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At least 469 records · Page 26

Operational Implications from Field Test Results: Sensorimotor Guidelines for Exploration Missions

Two key sensorimotor objectives of the joint NASA-Russian Field Test (FT) study were (1) to quantify functional performance on long duration crewmembers as close to landing as possible, and (2) to develop a recovery timeline back to preflight baseline. The purpose of this presentation is to provide an overview of the FT results and discuss the operational implications for future exploration missions. The NASA and Russian teams conducted a total of 48 Field Tests, including 18 using a reduced Pilot FT (PFT) protocol. The combined PFT/FT cohort included 14 first-time fliers, 4F, and nine cosmonauts who repeated FT during a second mission. The mission durations were 185 ± 42 days, mean ± std. Nominally, the initial postflight session was performed in the medical test at the Soyuz landing site or at the nearby airport (R+2.2 ± 1.3 hrs, mean ± std), and then repeated multiple times throughout the postflight recovery. The common tasks performed across PFT and full FT protocols included sit-to-stand, recovery from fall (prone to stand) and tandem walk, performed in that order of increasing difficulty. The full FT protocol also included seated tasks (eccentric gaze, dysmetria finger to nose, eye-hand coordination on a tablet, grip force discrimination), a standing posture test with an upper body perturbation, a timed up and go mobility test with obstacles, and a dynamic visual acuity task during vertical oscillations. While there was considerable variability in the postflight outcome measures across crewmembers, the level of vestibular/cerebellar and sensorimotor impairment was greater than previously observed during shorter spaceflight missions. Most striking was the higher incidence of motion sickness even without constraining the standard medical interventions. Motion sensitivity prevented some crewmembers from attempting and/or completing the early testing. The recovery timeline varied with task complexity, generally taking longer when either the basis of support was limited (e.g., tandem walk) or visual cues were deprived (eyes closed). Based on this evidence, mission planners need to expect a range of response across individuals and tasks following G-transitions. Individual health assessments are recommended along with development of pre-worked, prioritized content and timelines, with the ability to change roles depending on crew readiness. Handholds and balance aids are recommended to help stabilize the crewmembers to perform specific tasks (e.g., touch screen selection) or to allow the crewmember the ability to rest with onset of symptoms. Based on anecdotal reports and performance on computerized dynamic posturography, multiple testing on landing day appeared to be beneficial for some participants, while others may have pushed beyond their motion tolerance limit in an effort to complete more FT objectives. Instead of delaying planetary surface operations to allow for recovery, our results suggest that early mobility may be important. Early active self-administered retraining, individualized based on the level of initial impairment and motion sensitivity, will enable a more efficient motor learning and enhance crew performance.

S J Wood↗

Deployable and retractable telescoping tubular structure development

A new deployable and retractable telescoping boom capable of high deployed stiffness and strength is described. Deployment and retraction functions are controlled by simple, reliable, and fail-safe latches between the tubular segments. The latch and a BI-STEM (Storable Tubular Extendible Member) actuator work together to eliminate the need for the segments to overlap when deployed. This yields an unusually lightweight boom and compact launch configuration. An aluminum space-flight prototype with three joints displays zero structural deadband, low hysteresis, and high damping. The development approach and difficulties are discussed. Test results provide a joint model for sizing flight booms of any diameter and length.

Thomson, M. W.↗

Development of Guidelines for In-Situ Repair of SLS-Class Composite Flight Hardware

The purpose of composite repair development at KSC (John F. Kennedy Space Center) is to provide support to the CTE (Composite Technology for Exploration) project. This is a multi-space center effort with the goal of developing bonded joint technology for SLS (Space Launch System) -scale composite hardware. At KSC, effective and efficient repair processes need to be developed to allow for any potential damage to composite components during transport or launch preparation. The focus of the composite repair development internship during the spring of 2018 was on the documentation of repair processes and requirements for process controls based on techniques developed through hands-on work with composite test panels. Three composite test panels were fabricated for the purpose of repair and surface preparation testing. The first panel included a bonded doubler and was fabricated to be damaged and repaired. The second and third panels were both fabricated to be cut into lap-shear samples to test the strength of bond of different surface preparation techniques. Additionally, jointed composite test panels were impacted at MSFC (Marshall Space Flight Center) and analyzed for damage patterns. The observations after the impact tests guided the repair procedure at KSC to focus on three repair methods. With a finalized repair plan in place, future work will include the strength testing of different surface preparation techniques, demonstration of repair methods, and repair of jointed composite test panels being impacted at MSFC.

