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Research in computerized structural sizing technology was reviewed. Areas covered include: overall design; structural subassembly design; thermal structures; and stiffened panels. In each case, sample results are presented.
Hot forming process has been developed in which structural shapes and panels are fabricated directly from stabilized graphite/polyimide preforms. Process can be used with thermosetting polymers that have high-temperature melt phase just before final cure. This phase allows fibers to move without destroying matrix-to-fiber adhesion. One of key advantages of this process is that prestages preforms are very stable and do not require refrigerated storage.
Presented is a procedure for using the FLEXSTAB External Structural Influence Coefficients (ESIC) computer program to produce the structural data necessary for the FLEXSTAB Stability Derivatives and Static Stability (SD&SS) program. The SD&SS program computes trim state, stability derivatives, and pressure and deflection data for a flexible airplane having a plane of symmetry. The procedure used a NASTRAN finite-element structural model as the source of structural data in the form of flexibility matrices. Selection of a set of degrees of freedom, definition of structural nodes and panels, reordering and reformatting of the flexibility matrix, and redistribution of existing point mass data are among the topics discussed. Also discussed are boundary conditions and the NASTRAN substructuring technique.
At the request of the Aeroelasticity Subcommittee of the AGARD Structures and Materials Panel, a survey of member countries has been conducted to seek candidates for a prospective set of standard configurations to be used for comparison of calculated and measured dynamic aeroelastic behavior with emphasis on the transonic speed range. This set is a sequel to that established several years ago for comparisons of calculated and measured aerodynamic pressures and forces. Approximately two dozen people in the United States, and more than three dozen people in the other member countries, were contacted. This preliminary report presents the results of the survey and an analysis of those results along with recommendations for the initial set of standard configurations and for additional experimental work needed to fill significant gaps in the available information.
An approach for augmenting vibration damping characteristics in space structures with large panels is presented. It is based on generation of bending moments rather than forces. The moments are generated using bimetallic strips, suitably mounted at selected stations on both sides of the large panels, under the influence of differential solar heating, giving rise to thermal gradients and stresses. The collocated angular velocity sensors are utilized in conjunction with mini-servos to regulate the control moments by flipping the bimetallic strips. A simple computation of the rate of dissipation of vibrational energy is undertaken to assess the effectiveness of the proposed approach.
Formal approaches are summarized to evaluate design concepts and perform sensitivity analyses on design parameters of composite structural components for vehicles. The formal approaches include structural analyses coupled with composite micromechanics to assess the structural response of beams made from various intraply hybrids, finite element analysis in conjunction with composite mechanics to assess the structural response of panels made from strip hybrids, and sensitivity analysis through optimization to assess the effects of various design parameters on the optimum design of a panel made from angleplied composite laminates. Results obtained from these approaches are presented in graphical and tabular form to illustrate parametric studies and acceptable ranges of various design parameters.
To promote the evaluation of existing and emerging unsteady aerodynamic codes and methods for applying them to aeroelastic problems, especially for the transonic range, a limited number of aerodynamic configurations and experimental dynamic response data sets are to be designated by the AGARD Structures and Materials Panel as standards for comparison. This set is a sequel to that established several years ago for comparisons of calculated and measured aerodynamic pressures and forces. This report presents the information needed to perform flutter calculations for the first candidate standard configuration for dynamic response along with the related experimental flutter data.
Taut fastener formed from flat tape and buckles. Flexible, tiedown composite fastener for joining two or more material panels or other structural components dispensed from roll and cut to desired length. Fastener made partly of polyvinyl chloride or other resilient synthetic material and designed for joining components for which snug all-around fits required. Easily installed and removed by hand without use of tools. Potential application extends to many areas. One use of fastener is to bind pages and covers together to make book. Also utilized to provide energy-absorbing and breakaway structural fasteners for fail-safe vehicles in crashes.
