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All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Ocean tides for satellite geodesy

Spherical harmonic tidal solutions have been obtained at the frequencies of the 32 largest luni-solar tides using prior theory of the author. That theory was developed for turbulent, nonglobal, self-gravitating, and loading oceans possessing realistic bathymetry and linearized bottom friction; the oceans satisfy no-flow boundary conditions at coastlines. In this theory the eddy viscosity and bottom drag coefficients are treated as spatially uniform. Comparison of the predicted degree-2 components of the Mf, P1, and M2 tides with those from numerical and satellite-based tide models allows the ocean friction parameters to be estimated at long and short periods. Using the 32 tide solutions, the frequency dependence of tidal admittance is investigated, and the validity of sideband tide models used in satellite orbit analysis is examined. The implications of admittance variability for oceanic resonances are also explored.

Dickman, S. R.↗
NASA NTRS2016

Automated Generation of Finite-Element Meshes for Aircraft Conceptual Design

This paper presents a novel approach for automated generation of fully connected finite-element meshes for all internal structural components and skins of a given wing-body geometry model, controlled by a few conceptual-level structural layout parameters. Internal structural components include spars, ribs, frames, and bulkheads. Structural layout parameters include spar/rib locations in wing chordwise/spanwise direction and frame/bulkhead locations in longitudinal direction. A simple shell thickness optimization problem with two load conditions is used to verify versatility and robustness of the automated meshing process. The automation process is implemented in ModelCenter starting from an OpenVSP geometry and ending with a NASTRAN 200 solution. One subsonic configuration and one supersonic configuration are used for numerical verification. Two different structural layouts are constructed for each configuration and five finite-element meshes of different sizes are generated for each layout. The paper includes various comparisons of solutions of 20 thickness optimization problems, as well as discussions on how the optimal solutions are affected by the stress constraint bound and the initial guess of design variables.

Li, Wu↗
NASA NTRS2013

The Digital Astronaut Project Computational Bone Remodeling Model (Beta Version) Bone Summit Summary Report

Under the conditions of microgravity, astronauts lose bone mass at a rate of 1% to 2% a month, particularly in the lower extremities such as the proximal femur [1-3]. The most commonly used countermeasure against bone loss in microgravity has been prescribed exercise [4]. However, data has shown that existing exercise countermeasures are not as effective as desired for preventing bone loss in long duration, 4 to 6 months, spaceflight [1,3,5,6]. This spaceflight related bone loss may cause early onset of osteoporosis to place the astronauts at greater risk of fracture later in their lives. Consequently, NASA seeks to have improved understanding of the mechanisms of bone demineralization in microgravity in order to appropriately quantify this risk, and to establish appropriate countermeasures [7]. In this light, NASA's Digital Astronaut Project (DAP) is working with the NASA Bone Discipline Lead to implement well-validated computational models to help predict and assess bone loss during spaceflight, and enhance exercise countermeasure development. More specifically, computational modeling is proposed as a way to augment bone research and exercise countermeasure development to target weight-bearing skeletal sites that are most susceptible to bone loss in microgravity, and thus at higher risk for fracture. Given that hip fractures can be debilitating, the initial model development focused on the femoral neck. Future efforts will focus on including other key load bearing bone sites such as the greater trochanter, lower lumbar, proximal femur and calcaneus. The DAP has currently established an initial model (Beta Version) of bone loss due to skeletal unloading in femoral neck region. The model calculates changes in mineralized volume fraction of bone in this segment and relates it to changes in bone mineral density (vBMD) measured by Quantitative Computed Tomography (QCT). The model is governed by equations describing changes in bone volume fraction (BVF), and rates of changes in bone cell populations that remove and replace bone in packets within the bone region. The DAP bone model is unique in several respects. In particular in takes former models of volume fraction changes one step higher in fidelity and separates BVF into separate equations for mineralized and osteoid volume fractions governed by a mineralization rate. This more closely follows the physiology of the remodeling unit cycles where bone is first resorbed and then followed by the action of osteoblasts to lay down collagen matrix which eventually becomes mineralized. In another respect, the modules allow the functional description of the time rate of change of other parameters and variables in the model during a computational simulation. More detailed description of the model, preliminary validation results, current limitation and caveats, and planned advancements are provided in sections 2 through 5. The DAP bone model is being developed primarily as a research tool, and not as a clinical tool like QCT. Even if it transitions to a clinical tool, it is not intended to replace QCT or any other clinical tool. Moreover, the DAP bone model does not predict bone fracture. Its purpose is to provide valuable additional data via "forward prediction" simulations for during and after spaceflight missions to gain insight on, (1) mechanisms of bone demineralization in microgravity, and (2) the volumetric changes at the various bone sites in response to in-flight and post-flight exercise countermeasures. This data can then be used as input to the Keyak [8] (or equivalent) FE analysis method to gain insight on how bone strength may change during and after flight. This information can also be useful to help optimize exercise countermeasure protocols to minimize changes in bone strength during flight, and improve regain of bone strength post-flight. To achieve this goal, the bone model will be integrated with DAP's exercise countermeasure models to simulate the effect of exercise prescriptions on preserving bone. More specifically, the model will accept loading history due to muscle and joint force on bone and produce quantified remodeling within the bone region under influence of the applied stress. Furthermore, because they tend to respond differently, the bone remodeling model includes both trabecular bone and cortical bone.

