducer diaphragm, centripetal acceleration, and pressure. Test results show no failures of transducers or mountings and indicate an uncertainty of unsteady pressure measurement of approximately + or - 6 percent + 0.1 kPa for a typical application. Two configurations were used on a rotating fan flutter program. Examples of transducer data and correction factors are presented.
One approach for detection of the coal interface is measurement of the pick cutting hoads and shock through the use of pick strain gage load cells and accelerometers. The cutting drum of a long wall mining machine contains a number of cutting picks. In order to measure pick loads and shocks, one pick was instrumented and telementry used to transmit the signals from the drum to an instrument-type tape recorder. A data system using FM telemetry was designed to transfer cutting bit load and shock information from the drum of a longwall shearer coal mining machine to a chassis mounted data recorder.
Tensile and compressive strain compatibility testing was performed on as-sprayed samples of the Shuttle Solid Rocket Booster external ablator material, MSA-1. Strain gages on the aluminum substrate were used to monitor strain. Strain compatibility was determined as the percent strain in the substrate at first visual evidence of MSA-1 failure. The 1/8-in. MSA-1, baselined for large areas of the SRB external skin, was characterized by a strain compatibility of 1.5 to 1.8 percent, which far exceeded the yield range of the metal substrate. Thicker MSA-1 applications (1.4 to 3/8 in.) were characterized by a lower level of strain compatibility, which appeared to be a manifestation of application limitations.
Hardware and controls developed for an electrolysis demonstration unit for use with the life sciences payload program and in NASA's regenerative life support evaluation program are described. Components discussed include: the electrolysis module; power conditioner; phase separator-pump and hydrogen differential regulator; pressure regulation of O2, He, and N2; air-cooled heat exchanger; water accumulator; fluid flow sight gage assembly; catalytic O2/H2 sensor; gas flow sensors; low voltage power supply; 100 Amp DC contactor assembly; and the water purifier design.
The analysis of pressure and gage wind tunnel data from space shuttle wind tunnel test IA138 was performed to define the aerodynamic influence of the main propulsion system and solid rocket booster plumes on the total vehicles, elements, and components of the space shuttle vehicle during the supersonic portion of ascent flight. A math model of the plume induced aerodynamic characteristics was developed for a range of Mach numbers to match the forebody aerodynamic math model. The base aerodynamic characteristics are presented in terms of forces and moments versus attitude. Total vehicle base and forebody aerodynamic characteristics are presented in terms of aerodynamic coefficients for Mach numbers from 1.55 to 2.5.
A full scale engine research (FSER) program conducted with the F100 engine is presented. The program mechanism is described and the F100 test vehicles utilized are illustrated. Technology items were addressed in the areas of swirl augmentation, flutter phenomenon, advanced electronic control logic theory, strain gage technology and distortion sensitivity. The associated test programs are described. The FSER approach utilizes existing state of the art engine hardware to evaluate advanced technology concepts and problem areas. Aerodynamic phenomenon previously not considered by design systems were identified and incorporated into industry design tools.
In order to improve aerodynamic performance, a twist criterion was used to design the canard and wing lifting surfaces of two graphite-epoxy research aircraft. To meet that twist criterion, the lifting surfaces were tailored using graphite-epoxy tape. The outer surface of the aircraft is essentially constructed of 95 percent graphite epoxy materials. The analytical tools and methodology used to design those lifting surfaces are described. One aircraft was subjected to an 8g ground test in order to verify structural integrity and to determine how well the desired twist was achieved. Test results are presented and the reductions of both flight and ground strain test gages and their associated stresses are discussed.
Flutter frequency was determined and rotor vibratory amplitude and phase distributions during flutter were reconstructed from stationary aerodynamic type measurements. A previously reported optical method for measuring blade-tip displacement during flutter was extended by means of digital analysis. Displacement amplitudes and phase angle were determined based on this method. For selected blades, spectral results were also obtained from strain gage measurements. The results from these three types of measurement were compared and critically evaluated.
The paper briefly reviews the role of helicopter systems in the provision of airport access services and evaluates the potential for the future development of such services in major metropolitan areas in the United States. The evaluation is based on a computer simulation of potential helicopter system proposed for 20 metropolitan areas. The simulation provides two indicators that are used to gage the extent of the feasibility of developing successful systems in these areas: (1) the cost per seat mile, and (2) the break-even number of passengers, expressed as a percentage of total air travelers. It is found that a few metropolitan areas presently have the potential of marginally supporting intra-urban helicopter airport access service. The access systems offer a viable alternative for air passengers placing a high value on their time, and provides the opportunity for better integrating the air transportation service of multiple airports in a given urban region.
