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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

The International Space Station Assembly on Schedule

As engineers continue to prepare the International Space Station (ISS) for in-orbit assembly in the year 2002, ANSYS software has proven instrumental in resolving a structural problem in the project's two primary station modules -- Nodes 1 and 2. Proof pressure tests performed in May revealed "low temperature, post-yield creep" in some of the Nodes' gussets, which were designed to reinforce ports for loads from station keeping and reboost motion of the entire space station. An extensive effort was undertaken to characterize the creep behavior of the 2219-T851 aluminum forging material from which the gussets were made. Engineers at Sverdrup Technology, Inc. (Huntsville, AL) were responsible for conducting a combined elastic-plastic-creep analysis of the gussets to determine the amount of residual compressive stress which existed in the gussets following the proof pressure tests, and to determine the stress-strain history in the gussets while on-orbit. Boeing, NASA's Space Station prime contractor, supplied the Finite Element Analysis (FEA) model geometry and developed the creep equations from the experimental data taken by NASA's Marshall Space Flight Center and Langley Research Center. The goal of this effort was to implement the uniaxial creep equations into a three dimensional finite element program, and to determine analytically whether or not the creep was something that the space station program could live with. The objective was to show analytically that either the creep rate was at an acceptable level, or that the node module had to be modified to lower the stress levels to where creep did not occur. The elastic-plastic-creep analysis was performed using the ANSYS finite element program of ANSYS, Inc. (Houston, PA). The analysis revealed that the gussets encountered a compressive stress of approximately 30,000 pounds per square inch (psi) when unloaded. This compressive residual stress significantly lowered the maximum tension stress in the gussets which decreased the creep strain rate. The analysis also showed that the gussets would not experience a great deal of creep from future pressure tests if braces or struts proposed by Boeing were installed to redistribute stress away from them. Subsequent analysis of on-orbit station keeping and reboost loads convinced Boeing that the gussets should be removed altogether.

Source record↗
NASA NTRS1999

Modeling of SiC Lateral Resonant Devices Over a Broad Temperature Range

Finite-element analysis (FEA) modal results of 3C-SiC lateral resonant devices anchored to a Si substrate are presented as resonant frequency versus temperature. The suspended elements are etched from a 2 micron, 3C-SiC film grown at 1600 K on a 500 micron-thick, Si substrate. The analysis includes, temperature-dependent properties, shape change due to volume expansion with temperature, and thermal stress caused by differential thermal expansion of different materials. Two designs are considered: type I has anchor locations close to the geometric centroid and a small shuttle; type 11 has a large shuttle with anchors far from the centroid, The resonant frequency decreases approximately 3.5% over a 1000 K temperature increase for the type-I device, and behaves according to theory. The resonant frequency of the type-11 device decreases by 2% over the first 400 K, then rises slightly over the remaining 600 K. This device deviates from theory because of the high thermal stress induced in the beams. The thermal stress is caused by the differential thermal expansion of the suspended element relative to the substrate. The results show that the device geometry must be properly chosen if the resonant frequency of that device will be used to calculate the temperature coefficient of Young's modulus. These results apply only to resonators of one material on a substrate of a different material.

DeAnna, Russell G.↗
NASA NTRS2000

Efficient Analysis of Complex Structures

Last various accomplishments achieved during this project are : (1) A Survey of Neural Network (NN) applications using MATLAB NN Toolbox on structural engineering especially on equivalent continuum models (Appendix A). (2) Application of NN and GAs to simulate and synthesize substructures: 1-D and 2-D beam problems (Appendix B). (3) Development of an equivalent plate-model analysis method (EPA) for static and vibration analysis of general trapezoidal built-up wing structures composed of skins, spars and ribs. Calculation of all sorts of test cases and comparison with measurements or FEA results. (Appendix C). (4) Basic work on using second order sensitivities on simulating wing modal response, discussion of sensitivity evaluation approaches, and some results (Appendix D). (5) Establishing a general methodology of simulating the modal responses by direct application of NN and by sensitivity techniques, in a design space composed of a number of design points. Comparison is made through examples using these two methods (Appendix E). (6) Establishing a general methodology of efficient analysis of complex wing structures by indirect application of NN: the NN-aided Equivalent Plate Analysis. Training of the Neural Networks for this purpose in several cases of design spaces, which can be applicable for actual design of complex wings (Appendix F).

