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Buckling Test Results and Preliminary Test and Analysis Correlation from the 8-Foot-Diameter Orthogrid-Stiffened Cylinder Test Article TA02

Results from the testing of cylinder test article SBKF-P2-CYL-TA02 (referred to herein as TA02) are presented. TA02 is an 8-foot-diameter (96-inches), 78.0-inch-long, aluminum-lithium (Al-Li), orthogrid-stiffened cylindrical shell similar to those used in current state-of-the-art launch-vehicle structures and was designed to exhibit global buckling when subjected to combined compression and bending loads. The testing was conducted at the Marshall Space Flight Center (MSFC), February 3-6, 2009, in support of the Shell Buckling Knockdown Factor Project (SBKF). The test was used to verify the performance of a newly constructed buckling test facility at MSFC and to verify the test article design and analysis approach used by the SBKF researchers.

Hilburger, Mark W.↗

State-of-the-Art: Small Spacecraft Technology

When the first edition of NASA’s Small Spacecraft Technology State-of-the-art report was published in 2013, 247 CubeSats and 105 other non-CubeSat small spacecraft under 50 kilograms (kg) had been launched worldwide, representing less than 2% of launched mass into orbit over multiple years. In 2013 alone, around 60% of the total spacecraft launched had a mass under 600 kg, and of those under 600 kg, 83% were under 200 kg and 37% were nanosatellites (1). Of the total 1,849 spacecraft launched in 2021, 94% were small spacecraft with an overall mass under 600 kg, and of those under 600 kg, 40% were under 200 kg, and 11% were nanosatellites (1). Since 2013, the fight heritage for small spacecraft has increased by over 30% and has become the primary source to space access for commercial, government, private, and academic institutions. The total number of spacecraft launched in the past 10 years is 5,681 and 45% of those had a mass. As with all previous editions of this report, the 2022 edition captures and distills a wealth of new information available on small spacecraft systems from NASA and other publicly available sources. This report is limited to publicly available information and cannot reflect major advances in development that are not publicly disclosed. We encourage any opportunity to publish mission outcomes and technology development milestones (e.g., via conference papers, press releases, company website) so they can be reflected in this report. Overall, this report is a survey of small spacecraft technologies sourced from open literature; it does not endeavor to be an original source, and only considers literature in the public domain to identify and classify devices. Commonly used sources for data include manufacturer datasheets, press releases, conference papers, journal papers, public filings with government agencies, news articles, presentations, the compendium of databases accessed via NASA’s Small Spacecraft Systems Virtual Institute (S3VI) Information Search, and engagement with companies. Data not appropriate for public dissemination, such as proprietary, export controlled, or otherwise restricted data, are not considered. As a result, this report includes many dedicated hours of desk research performed by subject matter experts reviewing resources noted above. Content in this 2022 edition is based on data available by October 2022. This report should not be considered as a comprehensive overview of all the technologies but a great reference for the current state-of-the-art SmallSat technologies. The organizational approach for each chapter is relatively consistent with previous editions and includes an introduction of the technology, current development status of the technology’s procurable systems, and summary tables of technologies surveyed. The content in each chapter is uniquely organized to present a mini-stand-alone report on spacecraft subsystems. As in previous years, chapters include information from previous editions but are updated with new and maturating technologies and reference missions. Tables in each section provide a convenient summary of the technologies discussed, with explanations and references in the body text. The authors have attempted to isolate trends in the small spacecraft industry to point out which technologies have been adopted after successful demonstration missions. Lastly, the authors tried to use the terms “SmallSat,” “microsatellite,” “nanosatellite,” and “CubeSat” in a consistent manner, even as these terms are often used interchangeably in the space industry. Every subsystem chapter contains updated information to reflect the growth in the small spacecraft market. Significant changes are included in several chapters. The “Complete Spacecraft Platforms” chapter now includes information on the two main market options, hosted payload services and dedicated buses. The “Power” chapter provides information on the development of solid-state batteries with significantly higher energy than the current state-of-theart lithium-ion batteries. A large effort was made to update the “Communications” chapter to appropriately capture the recent technology maturation of optical communications for SmallSats. The “Ground Data Systems and Mission Operations” chapter was updated to reflect the recent establishment of the Near Space Network and influx of SmallSat Optical Ground Stations. The “Guidance, Navigation and Control” chapter was updated to include Lidar sensor technology. The “Deorbit Systems” chapter includes a discussion of recently proposed changes by the Federal Communications Commission (FCC) to limit a spacecraft’s lifetime to no longer than 5 years after end-of-mission. The “Identification and Tracking” Chapter includes updated information on the progress of SmallSat tracking. Finally, this report now encompasses technology funded by NASA’s Small Spacecraft Technology (SST) program’s SmallSat Technology Partnerships (STP) initiative which is described further in this Introduction. The reader can find the included SST technology in the “On the Horizon” section of the “Thermal Systems”, “Communications”, and “Guidance, Navigation, and Control” chapters. A central element of this report is to list state-of-the-art technologies by NASA standard Technology Readiness Level (TRL) as defined by the 2020 NASA Engineering Handbook, found in NASA NPR 7123.1C NASA Systems Engineering Processes and Requirements. The authors have endeavored to independently verify the TRL value of each technology by reviewing and citing published test results or publicly available data to the best of their ability. Where test results and data disagree with vendors’ own advertised TRL, the authors have attempted to engage the vendors to discuss the discrepancy. Readers are strongly encouraged to follow the references cited in the literature describing the full performance range and capabilities of each technology. Readers of this report should reach out to individual companies to further clarify information. It is important to note that this report takes a broad system-level view. To attain a high TRL, the subsystem must be in a flight-ready configuration with all supporting infrastructure—such as mounting points, power conversion, and control algorithms—in an integrated unit. An accurate TRL assessment requires a high degree of technical knowledge on a subject device, and an in-depth understanding of the mission (including interfaces and environment) on which the device was flown. There is variability in TRL values depending on design factors for a specific technology. For example, differences in TRL assessment based on the operating environment may result from the thermal environment, mechanical loads, mission duration, or radiation exposure. If a technology has flown on a mission without success, or without providing valid confirmation to the operator, such claimed “flight heritage” was discounted. The authors believe TRLs are most accurately determined when assessed within the context of a program’s unique requirements. While the overall capability of small spacecraft has matured since the 2021 edition of this report, technologies are still being developed to make deep space SmallSat missions more routine and more cost effective. Future editions of this report may include content dedicated to the rapidly growing fields of assembly, integration, and testing services, and mission modeling and simulation–all of which are now extensively represented at small spacecraft conferences. Many of these subsystems and services are still in their infancy, but as they evolve and reliable conventions and standards emerge, the next iteration of this report may also evolve to include additional chapters.

