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We report on the design, fabrication and test of cryogenic sample cells and structures for the Critical Dynamics in Microgravity Experiment (DYNAMX), an experiment scheduled to fly on the space shuttle as part of the Microgravity Science Payload (MSP) in February 2001.
In the field of vibration testing, the interaction between the structure being tested and the instrumentation hardware used to perform the test is a critical issue. This is particularly true when testing massive structures (e.g. satellites), because due to physical design and manufacturing limits, the dynamics of the testing facility often couples with the test specimen one in the frequency range of interest. A further issue in this field is the standard use of a closed loop real-time vibration control scheme, which could potentially shift poles and change damping of the aforementioned coupled system. Virtual shaker testing is a novel approach to deal with these issues. It means performing a simulation which closely represents the real vibration test on the specific facility by taking into account all parameters which might impact the dynamic behavior of the specimen. In this paper, such a virtual shaker testing approach is developed. It consists of the following components: (1) Either a physical-based or an equation-based coupled electro-mechanical lumped parameter shaker model is created. The model parameters are obtained from manufacturer's specifications or by carrying out some dedicated experiments; (2) Existing real-time vibration control algorithm are ported to the virtual simulation environment; and (3) A structural model of the test object is created and after defining proper interface conditions structural modes are computed by means of the well-established Craig-Bampton CMS technique. At this stage, a virtual shaker test has been run, by coupling the three described models (shaker, control loop, structure) in a co-simulation routine. Numerical results have eventually been correlated with experimental ones in order to assess the robustness of the proposed methodology.
The nondestructive testing (NDT) on the Space Shuttle Solid Rocket Booster (SRB) filament wound case (FWC) short stact structural test articles 2 (STA-2A) during test of phases 1B-9C is described. The primary objective of this testing was to verify the structural integrity of the SRB-FWC for critical design loads. Another objective was to quantify the effect of load distributions in the aft skirt. The NDT objectives were to determine the acoustic emission characteristics of the FWC-SRB and to identify possible design deficiencies or defect growth. The results from the posttest inspection of the samples shows the depth measurements taken were accurate until exceeding .260 inches thickness. The data then show that pulse echo measurements exceeded actual part thickness by 10 to 14 percent. The mapping of forward boundaries of delaminations proved to be within the tolerance of the equipment. Using the ZIP probe, the maximum difference between the pulse echo boundary and the visual boundary was expected to be no greater than one half the diameter of the probe. The NDT performance on STA-2A shows how NDT can be used to assist design engineering in evaluating the structural integrity of composite test articles.
The Egrett aircraft has an all composite wing comprising CFC(carbon fiber composite)/Nomex sandwich skins, full length CFC main spar caps, and GFRP (glass fiber reinforced plastics) main and auxiliary spar webs. It also has short inboard CFC auxiliary spar caps. It has fine aluminum wires woven into the surface for protection. It has an integral fuel tank using the CFC/Nomex skins as the upper and lower tank walls, and lies between the forward auxiliary spar and the forward of the two main spar webs. The fuel tank is not bagged, i.e., it is in effect a wet wing tank. It has conventional capacitive type fuel gauging. The aircraft was cleared to IFR standards and so required full lightning protection and demonstration that it would survive the lightning environment. The lightning protection was designed for the wing (and also for the remainder of the aircraft). An inner wing test samples (which included a part of the fuel tank) were tested as part of the proving program. The protection design and the testing process are described. The intrinsic structural features are indicated that improve lightning protection design and which therefore minimize the weight and cost of any added lightning protection components.
Burner design modifications that will take advantage of the improved creep and cyclic oxidation resistance of oxide dispersion strengthened (ODS) alloys while accommodating the reduced fatigue properties of these materials were evaluated based on preliminary analysis and life predictions, on construction and repair feasibility, and on maintenance and direct operating costs. Two designs - the film cooled, segmented louver and the transpiration cooled, segmented twin Wall - were selected for low cycle fatigue (LCF) component testing. Detailed thermal and structural analysis of these designs established the strain range and temprature at critical locations resulting in predicted lives of 10,000 cycles for MA 956 alloy. The ODs alloys, MA 956 and HDA 8077, demonstrated a 167 C (300 F) temperature advantage over Hastelloy X alloy in creep strength and oxidation resistance. The MA 956 alloy was selected for mechanical property and component test evaluations. The MA 956 alloy was superior to Hastelloy X in LCF component testing of the film cooled, segmented louver design.