Boeing Rocketdyne is pursuing the development of Rocket Based Combined Cycle (RBCC), propulsion systems as demonstrated by significant contract work in the hypersonic arena (ART, NASP, SCT, system studies) and over 12 years of steady company discretionary investment. The Rocketdyne concept is a fixed geometry integrated rocket, ramjet, scramjet which is hydrogen fueled and uses hydrogen regenerative cooling. The baseline engine structural configuration uses an integral structure that eliminates panel seals. seal purge gas, and closeout side attachments. Rocketdyne's experimental RBCC engine (Engine A5) was constructed under contract with the NASA Marshall Space Flight Center. Engine A5 models the complete flight engine flowpath consisting of an inlet, isolator, airbreathing combustor and nozzle. High performance rocket thrusters are integrated into the engine to enable both air-augmented rocket (AAR) and pure rocket operation. Engine A5 was tested in CASL's new FAST facility as an air-augmented rocket, a ramjet and a pure rocket. Measured performance demonstrated vision vehicle performance levels for Mach 3 AAR operation and ramjet operation from Mach 3 to 4. Rocket mode performance was above predictions. For the first time. testing also demonstrated transition from AAR operation to ramjet operation. This baseline configuration has also been shown, in previous testing, to perform well in the scramjet mode.
With the continuous progress in hardware and numerical schemes, Computational Unsteady Aerodynamics (CUA), that is, the application of Computational Fluid Dynamics (CFD) to unsteady flowfields, is slowly finding its way as a useful and reliable tool (turbulence and transition modeling permitting) in the aircraft, helicopter, engine and missile design and development process. Before a specific code may be used with confidence it is essential to validate its capability to describe the physics of the flow correctly, or at least to the level of approximation required, for which purpose a comparison with accurate experimental data is needed. Unsteady wind tunnel testing is difficult and expensive; two factors which dramatically limit the number of organizations with the capability and/or resources to perform it. Thus, unsteady experimental data is scarce, often classified and scattered in diverse documents. Additionally, access to the reports does not necessarily assure access to the data itself. The collaborative effort described in this paper was conceived with the aim of collecting into a single easily accessible document as much quality data as possible. The idea is not new. In the early 80's NATO's AGARD (Advisory Group for Aerospace Research & Development) Structures and Material Panel (SMP) produced AGARD Report No. 702 "Compendium of Unsteady Aerodynamic Measurements", which has found and continues to find extensive use within the CUA Community. In 1995 AGARD's Fluid Dynamics Panel (FDP) decided to update and expand the former database with new geometries and physical phenomena, and launched Working Group WG-22 on "Validation Data for Computational Unsteady Aerodynamic Codes". Shortly afterwards AGARD was reorganized as the RTO (Research and Technology Organization) and the WG was renamed as AVT (Applied Vehicle Technolology) WG-003. Contributions were received from AEDC, BAe, DLR, DERA, Glasgow University, IAR, NAL, NASA, NLR, and ONERA. The final publication with the results of the exercise is expected in the second part of 1999. The aim of the present paper is to announce and present the new database to the Aeroelasticity community. It is also intended to identify, together with one of the groups of end users it targets, deficiencies in the compendium that should be addressed by means of new wind tunnel tests or by obtaining access to additionally existing data.
The development of rocket-based combined cycle (RBCC) propulsion systems is part of a 12 year effort under both company funding and contract work. The concept is a fixed geometry integrated rocket, ramjet, scramjet, which is hydrogen fueled and uses hydrogen regenerative cooling. The baseline engine structural configuration uses an integral structure that eliminates panel seals, seal purge gas, and closeout side attachments. Engine A5 is the current configuration for NASA Marshall Space Flight Center (MSFC) for the ART program. Engine A5 models the complete flight engine flowpath of inlet, isolator, airbreathing combustor, and nozzle. High-performance rocket thrusters are integrated into the engine enabling both low speed air-augmented rocket (AAR) and high speed pure rocket operation. Engine A5 was tested in GASL's new Flight Acceleration Simulation Test (FAST) facility in all four operating modes, AAR, RAM, SCRAM, and Rocket. Additionally, transition from AAR to RAM and RAM to SCRAM was also demonstrated. Measured performance demonstrated vision vehicle performance levels for Mach 3 AAR operation and ramjet operation from Mach 3 to 4. SCRAM and rocket mode performance was above predictions. For the first time, testing also demonstrated transition between operating modes.
