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Woven fiberglass fluted-core simulated aircraft interior panels were flame tested and structurally evaluated against the Boeing 747 present baseline interior panels. The NASA-defined panels, though inferior on a strength-to-weight basis, showed better structural integrity after flame testing, due to the woven fiberglass structure.
Two design procedures for composite panels with cutouts are described and illustrated by example applications. One of these procedures uses a specialized cutout analysis code to obtain preliminary sizing information for the panel laminate, cutout padup, and cutout stiffener reinforcements. The other procedure uses a finite element based structural optimization code to develop a minimum weight panel design. The best features of both procedures form the basis of a design strategy for weight-efficient cutout panels.
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.
Non-destructive evaluation (NDE) methods for quantifying and locating damage are essential for inspecting structures to ensure safety and reliability. Transmittance function monitoring is a potentially new NDE technique being tested as a tool to detect, quantify, and locate damage on flexible structures. The technique has a large spatial range that is practical for detecting damage on large composite material structures such as a reusable launch vehicle. The Transmittance Function (TF) theory is based on structural dynamics principles that define how vibration at one point in a structure is related to a force at another point. This relationship is called the Frequency Response Function (FRF). A Transmittance Function (TF) is derived as the ratio of FRFs, and can detect damage because the FRFs change due to damage. If one excitation is used for the testing, the force does not need to be measured to compute the TF. In the damage detection procedure, the structure is subjected to wide-band vibration and TFs are computed between different accelerometers to detect changes in the structure, presumably due to damage. In the first year of the project the TF method was tested on a bolted panel, a curved panel, and beams, all made of fiberglass. It was shown that damage could be detected using low frequency vibration, 250 to 1,250 Hz. The technique is sensitive to damage, but it requires storage of historical or pre-damage TFs for the healthy structure. This would become a large data storage requirement for large structures. Thus one objective for the second year of the project was to eliminate the need to store historical data. The second year report gives details of how storage of historical data was eliminated. Further results of testing panel structures are also given.
The thermal and structural performance of a large panel of mullite reusable surface insulation (RSI) tiles was determined by a series of aerothermal tests in the Langley 8-foot high-temperature structures tunnel. The test panel was designed to represent a portion of the surface structure on a space shuttle orbiter fuselage along a 1,150 K isotherm with the mullite tile system bonded directly to the primary structure. Aerothermal tests were conducted at a free-stream Mach number of 6.7, a total temperature of 1,880 K, a unit Reynolds number of 4.6 million per meter, and dynamic pressure of 62 kPa. The thermal response of the mullite tile was as predicted, and the bond-line temperature did not exceed the design level of 570 K during a typical entry-heat cycle. Geometric irregularities of the tile gaps affected the tile edge temperatures when exposed to hypersonic flow. The tile coating demonstrated good toughness to particle impacts, but the coating cracked and flaked with thermal cycles. The gap filler of woven silica fibers appeared to hinder flow penetration into the gaps and withstood the flow shear of the present tests.
The NASA Johnson Space Center (JSC) in Houston, Texas is the home of the NASA WB-57 High Altitude Research Program. Three fully operational WB-57 aircraft are based near JSC at Ellington Field. The aircraft have been flying research missions since the early 1960's, and continue to be an asset to the scientific community with professional, reliable, customer-oriented service designed to meet all scientific objectives. The NASA WB-57 Program provides unique, high-altitude airborne platforms to US Government agencies, academic institutions, and commercial customers in order to support scientific research and advanced technology development and testing at locations around the world. Mission examples include atmospheric and earth science, ground mapping, cosmic dust collection, rocket launch support, and test bed operations for future airborne or spaceborne systems. During the return from a 6 hour flight, at 30,000 feet, in the clean configuration, traveling at 175 knots indicated airspeed, in un-accelerated flight with the auto pilot engaged, in calm air, the 2-man crew heard a mechanical bang and felt a slight shudder followed by a few seconds of high frequency vibration. The crew did not notice any other abnormalities leading up to, or for the remaining 1 hour of flight and made an uneventful landing. Upon taxi into the chocks, the recovery ground crew noticed the high frequency long wire antenna had become disconnected from the vertical stabilizer and was trailing over the left inboard wing, and that the left engine upper center removable cowling panel was missing, with noticeable damage to the left engine inboard cowling fixed structure. The missing cowling panel was never recovered. Each engine cowling panel is attached to the engine nacelle using six bushings made of 17-4 PH steel. The cylinder portions of four of the six bushings were found still attached to the aircraft (Fig 1). The other two bushings were lost with the panel. The other four bushings exhibited ratchet marks (multiple fatigue origins) which initiated in the sharp radius of the flange/cylinder fillet and were observed 300 degrees around the flange perimeter (Fig 2-3). Low stress, high cycle fatigue (HCF) was observed on the fracture surfaces of all four bushings (Fig 4). To improve the cowling panel joint design and enable return to flight, new cowling bushings with thicker flanges and a larger machined flange/cylinder fillet radius were installed on all cowling panels. In addition, a spacer was added to the joint to achieve the proper stack tolerance. Finally, a time change requirement for all cowling bushings was instituted.
