SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Individual-pressure-vessel (IPV) nickel-hydrogen technology adanced with intention of improving cycle life and performance. One advancement to use 26 percent potassium hydroxide electrolyte to improve cycle life. Another to modify state-of-art cell design to eliminate identified failure modes.
The Elastic Plastic Fracture Mechanics (EPFM) Methodology has evolved significantly in the last several years. Nevertheless, some of these concepts need to be extended further before the whole methodology can be safely applied to structural parts. Specifically, there is a need to include the effect of constraint in the characterization of material resistance to crack growth and also to extend these methods to the case of 3D defects. As a consequence, this project was started as a 36 month research program with the general objective of developing an EPFM methodology to assess the structural reliability of pressure vessels and other parts of interest to NASA containing defects. This report covers a computer modelling algorithm used to simulate the growth of a semi-elliptical surface crack; the presentation of a finite element investigation that compared the theoretical (HRR) stress field to that produced by elastic and elastic-plastic models; and experimental efforts to characterize three dimensional aspects of fracture present in 'two dimensional', or planar configuration specimens.
Design and research efforts at the University of Puerto Rico have focused on the evaluation and refinement of the Habitability Criteria for a prolonged human presence in space during the last four years. Living quarters for a Mars mission and a third generation lunar base concept were proposed. This academic year, 1991-92, work on further refinement of the habitability criteria and design of partial gravity furniture was carried on. During the first semester, design alternatives for furniture necessary in a habitat design optimized for lunar and Martian environments were developed. Designs are based on recent research data from lunar and Mars gravity simulations, and current NASA standards. Artifacts will be submitted to NASA architects to be tested in KC-135 flights. Test findings will be submitted for incorporation in future updates to NASA habitat design standards. Second semester work was aimed at integrating these findings into the First Lunar Outpost (FLO), a mission scenario currently being considered by NASA. The mission consists of a manned return to the moon by crews of four astronauts for periods of 45 days. The major hardware components of the mission are as follows: (1) a Crew Module for the delivery of the crew and their supplies, and (2) the Habitat Module, which will arrive on the Moon unmanned. Our design efforts concentrated on this Habitat Module and on application of habitability criteria. Different geometries for the pressure vessel and their impact on the interior architecture were studied. Upon the selection of a geometry, a more detailed analysis of the interior design was performed, taking into consideration the reduced gravity, and the protection against radiation, micrometeorites, and the extreme temperature variation. A proposal for a FLO was submitted by the students, consisting essentially of a 24-feet (7.3 m.) by 35-feet (10.67 m) high vertical cylinder with work areas, crew quarters, galley, wardroom, leisure facilities, health maintenance, waste management, EVA operations facilities, and safe havens.
The Advanced Solid Rocket Motor program determined the need to inspect ASRM forgings and segments for potentially catastrophic defects. To minimize costs, an automated eddy current inspection system was designed and manufactured for inspection of ASRM forgings in the initial phases of production. This system utilizes custom manipulators and motion control algorithms and integrated six channel eddy current data acquisition and analysis hardware and software. Total system integration is through a personal computer based workcell controller. Segment inspection demands the use of a gantry robot for the EMAT/ET inspection system. The EMAT/ET system utilized similar mechanical compliancy and software logic to accommodate complex part geometries. EMAT provides volumetric inspection capability while eddy current is limited to surface and near surface inspection. Each aspect of the systems are applicable to other industries, such as, inspection of pressure vessels, weld inspection, and traditional ultrasonic inspection applications.
Structural models are examined for the influence of a ring with an asymmetrical cross section on the linear elastic response of an orthogonally stiffened cylindrical shell subjected to internal pressure. The first structural model employs classical theory for the shell and stiffeners. The second model employs transverse shear deformation theories for the shell and stringer and classical theory for the ring. Closed-end pressure vessel effects are included. Interacting line load intensities are computed in the stiffener-to-skin joints for an example problem having the dimensions of the fuselage of a large transport aircraft. Classical structural theory is found to exaggerate the asymmetric response compared to the transverse shear deformation theory.
The Elastic Plastic Fracture Mechanics Methodology has evolved significantly in the last several years. Nevertheless, some of these concepts need to be extended further before the whole methodology can be safely applied to structural parts. Specifically, there is a need to include the effect of constraint in the characterization of material resistance to crack growth and also to extend these methods to the case of 3D defects. As a consequence, this project was started as a 36 month research program with the general objective of developing an elastic plastic fracture mechanics methodology to assess the structural reliability of pressure vessels and other parts of interest to NASA which may contain flaws. The project is divided into three tasks that deal with (1) constraint and thickness effects, (2) three-dimensional cracks, and (3) the Leak-Before-Burst (LBB) criterion. This report period (March 1994 to August 1994) is a continuation of attempts to characterize three dimensional aspects of fracture present in 'two dimensional' or planar configuration specimens (Chapter Two), especially, the determination of, and use of, crack face separation data. Also, included, are a variety of fracture resistance testing results (J(m)R-curve format) and a discussion regarding two materials of NASA interest (6061-T651 Aluminum alloy and 1N718-STA1 nickel-base super alloy) involving a bases for like constraint in terms of ligament dimensions, and their comparison to the resulting J(m)R-curves (Chapter Two).