Kapania, Rakesh K.↗
NASA NTRS2000

Technology Development for a Stirling Radioisotope Power System

NASA Glenn Research Center and the Department of Energy are developing a Stirling convertor for an advanced radioisotope power system to provide spacecraft on-board electric power for NASA deep space missions. NASA Glenn is addressing key technology issues through the use of two NASA Phase II SBIRs with Stirling Technology Company (STC) of Kennewick, WA. Under the first SBIR, STC demonstrated a synchronous connection of two thermodynamically independent free-piston Stirling convertors and a 40 to 50 fold reduction in vibrations compared to an unbalanced convertor. The second SBIR is for the development of an Adaptive Vibration Reduction System (AVRS) that will essentially eliminate vibrations over the mission lifetime, even in the unlikely event of a failed convertor. This paper presents the status and results for these two SBIR projects and also discusses a new NASA Glenn in-house project to provide supporting technology for the overall Stirling radioisotope power system development. Tasks for this new effort include convertor performance verification, controls development, heater head structural life assessment, magnet characterization and thermal aging tests, FEA analysis for a lightweight alternator concept, and demonstration of convertor operation under launch and orbit transfer load conditions.

Thieme, Lanny G.↗
NASA NTRS2000

NASA GRC Technology Development Project for a Stirling Radioisotope Power System

NASA Glenn Research Center (GRC), the Department of Energy (DOE), and Stirling Technology Company (STC) are developing a Stirling convertor for an advanced radioisotope power system to provide spacecraft on-board electric power for NASA deep space missions. NASA GRC is conducting an in-house project to provide convertor, component, and materials testing and evaluation in support of the overall power system development. A first characterization of the DOE/STC 55-We Stirling Technology Demonstration Convertor (TDC) under the expected launch random vibration environment was recently completed in the NASA GRC Structural Dynamics Laboratory. Two TDCs also completed an initial electromagnetic interference (EMI) characterization at NASA GRC while being tested in a synchronized, opposed configuration. Materials testing is underway to support a life assessment of the heater head, and magnet characterization and aging tests have been initiated. Test facilities are now being established for an independent convertor performance verification and technology development. A preliminary Failure Mode Effect Analysis (FMEA), initial finite element analysis (FEA) for the linear alternator, ionizing radiation survivability assessment, and radiator parametric study have also been completed. This paper will discuss the status, plans, and results to date for these efforts.

Thieme, Lanny G.↗
NASA NTRS2000

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction

Four roller profiles used in cylindrical roller bearing design and manufacture were analyzed using both a closed form solution and finite element analysis (FEA) for stress and life. The roller profiles analyzed were flat, tapered end, aerospace, and fully crowned loaded against a flat raceway. Four rolling-element bearing life models were chosen for this analysis and compared. These were those of Weibull, Lundberg and Palmgren, Ioannides and Harris, and Zaretsky. The flat roller profile without edge loading has the longest predicted life. However, edge loading can reduce life by as much as 98 percent. The end tapered profile produced the highest lives but not significantly different than the aerospace profile. The fully crowned profile produces the lowest lives. The resultant predicted life at each stress condition not only depends on the life equation used but also on the Weibull slope assumed. For Weibull slopes of 1.5 and 2, both Lundberg-Palmgren and Iaonnides-Harris equations predict lower lives than the ANSI/ABMAJISO standards. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field.

Poplawski, Joseph V.↗
NASA NTRS2001

Slow Crack Growth and Fatigue Life Prediction of Ceramic Components Subjected to Variable Load History

Present capabilities of the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (stress corrosion), and cyclic fatigue failure modes. Currently, this code has the capability to compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in slow crack growth (SCG) type failure conditions CARES/Life can handle the cases of sustained and linearly increasing time-dependent loads, while for cyclic fatigue applications various types of repetitive constant amplitude loads can be accounted for. In real applications applied loads are rarely that simple, but rather vary with time in more complex ways such as, for example, engine start up, shut down, and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and or thermal conditions, the material properties also vary with time. The objective of this paper is to demonstrate a methodology capable of predicting the time-dependent reliability of components subjected to transient thermomechanical loads that takes into account the change in material response with time. In this paper, the dominant delayed failure mechanism is assumed to be SCG. This capability has been added to the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code, which has also been modified to have the ability of interfacing with commercially available FEA codes executed for transient load histories. An example involving a ceramic exhaust valve subjected to combustion cycle loads is presented to demonstrate the viability of this methodology and the CARES/Life program.

