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Aging Theories for Establishing Safe Life Spans of Airborne Critical Structural Components

New aging theories have been developed to establish the safe life span of airborne critical structural components such as B-52B aircraft pylon hooks for carrying air-launch drop-test vehicles. The new aging theories use the equivalent-constant-amplitude loading spectrum to represent the actual random loading spectrum with the same damaging effect. The crack growth due to random loading cycling of the first flight is calculated using the half-cycle theory, and then extrapolated to all the crack growths of the subsequent flights. The predictions of the new aging theories (finite difference aging theory and closed-form aging theory) are compared with the classical flight-test life theory and the previously developed Ko first- and Ko second-order aging theories. The new aging theories predict the number of safe flights as considerably lower than that predicted by the classical aging theory, and slightly lower than those predicted by the Ko first- and Ko second-order aging theories due to the inclusion of all the higher order terms.

Ko, William L.↗

X-34 Vehicle Aerodynamic Characteristics

The X-34, being designed and built by the Orbital Sciences Corporation, is an unmanned sub-orbital vehicle designed to be used as a flying test bed to demonstrate key vehicle and operational technologies applicable to future reusable launch vehicles. The X-34 will be air-launched from an L-1011 carrier aircraft at approximately Mach 0.7 and 38,000 feet altitude, where an onboard engine will accelerate the vehicle to speeds above Mach 7 and altitudes to 250,000 feet. An unpowered entry will follow, including an autonomous landing. The X-34 will demonstrate the ability to fly through inclement weather, land horizontally at a designated site, and have a rapid turn-around capability. A series of wind tunnel tests on scaled models was conducted in four facilities at the NASA Langley Research Center to determine the aerodynamic characteristics of the X-34. Analysis of these test results revealed that longitudinal trim could be achieved throughout the design trajectory. The maximum elevon deflection required to trim was only half of that available, leaving a margin for gust alleviation and aerodynamic coefficient uncertainty. Directional control can be achieved aerodynamically except at combined high Mach numbers and high angles of attack, where reaction control jets must be used. The X-34 landing speed, between 184 and 206 knots, is within the capabilities of the gear and tires, and the vehicle has sufficient rudder authority to control the required 30-knot crosswind.

Brauckmann, Gregory J.↗

Incorporation of Half-Cycle Theory Into Ko Aging Theory for Aerostructural Flight-Life Predictions

The half-cycle crack growth theory was incorporated into the Ko closed-form aging theory to improve accuracy in the predictions of operational flight life of failure-critical aerostructural components. A new crack growth computer program was written for reading the maximum and minimum loads of each half-cycle from the random loading spectra for crack growth calculations and generation of in-flight crack growth curves. The unified theories were then applied to calculate the number of flights (operational life) permitted for B-52B pylon hooks and Pegasus adapter pylon hooks to carry the Hyper-X launching vehicle that air launches the X-43 Hyper-X research vehicle. A crack growth curve for each hook was generated for visual observation of the crack growth behavior during the entire air-launching or captive flight. It was found that taxiing and the takeoff run induced a major portion of the total crack growth per flight. The operational life theory presented can be applied to estimate the service life of any failure-critical structural components.

Ko, William L.↗