Joint preload properties of structural threaded fasteners
Proper installation techniques are described and reliable torque-tension values are presented on joint preload /or clamp load/ properties of structural threaded fasteners.
Brenner, H. S.↗
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Ultrasonic Inspection During Autoclave Cure of Reflowable-Interface Composite Joints
In structural bonds, the interface between adherend and adhesive is nearly two-dimensional making the interface susceptible to minute quantities of contamination, which can cause weak bonds. Regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded primary-structures due to uncertainty in bond performance. To address this issue, the NASA Convergent Aeronautics Solutions (CAS): Adhesive Free Bonding of Composites (AERoBOND) project is investigating reformulated aerospace epoxy-matrix resins to enable reflow and diffusion of the resin at the joint interface during a secondary bonding and cure process that can eliminate the material discontinuity at the interface. Implementing in-situ process monitoring enables assessing the bond quality during processing rather than waiting for post-fabrication mechanical testing to be completed. In this paper, an in-situ ultrasonic inspection system is used to monitor the joining of three composite laminates assembled using the AERoBOND technique. For each panel, the amplitude of the wave reflection at the joint was measured throughout the cure cycle. The results indicate the timing and extent of reflow and cure of the epoxy resin at the joint. Factors indicating end of cure were ascertained and a metric was developed to qualitatively predict acceptable mode-II fracture toughness based on the ultrasonic amplitude at the joint line during cure. In addition, since the inspection system scans an area of the joint, high-resolution localized results can be obtained across the joint.
Tyler B Hudson↗
Simulating the Structural Response of a Preloaded Bolted Joint
The present paper describes the structural analyses performed on a preloaded bolted-joint configuration. The joint modeled was comprised of two L-shaped structures connected together using a single bolt. Each L-shaped structure involved a vertical flat segment (or shell wall) welded to a horizontal segment (or flange). Parametric studies were performed using elasto-plastic, large-deformation nonlinear finite element analyses to determine the influence of several factors on the bolted-joint response. The factors considered included bolt preload, washer-surface-bearing size, edge boundary conditions, joint segment length, and loading history. Joint response is reported in terms of displacements, gap opening, and surface strains. Most of the factors studied were determined to have minimal effect on the bolted-joint response; however, the washer-bearing-surface size affected the response significantly.
Knight, Norman F., Jr.↗
Comparison of structural performance of one- and two-bay rotary joints for truss applications
The structural performance of one- and two-bay large-diameter discrete-bearing rotary joints was addressed for application to truss-beam structures such as the Space Station Freedom. Finite element analyses are performed to determine values for rotary joint parameters that give the same bending vibration frequency as the parent truss beam. The structural masses and maximum internal loads of these joints are compared to determine their relative structural efficiency. Results indicate that no significant difference exists in the masse of one- and two-bay rotary joints. This conclusion is reinforced with closed-form calculations of rotary joint structural efficiency in extension. Also, transition truss-member loads are higher in the one-bay rotary joint. However, because of the increased buckling strength of these members, the external load-carrying capability of the one-bay concept is higher than that of the two-bay concept.
Vail, J. Douglas↗
Mechanisms of Oxide Formation in the Self-Reacting Friction Stir Weld Process
The initial objective of this study was to evaluate the effect of an extended delay time between preweld cleaning and the completion of a self-reacting friction stir welding (SRFSW) process on the resulting quality of various thickness panels of AA2219-T87. The current NASA standard specifies no more than a 48 hour delay between preweld cleaning and actual welding. The concern is whether increasing the cleaning delay time results in development of the residual oxide defect (ROD) in SRFSW. This concern emanates from the possibility of increased time correlating with increased oxide layer thickness on the faying surfaces. Oxide content on the faying surfaces has been reported to correlate with the occurrence of the ROD which reduces mechanical properties. When the SRFSW process was first adopted by the NASA Marshall Space Flight Center (MSFC), unexpected low tensile values that resulted were attributed to oxides within the weld that appeared to follow the former faying surface contours. Mitigation of the ROD was achieved through a combination of modifications to the processing parameters, tool designs, and incorporation of a weld seam offset. Two operations are involved in preweld cleaning: the first is removal of oil and grease, and the second is removal of surface oxides. In arc welding, improper cleaning of the faying surfaces of aluminum welded joints can increase the sensitivity toward development of defects. As the aluminum is locally melted, these contaminants contribute toward the development of porosity, inclusions, entrapped oxides, and other discontinuities which can degrade the strength of the weld joint. For weldment of large structures, the weld joint is typically cleaned, fit-up, and tack welded prior to the final full penetration welding pass. Because of the stringent joint fit-up requirements for mismatch and peaking for launch vehicle structures, the joint fit-up can sometimes contribute to lengthy delays between cleaning and tack welding, especially for circumferential weld joints on large diameter components. When the conventional friction stir welding (CFSW) process was introduced at the NASA MSFC, there was no procedure for cleaning prior to the solid-state joining process. As the process expanded to include SRFSW, preparation of the faying, crown, and root surfaces were implemented to overcome the ROD. Although the solid-state process is not expected to reach temperatures high enough for dissociation of the native oxide layer, concern remained regarding the redeposition of the native oxide layer within the stir zone. NASA has previously established the allowable time at 48 hours between preweld cleaning and a SRFSW process. The effect of potential 2 contamination resulting from an extended delay to 188 hours was subsequently evaluated for SRFSWs using tensile testing and metallographic imaging. Tensile specimens were tested at room temperature (RT), and at cryogenic conditions of liquid nitrogen (LN2) and liquid hydrogen. No detrimental effect on weld quality, as determined by weld strength, was reported for cleaning delays of 48, 120, 168, 240 or 288 hours. While no trends were established in this study, which extended the delay from 48 to 188 hours, there were a few outliers in terms of ultimate tensile strength (UTS). According to M. Fisher's 2014 Boeing Company Memo no. EYBF-MAF-14-029, all outliers were above the minimum acceptance criteria, but out of family with respect to the average values. As the robustness and reliability of any process ultimately depends on the average values as well as the outliers, an understanding of the cause of these outliers will ultimately improve the process. This report examines those outliers and their possible causes.