Jadaan, Osama↗
NASA NTRS2001

Free Vibration of Uncertain Unsymmetrically Laminated Beams

Monte Carlo Simulation and Stochastic FEA are used to predict randomness in the free vibration response of thin unsymmetrically laminated beams. For the present study, it is assumed that randomness in the response is only caused by uncertainties in the ply orientations. The ply orientations may become random or uncertain during the manufacturing process. A new 16-dof beam element, based on the first-order shear deformation beam theory, is used to study the stochastic nature of the natural frequencies. Using variational principles, the element stiffness matrix and mass matrix are obtained through analytical integration. Using a random sequence a large data set is generated, containing possible random ply-orientations. This data is assumed to be symmetric. The stochastic-based finite element model for free vibrations predicts the relation between the randomness in fundamental natural frequencies and the randomness in ply-orientation. The sensitivity derivatives are calculated numerically through an exact formulation. The squared fundamental natural frequencies are expressed in terms of deterministic and probabilistic quantities, allowing to determine how sensitive they are to variations in ply angles. The predicted mean-valued fundamental natural frequency squared and the variance of the present model are in good agreement with Monte Carlo Simulation. Results, also, show that variations between plus or minus 5 degrees in ply-angles can affect free vibration response of unsymmetrically and symmetrically laminated beams.

Kapania, Rakesh K.↗
NASA NTRS2001

The Effect of Heat Treatment on Residual Stress and Machining Distortions in Advanced Nickel Base Disk Alloys

This paper describes an extension of NASA's AST and IDPAT Programs which sought to predict the effect of stabilization heat treatments on residual stress and subsequent machining distortions in the advanced disk alloy, ME-209. Simple "pancake" forgings of ME-209 were produced and given four heat treats: 2075F(SUBSOLVUS)/OIL QUENCH/NO AGE; 2075F/OIL QUENCH/1400F@8HR;2075F/OIL QUENCH/1550F@3HR/l400F@8HR; and 2160F(SUPERSOLVUS)/OIL QUENCH/1550F@3HR/ 1400F@8HR. The forgings were then measured to obtain surface profiles in the heat treated condition. A simple machining plan consisting of face cuts from the top surface followed by measurements of the surface profile opposite the cut were made. This data provided warpage maps which were compared with analytical results. The analysis followed the IDPAT methodology and utilized a 2-D axisymmetric, viscoplastic FEA code. The analytical results accurately tracked the experimental data for each of the four heat treatments. The 1550F stabilization heat treatment was found to significantly reduce residual stresses and subsequent machining distortions for fine grain (subsolvus) ME209, while coarse grain (supersolvus) ME209 would require additional time or higher stabilization temperatures to attain the same degree of stress relief.

Gayda, John↗
NASA NTRS2002

Design, Progressive Modeling, Manufacture, and Testing of Composite Shield for Turbine Engine Blade Containment

An effective design methodology was established for composite jet engine containment structures. The methodology included the development of the full and reduced size prototypes, and FEA models of the containment structure, experimental and numerical examination of the modes of failure clue to turbine blade out event, identification of materials and design candidates for future industrial applications, and design and building of prototypes for testing and evaluation purposes.

