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At least 73 records · Page 4

Structural Concepts and Materials for Lunar Exploration Habitats

A new project within the Exploration Systems Mission Directorate s Technology Development Program at NASA involves development of lightweight structures and low temperature mechanisms for Lunar and Mars missions. The Structures and Mechanisms project is to develop advanced structure technology for the primary structure of various pressurized elements needed to implement the Vision for Space Exploration. The goals are to significantly enhance structural systems for man-rated pressurized structures by 1) lowering mass and/or improving efficient volume for reduced launch costs, 2) improving performance to reduce risk and extend life, and 3) improving manufacturing and processing to reduce costs. The targeted application of the technology is to provide for the primary structure of the pressurized elements of the lunar lander for both sortie and outpost missions, and surface habitats for the outpost missions. The paper presents concepts for habitats that support six month (and longer) lunar outpost missions. Both rigid and flexible habitat wall systems are discussed. The challenges of achieving a multi-functional habitat that provides micro-meteoroid, radiation, and thermal protection for explorers are identified.

Belvin, W. Keith↗

Technology for aircraft energy efficiency

Six technology programs for reducing fuel use in U.S. commercial aviation are discussed. The six NASA programs are divided into three groups: Propulsion - engine component improvement, energy efficient engine, advanced turboprops; Aerodynamics - energy efficient transport, laminar flow control; and Structures - composite primary structures. Schedules, phases, and applications of these programs are considered, and it is suggested that program results will be applied to current transport derivatives in the early 1980s and to all-new aircraft of the late 1980s and early 1990s.

Klineberg, J. M.↗

Test plan. GCPS task 7, subtask 7.1: IHM development

The overall objective of Task 7 is to identify cost-effective life cycle integrated health management (IHM) approaches for a reusable launch vehicle's primary structure. Acceptable IHM approaches must: eliminate and accommodate faults through robust designs, identify optimum inspection/maintenance periods, automate ground and on-board test and check-out, and accommodate and detect structural faults by providing wide and localized area sensor and test coverage as required. These requirements are elements of our targeted primary structure low cost operations approach using airline-like maintenance by exception philosophies. This development plan will follow an evolutionary path paving the way to the ultimate development of flight-quality production, operations, and vehicle systems. This effort will be focused on maturing the recommended sensor technologies required for localized and wide area health monitoring to a technology readiness level (TRL) of 6 and to establish flight ready system design requirements. The following is a brief list of IHM program objectives: design out faults by analyzing material properties, structural geometry, and load and environment variables and identify failure modes and damage tolerance requirements; design in system robustness while meeting performance objectives (weight limitations) of the reusable launch vehicle primary structure; establish structural integrity margins to preclude the need for test and checkout and predict optimum inspection/maintenance periods through life prediction analysis; identify optimum fault protection system concept definitions combining system robustness and integrity margins established above with cost effective health monitoring technologies; and use coupons, panels, and integrated full scale primary structure test articles to identify, evaluate, and characterize the preferred NDE/NDI/IHM sensor technologies that will be a part of the fault protection system.

Greenberg, H. S.↗

Fabrication and evaluation of advanced titanium structural panels for supersonic cruise aircraft

Flightworthy primary structural panels were designed, fabricated, and tested to investigate two advanced fabrication methods for titanium alloys. Skin-stringer panels fabricated using the weldbraze process, and honeycomb-core sandwich panels fabricated using a diffusion bonding process, were designed to replace an existing integrally stiffened shear panel on the upper wing surface of the NASA YF-12 research aircraft. The investigation included ground testing and Mach 3 flight testing of full-scale panels, and laboratory testing of representative structural element specimens. Test results obtained on full-scale panels and structural element specimens indicate that both of the fabrication methods investigated are suitable for primary structural applications on future civil and military supersonic cruise aircraft.

