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NASA NTRS2010

Northrop Grumman TR202 LOX/LH2 Deep Throttling Engine Technology Project Status

NASA's Propulsion and Cryogenic Advanced Development (PCAD) project is currently developing enabling propulsion technologies in support of future lander missions. To meet lander requirements, several technical challenges need to be overcome, one of which is the ability for the descent engine(s) to operate over a deep throttle range with cryogenic propellants. To address this need, PCAD has enlisted Northrop Grumman Aerospace Systems (NGAS) in a technology development effort associated with the TR202 engine. The TR202 is a LOX/LH2 expander cycle engine driven by independent turbopump assemblies and featuring a variable area pintle injector similar to the injector used on the TR200 Apollo Lunar Module Descent Engine (LMDE). Since the Apollo missions, NGAS has continued to mature deep throttling pintle injector technology. The TR202 program has completed two series of pintle injector testing. The first series of testing used ablative thrust chambers and demonstrated igniter operation as well as stable performance at discrete points throughout the designed 10:1 throttle range. The second series was conducted with calorimeter chambers and demonstrated injector performance at discrete points throughout the throttle range as well as chamber heat flow adequate to power an expander cycle design across the throttle range. This paper provides an overview of the TR202 program, describing the different phases and key milestones. It describes how test data was correlated to the engine conceptual design. The test data obtained has created a valuable database for deep throttling cryogenic pintle technology, a technology that is readily scalable in thrust level.

Gromski, Jason↗

NASA NTRS2018

Test and Analysis of Full-Scale 27.5-Foot-Diameter Stiffened Metallic Launch Vehicle Cylinders

The Shell Buckling Knockdown Factor Project (SBKF) was established with the goal of developing improved (i.e., less-conservative, more robust) shell buckling knockdown factors (KDFs) for modern launch-vehicle structures. To this end, SBKF has engaged in several activities to support the development, validation, and implementation of the new design factors, including subscale and full-scale structural testing. Tests on eight different subscale, 8-foot-diameter, integrally stiffened aluminum-lithium 2195 (Al-Li 2195) cylinders were conducted in order to obtain the majority of the required validation data. In addition, two full-scale, 27.5-foot-diameter, Al-Li 2195, integrally stiffened cylinders were tested to provide additional validation data and to determine structural scaling trends. Presented herein are the details of a recent analysis model development and test and analysis correlation effort on the full-scale test articles. The effects of selected modeling assumptions and approaches are discussed, and results from a modeling sensitivity study are presented. It was found that simplified finite element models, that assume nominal test article geometry and material properties, can predict the overall response characteristics well. However, several discrepancies in the test and analysis results were observed. A sensitivity study was performed to determine the effects of several modeling assumptions and address the observed discrepancies. The results from the study indicated that the evolution of local skin pocket buckling and the presence of residual stresses due to the manufacturing process can have a significant influence on the predicted buckling response of the cylinders considered.

Lovejoy, Andrew E.↗

NASA NTRS1981

Space Shuttle main engine nozzle-steerhorn dynamics

On two occasions during the Space Shuttle main engine development, the LH2 feedline (called the steerhorn, because of its shape) failed during the cutoff transient. A dynamic test was undertaken, and an analytical model was developed and correlated to the dynamic test. Detailed models of the tube bundle were required to obtain the equivalent shell coefficients. All-shell models of the nozzle wall were found better than beam-shell models. The most difficult part of the structure to simulate was the felt-metal pad between the feedline and its mount, which introduced nonlinear stiffness and damping and led to the use of separate low amplitude and high amplitude models. The total structure was found to have 400 modes in the frequency range of interest, 0 to 500 Hz. Good test analysis correlation was obtained and a modified feedline configuration was found to demonstrate a 40% reduction of response stress from the original configuration.

Kiefling, L.↗

NASA NTRS2010

Ares I-X Thermal Model Correlation and Lessons Learned

The Ares I-X vehicle launched and flew successfully on October 28, 2009. This paper will describe the correlation of the vehicle thermal model to both ground testing and flight data. A main purpose of the vehicle model and ground testing was to ensure that the avionics within the vehicle were held within their thermal limits prior to launch and during flight. The correlation of the avionics box temperatures will be shown. Also, the lessons learned in the thermal discipline during the modeling, test, correlation to test, and flight of the Ares I-X flight test vehicle will be described. Lessons learned will cover thermal modeling, as well as management of the thermal discipline, thermal team, and thermal-related actions in design, testing, and flight.

