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At least 217 records · Page 12

Permeability Testing of Impacted Composite Laminates for Use on Reusable Launch Vehicles

Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite, and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented, and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a nonlinear fashion for almost all the specimens tested.

Nettles, A. T.↗

Permeability Testing of Impacted Composite Laminates for Use on Reusable Launch Vehicles

Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite, and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented, and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a nonlinear fashion for almost all the specimens tested.

Nettles, Alan T.↗

Improved impact-resistant boron/aluminum composites for use as turbine engine fan blades

Thin-sheet Charpy and Izod impact tests and standard full-size Charpy impact tests were conducted on unidirectional and angleply composites containing 4, 5.6 and 8 mil boron in 1100, 2024, 5052 and 6061 Al matrices. Impact failure modes of B/Al are proposed to describe the mechanisms involved and to provide insight for maximizing impact resistance. The impact strength of B/Al was significantly increased by proper selection of materials and processing. The use of more ductile matrices and larger diameter boron fibers gave the highest impact strengths by allowing matrix shear deformation and multiple fiber breakage. Pendulum impact test results of improved B/Al were higher than notched titanium and indicate sufficient foreign object damage protection to warrant consideration of B/Al for application to fan blades in aircraft gas turbine engines.

Mcdanels, D. L.↗

Particle Impact Ignition Test Data on a Stainless Steel Hand Valve

This slide presentation reviews the particle impact ignition test of a stainless steel hand valve. The impact of particles is a real fire hazard with stainless steel hand valves, however 100 mg of particulate can be tolerated. Since it is unlikely that 100 mg of stainless steel contaminant particles can be simultaneously released into this type of valve in the WSTF configuration, this is acceptable and within statistical confidence as demonstrated by testing.

Peralta, Stephen↗

Analysis of Darkened Fragments Resulting from Laboratory Hypervelocity Experiments

NASA’s Orbital Debris Program Office (ODPO) relies on measurements from optical, radar, and in situ measurements to facilitate the development of data-driven orbital debris environmental engineering models such as the NASA Orbital Debris Engineering Model (ORDEM). For optical measurements, the ODPO relies on ground-based optical telescopes to statistically assess objects in geosynchronous orbit and, in the future, low Earth orbit (LEO). The data collected include the detected object’s orbital parameters, time of observation, and optical magnitude. The latter parameter can be converted to a size using NASA’s optical Size Estimation Model (oSEM). It is well known that the observed magnitude of orbital debris can vary based on an object's material constituents, observational geometry, and the effects of space weathering. To assess these magnitude variations, the ODPO uses the Optical Measurement Center (OMC) at NASA Johnson Space Center to characterize a variety of materials and fragments from laboratory impact tests representative of fragments that constitute the orbital debris population. One experiment was DebriSat: a 56 kg spacecraft was built to incorporate structural elements of a modern LEO spacecraft and was subjected to a hypervelocity impact test at the U.S. Air Force’s Arnold Engineering Development Complex using test parameters that may be encountered in LEO. The DebriSat project has provided an abundance of information for assessing fragmentation debris in terms of material, color, shape, size, density, mass, and other derived parameters. Prior to the impact test, the ODPO collected spectral measurements on a subset of the materials used to construct DebriSat for a “ground-truth” of their optical properties. After the successful hypervelocity impact test, the DebriSat team observed a fine, dark dust coating all the fragments. Prior research has suggested that this came from ablated material deposited on the fragments during the impact test, causing a change in the reflective properties [1]. Given that this lower reflectivity on the DebriSat fragments will influence the laboratory-acquired magnitudes used to calculate size and inform potential updates to the oSEM, it is critical to assess if this darkening effect on the DebriSat fragments is a laboratory bias or something that could occur in on-orbit breakup events. This paper will provide a brief overview of the OMC and DebriSat experiment, focused on the optical characterization of a subset of materials using broadband photometric measurements and spectroscopic measurements. In addition, elemental analysis of various DebriSat fragments and the soft-catch foam used in the hypervelocity experiment compared with pristine foam will be examined to further evaluate the source of the dark material coating all fragments. Finally, the authors will present a twofold plan 1) for assessing potential biases in laboratory impact experiments that could affect laboratory optical characterization and 2) for mitigating biases when compared with ground-based optical telescopic measurements of the orbital debris environment.

