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SPLICE project annual program review presentation. SPLICE Precision Landing and Hazard Avoidance (PL&HA) technologies will improve landing precision by an order of magnitude and enable high-resolution real-time 3-D mapping for hazard detection and avoidance during descent.
Thermocouple measures continuously in flowing gaseous hydrogen at temperatures up to 4000 deg F, in environments made hazardous by radiation, and where rapid response and calibration reproducibility are critically important. Thermocouple wires extend continuously, without splice or foreign material, from cold junction to probe's tip.
Fourteen C-130 airplane center wings, each containing service-imposed fatigue damage resulting from 4000 to 13,000 accumulated flight hours, were tested to determine their fatigue crack propagation and static residual strength characteristics. Eight wings were subjected to a two-step constant amplitude fatigue test prior to static testing. Cracks up to 30 inches long were generated in these tests. Residual static strengths of these wings ranged from 56 to 87 percent of limit load. The remaining six wings containing cracks up to 4 inches long were statically tested as received from field service. Residual static strengths of these wings ranged from 98 to 117 percent of limit load. Damage-tolerant structural design features such as fastener holes, stringers, doublers around door cutouts, and spanwise panel splices proved to be effective in retarding crack propagation.
Damaged tapes can now be repaired at home as long as damage does not extend to layer-to-layer adhesion within tape roll. Splice repaired section into good roll or cassette for copying. Every effort should be made to complete copying on first run, because fidelity in repaired section deteriorates with each repetition.
Antenna was produced in segments. Parabole sections were built up as aluminum foil sandwich with core bonded by film adhesive; whole structure was oven-cured after assembly. Structure was assembled with special tool for splice-bonding segments into complete dish, and inflatable bladder to apply pressure at joints during cure.
The off-scale low indications of the voltmeters for batteries one and two at initial powerup of the Apollo 16 lunar roving vehicle were analyzed. No single condition was found that would explain the anomalous meter indications. It is concluded that the intermittent conditions must have existed in the multiple wire splices to the meters.
A flat conductor cabling system for electrical/electronic interwiring is described. Six major items comprise the system: the cables, splices - one for flat cable to round wires and one for flat cable to flat cable; a series of flat cable connectors; the distributor, which is used for interconnecting the circuits; and a repair technique for the falt cable. Polyarylene, a new high performance melt-processable insulation material, permits the design of a completely standardized, modular flat conductor flat cable. The development of an advanced heat-shrinkable plastics technology involving the use of selectively bonded plastic film has resulted in the multiple termination module, used for making high-reliability sealed solder terminations to either flat conductor cable or round wires. All necessary tools and application equipment are included in the system design.
Bonded lap joints were manufactured and tested under static and fatigue loading. Specimens were designed to fail in the bondline, and all fatigue tests included monitoring the crack growth to failure. Test specimens included aluminum details joined by two different adhesives. Specimens also included titanium and boron-epoxy details joined by an epoxy laminating resin. Additonal program variables included bondline thickness, adherend and spice plate thickness, specimen width, and specimen fabrication procedure. Adhesive aging was found to be generally detrimental to the lives of most of the specimens bonded with one adhesive system. Adhesive material was found to have a major influence on debond rate. Co-cured titanium/boron-epoxy specimens were found to resist debonding better than specimens fabricated with a sequential cure. Splice plate thickness and test section width were found to have little effect on debond rate. The data also suggested the existence of an optimum bondline thickness.
A program was performed to determine the repairability of boron/aluminum aerospace structural components. During the program, a list of repair guidelines was prepared to aid in determining the proper repair techniques for a given structure. These guidelines included specifying types of repair material and their applicability, corrosion prevention procedures, design criteria, and inspection criteria. Six sets of boron/aluminum structural components were repaired and tested to compare as-fabricated and repaired performance. The specimens included a honeycomb-stiffened panel, elastically buckled tubes, a skin-stringer panel, a tube combining bending and tension, a splice joint specimen, and a tension field panel. All but one set of specimens, when repaired, exceeded the strength of the original specimens. The repairs resulted in an average weight increase per structure of 9% and an average performance increase of 27%. It is concluded that metal-matrix composite material, damaged in service, can be repaired by techniques not very different from those currently in use for conventional materials.
Instrument can be used to isolate fault at specific multiple-cable splice location.
