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NASA NTRS1983

Safe structures for future aircraft

The failure mechanisms, design lessons, and test equipment employed by NASA in establishing the airworthiness and crashworthiness of aircraft components for commercial applications are described. The composites test programs have progressed to medium primary structures such as stabilizers and a vertical fin. The failures encountered to date have been due to the nonyielding nature of composites, which do not diffuse loads like metals, and the presence of eccentricities, irregular shapes, stiffness changes, and discontinuities that cause tension and shear. Testing to failure, which always occurred in first tests before the design loads were reached, helped identify design changes and reinforcements that produced successful products. New materials and NDE techniques are identified, together with aircraft structural design changes that offer greater protection to the passengers, fuel antimisting agents, and landing gear systems.

Mccomb, H. G., Jr.↗

DOE OSTI2021

Enhancing functionalities in carbon fiber composites by titanium dioxide nanoparticles

Carbon fiber composite's high specific strength makes it incredibly useful for structural applications. However, their low strain-to-failure can be problematic in structural applications that can potentially see high strain conditions or high fatigue cycles resulting in sudden, catastrophic failure. This is further complicated by damage manifesting within the composite thus not showing damage indicators on the surface. Therefore, monitoring the structural integrity and strain history of the composite in application by itself—while maintaining positive composite performance—is vital to ensure safe operation. In this study, a homogeneous dispersion of TiO 2 nanoparticles on carbon fiber is demonstrated to generate a piezoresistive carbon fiber polymer matrix composite with enhanced self-sensing capabilities. The nanoparticle-embedded composites also exhibited superior strength and damping potential compared to the nanoparticle-free composites. The apparent interlaminar shear strength increased by up to 15% and the damping loss factor increased by an average of 150% while the piezoresistive sensitivity increased by up to 180% with the addition of a small weight fraction of nanoparticles to the fiber surface. These results demonstrate an approach to simultaneously improve the sensing capabilities, damping behavior and mechanical strength of carbon fiber composites by simply adding nanoparticles in the fiber sizing using a commercially scalable deposition method.

36 MATERIALS SCIENCE↗

NASA NTRS1994

Significance of shock structure on supersonic jet mixing noise of axisymmetric nozzles

One of the key technical elements in NASA's high speed research program is reducing the noise level to meet the federal noise regulation. The dominant noise source is associated with the supersonic jet discharged from the engine exhaust system. Whereas the turbulence mixing is largely responsible for the generation of the jet noise, a broadband shock-associated noise is also generated when the nozzle operates at conditions other than its design. For both mixing and shock noise components, because the source of the noise is embedded in the jet plume, one can expect that jet noise can be predicted from the jet flowfield computation. Mani et al. developed a unified aerodynamic/acoustic prediction scheme by applying an extension of Reichardt's aerodynamic model to compute turbulent shear stresses which are utilized in estimating the strength of the noise source. Although this method produces a fast and practical estimate of the jet noise, a modification by Khavaran et al. has led to an improvement in aerodynamic solution. The most notable feature in this work is that Reichardt's model is replaced with the computational fluid dynamics (CFD) solution of Reynolds-averaged Navier-Stokes equations. The major advantage of this work is that the essential, noise-related flow quantities such as turbulence intensity and shock strength can be better predicted. The predictions were limited to a shock-free design condition and the effect of shock structure on the jet mixing noise was not addressed. The present work is aimed at investigating this issue. Under imperfectly expanded conditions the existence of the shock cell structure and its interaction with the convecting turbulence structure may not only generate a broadband shock-associated noise but also change the turbulence structure, and thus the strength of the mixing noise source. Failure in capturing shock structures properly could lead to incorrect aeroacoustic predictions.

