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At least 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Unitized Regenerative Fuel Cell System Dryer-Humidifier Analytical Model Development

A Unitized Regenerative Fuel Cell (URFC) Energy Storage System is being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses regenerative gas dryers/humidifiers that are mounted on the surface of the gas storage tanks that act as the radiators for thermal control of the URFC system. As the gas storage tanks cool down during URFC charging the regenerative gas dryers/humidifiers dry the hydrogen and oxygen gases produced by electrolysis. As the gas storage tanks heat up during URFC discharging, the regenerative gas dryers/humidifiers humidify the hydrogen and oxygen gases used by fuel cell. An analytical model was developed to simulate the URFC system's regenerative gas dryers/humidifiers. The model is in the form of an EXCEL@ worksheet that allows the investigation of the regenerative gas dryers/humidifier performance as a function of time and position within the regenerative gas dryers/humidifiers, as well as other key system variables. Finite Element Analysis (FEA) modeling of the regenerative gas dryers/humidifier and gas storage tank wall was also done to analyze spatial temperature distribution within the regenerative gas dryers/humidifiers and the localized tank wall. Test results obtained from the testing of the regenerative gas dryers/humidifiers in a thermal vacuum environment were used to corroborate the analyses.

Burke, Kenneth A.↗
NASA NTRS2005

Development and Optimization of Kinematic Mounts for NIRCam: a JWST Science Instrument

Finite element analysis was vital to the design and optimization of the kinematic mounts for the Near Infrared Camera (NIRCam) instrument The design had to meet dueling structural requirements driven by 12G launch loads, a survivability of bulk cool down from room temperature to 22 K, minimum first mode of 50 Hz and mass allocation constraints. Additionally the design has to meet stability and Integrated Science Instrument Module (ISIM) interfaces when cooled to 22K.

Young, Daniel↗
NASA NTRS2003

Superalloy Disk With Dual-Grain Structure Spin Tested

Advanced nickel-base disk alloys for future gas turbine engines will require greater temperature capability than current alloys, but they must also continue to deliver safe, reliable operation. An advanced, nickel-base disk alloy, designated Alloy 10, was selected for evaluation in NASA s Ultra Safe Propulsion Project. Early studies on small test specimens showed that heat treatments that produced a fine grain microstructure promoted high strength and long fatigue life in the bore of a disk, whereas heat treatments that produced a coarse grain microstructure promoted optimal creep and crack growth resistance in the rim of a disk. On the basis of these results, the optimal combination of performance and safety might be achieved by utilizing a heat-treatment technology that could produce a fine grain bore and coarse grain rim in a nickel-base disk. Alloy 10 disks that were given a dual microstructure heat treatment (DMHT) were obtained from NASA s Ultra-Efficient Engine Technology (UEET) Program for preliminary evaluation. Data on small test specimens machined from a DMHT disk were encouraging. However, the benefit of the dual grain structure on the performance and reliability of the entire disk still needed to be demonstrated. For this reason, a high temperature spin test of a DMHT disk was run at 20 000 rpm and 1500 F at the Balancing Company of Dayton, Ohio, under the direction of NASA Glenn Research Center personnel. The results of that test showed that the DMHT disk exhibited significantly lower crack growth than a disk with a fine grain microstructure. In addition, the results of these tests could be accurately predicted using a two-dimensional, axisymmetric finite element analysis of the DMHT disk. Although the first spin test demonstrated a significant performance advantage associated with the DMHT technology, a second spin test on the DMHT disk was run to determine burst margin. The disk burst in the web at a very high speed, over 39 000 rpm, in line with the predicted location and speed. Furthermore, significant growth of the disk was observed before failure, in line with predictions, clearly demonstrating the reliability and safety of the DMHT technology. Although successful spin testing in Ultra Safe's Nickel Disk Program represents a significant milestone for DMHT technology, realistic engine operation will require repeated loading of a DMHT nickel disk. For this reason, a cyclic spin test study of DMHT nickel disk technology has been proposed to start in fiscal year 2003 under NASA's Aviation Safety Program. The goal of this program will be to determine the fatigue failure mechanism in DMHT nickel disks, thereby demonstrating the reliability and safety of DMHT technology under repetitive loading conditions encountered in realistic engine operation.

