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AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗

Design, analysis, and fabrication of a pressure box test fixture for tension damage tolerance testing of curved fuselage panels

A pressure box test fixture was designed and fabricated to evaluate the effects of internal pressure, biaxial tension loads, curvature, and damage on the fracture response of composite fuselage structure. Previous work in composite fuselage tension damage tolerance, performed during NASA contract NAS1-17740, evaluated the above effects on unstiffened panels only. This work extends the tension damage tolerance testing to curved stiffened fuselage crown structure that contains longitudinal stringers and circumferential frame elements. The pressure box fixture was designed to apply internal pressure up to 20 psi, and axial tension loads up to 5000 lb/in, either separately or simultaneously. A NASTRAN finite element model of the pressure box fixture and composite stiffened panel was used to help design the test fixture, and was compared to a finite element model of a full composite stiffened fuselage shell. This was done to ensure that the test panel was loaded in a similar way to a panel in the full fuselage shell, and that the fixture and its attachment plates did not adversely affect the panel.

Smith, P. J.↗

Semantic Search with Sentence-BERT for Design Information Retrieval

Managing and referencing design knowledge is a critical activity in the design process. However, reliably retrieving useful knowledge can be a frustrating experience for users of knowledge management systems due to inherent limitations of standard keyword-based searches. In this research, we consider the task of retrieving relevant lessons learned from the NASA Lessons Learned Information System (LLIS). To this end, we apply a state-of-the-art natural language processing (NLP) technique for information retrieval (IR): semantic search with sentence-BERT, which is a modification of a Bidirectional Encoder Representations from Transformers (BERT) model that uses siamese and triplet network architectures to obtain semantically meaningful sentence embeddings. While the pre-trained sBERT model performs well out-of-the-box, we further fine-tune the model on data from the LLIS so that it learns on design engineering-relevant vocabulary. We quantify the improvement in query results using both standard sBERT and fine-tuned sBERT over a keyword search. Our use case throughout the paper is to use queries related to specific requirements from a NASA project. Fine tuning the sBERT model on LLIS data yields a mean average precision (MAP) of 0.807 on queries based on information needs from a real NASA project. Results indicate that applying state-of-the-art natural language processing techniques, especially when finetuned using engineering data, to design information retrieval tasks shows significant promise in modernizing design knowledge management systems.

Hannah S. Walsh↗

Modeling radiation forces acting on TOPEX/Poseidon for precision orbit determination

Geodetic satellites such as GEOSAT, SPOT, ERS-1, and TOPEX/Poseidon require accurate orbital computations to support the scientific data they collect. Until recently, gravity field mismodeling was the major source of error in precise orbit definition. However, albedo and infrared re-radiation, and spacecraft thermal imbalances produce in combination no more than a 6-cm radial root-mean-square (RMS) error over a 10-day period. This requires the development of nonconservative force models that take the satellite's complex geometry, attitude, and surface properties into account. For TOPEX/Poseidon, a 'box-wing' satellite form was investigated that models the satellite as a combination of flat plates arranged in a box shape with a connected solar array. The nonconservative forces acting on each of the eight surfaces are computed independently, yielding vector accelerations which are summed to compute the total aggregate effect on the satellite center-of-mass. In order to test the validity of this concept, 'micro-models' based on finite element analysis of TOPEX/Poseidon were used to generate acceleration histories in a wide variety of orbit orientations. These profiles are then compared to the box-wing model. The results of these simulations and their implication on the ability to precisely model the TOPEX/Poseidon orbit are discussed.

Marshall, J. A.↗

Static internal performance of a single-engine onaxisymmetric-nozzle vaned-thrust-reverser design with thrust modulation capabilities

An investigation has been conducted at wind-off conditions in the stati-test facility of the Langley 16-Foot Transonic Tunnel. The tests were conducted on a single-engine reverser configuration with partial and full reverse-thrust modulation capabilities. The reverser design had four ports with equal areas. These ports were angled outboard 30 deg from the vertical impart of a splay angle to the reverse exhaust flow. This splaying of reverser flow was intended to prevent impingement of exhaust flow on empennage surfaces and to help avoid inlet reingestion of exhaust gas when the reverser is integrated into an actual airplane configuration. External vane boxes were located directly over each of the four ports to provide variation of reverser efflux angle from 140 deg to 26 deg (measured forward from the horizontal reference axis). The reverser model was tested with both a butterfly-type inner door and an internal slider door to provide area control for each individual port. In addition, main nozzle throat area and vector angle were varied to examine various methods of modulating thrust levels. Other model variables included vane box configuration (four or six vanes per box), orientation of external vane boxes with respect to internal port walls (splay angle shims), and vane box sideplates. Nozzle pressure ratio was varied from 2.0 approximately 7.0.

Leavitt, L. D.↗

Computer based analyses of the response of box type structures to random pressures.

