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A shock test of the electron-proton spectrometer structural test unit was conducted. The purpose of the shock test was to verify the structural integrity of the electron-spectrometer design and to obtain data on the shock response of the electronics and electronic housing. The test equipment is described and typical shock response data are provided.
The large test sections of the National Full-scale Aerodynamics Complex (NFAC) wind tunnels provide ideal controlled wind environments to test ground-based objects and vehicles. Though this facility was designed and provisioned primarily for aeronautical testing requirements, several experiments have been designed to utilize existing model mount structures to support "non-flying" systems. This presentation will discuss some of the ground-based testing capabilities of the facility and provide examples of groundbased tests conducted in the facility to date. It will also address some future work envisioned and solicit input from the SATA membership on ways to improve the service that NASA makes available to customers.
Precision space structures may require active vibration control to satisfy critical performance requirements relating to line-of-sight pointing accuracy and the maintenance of precise, internal alignments. In order for vibration control concepts to become operational, it is necessary that their benefits be practically demonstrated in large scale ground-based experiments. A unique opportunity to carry out such demonstrations on a wide variety of experimental testbeds was provided by the NASA Control-Structure Integration (CSI) Guest Investigator (GI) Program. This report surveys the experimental results achieved by the Harris Corporation GI team on both Phases 1 and 2 of the program and provides a detailed description of Phase 2 activities. The Phase 1 results illustrated the effectiveness of active vibration control for space structures and demonstrated a systematic methodology for control design, implementation test. In Phase 2, this methodology was significantly streamlined to yield an on-site, single session design/test capability. Moreover, the Phase 2 research on adaptive neural control techniques made significant progress toward fully automated, self-reliant space structure control systems. As a further thrust toward productized, self-contained vibration control systems, the Harris Phase II activity concluded with experimental demonstration of new vibration isolation hardware suitable for a wide range of space-flight and ground-based commercial applications.The CSI GI Program Phase 1 activity was conducted under contract NASA1-18872, and the Phase 2 activity was conducted under NASA1-19372.
A Lamilloy combustor liner was designed, fabricated and tested in a combustor at pressures up to 8 atmospheres. The liner was fabricated of a three layer Lamilloy structure and designed to replace a conventional step louver liner. The liner is to be used in a combustor that provides hot gases to a turbine cooling test facility at pressures up to 40 atmospheres. The Lamilloy liner was tested extensively at lower pressures and demonstrated lower metal temperatures than the conventional liner, while at the same time requiring about 40 percent less cooling air flow. Tests conducted at combustor exit temperatures in excess of 2200 K have not indicated any cooling or durability problems with the Lamilloy linear.
A Lamilloy combustor liner has been designed, fabricated and tested in a combustor at pressures up to 8 atmospheres. The liner was fabricated of a three layer Lamilloy structure and designed to replace a conventional step-louver liner. The liner will be used in a combustor that provides hot gases to a turbine cooling test facility at pressures up to 40 atmospheres. The Lamilloy liner was tested extensively at lower pressures and demonstrated lower metal temperatures than the conventional liner, while at the same time requiring about 40 percent less cooling air flow. Tests conducted at combustor exit temperatures in excess of 2200 K have not indicated any cooling or durability problems with the Lamilloy liner.
A titanium multiwall thermal protection system panel was designed. The panel is a nine sheet sandwich structure consisting of an upper and lower face sheet; four dimpled sheets, three septum sheets, and clips for attachment to a vehicle structure. An acceptable fabrication process was developed, and the panel design was verified through mechanical and thermal testing of component specimens. A design was completed which takes into consideration fabrication techniques, thermal properties, mechanical properties, and materials availability.
A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.
Materials selection, structural geometry, proof testing and statistical screening, prestressing, and system energy as tools for designing optimum trusses and other high performance structures
A static and dynamic finite element analysis is conducted on a U.S. Army OH-58 composite tail boom and compared with test data. The tail boom is a filament-wound graphite/epoxy monocoque structure. The structural design of the composite tail boom skin is based on 50-percent graphite fiber volume. However, material tests on representative samples of the tail boom skin reveal that the graphite fiber-volume fraction varied from 44.6 to 49.3 percent. To determine the effect of using measured material properties, static and dynamic finite element analyses are conducted for three fiber-volume conditions of 45, 48, and 50 percent. The static and dynamic model with the 45-percent fiber-volume graphite skins gives the closest agreement with test data.