Weber, Thomas P., Jr.↗

Hot gas ingestion: From model results to full scale engine testing

An overview is presented of a joint NASA Lewis McDonnell Aircraft Co. Hot Gas Ingestion (HGI) test program in NASA Lewis' 9 x 15 foot Low Speed Wind Tunnel (LSWT). Advanced short takeoff vertical landing (ASTOVL) aircraft capable of operating from remote sites, damaged runways, aircraft carriers and small air-capable ships are being pursued for deployment around the turn of the century. To achieve this goal, it is important that technologies critical to this unique class of aircraft be developed. One of the ASTOVL concepts, the vectored thrust, has as its critical technology item, the potential of hot gas ingestion (which occurs during vertical flight operation while in ground effect) as a key development issue. Recognizing this need, NASA Lewis Powered Lift Section and McAir have defined a cooperative program for testing in the Lewis 9 x 15 foot LSWT. This program is described in detail.

Johns, Albert L.↗

Fabrication and evaluation of superplastically formed/weld-brazed corrugated compression panels with beaded webs

A study was made to investigate the feasibility of superplastically forming corrugated panels with beaded webs and to demonstrate the structural integrity of these panels by testing. The test panels in the study consist of superplastically formed titanium alloy Ti-6Al-4V half-hat elements that are joined by weld-brazing to titanium alloy Ti-6Al-4V caps to form either single-corrugation compression panels or multiple-corrugation compression panels. Stretching and subsequent thinning of the titanium sheet during superplastic forming is reduced by approximately 35 percent with a shallow half-hat die concept instead of a deep die concept and results in a more uniform thickness across the beaded webs. The complete panels are tested in end compression at room temperature and the results compared with analysis. The heavily loaded panels failed at loads approaching the yield strength of the titanium material. At maximum load, the caps wrinkled locally accompanied with separation of the weld-braze joint in the wrinkle. None of the panels tested, however, failed catastrophically in the weld-braze joint. Experimental test results are in good agreement with structural analysis of the panels.

Royster, D. M.↗

Super-Zip separation joint performance investigation

Following functional failures of two of five Lockheed Super-Zip spacecraft separation joints in a development test series to quantify thermal effects, an investigation program was initiated on this and related systems to assist in preventing recurrence. The Super-Zip joint, applied in a ring configuration, utilizes an explosively expanded tube to fracture surrounding prenotched aluminum plates to achieve planar separation. A unique test method was developed and more than 300 individual test firings were conducted to provide an understanding of severance mechanisms, the functional performance effects of system variables, and the most likely cause of system failure. An approach for defining functional margin was developed, as well as specific recommendations for improving existing and future systems.

Bement, Laurence J.↗

Experimental Study of the Compression Response of Fluted-Core Composite Panels with Joints

Fluted-core sandwich composites consist of integral angled web members spaced between laminate face sheets, and may have the potential to provide benefits over traditional sandwich composites for certain aerospace applications. However, fabrication of large autoclave-cured fluted-core cylindrical shells with existing autoclaves will require that the shells be fabricated in segments, and joined longitudinally to form a complete barrel. Two different longitudinal fluted-core joint designs were considered experimentally in this study. In particular, jointed fluted-core-composite panels were tested in longitudinal compression because longitudinal compression is the primary loading condition in dry launch-vehicle barrel sections. One of the joint designs performed well in comparison with unjointed test articles, and the other joint design failed at loads approximately 14% lower than unjointed test articles. The compression-after-impact (CAI) performance of jointed fluted-core composites was also investigated by testing test articles that had been subjected to 6 ft-lb impacts. It was found that such impacts reduced the load-carrying capability by 9% to 40%. This reduction is dependent on the joint concept, component flute size, and facesheet thickness.

Schultz, Marc R.↗

Composite material characterization for large space structures.

