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NASA NTRSDate not supplied

Lessons Learned from Large-Scale Aerospace Structural Testing

Large-scale testing of aerospace structures is frequently the final step in a development project to validate the structural performance, and that typically involves a large cost and time investment. In order to ensure that the testing provides the required data, avoiding errors that can result in an unsuccessful test and failure to meet objectives is critical. Presented herein are five lessons learned to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five subject large-scale tests are described, and include two composite wing tests, a composite hybrid-wing body center section test, a full-scale 27.5-ft diameter metallic barrel test, and an 8-ft diameter metallic barrel test. Problems identified during the testing and mitigation approaches to solve the problems are presented, then the lessons learned are summarized.

Lessons Learned↗

NASA NTRSDate not supplied

Lessons Learned from Large-Scale Aerospace Structural Testing

Lessons Learned↗

NASA NTRSDate not supplied

FEA-Based Failure Analysis of Post-Buckled Composite Multi-Hat Stiffened Panel Under Static Compression

The aerospace industry uses composite multi-hat stiffened panels for skins because of their high strength-to-weight and stiffness-to-weight ratios. However, laminated composites with initial flaws are susceptible to delamination under buckling loads. The goal is to ensure damage initiation occurs past the buckled state, only stable damage progression at loads below the ultimate compressive load, and debonding failure past the ultimate compressive load. This approach reduces weight and addresses a potential design review for future aircraft repairs. The need exists to better understand damage initiation and growth mechanisms in composite structures while assisting in the design, analysis, and sustainment methods. Teflon inserts simulate damage defects during manufacturing, while barely visible impact helps capture human error during manufacturing. This work shows the interaction between the skin-stringer and ply-ply separations at the post-buckled state for both defect events using Abaqus Virtual Crack Closure Technique (VCCT). The initial configuration for the Teflon case was to leave the Teflon region unbonded, and the initial impact damage region approximation came from the experimental data and was considered the initial configuration. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage transition from skin-hat to ply1-ply2. The model validations were within ~5% of the experimental data.

composite↗

DOE OSTI2016

Supporting the future nuclear workforce with computer-based procedures

Here we see that computer-based tools have dramatically increased ease and efficiency of everyday tasks. Gone are the days of paging through a paper catalog, transcribing product numbers, and calculating totals. Today, a consumer can find a product online with a simple search engine, and then purchase it in a matter of a few clicks. Paper catalogs have their place, but it is hard to imagine life without on-line shopping sites. All tasks conducted in a nuclear power plant are guided by procedures, which helps ensure safe and reliable operation of the plants. One prominent goal of the nuclear industry is to minimize the risk of human errors. To achieve this goal one has to ensure tasks are correctly and consistently executed. This is partly achieved by training and by a structured approach to task execution, which is provided by procedures and work instructions. Procedures are used in the nuclear industry to direct workers' actions in a proper sequence. The governing idea is to minimize the reliance on memory and choices made in the field. However, the procedure document may not contain sufficient information to successfully complete the task. Therefore, the worker might have to carry additional documents such as turnover sheets, operation experience, drawings, and other procedures to the work site. The nuclear industry is operated with paper procedures like paper catalogs of the past. A field worker may carry a large stack of documents needed to complete a task to the field. Even though the paper process has helped keep the industry safe for decades, there are limitations to using paper. Paper procedures are static (i.e., the content does not change after the document is printed), difficult to search, and rely heavily on the field worker’s situational awareness and ability to consistently meet the high expectation of human performance excellence. With computer-based procedures (CBPs) that stack of papers may be reduced to the size of a small tablet or even a smart phone. Instead of manually matching equipment identification numbers listed in the procedure with the number on the physical equipment the field worker can simply scan a barcode to ensure the correct valve is opened while simultaneously creating a record. Instead of navigating through a maze of cross-references, CBPs enable intelligent work path navigation which accounts for past decisions and observation, thereby enabling more efficient and safe task completion.

47 OTHER INSTRUMENTATION↗

DOE OSTI2016

Analysis of dpa rates in the HFIR reactor vessel using a hybrid Monte Carlo/deterministic method

The Oak Ridge High Flux Isotope Reactor (HFIR), which began full-power operation in 1966, provides one of the highest steady-state neutron flux levels of any research reactor in the world. An ongoing vessel integrity analysis program to assess radiation-induced embrittlement of the HFIR reactor vessel requires the calculation of neutron and gamma displacements per atom (dpa), particularly at locations near the beam tube nozzles, where radiation streaming effects are most pronounced. In this study we apply the Forward-Weighted Consistent Adjoint Driven Importance Sampling (FW-CADIS) technique in the ADVANTG code to develop variance reduction parameters for use in the MCNP radiation transport code. We initially evaluated dpa rates for dosimetry capsule locations, regions in the vicinity of the HB-2 beamline, and the vessel beltline region. We then extended the study to provide dpa rate maps using three-dimensional cylindrical mesh tallies that extend from approximately 12 below to approximately 12 above the axial extent of the core. The mesh tally structures contain over 15,000 mesh cells, providing a detailed spatial map of neutron and photon dpa rates at all locations of interest. Relative errors in the mesh tally cells are typically less than 1%.

