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At least 649 records · Page 36

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NASA NTRS1990

Graphite/epoxy composite adapters for the Space Shuttle/Centaur vehicle

The decision to launch various NASA satellite and Air Force spacecraft from the Space Shuttle created the need for a high-energy upper stage capable of being deployed from the cargo bay. Two redesigned versions of the Centaur vehicle which employed a graphite/epoxy composite material for the forward and aft adapters were selected. Since this was the first time a graphite/epoxy material was used for Centaur major structural components, the development of the adapters was a major effort. An overview of the composite adapter designs, subcomponent design evaluation test results, and composite adapter test results from a full-scale vehicle structural test is presented.

Kasper, Harold J.↗

NASA NTRS1974

Apollo experience report: Spacecraft structure subsystem

The flightworthiness of the Apollo spacecraft structure was verified primarily through a rigorous, vehicle level, ground test program and flight tests. The failures and anomalies encountered during this testing were the major factors considered in determining necessary modifications to the basic design of the spacecraft structure. In this report, these failures, their causes, and their resolutions are discussed. A description of the spacecraft structure and discussions of the ground and flight test programs are presented.

Smith, P. D.↗

NASA NTRS1960

Ranger Spacecraft

The thermal-control philosophy of the spacecraft currently under development by the Jet Propulsion Laboratory is design by passive means to maintain all components within the tolerances specified by cognizant engineers. Due to the complexity of the configurations, calculations are) of necessity, fairly generalized and final design is based upon tests in an environmental chamber. The Ranger series spacecraft is designed with a basic structure which is common to all models, with additional hardware to suit the individual mission. This basic structure of Rangers A-1 and A-2 is seen as the hexagonal instrument section, the erectable solar panels, the movable antenna, and the omniantenna. The Ranger A-1 and A-2 configuration is for engineering tests and space-exploration, with the scientific instrumentation isolation requirement dictating the spread-out design. The spacecraft stands 12 feet high, weighs 700 to 800 pounds, and has an internal power of 150 watts. Rangers A-3, A-4, and A-5 are designed to rough land a capsule on the moon. For these, a capsule and retrorocket replace the scientific instruments, occupying the space inside the tower structure. The spacecraft must survive many environments. Chronologically they are: 1) Folded configuration inside an aerodynamic shroud on the pad. 2) Thermal flux from shroud aerodynamically heated during boost phase. 3) Coasting up to 30 minutes attached to Agena stage after booster and shroud are separated. 4) Agena stage burning. 5) Coasting and tumbling after separation from Agena until it passes from earth's shadow. 6) Upon reaching sunlight, panels open and begin sun acquisition. 7) Antenna seeks earth after spacecraft locks onto sun. 8) Space phase- "steady state" with vehicle's vertical axis locked on sun, communicating with earth. The philosophy is to design for the sun-acquired mode, making allowances for the transient conditions.

Thostesen, T. O.↗

NASA NTRS2013

Follow on Research for Multi-Utility Technology Test Bed Aircraft at NASA Dryden Flight Research Center (FY13 Progress Report)

Modern aircraft employ a significant fraction of their weight in composite materials to reduce weight and improve performance. Aircraft aeroservoelastic models are typically characterized by significant levels of model parameter uncertainty due to the composite manufacturing process. Small modeling errors in the finite element model will eventually induce errors in the structural flexibility and mass, thus propagating into unpredictable errors in the unsteady aerodynamics and the control law design. One of the primary objectives of Multi Utility Technology Test-bed (MUTT) aircraft is the flight demonstration of active flutter suppression, and therefore in this study, the identification of the primary and secondary modes for the structural model tuning based on the flutter analysis of MUTT aircraft. The ground vibration test-validated structural dynamic finite element model of the MUTT aircraft is created in this study. The structural dynamic finite element model of MUTT aircraft is improved using the in-house Multi-disciplinary Design, Analysis, and Optimization tool. In this study, two different weight configurations of MUTT aircraft have been improved simultaneously in a single model tuning procedure.

multi-utility technology test bed aircraft↗

NASA NTRS2005

Occulting focal plane masks for Terrestrial Planet Finder Coronagraph: design, fabrication, simulations and test results