Binienda, Wieslaw K.↗
NASA NTRS1999

Stress Analysis and Permeability Testing of Cryogenic Composite Feed Line

For the next generation Single-Stage-To-Orbit (SSTO) Reusable Launch Vehicle (RLV), the use of advanced composite materials is highly desirable and critical to the success of the mission. NASA Marshall Space Flight Center (MSFC) has been working with the aerospace industry for many years to develop and demonstrate the cryogenic composite propellant tanks and feed lines technologies. A 50.8-mm diameter composite feed line for the Clipper Graham (DCY.A) was developed and tested. The purpose of the program is to demonstrate the LH2 permeability, composite to composite and metal joints, as well as composite flange interface of the composite feed line. Stress analysis and permeability testing have been performed on this article. Recently, a larger composite feed line design is being investigated and developed at MSFC for potential use in future RLV. The diameter of the feed line is 203 mm and the overall length is approximately 2.2 meters. This one piece unlined feed line consists of three straight tubular sections joined by two 90 degree elbows. The material chosen is IM7/977-3 prepreg fabric. The lay-up pattern is [0/90, plus or minus 45]s and is built up to 18 plies to the flanges at both ends. A preliminary stress analysis has been conducted to identify potential critical stresses and to develop the finite element analysis (FEA) capability of composite feed lines. As expected, the critical stresses occurred at the rims of some flange holes and the onset of the tapered tubular sections. Further analysis is required to determine the loads, flange deflection, vibration, and combined maximum loads. Two permeability-testing apparatuses were also designed for both flat panel specimens and curved feed line sections after impact damage. A larger permeant gas exposed area is required to accurately determine the effect of impact damage on the permeability of the feed line materials. The flat panel tester was fabricated and assembled. Three test coupons were made of graphite/epoxy plain weave prepreg and unidirectional prepreg. The flow rate was calculated by measuring the change of manometer fluid height per unit time. The permeability of the coupons is then calculated according to Darcy's Law. The pressure increase due to the head rise in the manometer was not considered for the initial estimation. The result of the unidirectional composite coupon agreed with that obtained from the DC-XA feed line testing of a similar material. Further improvement on the design may be required to improve the accuracy and efficiency of permeability testing.

Chu, Tsuchin Philip↗
NASA NTRS2002

Dynamic Stability of Uncertain Laminated Beams Under Subtangential Loads

Because of the inherent complexity of fiber-reinforced laminated composites, it can be challenging to manufacture composite structures according to their exact design specifications, resulting in unwanted material and geometric uncertainties. In this research, we focus on the deterministic and probabilistic stability analysis of laminated structures subject to subtangential loading, a combination of conservative and nonconservative tangential loads, using the dynamic criterion. Thus a shear-deformable laminated beam element, including warping effects, is derived to study the deterministic and probabilistic response of laminated beams. This twenty-one degrees of freedom element can be used for solving both static and dynamic problems. In the first-order shear deformable model used here we have employed a more accurate method to obtain the transverse shear correction factor. The dynamic version of the principle of virtual work for laminated composites is expressed in its nondimensional form and the element tangent stiffness and mass matrices are obtained using analytical integration The stability is studied by giving the structure a small disturbance about an equilibrium configuration, and observing if the resulting response remains small. In order to study the dynamic behavior by including uncertainties into the problem, three models were developed: Exact Monte Carlo Simulation, Sensitivity Based Monte Carlo Simulation, and Probabilistic FEA. These methods were integrated into the developed finite element analysis. Also, perturbation and sensitivity analysis have been used to study nonconservative problems, as well as to study the stability analysis, using the dynamic criterion.

Goyal, Vijay K.↗
NASA NTRS2002

A Capability to Generate Physics-based Mass Estimating Relationships for Conceptual Space Vehicle Design

This paper is written in support of the on-going research into conceptual space vehicle design conducted at the Space Systems Design Laboratory (SSDL) at the Georgia Institute of Technology. Research at the SSDL follows a sequence of a number of the traditional aerospace disciplines. The sequence of disciplines and interrelationship among them is shown in the Design Structure Matrix (DSM). The discipline of Weights and Sizing occupies a central location in the design of a new space vehicle. Weights and Sizing interact, either in a feed forward or feed back manner, with every other discipline in the DSM. Because of this principle location, accuracy in Weights and Sizing is integral to producing an accurate model of a space vehicle concept. Instead of using conceptual level techniques, a simplified Finite Element Analysis (FEA) technique is described as applied to the problem of the Liquid Oxygen (LOX) tank bending loads applied to the forward Liquid Hydrogen (LH2) tank of the Georgia Tech Air Breathing Launch Vehicle (ABLV).

Olds, John R.↗
NASA NTRS2003

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗
NASA NTRS2003

Structural Reliability Using Probability Density Estimation Methods Within NESSUS

