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NASA NTRS2019

Design and Analysis of a Tool for Automated Fiber Placement of Composite Wind Tunnel Blades

For decades, composite wind tunnel blades have been constructed using labor-intensive hand layup processes. Automated Fiber Placement (AFP) is a relatively new technology that has not seen widespread use in manufacturing composite wind tunnel blades. AFP offers the potential for reduced manufacturing time, reduced cost, and improved consistency compared to traditional hand layup procedures. These manufacturing qualities are becoming increasingly important as existing wind tunnel blades are replaced due to impact damage or wear and tear from decades of use. Researchers at the NASA Langley Research Center are currently using the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to investigate the feasibility of AFP for manufacturing composite wind tunnel blades. ISAAC uses manufacturing tools as surfaces on which to place fiber tows. A manufacturing tool was developed for using AFP to build a wind tunnel blade shape. This paper presents the structural design and analysis of this tool, for use with AFP, constructed from high temperature thermoplastics. The tool fabricated by this design process was successfully used for AFP and oven cure of two representative airfoil shaped composite structures.

Brian Mason↗

NASA NTRS2014

TPSAS-NF1676L-18913-DND

Composite materials and structures are enabling technology for modern aerospace vehicles. Numerical-control manufacturing, including automated fiber placement (AFP), is widely used to fabricate these components. However, weight and performance requirements for the next generation of aerospace vehicles will push the state-of-art even further, and require development of more advanced materials, manufacturing, and structures technologies that are both affordable and efficient. The Integrated Structural Assembly of Advanced Composites (ISAAC) system is intended to address much of NASA?s critical research needs in advanced composites. The baseline ISAAC system, combining a commercial robot with multiple redundant degrees of freedom, a tool changer interface, and a special-purpose AFP end effector, enables precise and accurate additive manufacturing of composite structures, as well as development of advanced tow-steered structures with tailored load paths. The highly capable baseline system can quickly change end effectors, thus enabling further research for composites manufacturing. This extended system is similar to a high-speed machining center, where interchangeable cutters are used for different operations during metal structures fabrication. This capability enables future development, integration and assessment of new advanced manufacturing technologies, such as in-situ curing and NDE, and through-thickness reinforcements to reduce delaminations. End effectors with these advanced capabilities may be purchased, developed internally or with industry or academia, and then integrated onto the existing robotic platform to perform advanced manufacturing operations and develop new techniques and processes. Technologies, techniques and processes developed using this research-oriented system could then be transitioned to the broader composites industry.

Rob Martin↗

NASA NTRSDate not supplied

TPSAS-NF1676L-26669-DND

The NASA Langley Research Center has acquired a state-of-art composites fabrication environment to support the Center's research and technology development mission. This overall system described in this paper is named ISAAC, or Integrated Structural Assembly of Advanced Composites. ISAAC's initial operational capability is a commercial robotic automated fiber placement system from Electroimpact, Inc. that consists of a multi-degree of freedom commercial robot platform, a tool changer mechanism, and a specialized automated fiber placement end effector. Examples are presented of how development of advanced composite materials, structures, fabrication processes and technology are enabled by utilizing the fiber placement end effector directly or with appropriate modifications. Several advanced capability end effectors have been procured, and alternate processes with different capabilities can be developed with NASA's partners in industry and academia.

K C Wu↗

NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

The goal of the current work was to develop an analytical framework for design of composite struts using various levels of model fidelity. An additional goal of this work was to perform an initial assessment of using automated fiber placement (AFP) and other advanced manufacturing methods to explore their feasibility for the fabrication of struts for lunar landers, strut-braced wings, and other aerospace components. In particular, designs were considered for fabrication at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at Langley Research Center (LaRC). The designs presented in this paper do not represent the exact geometry and material systems currently in use by the Artemis landing system, but they are considered to be representative. The designs produced during this study will be used to develop manufacturing demonstration units (MDU) that can be fabricated at ISAAC and tested in lab facilities at LaRC