Turbulent boundary layer (TBL) noise is considered a primary contribution to the interior noise present in commercial airliners. There are numerous investigations of interior noise control devoted to aircraft panels; however, practical realization is a potential challenge since physical boundary conditions are uncertain at best. In most prior studies, pinned or clamped boundary conditions were assumed; however, realistic panels likely display a range of boundary conditions between these two limits. Uncertainty in boundary conditions is a challenge for control system designers, both in terms of the compensator implemented and the location of transducers required to achieve the desired control. The impact of model uncertainties, specifically uncertain boundaries, on the selection of transducer locations for structural acoustic control is considered herein. The final goal of this work is the design of an aircraft panel structure that can reduce TBL noise transmission through the use of a completely adaptive, single-input, single-output control system. The feasibility of this goal is demonstrated through the creation of a detailed analytical solution, followed by the implementation of a test model in a transmission loss apparatus. Successfully realizing a control system robust to variations in boundary conditions can lead to the design and implementation of practical adaptive structures that could be used to control the transmission of sound to the interior of aircraft. Results from this research effort indicate it is possible to optimize the design of actuator and sensor location and aperture, minimizing the impact of boundary conditions on the desired structural acoustic control.
Accomplishments and the outlook for graphite-polyimide composite structures are briefly outlined. Laminates, skin-stiffened and honeycomb sandwich panels, chopped fiber moldings, and structural components were fabricated with Celion/LARC-160 and Celion/PMR-15 composite materials. Interlaminar shear and flexure strength data obtained on as-fabricated specimens and specimens that were exposed for 125 hours at 589 K indicate that epoxy sized and polyimide sized Celion graphite fibers exhibit essentially the same behavior in a PMR-15 matrix composite. Analyses and tests of graphite-polyimide compression and shear panels indicate that utilization in moderately loaded applications offers the potential for achieving a 30 to 50 percent reduction in structural mass compared to conventional aluminum panels. Data on effects of moisture, temperature, thermal cycling, and shuttle fluids on mechanical properties indicate that both LARC-160 and PMR-15 are suitable matrix materials for a graphite-polyimide aft body flap. No technical road blocks to building a graphite-polyimide composite aft body flap are identified.
The feasibility of fabricating large beryllium honeycomb panels was demonstrated. Both flat and curved sandwich structures were manufactured using practical, braze bonding techniques. The processes developed prove that metallurgically assembled beryllium honeycomb panels show decided potential where rigid, lightweight structures are required. Three panels, each 10 square feet in surface area, were fabricated, and radiographically inspected to determine integrity. This examination revealed a 97 percent braze in the final panel. It is believed that ceramic dies for forming and brazing would facilitate the fabrication techniques for higher production rates. Ceramic dies would yield a lower thermal gradient in the panel during the braze cycle. This would eliminate the small amount of face sheet wrinkling present in the panels. Hot forming the various panel components demonstrated efficient manufacturing techniques for scaling up and producing large numbers of hot formed beryllium components and panels. The beryllium honeycomb panel demonstrated very good vibrational loading characteristics under test with desirable damping characteristics.
Inexpensive set of modular semirigid box structures serve as multipurpose support for thin panels. Fixture holds several different, interchangeable, two-part, adjustable, contour-board subassemblies. Combining modules allows for accommodation to any length skin or panel.