The Orbiter radiator system consists of eight individual 4.6 m x 3.2 m panels located with four on each payload bay door. Forward panels #1 and #2 are 2.3 cm thick while the aft panels #3 and #4 have a smaller overall thickness of 1.3 cm. The honeycomb radiator panels consist of 0.028 cm thick Aluminum 2024-T81 facesheets and Al5056-H39 cores. The face-sheets are topped with 0.005 in. (0.127 mm) silver-Teflon tape. The radiators are located on the inside of the shuttle payload bay doors, which are closed during ascent and reentry, limiting damage to the on-orbit portion of the mission. Post-flight inspections at the Kennedy Space Center (KSC) following the STS-115 mission revealed a large micrometeoroid/orbital debris (MMOD) impact near the hinge line on the #4 starboard payload bay door radiator panel. The features of this impact make it the largest ever recorded on an orbiter payload bay door radiator. The general location of the damage site and the adjacent radiator panels can be seen in Figure 2. Initial measurements of the defect indicated that the hole in the facesheet was 0.108 in. (2.74 mm) in diameter. Figure 3 shows an image of the front side damage. Subsequent observations revealed exit damage on the rear facesheet. Impact damage features on the rear facesheet included a 0.03 in. diameter hole (0.76 mm), a approx.0.05 in. tall bulge (approx.1.3 mm), and a larger approx.0.2 in. tall bulge (approx.5.1 mm) that exhibited a crack over 0.27 in. (6.8 mm) long. A large approx.1 in. (25 mm) diameter region of the honeycomb core was also damaged. Refer to Figure 4 for an image of the backside damage to the panel. No damage was found on thermal blankets or payload bay door structure under the radiator panel. Figure 5 shows the front facesheet with the thermal tape removed. Ultrasound examination indicated a maximum facesheet debond extent of approximately 1 in. (25 mm) from the entry hole. X-ray examinations revealed damage to an estimated 31 honeycomb cells with an extent of 0.85 in. x 1.1 in. (21.6 x 27.9 mm). Pieces of the radiator at and surrounding the impact site were recovered during the repair procedures at KSC. They included the thermal tape, front facesheet, honeycomb core, and rear facesheet. These articles were examined at JSC using a scanning electron microscope (SEM) with an energy dispersive x-ray spectrometer (EDS). Figure 6 shows SEM images of the entry hole in the facesheet. The asymmetric height of the lip may be attributed to projectile shape and impact angle. Numerous instances of a glass-fiber organic matrix composite were observed in the facesheet tape sample. The fibers were approximately 10 micrometers in diameter and variable lengths. EDS analysis indicated a composition of Mg, Ca, Al, Si, and O. Figures 7 and 8 present images of the fiber bundles, which were believed to be circuit board material based on similarity in fiber diameter, orientation, consistency, and composition. A test program was initiated in an attempt to simulate the observed damage to the radiator facesheet and honeycomb. Twelve test shots were performed using projectiles cut from a 1.6 mm thick fiberglass circuit board substrate panel. Results from test HITF07017, shown in figures 9 and 10, correlates with the observed impact features reasonably well. The test was performed at 4.14 km/sec with an impact angle of 45 degrees using a cylindrical projectile with a diameter and length of 1.25 mm. The fiberglass circuit board material had a density of 1.65 g/cu cm, giving a projectile mass of 2.53 mg. An analysis was performed using the Bumper code to estimate the probability of impact to the shuttle from a 1.25 mm diameter particle. Table 1 shows a 1.6% chance (impact odds = 1 in 62) of a 1.25 mm or larger MMOD impact on the radiators of the vehicle during a typical ISS mission. There is a 0.4% chance (impact odds = 1 in 260) that a 1.25 mm or larger MMOD particle would impact the RCC wing leading edge and nose cap during a typical miion. Figure 11 illustrates the vulnerable areas of the wing leading edge reinforced carbon-carbon (RCC), an area of the vehicle that is very sensitive to impact damage. The highlighted red, orange, yellow, and light green areas would be expected to experience critical damage if impacted by an OD particle such as the one that hit the RH4 radiator panel on STS-115.