Pennline, James↗
NASA NTRS1999

Computer Modeling of Sand Transport on Mars Using a Compart-Mentalized Fluids Algorithm (CFA)

It has been postulated that aeolian transport on Mars may be significantly different from that on Earth. From laboratory experiments simulating martian grain transport [2], it has been observed that (saltating) grains striking the bed can cause hundreds of secondary reptation trajectories when impact occurs at speeds postulated for Mars. Some of the ballistically induced trajectories "die ouf' and effectively join the ranks on the creep population that is merely nudged along by impact. Many of the induced reptation trajectories, however, are sufficiently high for the grains to become part of the saltation load (it is irrelevant to the boundary layer how a grain attained its initial lift force). When these grains, in turn, strike the surface, they too are capable of inducing more reptating grains. This cascading effect has been discussed in connection with terrestrial aeolian transport in an attempt to dispel the notion that sand motion is divisible only into creep and saltation loads. On Earth, only a few grains are splashed by impact. On Mars, it may be hundreds. We developed a computer model to address this phenomenon because there are some important ramifications: First, this ratio may mean that martian aeolian transport is dominated by reptation flux rather than saltation. On Earth, the flux would be a roughly balanced mixture between reptation/creep and saltation. On Venus, there would be no transport other than by saltation. In other words, an understanding of planetary aeolian processes may not be necessarily understood by extrapolating from the "Earth case", with only gravity and atmospheric density/viscosity being considered as variables. Second, the reptation flux on Mars may be self sustaining, so that little input is required by the wind once transport has been initiated. The number of grains saturating the boundary layer near the bed may mean that average grain speed on Mars might conceivably be less than that on Earth. This would say much for models of sand comminution on Mars. A multiple-grain transport model using just the equations of grain motion describing lift and drag is impossible to develop owing to stochastic effects --the very effects we wish to model. Also, unless we were to employ supercomputing techniques and extremely complex computer codes that could deal with millions of grains simultaneously, it would also be difficult to model grain transport if we attempted to consider every grain in motion. No existing computer models were found that satisfactorily used the equations of motion to arrive at transport flux numbers for the different populations of saltation and reptation. Modeling all the grains in a transport system was an intractable problem within our resources, and thus we developed what we believe to be a new modeling approach to simulating grain transport. The CFA deals with grain populations, but considers them to belong to various compartmentalized fluid units in the boundary layer. In this way, the model circumvents the multigrain problem by dealing primarily with the consequences of grain transport --momentum transfer between air and grains, which is the physical essence of a dynamic grain-fluid mixture. We thus chose to model the aeolian transport process as a superposition of fluids. These fluids include the air as well as particle populations of various properties. The prime property distinguishing these fluids is upward and downward grain motion. In a normal saltation trajectory, a grain's downwind velocity increases with time, so a rising grain will have a smaller downwind velocity than a failing grain. Because of this disparity in rising and falling grain proper-ties, it seemed appropriate to track these as two separate grain populations within the same physical space. The air itself can be considered a separate fluid superimposed within and interacting with the various grain-cloud "fluids". Additional informaiton is contained in the original.