Schneider, J. A.↗
Two-stage gas measurement system
A quick-response, real-time gaseous measurement system allows for the continuous sampling of a low pressure gaseous environment. A sample of test gas from the low pressure gaseous environment is continuously extracted and pumped to a structural tee joint which is open to the atmosphere at one end to maintain the test gas at a constant pressure. The structural tee joint communicates at the other end with a heater for maintaining the test gas at a constant temperature. From the heater, the test gas is sent to a sensor which develops a voltage that is proportional to the partial pressure of the gaseous component to be measured in the test gas, a constant flow rate of test gas being provided through the heater and sensor. Since test gas pressure, temperature, and flow rate are being held constant, changes in sensor voltage are attributable only to changes in the concentration of the measured gas component.
Sprinkle, Danny R.↗
A finite element approach for large motion dynamic analysis of multibody structures in space
A three-dimensional finite element formulation for modeling the transient dynamics of constrained multibody space sructures with truss-like configurations is presented. Convected coordinate systems are used to define rigid-body motion of individual elements in the system. These systems are located at one end of each element and are oriented such that one axis passes through the other end of the element. Deformation of each element, relative to its convected coordinate system, is defined by cubic flexural shape functions as used in finite element methods of structural analysis. The formulation is oriented toward joint dominated structures and places the generalized coordinates at the joint. A transformation matrix is derived to integrate joint degree-of-freedom into the equations of motion of the element. Based on the derivation, a general-purpose code LATDYN (Large Angle Transient DYNamics) was developed. Two examples are presented to illustrate the application of the code. For the spin-up of a flexible beam, results are compared with existing solutions available in the literature. For the deployment of one bay of a deployable space truss (the Minimast), results are verified by the geometric knowledge of the system and converged solution of a successively refined model.
Chang, Che-Wei↗
Stiff, Strong Splice For A Composite Sandwich Structure
New type of splice for composite sandwich structure reduces peak shear stress in structure. Layers of alternating fiber orientation interposed between thin ears in adhesive joint. Developed for structural joint in spar of helicopter rotor blade, increases precision of control over thickness of adhesive at joint. Joint easy to make, requires no additional pieces, and adds little weight.
Schmaling, D.↗
The Load Distribution in Bolted or Riveted Joints in Light-Alloy Structures
This report contains a theoretical discussion of the load distribution in bolted or riveted joints in light-alloy structures which is applicable not only for loads below the limit of proportionality but also for loads above this limit. The theory is developed for double and single shear joints. The methods given are illustrated by numerical examples and the values assumed for the bolt (or rivet) stiffnesses are based partly on theory and partly on known experimental values. It is shown that the load distribution does not vary greatly with the bolt (or rivet) stiffnesses and that for design purposes it is usually sufficient to know their order of magnitude. The theory may also be directly used for spot-welded structures and, with small modifications, for seam-welded structures, The computational work involved in the methods described is simple and may be completed in a reasonable time for most practical problems. A summary of earlier theoretical and experimental investigations on the subject is included in the report.
Vogt, F.↗
Experimental Characterization of Hysteresis in a Revolute Joint for Precision Deployable Structures
Recent studies of the micro-dynamic behavior of a deployable telescope metering truss have identified instabilities in the equilibrium shape of the truss in response to low-energy dynamic loading. Analyses indicate that these micro-dynamic instabilities arise from stick-slip friction within the truss joints (e.g., hinges and latches). The present study characterizes the low-magnitude quasi-static load cycle response of the precision revolute joints incorporated in the deployable telescope metering truss, and specifically, the hysteretic response of these joints caused by stick-slip friction within the joint. Detailed descriptions are presented of the test setup and data reduction algorithms, including discussions of data-error sources and data-filtering techniques. Test results are presented from thirteen specimens, and the effects of joint preload and manufacturing tolerances are investigated. Using a simplified model of stick-slip friction, a relationship is made between joint load-cycle behavior and micro-dynamic dimensional instabilities in the deployable telescope metering truss.
