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NASA NTRSDate not supplied

Structures and Materials Research at NASA Langley Research Center

NASA explores the unknown in air and space, innovates for the benefit of humanity, and inspires the world through discovery. The Structures and Materials discipline at NASA Langley Research Center supports this mission through advanced materials and manufacturing approaches applied to innovative structural concepts. We start with synthesizing novel material systems and applying tools and methods to predict and validate their static, dynamic, durability and damage tolerance behavior. We mature materials from test tube to test flight by developing manufacturing techniques that enable the advancement of aerospace structures from concept to reality. We develop advanced measurement techniques for health management and nondestructive evaluation. We draw on our structures and materials core capabilities to enable safe, reliable lightweight aerospace structures for application in all environments. You will find the results of our work in the assembly of large structures in space and on other planets, vehicles that carry crew into space, vehicles that operate at high speeds and in extreme environments, and technology for passenger and crew safety in commercial aviation. This presentation will provide an overview of Langley Research Center’s role within the agency, then focus on how current Structures and Materials research areas support a variety of NASA missions in space operations, exploration, and aeronautics.

Structures↗

NASA NTRS2011

Full-Scaled Advanced Systems Testbed: Ensuring Success of Adaptive Control Research Through Project Lifecycle Risk Mitigation

The National Aeronautics and Space Administration's Dryden Flight Research Center completed flight testing of adaptive controls research on the Full-Scale Advance Systems Testbed (FAST) in January of 2011. The research addressed technical challenges involved with reducing risk in an increasingly complex and dynamic national airspace. Specific challenges lie with the development of validated, multidisciplinary, integrated aircraft control design tools and techniques to enable safe flight in the presence of adverse conditions such as structural damage, control surface failures, or aerodynamic upsets. The testbed is an F-18 aircraft serving as a full-scale vehicle to test and validate adaptive flight control research and lends a significant confidence to the development, maturation, and acceptance process of incorporating adaptive control laws into follow-on research and the operational environment. The experimental systems integrated into FAST were designed to allow for flexible yet safe flight test evaluation and validation of modern adaptive control technologies and revolve around two major hardware upgrades: the modification of Production Support Flight Control Computers (PSFCC) and integration of two, fourth-generation Airborne Research Test Systems (ARTS). Post-hardware integration verification and validation provided the foundation for safe flight test of Nonlinear Dynamic Inversion and Model Reference Aircraft Control adaptive control law experiments. To ensure success of flight in terms of cost, schedule, and test results, emphasis on risk management was incorporated into early stages of design and flight test planning and continued through the execution of each flight test mission. Specific consideration was made to incorporate safety features within the hardware and software to alleviate user demands as well as into test processes and training to reduce human factor impacts to safe and successful flight test. This paper describes the research configuration, experiment functionality, overall risk mitigation, flight test approach and results, and lessons learned of adaptive controls research of the Full-Scale Advanced Systems Testbed.

Pavlock, Kate M.↗

NASA NTRS2004

Foam on Tile Impact Modeling for the STS-107 Investigation

Following the breakup of the Space Shuttle Columbia during reentry a NASA/Contractor investigation team was formed to examine the probable damage inflicted on Orbiter Thermal Protection System elements by impact of External Tank insulating foam projectiles. The authors formed a working subgroup within the larger team to apply the Smooth Particle Hydrodynamics code SPHC to the damage estimation problem. Numerical models of the Orbiter's tiles and of the Tank's foam were constructed and used as inputs into the code. Material properties needed to properly model the tiles and foam were obtained from other working subgroups who performed tests on these items for this purpose. Two- and three-dimensional models of the tiles were constructed, including the glass outer layer, the main body of LI-900 insulation, the densified lower layer of LI-900, the Nomex felt mounting layer, and the Aluminum 2024 vehicle skin. A model for the BX-250 foam including porous compression, elastic rebound, and surface erosion was developed. Code results for the tile damage and foam behavior were extensively validated through comparison with Southwest Research Institute foam-on-tile impact experiments carried out in 1999. These tests involved small projectiles striking individual tiles and small tile arrays. Following code and model validation we simulated impacts of larger foam projectiles on the examples of tile systems used on the Orbiter. Results for impacts on the main landing gear door are presented in this paper, including effects of impacts at several angles, and of rapidly rotating projectiles. General results suggest that foam impacts on tiles at about 500 mph could cause appreciable damage if the impact angle is greater than about 20 degrees. Some variations of the foam properties, such as increased brittleness or increased density could increase damage in some cases. Rotation up to 17 rps failed to increase the damage for the two cases considered. This does not rule out other cases in which the rotational energy might lead to an increase in tile damage, but suggests that in most cases rotation will not be an important factor.

