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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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High efficiency solar cells required for the low cost modules was developed. The production tooling for the manufacture of the cells and modules was designed. The tooling consisted of: (1) back contact soldering machine; (2) vacuum pickup; (3) antireflective coating tooling; and (4) test fixture.
A graphite epoxy shear panel with bonded on J stiffeners was investigated. The panel, loaded to buckling in a picture frame shear test is described. Two finite element models, each of which included the doubler material bonded to the panel skin under the stiffeners and at the panel edges, were used to make a stress analysis of the panel. The shear load distributions in the panel from two commonly used boundary conditions, applied shear load and applied displacement, were compared with the results from one of the finite element models that included the picture frame test fixture.
An experimental study is described in which a quartz tube, hollow cathode was operated in a test fixture allowing the simultaneous measurement of internal cathode pressure, insert temperature profiles, and the emission currents from various cathode components as a function of discharge current and propellant (mercury) mass flow rate for a number of different cathode orifice diameters. Results show that the insert temperature profile is essentially independent of orifice diameter but depends strongly on internal cathode pressure and emission current. The product of internal cathode pressure and insert diameter is shown to be important in determining the emission location and the minimum keeper voltage.
Brittle lacquer unveils effects normally visible only by ultrasonic inspection. Laquer coating measures spread of cracking and delamination in graphite/epoxy panels subjected to cyclic compression loads after impact damage. Test specimen is coated with lacquer on side opposite surface at which projectile will be fired. Spalled area shows effect of impact without removing specimen from test fixture.
The ullage compression ignition sensitivity of NOS-365 monopropellant under the pressure condition expected to be found in a medium caliber regenerative liquid propellant gun is evaluated. The results from the rapidly loaded propellant tests performed to date are presented. For this case, the physical state of the propellant is characterized by the presence of turbulence and a finely distributed ullage field. A description of the test fixtures, procedures and results is given. It is argued that the results to date indicate that with relatively simple precautionary measures NOS-365 can be rendered sufficiently immune to the ullage compression ignition mechanism to permit it to be safely used in a regenerative liquid propellant gun.
The development of an electrostatic membrane antenna for large space structure applications is discussed. Problems encountered in fabricating 4.88 m (16 foot) diameter thin film membranes are addressed. The development of a test fixture for evaluating the membranes and the comparison of surface measurement systems are also discussed.
Chain of plates embedded in flexible seal enables it to withstand side loading of 2,300 psi (116MPa) while sealing gap of up to 0.5 inch (13 mm) between cylindrical chamber wall and test fixture. Pressure-actuated seal along inner edge forces seal into contact even though cylinder wall becomes eccentric as cylinder pressure increases. Seal has many industrial applications, particularly where heat or pressure causes distortion of chamber being sealed.
Finite element models were used to study the effects of notch angle variations on the stress state within an Iosipescu shear test speciment. These analytical results were also studied to determine the feasibility of using strain gage rosettes and a modified extensometer to measure shear strains in this test specimen. Analytical results indicate that notch angle variations produced only small differences in simulated shear properties. Both strain gage rosettes and the modified extensometer were shown to be feasible shear strain transducers for the test method. The Iosipoescu shear test fixture was redesigned to incorporate several improvements. These improvements include accommodation of a 50 percent larger specimen for easier measurement of shear train, a clamping mechanism to relax strict tolerances on specimen width, and a self contained alignment tool for use during specimen installation. A set of in-plane and interlaminar shear properties were measured for three graphite fabric/epoxy composites of T300/934 composite material. The three weave patterns were Oxford, 5-harness satin, and 8-harness satin.
A hot-film constant-temperature anemometer (CTA) system was flight-tested and evaluated as a candidate sensor for determining boundary-layer transition on high-performance aircraft. The hot-film gage withstood an extreme flow environment characterized by shock waves and high dynamic pressures, although sensitivity to the local total temperature with the CTA indicated the need for some form of temperature compensation. A temperature-compensation scheme was developed and two CTAs were modified and flight-tested on the F-104/Flight Test Fixture (FTF) facility at a variety of Mach numbers and altitudes, ranging from 0.4 to 1.8 and 5,000 to 40,000 ft respectively.
An experimental and analytical study was conducted of the postbuckling response and failure characteristics of 8-, 16-, and 24-ply unstiffened graphite/epoxy plates under shear loading, including orthotropic, quasi-orthotropic, entirely +, -45 deg ply, and (0/90)s-class plates. Postbuckling stiffness is noted to be influenced by the stacking sequence and by the inplane boundary condition imposed on the test section by a picture frame test fixture. The ratio of failure load to buckling load was higher for specimens that had higher width-to-thickness ratios. It is noted that high displacement gradients may induce transverse shear stresses, and that delamination was the failure mechanism for many of the 8-ply specimens. An adhesive failure between the composite specimen and metal edge reinforcements initiated failure of the 16- and 24-ply specimens.