carbon-epoxy↗

NASA NTRSDate not supplied

STITCHED COMPOSITES WITH THREE-DIMENSIONAL STITCH PATHS

Stitched composites have been shown to exhibit damage tolerance and to reduce weight compared to traditional layered composites through unitization of the structure by elimination of fasteners. Stitching capabilities have been incorporated into the Integrated Structural Assembly of Advanced Composites (ISAAC) system at NASA Langley Research Center with the introduction of two stitching heads. Stitching path control was initially implemented as straight lines in space, as was done for previous stitching development. However, more complex stitched structures such as a wind tunnel blade or around cutouts within a fuselage or wing skin, require that the stitching paths be implemented as three-dimensional (3D) stitching paths in space. Unfortunately, control programming output by an existing preprocessor program cannot stitch these curved paths due to problems that arise in stitch formation and the introduction of side forces on the needles using the conventional programming approach whereby the head is simultaneously controlled through translations and rotations. This lack of capability is most significant for the single-sided stitching head, where two needles are in the preform at the same time for the majority of the stitching process. A means to program 3D stitching paths in space was developed whereby the translation and rotation of each stitch were decoupled, thereby eliminating the problems associated with current control programming approach. Using this newly developed stitching path definition and control programming, complex stitching paths have successfully been stitched at the ISAAC facility. The ability to stitch general 3D stitching paths in space enables the use of stitching on more complex parts.

carbon-epoxy↗

NASA NTRSDate not supplied

Stitched Composites with Three-Dimensional Stitch Paths

carbon-epoxy↗

NASA NTRS2016

My Internship at NASA

My name is Isaac Lopez and I am a junior at the University of Houston majoring in Mechanical Engineering Technology. I will be completing my first tour at the NASA-Johnson Space Center ("JSC") as a Mechanical Engineer within the Human Interfaces Branch. Throughout my tour, I was given the opportunity to work on multiple projects that have expanded my knowledge and interest in acoustics and engineering design. One of the projects I worked on at JSC consisted of doing acoustic simulation of the EVA comm. cap. While working on the comm. cap headset, my main duty consisted of simulating the acoustics of the headset to find a solution to the condensing water that can accumulate and block the acoustic tube, causing attenuation or complete loss of audio in one ear for an astronaut using the EVA. For this project, I had to create a Creo model of the comm. cap so that I would be able to import it into Comsol for acoustic simulation. I also had the opportunity to design a portable and lightweight beam degrader for the EEE Parts and Radiation team. With the help of Creo, I was able to make a CAD design and put together a small working prototype for the radiation team to demonstrate the capabilities that the beam degrader had. In addition to these projects, JSC allowed me to work closely on projects with other interns. I had the opportunity to help another intern with his acoustic diverter, intended to improve the sound quality in Node 1 of the ISS. During this project, I helped with some of the acoustic testing inside the anechoic chamber as well as helping record data during testing at the ISS mock up. During the course of my first tour, I was able to learn and continually improve on my CAD drafting skills. With each project I worked on, I acquired new ways to create and improve various designs with various constraints. Furthermore, I also had the opportunity to work with electrical engineers and learn about the electronic components that would provide control of the beam degrader functions. I was able to take the knowledge, skills and designs I had acquired during my tour at JSC (such as Finite Element Analysis) and apply them to my work on the Comsol Multiphysics software for acoustics simulation. I was also able to use it to do some stress analysis on a proposed design for a proposed Habitat structure. My time at JSC has been invaluable as it helped me grow and more fully-comprehend my major as well as spark an interest in acoustics and how much it relates to mechanical engineering. This internship has taught me that engineering is much more than a profession - it is embedded in our daily lives as a puzzle that requires critical thinking as an everyday challenge that makes life more interesting.

Lopez, Isaac↗

NASA NTRS1965

Ballistocardiography, a Bibliography <1877 - 1964<

The publication of this bibliography on Ballistocardiography, NASA SP-7021 (FAA AM 65-15) fulfills a long-standing requirement for a comprehensive and retrospective collection of references on a subject that is of particular interest to medical investigators and cardiovascular physiologists engaged in aerospace studies. Ballistocardiography is a technique for producing a graphical representation of repetitive motions of the human body arising from the sudden ejection of blood into the great vessels with each heart beat. Standard ballistocardiographic techniques are emphasized in the references included in the bibliography, but attention is also given to several related methods that are used to record these phenomena and to the equipment and instrumentation employed in such investigations. The format of the citations in NASA SP-7021 (FAA AM 65-15) was chosen to resemble, as closely as possible, the format that is now being used in the Index Medicwl published by the National Library of Medicine, except that English titles of foreign language articles appear in parentheses instead of in brackets as they do in Index Medicus. In each case, an attempt was made to identify the language of the article, or the place of publication of the foreign language journal. Since the citations were gathered over a period of years and occasionally from sources which do not appear in standard indexes, complete information was not always available. Citations are arranged alphabetically by personal author. In a large measure, the comprehensivenes of this collection of references is due to information obtained from card files compiled and maintained by Dr. William R. Scarborough of the Georgetown Clinical Research Institute, Office of Aviation Medicine, FAA, supplemented by the private collections of Drs. Isaac Starr, Abraham Noordergraaf, and John L. Nickerson. Selection and preparation of individual references and general editing of the material was done by Dr. Scarborough, who received valuable assistance from Mrs. Claire Tedesco of the Medical Library Branch of the FAA Library. Final compilation and printing were completed under the supervision of NASA.