Developed at NASA's Langley Research Center, the Macro-Fiber Composite (MFC) is designed to control vibration, noise, and deflections in composite structural beams and panels. Smart Material Corporation specializes in the development of piezocomposite components, and licensed the MFC technology from Langley in 2002. To date, Smart Material Corporation has sold MFCs to over 120 customers, including such industry giants as Volkswagen, Toyota, Honda, BMW, General Electric, and the tennis company, HEAD. The company estimates that its customers have filed at least 100 patents for their various unique uses of the technology. In addition, the company's product portfolio has grown to include piezoceramic fibers and fiber composites, piezoceramic actuators and sensors, and test equipment for these products. It also offers a compact, lightweight power system for MFC testing and validation. Consumer applications already on the market include piezoelectric systems as part of audio speakers, phonograph cartridges and microphones, and recreational products requiring vibration control, such as skis, snowboards, baseball bats, hockey sticks, and tennis racquets.
Interlaminar fracture mechanics has proven useful for characterizing the onset of delaminations in composites and has been used with limited success primarily to investigate onset in fracture toughness specimens and laboratory size coupon type specimens. Future acceptance of the methodology by industry and certification authorities however, requires the successful demonstration of the methodology on the structural level. In this paper, the state-of-the-art in fracture toughness characterization, and interlaminar fracture mechanics analysis tools are described. To demonstrate the application on the structural level, a panel was selected which is reinforced with stringers. Full implementation of interlaminar fracture mechanics in design however remains a challenge and requires a continuing development effort of codes to calculate energy release rates and advancements in delamination onset and growth criteria under mixed mode conditions.
The presence of a honeycomb core in a multi-wall shielding configuration for protection against micrometeoroid and orbital debris (MMOD) particle impacts at hypervelocity is generally considered to be detrimental as the cell walls act to restrict fragment cloud expansion, creating a more concentrated load on the shield rear wall. However, mission requirements often prevent the inclusion of a dedicated MMOD shield, and as such, structural honeycomb sandwich panels are amongst the most prevalent shield types. Open cell metallic foams are a relatively new material with novel mechanical and thermal properties that have shown promising results in preliminary hypervelocity impact shielding evaluations. In this study, an ISS-representative MMOD shielding configuration has been modified to evaluate the potential performance enhancement gained through the substitution of honeycomb for open cell foam. The baseline shielding configuration consists of a double mesh outer layer, two honeycomb sandwich panels, and an aluminum rear wall. In the modified configuration the two honeycomb cores are replaced by open-cell foam. To compensate for the heavier core material, facesheets have been removed from the second sandwich panel in the modified configuration. A total of 19 tests on the double layer honeycomb and double layer foam configurations are reported. For comparable mechanical and thermal performance, the foam modifications were shown to provide a 15% improvement in critical projectile diameter at low velocities (i.e. 3 km/s) and a 3% increase at high velocities (i.e. 7 km/s) for normal impact. With increasing obliquity, the performance enhancement was predicted to increase, up to a 29% improvement at 60 (low velocity). Ballistic limit equations have been developed for the new configuration, and consider the mass of each individual shield component in order to maintain validity in the event of minor configuration modifications. Previously identified weaknesses of open cell foams for hypervelocity impact shielding such as large projectile diameters, low velocities, and high degrees of impact obliquity have all been investigated, and found to be negligible for the double-layer configuration.