Bruce Yost↗

Failure mechanisms of laminates transversely loaded by bolt push-through

Stiffened composite panels proposed for fuselage and wing design utilize a variety of stiffener-to-skin attachment concepts including mechanical fasteners. The attachment concept is an important factor influencing the panel's strength and can govern its performance following local damage. Mechanical fasteners can be an effective method for preventing stiffener-skin separation. One potential failure mode for bolted panels occurs when the bolts pull through the stiffener attachment flange or skin. The resulting loss of support by the skin to the stiffener and by the stiffener to the skin can result in local buckling and subsequent panel collapse. The characteristic failure modes associated with bolt push-through failure are described and the results of a parametric study of the effects that different material systems, boundary conditions, and laminates have on the forces and displacements required to cause damage and bolt pushthrough failure are presented.

Waters, W. A., Jr.↗

Study of the kinematic and load sharing properties of wormgearing with non-symmetric tooth profiles

The geometry of non-symmetric tooth profiles, i.e. tooth profiles with different pressure angles on the two sides of the tooth, is studied. A feasible non-symmetric tooth profile for application in helicopter transmissions is laid out as the best compromise among several conflicting factors. The non-symmetric tooth profile is then compared with the symmetric tooth profile studied previously. Based on the detailed comparisons it is concluded that the use of the non-symmetric tooth profile would severely limit the face width of the worm, consequently reduce the number of meshing teeth and cause much higher normal load on the individual gear teeth.

