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NASA NTRS2016

Analysis and Testing of a Composite Fuselage Shield for Open Rotor Engine Blade-Out Protection

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. LS-DYNA® was used to predict the thickness of the composite shield required to prevent blade penetration. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test LS-DYNA predictions. This paper documents the analysis conducted to predict the required thickness of a composite shield, the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

Composite↗

NASA NTRS1989

Structures technology for a new generation of rotorcraft

This paper presents an overview of structures research at the U. S. Army Aerostructures Directorate. The objectives of this research are to investigate, explore, and demonstrate emerging technologies that will provide lighter, safer, more survivable, and more cost-effective structures for rotorcraft in the 1990s and beyond. The emphasis of today's R&D is to contribute proven structures technology to the U. S. rotorcraft industry and Army aviation that directly impacts tomorrow's fleet readiness and mission capabilities. The primary contributor toward meeting these challenges is the development of high-strength and durable composites to minimize structural weight while maximizing cost effectiveness. Special aviation issues such as delamination of dynamic components, impact damage to thin skins, crashworthiness, and affordable manufacturing need to be resolved before the full potential of composites technology can be realized. To that end, this paper highlights research into composites structural integrity, crashworthiness, and materials applications which addresses these issues.

Bartlett, Felton D., Jr.↗

NASA NTRS2012

Time-Domain Terahertz Computed Axial Tomography NDE System

NASA has identified the need for advanced non-destructive evaluation (NDE) methods to characterize aging and durability in aircraft materials to improve the safety of the nation's airline fleet. 3D THz tomography can play a major role in detection and characterization of flaws and degradation in aircraft materials, including Kevlar-based composites and Kevlar and Zylon fabric covers for soft-shell fan containment where aging and durability issues are critical. A prototype computed tomography (CT) time-domain (TD) THz imaging system has been used to generate 3D images of several test objects including a TUFI tile (a thermal protection system tile used on the Space Shuttle and possibly the Orion or similar capsules). This TUFI tile had simulated impact damage that was located and the depth of damage determined. The CT motion control gan try was designed and constructed, and then integrated with a T-Ray 4000 control unit and motion controller to create a complete CT TD-THz imaging system prototype. A data collection software script was developed that takes multiple z-axis slices in sequence and saves the data for batch processing. The data collection software was integrated with the ability to batch process the slice data with the CT TD-THz image reconstruction software. The time required to take a single CT slice was decreased from six minutes to approximately one minute by replacing the 320 ps, 100-Hz waveform acquisition system with an 80 ps, 1,000-Hz waveform acquisition system. The TD-THZ computed tomography system was built from pre-existing commercial off-the-shelf subsystems. A CT motion control gantry was constructed from COTS components that can handle larger samples. The motion control gantry allows inspection of sample sizes of up to approximately one cubic foot (.0.03 cubic meters). The system reduced to practice a CT-TDTHz system incorporating a COTS 80- ps/l-kHz waveform scanner. The incorporation of this scanner in the system allows acquisition of 3D slice data with better signal-to-noise using a COTS scanner rather than the gchirped h scanner. The system also reduced to practice a prototype for commercial CT systems for insulating materials where safety concerns cannot accommodate x-ray. A software script was written to automate the COTS software to collect and process TD-THz CT data.

Zimdars, David↗

NASA NTRS2015

Dynamic Open-Rotor Composite Shield Impact Test Report

The Federal Aviation Administration (FAA) is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the aircraft. NASA Glenn and Naval Air Warfare Center (NAWC) China Lake collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test a shield that would protect the aircraft passengers and critical systems from a released blade that could impact the fuselage. This report documents the live-fire test from a full-scale rig at NAWC China Lake. NASA provided manpower and photogrammetry expertise to document the impact and damage to the shields. The test was successful: the blade was stopped from penetrating the shield, which validates the design analysis method and the parameters used in the analysis. Additional work is required to implement the shielding into the aircraft.

