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NASA NTRS2018

Modeling-Driven Damage Tolerant Design of Graphene Nanoplatelet/Carbon Fiber/Epoxy Hybrid Composite Panels for Full-Scale Aerospace Structures

The objective of this study is to design a new nano graphenecarbon fiberpolymer hybrid composite that can be used for the NASA SLS Composite Exploration Upper Stage (CEUS) forward skirt structure. The new material will improve the resistance to open-hole compression failure of the structure relative to traditional polymer fiber composites. The material is designed rapidly and with little cost using the Integrated Computational Materials Engineering (ICME) approach. Multiscale modeling and experiments are used to synergistically optimize the material design to yield improved properties and performance by controlling key processing parameters for manufacturing nano-enhanced materials. Specifically, the nanocomposite panel showed a 22 reduction in mass relative to the traditional composite panel, while both designs are equal in terms of ease of manufacture. This potential mass savings corresponds to an estimated 45 savings in materials and manufacturing costs. The multiscale ICME workflow developed for this project can be readily applied to the development of nano-enhanced composite materials and large aerospace structures. In addition, all key aspects of ICME were employed to complete this project including multiscale modeling, experimental characterization and visualization, data management, visualization, error and uncertainty quantification, and education. The results presented herein indicate a dramatic level of success, as well as the power and potential of ICME approach and multiscale modeling for composite materials.

computational mechanics↗

NASA NTRS2015

Evaluation of Solid Rocket Motor Component Data Using a Commercially Available Statistical Software Package

Commercially available software packages today allow users to quickly perform the routine evaluations of (1) descriptive statistics to numerically and graphically summarize both sample and population data, (2) inferential statistics that draws conclusions about a given population from samples taken of it, (3) probability determinations that can be used to generate estimates of reliability allowables, and finally (4) the setup of designed experiments and analysis of their data to identify significant material and process characteristics for application in both product manufacturing and performance enhancement. This paper presents examples of analysis and experimental design work that has been conducted using Statgraphics®(Registered Trademark) statistical software to obtain useful information with regard to solid rocket motor propellants and internal insulation material. Data were obtained from a number of programs (Shuttle, Constellation, and Space Launch System) and sources that include solid propellant burn rate strands, tensile specimens, sub‐scale test motors, full‐scale operational motors, rubber insulation specimens, and sub‐scale rubber insulation analog samples. Besides facilitating the experimental design process to yield meaningful results, statistical software has demonstrated its ability to quickly perform complex data analyses and yield significant findings that might otherwise have gone unnoticed. One caveat to these successes is that useful results not only derive from the inherent power of the software package, but also from the skill and understanding of the data analyst.

Stefanski, Philip L.↗

NASA NTRS2001

Analytical Method to Evaluate Failure Potential During High-Risk Component Development

Communicating failure mode information during design and manufacturing is a crucial task for failure prevention. Most processes use Failure Modes and Effects types of analyses, as well as prior knowledge and experience, to determine the potential modes of failures a product might encounter during its lifetime. When new products are being considered and designed, this knowledge and information is expanded upon to help designers extrapolate based on their similarity with existing products and the potential design tradeoffs. This paper makes use of similarities and tradeoffs that exist between different failure modes based on the functionality of each component/product. In this light, a function-failure method is developed to help the design of new products with solutions for functions that eliminate or reduce the potential of a failure mode. The method is applied to a simplified rotating machinery example in this paper, and is proposed as a means to account for helicopter failure modes during design and production, addressing stringent safety and performance requirements for NASA applications.

Tumer, Irem Y.↗

NASA NTRS1991

Structural evaluation of curved stiffened composite panels fabricated using a THERM-Xsm process