Butt-weld joints are most commonly designed into pressure vessels which then become as reliable as the weakest increment in the weld chain. In practice, weld material properties are determined from tensile test specimen and provided to the stress analyst in the form of a stress versus strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of welds. The weld specimens are analyzed using classical elastic and plastic theory to provide a basis for modeling the inelastic properties in a finite-element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of prediction methods. The weld considered in this study is a multiple-pass aluminum 2219-T87 butt weld with thickness of 1.40 in. The weld specimen is modeled using the finite-element code ABAQUS. The finite-element model is used to produce the stress-strain behavior in the elastic and plastic regimes and to determine Poisson's ratio in the plastic region. The value of Poisson's ratio in the plastic regime is then compared to experimental data. The results of the comparisons are used to explain multipass weld behavior and to make recommendations concerning the analysis and testing of welds.
This paper assesses the feasibility of using eddy current nondestructive examination of determine flaw sizes in completely assembled hydrazine propellant tanks. The study was performed by the NASA Goddard Space Flight Center for the Tropical Rainfall Measuring Mission (TRMM) project to help determine whether existing propellant tanks could meet the fracture analysis requirements of the current pressure vessel specification, MIL-STD-1522A and, therefore be used on the TRMM spacecraft. After evaluating several nondestructive test methods, eddy current testing was selected as the most promising method for determining flaw sizes on external and internal surfaces of completely assembled tanks. Tests were conducted to confirm the detection capability of the eddy current NDE, procedures were developed to inspect two candidate tanks, and the test support equipment was designed. The non-spherical tank eddy current NDE test program was terminated when the decision was made to procure new tanks for the TRMM propulsion subsystem. The information on the development phase of this test program is presented in this paper as a reference for future investigation on the subject.
Non-science students at William and Mary will soon be required to take a mathematics course in order to earn a bachelor's degree. A standard menu of technique courses is the usual way in which universities provide for this requirement: Trigonometry, probability, geometry for teachers, and the like. In this work, we attempt to break away from these largely unsuccessful choices. Our intent is to prepare material that sets a variety of simple mathematical procedures in the context of a commonly experienced part of students' lives: riding in commercial airplanes. The work, begun last summer at Langley, is now close to completion and trial in upcoming fall term at William and Mary. As of this writing, the narrative is complete for 12 to 14 projected sections. We have prepared material on wind triangles, wind roses, navigation maps, drag induced loss of velocity for unpowered missiles (tennis balls), luggage and its effect on center of gravity, localized magnetic declination and VOR orientation, geometry of great circles, terminal velocity for falling bodies, pressure vessels: tires and balloons and blimps, global structure of declination lines, map projections (mercator, azimuthal equidistant, Lambert), ears and their reaction to altitude change. The next section will treat lift, drag and thrust. The last will treat control surfaces. The entire approach avoids any effort to investigate mathematical topics that arise in the solution of problems. And by the same token, we avoid any organized attempt to explain aeronautical engineering, even on an elementary level. We look only at enough mathematics to do a problem and we select only engineering topics that permit some kind of (elementary) mathematical analysis. In the end, we will think of the material as successful if two things happen: Students must come away with some confidence that even lay people can quantify parts of their surroundings. Other potential instructors must be willing to gain enough familiarity with the physical content of the material so that it can be used at other universities.
Two-cell nickel-hydrogen common pressure vessel (CPV) units with some unusual design features have been successfully built and tested. The features of interest are half-normal platinum loading for the negative electrodes, the use of rabbit-ear terminals for a CPV unit, and the incorporation of a wall wick. The units have a nominal capacity of 20 Ah and are 3.5 inches in diameter. Electric performance data are provided. The data support the growing viability of the two-cell CPV design concept.
A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.
