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Device helps to aline laser for droplet-sizing interferometer. Monodispersing Droplet Generator creates uniformly sized droplets. Laser source and receiver of interferometer alined and focused on droplets. MDG mounted in high-pressure flange on tank. Line extensions pass through flange to outside. Flange allows MDG to operate at high injector back pressures used for tests.
Aspects of curved beam effects and their importance in designing composite frame structures are discussed. The curved beam effect induces radial flange loadings which in turn causes flange curling. This curling increases the axial flange stresses and induces transverse bending. These effects are more important in composite structures due to their general inability to redistribute stresses by general yielding, such as in metal structures. A detailed finite element analysis was conducted and used in the design of composite curved frame specimens. Five specimens were statically tested and compared with predicted and test strains. The curved frame effects must be accurately accounted for to avoid premature fracture; finite element methods can accurately predict most of the stresses and no elastic relief from curved beam effects occurred in the composite frames tested. Finite element studies are presented for comparative curved beam effects on composite and metal frames.
A double retention redundant pull pin release system is disclosed. The system responds to a single pull during an intentional release operation. A spiral threaded main pin is seated in a mating bore in a housing, which main pin has a flange fastened thereon at the part of the main pin which is exterior to the housing. Accidental release tends to rotate the main pin. A secondary pin passes through a slightly oversized opening in the flange and is seated in a second bore in the housing. The pins counteract against one another to prevent accidential release. A frictional lock is shared between the main and secondary pins to enhance further locking of the system. The secondary pin, in response to a first pull, is fully retracted from its bore and flange hole. Thereafter the pull causes the main pin to rotate free of the housing to release, for example, a parachute mechanism.
A numerical study of the postbuckling behavior of open-section stiffened composite compression panels is presented with emphasis on the effects of an anisotropic attached flange on results, the strain distribution near collapse, and the change of buckle pattern during postbuckling response. Results are obtained for a blade stiffened panel with orthotropic or anisotropic attached flanges from a new verison of STAGS, a general, branched shell, nonlinear computer program. Comparisons between these results indicate the effects of anisotropic flanges on the results. Elastic strain distributions are obtained from STAGS and indications are given about the collapse loads and modes of a particular panel. Change of buckle pattern is studied using STAGS and a special purpose computer program for long plates. Comparisons are made with experimental results.
Two-piece, all-metal, pressure-assisted static flange seal holds in pressurized helium satisfactorily at temperature of negative 80 degree F (negative 62 degree C). Installed between two flanges, then bolted together. New version includes one pressure-assisted metal sealing element held in place by metal plate and flanges. Certified for use in flight on helium joints of Space Shuttle main engine. Likely terrestrial applications include laboratory and industrial gas-distribution systems.
An efficient method for predicting the strength of debonded composite skin-stiffener configurations is presented. This method, which is based on fracture mechanics, models the skin and the stiffener with two-dimensional (2D) plate elements instead of three-dimensional (3D) solid elements. The skin and stiffener flange nodes are tied together by two modeling techniques. In one technique, the corresponding flange and skin nodes are required to have identical translational and rotational degrees-of-freedom. In the other technique, the corresponding flange and skin nodes are only required to have identical translational degrees-of-freedom. Strain energy release rate formulas are proposed for both modeling techniques. These formulas are used for skin-stiffener debond cases with and without cylindrical bending deformations. The cylindrical bending results are compared with plane-strain finite element results. Excellent agreement between the two sets of results is obtained when the second technique is used. Thus, from these limited studies, a preferable modeling technique for skin-stiffener debond analysis using plate elements is established.
Stiffener attachment concepts for suppressing or delaying the onset of the skin-stiffener separation failure mode in graphite-epoxy compression panels designed for postbuckling strength were experimentally studied. The effectiveness of these concepts was evaluated using panels with 16-ply skins and a single centrally-located I-shaped stiffener with both static and cyclic compressive loadings. Analytical results suggest that tailoring the relative thicknesses of the panel skin, stiffener attachment flange, and the stiffener web rotational stiffness can minimize the adverse effects of high interface shear and normal stresses. Interface stress levels may be reduced by tapering the thickness of the stiffener attachment flange and properly selecting the stacking sequences of the skin and stiffener attachment flange laminates.