Significant improvements in engine readiness with reductions in maintenance costs and turn-around times can be achieved with an engine condition monitoring systems (CMS). The CMS provides health status of critical engine components, without disassembly, through monitoring with advanced sensors. Engine failure reports over 35 years were categorized into 20 different modes of failure. Rotor bearings and turbine blades were determined to be the most critical in limiting turbopump life. Measurement technologies were matched to each of the failure modes identified. Three were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiberoptic deflectometer (bearings), and the fiberoptic pyrometer (blades). Signal processing algorithms were evaluated for their ability to provide useful health data to maintenance personnel. Design modifications to the Space Shuttle Main Engine (SSME) high pressure turbopumps were developed to incorporate the sensors. Laboratory test fixtures have been designed for monitoring the rotor bearings and turbine blades in simulated turbopump operating conditions.
Large deformation response of simple composite structural elements to intense dynamic loadings is studied by focusing on the response of beams. Overall goals are to: design a simple test fixture to introduce crash related bending loads in beams; determine any difference between large deformation static and large deformation dynamic response; determine the influence of laminate stacking arrangements on the dynamic response, failure mode, and energy absorbed; and predict the dynamic response. Twelve different laminate orientations were investigated. Modeling of the response was done with an existing finite element program. The program computed nonlinear transient response analysis of a structure objected to a time varying load.
A hot-film constant-temperature anemometer (CTA) system was flight-tested and evaluated as a candidate sensor for determining boundary-layer transition on high-performance aircraft. The hot-film gage withstood an extreme flow environment characterized by shock waves and high dynamic pressures, although sensitivity to the local total temperature with the CTA indicated the need for some form of temperature compensation. A temperature-compensation scheme was developed and two CTAs were modified and flight-tested on the F-104/Flight Test Fixture (FTF) facility at a variety of Mach numbers and altitudes, ranging from 0.4 to 1.8 and 5,000 to 40,000 ft respectively.
The acceptance of surface mounting in the electronics industry has been slowed by problems with component availability, electrical testing, and inspection. Industry suppliers and users have been working to solve these problems, and they are easing. Component manufacturers are offering substantially more devices in surface mountable packages. Automated test equipment vendors are offering test fixtures for surface mount circuit boards. And just recently, solder connection inspection has been automated through a partership effort with a major electronics manufacturer. The results achieved in this effort are presented.
An error analysis of results from finite-element solutions of problems in shell structures is further developed, incorporating the results of an additional numerical analysis by which oscillatory behavior is eliminated. The theory is extended to plates with initial geometric imperfections, and this novel analysis is programmed as a postprocessor for a general-purpose finite-element code. Numerical results are given for the case of a stiffened panel in compression and a plate loaded in shear by a 'picture-frame' test fixture.
Losses in short-haul broadband fiber-optic links are primarily due to many characteristics of electrooptic devices. In particular, electrical mismatch at the electrical/optical interfaces have been the dominant source of loss. Losses can be significantly reduced and link performance enhanced by reactive matching of the laser and detector modules. The steps in the design of low-loss fiber-optic links are presented, which are on the basis of (1) two-tier deembedding of laser and photodiodes from test fixtures and (2) reactively matching them to a standard 50-ohm system. These concepts are demonstrated by design of a link operating at 0.5 to 1 GHz using reactively matched optical transmitter and receiver modules.
Leakage rates of an innovative hypersonic engine seal were measured using a specially developed static high temperature seal test fixture at NASA Lewis Research Center. The three foot long structural panel-edge seal is designed to minimize leakage of high temperature, high pressure gases past the movable panels of advanced ramjet/scramjet engines. The seal is made of a stack of precision machined ceramic wafer pieces that are inserted into a closely conforming seal channel in the movable engine panel. The wafer seal accommodates the significant distortions in the adjacent engine walls through relative sliding between adjacent wafers. Seal leakage rates are presented for engine simulated air temperatures up to 1350 F and for engine pressures up to 100 psi. Leakage rates are also presented for the seal, sealing both a flat wall condition, and an engine simulated distorted wall condition in which the distortion was 0.15 in. in only an 18 in. span. Seal leakage rates were low, meeting an industry-established tentative leakage limit for all combinations of temperature, pressure, and wall conditions considered. Comparisons are made between the measured leakage rates and leakage rates predicted using a seal leakage model developed from externally-pressurized gas film bearing theory.
This paper summarizes some of the efforts to advance hypersonic structures technology through the National Aero-Space Plane (NASP) Structures Technology Maturation Program. The ranges of expected structural loads and results from analysis and test activities are described. Topics briefly covered include shock impingement effects on aerothermal loads, actively-cooled structures concepts and test results to date for leading edges and panels, design and fabrication of a carbon-carbon control surface, a program for predicting performance of metal matrix composites, an analysis and sizing procedure for thermal structures, and some recently-developed test fixtures for seals, thermal insulation, and actively-cooled panels.