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This presentation discusses the development and results of composite patch repair perfromed at Kennedy Space Center. This includes impact damage, patch repair methods, nondestructive evaluation, and edgewise compression testing.
The Common Habitat Architecture seeks to increase the habitability of long-duration human spaceflight systems. A key aspect of this is vehicle survivability. Missions beyond low Earth orbit need onboard capabilities for Repair, Maintenance, And Fabrication (RMAF) to overcome potential contingency scenarios. Strategies employed in historic human spaceflight such as redundancy management, reliability, sparing, orbital replacement units, and aborts may be insufficient by themselves. Based on subject matter input, a list of 53 critical failures defining a set of incidents that can render a key spacecraft subsystem inoperable were generated. A subsequent analysis found that a robust in-space RMAF system capable of performing 14 key functions can potentially repair a subsystem plagued by any of these failures. An ancillary benefit is this capability may provide psychological benefits to the crew, by enabling greater self-sufficiency in earth-independent problem solving. A basic RMAF facility has been defined for the Common Habitat, consisting of five workstations. A work bench and computer workstation provide a multipurpose horizontal work surface, computing interface, and tools storage. A CNC machining center provides a subtractive manufacturing capability for metals and plastics. A multi-material 3D printing facility provides additive manufacturing capabilities for plastic, metals, and printed electronics. A welding facility is used for joining metal components where a higher strength is needed than can be achieved with fasteners or adhesives. A glovebox facility is used to perform work that is too hazardous for any of the other workstations. This may include hardware brought in from outside the spacecraft that could potentially contaminate the cabin environment. Forward work includes considering the accommodation of additional manufacturing processes not modeled in the current system, assessing the ability of systems to operate in partial gravity and microgravity environments, incorporation of the system into the Common Habitat Computer Aided Design (CAD) model, bottoms-up mass estimating, and a crew time analysis.
Punctures in thin-walled aluminum pressure vessels are repaired by plugging the hole with an interference-fit disc and welding the unit. The repaired vessels withstood test pressures in excess of vessel ultimate design values for 2-, 4-, and 6-inch holes in 0.202-inch-thick aluminum alloy parent material.
Damaged metallic honeycomb panels can be repaired by drilling holes and welding breakaway studs to both facing sheets. Minimal heat required for welding reduces distortion of highly stressed panels. Repairs can be made without the use of doublers and with greater strength when doublers are used.
Vertical steel tubular pins restore the shear strength of honeycomb panels and improve the quality of the repaired panel. New repair method eliminates diagonal pins. Vertical pins are welded to face sheets, forming ''Vierendeel Truss'' arrangement to transmit shear loads.
The spares and repair parts program for the ultraviolet spectrometer experiment is outlined. The plan includes information on the selection, purchase, acceptance, and storage of spare parts, and on repair procedures.
A review of past failures indicates that module exchange can satisfy most repair requirements of communications satellites. Emphasis is placed on the design of a serviceable communications satellites with 20 modules, on the development of an on-orbit servicer designed to remove failed modules from a body-stabilized spacecraft and to replace them with good modules, and on servicing operations. Benefits of servicing or repair include increased satellite availability, increased reliability, decreased life cycle costs, replacement of worn-out items, installation of updated equipment, and correction of design failures. The use of servicing instead of replacement could result in cost savings in excess of 40 percent. Significant savings are possible when the lifetime of a program is long relative to the satellite lifetime.
Inexpensive technique avoids high temperatures that deform thin stainless steel plates. Because repair disks have small diameters, repaired area can sustain greater loads that larger unsupported areas of faceplate.
The average time required to discover and repair anomalies which appear randomly in the end-to-end tests performed after program completion is evaluated. A model which explains anomaly discovery and repair phenomena when applied to variations in work load and multiple-stage testing is presented. The theory shows that estimates of anomaly levels and team capability can be predicted after a significant fraction of the anomalies have been found, and indicates procedures for applying these figures to schedule estimation and work-load assignment. Of particular interest is the demonstration that end-to-end testing of programs in other than the operational environment is not generally cost effective.