The goal of this project was to design, build, and test an example of the seal invented by the author for use on Space Station Freedom and patented in 1991. The seal features a metallic spring core and replaceable elastomeric sealing elements. The metallic spring is designed to retain the sealing force of the elastomeric element against both sides of face seal gland for any specified amount of waviness or separation of the glands. A seal able to tolerate at least 1.3 mm (0.05 in) of flange distortion or separation and a test fixture of this seal which allowed direct comparison testing of O-rings were built. These designs were tested to compare leakage at different amounts of flange deflection. Results of the testing show the development seal exceeded its requirement to seal 1.3 mm of flange separation by 1 mm. This compared with the O-ring leakage, increasing dramatically at 0.5 mm of separation. The development seal also leaked at a lower rate than the O-ring seals in all tests.
Now that the International Space Station (ISS) is being constructed, payload developers have to not only verify the Shuttle-to-payload interface, but also the interfaces their payload will have with the ISS. The Multi Purpose Logistic Module (MPLM) being designed and built by Alenia Spazio in Torino, Italy is one such payload. The MPLM is the primary carrier for the ISS Payload Racks, Re-supply Stowage Racks, and the Resupply Stowage Platforms to re-supply the ISS with food, water, experiments, maintenance equipment and etc. During the development of the MPLM there was no requirement for verification of the on-orbit interfaces with the ISS. When this oversight was discovered, all the dynamic test stands had already been disassembled. A method was needed that would not require an extensive testing stand and could be completed in a short amount of time. The residual flexibility testing technique was chosen. The residual flexibility modal testing method consists of measuring the free-free natural frequencies and mode shapes along with the interface frequency response functions (FRF's). Analytically, the residual flexibility method has been investigated in detail by, MacNeal, Martinez, Carne, and Miller, and Rubin, but has not been implemented extensively for model correlation due to difficulties in data acquisition. In recent years improvement of data acquisition equipment has made possible the implementation of the residual flexibility method as in Admire, Tinker, and Ivey, and Klosterman and Lemon. The residual flexibility modal testing technique is applicable to a structure with distinct points (DOF) of contact with its environment, such as the MPLM-to-Station interface through the Common Berthing Mechanism (CBM). The CBM is bolted to a flange on the forward cone of the MPLM. During the fixed base test (to verify Shuttle interfaces) some data was gathered on the forward cone panels. Even though there was some data on the forward cones, an additional modal test was performed to better characterize its behavior. The CBM mounting flange is the only remaining structure of the MPLM that no test data was available. This paper discusses the implementation of the residual flexibility modal testing technique on the CBM flange and the modal test of the forward cone panels.
An analysis was developed for calculating the radial temperature distribution in a gas turbine with only the temperatures of the gas and the cooling air and the surface heat-transfer coefficient known. This analysis was applied to determine the temperatures of a complete wheel of a conventional single-stage impulse exhaust-gas turbine. The temperatures were first calculated for the case of the turbine operating at design conditions of speed, gas flow, etc. and with only the customary cooling arising from exposure of the outer blade flange and one face of the rotor to the air. Calculations were next made for the case of fins applied to the outer blade flange and the rotor. Finally the effects of using part of the nozzles (from 0 to 40 percent) for supplying cooling air and the effects of varying the metal thermal conductivity from 12 to 260 Btu per hour per foot per degree Farenheit on the wheel temperatures were determined. The gas temperatures at the nozzle box used in the calculations ranged from 1600F to 2000F. The results showed that if more than a few hundred degrees of cooling of turbine blades are required other means than indirect cooling with fins on the rotor and outer blade flange would be necessary. The amount of cooling indicated for the type of finning used could produce some improvement in efficiency and a large increase in durability of the wheel. The results also showed that if a large difference is to exist between the effective temperature of the exhaust gas and that of the blade material, as must be the case with present turbine materials and the high exhaust-gas temperatures desired (2000F and above), two alternatives are suggested: (a) If metal with a thermal conductivity comparable with copper is used, then the blade temperature can be reduced by strong cooling at both the blade tip and root. The center of the blade will be less than 2000F hotter than the ends; (b) With low conductivity materials some method of direct cooling other than partial admission of cooling air is essential. From this study, it can be deduced that indirect cooling of turbine blades will not make possible large increases in gas temperature.