Shielding↗

NASA NTRS1977

The 737 graphite composite flight spoiler flight service evaluation

The flight service experience of 110 graphite epoxy spoilers on 737 transport aircraft was reviewed as well as ground based environmental exposure of graphite epoxy material specimens for the period from April 1976 through April 1977. Several spoilers were installed on each of 27 aircraft representing seven major airlines operating throughout the world. A flight service evaluation program of at least 5 years is under way. As of April 30, 1977, a total of 766,938 spoiler flight hours and 1,168,090 spoiler landings were accumulated by the fleet. Based on visual ultrasonic, and destructive testing, there was no evidence of moisture migration into the honeycomb core and no core corrosion. Tests of removed spoilers and of ground based exposure specimens after the third year of service continue to indicate modest changes in composite strength properties.

Stoecklin, R. L.↗

NASA NTRS1972

Economic impact of applying advanced technologies to transport airplanes.

Various technologies have been studied which could have application to the design of future transport airplanes. These technologies include the use of supercritical aerodynamics, composite materials, and active control systems, together with advanced engine designs that provide lower noise and pollutant levels. The economic impact of each technology is shown for a typical fleet of 195-passenger, transcontinental commercial transports cruising at both 0.9M and 0.98M. Comparisons are made with conventional transports cruising at 0.82M. Effects of combining the technologies are discussed. An R & D program aimed at bringing the technologies to fruition is outlined.

Carline, A. J. K.↗

NASA NTRS2010

Ares I First Stage Propulsion System Status

With the retirement of the Space Shuttle inevitable, the US is faced with the need to loft a reliable cost-effective, technologically viable solution to bring the nation s fleet of spacecraft back up to industry standard. It must not only support the International Space Station (ISS), it must also be capable of supporting human exploration beyond low Earth orbit (LEO). NASA created the Constellation Program to develop a new fleet including the launch vehicles, the spacecraft, and the mission architecture to meet those objectives. The Ares First Stage Team is tasked with developing a propulsion system capable of safely, dependably and repeatedly lofting that new fleet. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle were used as a starting point in the design and production of a new first stage element. While the first stage will provide the foundation, the structural backbone, power, and control for launch, the new propulsive element will also provide a greater total impulse to loft a safer, more powerful, fleet of space flight vehicles. Substantial design and system upgrades were required to meet the mass and trajectory requisites of the new fleet. Noteworthy innovations and design features include new forward structures, new propellant grain geometry, a new internal insulation system, and a state-of-the art avionics system. Additional advances were in materials and composite structures development, case bond liners, and thermal protection systems. Significant progress has been made in the design, development and testing of the propulsion and avionics systems for the new first stage element. Challenges, such as those anticipated with thrust oscillation, have been better characterized, and are being effectively mitigated. The test firing of the first development motor (DM-1) was a success that validated much of the engineering development to date. Substantive data has been collected and analyzed, allowing the Ares First Stage team to move forward, fine-tune the design, and advance to production of the second development motor (DM-2), which is now in fabrication. This paper will provide an overview of the design, development, challenges, and progress on the production of the new Ares First Stage propulsion system

Priskos, Alex S.↗

NASA NTRS1976

Improving aircraft energy efficiency

Investigations conducted by a NASA task force concerning the development of aeronautical fuel-conservation technology are considered. The task force estimated the fuel savings potential, prospects for implementation in the civil air-transport fleet, and the impact of the technology on air-transport fuel use. Propulsion advances are related to existing engines in the fleet, to new production of current engine types, and to new engine designs. Studies aimed at the evolutionary improvement of aerodynamic design and a laminar flow control program are discussed and possibilities concerning the use of composite structural materials are examined.