Amundsen, Ruth M.↗

NASA NTRS1987

Correlation of SA349/2 helicopter flight-test data with a comprehensive rotorcraft model

A comprehensive rotorcraft analysis model was used to predict blade aerodynamic and structural loads for comparison with flight test data. The data were obtained from an SA349/2 helicopter with an advanced geometry rotor. Sensitivity of the correlation to wake geometry, blade dynamics, and blade aerodynamic effects was investigated. Blade chordwise pressure coefficients were predicted for the blade transonic regimes using the model coupled with two finite-difference codes.

Yamauchi, Gloria K.↗

NASA NTRS1986

Correlation of SA349/2 helicopter flight-test data with a comprehensive rotorcraft model

Yamauchi, Gloria K.↗

NASA NTRS2003

Water Impact Test and Simulation of a Composite Energy Absorbing Fuselage Section

In March 2002, a 25-ft/s vertical drop test of a composite fuselage section was conducted onto water. The purpose of the test was to obtain experimental data characterizing the structural response of the fuselage section during water impact for comparison with two previous drop tests that were performed onto a rigid surface and soft soil. For the drop test, the fuselage section was configured with ten 100-lb. lead masses, five per side, that were attached to seat rails mounted to the floor. The fuselage section was raised to a height of 10-ft. and dropped vertically into a 15-ft. diameter pool filled to a depth of 3.5-ft. with water. Approximately 70 channels of data were collected during the drop test at a 10-kHz sampling rate. The test data were used to validate crash simulations of the water impact that were developed using the nonlinear, explicit transient dynamic codes, MSC.Dytran and LS-DYNA. The fuselage structure was modeled using shell and solid elements with a Lagrangian mesh, and the water was modeled with both Eulerian and Lagrangian techniques. The fluid-structure interactions were executed using the fast general coupling in MSC.Dytran and the Arbitrary Lagrange-Euler (ALE) coupling in LS-DYNA. Additionally, the smooth particle hydrodynamics (SPH) meshless Lagrangian technique was used in LS-DYNA to represent the fluid. The simulation results were correlated with the test data to validate the modeling approach. Additional simulation studies were performed to determine how changes in mesh density, mesh uniformity, fluid viscosity, and failure strain influence the test-analysis correlation.

Fasanella, Edwin L.↗

NASA NTRS2002

Novel Optical Technique Developed and Tested for Measuring Two-Point Velocity Correlations in Turbulent Flows

A novel technique for characterizing turbulent flows was developed and tested at the NASA Glenn Research Center. The work is being done in collaboration with the University of Pittsburgh, through a grant from the NASA Microgravity Fluid Physics Program. The technique we are using, Homodyne Correlation Spectroscopy (HCS), is a laser-light-scattering technique that measures the Doppler frequency shift of light scattered from microscopic particles in the fluid flow. Whereas Laser Doppler Velocimetry gives a local (single-point) measurement of the fluid velocity, the HCS technique measures correlations between fluid velocities at two separate points in the flow at the same instant of time. Velocity correlations in the flow field are of fundamental interest to turbulence researchers and are of practical importance in many engineering applications, such as aeronautics.

Zimmerli, Gregory A.↗

NASA NTRS2018

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗

NASA NTRS1991

Flying quality analysis and flight evaluation of a highly augmented combat rotorcraft

This paper discusses implications of digital flight control system design for rotorcraft and illustrates the analysis of the resulting handling qualities obtained with the Advanced Digital Optical Control System demonstrator in the context of the proposed new handling-qualities specification for rotorcraft. Topics covered are digital flight control design and analysis methods, flight testing techniques, handling-qualities evaluation results, and correlation of flight test results with analytical models and the proposed handling-qualities specification. The evaluation of the demonstrator system indicates desirable response characteristics based on equivalent damping and frequency, but undersirably large effective time delays (exceeding 240 ms in all axes). Piloted handling qualities are found to be desirable or adequate for all low, medium, and high pilot gain tasks, but handling qualities are inadequate for ultrahigh gain tasks such as slope and running landings. Correlation of these results with the proposed handling-qualities specification indicates good agreement for the bandwidth boundaries, but suggests the need for more stringent limits on allowable phase delay. Analytical models based on emulation (s-plane) techniques compare favorably with flight-extracted frequency-domain characteristics of the overall (end-to-end) system responses.