The behavior of blade-stiffened graphite-epoxy panels with impact damage is examined to determine the effect of adding through-the-thickness stitches in the stiffener flange-to-skin interface. The influence of stitches is evaluated by examining buckling and failure for panels with failure loads up to 3.5 times greater than buckling loads. Analytical and experimental results from four configurations of panel specimens are presented. For each configuration, two panels were manufactured with skin and flanges held together with through-the-thickness stitches introduced prior to resin infusion and curing and one panel was manufactured with no stitches holding the flange to the skin. No mechanical fasteners were used for the assembly of any of these panels. Panels with and without low-speed impact damage were loaded to failure in compression. Buckling and failure modes are discussed. Stitching had little effect on buckling loads but increased the failure loads of impact-damaged panels by up to 30%.
A combustor includes a dome assembly having radially outer and inner liners joined thereto and defining therebetween a combustion zone. The dome assembly includes at least one annular dome having a pair of axially extending first flanges between which are disposed a plurality of circumferentially spaced apart carburetors for discharging a fuel/air mixture into the combustion zone for generating combustion gases. An annular heat shield includes a pair of axially extending legs integrally joined to a radially extending face in a generally U-shaped configuration, with the face including a plurality of circumferentially spaced apart ports disposed concentrically with perspective ones of the carburetors for allowing the fuel/air mixture to be discharged therefrom through the heat shield. At least one of the heat shield legs includes a plurality of circumferentially spaced apart mounting holes disposed adjacent to a respective one of the dome flanges, and a plurality of mounting pins are fixedly joined to the dome flange and extend radially through respective ones of the mounting holes without interference therewith for allowing unrestrained thermal movement between the heat shield and the dome while supporting the heat shield against axial pressure loads thereon. In a preferred embodiment, the dome assembly includes three domes having respective ones of the heat shield, and respective baffles are spaced from the heat shields for providing impingement cooling thereof.
A double-retention redundant pull pin release system is disclosed. The system responds to a single pull during an intentional release operation. A spiral-threaded main pin is seated in a mating bore in a housing, which main pin has a flange fastened thereon at the part of the main pin which is exterior to the housing. Accidental release tends to rotate the main pin. A secondary pin passes through a slightly oversized opening in the flange and is seated in a second bore in the housing. The pins counteract against one another to prevent accidental release. A frictional lock is shared between the main and secondary pins to enhance further locking of the system. The secondary pin, in response to a first pull, is fully retracted from its bore and flange hole. Thereafter the pull causes the main pin to rotate free of the housing to release, for example, a parachute mechanism.
An improved rotor assembly shroud includes at least one reinforcing flange on the upper surface of the shroud. The strength provided by the reinforcing flange allows for a smaller shroud thickness resulting in a net reduction of shroud mass. The lower shroud mass reduces the centrifugal stress on the rotor assembly blade during operation. The strength provided by the reinforcing flanges also significantly reduces the centrifugal bending stress on the shroud during operation. The shroud mass may be further reduced by tapering the shroud leading and trailing edges or, for shrouds incorporating a damper, by providing a damper cavity with a lower diameter surface defining an opening therethrough.
The fatigue damage was characterized in specimens which consisted of a tapered composite flange bonded onto a composite skin. Quasi-static tension tests were performed first to determine the failure load. Subsequently, tension fatigue tests were performed at 40%, 50%, 60% and 70% of the failure load to evaluate the debonding mechanisms. For four specimens, the cycling loading was stopped at intervals. Photographs of the polished specimen edges were taken under a light microscope to document the damage. At two diagonally opposite corners of the flange, a delamination appeared to initiate at the flange tip from a matrix crack in the top 45deg skin ply and propagated at the top 45deg/-45deg skin ply interface. At the other two diagonally opposite corners, a delamination running in the bondline initiated from a matrix crack in the adhesive pocket. In addition, two specimens were cut longitudinally into several sections. Micrographs revealed a more complex pattern inside the specimen where the two delamination patterns observed at the edges are present simultaneously across most of the width of the specimen. The observations suggest that a more sophisticated nondestructive evaluation technique is required to capture the complex damage pattern of matrix cracking and multi-level delaminations.