Gayda, John↗
NASA NTRS2002

Preliminary Sizing Completed for Single- Stage-To-Orbit Launch Vehicles Powered By Rocket-Based Combined Cycle Technology

Single-stage-to-orbit (SSTO) propulsion remains an elusive goal for launch vehicles. The physics of the problem is leading developers to a search for higher propulsion performance than is available with all-rocket power. Rocket-based combined cycle (RBCC) technology provides additional propulsion performance that may enable SSTO flight. Structural efficiency is also a major driving force in enabling SSTO flight. Increases in performance with RBCC propulsion are offset with the added size of the propulsion system. Geometrical considerations must be exploited to minimize the weight. Integration of the propulsion system with the vehicle must be carefully planned such that aeroperformance is not degraded and the air-breathing performance is enhanced. Consequently, the vehicle's structural architecture becomes one with the propulsion system architecture. Geometrical considerations applied to the integrated vehicle lead to low drag and high structural and volumetric efficiency. Sizing of the SSTO launch vehicle (GTX) is itself an elusive task. The weight of the vehicle depends strongly on the propellant required to meet the mission requirements. Changes in propellant requirements result in changes in the size of the vehicle, which in turn, affect the weight of the vehicle and change the propellant requirements. An iterative approach is necessary to size the vehicle to meet the flight requirements. GTX Sizer was developed to do exactly this. The governing geometry was built into a spreadsheet model along with scaling relationships. The scaling laws attempt to maintain structural integrity as the vehicle size is changed. Key aerodynamic relationships are maintained as the vehicle size is changed. The closed weight and center of gravity are displayed graphically on a plot of the synthesized vehicle. In addition, comprehensive tabular data of the subsystem weights and centers of gravity are generated. The model has been verified for accuracy with finite element analysis. The final trajectory was rerun using OTIS (Boeing Corporation's trajectory optimization software package), and the sizing output was incorporated into a solid model of the vehicle using PRO/Engineer computer-aided design software (Parametric Technology Corporation, Waltham, MA).

Roche, Joseph M.↗
NASA NTRS2005

Compression-Loaded Composite Panels With Elastic Edge Restraints and Initial Prestress

A parametric study of the effects of test-fixture-induced initial prestress and elastic edge restraints on the prebuckling and buckling responses of a compression-loaded, quasi-isotropic curved panel is presented. The numerical results were obtained by using a geometrically nonlinear finite element analysis code with high-fidelity models. The results presented show that a wide range of prebuckling and buckling behavior can be obtained by varying parameters that represent circumferential loaded-edge restraint and rotational unloaded-edge restraint provided by a test fixture and that represent the mismatch in specimen and test-fixture radii of curvature. For a certain range of parameters, the panels exhibit substantial nonlinear prebuckling deformations that yield buckling loads nearly twice the corresponding buckling load predicted by a traditional linear bifurcation buckling analysis for shallow curved panels. In contrast, the results show another range of parameters exist for which the nonlinear prebuckling deformations either do not exist or are relatively benign, and the panels exhibit buckling loads that are nearly equal to the corresponding linear bifurcation buckling load. Overall, the results should be of particular interest to scientists, engineers, and designers involved in simulating flight-hardware boundary conditions in structural verification and certification tests, involved in validating structural analysis tools, and interested in tailoring buckling performance.

Hilburger, Mark W.↗
NASA NTRS2005

Evolutionary optimization of a Genetically Refined Truss

Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This paper will present a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: Genetic Algorithms and Differential Evolution to successfully optimize a benchmark structural optimization problem. An non-traditional solution to the benchmark problem is presented in this paper, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.