Povinelli, F. P.↗

NASA NTRS1992

Economic benefits of supersonic overland operation

Environmental concerns are likely to impose some restrictions on the next generation of supersonic commercial transport. There is a global concern over the effects of engine emissions on the ozone layer which protects life on Earth from ultraviolet radiation. There is also some concern over community noise. The High Speed Civil Transport (HSCT) must meet at least the current subsonic noise certification standards to be compatible with the future subsonic fleet. Concerns over sonic boom represent another environmental and marketing challenge to the HSCT program. The most attractive feature of the supersonic transport is speed, which offers the traveling public significant time-savings on long range routes. The sonic boom issue represents a major environmental and economic challenge as well. Supersonic operation overland produces the most desirable economic results. However, unacceptable overland sonic boom raise levels may force HSCT to use subsonic speeds overland. These environmental and economic challenges are likely to impose some restrictions on supersonic operation, thus introducing major changes to existing route structures and future supersonic network composition. The current subsonic route structure may have to be altered for supersonic transports to avoid sensitive areas in the stratosphere or to minimize overland flight tracks. It is important to examine the alternative route structure and the impact of these restrictions on the economic viability of the overall supersonic operation. Future market potential for HSCT fleets must be large enough to enable engine and airframe manufacturers to build the plane at a cost that provides them with an attractive return on investment and to sell it at a price that allows the airlines to operate with a reasonable margin of profit. Subsonic overland operation of a supersonic aircraft hinders its economic viability. Ways to increase the market potential of supersonic operation are described.

Metwally, Munir↗

NASA NTRS1991

Human factors in aircraft maintenance and inspection

The events which have led to the intensive study of aircraft structural problems have contributed in no less measure to study of the human factors which influence aircraft maintenance and inspection. Initial research emphasis on aging aircraft maintenance and inspection has since broadened to include all aircraft types, both new and old. The role of today's aircraft maintenance workforce is indeed a complex one as it is strongly influenced by the need to maintain the broad technology mix embodied in the current fleet. Technicians must be equally adept at diagnosing and repairing "old-tech" 727, DC-9 type aircraft and "new-tech" 767, and MD-ll's. Their skills must include ability to repair sheet metal and composite materials; control cables and flyby-wire systems; round dials and glass cockpits. Their work performance is heavily influenced by others such as designers, technical writers, job card authors, schedulers and trainers. This paper describes activities concerning aircraft maintenance and inspection human factors.

Aging Aircraft↗

NASA NTRS1999

A New Satellite System for Measuring BRDF from Space

Formation flying of satellites is at the beginning of an explosive growth curve. Spacecraft buses are shrinking to the point where we will soon be able to launch 10 micro-satellites or 100 nano-satellites on a single launch vehicle. Simultaneously, spectrometers are just beginning to be flown in space by both the U.S. and Europe. On-board programmable band aggregation will soon allow exactly the spectral bands desired to be returned to Earth. Further efforts are being devoted to radically shrink spectrometers both in size and weight. And GPS positioning and attitude determination, plus new technologies for attitude control, will allow fleets of satellites to all point at the same Earth target. All these advances, in combination, make possible for the first time the proper measurement of Bidirectional Reflectance Distribution (BRDF) form space. Previously space BDRF's were mere composites, built up over time by viewing different types of scenes at different times, then creating catalogs of BDRF functions whose use relied upon correct "scene identification" --the weak link. Formation-flying micro-satellites, carrying programmable spectrometers and precision-pointing at the same Earth target, can measure the full BDRF simultaneously, in real time. This talk will review these technological advances and discuss an actual proposed concept, based on these advances, to measure Earth-target BDRF's (clouds as well as surface) across the full solar spectrum in the 2010 timeframe. This concept is part of a larger concept called Leonardo for properly measuring the radiative forcing of Earth for climate purposes; lack of knowing of BDRF and of diurnal cycle are at present the two limiting factors preventing improved estimates of this forcing.

Wiscombe, W.↗

NASA NTRS2005

DMBZ Polyimides Provide an Alternative to PMR-15 for High-Temperature Applications