Tischler, Mark B.↗

NASA NTRS1986

Deployable truss structure advanced technology

The 5-meter technology antenna program demonstrated the overall feasibility of integrating a mesh reflector surface with a deployable truss structure to achieve a precision surface contour compatible with future, high-performance antenna requirements. Specifically, the program demonstrated: the feasibility of fabricating a precision, edge-mounted, deployable, tetrahedral truss structure; the feasibility of adjusting a truss-supported mesh reflector contour to a surface error less than 10 mils rms; and good RF test performance, which correlated well with analytical predictions. Further analysis and testing (including flight testing) programs are needed to fully verify all the technology issues, including structural dynamics, thermodynamics, control, and on-orbit RF performance, which are associated with large, deployable, truss antenna structures.

Dyer, J. E.↗

NASA NTRS1987

Self-regulating heater application to Shuttle/Centaur hydrazine fuel line thermal control

The Shuttle/Centaur high energy upper stage vehicle thermal environments were more severe than previous Centaur vehicle thermal environments, creating need for a new hydrazine fuel line thermal control technique. Constant power heaters did not satisfy power dissipation requirements, because the power required to maintain fuel line thermal control during cold conditions exceeded the maximum power allowable during hot conditions. Therefore, a Raychem Thermolimit self-regulating heater was selected for this application, and was attached to the hydrazine fuel line with Kapton and aluminum foil tapes. Fuel line/heater thermal modeling and subsequent thermal vacuum chamber testing simulated heater thermal performance during all worst-case Shuttle/Centaur thermal environmental conditions. Fuel line temperatures were maintained between the 4C to 71C limits during all analytical and test cases. Finally, the thermal model predictions were correlated with the test data, thereby ensuring that the model would provide satisfactory predictions for future missions and/or vehicles.

Unkrich, David B.↗

NASA NTRS2004

Wind Tunnel to Atmospheric Mapping for Static Aeroelastic Scaling

Wind tunnel to Atmospheric Mapping (WAM) is a methodology for scaling and testing a static aeroelastic wind tunnel model. The WAM procedure employs scaling laws to define a wind tunnel model and wind tunnel test points such that the static aeroelastic flight test data and wind tunnel data will be correlated throughout the test envelopes. This methodology extends the notion that a single test condition - combination of Mach number and dynamic pressure - can be matched by wind tunnel data. The primary requirements for affecting this extension are matching flight Mach numbers, maintaining a constant dynamic pressure scale factor and setting the dynamic pressure scale factor in accordance with the stiffness scale factor. The scaling is enabled by capabilities of the NASA Langley Transonic Dynamics Tunnel (TDT) and by relaxation of scaling requirements present in the dynamic problem that are not critical to the static aeroelastic problem. The methodology is exercised in two example scaling problems: an arbitrarily scaled wing and a practical application to the scaling of the Active Aeroelastic Wing flight vehicle for testing in the TDT.

Heeg, Jennifer↗

NASA NTRS1989

The Shane Wirtanen counts - Observability of the galaxy correlation function

An explicit test of the ability of the galaxy two-point correlation function to be recovered from the Lick counts of galaxies (Shane and Wirtanen, 1967) is reported. High-fidelity simulations are created, starting with the distribution of galaxies in space. These distributions are projected onto a set of simulated Lick plates which are reduced to a uniform limiting magnitude with the method of Seldner et al. (1977). The simulated catalogs are then analyzed with the methods of Groth and Peebles (1977). The resulting correlation functions are found to reproduce accurately the correlation functions that were built in during the first step of the simulations.

Brown, Michael E.↗

NASA NTRS1995

BMDO materials testing in the EOIM-3 experiment

The NASA Evaluation of Oxygen Interactions with Materials-3 (EOIM-3) experiment served as a testbed for a variety of materials that are candidates for Ballistic Missile Defense Organization (BMDO) space assets. The materials evaluated on this flight experiment were provided by BMDO contractors and technology laboratories. A parallel ground-based exposure evaluation was conducted using the Fast Atom Sample Tester (FAST) atomic-oxygen simulation facility at Physical Sciences, Inc. The EOIM-3 flight materials were exposed to an atomic oxygen fluence of approximately 2.3 x 10(exp 20) atoms/sq cm. The ground-based exposure fluence of 2.0 - 2.5 x 10(exp 20) atoms/sq cm permits direct comparison with that of the flight-exposed specimens. The results from the flight test conducted aboard STS-46 and the correlative ground-based exposure are summarized here. A more detailed correlation study is presented in the JPL Publication 93-31 entitled 'Flight-and Ground-Test Correlation Study of BMDO SDS Materials: Phase 1 Report'. In general, the majority of the materials survived the AO environment with their performance tolerances maintained for the duration of the exposure. Optical materials, baffles, and coatings performed extremely well as did most of the thermal coatings and tribological materials. A few of the candidate radiator, threat shielding, and structural materials showed significant degradation. Many of the coatings designed to protect against AO erosion of sensitive materials performed this function well.