Marshall, J.↗
NASA NTRS2018

A Fast Monte Carlo Method for Model-Based Prognostics Based on Stochastic Calculus

This work proposes a fast Monte Carlo method to solve differential equations utilized in model-based prognostics. The methodology is derived from the theory of stochastic calculus, and the goal of such a method is to speed up the estimation of the probability density functions describing the independent variable evolution over time. In the prognostic scenarios presented in this paper, the stochastic differential equations describe variables directly or indirectly related to the degradation of a monitored system. The method allows the estimation of the probability density functions by solving the deterministic equation and approximating the stochastic integrals using samples of the model noise. By so doing, the prognostic problem is solved without the Monte Carlo simulation based on Euler's forward method, which is typically the most time consuming task of the prediction stage. Three different prognostic scenarios are presented as proof of concept: (i) life prediction of electrolytic capacitors, (ii) remaining time to discharge of Lithium-ion batteries, and (iii) prognostic of cracked structures under fatigue loading. The paper shows how the method produces probability density functions that are statistically indistinguishable from the distributions estimated with Euler's forward Monte Carlo simulation. However, the proposed solution is orders of magnitude faster when computing the time-to-failure distribution of the monitored system. The approach may enable complex real-time prognostics and health management solutions with limited computing power.

Corbetta, M.↗
NASA NTRS2019

A Fast Monte Carlo Method for Model-Based Prognostics Based on Stochastic Calculus

This work proposes a fast Monte Carlo method to solve differential equations utilized in model-based prognostics. The methodology is derived from the theory of stochastic calculus, and the goal of such a method is to speed up the estimation of the probability density functions describing the independent variable evolution over time. In the prognostic scenarios presented in this paper, the stochastic differential equations describe variables directly or indirectly related to the degradation of a monitored system. The method allows the estimation of the probability density functions by solving the deterministic equation and approximating the stochastic integrals using samples of the model noise. By so doing, the prognostic problem is solved without the Monte Carlo simulation based on Euler's forward method, which is typically the most time consuming task of the prediction stage. Three different prognostic scenarios are presented as proof of concept: (i) life prediction of electrolytic capacitors, (ii) remaining time to discharge of Lithium-ion batteries, and (iii) prognostic of cracked structures under fatigue loading. The paper shows how the method produces probability density functions that are statistically indistinguishable from the distributions estimated with Euler's forward Monte Carlo simulation. However, the proposed solution is orders of magnitude faster when computing the time-to-failure distribution of the monitored system. The approach may enable complex real-time prognostics and health management solutions with limited computing power.

stochastic calculus↗
NASA NTRS1972

Hypersonic aerodynamics and entry-maneuver: Aerothermodynamic interactions for two lifting entry vehicles

The longitudinal, directional, and lateral static stability and control characteristics of a delta lifting body and a delta-wing body were obtained at a Mach number of 20 in helium for operational Reynolds numbers over an angle-of-attack range of -4 deg to 55 deg. The aerodynamic characteristics of the wing body were then evaluated in an entry study to examine the effects of vehicle performance on the aerothermodynamic parameters associated with constant and variable angle-of-attack modes for a 1500-n. mi. cross range. The experimental results indicated that the vehicles were stable, except for neutral directional stability for the wing-body shape, and could be trimmed over the operational angle-of-attack range; however, the wing-body vehicle had adverse yaw due to roll control. This roll-yaw coupling was not examined for the lifting body. The trajectory analysis indicated that a 17-percent decrease in performance required little change in the constant angle-of-attack entry mode and, in turn, resulted in a small decrease in the total heat load. For the pitch-modulated entry, the performance decrease required the pitch maneuver to begin earlier during entry and to last longer in order to meet the 1500-n. mi. cross range without a major heating penalty. The performance reduction also had little effect on the maximum laminar radiation equilibrium temperature over a major portion of the lower surface of the wing-body vehicle regardless of the entry mode.

Arrington, J. P.↗
NASA NTRS1984

Shutdown characteristics of the Mod-O wind turbine with aileron controls

Horizontal-axis wind turbines utilize partial or full variable blade pitch to regulate rotor speed. The weight and costs of these systems indicated a need for alternate methods of rotor control. Aileron control is an alternative which has potential to meet this need. The NASA Lewis Research Center has been experimentally testing aileron control rotors on the Mod-U wind turbine to determine their power regulation and shutdown characteristics. Experimental and analytical shutdown test results are presented for a 38 percent chord aileron-control rotor. These results indicated that the 38 percent chord ailerons provided overspeed protection over the entire Mod-O operational windspeed range, and had a no-load equilibrium tip speed ratio of 1.9. Thus, the 38 percent chord ailerons had much improved aerodynamic braking capability when compared with the first aileron-control rotor having 20 percent chord ailerons.