Heather Cowardin↗

Analysis of Darkened Fragments Resulting from Laboratory Hypervelocity Experiments

NASA’s Orbital Debris Program Office (ODPO) relies on measurements from optical, radar, and in situ measurements to facilitate the development of data-driven orbital debris environmental engineering models such as the NASA Orbital Debris Engineering Model (ORDEM). For optical measurements, the ODPO relies on ground-based optical telescopes to statistically assess objects in geosynchronous orbit and, in the future, low Earth orbit (LEO). The data collected include the detected object’s orbital parameters, time of observation, and optical magnitude. The latter parameter can be converted to a size using NASA’s optical Size Estimation Model (oSEM). It is well known that the observed magnitude of orbital debris can vary based on an object's material constituents, observational geometry, and the effects of space weathering. To assess these magnitude variations, the ODPO uses the Optical Measurement Center (OMC) at NASA Johnson Space Center to characterize a variety of materials and fragments from laboratory impact tests representative of fragments that constitute the orbital debris population. One experiment was DebriSat: a 56 kg spacecraft was built to incorporate structural elements of a modern LEO spacecraft and was subjected to a hypervelocity impact test at the U.S. Air Force’s Arnold Engineering Development Complex using test parameters that may be encountered in LEO. The DebriSat project has provided an abundance of information for assessing fragmentation debris in terms of material, color, shape, size, density, mass, and other derived parameters. Prior to the impact test, the ODPO collected spectral measurements on a subset of the materials used to construct DebriSat for a “ground-truth” of their optical properties. After the successful hypervelocity impact test, the DebriSat team observed a fine, dark dust coating all the fragments. Prior research has suggested that this came from ablated material deposited on the fragments during the impact test, causing a change in the reflective properties [1]. Given that this lower reflectivity on the DebriSat fragments will influence the laboratory-acquired magnitudes used to calculate size and inform potential updates to the oSEM, it is critical to assess if this darkening effect on the DebriSat fragments is a laboratory bias or something that could occur in on-orbit breakup events. This presentation will provide a brief overview of the OMC and DebriSat experiment, focused on the optical characterization of a subset of materials using broadband photometric measurements and spectroscopic measurements. In addition, elemental analysis of various DebriSat fragments and the soft-catch foam used in the hypervelocity experiment compared with pristine foam will be examined to further evaluate the source of the dark material coating all fragments. Finally, the authors will present a twofold plan 1) for assessing potential biases in laboratory impact experiments that could affect laboratory optical characterization and 2) for mitigating biases when compared with ground-based optical telescopic measurements of the orbital debris environment.

Heather Cowardin↗

Tomographic assessment of peening for metallurgical bonding in cold spray

It is widely asserted that peening densifies cold spray coatings and improves particle–particle and particle–substrate bonding, yet systematic studies analyzing the evolution of bonding due to peening particle strikes are scarce. We explore peening at the level of individual particle impacts, by creating two-particle Cu-on-Cu stacks using laser-induced particle impact testing. Exploring impact velocities that range from the onset of bonding at the “critical velocity”, V cr , to its peak near 1.4⋅V cr , we perform full 3D tomography of the particle stacks to characterize the bonding state at the particle-substrate interface. Direct labeling of non-bonded patches and the total particle-substrate interface permits quantification and comparison of bonding in single impacts with bonding after subsequent impacts to reveal the origins of the peening effect. The data reveal a surprising finding: although a second impact directly atop the first particle increases the area of the particle-substrate interface (~40% area increase), there is no improvement in metallurgical bonding. Analysis of these data suggest that not only area expansion (and associated oxide rarefication), but also stress-induced extrusion of metal at that interface needs to occur to achieve metal-on-metal contact to see an enhancement in bonding. Furthermore, our analysis suggests that the subsequent impacting particle needs to have ~70% more kinetic energy to produce additional bonding; this implies that particle and velocity distributions within a spray may be helpful, and that peening may rely on unaligned impacts.

Bonding↗

Multilayer high performance insulation materials

A number of tests are required to evaluate both multilayer high performance insulation samples and the materials that comprise them. Some of the techniques and tests being employed for these evaluations and some of the results obtained from thermal conductivity tests, outgassing studies, effect of pressure on layer density tests, hypervelocity impact tests, and a multilayer high performance insulation ambient storage program at the Kennedy Space Center are presented.