Sun, D. C.↗

Friction and Wear of Unlubricated NiTiHf with Nitriding Surface Treatments

The unlubricated friction and wear properties of the superelastic materials NiTi and NiTiHf, treated by either gas nitriding or plasma nitriding, have been investigated. Pin on disk testing of the studied materials was performed at sliding speeds from 0.01 to 1m/s at normal loads of 1, 5 or 10N. For all of the studied friction pairs (NiTiHf pins vs. NiTi and NiTiHf disks) over the given parameters, the steady-state coefficients of friction varied from 0.22 to 1.6. Pin wear factors ranged from approximately 1E-6 against the NiTiHf and plasma nitrided disks to approximately 1E-4 for the gas nitrided disks. The plasma nitrided disks provided wear protection in several cases and tended to wear by adhesion. The gas nitrided treatment generated the most pin wear but had essentially no disk wear except at the most severe of the studied conditions (1N load and 1m/s sliding speed). The results of this study are expected to provide guidance for design of components such as gears and fasteners.

friction↗

Fluid shear stress stimulates prostaglandin and nitric oxide release in bone marrow-derived preosteoclast-like cells

Bone is a porous tissue that is continuously perfused by interstitial fluid. Fluid flow, driven by both vascular pressure and mechanical loading, may generate significant shear stresses through the canaliculi as well as along the bone lining at the endosteal surface. Both osteoblasts and osteocytes produce signaling factors such as prostaglandins and nitric in response to fluid shear stress (FSS); however, these humoral agents appear to have more profound affects on osteoclast activity at the endosteal surface. We hypothesized that osteoclasts and preosteoclasts may also be mechanosensitive and that osteoclast-mediated autocrine signaling may be important in bone remodeling. In this study, we investigated the effect of FSS on nitric oxide (NO), prostaglandin E(2) (PGE(2)), and prostacyclin (PGI(2)) release by neonatal rat bone marrow-derived preosteoclast-like cells. These cells were tartrate-resistant acid phosphatase (TRAP) positive, weakly nonspecific esterase (NSE) positive, and capable of fusing into calcitonin-responsive, bone-resorbing, multinucleated cells. Bone marrow-derived preosteoclast-like cells exposed for 6 h to a well-defined FSS of 16 dynes/cm(2) produced NO at a rate of 7.5 nmol/mg protein/h, which was 10-fold that of static controls. This response was completely abolished by 100 microM N(G)-amino-L-arginine (L-NAA). Flow also stimulated PGE(2) production (3.9 microg/mg protein/h) and PGI(2) production (220 pg/mg protein/h). L-NAA attenuated flow-induced PGE(2) production by 30%, suggesting that NO may partially modulate PGE(2) production. This is the first report demonstrating that marrow derived cells are sensitive to FSS and that autocrine signaling in these cells may play an important role in load-induced remodeling and signal transduction in bone. Copyright 2000 Academic Press.

NASA Discipline Cell Biology↗

Effects of orbital spaceflight on human osteoblastic cell physiology and gene expression

During long-term spaceflight, astronauts lose bone, in part due to a reduction in bone formation. It is not clear, however, whether the force imparted by gravity has direct effects on bone cells. To examine the response of bone forming cells to weightlessness, human fetal osteoblastic (hFOB) cells were cultured during the 17 day STS-80 space shuttle mission. Fractions of conditioned media were collected during flight and shortly after landing for analyses of glucose utilization and accumulation of type I collagen and prostaglandin E(2) (PGE(2)). Total cellular RNA was isolated from flight and ground control cultures after landing. Measurement of glucose levels in conditioned media indicated that glucose utilization occurred at a similar rate in flight and ground control cultures. Furthermore, the levels of type I collagen and PGE(2) accumulation in the flight and control conditioned media were indistinguishable. The steady-state levels of osteonectin, alkaline phosphatase, and osteocalcin messenger RNA (mRNA) were not significantly changed following spaceflight. Gene-specific reductions in mRNA levels for cytokines and skeletal growth factors were detected in the flight cultures using RNase protection assays. Steady-state mRNA levels for interleukin (IL)-1alpha and IL-6 were decreased 8 h following the flight and returned to control levels at 24 h postflight. Also, transforming growth factor (TGF)-beta(2) and TGF-beta(1) message levels were modestly reduced at 8 h and 24 h postflight, although the change was not statistically significant at 8 h. These data suggest that spaceflight did not significantly affect hFOB cell proliferation, expression of type I collagen, or PGE(2) production, further suggesting that the removal of osteoblastic cells from the context of the bone tissue results in a reduced ability to respond to weightlessness. However, spaceflight followed by return to earth significantly impacted the expression of cytokines and skeletal growth factors, which have been implicated as mediators of the bone remodeling cycle. It is not yet clear whether these latter changes were due to weightlessness or to the transient increase in loading resulting from reentry.