The use of composites in aircraft structures is often limited by material and manufacturing costs which, for some designs and applications, are prohibitively high. To increase the frequency of application of composites in primary airframe components alternative manufacturing processes are sought that reduce cost and/or enhance structural efficiency. One alternative process involves the use of THERM-Xsm as the pressure transfer medium during autoclave curing. THERM-Xsm, a silicon-based flow able polymer which behaves like a liquid under autoclave presssure, transmits quasi-hydrostatic pressure to all contacting surfaces of the part to be cured. Once the autoclave pressure is relieved, THERM-Xsm reverts back to the powdery solid state and can be reused many times. The THERM-Xsm process to be evaluated is depicted and consists of (1) enclosing the tool and part to be cured by a set of frames that create a box, (2) pouring THERM-Xsm powder onto the part and filling the box, and (3) placing a vacuum bag over the box assembly. In this program, a separating non-porous film (Teflon) was placed between the part to be cured and THERM-Xsm powder to avoid any contamination. The use of THERM-Xsm has two significant advantages over conventional manufacturing procedures. First, it eliminates complicated hard tooling since it guarantees uniform pressure transfer and thus, good compaction at complex structural details (such as frame-stiffener intersections and corners). Second, it greatly simplifies vacuum bagging, since once the part to be cured is covered by THERM-Xsm powder, the vacuum bag need only conform to a relatively flat shape reducing significantly the number of pleats required. A program is on-going at Sikorsky Aircraft to evaluate the structural performance of complex composite fuselage structures made with this THERM-Xsm process and to quantify the impact of THERM-Xsm on manufacturing labor hours and cost. The program involves fuselage panel optimization analysis, a building block test program where structural details representative of the full-scale article are analyzed and tested, and static and fatigue test/analysis of the full-scale test articles. The main results of this program are reported.

Kassapoglou, Christos↗

NASA NTRS2003

The Application of Metal Matrix Composite Materials in Propulsion System Valves

Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.

Laszar, John↗

NASA NTRS2011

Low Cost Nuclear Thermal Rocket Cermet Fuel Element Environment Testing

Deep space missions with large payloads require high specific impulse (Isp) and relatively high thrust in order to achieve mission goals in reasonable time frames. Conventional, storable propellants produce average Isp. Nuclear thermal rockets (NTR) capable of high Isp thrust have been proposed. NTR employs heat produced by fission reaction to heat and therefore accelerate hydrogen which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000K) and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high temperature hydrogen exposure on fuel elements is limited. The primary concern is the mechanical failure of fuel elements which employ high-melting-point metals, ceramics or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. It is not necessary to include fissile material in test samples intended to explore high temperature hydrogen exposure of the structural support matrices. A small-scale test bed designed to heat fuel element samples via non-contact RF heating and expose samples to hydrogen is being developed to assist in optimal material and manufacturing process selection without employing fissile material. This paper details the test bed design and results of testing conducted to date.

Bradley, David E.↗

NASA NTRS2013

Integration of Mirror Design with Suspension System using NASA's New Mirror Modeling Software

Advances in mirror fabrication is making very large space based telescopes possible. In the many applications, only monolithic mirrors meet the performance requirements. The existing and near-term planned heavy launch vehicles place a premium on lowest possible mass. Again, available and planned payload shroud size limits near term designs to 4 meter class mirror. Practical 8 meter and beyond designs could encourage planners to include larger shrouds if it can be proven that such mirrors can be manufactured. These two factors lower mass and larger mirrors, presents the classic optimization problem. There is a practical upper limit to how large a mirror can be supported by a purely kinematic mount system and be launched. This paper shows how the design of the suspension system and mirror blank needs to be designed simultaneously. We will also explore the concepts of auxiliary support systems, which act only during launch and disengage on orbit. We will define required characteristics of these systems and show how they can substantially reduce the mirror mass. The AMTD project is developing and maturing the processes for future replacements for HUBBLE, creating the design tools, validating the methods and techniques necessary to manufacture, test and launch extremely large optical missions. This paper will use the AMTD 4 meter "design point" as an illustration of the typical use of the modeler in generating the multiple models of mirror and suspension systems used during the conceptual design phase of most projects. The influence of Hexapod geometry, mirror depth, cell size and construction techniques (Exelsis Deep Core Low Temperature Fusion (c) versus Corning Frit Bonded (c) versus Schott Pocket Milled Zerodur (c) in this particular study) are being evaluated. Due to space and time consideration we will only be able to present snippets of the study in this paper. The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond.

Arnold, William↗

NASA NTRS2000

Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

Cooper, K. G.↗

NASA NTRS1963

Component design, construction and evaluation for satellites

Components for a high-reliability system such as the Telstar project are obtained by: (a) design of the component for the required environment, (b) careful control of manufacturing processes, (c) elimination of potential early failures by screening tests, and (d) selection of the most stable components. For passive components, these methods could be applied by using design parameters, suppliers and screening techniques established in the earlier submarine cable program, with consideration being given to the additional effects of the satellite launch and orbit environments. Semiconductor component designs were selected by qualification tests using accelerated electrical and environmental stress conditions. Screening tests were applied to eliminate early failures, and resulting components were aged from two to six months before selection for the satellite. The recognition of the effect of ionizing radiation on transistors caused the addition of a radiation qualification test, or a screening to assure selection of the least sensitive devices. Tests have shown this screening to be effective for the radiation intensity expected. Experience with the passive components, and evaluation of the accelerated test results and aging data of the semiconductor devices, indicate that the reliability objective was obtained.