Miller, D. R.↗
NASA NTRS2018

Development of the Multi Purpose Transportation System for the Space Launch System (SLS) Core Stage (CS) Flight Article

NASA’s Multi Purpose Transportation System (MPTS) is designed to transport the Space Launch System vehicle segments by waterway and roadway. It is tasked with transporting the vehicle from where it is manufactured to its intermediate test location and final launch destination. Its design incorporates mechanisms that release degrees of freedom to prevent excessive loading during transit and ensure a successful delivery of the vehicle to its intended destination. In addition to the CS (Core Stage) flight article, the system will also move three structural test articles and a simulated CS Pathfinder (weight, center of gravity, outer mold line dimensions, and overall length) over road terrain on four NASA centers and on the Pegasus barge. The MPTS independently supports the article at both ends while communicating as a combined unit through automated monitoring of its released degree of freedom and corrective responses. This allows the system to constrain its payload in a statically determinate manner while traversing across highly variable terrain. Multi-body simulation of the transportation route is useful to predict free-body motion within the specified travel ranges. The MPTS has completed its design and analysis developmental cycles. This unpublished paper will describe the design challenges encountered in developing this system of large scale structure which incorporates complex mechanisms. The unique techniques and methodologies developed for analytical assessment of the hardware will be also be discussed. Key results from analytical evaluations as well as ongoing performance testing will be presented.

Sandridge, Sarah↗
NASA NTRS1993

Ducted fan acoustic radiation including the effects of nonuniform mean flow and acoustic treatment

Forward and aft acoustic propagation and radiation from a ducted fan is modeled using a finite element discretization of the acoustic field equations. The fan noise source is introduced as equivalent body forces representing distributed blade loading. The flow in and around the nacelle is assumed to be nonuniform, reflecting the effects of forward flight and flow into the inlet. Refraction due to the fan exit jet shear layer is not represented. Acoustic treatment on the inlet and exhaust duct surfaces provides a mechanism for attenuation. In a region enclosing the fan a pressure formulation is used with the assumption of locally uniform flow. Away from the fan a velocity potential formulation is used and the flow is assumed nonuniform but irrotational. A procedure is developed for matching the two regions by making use of local duct modal amplitudes as transition state variables and determining the amplitudes by enforcing natural boundary conditions at the interface between adjacent regions in which pressure and velocity potential are used. Simple models of rotor alone and rotor/exit guide vane generated noise are used to demonstrate the calculation of the radiated acoustic field and to show the effect of acoustic treatment. The model has been used to assess the success of four techniques for acoustic lining optimization in reducing far field noise.

Eversman, Walter↗
NASA NTRS2011

Active Flow Effectors for Noise and Separation Control

New flow effector technology for separation control and enhanced mixing is based upon shape memory alloy hybrid composite (SMAHC) technology. The technology allows for variable shape control of aircraft structures through actively deformable surfaces. The flow effectors are made by embedding shape memory alloy actuator material in a composite structure. When thermally actuated, the flow effector def1ects into or out of the flow in a prescribed manner to enhance mixing or induce separation for a variety of applications, including aeroacoustic noise reduction, drag reduction, and f1ight control. The active flow effectors were developed for noise reduction as an alternative to fixed-configuration effectors, such as static chevrons, that cannot be optimized for airframe installation effects or variable operating conditions and cannot be retracted for off-design or fail-safe conditions. Benefits include: Increased vehicle control, overall efficiency, and reduced noise throughout all f1ight regimes, Reduced flow noise, Reduced drag, Simplicity of design and fabrication, Simplicity of control through direct current stimulation, autonomous re sponse to environmental heating, fast re sponse, and a high degree of geometric stability. The concept involves embedding prestrained SMA actuators on one side of the chevron neutral axis in order to generate a thermal moment and def1ect the structure out of plane when heated. The force developed in the host structure during def1ection and the aerodynamic load is used for returning the structure to the retracted position. The chevron design is highly scalable and versatile, and easily affords active and/or autonomous (environmental) control. The technology offers wide-ranging market applications, including aerospace, automotive, and any application that requires flow separation or noise control.