Non-NASA Center↗

An assessment of the small-crack effect for 2024-T3 aluminum alloy

Data on small-crack behavior were obtained for a single-edge-notched tensile specimen made of 2024-T3 Al alloy and used to evaluate the capability of a semiempirical crack-growth and closure model to predict the fatigue life of notched specimens. Fatigue tests were conducted under either constant-amplitude loading (with stress ratios of 0.5, 0, -1, and -2) or spectrum loading, using a replication technique to record growth. It was found that small cracks exhibited the 'small-crack' effect in that they grew faster than large cracks when subjected to the same stress intensity factor range. Experimental small-crack growth rates agreed well with the model predictions. For making predictions of fatigue life, an initial surface defect void size of 3 x 12 x 0.4 microns was used in all calculations; predicted fatigue lives agreed well with experimentally determined values obtained in all tests. The crack-closure model indicated that the 'small-crack' effect on fatigue life was greatest in tests involving significant compressive loads.

Newman, J. C., Jr.↗

Factors in Evaluating Fatigue Life of Structural Parts

Three facets of fatigue testing are discussed in relation to problems involved in evaluating the fatigue life of structural parts. These facets are variable-amplitude loading, fatigue-crack propagation, and equivalent fatigue loading. Experimental test results are included to support conclusions.

Illg, Walter↗

Short Duration Bioastronautics Investigation 1904: Human Factors Assessment of Vibration Effects on Visual Performance during Launch

The primary objective of the Short Duration Bioastronautics Investigation (SDBI) 1904 was to determine visual performance limits during Shuttle operational vibration and g-loads, specifically through the determination of minimal usable font sizes using Orion-type display formats. Currently there is little to no data available to quantify human visual performance under the extreme g- and vibration conditions of launch. Existing data on shuttle vibration magnitude and frequency is incomplete and does not address human visual performance. There have been anecdotal reports of performance decrements from shuttle crews, but no structured data have been collected. Previous work by NASA on the effects of vibration and linear g-loads on human performance was conducted during the Gemini era, but these experiments were performed using displays and controls that are dramatically different than current concepts being considered by the Constellation Program. Recently, three investigations of visual performance under vibration have been completed at NASA Ames Research Center: the first examining whole-body vibration, the second employing whole-body vibration coupled with a sustained g-load, and a third examining the effects of peak versus extended duration vibration. However, all of these studies were conducted using only a single x-axis direction (eyeballs in/out). Estimates of thrust oscillations from the Constellation Ares-I first stage are driving the need for realistic human performance requirements. SDBI 1904 was an opportunity to address the need for requirements by conducting a highly focused and applied evaluation in a relevant spaceflight environment. The SDBI was a companion effort to Detailed Test Objective (DTO) 695, which measured shuttle seat accelerations (vibration) during ascent. Data from the SDBI will serve an important role in interpreting the DTO vibration data. Both SDBI 1904 and DTO 695 were low impact with respect to flight resources, and combined, they represent an efficient and focused problem solving approach. This project provided (a) immediate data for developing preliminary human performance vibration requirements; (b) flight validated inputs for ongoing and future ground-based research; and (c) preliminary information related to Orion display format design.

Thompson, Shelby↗

The basic characteristics of hybrid aircraft

The transportation of very heavy or very bulky loads by airships, and the ability to carry out extended duration flights at low speeds and low costs was studied. Structural design and weight factors for airship construction are examined. The densities of various light gases to be used in airships are given, along with their lifting capacities. The aerodynamic characteristics of various airship configurations was studied. Propulsion system requirements for airships are briefly considered.

Nichols, J. B.↗

The crack problem for a nonhomogeneous plane

The plane elasticity problem for a nonhomogeneous medium containing a crack is considered. It is assumed that the Poisson's ratio of the medium is constant and the Young's modulus E varies exponentially with the coordinate parallel to the crack. First the half plane problem is formulated and the solution is given for arbitrary tractions along the boundary. Then the integral equation for the crack problem is derived. It is shown that the integral equation having the derivative of the crack surface displacement as the density function has a simple Cauchy type kernel. Hence, its solution and the stresses around the crack tips have the conventional square root singularity. The solution is given for various loading conditions. The results show that the effect of the Poisson's ratio and consequently that of the thickness constraint on the stress intensity factors are rather negligible.