AEROSPACE MEDICINE↗

NASA NTRS1974

Systems identification - reprise and projections

A state-of-the-arts review is given for the field of system identification. Progress in the field is traced from the early models of dynamic systems by Sir Isaac Newton up to the present day use of advanced techniques for numerous applications.

Taylor, L. W., Jr.↗

NASA NTRS1991

Evidence for CNO processed material in the accretion disk of GP Comae

NIR spectroscopic observations of GP Com are reported. Data obtained using the 2.5-m Isaac Newton Telescope and the 4.2-m William Herschel Telescope at La Palma during April and June 1988 and with the 5-m Hale reflector at Palomar Observatory during January 1983 are presented in tables and sample spectra and discussed in detail. Number ratios H/He less than 0.00001, N/O = about 50, and N/C greater than 100 are calculated under the assumption of a uniform optically thin slab of gas in LTE. From the N overabundance it is inferred that the material observed is being extracted by Roche-lobe overflow from the secondary's H-exhausted core, at a time after most C and O have been converted to N in the CNO cycle.

Marsh, T. R.↗

NASA NTRS1991

Simultaneous temperature and multi-species measurements in opposed jet flames of nitrogen-diluted hydrogen and air

A narrowband UV Raman scattering system is used to obtain measurement profiles of major and minor species concentrations, temperature, and mixture fraction in opposed jet diffusion flames. The measurement profiles can be compared to previously obtained temperature and concentration profiles (Pellett et al., 1989), obtained using CARS, and they can also be qualitatively compared to the predicted concentration and temperature profiles in pure hydrogen/air flames (Gutheil and Williams, 1990) and in diluted hydrogen/air flames (Dixon-Lewis and Missaghi, 1988; Ho and Isaac, 1991). The applied stress-rates for the two flame conditions studied are 240/s and 340/s, with respective hydrogen concentrations in the fuel jet of 0.67 and 0.83, on a mole fraction basis (0.13 and 0.26 hydrogen mass fractions, respectively).

Wehrmeyer, J. A.↗

NASA NTRS1992

Shuttle flight experiment preliminary proposal: Demonstration of welding applications in space

In June 1991 work was initiated at MSFC on an end-effector for 'Robotic Assembly of Welded Truss Structures in Space'. The case for welded joint assembly on orbit was discussed in the 1991 SFFP Final Report 'D'. Data drawn from Aerobrake studies (supported by the ISAAC program) allowed the more detailed investigations that accompany a design with relatively concrete goals. This principle guides current efforts to develop scenarios that further demonstrate the utility of welding for space construction and/or repair.

Brewer, William V.↗

NASA NTRS1993

Magnetic Earth Ionosphere Resonant Frequencies (MEIRF) project

The West Virginia State College Community College Division NASA Magnetic Earth Ionosphere Resonant Frequencies (MEIRF) study is described. During this contract period, the two most significant and professionally rewarding events were the presentation of the research activity at the Sir Isaac Newton Conference in St. Petersburg, Russia, and the second Day of Discovery Conference, focusing on economic recovery in West Virginia. An active antenna concept utilizing a signal feedback principle similar to regenerative receivers used in early radio was studied. The device has potential for ELF research and other commercial applications for improved signal reception. Finally, work continues to progress on the development of a prototype monitoring station. Signal monitoring, data display, and data storage are major areas of activity. In addition, we plan to continue our dissemination of research activity through presentations at seminars and other universities.

Spaniol, Craig↗

NASA NTRS1993

Rockets: Physical science teacher's guide with activities

This guide begins with background information sections on the history of rocketry, scientific principles, and practical rocketry. The sections on scientific principles and practical rocketry are based on Isaac Newton's three laws of motion. These laws explain why rockets work and how to make them more efficient. The background sections are followed with a series of physical science activities that demonstrate the basic science of rocketry. Each activity is designed to be simple and take advantage of inexpensive materials. Construction diagrams, materials and tools lists, and instructions are included. A brief discussion elaborates on the concepts covered in the activities and is followed with teaching notes and discussion questions. The guide concludes with a glossary of terms, suggested reading list, NASA educational resources, and an evaluation questionnaire with a mailer.