Turner, Travis L.↗
NASA NTRS2018

Relationships Between the Planetary Boundary Layer Height and Surface Pollutants Derived from Lidar Observations over China: Regional Pattern and Influencing Factors

The frequent occurrence of severe air pollution episodes in China has been a great concern and thus the focus of intensive studies. Planetary boundary layer height (PBLH) is a key factor in the vertical mixing and dilution of near-surface pollutants. However, the relationship between PBLH and surface pollutants, especially particulate matter (PM) concentration across China, is not yet well understood. We investigate this issue at 1600 surface stations using PBLH derived from space-borne and ground-based lidar, and discuss the influence of topography and meteorological variables on the PBLH–PM relationship. Albeit the PBLH–PM correlations are roughly negative for most cases, their magnitude, significance, and even sign vary considerably with location, season, and meteorological conditions. Weak or even uncorrelated PBLH–PM relationships are found over clean regions (e.g., Pearl River Delta), whereas nonlinearly negative responses of PM to PBLH evolution are found over polluted regions (e.g., North China Plain). Relatively strong PBLH–PM interactions are found when the PBLH is shallow and PM concentration is high, which typically corresponds to wintertime cases. Correlations are much weaker over the highlands than the plains regions, which may be associated with lighter pollution loading at higher elevations and contributions from mountain breezes. The influence of horizontal transport on surface PM is considered as well, manifested as a negative correlation between surface PM and wind speed over the whole nation. Strong wind with clean upwind air plays a dominant role in removing pollutants, and leads to obscure PBLH–PM relationships. A ventilation rate is used to jointly consider horizontal and vertical dispersion, which has the largest impact on surface pollutant accumulation over the North China Plain. As such, this study contributes to improved understanding of aerosol–planetary boundary layer (PBL) interactions and thus our ability to forecast surface air pollution.

Su, Tianning↗
NASA NTRS1986

Outdoor test stand performance of a convertible engine with variable inlet guide vanes for advanced rotorcraft propulsion

A variable inlet guide van (VIGV) type convertible engine that could be used to power future high-speed rotorcraft was tested on an outdoor stand. The engine ran stably and smoothly in the turbofan, turboshaft, and dual (combined fan and shaft) power modes. In the turbofan mode with the VIGV open fuel consumption was comparable to that of a conventional turbofan engine. In the turboshaft mode with the VIGV closed fuel consumption was higher than that of present turboshaft engines because power was wasted in churning fan-tip airflow. In dynamic performance tests with a specially built digital engine control and using a waterbrake dynamometer for shaft load, the engine responded effectively to large steps in thrust command and shaft torque. Previous mission analyses of a conceptual X-wing rotorcraft capable of 400-knot cruise speed were revised to account for more fan-tip churning power loss than was originally estimated. The new calculations confirm that using convertible engines rather than separate lift and cruise engines would result in a smaller, lighter craft with lower fuel use and direct operating cost.

Mcardle, Jack G.↗
NASA NTRS1988

The convertible engine: A dual-mode propulsion system

A variable inlet guide vane (VIGV) convertible engine that could be used to power future high-speed rotorcraft was tested on an outdoor stand. The engine ran stably and smoothly in the turbofan, turboshaft, and dual (combined fan and shaft) power modes. In the turbofan mode with the VIGV open, fuel consumption was comparable to that of a conventional turbofan engine. In the turboshaft mode with the VIGV closed, fuel consumption was higher than that of present turboshaft engines because power was wasted in churning fan-tip air flow. In dynamic performance tests with a specially built digital engine control and using a waterbrake dynamometer for shaft load, the engine responded effectively to large steps in thrust command and shaft torque. Previous mission analyses of a conceptual X-wing rotorcraft capable of 400-knot cruise speed were revised to account for more fan-tip churning power loss that was originally estimated. The calculations confirm that using convertible engines rather than separate life and cruise engines would result in a smaller, lighter craft with lower fuel use and direct operating cost.

