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At least 217 records · Page 12

Development of the Multi-Purpose Transportation System for the Space Launch System (SLS) Core Stage (CS) Flight Article

NASA's Multi-Purpose Transportation System (MPTS) is designed to transport the Space Launch System (SLS) vehicle segments by waterway and roadway. It is tasked with transporting the vehicle from where it is manufactured to its intermediate test location and final launch destination. Its design incorporates mechanisms that release degrees of freedom to prevent excessive loading during transit and ensure a successful delivery of the vehicle to its intended destination. In addition to the Core Stage (CS) flight article, the system will also move three Structural Test Articles (STAs), the Dynamic Demonstration Unit (DDU), and a simulated CS Pathfinder (weight, center of gravity, outer mold line dimensions, and overall length) over road terrain at four NASA centers and on the Pegasus barge. The MPTS independently supports the article at both ends while operating as a combined unit through automated monitoring of its released degree of freedom and corrective responses. This allows the system to constrain its payload in a statically determinate manner while traversing highly variable terrain. Multi-body simulation of the transportation route is useful to predict free-body motion within its range of mobility. The MPTS has completed its design and analysis developmental cycles. This paper describes the design challenges encountered in developing this system of large-scale structure, which incorporates complex mechanisms. The unique techniques and methodologies developed for analytical assessment of the hardware are also discussed.

Sandridge, Sarah↗

Nonlinear response of boron/aluminum angleplied laminates under cyclic tensile loading: Contributing mechanisms and their effects

The nonlinear response of boron/aluminum angleplied laminates subjected to cyclic loads was investigated. A procedure is outlined and criteria are proposed which can be used to assess the nonlinear response. The procedure consists of testing strategically selected laminate configurations and analyzing the results using composite mechanics. Results from the investigation show the contributions to nonlinear behavior are from: premature random fiber breaks where the ply orientation angle is small relative to the load direction, ply relative rotation at intermediate values of the ply orientation angle, and nonlinear aluminum matrix behavior at large values of the orientation angle. Premature fiber breaks result in progressively more compliant material; large ply relative rotations result in progressively stiffer material; and pronounced matrix nonlinear behavior results in no significant change in the stiffness of the initial load portion.

Chamis, C. C.↗

Nonlinear response of boron/aluminum angleplied laminates under cyclic tensile loading - Contributing mechanisms and their effects

The nonlinear response of boron/aluminum angleplied laminates subjected to cyclic loads was investigated. A procedure is outlined and criteria are proposed which can be used to assess the nonlinear response. The procedure consists of testing strategically selected laminate configurations and analyzing the results using composite mechanics. Results from the investigation show the contributions to nonlinear behavior are from: premature random fiber breaks where the ply orientation angle is small relative to the load direction, ply relative rotation at intermediate values of the ply orientation angle, and nonlinear aluminum matrix behavior at large values of the orientation angle. Premature fiber breaks result in progressively more compliant material; large ply relative rotations result in progressively stiffer material; and pronounced matrix nonlinear behavior results in no significant change in the stiffness of the initial load portion.

Chamis, C. C.↗

Initiation and Propagation of Skin/Stiffener Separation in Postbuckled Structures Subjected to Cyclic Loads

A methodology is proposed to evaluate experimentally and numerically the initiation and propagation of skin/stiffener separation in postbuckled panels subjected to cyclic loads. The response mechanisms that characterize skin/stiffener separation were investigated using a three point bend (3PB) test specimen, which is a simple specimen consisting of a laminate representing the skin and a doubler representing the stiffener flange. The 3PB tests were performed under quasi-static and cyclic loads. A fatigue cohesive model was used to analyze the initiation and propagation of skin/stiffener separation in the 3PB. The results indicate that the fatigue cohesive model with model parameters obtained from quasi-static fracture tests can provide accurate predictions of initiation from a pristine state, and the rate of fatigue crack propagation for a variety of mode mixities, load levels, and stress ratios.

Carlos G Davila↗

Initiation and Propagation of Skin/Stiffener Separation in Postbuckled Structures

A methodology is proposed to experimentally and numerically evaluate the initiation and propagation of skin/stiffener separation in postbuckled panels subjected to cyclic loads. The response mechanisms that characterize skin/stiffener separation were investigated using a three point bend (3PB) test specimen, which is a simple specimen consisting of a laminate representing the skin and a doubler representing the stiffener flange. The 3PB tests were performed under quasi-static and cyclic loads. A fatigue cohesive model was used to analyze the initiation and propagation of skin/stiffener separation in the 3PB specimen. The results indicate that the fatigue cohesive model with model parameters obtained from quasi-static fracture tests can provide accurate predictions of initiation from a pristine state, and the rate of fatigue crack propagation for a variety of mode mixities, load levels, and stress ratios.

