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At least 73 records · Page 4

Debonding characteristics of adhesively bonded woven Kevlar composites

The fatigue damage mechanism of an adhesively bonded joint between fabric reinforced composite adherends was investigated with cracked-lap-shear specimens. Two bonded systems were studied: fabric Kevlar 49/5208 epoxy adherends bonded together with either EC 3445 or FM-300 adhesive. For each bonded system, two specimen geometries were tested. In all specimens tested, fatigue damage occurred in the form of cyclic debonding; however, the woven Kevlar specimens gave significantly slower debond growth rates and higher fracture toughness than previously found in the nonwoven adherend specimens. The surfaces for the woven adherends were not smooth; rather, they had regular crests (high spots) and troughs (low spots) due to the weave pattern. Radiographs of the specimens and examination of their failure surfaces revealed that fiber bridging occurred between the crests of the two adherends in the debonded region. The observed improvements in debond growth resistance and static fracture toughness are attributed to this bridging.

Mall, S.↗

TPS In-Flight Health Monitoring Project Progress Report

Progress in the development of new thermal protection systems (TPS) is reported. New approaches use embedded lightweight, sensitive, fiber optic strain and temperature sensors within the TPS. Goals of the program are to develop and demonstrate a prototype TPS health monitoring system, develop a thermal-based damage detection algorithm, characterize limits of sensor/system performance, and develop ea methodology transferable to new designs of TPS health monitoring systems. Tasks completed during the project helped establish confidence in understanding of both test setup and the model and validated system/sensor performance in a simple TPS structure. Other progress included complete initial system testing, commencement of the algorithm development effort, generation of a damaged thermal response characteristics database, initial development of a test plan for integration testing of proven FBG sensors in simple TPS structure, and development of partnerships to apply the technology.

Kostyk, Chris↗

Hazard Analysis for Building 34 Vacuum Glove Box Assembly

One of the characteristics of an effective safety program is the recognition and control of hazards before mishaps or failures occur. Conducting potentially hazardous tests necessitates a thorough hazard analysis in order to prevent injury to personnel, and to prevent damage to facilities and equipment. The primary purpose of this hazard analysis is to define and address the potential hazards and controls associated with the Building 34 Vacuum Glove Box Assembly, and to provide the applicable team of personnel with the documented results. It is imperative that each member of the team be familiar with the hazards and controls associated with his/her particular tasks, assignments and activities while interfacing with facility test systems, equipment and hardware. In fulfillment of the stated purposes, the goal of this hazard analysis is to identify all hazards that have the potential to harm personnel, damage the facility or its test systems or equipment, test articles, Government or personal property, or the environment. This analysis may also assess the significance and risk, when applicable, of lost test objectives when substantial monetary value is involved. The hazards, causes, controls, verifications, and risk assessment codes have been documented on the hazard analysis work sheets in Appendix A of this document. The preparation and development of this report is in accordance with JPR 1700.1, "JSC Safety and Health Handbook" and JSC 17773 Rev D "Instructions for Preparation of Hazard Analysis for JSC Ground Operations".

Meginnis, Ian↗

Leveraging Gaussian Mixture Models for Detecting Anomalies in Time-Series Data

Test systems must be capable of classifying measured data as expected or anomalous in real time. Anomalous results may portend system failure, and, if undetected, may result in damage to the unit, test equipment, or potential harm to personnel. This report investigates the use of Gaussian Mixture Models (GMMs) as a clustering tool in classifying time-series data.