Output from the 200-kilowatt machine will be enough to meet the power requirements of about 60 families. The experimental wind turbine generator (WTG) is a two-bladed, horizontal-axis, rotor system driving a synchronous electric generator through a step-up gear box located within a nacelle. The nacelle is mounted on top of a 100-foot tower with the rotor located downwind from the tower. The 200-kilowatt rated power output of the wind turbine is achieved at a turbine rotor speed of 40 rpm and a rated wind speed of 18.3 mph. The rated wind speed is defined as the lowest wind speed at which full power is achieved. Attention is given to operational details, aspects of blade design, blade fabrication, the use of strain gages, questions of aeroelastic stability, and an early analysis of test data.
The results of uniaxial tensile tests conducted on a variety of graphite/epoxy laminates containing narrow rectangular slits and square or circular holes with various aspect ratios are discussed. The techniques used to study stable-crack or damage-zone growth - namely, birefringence coatings, COD gages, and microscopic observations are discussed. Initial and final-fracture modes are discussed as well as the effect of notch size and shape and laminate type on the fracture process. Characteristic lengths are calculated using the point, average and inherent flaw theories and comparisons with observations are discussed. Further, the effect of flaw geometry on stress states and deformations is assessed.
Compressor rotor strain gage data from an engine test conducted with an inlet screen distortion were reduced and analyzed. The data were compared to results obtained from the same engine without inlet pressure distortion to determine the net effect of the distortion on the vibratory response of the compressor blades. The effect of the distortion was found to be most prominent in the first three compressor stages, with the rotor speed establishing the period of the complex wave and, consequently, the frequencies of all the higher engine order excitations. At certain speeds it was observed that the complex pressure wave had the frequency content to excite a number of modes simultaneously, although the overall magnitudes were small and well within allowable stress limits.
Orbital transfer of cryogenic propellants could benefit spacecraft and Orbital Transfer Vehicle (OTV) missions in the 1980s by supplying main propulsion, attitude control, or other fluid systems. The Space Shuttle can operate as a tanker when equipped with cryogenic propellant storage and orbital transfer systems. The key technologies are multilayer insulation, capillary propellant acquisition, zero-g gaging, orbital chilldown, and possibly large flight weight dewars. The technologies and operations could be realistically demonstrated using a Centaur that has been integrated with the Shuttle. Orbital refueling capability can enhance the usefulness of the whole Shuttle program
Advances in materials, coatings, turbine cooling technology, structural and design concepts, and component-life prediction of helicopter gas-turbine-engine components are presented. Stationary parts including the inlet particle separator, the front frame, rotor tip seals, vanes and combustors and rotating components - compressor blades, disks, and turbine blades - are discussed. Advanced composite materials are considered for the front frame and compressor blades, prealloyed powder superalloys will increase strength and reduce costs of disks, the oxide dispersion strengthened alloys will have 100C higher use temperature in combustors and vanes than conventional superalloys, ceramics will provide the highest use temperature of 1400C for stator vanes and 1370C for turbine blades, and directionally solidified eutectics will afford up to 50C temperature advantage at turbine blade operating conditions. Coatings for surface protection at higher surface temperatures and design trends in turbine cooling technology are discussed. New analytical methods of life prediction such as strain gage partitioning for high temperature prediction, fatigue life, computerized prediction of oxidation resistance, and advanced techniques for estimating coating life are described.
This paper summarizes a joint NASA/Air Force Full Scale Engine Research (FSER) program conducted with the F100 engine during the period 1974 through 1979. The program mechanism is described and the F100 test vehicles utilized are illustrated. Technology items which have been addressed in the areas of swirl augmentation, flutter phenomenon, advanced electronic control logic theory, strain gage technology, and distortion sensitivity are identified and the associated test programs conducted at the NASA-Lewis Research Center are described. Results presented show that the FSER approach, which utilizes existing state-of-the-art engine hardware to evaluate advanced technology concepts and problem areas, can contribute a significant data base for future system applications. Aerodynamic phenomenon previously not considered by current design systems have been identified and incorporated into current industry design tools.
Simple handtool helps form contours and complex shapes from laminae of resin-impregnated fabric. Tool, which consists of yoke having ballpoint pen and spindle and gage, is placed so that it straddles model. As toll is moved, pen draws constant thickness focus that is used as template.