Engineering topics
Publications and source records attributed to Dunn, T. J..
Structural members of any size, consisting of wire gridwork, fabricated onsite. Rigid beam or column formed from intersecting helices and straight members of relatively flexible wire. Wires joined at their intersections: short wire sections between joints therefore approximate sides of rigid triangular structural subunits. Although originally intended for manufacturing large structures in space, technique has potential for use on Earth.
Panels held securely with minimum of mounting hardware. Each panel held in place by single screw that pulls it into flat shape from its original shallow-dish shape. Shape and prestressing make panel stiff: resists vibration and withstands large mechanical loads. Panel shape and mounting arrangement not limited to thermal-protection systems but also used on aircraft, building walls, or wherever large surfaces must be covered with stiff, flat sheets easily removed for maintenance.
A hexagonal protective and high temperature resistant system for the Space Shuttle Orbiter consists of a multiplicity of pockets formed by hexagonally oriented spacer bars secured on the vehicle substructure. A packing of low density insulating batt material 18 in each pocket, and a thin protective panel of laterally resilient advanced carbon-carbon material surmounting the peripherals bars and packing. Each panel has three stepped or offset lips on contiguous edges. At the center of each pocket is a fully insulated stanchion secured to and connecting the substructure and panel for flexing the panel toward the substructure and thereby prestressing the panel and forcing the panel edges firmly against the spacer bars.
Graphite, glass, and resin composite is very strong, stiff, and thermally stable. As mounting material for antennas, mirrors and lenses, composite minimizes structural distortion and misalignment. Rods of substance are made by pulling preimpregnated ribbon of glass and graphite through die. When materials are combined in proper proportion, graphite contracts, and glass and resin expand as temperature increases. Matrix for fiber may be polysulfane, epoxy, polyimide, or othe resin.
The paper examines a construction capability to build large structures in space, its use in conjunction with the Shuttle Orbiter and a large Space Construction Base, and its relationship to system performance and cost. The geodetic beam design using a tetrahedral truss structure and reinforced plastics and its structural analysis, tests of demonstration cylinders, and preliminary machine design are discussed. The geodetic structure is shown to have high buckling stability, low thermal distortion, high stiffness, and its simple shape permits high-production-rate automatic fabrication. The geodetic beam fabrication machine which will automatically fabricate cylindrical beams in space from earth-prefabricated rods, and on-orbit beam and platform fabrication are described. Preliminary results of system performance and cost studies indicate that on-orbit fabrication using a small geodetic beam machine can be economically superior to the deployable and erectable modes of construction for many near term applications.