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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 step typically involves a large cost and time investment. 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. Five lessons learned are presented herein to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five 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 identified and discussed.

Lessons Learned

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

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

Combined Loads Test Fixture for Thermal-Structural Testing Aerospace Vehicle Panel Concepts

A structural test requirement of the National Aero-Space Plane (NASP) program has resulted in the design, fabrication, and implementation of a combined loads test fixture. Principal requirements for the fixture are testing a 4- by 4-ft hat-stiffened panel with combined axial (either tension or compression) and shear load at temperatures ranging from room temperature to 915 F, keeping the test panel stresses caused by the mechanical loads uniform, and thermal stresses caused by non-uniform panel temperatures minimized. The panel represents the side fuselage skin of an experimental aerospace vehicle, and was produced for the NASP program. A comprehensive mechanical loads test program using the new test fixture has been conducted on this panel from room temperature to 500 F. Measured data have been compared with finite-element analyses predictions, verifying that uniform load distributions were achieved by the fixture. The overall correlation of test data with analysis is excellent. The panel stress distributions and temperature distributions are very uniform and fulfill program requirements. This report provides details of an analytical and experimental validation of the combined loads test fixture. Because of its simple design, this unique test fixture can accommodate panels from a variety of aerospace vehicle designs.

Fields, Roger A.

Reliability-based econometrics of aerospace structural systems: Design criteria and test options

The design criteria and test options for aerospace structural reliability were investigated. A decision methodology was developed for selecting a combination of structural tests and structural design factors. The decision method involves the use of Bayesian statistics and statistical decision theory. Procedures are discussed for obtaining and updating data-based probabilistic strength distributions for aerospace structures when test information is available and for obtaining subjective distributions when data are not available. The techniques used in developing the distributions are explained.

Thomas, J. M.

Improving Structural Test and Analysis Correlation Using Digital Image Correlation Boundary Measurements

Simplified idealizations, such as clamped or simply supported, are commonly used as support boundary conditions in modeling and analysis of tested aerospace structures. However, these simplifications are not always appropriate and characterization of the response of non-rigid boundaries is often required to improve test and analysis correlation. While e analysis models are typically modified to better represent the test, this modification is often not practical due to the complexities of the boundary response. A study is conducted to examine the use of digital image correlation (DIC) to measure the boundary support structure response and then to adjust the test data to remove the effects of the boundary response in order to improve test and analysis correlation. A high-aspect ratio composite wing test is the subject of the study. Three sources of boundary flexibility contributing to rigid body rotation of the test wing are identified and quantified using both DIC and conventional test data. The wing displacement test data are adjusted using DIC data for these sources. Wing displacement test data is also adjusted using direct measurement of wing rotation from a DIC system that monitored the top surface, root region of the wing, and using available conventional instrumentation. The adjusted data exhibits improved test and analysis correlation and demonstrated the benefit of using DIC along with conventional instrumentation to collect and interpret test data.

Andrew E Lovejoy

Space Launch System Mobile Launcher Modal Pretest Analysis

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation from the Vehicle Assembly Building out to the launch pad, and provides the launch platform at the launch pad. The previous Saturn/Apollo and Space Shuttle programs had integrated vehicle ground vibration tests of their integrated launch vehicles performed with simulated free-free boundary conditions to experimentally anchor and validate structural and flight controls analysis models. For the Space Launch System program, the Mobile Launcher will be used as the modal test fixture for the ground vibration test of the first Space Launch System flight vehicle, Exploration Mission ? 1( now referred to as Artemis 1), programmatically referred to as the Integrated vehicle modal test. The Integrated vehicle modal test of the Exploration Mission - 1 integrated launch vehicle will have its core and second stages unfueled while mounted to the ML while inside the Vehicle Assembly Building, which is currently scheduled for the late spring or early summer of 2020. The Space Launch System program has implemented a building block approach for dynamic model validation. The modal test of the Mobile Launcher is an important part of this building block approach in supporting the integrated vehicle modal test since the Mobile Launcher will serve as a structurally dynamic test fixture whose modes will couple with the modes of the Exploration Mission ? 1 test vehicle. The Mobile Launcher modal test will further support understanding the structural dynamics of the Mobile Launcher and SLS during rollout to the launch pad, which will play a key role in better understanding and prediction of the rollout forces acting on the launch vehicle. The Mobile Launcher modal test is currently scheduled for the summer of 2019. Due to a very tight modal testing schedule, this Mobile Launcher modal pretest analysis has been performed to ensure there is a high likelihood of being able to successfully complete the modal test (i.e. identify the primary target modes) using the planned instrumentation, shakers, and excitation types. This paper will discuss this Mobile Launcher modal pretest analysis and the unique challenges faced due to the Mobile Launcher's size and weight, which are typically not faced when modal testing aerospace structures.

Akers, James C.