Carlos G. Dávila↗

Elysium Region, Mars: Tests of Lithospheric Loading Models for the Formation of Tectonic Features

In an effort to constrain the tectonic history and mechanical properties of the lithosphere in the Elysium province, the stress fields predicted by different models are compared to the observed tectonic features of the region. The models are all products of volcanic loading of the Martian lithosphere, but at three different scales: global (Tharsis), regional (Elysium Planitia), and local (individual shields). Conclusions: The concentric graben surrounding Elysium Mons can be ascribed to the flexural response of an approximately 50-km-thick elastic lithosphere to loading by the volcano. No tectonic evidence for the support of larger-scale Elysium Planitia volcanic units by lithospheric flexure. The quasi-global loading of the Tharsis rise appears to have produced identifiable tectonic effects in the Elysium region.

Hall, J. L.↗

Thermal and Mechanical Performance of a Carbon/Carbon Composite Spacecraft Radiator

Carbon-carbon composite materials offer greater thermal efficiency, stiffness to weight ratio, tailorability, and dimensional stability than aluminum. These lightweight thermal materials could significantly reduce the overall costs associated with satellite thermal control and weight. However, the high cost and long lead-time for carbon-carbon manufacture have limited their widespread usage. Consequently, an informal partnership between government and industrial personnel called the Carbon-Carbon Spacecraft Radiator Partnership (CSRP) was created to foster carbon-carbon composite use for thermally and structurally demanding space radiator applications. The first CSRP flight opportunity is on the New Millennium Program (NMP) Earth Orbiter-1 (EO-1) spacecraft, scheduled for launch in late 1999. For EO-1, the CSRP designed and fabricated a Carbon-Carbon Radiator (CCR) with carbon-carbon facesheets and aluminum honeycomb core, which will also serve as a structural shear panel. While carbon-carbon is an ideal thermal candidate for spacecraft radiators, in practice there are technical challenges that may compromise performance. In this work, the thermal and mechanical performance of the EO-1 CCR is assessed by analysis and testing. Both then-nal and mechanical analyses were conducted to predict the radiator response to anticipated launch and on-orbit loads. The thermal model developed was based on thermal balance test conditions. The thermal analysis was performed using SINDA version 4.0. Structural finite element modeling and analysis were performed using SDRC/1-DEAS and UAI/NASTRAN, respectively. In addition, the CCR was subjected to flight qualification thermal/vacuum and vibration tests. The panel meets or exceeds the requirements for space flight and demonstrates promise for future satellite missions.

Kuhn, Jonathan↗

A method for continuous monitoring of the Ground Reaction Force during daily activity

Theoretical models and experimental studies of bone remodeling have identified peak cyclic force levels (or cyclic tissue strain energy density), number of daily loading cycles, and load (strain) rate as possible contributors to bone modeling and remodeling stimulus. To test our theoretical model and further investigate the influence of mechanical forces on bone density, we have focused on the calcaneus as a model site loaded by calcaneal surface tractions which are predominantly determined by the magnitude of the external ground reaction force (GRF).

Whalen, Robert↗

Bithermal fatigue: A simplified alternative to thermomechanical fatigue

A bithermal fatigue test technique was proposed as a simplified alternative to the thermomechanical fatigue test. Both the thermomechanical cycle and the bithermal technique can be used to study nonisothermal fatigue behavior. The difference between the two cycles is that in a conventional thermomechanical fatigue cycle the temperature is continuously varied concurrently with the applied mechanical strains, but in the bithermal fatigue cycle the specimen is held at zero load during the temperature excursions and all the loads are applied at the two extreme temperatures of the cycle. Experimentally, the bithermal fatigue test technique offers advantages such as ease in synchronizing the temperature and mechanical strain waveforms, in minimizing temperature gradients in the specimen gauge length, and in reducing and interpreting thermal fatigue such as the influence of alternate high and low temperatures on the cyclic stress-strain response characteristics, the effects of thermal state, and the possibility of introducing high- and low-temperature deformation mechanisms within the same cycle. The bithermal technique was used to study nonisothermal fatigue behavior of alloys such as single-crystal PWA 1480, single-crystal Rene N4, cast B1900+Hf, and wrought Haynes 188.