Hull, Patrick V.↗
NASA NTRS2006

Imperfection and Thickness Measurement of Panels Using a Coordinate Measurement Machine

This paper summarizes the methodology used to measure imperfection and thickness variation for flat and curved panels using a Coordinate Measurement Machine (CMM) and the software program MeasPanel. The objective is to provide a reference document so that someone with a basic understanding of CMM operation can measure a panel with minimal training. Detailed information about both the measurement system setup and computer software is provided. Information is also provided about the format of the raw data, as well as how it is post-processed for use in finite-element analysis.

Thornburgh, Robert P.↗
NASA NTRS2006

A Bearingless Switched-Reluctance Motor for High Specific Power Applications

A 12-8 switched-reluctance motor (SRM) is studied in bearingless (or self-levitated) operation with coil currents limited to the linear region to avoid magnetic saturation. The required motoring and levitating currents are summed and go into a single motor coil per pole to obtain the highest power output of the motor by having more space for motor coil winding. Two controllers are investigated for the bearingless SRM operation. First, a model-based controller using the radial force, which is adjusted by a factor derived from finite element analysis, is presented. Then a simple and practical observation-based controller using a PD (proportional-derivative) control algorithm is presented. Both controllers were experimentally demonstrated to 6500 rpm. This paper reports the initial efforts toward eventual self levitation of a SRM operating into strong magnetic core saturation at liquid nitrogen temperature.

Choi, Benjamin B.↗
NASA NTRS2007

Wire Crimp Termination Verification Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp termination and wire is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. Various crimp junction pathologies such as undercrimping, missing wire strands, incomplete wire insertion, partial insulation removal, and incorrect wire gauge are ultrasonically tested, and their results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently (as evidenced with destructive testing) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. Finally, an approach for application to multipin indenter type crimps will be discussed.

Perey, Daniel F.↗
NASA NTRS2007

Evolutionary Optimization of a Geometrically Refined Truss

Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection, and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This Technical Publication (TP) presents a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: genetic algorithms and differential evolution to successfully optimize a benchmark structural optimization problem. A nontraditional solution to the benchmark problem is presented in this TP, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.

Hull, P. V.↗
NASA NTRS2007

Wire Crimp Connectors Verification using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp connections is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp connector and wire is shown to correlate with the results of a destructive pull test, which previously has been used to assess crimp wire junction quality. Various crimp junction pathologies (missing wire strands, incorrect wire gauge, incomplete wire insertion in connector) are ultrasonically tested, and their results are correlated with pull tests. Results show that the ultrasonic measurement technique consistently (as evidenced with pull-testing data) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying the technique while wire crimps are installed is also presented.

Cramer, K. Elliott↗
NASA NTRS2004

Design and Performance of the Terrestrial Planet Finder Coronagraph

Terrestrial Planet Finder Coronagraph, one of two potential architectures, is described. The telescope is designed to make a visible wavelength survey of the habitable zones of at least thirty stars in search of earth-like planets. The preliminary system requirements, optical parameters, mechanical and thermal design, operations scenario and predicted performance is presented. The 6-meter aperture telescope has a monolithic primary mirror, which along with the secondary tower, are being designed to meet the stringent optical tolerances of the planet-finding mission. Performance predictions include dynamic and thermal finite element analysis of the telescope optics and structure, which are used to make predictions of the optical performance of the system.

designs↗
NASA NTRS2008

Design and Field Test of a Mass Efficient Crane for Lunar Payload Handling and Inspection: The Lunar Surface Manipulation System