Analysis of the vibration of the internal structure of a relatively simple flight vehicle structural model consisting of a multicellular box in which two parallel outer face plates (skins) are connected together by several internal plates (ribs) which are parallel to each other and normal to the face plates. Such a box is representative of a wing or stabilizer structure. Three representations of the structure were considered in the computation. The simplest model which can account for the coupling between the face plates and the ribs is a two-dimensional assembly of beams. A more realistic, yet still simple, three-dimensional model has been developed using the Rayleigh-Ritz method. The third computational method employed was the NASTRAN finite-element displacement method. The computational results are compared with experimental data.

Clarkson, B. L.↗

On Looking into the Black Box: Prospects and Limits in the Search for Mental Models

To place the arguments advanced in this paper in alternative points of view with regard to mental models are reviewed. Use of the construct in areas such as neural information processing, manual control, decision making, problem solving, and cognitive science are discussed. Also reviewed are several taxonomies of mental models. The available empirical evidence for answering questions concerning the nature and usage of mental models is then discussed. A variety of studies are reviewed where the type and form of humans' knowledge have been manipulated. Also considered are numerous transfer of training studies whose results provide indirect evidence of the nature of mental models. The alternative perspectives considered and the spectrum of empirical evidence are combined to suggest a framework within which research on mental models can be viewed. By considering interactions of dimensions of this framework, the most salient unanswered questions can be identified.

Rouse, W. B.↗

Semantic Search with Sentence-BERT for Design Information Retrieval

Managing and referencing design knowledge is a critical activity in the design process. However, reliably retrieving useful knowledge can be a frustrating experience for users of knowledge management systems due to inherent limitations of standard keyword-based searches. In this research, we consider the task of retrieving relevant lessons learned from the NASA Lessons Learned Information System (LLIS). To this end, we apply a state-of-the-art natural language processing (NLP) technique for information retrieval: semantic search with sentence-BERT, which is a modification of a Bidirectional Encoder Representations from Transformers (BERT) model that uses siamese and triplet network architectures to obtain semantically meaningful sentence embeddings. While the pretrained sBERT model shows excellent out-of-the-box performance, we further fine-tune the model on data from the LLIS so that it learns on design engineering-relevant vocabulary. We quantify the improvement in query results using both standard sBERT and fine-tuned sBERT over the LLIS’s built-in keyword search. Additionally, we demonstrate a use case for the query system by searching for lessons learned relevant to specific requirements from a NASA project as part of a broader knowledge management and retrieval system. Results indicate that applying state-of-the-art natural language processing techniques, especially when fine-tuned using engineering data, to design information retrieval tasks shows significant promise in modernizing design knowledge management systems.

Hannah S. Walsh↗

Global dynamic modeling of a transmission system

The work performed on global dynamic simulation and noise correlation of gear transmission systems at the University of Akron is outlined. The objective is to develop a comprehensive procedure to simulate the dynamics of the gear transmission system coupled with the effects of gear box vibrations. The developed numerical model is benchmarked with results from experimental tests at NASA Lewis Research Center. The modal synthesis approach is used to develop the global transient vibration analysis procedure used in the model. Modal dynamic characteristics of the rotor-gear-bearing system are calculated by the matrix transfer method while those of the gear box are evaluated by the finite element method (NASTRAN). A three-dimensional, axial-lateral coupled bearing model is used to couple the rotor vibrations with the gear box motion. The vibrations between the individual rotor systems are coupled through the nonlinear gear mesh interactions. The global equations of motion are solved in modal coordinates and the transient vibration of the system is evaluated by a variable time-stepping integration scheme. The relationship between housing vibration and resulting noise of the gear transmission system is generated by linear transfer functions using experimental data. A nonlinear relationship of the noise components to the fundamental mesh frequency is developed using the hypercoherence function. The numerically simulated vibrations and predicted noise of the gear transmission system are compared with the experimental results from the gear noise test rig at NASA Lewis Research Center. Results of the comparison indicate that the global dynamic model developed can accurately simulate the dynamics of a gear transmission system.

Choy, F. K.↗

Global and Local Stress Analyses of McDonnell Douglas Stitched/RFI Composite Wing Stub Box

This report contains results of structural analyses performed in support of the NASA structural testing of an all-composite stitched/RFI (resin film infusion) wing stub box. McDonnell Douglas Aerospace Company designed and fabricated the wing stub box. The analyses used a global/local approach. The global model contains the entire test article. It includes the all-composite stub box, a metallic load-transition box and a metallic wing-tip extension box. The two metallic boxes are connected to the inboard and outboard ends of the composite wing stub box, respectively. The load-transition box was attached to a steel and concrete vertical reaction structure and a load was applied at the tip of the extension box to bend the wing stub box upward. The local model contains an upper cover region surrounding three stringer runouts. In that region, a large nonlinear deformation was identified by the global analyses. A more detailed mesh was used for the local model to obtain more accurate analysis results near stringer runouts. Numerous analysis results such as deformed shapes, displacements at selected locations, and strains at critical locations are included in this report.