Blakeman, Edward↗

NASA NTRS1971

An Evaluation of Current NASTRAN Discrete Element Models for Monocoque and Semimonocoque Structures

The current discrete element analysis models in NASTRAN, Levels 8. 1.0 and 11. 1. 0, are evaluated for semi-rnonocoque and monocoque structures. Comparative results are presented with the FORMAT-I11 general-purpose code for a swept wing statics analysis and a Skylab substructure vibration analysis. Good agreement between Level i I. 1.0 and FORMAT-111 is demonstrated; however, a major error in Level 8. 1.0 was discovered on the Skylab vibration problem. The computational performance of NASTRAN was superior to FORMAT, but the vibration rigid format was found to have several inefficiencies. Comparative results are also presented between Level 11. 1. 0 and STACUSS, SLADE, BOND, UNIVALVE, and another special-purpose code. Results for two of the structures analyzed, a cylindrical shell and an elliptic plate, indicate curved discrete elements are significantly more accurate than the plate elements in NASTRAN for the same number of degrees of freedom.

Edward L. Stanton↗

NASA NTRS1994

First Order Reliability Application and Verification Methods for Semistatic Structures

Escalating risks of aerostructures stimulated by increasing size, complexity, and cost should no longer be ignored by conventional deterministic safety design methods. The deterministic pass-fail concept is incompatible with probability and risk assessments, its stress audits are shown to be arbitrary and incomplete, and it compromises high strength materials performance. A reliability method is proposed which combines first order reliability principles with deterministic design variables and conventional test technique to surmount current deterministic stress design and audit deficiencies. Accumulative and propagation design uncertainty errors are defined and appropriately implemented into the classical safety index expression. The application is reduced to solving for a factor that satisfies the specified reliability and compensates for uncertainty errors, and then using this factor as, and instead of, the conventional safety factor in stress analyses. The resulting method is consistent with current analytical skills and verification practices, the culture of most designers, and with the pace of semistatic structural designs.

Verderaime, Vincent↗

NASA NTRS2012

Structural Verification of the First Orbital Wonder of the World - The Structural Testing and Analysis of the International Space Station (ISS)

The International Space Station (ISS) can be considered one of the structural engineering wonders of the world. On par with the World Trade Center, the Colossus of Rhodes, the Statue of Liberty, the Great Pyramids, the Petronas towers and the Burj Khalifa skyscraper of Dubai, the ambition and scope of the ISS structural design, verification and assembly effort is a truly global success story. With its on-orbit life projected to be from its beginning in 1998 to the year 2020 (and perhaps beyond), all of those who participated in its development can consider themselves part of an historic engineering achievement representing all of humanity. The structural design and verification of the ISS could be the subject of many scholarly papers. Several papers have been written on the structural dynamic characterization of the ISS once it was assembled on-orbit [1], but the ground-based activities required to assure structural integrity and structural life of the individual elements from delivery to orbit through assembly and planned on-orbit operations have never been totally summarized. This paper is intended to give the reader an overview of some of the key decisions made during the structural verification planning for the elements of the U.S. On-Orbit Segment (USOS) as well as to summarize the many structural tests and structural analyses that were performed on its major elements. An effort is made for this paper to be summarily comprehensive, but as with all knowledge capture efforts of this kind, there are bound to be errors of omission. Should the reader discover any of these, please feel free to contact the principal author. The ISS (Figure 1) is composed of pre-integrated truss segments and pressurized elements supplied by NASA, the Russian Federal Space Agency (RSA), the European Space Agency (ESA) and the Japanese Aerospace Exploration Agency (JAXA). Each of these elements was delivered to orbit by a launch vehicle and connected to one another either robotically or autonomously. The primary structure of each element was assembled and verified by teams of responsible structural engineers within and among their respective agencies and agency contractors.

