Loading conditions measured during aerobatic maneuvers
Loading conditions measured during aerobatic maneuvers in flight test to determine structural design requirements for aerobatic-type aircraft
Hall, A. W.↗
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Prediction of hail damage to aircraft.
Description of a hailstone impact simulator, a valuable laboratory apparatus which can be used for such hailstone research as the testing of prospective structural designs or generating data to compare with theory. The simulator consists of a launcher and a velocity-measuring system. It has been successfully used to obtain deformation data on flat sheets and spherical caps of various sizes impacted by hailstones at typical flight velocities. A computer program is described which adequately predicts the damage to a simple structure when impacted by a hailstone.
Hayduk, R. J.↗
Graphite/Polyimide Composites
Technology developed under the Composites for Advanced Space Transportation System Project is reported. Specific topics covered include fabrication, adhesives, test methods, structural integrity, design and analysis, advanced technology developments, high temperature polymer research, and the state of the art of graphite/polyimide composites.
Dexter, H. B.↗
Radial SI latches vibration test data review
Dynamic testing of the Space Telescope Scientific Instrument Radial Latches was performed as specified by the designated test criteria. No structural failures were observed during the test. The alignment stability of the instrument simulator was within required tolerances after testing. Particulates were discovered around the latch bases, after testing, due to wearing at the B and C latch interface surfaces. This report covers criteria derivation, testing, and test results.
Harrison, P. M.↗
HgI2 low energy beta particle detector
An HgI2 device structure was designed and tested which allows HgI2 to be used to make low-energy beta-particle detectors. The devices detected tritium beta particles with an efficiency of about 25 percent. A protective encapsulant has been developed which should protect the devices for up to 20 years and will attenuate only a small fraction of the beta particles. It is noted that the devices hold significant promise to provide a practical alternative to liquid scintillation counters and gas flow-through proportional counters.
Shah, K. S.↗
Preliminary design of a meteoroid/orbital debris shield system for a Mars mission spacecraft
A preliminary design of a spacecraft shield system to defeat meteoroids and orbital debris during a Mars mission is presented. The mission scenario is first defined in terms of stage times which include LEO, transit, low-Mars orbit, and Mars surface periods. The environment definitions for earth-orbital space debris, planetary meteoroids, and interplanetary meteoroids are next introduced. Shield system design approaches incorporate stochastic simulation, hydrocode analyses, hypervelocity impact testing, and optimization techniques. Structural design trades presented include spacecraft configuration, mission schedule, penetration risk, and total standoff distance between the bumper and wall.
Robinson, J. H.↗
Development of thermoplastic composite aircraft structures
Efforts focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. In support of these designs, mechanics developments were conducted in two areas. First, a dissipative strain energy approach to material characterization and failure prediction, developed at the Naval Research Laboratory, was evaluated as a design/analysis tool. Second, a finite element formulation for thick composites was developed and incorporated into a lug analysis method which incorporates pin bending effects. Manufacturing concepts were developed for an upper fuel cell cover. A detailed trade study produced two promising concepts: fiber placement and single-step diaphragm forming. Based on the innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldine concepts. Manufacturing techniques included autoclave consolidation, single diaphragm consolidation (SDCC) and roll-forming.
Renieri, Michael P.↗
ACT/ICAPS: Thermoplastic composite activities
McDonnell Aircraft Company (MCAIR) is teamed with Douglas Aircraft Company (DAC) under NASA's Advanced Composite Technology (ACT) initiative in a program entitled Innovative Composite Aircraft Primary Structures (ICAPS). Efforts at MCAIR have focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. Based on innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldline concepts. Manufacturing techniques included autoclave consideration, single diaphragm co-consolidation (SDCC), and roll-forming.
Renieri, M. P.↗
Recent Development in Structural Verification of Spacecraft
This paper gives a summary discussion of recent developments in the structural design, analysis, and test verification requirements applied to NASA spacecraft.
launch authority developing organization cost-effe↗
Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails
State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.
Fernandez, Juan M.↗
TriTruss Packaging and Deployment Trade Study
An architecture and feasibility study of next generation In-Space Assembled Telescopes (iSAT) concluded that robotic in-space assembly of modular components is necessary to enable large (>15-meter diameter) primary apertures. The iSAT study recommended that the foundational structure be assembled from modular TriTruss modules that are packaged for launch, deployed on-orbit and robotically assembled into the final configuration. This paper will describe and summarize the results of a trade study that investigated viable concept of operations (ConOps) for the packaging and deployment (P&D) of individual planar TriTruss modules that could be assembled to form a large aperture iSAT. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging; has sufficient geometric versatility to be launch vehicle independent; provides a stiff and lightweight structure; has low mechanical complexity; and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept would be kinematically simple and be robotically deployed using a minimum number of specialized tools. In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.
in-space assembly (ISA)↗
TriTruss Packaging and Deployment Trade Study
A trade study was conducted that evaluated viable concepts of operation for the packaging and deployment (P&D) of novel deployable modular truss modules, called TriTruss modules, that can be assembled to form a large aperture In-Space Assembled Telescopes (iSAT). In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging, has sufficient geometric versatility to be launch vehicle independent, provides a stiff and lightweight structure, has low mechanical complexity, and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept should be kinematically simple and be robotically deployed using a minimum number of specialized tools. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have been selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.