The USAF Rome Laboratory and NASA Marshall Space Flight Center, through contract to Grumman Corporation, have developed a space-qualifiable test article for the Strategic Defense Initiative Organization to demonstrate the critical structural and mechanical elements of single-axis roll-out membrane deployment for Space Based Radar (SBR) applications. The Lens Antenna Deployment Demonstration (LADD) test article, originally designed as a shuttle-attached flight experiment, is a large precision space structure which is representative of operational designs for space-fed lens antennas. Although the flight experiment was cancelled due to funding constraints and major revisions in the Strategic Defense System (SDS) architecture, development of this test article was completed in June 1989. To take full advantage of the existence of this unique structure, a series of ground tests are proposed which include static, dynamic, and thermal measurements in a simulated space environment. An equally important objective of these tests is the verification of the analytical tools used to design and develop large precision space structures.
Design and testing of beryllium-structure solar panel for Mars mission
Analyses were conducted to define a practical design for an advanced technology laminar flow control (LRC) transport for initial passenger operation in the early 1990's. Mission requirements, appropriate design criteria, and level of technology for the study aircraft were defined. The characteristics of the selected configuration were established, aircraft and LFC subsystems compatible with the mission requirements were defined, and the aircraft was evaluated in terms of fuel efficiency. A wing design integrating the LFC ducting and metering system into advanced composite wing structure was developed, manufacturing procedures for the surface panel design were established, and environmental and structural testing of surface panel components were conducted. Test results revealed a requirement for relatively minor changes in the manufacturing procedures employed, but have shown the general compatibility of both the selected design and the use of composite materials with the requirements of LFC wing surface panels.
Action to be taken to prepare to implement efficient, modern commuter aircraft for the 1990s is outlined. The increase in the contribution of jet fuel costs to aircraft direct operating costs (DOC) is noted as the motivation for the introduction of turboprop-powered commuter aircraft, which use 15-20% less fuel per seat mile at short stage lengths, to replace larger jet transports. Designs proposed by various manufacturers which will make use of existing technology for 19-, 30- and 50-seat aircraft capable of carrying a full payload of passengers and baggage for 600 n mi and optimized for minimum DOC over a 100-n mi stage length are presented, and the improvements in fuel usage, DOC and passenger comfort to be obtained with the use of advanced technology are pointed out. The goals and considered technologies of the dedicated small-transport aircraft technology program recommended by a commuter air transport subcommittee of the NASA Advisory Council Aeronautics Advisory Committee to speed the development of commuter technology are then presented, with attention given to efforts of analysis, design and testing of propulsion systems, structures, aerodynamics and systems intended to result in 16-24% savings in DOC and up to 40% savings in fuel. The commuter development plans of various manufacturers are also indicated.
This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.
A low-cost, narrowband, millimeter wave space communications TWT design was studied. Cold test interaction structure scale models were investigated and analyses were undertaken to predict the electrical and thermal response of the hypothetical 200 W TWT at 42 GHz and 21 kV beam voltage. An intentionally narrow instantaneous bandwidth (1%, with the possibility of electronic tuning of the center frequency over several percent) was sought with a highly dispersive, high impedance "forward wave' interaction structure based on a ladder (for economy in fabrication) and nonspace harmonic interaction, for a high gain rate and a short, economically focused tube. The "TunneLadder' interaction structure devised combines ladder properties with accommodation for a pencil beam. Except for the impedance and bandwidth, there is much in common with the millimeter wave helix TWTs which provided the ideal of diamond support rods. The benefits of these are enhanced in the TunneLadder case because of spatial separation of beam interception and RF current heating.
This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.
Supersonic jet plume interaction with a flat plate was studied using a model scaled test apparatus designed to simulate plume/aircraft structure interaction for the cruise configuration. The generic configuration consisted of a rectangular supersonic nozzle of aspect ratio 7, and a large flat plate located beneath the nozzle at various nozzle plate distances; the plate was instrumented to measure surface dynamic pressure and mean wall temperature, with provisions for measurements of acceleration and strain on coupon size panels that could be inserted in the plate. Phase-averaged schlieren measurements revealed the presence of high-intensity acoustic emission from the supersonic plume above the plate, directed upstream; this radiation could be associated with the shock noise generation. Narrow band spectra of surface dynamic pressure show spectral peaks with amplitude levels reaching 1 psi, related to the screech tones. Temperature measurements indicated elevated surface temperatures in regions of high turbulence intensity.
The following subject areas are covered: current rocket engine certification process; certification issues; engine characteristics; engine design and mission requirements; structural design criteria; structural design factors of safety; component/subsystem testing; system level development tests; certification/qualification tests; observations; and proposed actions/programs.