Occulting focal plane masks for the Terrestrial Planet Finder Coronagraph (TPF-C) could be designed with continuous gray scale profile of the occulting pattern such as 1-sinc2 on a suitable material or with micron-scale binary transparent and opaque structures of metallic pattern on glass. We have designed, fabricated and tested both kinds of masks. The fundamental characteristics of such masks and initial test results from the High Contrast Imaging Test bed (HCIT) at JPL are presented.

adaptive optics↗

NASA NTRS1989

Structural stability augmentation system design using BODEDIRECT: A quick and accurate approach

A methodology is presented for a modal suppression control law design using flight test data instead of mathematical models to obtain the required gain and phase information about the flexible airplane. This approach is referred to as BODEDIRECT. The purpose of the BODEDIRECT program is to provide a method of analyzing the modal phase relationships measured directly from the airplane. These measurements can be achieved with a frequency sweep at the control surface input while measuring the outputs of interest. The measured Bode-models can be used directly for analysis in the frequency domain, and for control law design. Besides providing a more accurate representation for the system inputs and outputs of interest, this method is quick and relatively inexpensive. To date, the BODEDIRECT program has been tested and verified for computational integrity. Its capabilities include calculation of series, parallel and loop closure connections between Bode-model representations. System PSD, together with gain and phase margins of stability may be calculated for successive loop closures of multi-input/multi-output systems. Current plans include extensive flight testing to obtain a Bode-model representation of a commercial aircraft for design of a structural stability augmentation system.

Goslin, T. J.↗

NASA NTRS2010

High-Temperature Surface-Acoustic-Wave Transducer

Aircraft-engine rotating equipment usually operates at high temperature and stress. Non-invasive inspection of microcracks in those components poses a challenge for the non-destructive evaluation community. A low-profile ultrasonic guided wave sensor can detect cracks in situ. The key feature of the sensor is that it should withstand high temperatures and excite strong surface wave energy to inspect surface/subsurface cracks. As far as the innovators know at the time of this reporting, there is no existing sensor that is mounted to the rotor disks for crack inspection; the most often used technology includes fluorescent penetrant inspection or eddy-current probes for disassembled part inspection. An efficient, high-temperature, low-profile surface acoustic wave transducer design has been identified and tested for nondestructive evaluation of structures or materials. The development is a Sol-Gel bismuth titanate-based surface-acoustic-wave (SAW) sensor that can generate efficient surface acoustic waves for crack inspection. The produced sensor is very thin (submillimeter), and can generate surface waves up to 540 C. Finite element analysis of the SAW transducer design was performed to predict the sensor behavior, and experimental studies confirmed the results. One major uniqueness of the Sol-Gel bismuth titanate SAW sensor is that it is easy to implement to structures of various shapes. With a spray coating process, the sensor can be applied to surfaces of large curvatures. Second, the sensor is very thin (as a coating) and has very minimal effect on airflow or rotating equipment imbalance. Third, it can withstand temperatures up to 530 C, which is very useful for engine applications where high temperature is an issue.

Zhao, Xiaoliang↗

NASA NTRS2015

[Fall 2015 Abstract by Stephanie Scharf]