A program phase to characterize advanced composite materials for a large reflector support truss on the ATS F & G spacecraft is described. The selection of a Hercules Incorporated, 2002M graphite fiber reinforced epoxy material was based on criteria of spacecraft system requirements and the potential of this material to meet these requirements. The objective of this phase was to develop materials data required for development, design, fabrication, test, and flight of a graphite-fiber, reinforced-plastic spacecraft structure. Testing within a temperature range from -300 F to +200 F covered the generation of data for physical, mechanical, thermophysical, and space environmental properties for the selected material. Additional testing covered adhesive bonded joint materials within the temperature ranges of the spacecraft environment. Descriptions of the spacecraft, reflector support truss, design, requirements, materials, tests, and developed data are presented.

Macneill, C. E.↗

Predictive Models and Novel Accelerated Tests for the Reliability of Cell Metallization and Solder Joints in Photovoltaic Modules

Interconnect, solder, and metallization-related failures are the primary reason for premature Si-based photovoltaic panel failure [1, 2] and can lead to a cascade of other failures, including thermal events. This combination of high severity and high occurrence means that understanding interconnect-related failures is key to the long-term health of the photovoltaic industry, and it is crucial that the industry adopt efficient and effective tests that aid in design-for-reliability and manufacturing quality control.

14 SOLAR ENERGY↗

Modeling and data analysis of the NASA-WSTF frictional heating apparatus - Effects of test parameters on friction coefficient

A theoretical model is being developed jointly by the NASA White Sands Test Facility (WSTF) and the University of California at Santa Barbara (UCSB) to analyze data generated from the WSTF frictional heating test facility. Analyses of the data generated in the first seconds of the frictional heating test are shown to be effective in determining the friction coefficient between the rubbing interfaces. Different friction coefficients for carobn steel and Monel K-500 are observed. The initial condition of the surface is shown to affect only the initial value of the friction coefficient but to have no significant influence on the average steady-state friction coefficient. Rotational speed and the formation of oxide film on the rotating surfaces are shown to have a significant effect on the friction coefficient.

Zhu, Sheng-Hu↗

Evaluation of Corrosion and Its Impact on the Mechanical Performance of Al–Steel Joints

Aluminum–steel joints are increasingly used in the automotive industry to meet the requirements for energy saving and emission reduction. Among various joining technologies, self-pierce riveting (SPR) and resistance spot welding (RSW) are two well-established technologies for fabricating dissimilar joints with stable and high mechanical performance. However, corrosion will occur in these joints inevitably due to different electrochemical properties, which can degrade the surface quality and the mechanical performance, such as strength. This paper presents a method of understanding the corrosion mechanisms in joining aluminum and steel. For this understanding, a hybrid method combining experimental observations, mechanical properties identification, and analytical approaches was used to assess the evolution of the impact of corrosion on the joining performance, such as traction separation curves. The study was conducted on common combinations used in the vehicles, e.g., a 1.2 mm thickness aluminum alloy (AA 6022) and 2.0 mm thickness hot deep galvanized steel (HDG HSLA 340) joined by SPR and RSW. After the fabrication of these joints, accelerated cyclic corrosion tests of up to 104 cycles were performed, which reproduced the environmental conditions to which a vehicle was exposed. By investigating the microstructural evolution within the joints, the corrosion mechanisms of SPR and RSW joints were revealed, including the initiation and propagation. Moreover, the intrinsic impact of the corrosion on the mechanical performance, including the strength, axial stiffness, and crashworthiness, was analyzed by performing a lap-shear test. It showed that as corrosion proceeds, the fracture modes and mechanical performance are affected significantly.

Chemistry↗

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Friction stir welded (FSW) aluminum–magnesium lightweight vehicle joints have gained significant interest due to their high strength-to-weight ratio. In this work, the corrosion resistance of this material is analyzed through electrochemical tests, which include open circuit potential (OCP) inspection and potentiodynamic polarization (PD) scanning. Weight loss measurements tested the corrosion rate of the FSW weld through cyclic corrosion testing (CCT) according to the standard SAEJ 2334. Mechanical properties were also investigated, including lap-shear strength, micro- and nano-hardness mapping, and true stress–strain curves as a function of local processing history. The electrochemical results indicate that the center weld zone’s corrosion property stays between the two base alloys. Indentation-based testing demonstrated that the weld zone behaves differently from base alloys. Lap shear strength surprisingly did not drop much even after eight weeks of cyclic corrosion tests, indicating that the joint did not allow any ingress of the electrolyte.