Payne, L.↗

Consolidation of graphite thermoplastic textile preforms for primary aircraft structure

The use of innovative cost effective material forms and processes is being considered for fabrication of future primary aircraft structures. Processes that have been identified as meeting these goals are textile preforms that use resin transfer molding (RTM) and consolidation forming. The Novel Composites for Wing and Fuselage Applications (NCWFA) program has as its objective the integration of innovative design concepts with cost effective fabrication processes to develop damage-tolerant structures that can perform at a design ultimate strain level of 6000 micro-inch/inch. In this on-going effort, design trade studies were conducted to arrive at advanced wing designs that integrate new material forms with innovative structural concepts and cost effective fabrication methods. The focus has been on minimizing part count (mechanical fasteners, clips, number of stiffeners, etc.), by using cost effective textile reinforcement concepts that provide improved damage tolerance and out-of-plane load capability, low-cost resin transfer molding processing, and thermoplastic forming concepts. The fabrication of representative Y spars by consolidation methods will be described. The Y spars were fabricated using AS4 (6K)/PEEK 150g commingled angle interlock 0/90-degree woven preforms with +45-degree commingled plies stitched using high strength Toray carbon thread and processed by autoclave consolidation.

Suarez, J.↗

3D Printed Structural Core with MMOD Protection

Deep space exploration requires large habitats for both orbital and surface missions. The weight of a habitat is driven largely by its structure and future vehicles require lighter weight structures to minimize launch mass and cost. Unlike honeycomb core materials used in the past, a 3D printed core can be analyzed and optimized for specific load environments, further cutting down mass of the vehicle. Multi-functional structures can integrate features into the primary structure that are traditionally added mass. MMOD (Micro Meteor and Orbital Debris) protection, for example, can be integrated directly into the primary structure of a habitat. This minimizes the mass of the structure and eliminates the need for additional MMOD layers and attachment hardware. This project seeks to develop 3D printed structural core that can be optimized for flights loads and provide integrated MMOD protection.

Hagen, Richard↗

Development and Sizing of the JWST Integrated Science Instrument Module (ISIM) Metering Structure

The JWST Integrated Science Instrument Module (ISIM) includes a large metering structure (approx. 2m x 2m x 1.5m) that houses the science instruments and guider. Stringent dimensional stability and repeatability requirements combined with mass limitations led to the selection of a composite bonded frame design comprised of biased laminate tubes. Even with the superb material specific stiffness, achieving the required frequency for the given mass allocations in conjunction with severe spatial limitations imposed by the instrument complement has proven challenging. In response to the challenge, the ISIM structure team considered literally over 100 primary structure topology and kinematic mount configurations, and settled on a concept comprised of over 70 m of tubes, over 50 bonded joint assemblies, and a "split bi-pod" kinematic mount configuration. In this paper, we review the evolution of the ISIM primary structure topology and kinematic mount configuration to the current baseline concept.

Johnston, John↗

Parametric Studies of Human Mars Entry, Descent, and Landing Systems

This paper will present a parametric analysis for entry, descent, and landing (EDL) concepts, enabling rapid systems assessment and tradespace exploration. The entry system uses a hypersonic inflatable aerodynamic decelerator (HIAD) technology. The baseline system includes elements for Mars aerocapture (AC) and EDL segments of the mission. The mission concept of operations (ConOps) begins at Mars arrival in a polar inclination. After performing an aerocapture (AC) maneuver into a pre-defined Mars parking orbit, the AC HIAD is jettisoned. The rest of thevehicle stays in the parking orbit for up to one year. The EDL sequence starts with a deorbit burn at the apoapsis of the parking orbit. After hypersonic entry with the EDL HIAD, the entry system uses a supersonic retropropulsion maneuver to slow the vehicle for the descent and landing segments of the mission. The vehicle will maintain a constant velocity of 2.5 m/s for 5 seconds prior to landing.The system includes a Mars Ascent Vehicle (MAV), Mars Descent Module (MDM), and two HIADs. The MDM includes a primary structure, tanks, engines, and radiators. The primary structure is an aluminum-lithium (Al-Li)cruciform design similar to the structural design of the Apollo Lunar Module. The cruciform planform layout results in four outer bays, with adequate volume in the corners between outer bays to package four landing gears. The central bay is reserved for packaging the MAV and the recessed MAV engines. Two of the outer bays accommodate main propellant tanks, with one LOX and one CH4 tank in each bay. The two remaining outer bays each house four rocket engine systems and associated support structure. Each HIAD comprises an inflatable structure, flexible thermal protection system, gas, and gas generators. The HIAD design used in this study is a stacked-toroid concept with pairing loop straps and radial/chevron straps. The baseline system lands a 20-t payload on the Mars surface. It is assumed the vehicle arrives at 6.2 km/s relative velocity at 90° inclination and is captured to a 1-Sol parking orbit.The baseline design includes many assumptions such as margins, arrival state, ConOps options, parking orbit, physical dimensions, propellant options, and technology concepts. The impact of these parameters are quantified through systems-level sensitivity analyses, which capture the global impact—not at a component level—but at the systems level. The systems-level sensitivities expose major design drivers and importance of each assumption for a design.Through tradespace exploration, a wide range of systems parameters are examined and compared for several feasible design options. Studies have been completed for the following input parameters: payload mass, propellant options, AC/EDL ballistic coefficient, lander thrust to weight ratio (T/W) (surrogate for the maximum EDL g’s),engine specific impulse (Isp), parking orbit, and inclination.The final paper will present and discuss the parametric approach used in the study. It will also include the results of recent systems analyses, sensitivity analyses, and tradespace exploration