Zipay, John J.↗

DOE OSTI2016

Resilience Design Patterns - A Structured Approach to Resilience at Extreme Scale (version 1.0)

Reliability is a serious concern for future extreme-scale high-performance computing (HPC) systems. Projections based on the current generation of HPC systems and technology roadmaps suggest that very high fault rates in future systems. The errors resulting from these faults will propagate and generate various kinds of failures, which may result in outcomes ranging from result corruptions to catastrophic application crashes. Practical limits on power consumption in HPC systems will require future systems to embrace innovative architectures, increasing the levels of hardware and software complexities. The resilience challenge for extreme-scale HPC systems requires management of various hardware and software technologies that are capable of handling a broad set of fault models at accelerated fault rates. These techniques must seek to improve resilience at reasonable overheads to power consumption and performance. While the HPC community has developed various solutions, application-level as well as system-based solutions, the solution space of HPC resilience techniques remains fragmented. There are no formal methods and metrics to investigate and evaluate resilience holistically in HPC systems that consider impact scope, handling coverage, and performance & power eciency across the system stack. Additionally, few of the current approaches are portable to newer architectures and software ecosystems, which are expected to be deployed on future systems. In this document, we develop a structured approach to the management of HPC resilience based on the concept of resilience-based design patterns. A design pattern is a general repeatable solution to a commonly occurring problem. We identify the commonly occurring problems and solutions used to deal with faults, errors and failures in HPC systems. The catalog of resilience design patterns provides designers with reusable design elements. We define a design framework that enhances our understanding of the important constraints and opportunities for solutions deployed at various layers of the system stack. The framework may be used to establish mechanisms and interfaces to coordinate flexible fault management across hardware and software components. The framework also enables optimization of the cost-benefit trade-os among performance, resilience, and power consumption. The overall goal of this work is to enable a systematic methodology for the design and evaluation of resilience technologies in extreme-scale HPC systems that keep scientific applications running to a correct solution in a timely and cost-ecient manner in spite of frequent faults, errors, and failures of various types.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1992

Maximum likelihood techniques applied to quasi-elastic light scattering

There is a necessity of having an automatic procedure for reliable estimation of the quality of the measurement of particle size from QELS (Quasi-Elastic Light Scattering). Getting the measurement itself, before any error estimates can be made, is a problem because it is obtained by a very indirect measurement of a signal derived from the motion of particles in the system and requires the solution of an inverse problem. The eigenvalue structure of the transform that generates the signal is such that an arbitrarily small amount of noise can obliterate parts of any practical inversion spectrum. This project uses the Maximum Likelihood Estimation (MLE) as a framework to generate a theory and a functioning set of software to oversee the measurement process and extract the particle size information, while at the same time providing error estimates for those measurements. The theory involved verifying a correct form of the covariance matrix for the noise on the measurement and then estimating particle size parameters using a modified histogram approach.

Edwards, Robert V.↗

NASA NTRS1972

On the elastic properties of fiber composite laminates with statistically dispersed ply orientations

Structural application of advanced composite filamentary materials requires lamination of the basic orthotropic plies into angle-ply laminates. The resulting elastic and strength properties depend on the pattern of orientation and are influenced by inevitable errors and inaccuracy in placement of the angle plies. Reviewed is the effect on elastic properties of orientation dispersion. The conventional constitutive relations are recast in a homologous form to account for orientation dispersion by addition of a single parameter. Graphical results are presented to show the behavior of the most important advanced composite materials. The results are directly useful for estimating effects of manufacturing inaccuracy and for design of partially oriented reinforced structures.

Robinson, E. Y.↗

NASA NTRS1996

Adaptive grid methods for RLV environment assessment and nozzle analysis

Rapid access to highly accurate data about complex configurations is needed for multi-disciplinary optimization and design. In order to efficiently meet these requirements a closer coupling between the analysis algorithms and the discretization process is needed. In some cases, such as free surface, temporally varying geometries, and fluid structure interaction, the need is unavoidable. In other cases the need is to rapidly generate and modify high quality grids. Techniques such as unstructured and/or solution-adaptive methods can be used to speed the grid generation process and to automatically cluster mesh points in regions of interest. Global features of the flow can be significantly affected by isolated regions of inadequately resolved flow. These regions may not exhibit high gradients and can be difficult to detect. Thus excessive resolution in certain regions does not necessarily increase the accuracy of the overall solution. Several approaches have been employed for both structured and unstructured grid adaption. The most widely used involve grid point redistribution, local grid point enrichment/derefinement or local modification of the actual flow solver. However, the success of any one of these methods ultimately depends on the feature detection algorithm used to determine solution domain regions which require a fine mesh for their accurate representation. Typically, weight functions are constructed to mimic the local truncation error and may require substantial user input. Most problems of engineering interest involve multi-block grids and widely disparate length scales. Hence, it is desirable that the adaptive grid feature detection algorithm be developed to recognize flow structures of different type as well as differing intensity, and adequately address scaling and normalization across blocks. These weight functions can then be used to construct blending functions for algebraic redistribution, interpolation functions for unstructured grid generation, forcing functions to attract/repel points in an elliptic system, or to trigger local refinement, based upon application of an equidistribution principle. The popularity of solution-adaptive techniques is growing in tandem with unstructured methods. The difficultly of precisely controlling mesh densities and orientations with current unstructured grid generation systems has driven the use of solution-adaptive meshing. Use of derivatives of density or pressure are widely used for construction of such weight functions, and have been proven very successful for inviscid flows with shocks. However, less success has been realized for flowfields with viscous layers, vortices or shocks of disparate strength. It is difficult to maintain the appropriate mesh point spacing in the various regions which require a fine spacing for adequate resolution. Mesh points often migrate from important regions due to refinement of dominant features. An example of this is the well know tendency of adaptive methods to increase the resolution of shocks in the flowfield around airfoils, but in the incorrect location due to inadequate resolution of the stagnation region. This problem has been the motivation for this research.