Kim, Chan M.↗

DOE OSTI2022

Wind farm flow control: prospects and challenges

Abstract. Wind farm control has been a topic of research for more than two decades. It has been identified as a core component of grand challenges in wind energy science to support accelerated wind energy deployment and to transition to a clean and sustainable energy system for the 21st century. The prospect of collective control of wind turbines in an array, to increase energy extraction, reduce structural loads, improve the balance of systems, reduce operation and maintenance costs, etc. has inspired many researchers over the years to propose innovative ideas and solutions. However, practical demonstration and commercialization of some of the more advanced concepts has been limited by a wide range of challenges, which include the complex physics of turbulent flows in wind farms and the atmosphere, uncertainties related to predicting structural load and failure statistics, and the highly multi-disciplinary nature of the overall design optimization problem, among others. In the current work, we aim at providing a comprehensive overview of the state of the art and outstanding challenges, thus identifying the key research areas that could further enable commercial uptake and success of wind farm control solutions. To this end, we have structured the discussion on challenges and opportunities into four main areas: (1) insight in control flow physics, (2) algorithms and AI, (3) validation and industry implementation, and (4) integrating control with system design (co-design).

Meyers, Johan (ORCID:0000000228284397)↗

DOE OSTI2025

Maturing Rational Design Methodologies and Industry Consensus Engineering Standards: Critical Fastened Joints - Solar PV Industry

Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.

14 SOLAR ENERGY↗

NASA NTRS1973

Evaluation of coated columbium alloy heat shields for space shuttle thermal protection system application. Volume 2, phase 2: Subsize heat shield and small size TPS evaluation

Initially a trade study was conducted of seven heat shield configurations. These were evaluated for structural reliability, fabricability, weight, inspectability, and refurbishability. Two concepts, a tee-stiffened and an open corrugation, were selected as offering the most potential for system success. Fourteen subsize heat shields of a full scale section were fabricated from C-129Y and Cb-752 and silicide coated with R-512E. These subsize panels were subjected to a simulated flight profile representing temperature, local surface pressures, and applied pressure differential loads. All corrugated panels of both alloys sustained 100 cycles without structural or coating failure. All Cb-752/R-512E panels performed well with one panel being successfully repaired after 66 cycles and completing 100 cycles. As a result of this evaluating the Cb-752/R-512E system was selected for hardware application during the subsequent phases. In addition, the tee-stiffened configuration was selected for further development and application in Phase III. This selection was based on an overall assessment of relative weight, cost, and structural performance of the tee-stiffened and open corrugation TPS.

Black, W. E.↗

NASA NTRS2011

Highly Loaded Composite Strut Test Results

Highly loaded composite struts from a proposed truss-based Altair lunar lander descent stage concept were selected for development under NASA's Advanced Composites Technology program. Predicted compressive member forces during launch and ascent of over -100,000 lbs were much greater than the tensile loads. Therefore, compressive failure modes, including structural stability, were primary design considerations. NASA's industry partner designed and built highly loaded struts that were delivered to NASA for testing. Their design, fabricated on a washout mandrel, had a uniform-diameter composite tube with composite tapered ends. Each tapered end contained a titanium end fitting with facing conical ramps that are overlaid and overwrapped with composite materials. The highly loaded struts were loaded in both tension and compression, with ultimate failure produced in compression. Results for the two struts tested are presented and discussed, along with measured deflections, strains and observed failure mechanisms.

Wu, K. C.↗

NASA NTRS1992

Mode interaction in stiffened composite shells under combined mechanical and thermal loadings