in-space assembly (ISA)↗
Overview of the Orion Thermal Protection System
The Orion spacecraft is being developed as part of the Constellation Exploration Program and will serve as the United States crewed transportation system to the International Space Station after the retirement of the Space Shuttle in 2010 and as the eventual means to return U.S. astronauts to the Moon. Therefore, Orion is being designed for reentry missions from both low Earth orbit and from Lunar-return trajectories. This presentation will provide an overview of the development of the Orion TPS, a critical component in the development of the spacecraft. The thermal protection system (TPS) that protects the crew module from the extreme environments associated with Earth atmospheric reentry consists of a forward heatshield and an aft backshell. The requirements that drive the design of the TPS will be discussed, including several key requirements that establish a precedent for U.S. human-rated spacecraft. For the first time in U.S. human spaceflight, a vehicle s TPS is being designed with a specific, derived requirement for reliability. Also, due to the increased presence of spacecraft in Earth s orbit in recent decades, requirements for micro-meteoroid/orbital debris damage tolerance are also a driving requirement that has affected the selection of portions of the TPS. The efforts to select materials and to define a preliminary design for both the heatshield and the backshell will be described. This will include a discussion of the design challenges presented by the numerous penetrations on both the backshell and the heatshield. Finally, the verification and validation plan which is currently under development to certify the TPS for human-rated missions will be outlined. To support the execution of this plan, a ground test campaign for both thermal and structural performance is being designed. This test campaign will directly support thermal and thermal/structural analyses that also are fundamental to the certification effort.
Kowal, T. John↗
Design and fabrication of Rene 41 advanced structural panels
The efficiency was investigated of curved elements in the design of lightweight structural panels under combined loads of axial compression, inplane shear, and bending. The application is described of technology generated in the initial aluminum program to the design and fabrication of Rene 41 panels for subsequent performance tests at elevated temperature. Optimum designs for two panel configurations are presented. The designs are applicable to hypersonic airplane wing structure, and are designed specifically for testing at elevated temperature in the hypersonic wing test structure located at the NASA Flight Research Center. Fabrication methods developed to produce the Rene panels are described, and test results of smaller structural element specimens are presented to verify the design and fabrication methods used. Predicted strengths of the panels under several proposed elevated temperature test load conditions are presented.
Greene, B. E.↗
Hybrid Residual Flexibility/Mass-Additive Method for Structural Dynamic Testing
A large fixture was designed and constructed for modal vibration testing of International Space Station elements. This fixed-base test fixture, which weighs thousands of pounds and is anchored to a massive concrete floor, initially utilized spherical bearings and pendulum mechanisms to simulate Shuttle orbiter boundary constraints for launch of the hardware. Many difficulties were encountered during a checkout test of the common module prototype structure, mainly due to undesirable friction and excessive clearances in the test-article-to-fixture interface bearings. Measured mode shapes and frequencies were not representative of orbiter-constrained modes due to the friction and clearance effects in the bearings. As a result, a major redesign effort for the interface mechanisms was undertaken. The total cost of the fixture design, construction and checkout, and redesign was over $2 million. Because of the problems experienced with fixed-base testing, alternative free-suspension methods were studied, including the residual flexibility and mass-additive approaches. Free-suspension structural dynamics test methods utilize soft elastic bungee cords and overhead frame suspension systems that are less complex and much less expensive than fixed-base systems. The cost of free-suspension fixturing is on the order of tens of thousands of dollars as opposed to millions, for large fixed-base fixturing. In addition, free-suspension test configurations are portable, allowing modal tests to be done at sites without modal test facilities. For example, a mass-additive modal test of the ASTRO-1 Shuttle payload was done at the Kennedy Space Center launch site. In this Technical Memorandum, the mass-additive and residual flexibility test methods are described in detail. A discussion of a hybrid approach that combines the best characteristics of each method follows and is the focus of the study.
Tinker, M. L.↗
Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)
The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.
LESTR↗
Compact Radiative Control Structures for Millimeter Astronomy
We have designed, fabricated, and tested compact radiative control structures, including antireflection coatings and resonant absorbers, for millimeter through submillimeter wave astronomy. The antireflection coatings consist of micromachined single crystal silicon dielectric sub-wavelength honeycombs. The effective dielectric constant of the structures is set by the honeycomb cell geometry. The resonant absorbers consist of pieces of solid single crystal silicon substrate and thin phosphorus implanted regions whose sheet resistance is tailored to maximize absorption by the structure. We present an implantation model that can be used to predict the ion energy and dose required for obtaining a target implant layer sheet resistance. A neutral density filter, a hybrid of a silicon dielectric honeycomb with an implanted region, has also been fabricated with this basic approach. These radiative control structures are scalable and compatible for use large focal plane detector arrays.
Brown, Ari D.↗
Technical support package: Large, easily deployable structures. NASA Tech Briefs, Fall 1982, volume 7, no. 1
Design and test data for packaging, deploying, and assembling structures for near term space platform systems, were provided by testing light type hardware in the Neutral Buoyancy Simulator. An optimum or near optimum structural configuration for varying degrees of deployment utilizing different levels of EVA and RMS was achieved. The design of joints and connectors and their lock/release mechanisms were refined to improve performance and operational convenience. The incorporation of utilities into structural modules to determine their effects on packaging and deployment was evaluated. By simulation tests, data was obtained for stowage, deployment, and assembly of the final structural system design to determine construction timelines, and evaluate system functioning and techniques.
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