A reliability analysis studies a mathematical model of a physical system taking into account uncertainties of design variables and common results are estimations of a response density, which also implies estimations of its parameters. Some common density parameters include the mean value, the standard deviation, and specific percentile(s) of the response, which are measures of central tendency, variation, and probability regions, respectively. Reliability analyses are important since the results can lead to different designs by calculating the probability of observing safe responses in each of the proposed designs. All of this is done at the expense of added computational time as compared to a single deterministic analysis which will result in one value of the response out of many that make up the density of the response. Sampling methods, such as monte carlo (MC) and latin hypercube sampling (LHS), can be used to perform reliability analyses and can compute nonlinear response density parameters even if the response is dependent on many random variables. Hence, both methods are very robust; however, they are computationally expensive to use in the estimation of the response density parameters. Both methods are 2 of 13 stochastic methods that are contained within the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) program. NESSUS is a probabilistic finite element analysis (FEA) program that was developed through funding from NASA Glenn Research Center (GRC). It has the additional capability of being linked to other analysis programs; therefore, probabilistic fluid dynamics, fracture mechanics, and heat transfer are only a few of what is possible with this software. The LHS method is the newest addition to the stochastic methods within NESSUS. Part of this work was to enhance NESSUS with the LHS method. The new LHS module is complete, has been successfully integrated with NESSUS, and been used to study four different test cases that have been proposed by the Society of Automotive Engineers (SAE). The test cases compare different probabilistic methods within NESSUS because it is important that a user can have confidence that estimates of stochastic parameters of a response will be within an acceptable error limit. For each response, the mean, standard deviation, and 0.99 percentile, are repeatedly estimated which allows confidence statements to be made for each parameter estimated, and for each method. Thus, the ability of several stochastic methods to efficiently and accurately estimate density parameters is compared using four valid test cases. While all of the reliability methods used performed quite well, for the new LHS module within NESSUS it was found that it had a lower estimation error than MC when they were used to estimate the mean, standard deviation, and 0.99 percentile of the four different stochastic responses. Also, LHS required a smaller amount of calculations to obtain low error answers with a high amount of confidence than MC. It can therefore be stated that NESSUS is an important reliability tool that has a variety of sound probabilistic methods a user can employ and the newest LHS module is a valuable new enhancement of the program.

Chamis, Chrisos C.↗
NASA NTRS2003

RSRM Case Acceptance and Refurbishment Requirements

The RSRM (Reuseable Solid Rocket Motor) Program has been developed and implemented to support manned flight space travel. The Space Shuttle Vehicle utilizes two SRBs (Solid Rocket Boosters) to assist during the launch sequence and achieve the predefined orbit and mission objectives. A critical feature of this program involves post- flight SRB retrieval, disassembly and reuse of case structural components to manufacture future RSRM motors. To ensure these components can be safely reused, inspection criteria based on dimensional, structural and fracture requirements, has been established in the form of Engineering specifications and drawings. These criteria originated from actual hardware testing (both subscale and full scale) coupled with conventional Engineering hand calculations and computerized Finite Element Analyses (FEA). The intent of this paper is to provide an overview of the RSRM Case component refurbishment requirements and the associated case hardware inspection and evaluation processes that has been established to satisfy these requirements. Many of these processes have been recently upgraded to comply with environmental regulations, obsolescence concerns and technological advancements. Qualification of these process changes has been closely monitored and documented through test plans and reports.

Brinkerhoff, Gary Z.↗
NASA NTRS2003

Predicting the Reliability of Ceramics Under Transient Loads and Temperatures With CARES/Life

A methodology is shown for predicting the time-dependent reliability of ceramic components against catastrophic rupture when subjected to transient thermomechanical loads (including cyclic loads). The methodology takes into account the changes in material response that can occur with temperature or time (i.e., changing fatigue and Weibull parameters with temperature or time). This capability has been added to the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. The code has been modified to have the ability to interface with commercially available finite element analysis (FEA) codes executed for transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Nemeth, Noel N.↗
NASA NTRS2003

Fatigue Crack Growth Rate and Stress-Intensity Factor Corrections for Out-of-Plane Crack Growth

Fatigue crack growth rate testing is performed by automated data collection systems that assume straight crack growth in the plane of symmetry and use standard polynomial solutions to compute crack length and stress-intensity factors from compliance or potential drop measurements. Visual measurements used to correct the collected data typically include only the horizontal crack length, which for cracks that propagate out-of-plane, under-estimates the crack growth rates and over-estimates the stress-intensity factors. The authors have devised an approach for correcting both the crack growth rates and stress-intensity factors based on two-dimensional mixed mode-I/II finite element analysis (FEA). The approach is used to correct out-of-plane data for 7050-T7451 and 2025-T6 aluminum alloys. Results indicate the correction process works well for high DeltaK levels but fails to capture the mixed-mode effects at DeltaK levels approaching threshold (da/dN approximately 10(exp -10) meter/cycle).

Forth, Scott C.↗