Game changing advances come about by the introduction of new technologies at a time when societal needs create the opportunity for new market solutions. A unique opportunity exists for NASA to bring about such a mobility revolution in General Aviation, extendable to other aviation markets, to maintain leadership in aviation by the United States. This report outlines the research carried out so far under NASA's leadership towards developing a new mobility choice, called Zip Aviation1,2,3. The feasibility, technology and system gaps that need to be addressed, and pathways for successful implementation have been investigated to guide future investment. The past decade indicates exciting trends in transportation technologies, which are quickly evolving. Automobiles are embracing automation to ease driver tasks as well as to completely control the vehicle with added safety (Figure 1). Electric propulsion is providing zero tail-pipe emission vehicles with dramatically lower energy and maintenance costs. These technologies have not yet been applied to aviation, yet offer compelling potential benefits across all aviation markets, and in particular to General Aviation (GA) as an early adopter market. The benefits of such an adoption are applicable in the following areas: Safety: The GA market experiences accident rates that are substantially higher than automobiles or commercial airlines, with 7.5 fatal accidents per 100 million vehicle miles compared to 1.3 for automobiles and.068 for airlines. Approximately 80% of these accidents are caused by some form of pilot error, with another 13% caused by single point propulsion system failure. Emissions: Environmental constraints are pushing for the elimination of 100Low Lead (LL) fuel used in most GA aircraft, with aviation fuel the #1 source of lead emissions into the environment. Aircraft also have no emission control systems (i.e. no catalytic converters etc.), so they are gross hydrocarbon polluters compared to automobiles. Community Noise: Hub and smaller GA airports are facing increasing noise restrictions, and while commercial airliners have dramatically decreased their community noise footprint over the past 30 years, GA aircraft noise has essentially remained same, and moreover, is located in closer proximity to neighborhoods and businesses. Operating Costs: GA operating costs have risen dramatically due to average fuel costs of over $6 per gallon, which has constrained the market over the past decade and resulted in more than 50% lower sales and 35% less yearly operations. Infusion of autonomy and electric propulsion technologies can accomplish not only a transformation of the GA market, but also provide a technology enablement bridge for both larger aircraft and the emerging civil Unmanned Aerial Systems (UAS) markets. The NASA Advanced General Aviation Transport Experiments (AGATE) project successfully used a similar approach to enable the introduction of primary composite structures and flat panel displays in the 1990s, establishing both the technology and certification standardization to permit quick adoption through partnerships with industry, academia, and the Federal Aviation Administration (FAA). Regional and airliner markets are experiencing constant pressure to achieve decreasing levels of community emissions and noise, while lowering operating costs and improving safety. But to what degree can these new technology frontiers impact aircraft safety, the environment, operations, cost, and performance? Are the benefits transformational enough to fundamentally alter aircraft competiveness and productivity to permit much greater aviation use for high speed and On-Demand Mobility (ODM)? These questions were asked in a Zip aviation system study named after the Zip Car, an emerging car-sharing business model. Zip Aviation investigates the potential to enable new emergent markets for aviation that offer "more flexibility than the existing transportation solutions." These studies indicate that autonomy and electric propulsion technology infusions offer a unique opportunity to provide breakthrough capabilities for new high speed, on-demand travel alternatives that can leapfrog the need for future expensive ground-based infrastructure investment. At the same time, such investments offer a method of laying the foundation for these technologies to be incubated for commercial aviation at lower cost, and with lower initial certification thresholds due to the relatively poor capabilities of GA aircraft to permit early adoption and private market capitalization by rapid technology accelerations, as depicted in Figure 2.