PMR-15, a high-temperature polyimide developed in the mid-1970's at the NASA Lewis Research Center, offers the combination of ease of processing, low cost, and good stability and performance at temperatures up to 288 C (500 F). This material is widely regarded as one of the leading high-temperature matrix resins for polymer-matrix-composite aircraft engine components. PMR-15 is widely used in both military and civilian aircraft engines. The current worldwide market for PMR-15 is on the order of 50,000 lb, with a total sales of around $5 to $10 million. However, PMR-15 is made from methylene dianiline (MDA), a known animal mutagen and a suspected human mutagen. Recent concerns about the safety of workers involved in the manufacture and repair of PMR-15 components have led to the implementation of costly protective measures to limit worker exposure and ensure workplace safety. In some cases, because of safety and economic concerns, airlines have eliminated PMR-15 components from engines in their fleets. Current efforts at Lewis are focused on developing suitable replacements for PMR-15 that do not contain mutagenic constituents and have processability, stability, and mechanical properties comparable to that of PMR-15. A recent development from these efforts is a new class of thermosetting polyimides based on 2,2'-dimethylbenzidine (DMBZ). Autoclave processing developed for PMR-15 composites was used to prepare low-void-content T650-35 carbon-fiber-reinforced laminates from DMBZ-15 polyimides. The glass transition temperatures of these laminates were about 50 C higher than those of the T650- 35/PMR-15 composites (400 versus 348 C). In addition, DMBZ-15 polyimide composites aged for 1000 hr in air at 288 C (500 F) had weight losses close to those of comparable PMR-15 laminates (0.9 versus 0.7 percent). The elevated (288 C) and room temperature mechanical properties of T650-35-reinforced DMBZ-15 polyimide and PMR-15 laminates were comparable. Standard Ames tests are being conducted on this diamine to assess its mutagenicity.

Source record↗

NASA NTRS2017

Systems Engineering Challenges for GSFC Space Science Mission Operations

The NASA Goddard Space Flight Center Space Science Mission Operations (SSMO) project currently manages19 missions for the NASA Science Mission Directorate, within the Planetary, Astrophysics, and Heliophysics Divisions. The mission lifespans range from just a few months to more than20 years. The WIND spacecraft, the oldest SSMO mission, was launched in 1994. SSMO spacecraft reside in low earth, geosynchronous,highly elliptical, libration point, lunar, heliocentric,and Martian orbits. SSMO spacecraft range in size from 125kg (Aeronomy of Ice in the Mesosphere (AIM)) to over 4000kg (Fermi Gamma-Ray Space Telescope (Fermi)). The attitude modes include both spin and three-axis stabilized, with varying requirements on pointing accuracy. The spacecraft are operated from control centers at Goddard and off-site control centers;the Lunar Reconnaissance Orbiter (LRO), the Solar Dynamics Observatory (SDO) and Magnetospheric MultiScale (MMS)mission were built at Goddard. The Advanced Composition Explorer (ACE) and Wind are operated out of a multi-mission operations center, which will also host several SSMO-managed cubesats in 2017. This paper focuses on the systems engineeringchallenges for such a large and varied fleet of spacecraft.

Spacecraft↗

NASA NTRSDate not supplied

Present Day Volcanism on Venus: Evidence from Alteration Experiments

The crust of Venus is thought to be comprised of basaltic rocks with similar composition to terrestrial volcanics, but on Venus they are in contact with a hot caustic atmosphere that should alter them to produce weathering rinds. These weathering rinds should affect orbital measurements (both radar and spectroscopy) of the crust, such has been measured at Idunn Mons. However, the rate of alteration on Venus and specifically how alteration mineralogy affects orbital measurements are not well understood. With the upcoming decade of Venus exploration, laboratory measurements connecting alteration and spectroscopy are critically needed. Here, I will summarize what is known about the composition of Venus lava flows and the rate at which these rocks should alter on the Venus surface. I will then apply this work to Idunn Mons as a case study to show that it should be volcanically active, which may be detectable by the pcoming fleet of missions.

Justin Filiberto↗

NASA NTRS2024

Revision 1: Characterizing Basalt-Atmosphere Interactions on Venus: A Review of Thermodynamic and Experimental Results

The surface of Venus is in contact with a hot (~470° C), high pressure (92 bars), and caustic (CO 2 with S, but little H 2 O) atmosphere, which should cause progressive alteration of the crust in the form of sulfate and iron-oxide coatings; however, the exact rate of alteration and mineral species are not well constrained. Different experimental approaches, each with its own limitations, are currently being used to constrain mineralogy and alteration rate. One note is that no experimental approach has been able to fully replicate the necessary conditions and sustain them for a significant length of time. Further, geochemical modeling studies can also constrain surface alteration mineralogy, again with different assumptions and limitations. Here we review recent geochemical modeling and experimental studies to constrain the state of the art for alteration mineralogy, rate of alteration, open questions about the surface mineralogy of Venus, and what can be constrained before the fleet of missions arrive later this decade. Combining the new results confirm that basalt on the surface of Venus should react quickly and form coatings of sulfates and iron-oxides; however, the mineralogy and rate of alteration is dependent on physical properties of the protolith (including bulk composition, mineralogy, and crystallinity), as well as atmospheric composition, and surface temperature. Importantly, the geochemically modelling results show that the mineralogy is largely controlled by atmospheric oxygen fugacity, which is not well constrained for the near surface environment on Venus. Therefore, alteration experiments run over a range of oxygen and sulfur fugacities are needed across a wide range of Venus analog materials with varying mineralogy and crystallinity.