Stellingwerf, R. F.↗

NASA NTRS2004

On the Development of a Unique Arc Jet Test Apparatus for Control Surface Seal Evaluations

NASA Glenn has developed a unique test apparatus capable of evaluating control surface seal and flap designs under simulated reentry heating conditions in NASA Johnson's arc jet test facility. The test apparatus is capable of testing a variety of seal designs with a variety of control surface materials and designs using modular components. The flap angle can be varied during testing, allowing modification of the seal environment while testing is in progress. The flap angle is varied using an innovative transmission system which limits heat transfer from the hot flap structure to the motor, all while keeping the components properly aligned regardless of thermal expansion. A combination of active and passive cooling is employed to prevent thermal damage to the test fixture while still obtaining the target seal temperature.

Finkbeiner, Joshua R.↗

NASA NTRS2000

Vibration Testing of an Operating Stirling Convertor

The NASA John H. Glenn Research Center and the U.S. Department of Energy are currently developing a Stirling convertor for use as an advanced spacecraft power system for future NASA deep-space missions. As part of this development, a Stirling Technology Demonstrator Convertor (TDC) was recently tested to verify its survivability and capability of withstanding its expected launch random vibration environment. The TDC was fully operational (producing power) during the random vibration testing. The output power of the convertor was measured during the testing, and these results are discussed in this paper. Numerous accelerometers and force gauges were also present which provided information on the dynamic characteristics of the TDC and an indication of any possible damage due to vibration. These measurements will also be discussed in this paper. The vibration testing of the Stirling TDC was extremely successful. The TDC survived all its vibration testing with no structural damage or functional performance degradation. As a result of this testing, the Stirling convertor's capability to withstand vibration has been demonstrated, enabling its usage in future spacecraft power systems.

Hughes, William O.↗

NASA NTRS2013

Aerogel-Based Multilayer Insulation with Micrometeoroid Protection

Ultra-low-density, highly hydrophobic, fiber-reinforced aerogel material integrated with MLI (aluminized Mylar reflectors and B4A Dacron separators) offers a highly effective insulation package by providing unsurpassed thermal performance and significant robustness, delivering substantial MMOD protection via the addition of a novel, durable, external aerogel layer. The hydrophobic nature of the aerogel is an important property for maintaining thermal performance if the material is exposed to the environment (i.e. rain, snow, etc.) during ground installations. The hybrid aerogel/MLI/MMOD solution affords an attractive alternative because it will perform thermally in the same range as MLI at all vacuum levels (including high vacuum), and offers significant protection from micrometeoroid damage. During this effort, the required low-density and resilient aerogel materials have been developed that are needed to optimize the thermal performance for space (high vacuum) cryotank applications. The proposed insulation/MMOD package is composed of two sections: a stack of interleaved aerogel layers and MLI intended for cryotank thermal insulation, and a 1.5- to 1-in. (.2.5- to 3.8- cm) thick aerogel layer (on top of the insulation portion) for MMOD protection. Learning that low-density aerogel cannot withstand the hypervelocity impact test conditions, the innovators decided during the course of the program to fabricate a high-density and strong material based on a cross-linked aerogel (X-aerogel; developed elsewhere by the innovators) for MMOD protection. This system has shown a very high compressive strength that is capable of withstanding high-impact tests if a proper configuration of the MMOD aerogel layer is used. It was learned that by stacking two X-aerogel layers [1.5-in. (.3.8-cm) thick] separated by an air gap, the system would be able to hold the threat at a speed of 5 km/s and gpass h the test. The first aerogel panel stopped the projectile from damaging the second aerogel panel. The impacted X-aerogel (the back specimen from the successful test) was further tested in comparison to another similar sample (not impacted) at Kennedy Space Center for thermal conductivity evaluation at cryogenic conditions. The specimens were tested under high vacuum and cryogenic temperatures, using Cryostat 500. The results show that the specimen did not lose a significant amount of thermal performance due to the impact test, especially at high vacuum.