Mcardle, Jack G.↗
NASA NTRS2003

Baroreflex-mediated heart rate and vascular resistance responses 24 h after maximal exercise

INTRODUCTION: Plasma volume, heart rate (HR) variability, and stimulus-response relationships for baroreflex control of forearm vascular resistance (FVR) and HR were studied in eight healthy men after and without performing a bout of maximal exercise to test the hypotheses that acute expansion of plasma volume is associated with 1) reduction in baroreflex-mediated HR response, and 2) altered operational range for central venous pressure (CVP). METHODS: The relationship between stimulus (DeltaCVP) and vasoconstrictive reflex response (DeltaFVR) during unloading of cardiopulmonary baroreceptors was assessed with lower-body negative pressure (LBNP, 0, -5, -10, -15, -20 mm Hg). The relationship between stimulus (Deltamean arterial pressure (MAP)) and cardiac reflex response (DeltaHR) during loading of arterial baroreceptors was assessed with steady-state infusion of phenylephrine (PE) designed to increase MAP by 15 mm Hg alone and during application of LBNP (PE+LBNP) and neck pressure (PE+LBNP+NP). Measurements of vascular volume and autonomic baroreflex responses were conducted on two different test days, each separated by at least 1 wk. On one day, baroreflex response was tested 24 h after graded cycle exercise to volitional exhaustion. On another day, measurement of baroreflex response was repeated with no exercise (control). The order of exercise and control treatments was counterbalanced. RESULTS: Baseline CVP was elevated (P = 0.04) from a control value of 10.5 +/- 0.4 to 12.3 +/- 0.4 mm Hg 24 h after exercise. Average DeltaFVR/DeltaCVP during LBNP was not different (P = 0.942) between the exercise (-1.35 +/- 0.32 pru x mm Hg-1) and control (-1.32 +/- 0.36 pru x mm Hg-1) conditions. However, maximal exercise caused a shift along the reflex response relationship to a higher CVP and lower FVR. HR baroreflex response (DeltaHR/DeltaMAP) to PE+LBNP+NP was lower (P = 0.015) after maximal exercise (-0.43 +/- 0.15 beats x min-1 x mm Hg-1) compared with the control condition (-0.83 +/- 0.14 beats x min-1 x mm Hg-1). CONCLUSION: Expansion of vascular volume after acute exercise is associated with altered operational range for CVP and reduced HR response to arterial baroreceptor stimulation.

Non-NASA Center↗
NASA NTRS2021

Permittivity Measurement System Using Stripline Method for the Europa Clipper Mission

High radiation Jovian environment can deposit electrons in highly resistive dielectric materials, which could result in internal electrostatic discharge (IESD) causing damage to sensitive electronics such as the radar for Europa Assessment and Sounding: Ocean to Near-Surface (REASON) instrument on NASA’s Europa Clipper mission. Special dielectric materials like static dissipative Polyetheretherketone (PEEK) ESD are under consideration for the Europa Clipper mission. PEEK loaded with carbon nanofibers improves the ESD performance for this material but the RF characteristics are unknown. We have developed a method to characterize the dielectric constant of a material as a function of frequency and temperature down to 30K. We present the measurement results of four samples of ESD. The measured data shows the permittivity of TECAPEEK ESD 11 is in the range of 7 to 10 at HF and in the range of 6.8 to 8.3 for VHF frequencies. The change in permittivity of ESD 11 down to 30 K is less than 7% at HF and less than 3% at VHF frequency. The sample to sample variability can be attributed to the inhomogeneity of the material.

Decrossas, Emmanuel↗
NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗
NASA NTRS1981

Experimental program for the evaluation of turbofan/turboshaft c conversion technology

A TF34 turbofan engine is being modified to produce shaft power from an output coupling on the fan disk when variable inlet guide vanes are closed to reduce fan airflow. The engine, called a convertible engine, could be used on advanced rotorcraft such as X-wing, ABC (Advanced Blade Concept), and Folding Tilt Rotor, and on V/STOL craft in which two engines are cross-coupled. The engine will be tested on an outdoor static test stand at NASA Lewis Research Center. Steady-state tests will be made to measure performance in turbofan, turboshaft, and combined power output modes. Transient tests will be made to determine the response to the engine and a new digital engine control system for several types of rapid changes in thrust and shaft loads. The paper describes the engine modifications, the test facility equipment, proposed testing techniques for several types of tests, and typical test results predicted from engine performance computer programs.

Mcardle, J. G.↗