Thornburg, Hugh J.↗

NASA NTRSDate not supplied

Supervised Autonomous Assembly to Create and Evolve Persistent Assets

Supervised autonomous assembly (SAA) will create a paradigm shift in the planning and design of future persistent assets (PAs), both in near zero-g environments and on planetary surfaces. SAA refers to an autonomy approach that has the benefits of autonomous assembly as well as the benefits provided by a supervisor (operator) who is available to resolve unexpected situations. SAA provides both increased design freedom as well as reduced programmatic risk. SAA enables evolution of future PAs over decades as in-space operations transition from single purpose missions to creation of PAs, such as laboratories and experimental stations which more closely resembling terrestrial laboratories that can easily adapt and evolve to new missions leveraging repeated visits to the PA. The ability to evolve enables PAs to rapidly respond to changing objectives resulting from new questions as our understanding improves. A recently initiated National Aeronautics and Space Administration (NASA) project in the Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program called the Precision Assembled Space Structure (PASS), leverages the advantages of SAA to develop technologies that enable efficient creation and evolution of hexagonal topologies; both planar (example: fuel depots) and curved (examples: telescopes and shelters). PASS will be used to provide context for the philosophy and concepts discussed as well as the decision and selections made. PASS objectives are: a) Develop confidence in SAA and on-orbit servicing, assembly and manufacturing (OSAM) technologies by executing a test campaign that uses a path-to-flight autonomous precision assembly process directly applicable to future space telescopes. b) Test autonomous technologies including automated path planning and error recovery, to emphasize a robust approach that relies on generic robots and special purpose tools. c) Validate critical component models using a digital twin that includes the assembled primary mirror support structure and assembly process. A digital twin is a high-fidelity simulation of the asset capable of predicting the on-orbit performance. The paper concludes after identifying the critical need for a modest assembly flight experiment to validate and develop confidence in the SAA paradigm, thus accelerating adoption of the benefits described. SAA is a game changing paradigm that enhances the ability of an organization to infuse new technology through rapid evolution of PAs while leveraging OSAM technologies.

Structural Modeling↗

DOE OSTI2016

Sequential programmable self-assembly: Role of cooperative interactions

Here, we propose a general strategy of “sequential programmable self-assembly” that enables a bottom-up design of arbitrary multi-particle architectures on nano- and microscales. We show that a naive realization of this scheme, based on the pairwise additive interactions between particles, has fundamental limitations that lead to a relatively high error rate. This can be overcome by using cooperative interparticle binding. The cooperativity is a well known feature of many biochemical processes, responsible, e.g., for signaling and regulations in living systems. Here we propose to utilize a similar strategy for high precision self-assembly, and show that DNA-mediated interactions provide a convenient platform for its implementation. In particular, we outline a specific design of a DNA-based complex which we call “DNA spider,” that acts as a smart interparticle linker and provides a built-in cooperativity of binding. We demonstrate versatility of the sequential self-assembly based on spider-functionalized particles by designing several mesostructures of increasing complexity and simulating their assembly process. This includes a number of finite and repeating structures, in particular, the so-called tetrahelix and its several derivatives. Due to its generality, this approach allows one to design and successfully self-assemble virtually any structure made of a “GEOMAG” magnetic construction toy, out of nanoparticles. According to our results, once the binding cooperativity is strong enough, the sequential self-assembly becomes essentially error-free.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRS2019

Fast Steering Mirror Disturbance Effects on Overall System Optical Performance for the Large Ultraviolet/optical/infrared Surveyor (LUVOIR) Concept Using a Non-Contact Vibration Isolation and Precision Pointing System