This Fall I worked on two different projects that culminated into a redesign of the spacesuit LLB (long life battery). I also did some work on the PLSS (personal life support system) battery with EC. My first project was redlining the work instruction for completing DPAs (destructive physical analysis) on battery cells in the Branch. The purpose of this document is to create a standard process and ensure that the data is collected in the same way, no matter who carries out the analysis. I observed three DPAs, conducted one with help, and conducted two on my own, all while taking notes on the procedure. These notes were used to write the final work instruction, which will become the Branch standard. My second project continued the work of the Summer co-op before me. I tested aluminum heat sinks for their ability to provide good thermal conduction and structural support during a thermal runaway event. The heat sinks had been designed by the previous Summer co-op, but there was not much time for testing before he left. We thus ran tests with a heater on the bottom of a trigger cell to try to drive thermal runaway and ensure that it will not propagate to adjacent cells. We also ran heat-to-vent tests in an oven to see if the assembly provided structural support and prevented sidewall rupture during thermal runaway. These tests were carried out at ESTA (Energy Systems Test Area) and are providing very promising results, indicating that safe, high performing (>180 Wh/kg) designs are possible. My main project was a redesign of the LLB (Lightweight Lithium Battery). Another summer intern had done some testing and concluded that there was no simple fix to mitigate thermal runaway propagation hazards in the existing design. The only option was a clean sheet redesign of the battery. I was given a volume and ideal energy density, and the rest of the design was up to me. First, I created new heat sink banks in CREO, using the information gathered in the metal heat sink tests from the summer intern. After this, I made capture plates to hold the cells in place, and I worked on nickel bussings for the electrical connections between the cells. Finally, I designed the test box enclosure that included sections for flame arresting materials. The battery brick design, which is the heart of the battery, promises to become the first for a manned spacecraft application to achieve > 180 Wh/kg. My work in redlining the DPA work instructions will also be used in selecting the cells for the battery. We had a few options for cells that would provide the necessary power output and needed to make a choice. We repeatedly charged and discharged cells for around a month until they went through 100 lifecycles. The plan was to compare the DPA results on fresh and cycled cells from each manufacturer to see if cycling introduces any differences. After the complete LLB design was approved, the parts were ordered and testing should begin the first week of December. Cutting open a cell for DPA After photo from oven heat-to-vent test

Scharf, Stephanie↗

NASA NTRS2007

Materials Safety - Not just Flammability and Toxic Offgassing

For many years, the safety community has focused on a limited subset of materials and processes requirements as key to safety: Materials flammability, Toxic offgassing, Propellant compatibility, Oxygen compatibility, and Stress-corrosion cracking. All these items are important, but the exclusive focus on these items neglects many other items that are equally important to materials safety. Examples include (but are not limited to): 1. Materials process control -- proper qualification and execution of manufacturing processes such as structural adhesive bonding, welding, and forging are crucial to materials safety. Limitation of discussions on materials process control to an arbitrary subset of processes, known as "critical processes" is a mistake, because any process where the quality of the product cannot be verified by inspection can potentially result in unsafe hardware 2 Materials structural design allowables -- development of valid design allowables when none exist in the literature requires extensive testing of multiple lots of materials and is extremely expensive. But, without valid allowables, structural analysis cannot verify structural safety 3. Corrosion control -- All forms of corrosion, not just stress corrosion, can affect structural integrity of hardware 4. Contamination control during ground processing -- contamination control is critical to manufacturing processes such as adhesive bonding and also to elimination foreign objects and debris (FOD) that are hazardous to the crew of manned spacecraft in microgravity environments. 5. Fasteners -- Fastener design, the use of verifiable secondary locking features, and proper verification of fastener torque are essential for proper structural performance This presentation discusses some of these key factors and the importance of considering them in ensuring the safety of space hardware.

Pedley, Michael D.↗

NASA NTRS2016

Overview of the Space Launch System Ascent Aeroacoustic Environment Test Program

Characterization of accurate flight vehicle unsteady aerodynamics is critical for component and secondary structure vibroacoustic design. The Aerosciences Branch at the National Aeronautics and Space Administration (NASA) Marshall Space Flight Center has conducted a test at the NASA Ames Research Center (ARC) Unitary Plan Wind Tunnels (UPWT) to determine such ascent aeroacoustic environments for the Space Launch System (SLS). Surface static pressure measurements were also collected to aid in determination of local environments for venting, CFD substantiation, and calibration of the flush air data system located on the launch abort system. Additionally, this test supported a NASA Engineering and Safety Center study of alternate booster nose caps. Testing occurred during two test campaigns: August - September 2013 and December 2013 - January 2014. Four primary model configurations were tested for ascent aeroacoustic environment definition. The SLS Block 1 vehicle was represented by a 2.5% full stack model and a 4% truncated model. Preliminary Block 1B payload and manned configurations were also tested, using 2.5% full stack and 4% truncated models respectively. This test utilized the 11 x 11 foot transonic and 9 x 7 foot supersonic tunnel sections at the ARC UPWT to collect data from Mach 0.7 through 2.5 at various total angles of attack. SLS Block 1 design environments were developed primarily using these data. SLS Block 1B preliminary environments have also been prepared using these data. This paper discusses the test and analysis methodology utilized, with a focus on the unsteady data collection and processing.