Devices for lifting, translating and precisely placing payloads are critical for efficient Earthbased construction operations. Both recent and past studies have demonstrated that devices with similar functionality will be needed to support lunar outpost operations. Lunar payloads include: a) prepackaged hardware and supplies which must be unloaded from landers and then accurately located at their operational site, b) sensor packages used for periodic inspection of landers, habitat surfaces, etc., and c) local materials such as regolith which require grading, excavation and placement. Although several designs have been developed for Earth based applications, these devices lack unique design characteristics necessary for transport to and use on the harsh lunar surface. These design characteristics include: a) composite components, b) compact packaging for launch, c) simple in-field reconfiguration and repair, and d) support for tele-operated or automated operations. Also, in contrast to Earth-based construction, where special purpose devices dominate a construction site, a lunar outpost will require versatile devices which provide operational benefit from initial construction through sustained operations. This paper will detail the design of a unique, high performance, versatile lifting device designed for operations on the lunar surface. The device is called the Lunar Surface Manipulation System to highlight the versatile nature of the device which supports conventional cable suspended crane operations as well as operations usually associated with a manipulator such as precise positioning where the payload is rigidly grappled by a tool attached to the tip of the device. A first generation test-bed to verify design methods and operational procedures is under development at the NASA Langley Research Center and recently completed field tests at Moses Lake Washington. The design relied on non-linear finite element analysis which is shown to correlate favorably with laboratory experiments. A key design objective, reviewed in this paper, is the device s simplicity, resulting from a focus on the minimum set of functions necessary to perform payload offload. Further development of the device has the potential for significant mass savings, with a high performance device incorporating composite elements estimated to have a mass less than 3% of the mass of the maximum lunar payload lifted at the tip. The paper will conclude with future plans for expanding the operational versatility of the device.

Doggett, William R.↗
NASA NTRS2008

Assessment of Proper Bonding Methods and Mechanical Characterization FPGA CQFPs

This presentation discusses fractured leads on field-programmable gate array (FPGA) during flight vibration. Actions taken to determine root cause and resolution of the failure include finite element analysis (FEA) and vibration testing and scanning electron microscopy (with X-ray microanalysis) and energy dispersive spectrometry (SEM/EDS) failure assessment. Bonding methods for surface mount parts is assessed, including critical analysis and assessment of random fatigue damage. Regarding ceramic quad flat pack (CQFP) lead fracture, after disassembling the attitude control electronics (ACE) configuration, photographs showed six leads cracked on FPGA RTSX72SU-1 CQ208B package located on the RWIC card. An identical package (FPGA RTSX32SU-1 CQ208B) mounted on the RWIC did not results in cracked pins due to vibration. FPGA lead failure theories include workmanship issues in the lead-forming, material defect in the leads of the FPGA packages, and the insecure mounting of the board in the card guides, among other theories. Studies were conducted using simple calculations to determine the response and fatigue life of the package. Shorter packages exhibited more response when loaded by out-of-plane displacement of PCB while taller packages exhibit more response when loaded by in-plane acceleration of PCB. Additionally, under-fill did not contribute to reducing stress in leads due to out-of-plane PCB loading or from component twisting, as much as corner bonding. The combination of corner bond and under-fill is best to address mechanical and thermal S/C environment. Test results of bonded parts showed reduced (dampened) amplitude and slightly shifted peaks at the un-bonded natural frequency and an additional response at the bonded frequency. Stress due to PCBB out-of-plane loading was decreased on in the corners when only a corner bond was used. Future work may address CQFP fatigue assessment, including the investigation of discrepancy in predicted fatigue damage, as well as comparing fatigue life and fatigue damage cycle ration computed using FEA and Miner's rule to results from a fatigue assessment software program.

Davis, Milton C.↗
NASA NTRS2008

Reliability Assessment of Graphite Specimens under Multiaxial Stresses

An investigation was conducted to predict the failure strength response of IG-100 nuclear grade graphite exposed to multiaxial stresses. As part of this effort, a review of failure criteria accounting for the stochastic strength response is provided. The experimental work was performed in the early 1990s at the Oak Ridge National Laboratory (ORNL) on hollow graphite tubes under the action of axial tensile loading and internal pressurization. As part of the investigation, finite-element analysis (FEA) was performed and compared with results of FEA from the original ORNL report. The new analysis generally compared well with the original analysis, although some discrepancies in the location of peak stresses was noted. The Ceramics Analysis and Reliability Evaluation of Structures Life prediction code (CARES/Life) was used with the FEA results to predict the quadrants I (tensile-tensile) and quadrant IV (compression-tension) strength response of the graphite tubes for the principle of independent action (PIA), the Weibull normal stress averaging (NSA), and the Batdorf multiaxial failure theories. The CARES/Life reliability analysis showed that all three failure theories gave similar results in quadrant I but that in quadrant IV, the PIA and Weibull normal stress-averaging theories were not conservative, whereas the Batdorf theory was able to correlate well with experimental results. The conclusion of the study was that the Batdorf theory should generally be used to predict the reliability response of graphite and brittle materials in multiaxial loading situations.