Seal allows electrical wires to pass directly from sensors inside of liquid nitrogen storage vessel to outside instruments. No splices or connectors are required, so errors created by contact resistance are avoided. With method, measurements with highly sensitive instrumentation are made with greater accuracy.
When proper procedures are followed, hand crimping tool makes reliable, low-cost thermocouple connections. Procedure reduces time and expense of splicing solid and stranded platinum thermocouple wires.
Major areas of study include: (1) edge effects in finite width laminated composites subjected to mechanical, thermal and hygroscopic loading with temperature dependent material properties and the influence of edge effects on the initiation of failure; (2) shear and compression testing of composite materials at room and elevated temperatures; (3) optical techniques for precise measurement of coefficients of thermal expansion of composites; (4) models for the nonlinear behavior of composites including material nonlinearity and damage accumulation and verification of the models under biaxial loading; (5) compressive failure of graphite/epoxy plates with circular holes and the buckling of composite cylinders under combined compression and torsion; (6) nonlinear mechanical properties of borsic/aluminum, graphite/polyimide and boron/aluminum; (7) the strength characteristics of spliced sandwich panels; and (8) curved graphite/epoxy panels subjected to internal pressure.
The structural development work performed on the Learjet 28/29 wing using NASTRAN analysis is discussed. The work included the basic sizing of primary structural members such as wing skins, wing skin splices, and spar caps, as well as the calculation of preliminary weight estimates utilizing the weight computation routine in NASTRAN. The eight spar redundancy of the Learjet wing made this task somewhat more complex than for more determinate type wing structures. Some of the problems that were encountered and the solutions and methods that were used are described.
Alternate concepts and design approaches were developed for suction panels and techniques were defined for integrating these panel designs into a complete LFC 200R wing. The design concepts and approaches were analyzed to assure that they would meet the strength, stability, and internal volume requirements. Cost and weight comparisions of the concepts were also made. Problems of integrating the concepts into a complete aircraft system were addressed. Methods for making splices both chordwise and spanwise, fuel light joints, and internal duct installations were developed. Manufacturing problems such as slot aligment, tapered slot spacing, production methods, and repair techniques were addressed. An assessment of the program was used to developed recommendations for additional research in the development of SPF/DB for LFC structure.
The theory, design, and results of optical fiber pulse dispersion measurements are considered. Both the hardware and software required to perform this type of measurement are described. Hardware includes a thermoelectrically cooled injection laser diode source, an 800 GHz gain bandwidth produce avalanche photodiode and an input mode scrambler. Software for a HP 9825 computer includes fast Fourier transform, inverse Fourier transform, and optimal compensation deconvolution. Test set construction details are also included. Test results include data collected on a 1 Km fiber, a 4 Km fiber, a fused spliced, eight 600 meter length fibers concatenated to form 4.8 Km, and up to nine optical connectors.
A method is devised to accurately calculate broad band limb radiance based on a precalculated data base consisting of homogeneous path emissivity as a function of mass path data for various temperatures and pressures. Accurately estimating limb radiance by splicing together interpolated information from the emissivity curves requires no temperature or pressure weighting, and only two interpolations per layer path. The emissivity growth approximation (EGA) technique is applied in a simulated inversion study to the inference of O3, H2O, NO2 and HNO3, and it is found to have comparable accuracies to more sophisticated many-degree band models. The EGA technique is also found to be two orders of magnitude faster, while requiring one second per inversion for one constituent at one-km resolution, allowing a completely nonlinear relaxation time inversion to be done at linear speeds. The technique is also expected to work well for nadir calculations, and prove adequate for estimating occultation radiances.
An extemely lightweight type of precision reflector antenna, being developed for potential deployment from the space shuttle, uses electrostatic forces to tension a thin membrane and form it into a concave reflector surface. The typical shuttle-deployed antenna would have a diameter of 100 meters and an RMS surface smoothness of 10 to 1 mm for operation at 1 to 10 GHz. NASA Langley Research Center built and is currently testing a subscale (16 foot diameter) model of the membrane reflector portion of such an antenna. Preliminary test results and principal factors affecting surface quality are addressed. Factors included are the effect of the perimeter boundary, splicing of the membrane, the long-scale smoothness of commercial membranes, and the spatial controllability of the membrane using voltage adjustments to alter the electrostatic pressure. Only readily available commercial membranes are considered.