Wang, John T.↗

Elemental technetium as a cosmic-ray clock

Several radioactive isotopes have been proposed as clocks for the study of the mean cosmic ray confinement time, T sub e. Measurements of Be-10 and Al-26 give a value for T sub e of about 10 Myr when one uses a leaky box cosmic ray propagation model. It is important to obtain additional measurements of T sub e from other radioactive isotopes in order to check whether the confinement is the same throughout the periodic table. The possible use of Tc (Z = 43) as a cosmic clock is investigated. Since all isotopes of Tc are radioactive, one might be able to group these isotopes and use the elemental abundance as a whole. The results of the calculations are somewhat inconclusive for two reasons. First, the beta + decay half lives of two of the Tc isotopes relevant to our calculation are not known. Second, the dependence of the Tc abundance on the mean confinement time is rather weak when one considers the number of events expected in 4 trays of plastic track detectors. However, a future, finite measurement of the Beta + half lives and the possible use of the entire collecting area of the HNC to detect Tc nuclei could make the use of Tc as a cosmic ray clock more attractive.

Drach, J.↗

Squeezed states of electrons and transitions of the density of states

Electron systems which have low dimensional properties have been constructed by squeezing the motion in zero, one, or two-directions. An isolated quantum dot is modeled by a potential box with delta-profiled, penetrable potential walls embedded in a large outer box with infinitely high potential walls which represent the world function with respect to vacuum. We show the smooth crossover of the density of states from the three-dimensional to the quasi-zero dimensional electron gas.

Lee, Seung Joo↗

Modeling the decay of energy containing eddies: A source of solar wind heating

To understand the solar wind heating and acceleration mechanisms one needs to understand the decay of energy containing eddies. With this goal in mind, attempts have been made to extend the fluid dynamic phenomenology of large scale quasi-equilibrium to the case of magnetohydrodynamics. Matthaeus et al. have proposed a model for the inhomogeneous transport and decay of five mean variables, namely, two mean square Elsasser variables z(exp 2) (sub +/-) their correlation lengths, and the difference between the kinetic and magnetic energies. We test the validity of this model in the simplified case of homogeneous turbulence simulated in a periodic box. We propose a class of models and show that they may fit the simulation satisfactorily. Analytic solutions of this class of model reveal their inherent properties and demonstrate the difficulties associated with finite cross helicity. It is noted that adjustments are required to make the simplest models, which are based upon isotropic turbulence, scale properly with respect to the strength of the mean magnetic field. This can be interpreted as due to anisotropic turbulence, which can be modelled by simple parameterization in the phenomenology.

Hossain, M.↗

Impact of Albedo Contrast Between Cirrus and Boundary-Layer Clouds on Climate Sensitivity

In assessing the iris effect suggested by Lindzen et al. (2001), Fu et al. (2001) found that the response of high-level clouds to the sea surface temperature had an effect of reducing the climate sensitivity to external radiative forcing, but the effect was not as strong as LCH found. This weaker reduction in climate sensitivity was due to the smaller contrasts in albedos and effective emitting temperatures between cirrus clouds and the neighboring regions. FBH specified the albedos and the outgoing longwave radiation (OLR) in the LCH 3.5-box radiative-convective model by requiring that the model radiation budgets at the top of the atmosphere be consistent with that inferred from the Earth Radiation Budget Experiment (ERBE). In point of fact, the constraint by radiation budgets alone is not sufficient for deriving the correct contrast in radiation properties between cirrus clouds and the neighboring regions, and the approach of FBH to specifying those properties is, we feel inappropriate for assessing the iris effect.

Chou, Ming-Dah↗

Constructing an Educational Mars Simulation

Working in the Educational Programs Office, my task this summer is to model a 3D habitat that will be part of a future Mars base. With the President's charge to further explore mars by way of robotic-led and human-led missions, there has been a surge in the activity regarding the "red planet". Since all present designs are merely conjecture, I have some creative freedom in deciding what the habitat will look like. To get ideas for what a Mars habitat might be like, I looked at several references including websites and NASA documents. One of these was a NASA Technical Memorandum about Space Transportation Systems that I looked at to get insight on spaceship design. Information about the planet's environment, such as the gravity and the weather, is useful as well when designing the structure. The main software that I am using is Lightwave 3D and Modeler 7.5 that comes along with it. Lightwave is very complex in that it lets you model, surface, and animate so there was a lot to learn. To learn the software I watched a series of instructional videos, looked at online tutorials, and referenced several books. Modeling is like shaping clay with a computer. Every item modeled is made of smaller shapes called polygons. For example, each side of a box would be a different polygon. Modelers must be careful to design with users' systems in mind. Having a model made with too many polygons can slow down a walk-through, but it usually improves the small details on a model. Getting speed and quality proved tricky. An important thing for me to remember when modeling the habitat was to save space. Also, I must consider that technology in the future will be much different than now, so I must be especially creative. My project will be used in an educational walkthough simulation in which users can interact with the environment. I worked closely with intern Stephen Henke who built a Mars Rover, terrain and programmed code for the simulation. This summer's project will help me with future aspirations in computer graphics. Modeling is a valuable skill that I appreciate having the chance to learn and practice.