Jamshid Samareh↗

Vibration and stress analysis of soft-bonded shuttle insulation tiles. Modal analysis with compact widely space stringers

An efficient iterative procedure is described for the vibration and modal stress analysis of reusable surface insulation (RSI) of multi-tiled space shuttle panels. The method, which is quite general, is rapidly convergent and highly useful for this application. A user-oriented computer program based upon this procedure and titled RESIST (REusable Surface Insulation Stresses) has been prepared for the analysis of compact, widely spaced, stringer-stiffened panels. RESIST, which uses finite element methods, obtains three dimensional tile stresses in the isolator, arrestor (if any) and RSI materials. Two dimensional stresses are obtained in the tile coating and the stringer-stiffened primary structure plate. A special feature of the program is that all the usual detailed finite element grid data is generated internally from a minimum of input data. The program can accommodate tile idealizations with up to 850 nodes (2550 degrees-of-freedom) and primary structure idealizations with a maximum of 10,000 degrees-of-freedom. The primary structure vibration capability is achieved through the development of a new rapid eigenvalue program named ALARM (Automatic LArge Reduction of Matrices to tridiagonal form).

Ojalvo, I. U.↗

Progress in manufacturing large primary aircraft structures using the stitching/RTM process

The Douglas Aircraft/NASA Act contract has been focused over the past three years at developing a materials, manufacturing, and cost base for stitched/Resin Transfer Molded (RTM) composites. The goal of the program is to develop RTM and stitching technology to provide enabling technology for application of these materials in primary aircraft structure with a high degree of confidence. Presented in this paper will be the progress to date in the area of manufacturing and associated cost values of stitched/RTM composites.

Markus, Alan↗

Long Duration Exposure Facility (LDEF) structural verification test report

Structural load tests on the Long Duration Exposure Facility's (LDEF) primary structure were conducted. These tests had three purposes: (1) demonstrate structural adequacy of the assembled LDEF primary structure when subjected to anticipated flight loads; (2) verify analytical models and methods used in loads and stress analysis; and (3) perform tests to comply with the Space Transportation System (STS) requirements. Test loads were based on predicted limit loads which consider all flight events. Good agreement is shown between predicted and observed load, strain, and deflection data. Test data show that the LDEF structure was subjected to 1.2 times limit load to meet the STS requirements. The structural adequacy of the LDEF is demonstrated.

Jones, T. C.↗

A study of component design loads due to dynamic environment

The random vibration of the components of the space shuttle causing internal cargo bay acoustic impingement on the payload was investigated. The import factors to be considered in the design of acoustically loaded structures are the prediction of acoustic environment, prediction of structural response to this environment, and to determine the effect of the response on the structural strength requirements. Two basic responses were analyzed. The primary structure response due to random vibration is first analyzed. The output of primary structure response is used as an input to the secondary structure to calculate the component response.