Accomplishments in the following research areas are summarized: structure based testing, reliability growth, and design testability with risk evaluation; reliability growth models and software risk management; and evaluation of consensus voting, consensus recovery block, and acceptance voting. Four papers generated during the reporting period are included as appendices.
Topics addressed are: (1) cryogenic tankage; (2) launch vehicle TPS/insulation; (3) durable passive thermal control devices and/or coatings; (4) development and characterization of processing methods to reduce anisotropy of material properties in Al-Li; (5) durable thermal protection system (TPS); (6) unpressurized Al-Li structures (interstages, thrust structures); (7) near net shape sections; (8) pressurized structures; (9) welding and joining; (10) micrometeoroid and debris hypervelocity shields; (11) state-of-the-art shell buckling structure optimizer program to serve as a rapid design tool; (12) test philosophy; (13) reduced load cycle time; (14) structural analysis methods; (15) optimization of structural criteria; and (16) develop an engineering approach to properly trade material and structural concepts selection, fabrication, facilities, and cost.
The NASA Langley Research Center has constructed several testbeds to assess the viability of flexible structure control. It is found, however, that simply adding sensors, actuators, and a control system to an existing structure (i.e. space platform) is not the preferred methodology for improving pointing performance. When the structure is designed without regard to pointing control, significant design freedom is lost. The preferred design procedure is to simultaneously design the structure and the control system, hence, the name Controls-Structures Integration. By designing the structure and control system simultaneously, much higher efficiency can be achieved. In this study, an 18 m long truss structure with several appendages was enhanced through integrated controls and structures design. The design was fabricated and tested for validation of the methodology. Test results collaborated predictions and showed a 60 percent reduction in control energy for the enhanced test article.
The focus of the NASA / Marshall Space Flight Center (MSFC) Advanced Reusable Technologies (ART) project is to advance and develop Rocket-Based Combined-Cycle (RBCC) technologies. The ART project began in 1996 as part of the Advanced Space Transportation Program (ASTP). The project is composed of several activities including RBCC engine ground testing, tool development, vehicle / mission studies, and component testing / development. The major contractors involved in the ART project are Aerojet and Rocketdyne. A large database of RBCC ground test data was generated for the air-augmented rocket (AAR), ramjet, scramjet, and ascent rocket modes of operation for both the Aerojet and Rocketdyne concepts. Transition between consecutive modes was also demonstrated as well as trajectory simulation. The Rocketdyne freejet tests were conducted at GASL in the Flight Acceleration Simulation Test (FAST) facility. During a single test, the FAST facility is capable of simulating both the enthalpy and aerodynamic conditions over a range of Mach numbers in a flight trajectory. Aerojet performed freejet testing in the Pebble Bed facility at GASL as well as direct-connect testing at GASL. Aerojet also performed sea-level static (SLS) testing at the Aerojet A-Zone facility in Sacramento, CA. Several flight-type flowpath components were developed under the ART project. Aerojet designed and fabricated ceramic scramjet injectors. The structural design of the injectors will be tested in a simulated scramjet environment where thermal effects and performance will be assessed. Rocketdyne will be replacing the cooled combustor in the A5 rig with a flight-weight combustor that is near completion. Aerojet's formed duct panel is currently being fabricated and will be tested in the SLS rig in Aerojet's A-Zone facility. Aerojet has already successfully tested a cooled cowl panel in the same facility. In addition to MSFC, other NASA centers have contributed to the ART project as well. Inlet testing and parametrics were performed at NASA / Glenn Research Center (GRC) and NASA / Langley Research Center (LaRC) for both the Aerojet and Rocketdyne concepts. LaRC conducted an Air-Breathing Launch Vehicle (ABLV) study for several vehicle concepts with RBCC propulsion systems. LaRC is also performing a CFD analysis of the ramjet mode for both flowpaths based on GASL test conditions. A study was performed in 1999 to investigate the feasibility of performing an RBCC flight test on the NASA / Dryden Flight Research Center (DFRC) SR-71 aircraft. Academia involvement in the ART project includes parametric RBCC flowpath testing by Pennsylvania State University (PSU). In addition to thrust and wall static pressure measurements, PSU is also using laser diagnostics to analyze the flowfield in the test rig. MSFC is performing CFD analysis of the PSU rig at select test conditions for model baseline and validation. Also, Georgia Institute of Technology (GT) conducted a vision vehicle study using the Aerojet RBCC concept. Overall, the ART project has been very successful in advancing RBCC technology. Along the way, several major milestones were achieved and "firsts" accomplished. For example, under the ART project, the first dynamic trajectory simulation testing was performed and the Rocketdyne engine A5 logged over one hour of accumulated test time. The next logical step is to develop and demonstrate a flight-weight RBCC engine system.