Composite skin/stringer flange debond specimens manufactured from composite prepreg containing interleaf layers with a polymer based healing agent encapsulated in thin walled spheres were tested. As a crack develops and grows in the base polymer, the spheres fracture releasing the healing agent. The agent reacts with catalyst and polymerizes healing the crack. In addition, through-thickness reinforcement, in the form of pultruded carbon z-pins were included near the flange tips to improve the resistance to debonding. Specimens were manufactured with 14 plies in the skin and 10 plies in the stiffener flange. Three-point bend tests were performed to measure the skin/stiffener debonding strength and the recovered strength after healing. The first three tests performed indicated no healing following unloading and reloading. Micrographs showed that delaminations could migrate to the top of the interleaf layer due to the asymmetric loading, and hence, bypass most of the embedded capsules. For two subsequent tests, specimens were clamped in reverse bending before reloading. In one case, healing was observed as evidenced by healing agent that leaked to the specimen edge forming a visible "scar". The residual strength measured upon reloading was 96% of the original strength indicating healing had occurred. Hence, self-healing is possible in fiber reinforced composite material under controlled conditions, i.e., given enough time and contact with pressure on the crack surfaces. The micro-encapsulation technique may prove more robust when capsule sizes can be produced that are small enough to be embedded in the matrix resin without the need for using an interleaf layer. However, in either configuration, the amount of healing that can occur may be limited to the volume of healing agent available relative to the crack volume that must be filled.
Uninsulated areas on cryogenic propellant tanks and feedlines cause moisture in the air to condense or ice to form. Flange joints, bracket supports, expansion bellows, and other cavities are uninsulated by design. These areas cannot be sealed because conventional thermal insulation materials would restrict mechanical articulations. Aerogel-based thermal insulation systems are able to seal critical locations such as the liquid-oxygen (LO2) feedline bellows. A new thermal insulation system was also necessary between the intertank wall, flange, and the liquid-hydrogen (LH2) tank dome, where there is a cavity (or crevice) with an exposed 20-K surface. When nitrogen gas is used for purging within the intertank volume, it condenses on this cold surface. Some solid nitrogen may also form on the colder side of the crevice. Voids or discontinuities within the foam can pressurize and cause areas of foam to weaken and break off, reducing thermal efficiency and creating potentially dangerous debris. To prevent this foam loss, we developed a thermal insulation system using bulk-fill aerogel material and demonstrated it with a one-tenth-scale model of the LH2 intertank flange area
Traditionally, infrared (IR) space instruments have been focused by iterating with a number of different thickness shim rings in a thermal vacuum chamber until the focus meets requirements. This has required a number of thermal cycles that are very expensive as they tie up many integration and test (I&T)/ environmental technicians/engi neers work ing three shifts for weeks. Rather than creating a test shim for each iteration, this innovation replaces the test shim and can focus the instrument while in the thermal vacuum chamber. The focus tool consists of three small, piezo-actuated motors that drive two sets of mechanical interface flanges between the instrument optics and the focal- plane assembly, and three optical-displacement metrology sensors that can be read from outside the thermal vacuum chamber. The motors are used to drive the focal planes to different focal distances and acquire images, from which it is possible to determine the best focus. At the best focus position, the three optical displacement metrology sensors are used to determine the shim thickness needed. After the instrument leaves the thermal vacuum chamber, the focus tool is replaced with the precision-ground shim ring. The focus tool consists of two sets of collars, one that mounts to the backside of the interface flange of the instrument optics, and one that mounts to the backside of the interface flange of the focal plane modules. The collars on the instrument optics side have the three small piezo-actuated motors and the three optical displacement metrology systems. Before the instrument is focused, there is no shim ring in place and, therefore, no fasteners holding the focal plane modules to the cameras. Two focus tooling collars are held together by three strong springs. The Orbiting Carbon Observatory (OCO) mission spectrometer was focused this way (see figure). The motor described here had to be moved five times to reach an acceptable focus, all during the same thermal cycle, which was verified using pupil slicing techniques. A focus accuracy of .20.100 microns was achieved.