36 MATERIALS SCIENCE↗

Flight motor set 360L001 (STS-26R). (Reconstructed dynamic loads analysis)

A transient analysis was performed to correlate the predicted versus measured behavior of the Redesigned Solid Rocket Booster (RSRB) during Flight 360L001 (STS-26R) liftoff. Approximately 9 accelerometers, 152 strain gages, and 104 girth gages were bonded to the motors during this event. Prior to Flight 360L001, a finite element model of the RSRB was analyzed to predict the accelerations, strains, and displacements measured by this developmental flight instrumentation (DFI) within an order of magnitude. Subsequently, an analysis has been performed which uses actual Flight 360L001 liftoff loading conditions, and makes more precise predictions for the RSRB structural behavior. Essential information describing the analytical model, analytical techniques used, correlation of the predicted versus measured RSRB behavior, and conclusions, are presented. A detailed model of the RSRB was developed and correlated for use in analyzing the motor behavior during liftoff loading conditions. This finite element model, referred to as the RSRB global model, uses super-element techniques to model all components of the RSRB. The objective of the RSRB global model is to accurately predict deflections and gap openings in the field joints to an accuracy of approximately 0.001 inch. The model of the field joint component was correlated to Referee and Joint Environment Simulation (JES) tests. The accuracy of the assembled RSRB global model was validated by correlation to static-fire tests such DM-8, DM-9, QM-7, and QM-8. This validated RSRB global model was used to predict RSRB structural behavior and joint gap opening during Flight 360L001 liftoff. The results of a transient analysis of the RSRB global model with imposed liftoff loading conditions are presented. Rockwell used many gage measurements to reconstruct the load parameters which were imposed on the RSRB during the Flight 360L001 liftoff. Each load parameter, and its application, is described. Also presented are conclusions and recommendations based on the analysis of this load case and the resulting correlation between predicted and measured RSRB structural behavior.

Call, V. B.↗

Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking

A new technique called friction stir interlocking (FSI) was applied for lap-joining of AZ31 magnesium sheet and thermoset carbon fiber reinforced polymer (TS-CFRP) sheet. Instead of directly joining AZ31 and TS-CFRP, a series of magnesium interlocks were used to friction stir weld with AZ31 sheet to enable joining with TS-CFRP. Microstructural characterization of joint cross sections showed that a tool rotation rate of 800 rpm produced incomplete mixing of magnesium interlocks and the top AZ31 sheet, while 1200 rpm achieved sufficient material mixing to avoid unwelded regions. Mechanical property characterization showed that AZ31/TS-CFRP dissimilar joints failed through the magnesium interlock shanks during lap shear tensile testing, with a maximum normalized joint strength reaching ~100 MPa.

Wang, Tianhao↗

Internal rotor friction instability

The analytical developments and experimental investigations performed in assessing the effect of internal friction on rotor systems dynamic performance are documented. Analytical component models for axial splines, Curvic splines, and interference fit joints commonly found in modern high speed turbomachinery were developed. Rotor systems operating above a bending critical speed were shown to exhibit unstable subsynchronous vibrations at the first natural frequency. The effect of speed, bearing stiffness, joint stiffness, external damping, torque, and coefficient of friction, was evaluated. Testing included material coefficient of friction evaluations, component joint quantity and form of damping determinations, and rotordynamic stability assessments. Under conditions similar to those in the SSME turbopumps, material interfaces experienced a coefficient of friction of approx. 0.2 for lubricated and 0.8 for unlubricated conditions. The damping observed in the component joints displayed nearly linear behavior with increasing amplitude. Thus, the measured damping, as a function of amplitude, is not represented by either linear or Coulomb friction damper models. Rotordynamic testing of an axial spline joint under 5000 in.-lb of static torque, demonstrated the presence of an extremely severe instability when the rotor was operated above its first flexible natural frequency. The presence of this instability was predicted by nonlinear rotordynamic time-transient analysis using the nonlinear component model developed under this program. Corresponding rotordynamic testing of a shaft with an interference fit joint demonstrated the presence of subsynchronous vibrations at the first natural frequency. While subsynchronous vibrations were observed, they were bounded and significantly lower in amplitude than the synchronous vibrations.

Walton, J.↗