Stuckey, J. M.↗

Environmental effects on FOD resistance of composite fan blade

The sensitivity of the impact characteristics of typical polymeric composite fan blade materials to potential limiting combinations of moisture, temperature level and temperature transients was established. The following four technical tasks are reported: (1) evaluation and characterization of constituent blade materials; (2) ballistic impact tests; (3) leading edge impact protection systems; and (4) simulated blade spin impact tests.

Murphy, G. C.↗

Optimization techniques applied to passive measures for in-orbit spacecraft survivability

Spacecraft designers have always been concerned about the effects of meteoroid impacts on mission safety. The engineering solution to this problem has generally been to erect a bumper or shield placed outboard from the spacecraft wall to disrupt/deflect the incoming projectiles. Spacecraft designers have a number of tools at their disposal to aid in the design process. These include hypervelocity impact testing, analytic impact predictors, and hydrodynamic codes. Analytic impact predictors generally provide the best quick-look estimate of design tradeoffs. The most complete way to determine the characteristics of an analytic impact predictor is through optimization of the protective structures design problem formulated with the predictor of interest. Space Station Freedom protective structures design insight is provided through the coupling of design/material requirements, hypervelocity impact phenomenology, meteoroid and space debris environment sensitivities, optimization techniques and operations research strategies, and mission scenarios. Major results are presented.

Mog, Robert A.↗

Meteoroid Risk Assessment of Lunar Habitat Concepts

Preliminary analyses have been performed of meteoroid impacts on lunar surface structures built with elements made from in situ materials. The SPHC hydrodynamic code was used to simulate impacts, and was validated against hypervelocity impact test results. Impact risk will affect necessary wall thicknesses, depth of burial, and placement of lunar base structures.

Evans, Steven W.↗

Environmental Program

NASA's White Sands Test Facility has six core environmental compliance capabilities: remote hazardous testing of reactive, explosive and toxic materials and fluids; hypergolic fluids materials and systems testing; oxygen materials and system testing; hypervelocity impact testing; flight hardware processing; and, propulsion testing. The facility's permit status and challenges are reviewed. Historic operations and practices dating from the 1960s through the early 1980s resulted in contamination of the facility's groundwater. An environmental restoration effort has been employed to protect public health and the health of the workforce. The restoration seeks to properly handle hazardous materials and waste processes; determine the nature and extent of the contamination; stop the migration of contaminated groundwater; stabilize the plume front which has been assessed as the greatest risk to public health; and, clean-up the environment to restore it to preexisting conditions. The Plume Front Treatment System is operational and seeks to stop the westward movement of the plume to protect drinking water and irrigation well. Specifically, the treatment system will extract contaminated water from the aquifer, remove chemical using the best available technology, and return (inject) the treated water back to the aquifer. The Mid-Plume Interception Treatment System also seeks to stop the migration of containment, as well as to evaluate new technologies to accelerate cleanup, such as bioremediation.

Fischer, Holger↗

Space Shuttle Systems Engineering Processes for Liftoff Debris Risk Mitigation

This slide presentation reviews the systems engineering process designed to reduce the risk from debris during Space Shuttle Launching. This process begins the day of launch from the tanking to the vehicle tower clearance. Other debris risks (i.e., Ascent, and micrometeoroid orbital debit) are mentioned) but are not the subject of this presentation. The Liftoff debris systems engineering process and an example of how it works are reviewed (i.e.,STS-119 revealed a bolt liberation trend on the Fixed Service Structure (FSS) 275 level elevator room). The process includes preparation of a Certification of Flight Readiness (CoFR) that includes (1) Lift-off debris from previous mission dispositioned, (2) Flight acceptance rationale has been provided for Lift-off debris sources/causes (3) Lift-off debris mission support documentation, processes and tools are in place for the up-coming mission. The process includes a liftoff debris data collection that occurs after each launch. This includes a post launch walkdown, that records each liftoff debris, and the entry of the debris into a database, it also includes a review of the imagery from the launch, and a review of the instrumentation data. There is also a review of the debris transport analysis process, that includes temporal and spatial framework and a computational fluid dynamics (CFD) analysis. which incorporates a debris transport analyses (DTA), debris materials and impact tests, and impact analyses.