Stiffened shells of various configurations fabricated out of composite materials find extensive applications in aircraft structures. Two distinctive modes of buckling dominate structural response of stiffened panels, viz. the short-wave local mode in which the shell skin buckles essentially between the stiffeners and the long-wave overall mode in which the shell skin buckles carrying the stiffeners with it. In optimized designs, the critical stresses corresponding to these modes of buckling would be close to each other. This leads to a nonlinear mode interaction which is recognized to be the principal cause of the failure of stiffened structures. If the structure is subjected to through-the-thickness thermal gradients, then large-wave bending effects would begin to occur well below the overall critical load and these would play the role of overall imperfections. The load carrying capacity would be significantly diminished as a result of interaction of local buckling with overall thermal distortions. The analysis of this problem using standard finite element techniques can be shown to be prohibitively expensive for design iterations. A concept which would greatly facilitate the analysis of mode interaction is advanced. We note that the local buckling occurs in a more or less periodic pattern in a structure having regular spacings of stiffeners. Thus it is a relatively simple matter to analyze the local buckling and the second order effects (which are essential for modeling postbuckling phenomena) using a unit cell of the structure. Once analyzed, these dormations are embedded in a shell element. Thus, a shell element could span several half-waves of local buckling and still be able to depict local buckling effects with requisite accuracy. A major consequence of the interaction of overall buckling/bending is the slow variation of the local buckling amplitude across the structure - the phenomenon of 'amplitude modulation' - and this is accounted for in the present model by letting the scaling parameter of the local mode vary according to a 'slowly varying' function. The construction of the analytical model involves essentially two stages and these are described briefly.

Sridharan, Srinivasan↗

NASA NTRS2011

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗

NASA NTRS2016

Effects of Near Field Pyroshock on the Performance of a Nitramine Nitrocellulose Propellant

The overall purpose of this study is to investigate the effects of a pyroshock environment on the performance characteristics of a propellant used in pyrotechnic devices such as guillotine cutters. Near field pyroshock which is defined by acceleration amplitudes in excess of 10,000g at a frequency of greater than 10,000 Hz is a highly transient environment that has a known potential to cause failure in both structural and electronic components. A heritage pressure cartridge assembly which uses a nitramine nitrocellulose propellant with a known performance baseline will be exposed to a near field pyroshock event. The pressure cartridge will then be fired in an ambient closed bomb firing to collect pressure time history. The two performance characteristics that will be evaluated are the pressure amplitude and time to peak pressure. This data will be compared to the base-lined ambient closed bomb data to evaluate the effects of the shock on the performance of the propellant. It is expected that the pyroshock environment will cause brittle failures of the propellant increasing the surface area of said propellant. This increase of surface area should result in increased combustion rate which should show as an increased pressure peak and decreased time to peak pressure in the pressure time data.

Baca, Arcenio B.↗

NASA NTRS2002

Structural Response of Compression-Loaded, Tow-Placed, Variable Stiffness Panels

Results of an analytical and experimental study to characterize the structural response of two compression-loaded variable stiffness composite panels are presented and discussed. These variable stiffness panels are advanced composite structures, in which tows are laid down along precise curvilinear paths within each ply and the fiber orientation angle varies continuously throughout each ply. The panels are manufactured from AS4/977-3 graphite-epoxy pre-preg material using an advanced tow placement system. Both variable stiffness panels have the same layup, but one panel has overlapping tow bands and the other panel has a constant-thickness laminate. A baseline cross-ply panel is also analyzed and tested for comparative purposes. Tests performed on the variable stiffness panels show a linear prebuckling load-deflection response, followed by a nonlinear response to failure at loads between 4 and 53 percent greater than the baseline panel failure load. The structural response of the variable stiffness panels is also evaluated using finite element analyses. Nonlinear analyses of the variable stiffness panels are performed which include mechanical and thermal prestresses. Results from analyses that include thermal prestress conditions correlate well with measured variable stiffness panel results. The predicted response of the baseline panel also correlates well with measured results.

Wu, K. Chauncey↗

NASA NTRS1991

Thermal and structural assessments of a ceramic wafer seal in hypersonic engines

The thermal and structural performances of a ceramic wafer seal in a simulated hypersonic engine environment are numerically assessed. The effects of aerodynamic heating, surface contact conductance between the seal and its adjacent surfaces, flow of purge coolant gases, and leakage of hot engine flow path gases on the seal temperature were investigated from the engine inlet back to the entrance region of the combustion chamber. Finite element structural analyses, coupled with Weibull failure analyses, were performed to determine the structural reliability of the wafer seal.