The small-scale broad area cooling (BAC) shield test panel represents a section of the cryogenic propellant storage and transfer ground test article, a flight-like cryogenic propellant storage tank. The test panel design includes an aluminum tank shell, primer, spray-on foam insulation, multilayer insulation (MLI), and BAC shield hardware. This assembly was sized to accurately represent the character of the MLI/BAC shield system, be quickly and inexpensively assembled, and be tested in the Marshall Space Flight Center Acoustic Test Facility. Investigating the BAC shield response to a worst-case launch dynamic load was the key purpose for developing the test article and performing the test. A preliminary method for structurally supporting the BAC shield using low-conductivity standoffs was designed, manufactured, and evaluated as part of the test. The BAC tube-standoff interface and unsupported BAC tube lengths were key parameters for evaluation. No noticeable damage to any system hardware element was observed after acoustic testing.
The NASA Langley Research Center is conducting and sponsoring research to explore the benefits of textile reinforced composites for civil transport aircraft primary structures. The objective of this program is to develop and demonstrate the potential of affordable textile reinforced composite materials to meet design properties and damage tolerance requirements of advanced aircraft structures. In addition to in-house research, the program includes major participation by the aircraft industry and aerospace textile companies. The major program elements include development of textile preforms, processing science, mechanics of materials, experimental characterization of materials, and development and evaluation of textile reinforced composite structural elements and subcomponents. The NASA Langley in-house research is focused on science-based understanding of resin transfer molding (RTM), development of powder-coated towpreg processes, analysis methodology, and development of a performance database on textile reinforced composites. The focus of the textile industry participation is on development of multidirectional, damage-tolerant preforms, and the aircraft industry participation is in the areas of innovative design concepts, cost-effective fabrication, and testing of textile reinforced composite structural elements and subcomponents. Textile processes such as 3-D weaving, 2-D and 3-D braiding, and knitting/stitching are being compared with conventional laminated tape processes for improved damage tolerance. Through-the-thickness reinforcements offer significant damage tolerance improvements. However, these gains must be weighed against potential loss in in-plane properties such as strength and stiffness. Analytical trade studies are underway to establish design guidelines for the application of textile material forms to meet specific loading requirements. Fabrication and testing of large structural components are required to establish the full potential of textile reinforced composite materials. The goals of the NASA Langley-sponsored research program are to demonstrate technology readiness with subscale composite components by 1995 and to verify the performance of full-scale composite primary aircraft structural components by 1997. The status of textile reinforced composite structural elements under development by Boeing, Douglas, Lockheed, and Grumman are presented. Included are braided frames and woven/stitched wing and fuselage panels.
A dynamics and controls analyst is typically presented with a structural dynamics model and must perform various input/output tests and design control laws. The required time/frequency simulations need to be done many times as models change and control designs evolve. This paper examines some simple ways that open and closed loop frequency and time domain simulations can be done using the special structure of the system equations usually available. Routines were developed to run under Pro-Matlab in a mixture of the Pro-Matlab interpreter and FORTRAN (using the .mex facility). These routines are often orders of magnitude faster than trying the typical 'brute force' approach of using built-in Pro-Matlab routines such as bode. This makes the analyst's job easier since not only does an individual run take less time, but much larger models can be attacked, often allowing the whole model reduction step to be eliminated.
A program was performed to develop and demonstrate the impact dynamics and acoustic transmission technology for a composite fuselage which meets the design requirements of a 1990 large transport aircraft without substantial weight and cost penalties. The program developed the analytical methodology for the prediction of acoustic transmission behavior of advanced composite stiffened shell structures. The methodology predicted that the interior noise level in a composite fuselage due to turbulent boundary layer will be less than in a comparable aluminum fuselage. The verification of these analyses will be performed by NASA Langley Research Center using a composite fuselage shell fabricated by filament winding. The program also developed analytical methodology for the prediction of the impact dynamics behavior of lower fuselage structure constructed with composite materials. Development tests were performed to demonstrate that the composite structure designed to the same operating load requirement can have at least the same energy absorption capability as aluminum structure.