Mitchell, Michael↗

Foam-on-Tile Damage Model

An impact model was developed to predict how three specific foam types would damage the Space Shuttle Orbiter insulating tiles. The inputs needed for the model are the foam type, the foam mass, the foam impact velocity, the foam impact incident angle, the type being impacted, and whether the tile is new or aged (has flown at least one mission). The model will determine if the foam impact will cause damage to the tile. If it can cause damage, the model will output the damage cavity dimensions (length, depth, entry angle, exit angle, and sidewall angles). It makes the calculations as soon as the inputs are entered (less than 1 second). The model allows for the rapid calculation of numerous scenarios in a short time. The model was developed from engineering principles coupled with significant impact testing (over 800 foam impact tests). This model is applicable to masses ranging from 0.0002 up to 0.4 pound (0.09 up to 181 g). A prior tool performed a similar function, but was limited to the assessment of a small range of masses and did not have the large test database for verification. In addition, the prior model did not provide outputs of the cavity damage length, entry angle, exit angle, or sidewall angles.

Koharchik, Michael↗

NASA Centennial Challenge: 3D Printed Habitat, Phase 3 Final Results

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Construction↗

Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Centennial challenge↗

Evaluation of Human and Anthropomorphic Test Device Finite Element Models under Spaceflight Loading Conditions

In an effort to develop occupant protection standards for future multipurpose crew vehicles, the National Aeronautics and Space Administration (NASA) has looked to evaluate the test device for human occupant restraint with the modification kit (THOR‐K) anthropomorphic test device (ATD) in relevant impact test scenarios. With the allowance and support of the National Highway Traffic Safety Administration, NASA has performed a series of sled impact tests on the latest developed THOR‐K ATD. These tests were performed to match test conditions from human volunteer data previously collected by the U.S. Air Force. The objective of this study was to evaluate the THOR‐K finite element (FE) model and the Total HUman Model for Safety (THUMS) FE model with respect to the tests performed. These models were evaluated in spinal and frontal impacts against kinematic and kinetic data recorded in ATD and human testing. Methods: The FE simulations were developed based on recorded pretest ATD/human position and sled acceleration pulses measured during testing. Predicted responses by both human and ATD models were compared to test data recorded under the same impact conditions. The kinematic responses of the models were quantitatively evaluated using the ISO‐metric curve rating system. In addition, ATD injury criteria and human stress/strain data were calculated to evaluate the risk of injury predicted by the ATD and human model, respectively. Results: Preliminary results show well‐correlated response between both FE models and their physical counterparts. In addition, predicted ATD injury criteria and human model stress/strain values are shown to positively relate. Kinematic comparison between human and ATD models indicates promising biofidelic response, although a slightly stiffer response is observed within the ATD. Conclusion: As a compliment to ATD testing, numerical simulation provides efficient means to assess vehicle safety throughout the design process and further improve the design of physical ATDs. The assessment of the THOR‐K and THUMS FE models in a spaceflight testing condition is an essential first step to implementing these models in the computational evaluation of spacecraft occupant safety. Promising results suggest future use of these models in the aerospace field.

Putnam, Jacob P.↗

Low temperature mechanical properties, fractographic and metallographic evaluation of several alloy steels

The mechanical properties are presented of alloy steels, 4130, 4140, 4340, 6150, and 8740. Test specimens were manufactured from approximately 1.00 inch (2.54 cm) diameter bar stock which had been heat treated to two different hardness levels. The following mechanical tests were performed at temperatures of 80 F (+26.7 C), 0 F (-17.8 C), -100 F (-73 C), and -200 F (-129 C): (1) tensile test (Ultimate, yield, modulus, elongation, and reduction of area), (2) notched tensile test, (3) charpy V-notched impact test (impact energy), and (4) double shear strength test (ultimate and yield). The test data indicate excellent tensile strength, notched/unnotched tensile ratios, ductility, impact, and shear properties at all test temperatures, except at -200 F (-129 C) where the impact strength of the higher strength group of alloy steels, 4130 (Rc-37) and 4140 (Rc-44) decreased to approximately 9 ft. lbs. (12 joules) and 6 ft. lbs. (8 joules), respectively. Chemical, metallographic, and fractographic analyses were also performed to evaluate microstructure, microhardness and the effect of decrease in temperature on the ductile to brittle failure transition.

Montano, J. W.↗