This study examined the effects of varying certain important geometric parameters on the stresses in an adhesive repair of a thin composite laminate. The repair, a planar scarf joint with a doubler, was studied using finite element methods at scarf angles of 6 deg and 12 deg, damage lengths between 2.5 mm and 25 mm and doubler overlaps between 10 mm and 40 mm. Finite element models also showed that significant stress peaks occur at the ends of the scarf joint adhesive, similar to shear lag phenomena in lap joints. A bending model of the planar scarf joint with a doubler, based on mechanics of materials theory, was also developed.
Tetraethyl orthosilicate (TEOS) mixture fills chips and cracks in glazed tile surface. Filler is made by mixing hydrolyzed TEOS, silicon tetraboride powder, and pulverized tile material. Repaired tiles survived testing by intense acoustic emissions, arc jets, and intense heat radiation. Repair is reliable and rapid, performed in 1-1 1/2 hours with tile in any or orientation.
A thermal protection system (TPS) flight repair kit required for use on a flight of the Space Transportation System is defined. A means of making TPS repairs in orbit by the crew via extravehicular activity is discussed. A cure in place ablator, a precured ablator (large area application), and packaging design (containers for mixing and dispensing) for the TPS are investigated.
Experimental and analytical investigations of scarf joints indicate that slight bluntness of adherend tips induces adhesive stress concentrations which significantly reduce joint strength, and the stress distribution through the adhesive thickness is non-uniform and has significant stress concentrations at the ends of the joint. The laminate stacking sequence can have important effects on the adhesive stress distribution. A significant improvement in joint strength is possible by increasing overlap at the expense of raising the repair slightly above the original surface. Although a surface grinder was used to make most experimental specimens, a hand held rotary bur can make a surprisingly good scarf. Scarf joints wit doublers on one side, such as might be used for repair, bend under tensile loads and may actually be weaker than joints without doublers.
Self-repairing digital flight control systems and aircraft battle damage repair are addressed.
The Ti-5Al-2.5Sn extremely low interstitial alloy employed in the large castings which form the critical attachment fittings of the Space Shuttle External Tank was selected because of its high fracture resistance at cryogenic temperatures. Casting was selected over alternative fabrication methods because of its lower cost and adaptability to design changes, although it was found necessary to weld-repair surface and subsurface casting defects in order to reduce the scrap rate and maintain the inherent cost advantage of the castings. Hot Isostatic Pressing was experimentally found to heal the surface and internal defects of the castings, but did not improve tensile or fracture properties and was therefore rejected as a production technique. Production castings are instead weld-repaired, without any mechanical property degradation.
The notion that injury to mitochondrial DNA is a cause of intrinsic aging was tested by correlating the different respiration rates of several wild strains of Drosophila melanogaster with the life-spans. Respiration rate and aging in a mutant of D. melanogaster deficient in postreplication repair were also investigated. In agreement with the rate of living theory, there was an inverse relation between oxygen consumption and median life-span in flies having normal DNA repair. The mutant showed an abnormally low life-span as compared to the controls and also exhibited significant deficiency in mating fitness and a depressed metabolic rate. Therefore, the short life-span of the mutant may be due to the congenital condition rather than to accelerated aging.
About three years after the Goldstone Deep Space Station antenna was dedicated, grout under the hydrostatic bearing runner was found to be interacting with the runner, causing rust to form between the runner and the sole plates upon which it rests. The rust formed unevenly and the runner could not be kept flat so in 1969 the grout was removed and replaced with a Portland cement and sand dry pack grout that was less likely to produce rust. In the years that followed, oil leaking from the runner assembly caused progressive deterioration of the drypack grout. In 1982 over one thousand hours of spacecraft tracking time were lost due to this deterioration. A plan was developed to rehabilitate the bearing. The plan called for raising the rotating structure free from the concrete pedestal and placing it on three pairs of external support columns. With the weight of the structure transferred to the columns, the pads and runner could be removed and the repair started. The very successful repair included the replacement of a significant portion of the antenna pedestal.
Goals of the recently repaired Solar Maximum Mission Observatory are outlined, including continued emphasis on diagnosing impulsive phase of flares, studies of prominence and coronal plasmas, solar cycle variations of flares, the corona and solar irradiance, and comets. Some preliminary observations taken after the repair are shown, particularly of the X13 flare of April 1984.