As the optical performance requirements of space telescopes get more stringent, the need to analyze all possible error sources early in the mission design becomes critical. One large telescope with tight performance requirements is the Large Ultraviolet / Optical / Infrared Surveyor (LUVOIR) concept. The LUVOIR concept includes a 15-meter-diameter segmented-aperture telescope with a suite of serviceable instruments operating over a range of wavelengths between 100nm to 2.5um. Using an isolation architecture that involves no mechanical contact between the telescope and the host spacecraft structure allows for tighter performance metrics than current space-based telescopes being flown. Because of this separation, the spacecraft disturbances can be greatly reduced and disturbances on the telescope payload contribute more to the optical performance error. A portion of the optical performance error comes from the disturbances generated from the motion of the Fast Steering Mirror (FSM) on the payload. Characterizing the effects of this disturbance gives insight into the specifications on the FSM needed to achieve the tight optical performance requirements of the overall system. Through analysis of the LUVOIR finite element model and linear optical model given a range of input disturbances at the FSM, the optical performance of the telescope and recommendations for FSM specifications can be determined. The LUVOIR observatory control strategy consists of a multi-loop control architecture including the spacecraft Attitude Control System (ACS), Vibration Isolation and Precision Pointing System (VIPPS), and FSM. This paper focuses on the control loop containing the FSM disturbances and their effects on the telescope optical performance.

Sacks, Lia W.↗

DOE OSTI2015

SU-D-BRD-01: An Automated Physics Weekly Chart Checking System Supporting ARIA

Purpose: A software tool was developed in this study to perform automatic weekly physics chart check on the patient data in ARIA. The tool accesses the electronic patient data directly from ARIA server and checks the accuracy of treatment deliveries, and generates reports which summarize the delivery history and highlight the errors. Methods: The tool has four modules. 1) The database interface is designed to directly access treatment delivery data from the ARIA database before reorganizing the data into the patient chart tree (PCT). 2) PCT is a core data structure designed to store and organize the data in logical hierarchies, and to be passed among functions. 3) The treatment data check module analyzes the organized data in PCT and stores the checking results into PCT. 4) Report generation module generates reports containing the treatment delivery summary, chart checking results and plots of daily treatment setup parameters (couch table positions, shifts of image guidance). The errors that are found by the tool are highlighted with colors. Results: The weekly check tool has been implemented in MATLAB and clinically tested at two major cancer centers. Javascript, cascading style sheets (CSS) and dynamic HTML were employed to create the user-interactive reports. It takes 0.06 second to search the delivery records of one beam with PCT and compare the delivery records with beam plan. The reports, saved in the HTML files on shared network folder, can be accessed by web browser on computers and mobile devices. Conclusion: The presented weekly check tool is useful to check the electronic patient treatment data in Varian ARIA system. It could be more efficient and reliable than the manually check by physicists. The work was partially supported by a research grant from Varian Medical System.

60 APPLIED LIFE SCIENCES↗

NASA NTRS2015

Composition, Structure and Formation of Low-Density Planets Within 0.5 AU of Their Star

Kepler has discovered that tens of percent of sunlike stars possess one or more planets larger than Earth within 0.5 AU. Masses of dozens of small and mid-sized exoplanets have been measured using radial velocity or transit timing variations. Few transiting planets larger than 1.6 Earth radii are rocky. Rather, the planetary mass-radius diagram for planetary radius between 1.6 and 8 times that of Earth shows a tendency for mass to increase slowly with size. The scatter is larger than can be explained by observational errors and correlations with temperature, implying that the population is heterogeneous. Many Neptune-size planets have very low densities and must have a substantial fraction of their volumes occupied by hydrogen and/or helium. Models of the structure, growth and evolution of planets made of mixtures of rock and light gases will be presented and compared with observations of both individual bodies and of the characteristics of the population as a whole.

radial velocity↗

DOE OSTI2019

Exactly and Easily Applying Experimental Boundary Conditions in Computational Structural Dynamics

Most experimental setups and environment specifications define acceleration loads on the component. However, Sierra Structural Dynamics cannot apply acceleration boundary conditions in modal transient analysis. Modal analysis of these systems and environments must be done through the application of a huge artificial force to a large fictitious point mass. Introducing a large mass into the analysis is a common source of numerical error. In this report we detail a mathematical procedure to directly apply acceleration boundary conditions in modal analyses without the requirement of adding a non-physical mass to the system. We prototype and demonstrate this procedure in Matlab and scope the work required to integrate this procedure into Sierra Structural Dynamics.

97 MATHEMATICS AND COMPUTING↗