Henke, Stephen A.↗

Frequencies and Flutter Speed Estimation for Damaged Aircraft Wing Using Scaled Equivalent Plate Analysis

Equivalent plate analysis is often used to replace the computationally expensive finite element analysis in initial design stages or in conceptual design of aircraft wing structures. The equivalent plate model can also be used to design a wind tunnel model to match the stiffness characteristics of the wing box of a full-scale aircraft wing model while satisfying strength-based requirements An equivalent plate analysis technique is presented to predict the static and dynamic response of an aircraft wing with or without damage. First, a geometric scale factor and a dynamic pressure scale factor are defined to relate the stiffness, load and deformation of the equivalent plate to the aircraft wing. A procedure using an optimization technique is presented to create scaled equivalent plate models from the full scale aircraft wing using geometric and dynamic pressure scale factors. The scaled models are constructed by matching the stiffness of the scaled equivalent plate with the scaled aircraft wing stiffness. It is demonstrated that the scaled equivalent plate model can be used to predict the deformation of the aircraft wing accurately. Once the full equivalent plate geometry is obtained, any other scaled equivalent plate geometry can be obtained using the geometric scale factor. Next, an average frequency scale factor is defined as the average ratio of the frequencies of the aircraft wing to the frequencies of the full-scaled equivalent plate. The average frequency scale factor combined with the geometric scale factor is used to predict the frequency response of the aircraft wing from the scaled equivalent plate analysis. A procedure is outlined to estimate the frequency response and the flutter speed of an aircraft wing from the equivalent plate analysis using the frequency scale factor and geometric scale factor. The equivalent plate analysis is demonstrated using an aircraft wing without damage and another with damage. Both of the problems show that the scaled equivalent plate analysis can be successfully used to predict the frequencies and flutter speed of a typical aircraft wing.

Krishnamurthy, Thiagarajan↗

Broken Ergodicity in MHD Turbulence in a Spherical Domain

Broken ergodicity (BE) occurs in Fourier method numerical simulations of ideal, homogeneous, incompressible magnetohydrodynamic (MHD) turbulence. Although naive statistical theory predicts that Fourier coefficients of fluid velocity and magnetic field are zero-mean random variables, numerical simulations clearly show that low-wave-number coefficients have non-zero mean values that can be very large compared to the associated standard deviation. In other words, large-scale coherent structure (i.e., broken ergodicity) in homogeneous MHD turbulence can spontaneously grow out of random initial conditions. Eigenanalysis of the modal covariance matrices in the probability density functions of ideal statistical theory leads to a theoretical explanation of observed BE in homogeneous MHD turbulence. Since dissipation is minimal at the largest scales, BE is also relevant for resistive magnetofluids, as evidenced in numerical simulations. Here, we move beyond model magnetofluids confined by periodic boxes to examine BE in rotating magnetofluids in spherical domains using spherical harmonic expansions along with suitable boundary conditions. We present theoretical results for 3-D and 2-D spherical models and also present computational results from dynamical simulations of 2-D MHD turbulence on a rotating spherical surface. MHD turbulence on a 2-D sphere is affected by Coriolus forces, while MHD turbulence on a 2-D plane is not, so that 2-D spherical models are a useful (and simpler) intermediate stage on the path to understanding the much more complex 3-D spherical case.

Shebalin, John V.↗

Box truss analysis and technology development. Task 1: Mesh analysis and control

An analytical tool was developed to model, analyze and predict RF performance of box truss antennas with reflective mesh surfaces. The analysis system is unique in that it integrates custom written programs for cord tied mesh surfaces, thereby drastically reducing the cost of analysis. The analysis system is capable of determining the RF performance of antennas under any type of manufacturing or operating environment by integrating together the various disciplines of design, finite element analysis, surface best fit analysis and RF analysis. The Integrated Mesh Analysis System consists of six separate programs: The Mesh Tie System Model Generator, The Loadcase Generator, The Model Optimizer, The Model Solver, The Surface Topography Solver and The RF Performance Solver. Additionally, a study using the mesh analysis system was performed to determine the effect of on orbit calibration, i.e., surface adjustment, on a typical box truss antenna.

Bachtell, E. E.↗