Mehta, R. S.↗

Development of the Toggle Deployment Mechanism

The Toggle Deployment Mechanism (TDM) is a two fault tolerant, single point, low shock pyro/mechanical releasing device. Many forms of releasing are single fault tolerant and involve breaking of primary structure. Other releasing mechanisms, that do not break primary structure, are only pyrotechnically redundant and not mechanically redundant. The TDM contains 3 independent pyro actuators, and only one of the 3 is required for release. The 2 separating members in the TDM are held together by a toggle that is a cylindrical stem with a larger diameter spherical shape on the top and flares out in a conical shape at the bottom. The spherical end of the toggle sits in a socket with the top assembly and the bottom is held down by 3 pins or hooks equally spaced around the conical shaped end. Each of the TDM's 3 independent actuators shares a third of the separating load and does not require as much pyrotechnic energy as many single fault tolerant actuators. Other single separating actuators, i.e., separating nuts or pin pullers, have the pyrotechnic energy releasing the entire preload holding the separating members together. Two types of TDM's ,described in this paper, release the toggle with pin pullers, and the third TDM releases the toggle with hooks. Each design has different advantages and disadvantages. This paper describes the TDM's construction and testing up to the summer of 1993.

Brown, Christopher W.↗

Flight service environmental effects on composite materials and structures

NASA Langley and the U.S. Army have jointly sponsored programs to assess the effects of realistic flight environments and ground-based exposure on advanced composite materials and structures. Composite secondary structural components were initially installed on commercial transport aircraft in 1973; secondary and primary structural components were installed on commercial helicopters in 1979; and primary structural components were installed on commercial aircraft in the mid-to-late 1980's. Service performance, maintenance characteristics, and residual strength of numerous components are reported. In addition to data on flight components, 10 year ground exposure test results on material coupons are reported. Comparison between ground and flight environmental effects for several composite material systems are also presented. Test results indicate excellent in-service performance with the composite components during the 15 year period. Good correlation between ground-based material performance and operational structural performance has been achieved.

Dexter, H. Benson↗

Honeycomb vs. Foam: Evaluating Potential Upgrades to ISS Module Shielding

The presence of honeycomb cells in a dual-wall structure is advantageous for mechanical performance and low weight in spacecraft primary structures but detrimental for shielding against impact of micrometeoroid and orbital debris particles (MMOD). The presence of honeycomb cell walls acts to restrict the expansion of projectile and bumper fragments, resulting in the impact of a more concentrated (and thus lethal) fragment cloud upon the shield rear wall. The Multipurpose Laboratory Module (MLM) is a Russian research module scheduled for launch and ISS assembly in 2011 (currently under review). Baseline shielding of the MLM is expected to be predominantly similar to that of the existing Functional Energy Block (FGB), utilizing a baseline triple wall configuration with honeycomb sandwich panels for the dual bumpers and a thick monolithic aluminum pressure wall. The MLM module is to be docked to the nadir port of the Zvezda service module and, as such, is subject to higher debris flux than the FGB module (which is aligned along the ISS flight vector). Without upgrades to inherited shielding, the MLM penetration risk is expected to be significantly higher than that of the FGB module. Open-cell foam represents a promising alternative to honeycomb as a sandwich panel core material in spacecraft primary structures as it provides comparable mechanical performance with a minimal increase in weight while avoiding structural features (i.e. channeling cells) detrimental to MMOD shielding performance. In this study, the effect of replacing honeycomb sandwich panel structures with metallic open-cell foam structures on MMOD shielding performance is assessed for an MLM-representative configuration. A number of hypervelocity impact tests have been performed on both the baseline honeycomb configuration and upgraded foam configuration, and differences in target damage, failure limits, and derived ballistic limit equations are discussed.

Ryan, Shannon J.↗

Composite structures for commercial transport aircraft

The development of graphite-epoxy composite structures for use on commercial transport aircraft is considered. Six components, three secondary structures, and three primary structures, are presently under development. The six components are described along with some of the key features of the composite designs and their projected weight savings.

Vosteen, L. F.↗

A revolutionary approach to general aviation airplane design

The accumulation of such advanced technologies as digital guidance/display concepts, flow laminarization techniques, smart structures, and composite primary structures, is presently considered systematically with a view to such novel features' integration in a next-generation general aviation aircraft. This Advanced Personal Transport is conceived as a six-passenger aircraft with 1200 nautical mile range; a tractor and a pusher configuration were considered, with the pusher configuration being of twin-boom empennage, three-lifting-surface type. Attention is given to pilot-workload reductions achievable through the proposed Integrated GPS/Glonass system.