TELSTAR SATELLITE↗

NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗

NASA NTRS2013

Very-Low-Cost, Rugged Vacuum System

NASA, DoD, DHS, and commercial industry have a need for miniaturized, rugged, low-cost vacuum systems. Recent advances in sensor technology have led to the development of very small mass spectrometer detectors as well as other miniature analytical instruments. However, the vacuum systems to support these sensors remain large, heavy, and power-hungry. To meet this need, a miniaturized vacuum system was created based on a very small, rugged, and inexpensive- to-manufacture molecular drag pump (MDP). The MDP is enabled by the development of a miniature, veryhigh- speed, rugged, low-power, brushless DC motor optimized for wide temperature operation and long life. Such a pump represents an order-of-magnitude reduction in mass, volume, and cost over current, commercially available, state-ofthe- art vacuum pumps. The vacuum system consists of the MDP coupled to a ruggedized rough pump (for terrestrial applications or for planets with substantial atmospheres). The rotor in the MDP consists of a simple smooth cylinder of aluminum spinning at approximately 200,000 RPM inside an outer stator housing. The pump stator comprises a cylindrical aluminum housing with one or more specially designed grooves that serve as flow channels. To minimize the length of the pump, the gas is forced down the flow channels of the outer stator to the base of the pump. The gas is then turned and pulled toward the top through a second set of channels cut into an inner stator housing that surrounds the motor. The compressed gas then flows down channels in the motor housing to the exhaust port of the pump. The exhaust port of the pump is connected to a diaphragm or scroll pump. This pump delivers very high performance in a very small envelope. The design was simplified so that a smaller compression ratio, easier manufacturing process, and enhanced ruggedness can be achieved at the lowest possible cost. The machining of the rotor and stators is very simple compared to that necessary to fabricate TMP (turbo molecular pump) rotor and stator blades. Also, the symmetry of the rotor is such that dynamic balancing of the rotor is greatly simplified. Finally, because of the simplified design, the number of parts in the unit is cut by nearly a factor of three. In fact, there are only five parts, not counting the motor and off-the-shelf screws and O-rings. This reduces the amount of machining and also makes fit-up much simpler while allowing the maintenance of close tolerances.

Kline-Schoder, Robert↗

NASA NTRS1997

Structural Verification of the Space Shuttle's External Tank Super LightWeight Design: A Lesson in Innovation

The Super LightWeight Tank (SLWT) team was tasked with a daunting challenge from the outset: boost the payload capability of the Shuttle System by safely removing 7500 lbs. from the existing 65,400 lb. External Tank (ET). Tools they had to work with included a promising new Aluminum Lithium alloy, the concept of a more efficient structural configuration for the Liquid Hydrogen (LH2) tank, and a highly successful, mature Light Weight Tank (LWT) program. The 44 month schedule which the SLWT team was given for the task was ambitious by any measure. During this time the team had to not only design, build, and verify the new tank, but they also had to move a material from the early stages of development to maturity. The aluminum lithium alloy showed great promise, with an approximately 29% increase in yield strength, 15% increase in ultimate strength, 5 deg/O increase in modulus and 5 deg/O decrease in density when compared to the current 2219 alloy. But processes had to be developed and brought under control, manufacturing techniques perfected, properties characterized, and design allowable generated. Because of the schedule constraint, this material development activity had to occur in parallel with design and manufacturing. Initial design was performed using design allowable believed to be achievable with the Aluminum Lithium alloy system, but based on limited test data. Preliminary structural development tests were performed with material still in the process of iteration. This parallel path approach posed obvious challenges and risks, but also allowed a unique opportunity for interaction between the structures and materials disciplines in the formulation of the material.

Otte, Neil↗

NASA NTRS2016

Evaluation of Novel Liner Concepts for Fan and Airframe Noise Reduction

This paper presents a review of four novel liner concepts: soft vanes, over-the-rotor liners, external liners, and flap side-edge liners. A number of similarities in the design and evaluation of these concepts emerged during these investigations. Since these were the first attempts to study these particular liner concepts, there was limited information to guide the design process. In all cases, the target frequencies (or frequency range) were known, but the optimum acoustic impedance and optimum liner placement were typically not known. For these cases, the maximum available surface was used and a c-impedance was targeted based on the assumption the sound field impinges on the surface at normal incidence. This choice proved fruitful for every application. An impedance prediction model was used to design variable-depth liner configurations, and a graphical design code (ILIAD) was developed to aid in this process. The ability to build increasingly complex liner configurations via additive manufacturing was key, such that multiple designs could quickly be tested in a normal incidence impedance tube. The Two-Thickness Method was used to evaluate available bulk materials, such that bulk liners could also be considered for each application. These novel liner concepts provide sufficient noise reduction to warrant further investigations.