Justin Filiberto↗

NASA NTRS2007

Condition Assessment of Kevlar Composite Materials Using Raman Spectroscopy

This viewgraph presentation includes the following main concepts. Goal: To evaluate Raman spectroscopy as a potential NDE tool for the detection of stress rupture in Kevlar. Objective: Test a series of strand samples that have been aged under various conditions and evaluate differences and trends in the Raman response. Hypothesis: Reduction in strength associated with stress rupture may manifest from changes in the polymer at a molecular level. If so, than these changes may effect the vibrational characteristics of the material, and consequently the Raman spectra produced from the material. Problem Statement: Kevlar composite over-wrapped pressure vessels (COPVs) on the space shuttles are greater than 25 years old. Stress rupture phenomena is not well understood for COPVs. Other COPVs are planned for hydrogen-fueled vehicles using Carbon composite material. Raman spectroscopy is being explored as an non-destructive evaluation (NDE) technique to predict the onset of stress rupture in Kevlar composite materials. Test aged Kevlar strands to discover trends in the Raman response. Strength reduction in Kevlar polymer will manifest itself on the Raman spectra. Conclusions: Raman spectroscopy has shown relative changes in the intensity and FWHM of the ~1613 cm(exp -1) peak. Reduction in relative intensity for creep, fleet leader, and SIM specimens compared to the virgin strands. Increase in FWHM has been observed for the creep and fleet leader specimens compared to the virgin strands. Changes in the Raman spectra may result from redistributing loads within the material due to the disruption of hydrogen bonding between crystallites or defects in the crystallites from aging the Kevlar strands. Peak shifting has not been observed to date. Analysis is ongoing. Stress measurements may provide a tool in the short term.

Washer, Glenn↗

NASA NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗

NASA NTRS2019

LEAVES: Lofted Environmental and Atmospheric Venus Sensors

LEAVES (Lofted Environmental Atmospheric Venus Sensors) is a design exercise with the goal of dramatically decreasing the cost of obtaining prioritized chemical and physical data in planetary atmospheres. Through the application of a swarm approach this concept parallelizes atmospheric exploration, with geographic coverage far exceeding what is possible with conventional monolithic platforms or sondes. Each unit in the swarm is exceptionally compact, with a powered payload mass of only a few tens of grams and a high-drag, semi-rigid structure that acts to slow each probe as it descends through the atmosphere. This structural design can collapse into a planar form to allow for efficient stowage prior to arrival at the target body. With a total per-unit mass of only 120 g, a fleet of 100 (or more) units can be very reasonably accommodated on a carrier spacecraft.Science operations, which begin when the LEAVES probes reach an altitude of 100 km, are targeted for the cloud-bearing region of Venus' atmosphere. During the roughly 9 hour, terminal velocity descent through the atmosphere, LEAVES collects data of the state and composition of the atmosphere in parallel across multiple units. These data would represent an unprecedented constraint on the distribution and concentration of targeted chemical species, and the detection of local and regional variations in both chemistry and physical properties.A novel and compelling result of this exercise was that the same optimization that produced a structure with an exceptionally low areal mass density (0.126 kg/m2) also resulted in a probe that can be deployed directly from an aerobraking orbit (~140 km at 5 km/s) without the need for aeroshell protection. This translates to a tremendous mass savings and gives LEAVES the flexibility to be carried as a secondary payload aboard either a descending surface probe or an orbital radar mapper. Because such missions are under active development or have already been proposed (but not flown), we infer that LEAVES is well positioned as a technology

Swarm↗