Lake, Mark S.↗
Interlocking wedge joint is easily assembled
Wedge joint links structural members in manual, remote, or automated assemblies. Joint is simple enough to be assembled by undersea divers, workers in nuclear reactors, and other wearing gloves or bulky clothing. Combination of wedging angles on parts overcomes structural misalinements and forces assembly into true position as locking sleeve moves into place. Joint transmits tension, compression, bending moments and torsion and is inherently insensitive to thermal excursions, vibration, and machining tolerance buildup.
Long, M. J.↗
In-space technology flight experiments
The topics presented are covered in viewgraph form. The objectives are: (1) to measure effects of microgravity on the dynamic characteristics of jointed-truss structures (such as space station alpha-joint); and (2) to investigate the dynamics of fluid-spacecraft interaction in 0-G.
Venneri, Samuel L.↗
Microbial community structure at the U.S.-Joint Global Ocean Flux Study Station ALOHA: Inverse methods for estimating biochemical indicator ratios
Modeling biogeochemical fluxes in the marine plankton requires the application of factors for extrapolation of biomass indicators measured in the field (chlorophyll a, adenosine triphosphate, bacterial counts) to biomass carbon or nitrogen. These are often inferred from culture studies and are poorly constrained for natural populations. At least squares inverse method with a simple linear model constrains the values of several common indicator ratios, giving self-consistent solutions that provide useful information about the structure of the microbial community at our North Pacific Ocean study site (Station ALOHA (A Long-term Oligotrophic Habitat Assessment)). These results indicate that the fraction of the microbial biomass that is autotrophic (pigmented) is greater in the mixed layer than at the deep chlorophyll maximum layer and that heterotrophic bacteria are a significant but not necessarily predominant component of the microbial community in the euphotic zone.
Christian, James R.↗
Shear deformation plate continua of large double layered space structures
A simple method is presented to model large rigid-jointed lattice structures as continuous elastic media with couple stresses using energy equivalence. In the analysis, the transition from the discrete system to the continuous media is achieved by expanding the displacements and the rotations of the nodal points in a Taylor series about a suitable chosen origin. The strain energy of the continuous media with couple stresses is then specialized to obtain shear deformation plate continua. Equivalent continua for single layered grids, double layered grids, and three-dimensional lattices are then obtained.
Hefzy, Mohamed Samir↗
Lightweight structural design of a bolted case joint for the space shuttle solid rocket motor
The structural design of a bolted joint with a static face seal which can be used to join Space Shuttle Solid Rocket Motor (SRM) case segments is given. Results from numerous finite element parametric studies indicate that the bolted joint meets the design requirement of preventing joint opening at the O-ring locations during SRM pressurization. A final design recommended for further development has the following parameters: 180 one-in.-diam. studs, stud centerline offset of 0.5 in radially inward from the shell wall center line, flange thickness of 0.75 in, bearing plate thickness of 0.25 in, studs prestressed to 70 percent of ultimate load, and the intermediate alcove. The design has a mass penalty of 1096 lbm, which is 164 lbm greater than the currently proposed capture tang redesign.
Dorsey, John T.↗
Sandia Mechanics Challenge: Predicting the Behavior of Structures with Threaded Fastener Joints in Accidents
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Kramer, Sharlotte LorraineBolyard [Sandia National↗
Sensitivity of Space Station Alpha Joint robust controller to structural modal parameter variations
The baseline design of the photovoltaic-array sun-tracking control system is presented with special attention given to the optimization of design variables related to stability and performance. The procedures utilized to attenuate control/structure interaction are described, and controller sensitivity to variations in structural modal parameters is examined. Constrained optimization techniques determine the stability margin and tracking capability, which are then tested for sensitivity to variations in natural frequency, mode-shape amplitudes, and modal-damping ratios. The effect of variations in the modal parameters of the dominant modes on performance indicators is also examined to optimize tracking-performance responsiveness and satisfy the design requirements. It is concluded that accurate on-orbit modal data are necessary to make the reoptimization procedure effective in improving the performance of the control system.
Kumar, Renjith R.↗
Sensitivity of Space Station alpha joint robust controller to structural modal parameter variations
The photovoltaic array sun tracking control system of Space Station Freedom is described. A synthesis procedure for determining optimized values of the design variables of the control system is developed using a constrained optimization technique. The synthesis is performed to provide a given level of stability margin, to achieve the most responsive tracking performance, and to meet other design requirements. Performance of the baseline design, which is synthesized using predicted structural characteristics, is discussed and the sensitivity of the stability margin is examined for variations of the frequencies, mode shapes and damping ratios of dominant structural modes. The design provides enough robustness to tolerate a sizeable error in the predicted modal parameters. A study was made of the sensitivity of performance indicators as the modal parameters of the dominant modes vary. The design variables are resynthesized for varying modal parameters in order to achieve the most responsive tracking performance while satisfying the design requirements. This procedure of reoptimization design parameters would be useful in improving the control system performance if accurate model data are provided.
Kumar, Renjith R.↗