The NLPAN computer code uses a finite-strip approach to the analysis of thin-walled prismatic composite structures such as stiffened panels. The code can model in-plane axial loading, transverse pressure loading, and constant through-the-thickness thermal loading, and can account for shape imperfections. The NLPAN code represents an attempt to extend the buckling analysis of the VIPASA computer code into the geometrically nonlinear regime. Buckling mode shapes generated using VIPASA are used in NLPAN as global functions for representing displacements in the nonlinear regime. While the NLPAN analysis is approximate in nature, it is computationally economical in comparison with finite-element analysis, and is thus suitable for use in preliminary design and design optimization. A comprehensive description of the theoretical approach of NLPAN is provided. A discussion of some operational considerations for the NLPAN code is included. NLPAN is applied to several test problems in order to demonstrate new program capabilities, and to assess the accuracy of the code in modeling various types of loading and response. User instructions for the NLPAN computer program are provided, including a detailed description of the input requirements and example input files for two stiffened-panel configurations.
LS-DYNA simulations were conducted to study the influence of model complexity on the response of a typical Reinforced Carbon-Carbon (RCC) panel to a foam impact at a location approximately midway between the ribs. A structural model comprised of Panels 10, 11, and TSeal 11 was chosen as the baseline model for the study. A simulation was conducted with foam striking Panel 10 at Location 4 at an alpha angle of 10 degrees, with an impact velocity of 1000 ft/sec. A second simulation was conducted after removing Panel 11 from the model, and a third simulation was conducted after removing both Panel 11 and T-Seal 11. All three simulations showed approximately the same response for Panel 10, and the simplified simulation model containing only Panel 10 was shown to be significantly less expensive to execute than the other two more complex models.
This paper describes the novel method used for supporting the thermally controlled panel on the uncontrolled structure. The method described allows for large magnitude thermally induced relative motion between the panels while it simultaneously provides a controlled thermal resistivity between the two panels. The resulting design is also capable of withstanding the accelerations of atmospheric entry and provides sufficient stiffness to ensure its motion is significantly de-coupled from that of the launch vehicle.
The first nine months of experimental and computational studies of the thermal-structural behavior of thin panels subjected to localized heating are described. Initial experimental studies have focused on developing an experimental set-up with well-defined thermal-structure boundary conditions. Preliminary tests with a Heldenfels panel have demonstrated out of plane bending (thermal buckling) due to panel initial imperfections. Initial computational studies have focused on: (1) validation of a thermoviscoplastic code to predict thermal stresses in the unbuckled panel, and (2) investigating in-plane stresses for test panels under transient thermal loading. Plans for future research are described.
A brazed titanium honeycomb sandwich system for supersonic transport wing cover panels provides the most efficient structure spanwise, chordwise, and loadwise. Flutter testing shows that high wing stiffness is most efficient in a sandwich structure. This structure also provides good thermal insulation if liquid fuel is carried in direct contact with the wing structure in integral fuel tanks.
Fluid structural interaction problems that estimate panel vibration from an applied pressure field excitation are quite dependent on the spatial correlation of the pressure field. There is a danger of either over estimating a low frequency response or under predicting broad band panel response in the more modally dense bands if the pressure field spatial correlation is not accounted for adequately. Even when the analyst elects to use a fitted function for the spatial correlation an error may be introduced if the choice of patch density is not fine enough to represent the more continuous spatial correlation function throughout the intended frequency range of interest. Both qualitative and quantitative illustrations evaluating the adequacy of different patch density assumptions to approximate the fitted spatial correlation function are provided. The actual response of a typical vehicle panel system is then evaluated in a convergence study where the patch density assumptions are varied over the same finite element model. The convergence study results are presented illustrating the impact resulting from a poor choice of patch density. The fitted correlation function used in this study represents a Diffuse Acoustic Field (DAF) excitation of the panel to produce vibration response.
Initial optical communications experiments with a Vertex polished aluminum panel have been described. The polished panel was mounted on the main reflector of the DSN's research antenna at DSS-13. The PSF was recorded via remotely controlled digital camera mounted on the subreflector structure. Initial PSF generated by Jupiter showed significant tilt error and some mechanical deformation. After upgrades, the PSF improved significantly, leading to much better concentration of light. Communications performance of the initial and upgraded panel structure were compared. After the upgrades, simulated PPM symbol error probability decreased by six orders of magnitude. Work is continuing to demonstrate closed-loop tracking of sources from zenith to horizon, and better characterize communications performance in realistic daytime background environments.
A folding three dimensional truss and tripod assembly which deploys the SEASAT Synthetic Aperture Radar Antenna is described. The folding structure with the antenna panels and rf components stows in an 8.5-inch-thick package. Upon deployment, the structure produced is a flat and rigid support for the antenna.