Tong, Mike T.↗

NASA NTRS1991

Thermal and structural assessments of a ceramic wafer seal in hypersonic engine

Tong, Mike↗

NASA NTRS1992

Analysis of composite structures with delaminations under combined bending and compression

A methodology had been developed for strength prediction of composite structures with delaminations under combined bending and compression loads. The methodology is an extension of the delamination analysis method developed under the USAF/Boeing/Northrop 'Damage Tolerance of Composites' program. Delamination buckling and strain energy release rate analyses are used as basic tools in the strength prediction. In addition, failure mode interaction and structural configuration effects are considered. The influence of fasteners on the strength of a delaminated structure is incorporated to evaluate assembly-caused delaminations. The capabilities and limitations of the analysis method are shown by correlating the analytical results with the existing experimental data. The failure load, failure mode and failure sequence of a structure containing delaminations are predicted and the analytical results are compared with test data.

Kan, Han-Pin↗

NASA NTRS2014

Astronaut Bone Medical Standards Derived from Finite Element (FE) Models of QCT Scans from Population Studies

This work was accomplished in support of the Finite Element [FE] Strength Task Group, NASA Johnson Space Center [JSC], Houston, TX. This group was charged with the task of developing rules for using finite-element [FE] bone-strength measures to construct operating bands for bone health that are relevant to astronauts following exposure to spaceflight. FE modeling is a computational tool used by engineers to estimate the failure loads of complex structures. Recently, some engineers have used this tool to characterize the failure loads of the hip in population studies that also monitored fracture outcomes. A Directed Research Task was authorized in July, 2012 to investigate FE data from these population studies to derive these proposed standards of bone health as a function of age and gender. The proposed standards make use of an FE-based index that integrates multiple contributors to bone strength, an expanded evaluation that is critical after an astronaut is exposed to spaceflight. The current index of bone health used by NASA is the measurement of areal BMD. There was a concern voiced by a research and clinical advisory panel that the sole use of areal BMD would be insufficient to fully evaluate the effects of spaceflight on the hip. Hence, NASA may not have a full understanding of fracture risk, both during and after a mission, and may be poorly estimating in-flight countermeasure efficacy. The FE Strength Task Group - composed of principal investigators of the aforementioned population studies and of FE modelers -donated some of its population QCT data to estimate of hip bone strength by FE modeling for this specific purpose. Consequently, Human Health Countermeasures [HHC] has compiled a dataset of FE hip strengths, generated by a single FE modeling approach, from human subjects (approx.1060) with ages covering the age range of the astronauts. The dataset has been analyzed to generate a set of FE strength cutoffs for the following scenarios: a) Qualify an applicant for astronaut candidacy, b) Qualify an astronaut for a long-duration (LD) mission, c) Qualify a veteran LD astronaut for a second LD mission, and d) Establish a non-permissible, minimum hip strength following a given mission architecture. This abstract will present the FE-based standards accepted by the FE Strength Task Group for its recommendation to HHC in January 2015.