Chung, Shirley Y.↗

NASA NTRS1994

Correlation of finite element free vibration predictions using random vibration test data

Finite element analysis is regularly used during the engineering cycle of mechanical systems to predict the response to static, thermal, and dynamic loads. The finite element model (FEM) used to represent the system is often correlated with physical test results to determine the validity of analytical results provided. Results from dynamic testing provide one means for performing this correlation. One of the most common methods of measuring accuracy is by classical modal testing, whereby vibratory mode shapes are compared to mode shapes provided by finite element analysis. The degree of correlation between the test and analytical mode shapes can be shown mathematically using the cross orthogonality check. A great deal of time and effort can be exhausted in generating the set of test acquired mode shapes needed for the cross orthogonality check. In most situations response data from vibration tests are digitally processed to generate the mode shapes from a combination of modal parameters, forcing functions, and recorded response data. An alternate method is proposed in which the same correlation of analytical and test acquired mode shapes can be achieved without conducting the modal survey. Instead a procedure is detailed in which a minimum of test information, specifically the acceleration response data from a random vibration test, is used to generate a set of equivalent local accelerations to be applied to the reduced analytical model at discrete points corresponding to the test measurement locations. The static solution of the analytical model then produces a set of deformations that once normalized can be used to represent the test acquired mode shapes in the cross orthogonality relation. The method proposed has been shown to provide accurate results for both a simple analytical model as well as a complex space flight structure.

Chambers, Jeffrey A.↗

NASA NTRS1992

On testing models for the pressure-strain correlation of turbulence using direct simulations

Direct simulations of homogeneous turbulence have, in recent years, come into widespread use for the evaluation of models for the pressure-strain correlation of turbulence. While work in this area has been beneficial, the increasingly common practice of testing the slow and rapid parts of these models separately in uniformly strained turbulent flows is shown in this paper to be unsound. For such flows, the decomposition of models for the total pressure-strain correlation into slow and rapid parts is ambiguous. Consequently, when tested in this manner, misleading conclusions can be drawn about the performance of pressure-strain models. This point is amplified by illustrative calculations of homogeneous shear flow where other pitfalls in the evaluation of models are also uncovered. More meaningful measures for testing the performance of pressure-strain models in uniformly strained turbulent flows are proposed and the implications for turbulence modeling are discussed.

Speziale, Charles G.↗

NASA NTRS1995

System Identification of Damped Truss-Like Space Structures

A spacecraft payload flown on a launch vehicle experiences dynamic loads. The dynamic loads are caused by various phenomena ranging from the start-up of the launch vehicle engine to wind gusts. A spacecraft payload should be designed to meet launch vehicle dynamic loads. One of the major steps taken towards determining the dynamic loads is to correlate the finite element model of the spacecraft with the test results of a modal survey test. A test-verified finite element model of the spacecraft should possess the same spatial properties (stiffness, mass, and damping) and modal properties (frequencies and mode shapes) as the test hardware representing the spacecraft. The test-verified and correlated finite element model of the spacecraft is then coupled with the finite element model of the launch vehicle for analysis of loads and stress. Modal survey testing, verification of a finite element model, and modification of the finite element model to match the modal survey test results can easily be accomplished if the spacecraft structure is simple. However, this is rarely the case. A simple structure here is defined as a structure where the influence of nonlinearity between force and displacement (uncertainty in a test, for example, with errors in input and output), and the influence of damping (structural, coulomb, and viscous) are not pronounced. The objective of this study is to develop system identification and correlation methods with the focus on the structural systems that possess nonproportional damping. Two approaches to correct the nonproportional damping matrix of a truss structure were studied, and have been implemented on truss-like structures such as the National Aeronautics and Space Administration's space station truss. The results of this study showed nearly 100 percent improvement of the correlated eigensystem over the analytical eigensystem. The first method showed excellent results with up to three modes used in the system identification process. The second method could handle more modes, but required more computer usage time, and the results were less accurate than those of the first method.

Armand, Sasan↗