Space Launch System Mobile Launcher Modal Pretest Analysis

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation from the Vehicle Assembly Building out to the launch pad, and provides the launch platform at the launch pad. The previous Saturn/Apollo and Space Shuttle programs had integrated vehicle ground vibration tests of their integrated launch vehicles performed with simulated free-free boundary conditions to experimentally anchor and validate structural and flight controls analysis models. For the Space Launch System program, the Mobile Launcher will be used as the modal test fixture for the ground vibration test of the first Space Launch System flight vehicle, Artemis 1, programmatically referred to as the integrated vehicle modal test. The integrated vehicle modal test of the Artemis 1 integrated launch vehicle will have its core and second stages unfueled while mounted to the Mobile Launcher while inside the Vehicle Assembly Building, which is currently scheduled for the summer of 2020. The Space Launch System program has implemented a building block approach for dynamic model validation. The modal test of the Mobile Launcher is an important part of this building block approach in supporting the integrated vehicle modal test since the Mobile Launcher will serve as a structurally dynamic test fixture whose modes will couple with the modes of the Artemis 1 integrated vehicle. The Mobile Launcher modal test will further support understanding the structural dynamics of the Mobile Launcher and Space Launch System during rollout to the launch pad, which will play a key role in better understanding and prediction of the rollout forces acting on the launch vehicle. The Mobile Launcher modal test is currently scheduled for the summer of 2019. Due to a very tight modal testing schedule, this independent Mobile Launcher modal pretest analysis has been performed to ensure there is a high likelihood of successfully completing the modal test (i.e. identify the primary target modes) using the planned instrumentation, shakers, and excitation types. This paper will discuss this Mobile Launcher modal pretest analysis for its three test configurations and the unique challenges faced due to the Mobile Launcher’s size and weight, which are typically not faced when modal testing aerospace structures.

Akers, James C.

NASA Armstrong State of Discipline

- AFRC’s Overview Statement - AFRC is NASA's primary center for high-risk, atmospheric flight research and ground testing on modified or unique research vehicles and test articles - AFRC’s L&D Facility - Flight Loads Lab (FLL): High-bay test area with flight line access for large-scale structural & thermal testing of aerospace structures for component and airframe qualification/airworthiness & research - AFRC’s L&D Expertise - Mainly supports projects in the Aeronautics Research Mission - Aeroelasticity, Model Tuning, FEM & Flutter Analysis Airworthiness Clearance support - Modal Testing, Mass Property Testing & Flight Testing

Natalie Spivey

Soft Soil Impact Testing and Simulation of Aerospace Structures

In June 2007, a 38-ft/s vertical drop test of a 5-ft-diameter, 5-ft-long composite fuselage section that was retrofitted with a novel composite honeycomb Deployable Energy Absorber (DEA) was conducted onto unpacked sand. This test was one of a series of tests to evaluate the multi-terrain capabilities of the DEA and to generate test data for model validation. During the test, the DEA crushed approximately 6-in. and left craters in the sand of depths ranging from 7.5- to 9-in. A finite element model of the fuselage section with DEA was developed for execution in LS-DYNA, a commercial nonlinear explicit transient dynamic code. Pre-test predictions were generated in which the sand was represented initially as a crushable foam material MAT_CRUSHABLE_FOAM (Mat 63). Following the drop test, a series of hemispherical penetrometer tests were conducted to assist in soil characterization. The penetrometer weighed 20-lb and was instrumented with a tri-axial accelerometer. Drop tests were performed at 16-ft/s and crater depths were measured. The penetrometer drop tests were simulated as a means for developing a more representative soil model based on a soil and foam material definition MAT_SOIL_AND FOAM (Mat 5) in LS-DYNA. The model of the fuselage with DEA was reexecuted using the updated soil model and test-analysis correlations are presented.

Fasanella, Edwin L.

Evaluation of Conservatism in Low Frequency Vibration Test Control

Aerospace structures are typically qualified for low frequency flight environments by using a swept-sine vibration test method. However, this ground testing has a tendency to produce substantial overtesting at certain frequencies. This paper presents an evaluation of the response conservatism present with a typical swept-sine and two transient vibration tests when applied to a typical spacecraft component. The absolute conservatism between a typical launch transient response and the test environment responses is measured using alternative characterizations of transient vibrations previously used in shock testing. The characterizations used include the Shock Intensity Spectrum, Shock Response Spectrum, Acceleration Root Mean Square in both frequency and time domains, and Ranked Peaks. Control of the test/flight conservatism is shown to be possible through the overtest factor (OTF) parameter.

Conservatism

Theory to test comparisons for selected aerospace multishell structures and their interfaces under thermomechanical loadings

Guidelines for structural shell analyses were obtained on the basis of theory-to-test comparisons made on two large-scale aerospace structures subject to thermomechanical loads. The first structural test was the cylindrical aluminum skin-stringer-ring construction of the S-IC forward skirt and S-II interstage. The second structural test included the truncated, cone-shaped, bonded honeycomb sandwich shell of the Spacecraft Lunar Module Adapter; the cylindrical bonded aluminum honeycomb sandwich construction of the Instrument Unit; and the skin-stringer construction with rings and intercostals of the S-IVB forward skirt. Analyses were made for loadings simulating the flight environment. Elementary shear lag theory was superimposed on shell analysis for interface junctions between stages to obtain favorable theory-to-test stress comparisons.