Delale, F.↗

The crack problem for a nonhomogeneous plane

The plane elasticity problem for a nonhomogeneous medium containing a crack is considered. It is assumed that the Poisson's ratio of the medium is constant and the Young's modulus E varies exponentially with the coordinate parallel to the crack. First the half plane problem is formulated and the solution is given for arbitrary tractions along the boundary. Then the integral equation for the crack problem is derived. It is shown that the integral equation having the derivative of the crack surface displacement as the density function has a simple Cauchy type kernel. Hence, its solution and the stresses around the crack tips have the conventional square root singularity. The solution is given for various loading conditions. The results show that the effect of the Poisson's ratio and consequently that of the thickness constraint on the stress intensity factors are rather negligible.

Delale, F.↗

Specular and direct radiative loads on space structure

The use of special models for trusses, and of fast graphical computational techniques, are discussed to reduce the computation times of intersurface radiation loads and specularly reflected radiation. The conditions under which the One-Dimensional approximation can be used, and the computation of the obstructed view factors for arbitrary surfaces, including the One-Dimensional surface, are considered using both contour and double area integration. The Adaptive Ray Tracing method is found to be very fast for surface configurations and obstruction densities typical of space structures, and it is shown to be best suited to views of J from I which are relatively simple and cover only a few subareas of S.

Emery, A. F.↗

Example on how to model and simulate turbulence for flight simulators

Analytical developments relative to gust response are discussed. Turbulence length scale, spectral functions, zero crossing values, gust loads analysis, power spectral techniques for analyzing the response of aircraft in turbulence, the spectrum of the rolling moment coefficient, and the spectrum correction factor are among the issues considered.

Houbolt, John C.↗

Resonant AC power system proof-of-concept test program

Proof-of-concept testing was performed on a 20-kHz, resonant power system breadboard from 1981 through 1985. The testing began with the evaluation of a single, 1.0-kW resonant inverter and progressed to the testing of breadboard systems with higher power levels and more capability. The final breadboard configuration tested was a 25.0-kW breadboard with six inverters providing power to three user-interface modules over a 50-meter, 20-kHz bus. The breadboard demonstrated the ability to synchronize multiple resonant inverters to power a common bus. Single-phase and three-phase 20-kHz power distribution was demonstrated. Simple conversion of 20-kHz to dc and variable-frequency ac was demonstrated as was bidirectional power flow between 20-kHz and dc. Steady state measurements of efficiency, power-factor tolerance, and conducted emissions and conducted susceptibility were made. In addition, transient responses were recorded for such conditions as start up, shut down, load changes. The results showed the 20-kHz resonant system to be a desirable technology for a spacecraft power management and distribution system with multiple users and a utility-type bus.

Wappes, Loran J.↗

A Navier-Stokes flow simulation of the Space Shuttle Main Engine Hot Gas Manifold

Incompressible viscous flow inside the turnaround duct, the fuel bowl, the transfer duct and the racetrack of the Space Shuttle Main Engine (SSME) Hot Gas Manifold (HGM) has been computed using the method of pseudo-compressibility together with an implicit, approximate-factorization algorithm. A multiple-zone method is used to make solution of flows in complex geometries easy. A model which predicts the pressure loading for the shield and the injector post arrangement without solving the complex flow field in the main injector region is proposed. The computed results show good qualitative agreement with experimental data.

Yang, Ruey-Jen↗

Predicting The Propagation Of Cracks

Advanced Crack Propagation Predictive Analysis Program, FLAGR04, developed as aid in predicting growth of preexisting flaws and cracks in structural components. Provides fracture-mechanics analyst with computerized method of evaluation of "safe crack-growth life" capabilities of structural components. Also used to evaluate tolerance-to-damage aspects of given structural design. Predicts growth of crack by use of two-dimensional model independently predicting growth of flaw in two directions based on calculation of stress-intensity factors. Input to FLAGR04 consists of initial definition of crack, type of rate solution, type and geometry of flaw, properties of material, data on load spectrum, load-stress functions, and design-limit stress levels. Output includes echo of input with any error or warning message and history of propagation of crack. Written in FORTRAN IV.

Tianlai, HU↗