Herron, Andrew J.↗

NASA NTRS1997

Verification and Validation in a Rapid Software Development Process

The high cost of software production is driving development organizations to adopt more automated design and analysis methods such as rapid prototyping, computer-aided software engineering (CASE) tools, and high-level code generators. Even developers of safety-critical software system have adopted many of these new methods while striving to achieve high levels Of quality and reliability. While these new methods may enhance productivity and quality in many cases, we examine some of the risks involved in the use of new methods in safety-critical contexts. We examine a case study involving the use of a CASE tool that automatically generates code from high-level system designs. We show that while high-level testing on the system structure is highly desirable, significant risks exist in the automatically generated code and in re-validating releases of the generated code after subsequent design changes. We identify these risks and suggest process improvements that retain the advantages of rapid, automated development methods within the quality and reliability contexts of safety-critical projects.

Callahan, John R.↗

NASA NTRS2000

Experience with a Genetic Algorithm Implemented on a Multiprocessor Computer

Numerical experiments were conducted to find out the extent to which a Genetic Algorithm (GA) may benefit from a multiprocessor implementation, considering, on one hand, that analyses of individual designs in a population are independent of each other so that they may be executed concurrently on separate processors, and, on the other hand, that there are some operations in a GA that cannot be so distributed. The algorithm experimented with was based on a gaussian distribution rather than bit exchange in the GA reproductive mechanism, and the test case was a hub frame structure of up to 1080 design variables. The experimentation engaging up to 128 processors confirmed expectations of radical elapsed time reductions comparing to a conventional single processor implementation. It also demonstrated that the time spent in the non-distributable parts of the algorithm and the attendant cross-processor communication may have a very detrimental effect on the efficient utilization of the multiprocessor machine and on the number of processors that can be used effectively in a concurrent manner. Three techniques were devised and tested to mitigate that effect, resulting in efficiency increasing to exceed 99 percent.

Plassman, Gerald E.↗

NASA NTRS2000

Experience with a Genetic Algorithm Implemented on a Multiprocessor Computer

Plassman, Gerald E.↗

NASA NTRS1994

Design of scaled down structural models

In the aircraft industry, full scale and large component testing is a very necessary, time consuming, and expensive process. It is essential to find ways by which this process can be minimized without loss of reliability. One possible alternative is the use of scaled down models in testing and use of the model test results in order to predict the behavior of the larger system, referred to herein as prototype. This viewgraph presentation provides justifications and motivation for the research study, and it describes the necessary conditions (similarity conditions) for two structural systems to be structurally similar with similar behavioral response. Similarity conditions provide the relationship between a scaled down model and its prototype. Thus, scaled down models can be used to predict the behavior of the prototype by extrapolating their experimental data. Since satisfying all similarity conditions simultaneously is in most cases impractical, distorted models with partial similarity can be employed. Establishment of similarity conditions, based on the direct use of the governing equations, is discussed and their use in the design of models is presented. Examples include the use of models for the analysis of cylindrical bending of orthotropic laminated beam plates, of buckling of symmetric laminated rectangular plates subjected to uniform uniaxial compression and shear, applied individually, and of vibrational response of the same rectangular plates. Extensions and future tasks are also described.