Ferdie, R. D.

Acceleration Testing: A Better, Faster, Cheaper Alternative for Strength Qualification Testing

This paper addresses the advantages of utilizing a centrifuge test over the conventional static load test methods to structurally qualify aerospace structures. Three recent test cases are reviewed and used as examples to highlight these benefits. In addition, the overall capability of Goddard's High Capacity Centrifuge (HCC) is outlined along with some unique features that were designed specifically to reduce costs, test turn around time, and increase test item safety.

Mattiello, Carmine F.

Predicted vibration responses of Apollo structure and effects of pressure correlation lengths on response

Progressive wove and reverberant acoustic fields ore often used in the laboratory for qualification testing of aerospace structures that are subjected to unsteady aerodynamic environments which occur during flight through the atmosphere. Acoustic simulation of these in-flight environments i s achieved i f the structural vibration response to acoustic excitation is equivalent, over the frequency range of interest, to the response caused by aerodynamic turbulence. To determine the degree of response simulation that could be expected for such qualification testing of the Apollo Spacecraft, responses of a segment of the Apollo structure were estimated theoretically for both acoustic and flight environments. The vibration analysis presented in this report was performed for the Spacecraft Lunar Module Adaptor; and the three environments treated are turbulence at Mach 1 and Mach 2, a reverberant acoustic field, and a modified acoustic progressive wave field. The progressive wave field is assumed to be generated within a specially designed shroud of sixteen axially oriented ducts which is constructed around and contoured to the external skin of the vehicle. Each duct is open on the side adjacent to the skin and is driven acoustically at one end by an independent noise source, thus allowing for different pressure correlation patterns around the circumference of the vehicle. The purpose of the analysis was to determine the effects of surface pressure correlation lengths on the response characteristics of representative Apollo structure, and to select on this basis, the optimum acoustic environment for structural vibration qualification tests of the Apollo in the Spacecraft Acoustic Laboratory at MSC. The method of analysis employed consists of determining, independently, the space average, mean-square acceleration spectral density for each of the significant modes of vibration of an equivalent cylindrical shell, and then expressing the total structural response as a linear summation of these modal responses. Approximately 570 classical modes of a pinned-end cylinder were used in order to find the spectral response characteristics of the structure throughout the frequency range of 10 - 1,000 Hz. The effective forcing functions or joint acceptances of the various modes of vibration were computed and are presented graphically for each of the pressure excitation environments. A brief development of the response equations used is presented in the report. Space average acceleration response spectra were computed for twelve different cases including aerodynamic turbulence at Mach 1 and Mach 2, reverberant acoustic field, five duct correlation patterns, two cases of an axially damped progressive wave field, and two cases in which the structural damping constant was varied from the expected value. The response spectra were computed and plotted by a high speed digital computer far a flat excitation pressure spectrum; and the response spectra were numerically integrated to give one-third octave bond average responses. A complete set of digital computer programs has been developed for both flat plate and cylindrical shell structures for the above environments, and each requires run times of three minutes or less. Thus, the work presented herein, along with the results, constitutes a practical advancement to the existing state-of-the-art of vibration prediction.

R W White

Experimental Evaluation of Fatigue Crack Initiation from Corroded Hemispherical Notches in Aerospace Structural Materials

A test program was developed and executed to evaluate the influence of corroded hemispherical notches on the fatigue crack initiation and propagation in aluminum 7075-T7351, 4340 steel, and D6AC steel. Surface enhancements such as shot peening and laser shock peening were also incorporated as part of the test effort with the intent of improving fatigue performance. In addition to the testing, fracture mechanics and endurance limit based analysis methods were evaluated to characterize the results with the objective of challenging typical assumptions used in modeling fatigue cracks from corrosion pits. The results specifically demonstrate that the aluminum and steel alloys behave differently with respect to fatigue crack initiation from hemispherical corrosion pits. The aluminum test results were bounded by the fracture mechanics and endurance limit models while exhibiting a general insensitivity to the residual stress field generated by shot peening. The steel specimens were better characterized by the endurance limit fatigue properties and did exhibit sensitivities to residual stresses from the shot peening and laser shock peening

Garcia, Daniel B.

Enhanced Capabilities of the NASA Langley Thermal Acoustic Fatigue Apparatus

This paper presents newly enhanced acoustic capabilities of the Thermal Acoustic Fatigue Apparatus at the NASA Langley Research Center. The facility is a progressive wave tube used for sonic fatigue testing of aerospace structures. Acoustic measurements for each of the six facility configurations are shown and comparisons with projected performance are made.

Rizzi, Stephen A.