Jones, M. G.↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2011

External Tank Program - Legacy of Success

The largest single element of Space Shuttle is the External Tank (ET), which serves as the structural backbone of the vehicle during ascent and provides liquid propellants to the Orbiter s three Main Engines. The ET absorbs most of the seven million pounds of thrust exerted by the Solid Rocket Boosters and Main Engines. The design evolved through several block changes, reducing weight each time. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. The initial configuration, the standard weight tank, weighed 76,000 pounds and was an aluminum 2219 structure. The light weight tank weighed 66,000 pounds and flew 86 missions. The super light weight tank weighed 58,500 pounds and was primarily an aluminum-lithium structure. The final configuration and low weight enabled system level performance sufficient for assembly of the International Space Station in a high inclination orbit, vital for international cooperation. Another significant challenge was the minimization of ice formation on the cryogenic tanks. This was essential due to the system configuration and the choice of ceramic thermal protection system materials on the Orbiter. Ice would have been a major debris hazard. Spray on foam insulation materials served multiple functions including thermal insulation, conditioning of cryogenic propellants, and thermal protection for the tank structure during ascent and entry. The tank is large, and unique manufacturing facilities, tooling, and handling, and transportation operations were developed. Weld processes and tooling evolved with the design as it matured through several block changes. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the multi-decade program. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when hurricane Katrina damaged the manufacturing facility. Numerous lessons from these efforts, the manufacturing and material processing issues, the key design features, and evolution of the design will be discussed.

Pilet, Jeffery C.↗

NASA NTRS2011

The J-2X Fuel Turbopump - Turbine Nozzle Low Cycle Fatigue Acceptance Rationale

The J-2X Fuel Turbopump (FTP) turbine, which drives the pump that feeds hydrogen to the J-2X engine for main combustion, is based on the J-2S design developed in the early 1970 s. Updated materials and manufacturing processes have been incorporated to meet current requirements. This paper addresses an analytical concern that the J-2X Fuel Turbine Nozzle Low Cycle Fatigue (LCF) analysis did not meet safety factor requirements per program structural assessment criteria. High strains in the nozzle airfoil during engine transients were predicted to be caused by thermally induced stresses between the vane hub, vane shroud, and airfoil. The heritage J-2 nozzle was of a similar design and experienced cracks in the same area where analysis predicted cracks in the J-2X design. Redesign options that did not significantly impact the overall turbine configuration were unsuccessful. An approach using component tests and displacement controlled fracture mechanics analysis to evaluate LCF crack initiation and growth rate was developed. The results of this testing and analysis were used to define the level of inspection on development engine test units. The programmatic impact of developing crack initiation/growth rate/arrest data was significant for the J-2X program. Final Design Certification Review acceptance logic will ultimately be developed utilizing this test and analytical data.

Hawkins, Lakiesha V.↗

NASA NTRS1987

Robot design for a vacuum environment

The cleanliness requirements for many processing and manufacturing tasks are becoming ever stricter, resulting in a greater interest in the vacuum environment. Researchers discuss the importance of this special environment, and the development of robots which are physically and functionally suited to vacuum processing tasks. Work is in progress at the Center for robotic Systems in Microelectronics (CRSM) to provide a robot for the manufacture of a revolutionary new gyroscope in high vacuum. The need for vacuum in this and other processes is discussed as well as the requirements for a vacuum-compatible robot. Finally, researchers present details on work done at the CRSM to modify an existing clean-room compatible robot for use at high vacuum.

Belinski, S.↗

NASA NTRS1992

A basis for solid modeling of gear teeth with application in design and manufacture

A new approach to modeling gear tooth surfaces is discussed. A computer graphics solid modeling procedure is used to simulate the tooth fabrication process. This procedure is based on the principles of differential geometry that pertain to envelopes of curves and surfaces. The procedure is illustrated with the modeling of spur, helical, bevel, spiral bevel, and hypoid gear teeth. Applications in design and manufacturing are discussed. Extensions to nonstandard tooth forms, to cams, and to rolling element bearings are proposed.

Huston, Ronald L.↗