Simitses, George J.↗

DOE OSTI2024

Development and Test of a Large Aperture $Nb_3Sn$ Cos-Theta Dipole Coil with Stress Management

An innovative stress-management (SM) concept for cos-theta (CT) coils (SMCT coil concept) has been proposed at Fermilab. A large-aperture two-layer Nb3Sn SMCT dipole coil was designed and manufactured to validate and test the SM concept including coil design, fabrication technology, and performance. The first large-aperture SMCT coil (SMCT1) was fabricated and assembled with a small-aperture Nb3Sn coil inside a dipole mirror magnet. SMCT1 coil tests in a dipole mirror structure was performed in two configurations - SMCTM1a with only powered two-layer SMCT1 coil and SMCTM1b with the SMCT coil connected in series with an inner two-layer dipole coil. The test goals are to prove the SMCT coil concept in two-layer and four-layer mirror configurations; demonstrate that the magnet can reach the targeted quench current at the established preload; study magnet training, training memory after thermal cycle, ramp rate and temperature dependences of the magnet quench current; and test the SMCT1 coil quench protection parameters. This paper summarizes the SMCT1 coil design and parameters, the coil main fabrication steps, its assembly in the dipole mirror structure. The results of the SMCTM1a/b mirror test are presented and discussed.

43 PARTICLE ACCELERATORS↗

NASA NTRS1976

D-1A equipment module structure test

The Centaur Equipment Module (E/M) structural test program was performed in two parts due to an unscheduled hardware failure in the first test series. The objectives of the initial test program were to define the flexibility characteristics of the E/M, verify the design load capability, and determine its ultimate strength capability by loading to structural failure. However, during the first failure test attempt, the Intelsat IV MPA failed instead of the E/M. Therefore a new adapter was fabricated to simulate the HEAO mission adapter and the second series of tests were then performed. They concluded with the failure of the E/M forward interface ring resulting in about 3.5 degrees of permanent set on the high compression side. Nevertheless, the linear or useable strength capability of the E/M is greater or equal to that which is required for the HEAO missions. The E/M is deemed structurally qualified for the HEAO missions.

Niezgoda, T. F.↗

DOE OSTI2025

Design and Analysis of an Integrated Additively Manufactured Test Article for Plasma-Facing Components

Current plasma-facing components (PFCs) used in helium-cooled divertor modules are complex structures with tungsten tile, steel sleeve components, and cartridges, all assembled in a helium-cooled multiple jet (HEMJ) structure. The goal of this project is to simplify the complex PFC design using additive manufacturing techniques to create a single integrated tungsten test article. Apart from the flexibility this opens up in exploring a wide array of geometries for the article, having a single integrated article significantly reduces the number of joints and parts in the article, thus reducing chances of leaks. A process called electron beam melting has shown to produce very high-density samples and unique geometries, enabling HEMJ or similar designs. To validate and optimize this novel design, the model underwent a series of computational fluid dynamics and finite element analysis simulations to replicate steady-state heat flux in the divertors. The simulations presented in this study consider a steady-state base heat flux of 5 MW/m 2 , with water serving as the coolant. Future research will explore the use of helium as a coolant, simulate edge-localized-mode conditions, and include experimental validation. Since 3D-printed tungsten is anisotropic, the build direction versus build plane of the article are taken into consideration for the test article strength. Because of the high operating temperatures and low ductility of tungsten, thermal creep and brittle fracture are important failure mechanisms to consider. In conclusion, the cap is evaluated with various flow velocities and nozzle diameters, and an optimal design choice is made for which this cap will survive the divertor conditions with a conservative safety margin.

Divertor↗

NASA NTRSDate not supplied

Design and Analysis of the Rocket Experiment Demonstration of a Soft X-Ray (REDSoX) Polarimeter Mirror Module Assembly

The Rocket Experiment Demonstration of a Soft X-ray (REDSoX) Polarimeter is a NASA sounding rocket experiment that is designed to demonstrate the technology necessary for measuring linear X-ray polarization as a function of energy below 1 keV. In astrophysics, soft X-ray spectropolarimetry will be used to probe the nature of acceleration mechanisms in quasar jets and to test models of neutron star structure. NASA Marshall Space Flight Center (MSFC) has designed a grazing-incidence mirror module assembly (MMA) for the REDSoX payload and used Finite Element Modelling Software (ANSYS) to perform structural analysis of the design. In this paper we will describe the overall design of the REDSoX MMA, details of the analysis techniques used for predicting factor of safety in the mirror adhesive bonds and structural components, the buckling analysis of the outer housing, and the raytrace technique used to estimate the effect of gravity sag on optical performance during ground testing.

Structural Analysis↗