Begag, Redouane↗

NASA NTRS2004

Transmission Bearing Damage Detection Using Decision Fusion Analysis

A diagnostic tool was developed for detecting fatigue damage to rolling element bearings in an OH-58 main rotor transmission. Two different monitoring technologies, oil debris analysis and vibration, were integrated using data fusion into a health monitoring system for detecting bearing surface fatigue pitting damage. This integrated system showed improved detection and decision-making capabilities as compared to using individual monitoring technologies. This diagnostic tool was evaluated by collecting vibration and oil debris data from tests performed in the NASA Glenn 500 hp Helicopter Transmission Test Stand. Data was collected during experiments performed in this test rig when two unanticipated bearing failures occurred. Results show that combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spiral bevel gears duplex ball bearings and spiral bevel pinion triplex ball bearings in a main rotor transmission.

Dempsey, Paula J.↗

NASA NTRS2004

Selected Flight Test Results for Online Learning Neural Network-Based Flight Control System

The NASA F-15 Intelligent Flight Control System project team has developed a series of flight control concepts designed to demonstrate the benefits of a neural network-based adaptive controller. The objective of the team is to develop and flight-test control systems that use neural network technology to optimize the performance of the aircraft under nominal conditions as well as stabilize the aircraft under failure conditions. Failure conditions include locked or failed control surfaces as well as unforeseen damage that might occur to the aircraft in flight. This report presents flight-test results for an adaptive controller using stability and control derivative values from an online learning neural network. A dynamic cell structure neural network is used in conjunction with a real-time parameter identification algorithm to estimate aerodynamic stability and control derivative increments to the baseline aerodynamic derivatives in flight. This set of open-loop flight tests was performed in preparation for a future phase of flights in which the learning neural network and parameter identification algorithm output would provide the flight controller with aerodynamic stability and control derivative updates in near real time. Two flight maneuvers are analyzed a pitch frequency sweep and an automated flight-test maneuver designed to optimally excite the parameter identification algorithm in all axes. Frequency responses generated from flight data are compared to those obtained from nonlinear simulation runs. An examination of flight data shows that addition of the flight-identified aerodynamic derivative increments into the simulation improved the pitch handling qualities of the aircraft.

Williams, Peggy S.↗

NASA NTRS1997

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗

NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Kemmerer, Catherine C.↗

NASA NTRSDate not supplied

Best Practices, Lessons Learned, and Examples on the Application of Damage Tolerance in Space Structures

Damage tolerance is an important consideration in space structures applications. The intent of damage tolerance is to demonstrate that the structure is robust to the presence of flaws over the service life of the space vehicle. Damage tolerance requirements in documents such as those in NASA, AIAA, and ISO can be challenging to implement. The intent of this paper is three-fold: (1) Provide best practices in the application of damage tolerance requirements for space applications, (2) Provide lessons learned for each of class of hardware, (3) Provide examples of challenging situations encountered in the application of damage tolerance. Examples cover additive manufacturing, composite overwrapped pressure vessels, pressurized structures, liquid rocket engines, thermal protection systems, and other classes of hardware. The philosophy and limitations of leak before burst and proof test logic are also discussed. Finally, a discussion on elastic-plastic fracture mechanics with comparisons to test data will be presented.

Best Practices↗

NASA NTRS1999

Synergistic Effects of Physical Aging and Damage on Long-Term Behavior of Polymer Matrix Composites

The research consisted of two major parts, first modeling and simulation of the combined effects of aging and damage on polymer composites and secondly an experimental phase examining composite response at elevated temperatures, again activating both aging and damage. For the simulation, a damage model for polymeric composite laminates operating at elevated temperatures was developed. Viscoelastic behavior of the material is accounted for via the correspondence principle and a variational approach is adopted to compute the temporal stresses within the laminate. Also, the effect of physical aging on ply level stress and on overall laminate behavior is included. An important feature of the model is that damage evolution predictions for viscoelastic laminates can be made. This allows us to track the mechanical response of the laminate up to large load levels though within the confines of linear viscoelastic constitutive behavior. An experimental investigation of microcracking and physical aging effects in polymer matrix composites was also pursued. The goal of the study was to assess the impact of aging on damage accumulation, in ten-ns of microcracking, and the impact of damage on aging and viscoelastic behavior. The testing was performed both at room and elevated temperatures on [+/- 45/903](sub s) and [02/903](sub s) laminates, both containing a set of 90 deg plies centrally located to facilitate investigation of microcracking. Edge replication and X-ray-radiography were utilized to quantify damage. Sequenced creep tests were performed to characterize viscoelastic and aging parameters. Results indicate that while the aging times studied have limited ]Influence on damage evolution, elevated temperature and viscoelastic effects have a profound effect on the damage mode seen. Some results are counterintuitive, including the lower strain to failure for elevated temperature tests and the catastrophic failure mode observed for the [+/- 45/9O3](sub s), specimens. The fracture toughness for transverse cracks increases with increasing temperature for both systems: transverse cracking was completely absent prior to failure in [+/- 45/903](sub s), and was suppressed for [02/903](sub s). No significant effect of damage on aging or viscoelastic parameters was observed.