Vogt, Gregory L.↗

NASA NTRS1995

Blue lobes in the Hydra A cluster central galaxy

We present new U- and I-band images of the centrally dominant galaxy in the Hydra A cluster, obtained with the 2.5 m Isaac Newton Telescope at La Palma. The galaxy is centered in a poor, X-ray-luminous cluster whose gaseous intracluster medium is apparently cooling at a rate of m-dot(sub CF) approximately 3000 solar masses/yr. The galaxy's structure is that of a normal giant elliptical galaxy, apart from the central approximately 8 x 6 arcsec (approximately 12 x 9 kpc) region which contains an unusually blue, lobelike structure that is spatially coincident with a luminous emission-line nebula in rotation about the nucleus. Based on near spatial coincidence of the central continuum structure and the emission-line nebula, we suggest that the blue continuum is due to a warm stellar population in a central disk. In order to isolate and study the structure of the disk, we have subtracted a smooth galactic background model from the U-band image. The disk's surface brightness profiles along its major and minor axes decline roughly exponentially with radius. The disk's axial ratio is consistent with a nearly edge-on thick disk or a thin disk that is inclined with respect to the line of sight. The bluest regions, located a few arcsec on either side of the nucleus (giving the lobelike appearance), may be due to locally enhanced star formation or a seeing-blurred ring of young stars embedded in the disk observed nearly edge-on. If star-formation is occurring with the local initial mass function, the central color, surface brightness, and dynamical mass would be consistent with models for star formation at a rate of less than and approximately 1 solar masses/yr which has persisted for the past approximately 10(exp 9) yr, a short burst (10(exp 7) yr) of star formation at a rate of approximately 30 solar masses/yr which occurred less than and approximately 10(exp 8) yr ago, or an instantaneous burst of star formation which occurred approximately 5 x 10(exp 7) yr ago. While the young population contributes approximately 30%-40% of the central U-band luminosity, its mass would be less than and approximately 1% to less than and approximately 10% (10(exp 8) solar masses - 2 x 10(exp 9) solar masses of the galaxy's central dynamical mass. We consider a number of possible origins for the disk material.

Mcnamara, Brian R.↗

NASA NTRS1996

Prediction of Complex Aerodynamic Flows with Explicit Algebraic Stress Models

An explicit algebraic stress equation, developed by Gatski and Speziale, is used in the framework of K-epsilon formulation to predict complex aerodynamic turbulent flows. The nonequilibrium effects are modeled through coefficients that depend nonlinearly on both rotational and irrotational strains. The proposed model was implemented in the ISAAC Navier-Stokes code. Comparisons with the experimental data are presented which clearly demonstrate that explicit algebraic stress models can predict the correct response to nonequilibrium flow.

Abid, Ridha↗

NASA NTRS1999

Virtual Petaflop Simulation: Parallel Potential Solvers and New Integrators for Gravitational Systems

"The orbit of any one planet depends on the combined motion of all the planets, not to mention the actions of all these on each other. To consider simultaneously all these causes of motion and to define these motions by exact laws allowing of convenient calculation exceeds, unless I am mistaken, the forces of the entire human intellect" -Isaac Newton 1687. Epochal surveys are throwing down the gauntlet for cosmological simulation. We describe three keys to meeting the challenge of N-body simulation: adaptive potential solvers, adaptive integrators and volume renormalization. With these techniques and a dedicated Teraflop facility, simulation can stay even with observation of the Universe. We also describe some problems in the formation and stability of planetary systems. Here, the challenge is to perform accurate integrations that retain Hamiltonian properties for 10(exp 13) timesteps.

Lake, George↗

NASA NTRS1998

Numerical Study of Turbulence Model Predictions for the MD 30P/30N and NHLP-2D Three-Element Highlift Configurations

This report details calculations for the McDonnell-Douglas 30P/30N and the NHLP-2D three-element highlift configurations. Calculations were performed with the Reynolds averaged Navier-Stokes code ISAAC to study the effects of various numerical issues on high lift predictions. These issues include the effect of numerical accuracy on the advection terms of the turbulence equations, Navier-Stokes versus the thin-layer Navier-Stokes approximation, an alternative formulation of the production term, and the performance of several turbulence models. The effect of the transition location on the NHLP-2D flow solution was investigated. Two empirical transition models were used to estimate the transition location.

Turbulence modeling↗