The Lunar Atmosphere and Dust Environment Explorer (LADEE) mission launched on September 7, 2013 with a one month cruise before lunar insertion. The LADEE spacecraft is a power limited, octagonal, composite bus structure with solar panels on all eight sides with four vertical segments per side and 2 panels dedicated to instruments. One of these panels has the Lunar Laser Communications Demonstration (LLCD), which represents a furthering of the laser communications technology demonstration proved out by the Lunar Reconnaissance Orbiter (LRO). LLCD increases the bandwidth of communication to and from the moon with less mass and power than LROs technology demonstrator. The LLCD Modem and Controller boxes are mounted to an internal cruciform composite panel and have no dedicated radiator. The thermal design relies on power cycling of the boxes and radiation of waste heat to the inside of the panels, which then reject the heat when facing cold space. The LADEE mission includes a slow roll and numerous attitudes to accommodate the challenging thermal requirements for all the instruments on board. During the cruise phase, the internal Modem and Controller avionics for LLCD were warmer than predicted by more than modeling uncertainty would suggest. This caused concern that if the boxes were considerably warmer than expected while off, they would also be warmer when operating and could limit the operational time when in lunar orbit. The thermal group at Goddard Space Flight Center evaluated the models and design for these critical avionics for LLCD. Upon receipt of the spacecraft models and audit was performed and data was collected from the flight telemetry to perform a sanity check of the models and to correlate to flight where possible. This paper describes the efforts to correlate the model to flight data and to predict the thermal performance when in lunar orbit and presents some lessons learned.
This paper presents structural models of deformable linear objects (DLOs). DLOs are a subclass of deformable objects that encompasses common outfitting elements such as cables and ropes. Models are validated through hardware experiments, and integration in a robotic autonomy architecture for space environments is discussed. A persistent human presence on the lunar surface is one of the next major milestones in space exploration. This requires the development of robust extraplanetary construction technologies including structures and materials modeling and robotic systems. Previous robotic construction technology development has primarily focused on structural assembly, with significantly less focus on robotically performed outfitting tasks to instantiate subsystems providing power, data, life support, etc. These tasks involve manipulation of highly flexible elements, which are difficult to model, such as cable harnesses, ropes, and hoses. Robotic manipulation of DLOs, especially cable harnesses, is an active area of research as cable harnesses are essential for providing power and data to space assets. DLO models that can be used for robot manipulator trajectory generation are necessary for autonomous operation of lunar infrastructure. There are many proposed methods for modeling DLOs, and they primarily fall into three types: 1) discrete model-based, 2) continuum model-based, and 3) Neural Network-based. These types each have pros and cons, and the tradeoff between model accuracy and computational speed informs which type should be used. An understanding of this trade-off is imperative for real-time control of autonomous systems. High computational requirements reduce the speed of the model, making real-time control difficult, while accuracy is critical to preventing collisions. Discrete models, such as a mass-spring multibody representation, require relatively few calculations, and accuracy is directly tied to the step size of the discretization. Continuum models, such as a B-spline representation or a Cosserat rod model (a mix of continuous and discrete), are more informed of the structural properties of the cable and are much more accurate than a rigid body mass-spring model, but at significant computational cost. A Neural Network approach can provide an online solution with very few computational steps, but properly generating training data can be difficult and validation for an in-space application is not trivial. This paper explores the trade-off between different modeling approaches and compares accuracy and computational speed/complexity of the three types mentioned above. Model accuracy is evaluated using a cable in a static configuration. True cable shape is obtained using a depth camera for RGB images and point-cloud segmentation. The purpose of this experiment is to evaluate the trade-offs of different approaches to the DLO modeling problem. Understanding the tradeoffs between different cable modeling techniques paves the way for developing robotic control and planning architectures necessary for real-time manipulation of DLOs for lunar infrastructure outfitting. Real-time control is required for robotic systems to be able to actively manipulate a cable in a harsh environment where model and sensor errors compound, and environmental conditions can cause significant disturbances. Cable routing must be performed in areas with high density of objects/obstacles: through truss structures, near solar panels or mirror arrays, next to bundles of electrical equipment. Understanding the best way to plan and manipulate a cable without disrupting the environment or damaging the cable is imperative to robotic outfitting operations on the lunar surface.