Sookdeo, Steven↗
NASA NTRS2008

Structural Benchmark Creep Testing for the Advanced Stirling Convertor Heater Head

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for use on long duration Science missions such as lunar applications, Mars rovers, and deep space missions. For the inherent long life times required, a structurally significant design limit for the heater head component of the ASRG Advanced Stirling Convertor (ASC) is creep deformation induced at low stress levels and high temperatures. Demonstrating proof of adequate margins on creep deformation and rupture for the operating conditions and the MarM-247 material of construction is a challenge that the NASA Glenn Research Center is addressing. The combined analytical and experimental program ensures integrity and high reliability of the heater head for its 17-year design life. The life assessment approach starts with an extensive series of uniaxial creep tests on thin MarM-247 specimens that comprise the same chemistry, microstructure, and heat treatment processing as the heater head itself. This effort addresses a scarcity of openly available creep properties for the material as well as for the virtual absence of understanding of the effect on creep properties due to very thin walls, fine grains, low stress levels, and high-temperature fabrication steps. The approach continues with a considerable analytical effort, both deterministically to evaluate the median creep life using nonlinear finite element analysis, and probabilistically to calculate the heater head s reliability to a higher degree. Finally, the approach includes a substantial structural benchmark creep testing activity to calibrate and validate the analytical work. This last element provides high fidelity testing of prototypical heater head test articles; the testing includes the relevant material issues and the essential multiaxial stress state, and applies prototypical and accelerated temperature profiles for timely results in a highly controlled laboratory environment. This paper focuses on the last element and presents a preliminary methodology for creep rate prediction, the experimental methods, test challenges, and results from benchmark testing of a trial MarM-247 heater head test article. The results compare favorably with the analytical strain predictions. A description of other test findings is provided, and recommendations for future test procedures are suggested. The manuscript concludes with describing the potential impact of the heater head creep life assessment and benchmark testing effort on the ASC program.

Krause, David L.↗
NASA NTRS2008

Thermal Capacitance (Slug) Calorimeter Theory Including Heat Losses and Other Decaying Processes

A mathematical model, termed the Slug Loss Model, has been developed for describing thermal capacitance (slug) calorimeter behavior when heat losses and other decaying processes are not negligible. This model results in the temperature time slope taking the mathematical form of exponential decay. When data is found to fit well to this model, it allows a heat flux value to be calculated that corrects for the losses and may be a better estimate of the cold wall fully catalytic heat flux, as is desired in arc jet testing. The model was applied to the data from a copper slug calorimeter inserted during a particularly severe high heating rate arc jet run to illustrate its use. The Slug Loss Model gave a cold wall heat flux 15% higher than the value of 2,250 W/sq cm obtained from the conventional approach to processing the data (where no correction is made for losses). For comparison, a Finite Element Analysis (FEA) model was created and applied to the same data, where conduction heat losses from the slug were simulated. The heat flux determined by the FEA model was found to be in close agreement with the heat flux determined by the Slug Loss Model.

Hightower, T. Mark↗
NASA NTRS2009

Shuttle Orbiter-like Cargo Carrier on Crew Launch Vehicle

The following document summarizes the results of a conceptual design study for which the goal was to investigate the possibility of using a crew launch vehicle to deliver the remaining International Space Station elements should the Space Shuttle orbiter not be available to complete that task. Conceptual designs and structural weight estimates for two designs are presented. A previously developed systematic approach that was based on finite-element analysis and structural sizing was used to estimate growth of structural weight from analytical to "as built" conditions.

Martinovic, Zoran↗