Roskam, Jan↗

Future Homes in Space: Development of Concepts for Exploration Space Habitats

NASA’s Artemis campaign seeks to return humans to the moon and establish a sustained presence on the lunar surface. This session will emphasize how habitation capabilities on the moon and in cislunar space can potentially contribute to the sustainability objectives of Artemis. Habitable elements represent opportunities to enable longer duration stays, increase the number of crew members present, enhance science and utilization activities, drive technology development for future Mars exploration, perform analog missions, and fuel economic opportunities for US industry. Panelists include Paul Kessler (NASA Marshall Space Flight Center, deputy lead for lunar surface habitation); Andrew Choate (NASA Marshall Space Flight Center, Mars habitation lead); Krystofer Dudzinski (NASA Marshall Space Flight Center, a space architect within the MSFC Advanced Concepts Office); and Larry Toups (retired from NASA Johnson Space Center, currently an adjunct professor at University of Houston in space architecture). The panel is moderated by Tracie Prater (NASA Marshall Space Flight Center, Habitation Systems Development Office). The panel will begin with an overview of the history of habitation concepts and an academic perspective on general considerations in space habitat design (Larry Toups). Paul Kessler and Andrew Choate will introduce NASA’s principle of “architecting from the right” to help define objectives for Artemis missions, needs/characteristics, use cases, and functions (as published in the agency’s Architecture Definition Document) and provide perspective on how this principle informs habitation concept development work. NASA panelists will discuss key engineering challenges identified for developing, deploying, and operating habitable assets on the lunar surface and/or in deep space. These may include dust mitigation, outfitting of inflatable softgoods (for concepts which may use softgoods as a primary structural material), survival in lunar darkness, human health and performance considerations, maintenance/repair/sparing, and autonomy. These identified challenges represent risks for habitation systems development and relate closely to capability gaps identified by the agency. While the work of NASA Marshall Space Flight Center’s habitation development office is primarily focused on habitats which are launched from earth pre-integrated (referred to as Class I in the framework previously developed by NASA space architects Kennedy/Cohen) or launched from earth and deployed at the point of use (Class II), there is also extensive work in NASA, academia, and companies on constructed habitats, which would be built on a planetary surface using indigenous resources (Class III habitats). Panelist Krystopher Dudzinski will discuss potential evolutionary pathways from Class I and Class II habitats to Class III habitats, unique and common architectural challenges within each habitat class, and key gaps in implementing Class III habitats from an architectural perspective. NASA panelists and the moderator will also provide an overview of partnership opportunities and avenues for further engagement to advance habitation systems for the SpaceCom audience. NASA is currently developing notional concepts for a lunar surface habitat and Mars transit habitat, which will be discussed during this panel session and used as examples. These concepts represent options for habitation system design and are a point of departure. They do not represent a final plan or formal recommendation on the part of the agency. Based on the most recent analysis cycle, NASA’s lunar surface habitat (SH) concept nominally supports two crew members for 30 days, with the capacity to support four crew during a surge period where crew will swap between the SH and another surface asset, such as a pressurized rover. This example design has a metallic airlock for ingress/egress and the upper portion is an inflatable material system which serves as the habitation module. The notional interior of the habitat is a three-deck layout/configuration which supports all crew mission functions, including exercise, stowage, extravehicular activity (EVA), sleep, hygiene waste collection, maintenance and repair, and meal preparation. Under analysis assumptions for habitation, the Mars Transit Habitat (TH) concept would support four crew on an up to 1,200 day Mars mission. One option for the concept is to initially dock Transit Habitat at Gateway, where it can be used to increase the duration of crew stays in cislunar space and perform shakedown and analog missions prior to a Mars departure. One challenge in longer duration missions which involve both surface exploration and transit is understanding crew adaptation when transitioning between partial gravity and microgravity environments. TH at Gateway offers an opportunity to study this transition and in doing so reduce risks associated with future Mars exploration. Like lunar SH, the most recent analysis cycle concept of a Mars TH is a hybrid structure design, with a metallic section supporting EVAs, axial/radial docking, and Safe Haven capabilities, and an inflatable softgoods structure for the primary habitation function. Interior layouts to optimize crew usability and livability are currently under trade. The panel will include presentation material, but also seeks to engage the audience in a highly interactive conversation regarding the potential role for habitation in future exploration initiatives. Potential topics for discussion include the influence of the crew experience on habitation systems design and livability/usability considerations, the benefits of space habitation development in terrestrial applications, and challenges and opportunities in “feeding forward” lunar surface habitation systems development to Mars exploration.

space habitats↗