Brinson, L. Cate↗

NASA NTRS2014

A Multiple Parameters Biodosimetry Tool with Various Blood Cell Counts - the Hemodose Approach

There continue to be important concerns about the possibility of the occurrence of acute radiation syndromes following nuclear and radiological terrorism or accidents that may result in mass casualties in densely populated areas. To guide medical personnel in their clinical decisions for effective medical management and treatment of the exposed individuals, biological markers are usually applied to examine radiation induced biological changes to assess the severity of radiation injury to sensitive organ systems. Among these the peripheral blood cell counts are widely used to assess the extent of radiation induced bone marrow injury. This is due to the fact that the hematopoietic system is the most vulnerable part of the human body to radiation damage. Particularly, the lymphocyte, granulocyte, and platelet cells are the most radiosensitive of the blood elements, and monitoring their changes after exposure is regarded as a practical and recommended laboratory test to estimate radiation dose and injury. Based upon years of physiological and pathophysiological investigation of mammalian hematopoietic systems, and rigorous coarse-grained bio-mathematical modeling and validation on species from mouse, to dog, monkey, and human, we have developed a set of software tools Hemodose, which can use single or serial granulocyte, lymphocyte, leukocyte, or platelet counts after exposure to estimate absorbed doses of adult victims very rapidly and accurately. Some patient data from historical accidents are utilized as examples to demonstrate the capabilities of these tools as a rapid point-of-care diagnostic or centralized high-throughput assay system in a large-scale radiological disaster scenario. Most significant to the improvement of national and local preparedness of a potential nuclear/radiological disaster, this HemoDose approach establishes robust correlations between the absorbed doses and victim's various types of blood cell counts not only in the early time window (1 or 2 days), but also in the very late phase (up to 4 weeks) after exposure.

Hu, Shaowen↗

NASA NTRSDate not supplied

Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions. Since priming transients are difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test system and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.

Brian S Lusby↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Adaptive flight control systems have the potential to be more resilient to extreme changes in airplane behavior. Extreme changes could be a result of a system failure or of damage to the airplane. A direct adaptive neural-network-based flight control system was developed for the National Aeronautics and Space Administration NF-15B Intelligent Flight Control System airplane and subjected to an inflight simulation of a failed (frozen) (unmovable) stabilator. Formation flight handling qualities evaluations were performed with and without neural network adaptation. The results of these flight tests are presented. Comparison with simulation predictions and analysis of the performance of the adaptation system are discussed. The performance of the adaptation system is assessed in terms of its ability to decouple the roll and pitch response and reestablish good onboard model tracking. Flight evaluation with the simulated stabilator failure and adaptation engaged showed that there was generally improvement in the pitch response; however, a tendency for roll pilot-induced oscillation was experienced. A detailed discussion of the cause of the mixed results is presented.

Bosworth, John T.↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Bosworth, John T.↗

NASA NTRS2010

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Bosworth, John T.↗

NASA NTRS1974

The interaction of spacecraft high voltage power systems with the space plasma environment

Research work has shown that the interaction of a spacecraft and its high voltage power systems with the space plasma environment can result in harmful power loss and damage to insulators and metal surfaces. Insulator and solar panel tests were performed and flight tests are planned. High voltage power processing equipment was shown to be affected by power loss, and by transients due to plasma interactions. Power loss was determined to be roughly proportional to the square of the voltage and increases approximately as the square root of the area. Kapton, Teflon, and glass were found to be satisfactory insulating materials and it is concluded that for large space power stations should consider the effect of large pinhole currents.

Domitz, S.↗