Sibonga, J. D.↗

NASA NTRS2014

Prediction of Acoustic Environments from Horizontal Rocket Firings

In recent years, advances in research and engineering have led to more powerful launch vehicles which can reach areas of space not yet explored. These more powerful vehicles yield acoustic environments potentially destructive to the vehicle or surrounding structures. Therefore, it has become increasingly important to be able to predict the acoustic environments created by these vehicles in order to avoid structural and/or competent failure. The current industry standard technique for predicting launch-induced acoustic environments was developed by Eldred in the early 1970's and is published in NASA SP-80721. Recent work2 has shown Eldred's technique to be inaccurate for current state-of-the-art launch vehicles. Due to the high cost of full-scale and even sub-scale rocket experiments, very little rocket noise data is available. Furthermore, much of the work thought to be applicable to rocket noise has been done with heated jets. Tam3,4 has done an extensive amount of research on jets of different nozzle exit shape, diameter, velocity, and temperature. Though the values of these parameters, especially exit velocity and temperature, are often very low compared to these values in rockets, a lot can be learned about rocket noise from jet noise literature. The turbulent nature of jet and rocket exhausts is quite similar. Both exhausts contain turbulent structures of varying scale-termed the fine and large scale turbulence by Tam. The finescale turbulence is due to small eddies from the jet plume interacting with the ambient atmosphere. According to Tam et al., the noise radiated by this envelope of small-scale turbulence is statistically isotropic. Hence, one would expect the noise from the small scale turbulence of the jet to be nearly omni-directional. The coherent nature of the large-scale turbulence results in interference of the noise radiated from different spatial locations within the jet. This interference-whether it is constructive or destructive-results in highly directional noise radiation. Tam3 has proposed a model to predict the acoustic environment due to jets and while it works extremely well for jets, it was found to be inappropriate for rockets8. A model to predict the acoustic environment due to a launch vehicle in the far-field which incorporates concepts from both Eldred and Tam was created. This was done using five sets of horizontally fired rocket data, obtained between 2008 and 2012. Three of these rockets use solid propellant and two use liquid propellant. Through scaling analysis, it is shown that liquid and solid rocket motors exhibit similar spectra at similar amplitudes. This model is accurate for these five data sets within 5 dB of the measured data for receiver angles of 30deg to 160deg (with respect to the downstream exhaust centerline). The model uses the following vehicle parameters: nozzle exit diameter and velocity, radial distance from source to receiver, receiver angle, mass flow rate, and acoustic efficiency.

Giacomoni, Clothilde↗

NASA NTRS2019

Progressive Damage and Failure Analysis of Bonded Composite Joints at High Energy Dynamic Impacts

Both wing and fuselage structures utilize bonded composite joints for structural efficiency in modern commercial and military aircraft. To ensure compliance with certification requirements mechanical fasteners are typically used as a failsafe mechanism for appropriate strength in the event of complete stiffener disbond. However, the use of fasteners decreases the structural efficiency of the structure by adding weight. This establishes the requirement to better exploit the efficiency of bonded structures and fully understand the failure behavior of adhesively bonded composite structures, particularly when subjected to elevated loading rates due to high energy dynamic impacts (HEDI). For this reason, the NASA Advanced Composite Consortium (ACC) HEDI team developed an experimentation and numerical modeling program for high rate loading of composite joints. In the present work, the response of adhesively bonded composite joints subjected to elevated loading rates is studied numerically and validated against experimental results. Due to dynamic considerations of experiments, the idea of wedge insert was extended to use with Split Hopkinson Pressure Bar (SHPB) testing techniques. Mode-I and Mode-II test configurations were simulated to evaluate the capability of two continuum damage material (CDM) models in LS-DYNA, namely MAT162 and MAT261. Three different levels of fidelity were considered to investigate the level of detail required to numerically predict the failure behavior and the results from high fidelity analysis are presented.

MAT261↗

NASA NTRS1987

Verification of FANTASTIC integrated code

FANTASTIC is an acronym for Failure Analysis Nonlinear Thermal and Structural Integrated Code. This program was developed by Failure Analysis Associates, Palo Alto, Calif., for MSFC to improve the accuracy of solid rocket motor nozzle analysis. FANTASTIC has three modules: FACT - thermochemical analysis; FAHT - heat transfer analysis; and FAST - structural analysis. All modules have keywords for data input. Work is in progress for the verification of the FAHT module, which is done by using data for various problems with known solutions as inputs to the FAHT module. The information obtained is used to identify problem areas of the code and passed on to the developer for debugging purposes. Failure Analysis Associates have revised the first version of the FANTASTIC code and a new improved version has been released to the Thermal Systems Branch.

Chauhan, Rajinder Singh↗