USBI and NASA have been testing and investigating the use of high pressure water for coating removal for approximately the past 12 years at the Automated TPS (Thermal Protection System - ablative materials used for thermal protection during ascent and descent of the solid rocket boosters) Removal Facility located in the Productivity Enhancement Complex at Marshall Space Flight Center. Originally the task was to develop and automate the removal process and transfer the technology to a production facility at Kennedy Space Center. Since that time more and more applications and support roles for the waterjet technology have been realized. The facility has become a vital part of development activities ongoing at MSFC. It supports the development of environmentally compliant insulations, sealants, and coatings. It also supports bonding programs, test motors, and pressure vessels. The most recent role of the cell is supporting Thiokol Corporation's solid rocket motor program in the development of waterjet degreasing and paint stripping methods. Currently vapor degreasing methods use 500,000 lbs. of ozone depleting chemicals per year. This paper describes the major cell equipment, test methods practiced, and coatings that have been removed.
Robotic-welding apparatus developed for use in repairing main combustion chamber of rocket engine. Design features beneficial in other robotic-welding applications; for example, manufacture and repair of pressure vessels, chemical-processing vessels, etc. Design problem solved by iterative application of computer-aided techniques.
This handbook reviews the analysis of structural damage on spacecraft due to hypervelocity impacts by meteoroid and space debris. These impacts can potentially cause structural damage to a Space Station module wall. This damage ranges from craters, bulges, minor penetrations, and spall to critical damage associated with a large hole, or even rupture. The analysis of damage depends on a variety of assumptions and the area of most concern is at a velocity beyond well controlled laboratory capability. In the analysis of critical damage, one of the key questions is how much momentum can actually be transfered to the pressure vessel wall. When penetration occurs without maximum bulging at high velocity and obliquities (if less momentum is deposited in the rear wall), then large tears and rupture may be avoided. In analysis of rupture effects of cylindrical geometry, biaxial loading, bending of the crack, a central hole strain rate and R-curve effects are discussed.
Laser ultrasonic/thermographic inspection system is conceptual instrument used in nondestructive inspection of large areas of structures for subsurface defects. For example, operated in field to examine aircraft and pressure vessels for hidden cracks. System would not require contact with inspected structure or use of ultrasonic-coupling medium. Instrument obtains data in ultrasonic and thermographic C-scans over structural surfaces with contours characterized by surface normal vectors varying by angles as large as 45 degrees.
The design and performance of a highly reliable, 20 volt nickel hydrogen battery compatible with existing NiCad Mars observer based spacecraft components and an 800 psi, zirconium wall wick Common Pressure Vessel (CPV) are discussed. The objectives of the design process are: to meet or exceed all PD requirements by using existing technologies; to have high reliability hardware and parallel fabrication of components; and low schedule risk configurations. This paper discusses the tests performed on the batteries (capacity, charge retention, random vib., pyro shock, energy density, and packing factor) and the results of the tests. In addition to the design discussion, a brief introduction on Mars Global Surveyor (MGS) Satellite objectives (NASA's next interplanetary mission) is also presented.
Assembly of custom-shaped water-cooled chill bars developed for use during repair process in which cracks and pinholes in rocket-engine combustion chamber welded closed. Held in required relative geometric relationships by rigid framework, chill bars pressed against surface of chamber to conduct heat away from areas surrounding welds, preventing damage caused by overheating of areas not meant to be welded. Design features beneficial in other welding applications; for example, manufacture and repair of pressure vessels, chemical-processing vessels, and complexly shaped laboratory vacuum vessels.
Delamination in composite structure may be caused by imperfections introduced during the manufacturing process or by impact loads by foreign objects during the operational life. There are some nondestructive evaluation methods to detect delamination in composite structures such as x-radiography, ultrasonic testing, and thermal/infrared inspection. These methods are expensive and hard to use for on line detection. Acoustic emission testing can monitor the material under test even under the presence of noise generated under load. It has been used extensively in proof-testing of fiberglass pressure vessels and beams. In the present work, experimental studies are conducted to investigate the use of broadband acoustic emission signatures to detect delaminations in composite beams. Glass/epoxy beam specimens with full width, prescribed delamination sizes of 2 inches and 4 inches are investigated. The prescribed delamination is produced by inserting Teflon film between laminae during the fabrication of composite laminate. The objectives of this research is to develop a method for predicting delamination size and location in laminated composite beams by combining smart materials concept and broadband AE analysis techniques. More specifically, a piezoceramic (PZT) patch is bonded on the surface of composite beams and used as a pulser. The piezoceramic patch simulates the AE wave source as a 3 cycles, 50KHz, burst sine wave. One broadband AE sensor is fixed near the PZT patch to measure the AE wave near the AE source. A second broadband AE sensor, which is used as a receiver, is scanned along the composite beams at 0.25 inch step to measure propagation of AE wave along the composite beams. The acquired AE waveform is digitized and processed. Signal strength, signal energy, cross-correlation of AE waveforms, and tracking of specific cycle of AE waveforms are used to detect delamination size and location.