Verrilli, Michael J.↗

Modeling and Testing of Docking and Berthing Mechanisms

The Contact Dynamics Simulation Laboratory (CDSL) of the Marshall Space Flight Center provides for refined hardware-in-the-loop real-time simulation of docking and berthing mechanisms and associated control systems. This facility is employed to verify the performance of docking/berthing mechanisms during Earth-orbit operations, determine the capture envelope of dockingherthing devices, measure contact loads at vehicle interfaces, and evaluate visual cues for man-in-the-loop operations. The CDSL has developed test verified analytical models of such systems as the ISS Common Berthing Mechanism and HST Three Point Docking Mechanism. This paper will describe the modeling and test techniques employed at the CDSL and present results from recent programs.

Hall, D. P.↗

Rail shear test method

The results of both an experimental test program and a finite element analysis of selected graphite/polyimide rail shear test specimens are discussed. The two dimensional finite element analysis includes both mechanical and thermal loading (differential expansion) of the specimens and their elastic rails. Parameters in this analysis of unidirectional and symmetric, balanced angle-ply laminates include ply layup angles, the effect of flexible rails, the method of load introduction to the specimen and the effect of uniform heating of the specimen and rails. Two types of tensile rail shear fixtures were investigated experimentally: a uniform thickness, bolted-rail shear fixture loaded diagonally across the specimen test section; and a tapered thickness, bonded-rail shear fixture loaded axially along the center-line of the specimen test section. Test results include room-temperature and 589K strain data taken from the center of the specimen test section during loading.

Garcia, R.↗

In situ fatigue loading stage inside scanning electron microscope

A fatigue loading stage inside a scanning electron microscopy (SEM) was developed. The stage allows dynamic and static high-magnification and high-resolution viewing of the fatigue crack initiation and crack propagation processes. The loading stage is controlled by a closed-loop servohydraulic system. Maximum load is 1000 lb (4450 N) with test frequencies ranging up to 30 Hz. The stage accommodates specimens up to 2 inches (50 mm) in length and tolerates substantial specimen translation to view the propagating crack. At room temperature, acceptable working resolution is obtainable for magnifications ranging up to 10,000X. The system is equipped with a high-temperature setup designed for temperatures up to 2000 F (1100 C). The signal can be videotaped for further analysis of the pertinent fatigue damage mechanisms. The design allows for quick and easy interchange and conversion of the SEM from a loading stage configuration to its normal operational configuration and vice versa. Tests are performed entirely in the in-situ mode. In contrast to other designs, the NASA design has greatly extended the life of the loading stage by not exposing the bellows to cyclic loading. The loading stage was used to investigate the fatigue crack growth mechanisms in the (100)-oriented PWA 1480 single-crystal, nickel-based supperalloy. The high-magnification observations revealed the details of the crack growth processes.