Illustrated here is the concept of reinforced concrete structures by the use of computer simulation and an inexpensive hands-on design experiment. The students in our construction management program use disposable plastic as a reinforcement to demonstrate their understanding of reinforced concrete and prestressed concrete beams. The plastics used for such an experiment vary from plastic bottles to steel reinforced auto tires. This experiment will show the extent to which plastic reinforcement increases the strength of a concrete beam. The procedure of using such throw-away plastics in an experiment to explain the interaction between the reinforcement material and concrete, and a comparison of the test results for using different types of waste plastics are discussed. A computer analysis to simulate the structural response is used to compare the test results and to understand the analytical background of reinforced concrete design. This interaction of using computers to analyze structures and to relate the output results with real experimentation is found to be a very useful method for teaching a math-based analytical subject to our non-engineering students.
A survey was conducted of six aerospace companies and two NASA agencies to determine how prototype structural test articles are used in flight operations. The prototype structures are airframes and similar devices which are used for testing and generally are not flown. The survey indicated the following: (1) prototype test articles are not being discarded after development testing is complete, but are used for other purposes, (2) only two cases of prototypes being refurbished and flown were identified, (3) protective devices and inspection techniques are available to prevent or minimize test article damage, (4) substitute programs from design verification are availabel in lieu of using prototype structural articles, and (5) there is a trend away from dedicated test articles. Four options based on these study results were identified to reduce test and hardware costs without compromising reliability of the flight program.
The initial flight test phase of the modified C-8A airplane was conducted. The primary objective of the testing was to establish the basic airworthiness of the research vehicle. This included verification of the structural design and evaluation of the aircraft's systems. Only a minimum amount of performance testing was scheduled; this has been used to provide a preliminary indication of the airplane's performance and flight characteristics for future flight planning. The testing included flutter and loads investigations up to the maximum design speed. The operational characteristics of all systems were assessed including hydraulics, environmental control system, air ducts, the vectoring conical nozzles, and the stability augmentation system (SAS). Approaches to stall were made at three primary flap settings: up, 30 deg and 65 deg, but full stalls were not scheduled. Minimum control speeds and maneuver margins were checked. All takeoffs and landings were conventional, and STOL performance was not scheduled during this phase of the evaluation.
State-of-the-art solar arrays for spacecraft provide on the order of 20 kW of electrical power, and they usually consist of 3J solar cells bonded to hinged rigid panels about 1 inch in thickness. This structural construction allows specific mass and packaging volumes of up to approximately 70 W/kg and 15 kW/m3 to be achieved. Significant advances in solar array structures are required for future very-high-power spacecraft (300+ kW), such as those proposed for pre-positioning heavy cargo on or near the Moon, Mars, or asteroids using solar electric propulsion. These applications will require considerable increases in both W/kg and kW/m3, and will undoubtedly require the use of flexible-substrate designs. This presentation summarizes work sponsored by NASA's Game Changing Development Program since Oct. 2011 to address the challenge of developing 300+ kW solar arrays. The work is primarily being done at NASA Langley, NASA Glenn, and two contractor teams (ATK and DSS), with technical collaboration from AFRL/Kirtland. The near-tem objective of the project is design, analysis, and testing of 30-50 kW solar array designs that are extensible to the far-term objective of 300+ kW. The work is currently focused on three designs: the MegaFlex concept by ATK, the Mega-ROSA concept by DSS, and an in-house 300-kW Government Reference Array concept. Each of these designs will be described in the presentation. Results obtained to date by the team, as well as future work plans, for the design, analysis, and testing of these large solar array structures will be summarized.
A study on the application of spherical tensegrity structures to a passively mobile tumbleweed-like concept was developed and tested. Parameterized sizing tools were developed to understand environmental and geometrical sensitivities and maintain the ability to apply the concept to various environments. The sensitivity studies were then used to inform the design, and then a prototype model for an Earth environment was built to correlate the sizing tool outputs with experimental data. This prototype underwent testing in order to understand performance of the structure in more controlled (wind tunnel testing) environments and more realistic (field testing) environments. This paper will describe the design derivation and sensitivity studies performed along with the test results of the prototype structure.