Telesman, Jack↗

Comparison of Orion Flywheel to Commercially Available Flywheel Device

INTRODUCTION: The chosen exercise device for the Orion Multi-purpose Crew Vehicle (MPCV) for Artemis missions is the Orion Flywheel (OFW), which was selected in 2017 from a pool of exercise devices. The Orion Flywheel is to be installed in the MPCV for its first use during the Artemis II mission and will be utilized for subsequent Artemis missions. The OFW provides the capability to perform both resistive and aerobic exercises while taking up a small volume and not requiring power. Aerobic exercise consists of rowing while resistive exercise includes the deadlift, harness squat, and deadlift high pull among others. The efficacy of the OFW as an exercise countermeasure to spaceflight deconditioning has not yet been fully evaluated. A future HRP-funded study using head-down tilt bed rest is planned to evaluate the efficacy of the OFW to mitigate aerobic and muscular deconditioning. The OFW, made by KBR, is a specialized device that poses high costs for purchase and maintenance. The aim of the study is to determine if a commercially available alternative could be used as a backup for the OFW during the bed rest study or as an alternative in other studies. This study seeks to compare the loading profile and mechanics of a commercial flywheel device (kBox Pro) with the three resistance settings of the OFW using a controlled, instrumented setup to validate its acceptability as a backup. METHODS: An experimental setup was designed to simulate human use of the OFW. Flywheel devices can have varied actuated inertial mass and strap length. The inertial mass refers to the flywheel itself or the object that spins as the result of the movement of the strap. The OFW has three gears actuated with a lever, with the low gear used for aerobic rowing and the medium and high gears used for resistance exercises. These gears correspond to increasing flywheel inertia, which corresponds to a certain number and sizes of inertial plates on a commercial flywheel. The kBox Pro has varied sizes of inertial discs that are installed to the external shaft of the device and can be configured to roughly match the inertia seen in the OFW per gear setting. The strap length can be adjusted to allow for different ranges of motion. The experimental setup allows for the simulation of rowing, harness squats, and deadlift high pulls with corresponding exercise strap lengths. All three OFW gears are to be tested, as well as multiple combinations of kBox discs. The setup was created using a system of pulleys and cables to minimize friction loss. The system is actuated through the dropping of a connected mass which, through the pulley system, pulls the strap of the exercise device upwards as if a human was exercising. A string potentiometer and tensile force transducer are used to measure strap displacement and strap force, respectively. The masses dropped are exercise chains that simulate the decrease in force observed throughout a typical exercise. As the chains are lowered to the ground, they begin to spool and therefore are no longer subjecting the exercise device’s strap to their load. This setup was designed to provide realistic loads and protect the OFW from damage, an important precaution because it’s the only available unit for research and ground operations. Data is to be collected across simulated exercises and with different strap lengths, with the same conditions collected on both the OFW and the kBox Pro. RESULTS: Data collection is ongoing for the kBox and the Orion Flywheel. CONCLUSIONS: Study results will inform if the OFW and a kBox Pro device can be deemed mechanically similar. Depending on the results, additional data collection may be required to assess the user experience between the devices. A key result of this study is a mechanical characterization of the OFW device, demonstrating the load and force profile using a repeatable test method. This data will guide next steps on potential kBox Pro modifications needed to produce a comparable exercise experience to the OFW.

Exercise↗

Vibration and acoustic testing of spacecraft

Spacecraft are subjected to a variety of dynamics environments, which may include: quasi-static, vibration and acoustic loads at launch: pyrotechnic shocks generated by separation mechanisms; on orbit jitter; and sometimes, planetary landing loads. There is a trend in the aerospace industry to rely more on structural analyses and less on testing to simulate these environments, because dynamics testing of spacecraft is time consuming, risky and expensive.

vibration acoustics spacecraft↗

Low-velocity impact damage in graphite-fiber reinforced epoxy laminates

An experimental investigation was conducted to identify the failure mechanisms and to understand damage propagation in compression-loaded composite structures. The tests were conducted on several laminates of different ply orientation with thickness that ranged from 0.56 to 0.75 cm. The panels were damaged by 1.27-cm-diameter aluminum spheres propelled normal to the specimen surface at velocities ranging from 30 m/s to 140 m/s. Results indicate that there is significant internal laminate damage due to low-velocity impact with no surface damage. The internal damage consists of delamination and intraply cracking. Three damage propagation modes were identified as causing specimen failure; which are delamination, axial load-lateral deformation coupling, and local shear failure.

Rhodes, M. D.↗

Fatigue Testing of Heat-Exchanger Tubes

Acclerated fatigue-life testing of heat-exchanger tubes simplified by technique that substitutes mechanical side load for thermally-generated axisymmetric stress. Load amplitudes adjusted to produce strains equivalent to those produced by anticipated thermal stress.

Ackerman, P.↗

Assessment of Low Cycle Fatigue Behavior of Powder Metallurgy Alloy U720

The fatigue lives of modem powder metallurgy disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary as functions of variables the different steps of materials/component processing: powder atomization, consolidation, extrusion, forging, heat treating, and machining. It is important to understand the relationship between the statistical variations in life and these variables, as well as the change in life distribution due to changes in fatigue loading conditions. The objective of this study was to investigate these relationships in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were performed at 538 C (1000 F) at limited sets of test conditions. Analyses were performed to: (1) assess variations of microstructure, mechanical properties, and LCF failure initiation sites as functions of disk processing and loading conditions; and (2) compare mean and minimum fatigue life predictions using different approaches for modeling the data from assorted test conditions. Significant variations in life were observed as functions of the disk processing variables evaluated. However, the lives of all specimens could still be combined and modeled together. The failure initiation sites for tests performed at a strain ratio R(sub epsilon) = epsilon(sub min)/epsilon(sub max) of 0 were different from those in tests at a strain ratio of -1. An approach could still be applied to account for the differences in mean and maximum stresses and strains. This allowed the data in tests of various conditions to be combined for more robust statistical estimates of mean and minimum lives.

Gabb, Tomothy P.↗