Wilke, Rudeger H.T. [Sandia National Laboratories ↗

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗

Durability and damage tolerance of Large Composite Primary Aircraft Structure (LCPAS)

Analysis and testing addressing the key technology areas of durability and damage tolerance were completed for wing surface panels. The wing of a fuel-efficient, 200-passenger commercial transport airplane for 1990 delivery was sized using graphite-epoxy materials. Coupons of various layups used in the wing sizing were tested in tension, compression, and spectrum fatigue with typical fastener penetrations. The compression strength after barely visible impact damage was determined from coupon and structural element tests. One current material system and one toughened system were evaluated by coupon testing. The results of the coupon and element tests were used to design three distinctly different compression panels meeting the strength, stiffness, and damage-tolerance requirements of the upper wing panels. These three concepts were tested with various amounts of damage ranging from barely visible impact to through-penetration. The results of this program provide the key technology data required to assess the durability and damage-tolerance capability or advanced composites for use in commercial aircraft wing panel structure.

Mccarty, John E.↗

Development of Low Conductivity and Ultra High Temperature Ceramic Coatings Using A High-Heat-Flux Testing Approach

The development of low conductivity, robust thermal and environmental barrier coatings requires advanced testing techniques that can accurately and effectively evaluate coating thermal conductivity and cyclic resistance at very high surface temperatures (up to 17OOOC) under large thermal gradients. In this study, a laser high-heat-flux test approach is established for evaluating advanced low conductivity, ultra-high temperature ceramic thermal and environmental barrier coatings under the NASA Ultra Efficient Engine Technology (UEET) program. The test approach emphasizes the real-time monitoring and assessment of the coating thermal conductivity: the initial conductivity rise under a steady-state high temperature thermal gradient test due to coating sintering, and the later coating conductivity reduction under a subsequent cyclic thermal gradient test due to coating cracking/delamination. The coating system is then evaluated based on the damage accumulations and failure after the combined steady-state and cyclic thermal gradient tests. The lattice and radiation thermal conductivity of advanced ceramic coatings can also be evaluated using laser heat-flux techniques. The coating external radiation resistance is assessed based on the measured specimen temperature response under a laser heated intense radiation flux source. The coating internal radiation contribution is investigated based on the measured apparent coating conductivity increases with the coating surface test temperature under large thermal gradient test conditions. Since an increased radiation contribution is observed at these very high surface test temperatures, by varying the laser heat-flux and coating average test temperature, the complex relation between the lattice and radiation conductivity as a function of surface and interface test temperature is derived.

Zhu, Dongming↗

Aquatic plants for removal of mevinphos from the aquatic environment

Fragrant waterlily (Nymphaea odorata, Ait.), joint-grass (Paspalum distichum L.), and rush (Juncus repens, Michx.) were used to evaluate the effectiveness of vascular aquatic plants in removing the insecticide mevinphos (dimethyl-1-carbomethoxy-1propen-2-yl phosphate) from waters contaminated with this chemical. The emersed aquatic plants fragrant waterlily and joint-grass removed 87 and 93 ppm of mevinphos from water test systems in less than 2 weeks without apparent damage to the plants; whereas rush, a submersed plant, removed less insecticide than the water-soil controls. Water-soil control still contained toxic levels of this insecticide, as demonstrated by fish bioassay studies, after 35 days.

Wolverton, B. C.↗

Open Circuit Resonant (SansEC) Sensor Technology for Lightning Mitigation and Damage Detection and Diagnosis for Composite Aircraft Applications

Traditional methods to protect composite aircraft from lightning strike damage rely on a conductive layer embedded on or within the surface of the aircraft composite skin. This method is effective at preventing major direct effect damage and minimizes indirect effects to aircraft systems from lightning strike attachment, but provides no additional benefit for the added parasitic weight from the conductive layer. When a known lightning strike occurs, the points of attachment and detachment on the aircraft surface are visually inspected and checked for damage by maintenance personnel to ensure continued safe flight operations. A new multi-functional lightning strike protection (LSP) method has been developed to provide aircraft lightning strike protection, damage detection and diagnosis for composite aircraft surfaces. The method incorporates a SansEC sensor array on the aircraft exterior surfaces forming a "Smart skin" surface for aircraft lightning zones certified to withstand strikes up to 100 kiloamperes peak current. SansEC sensors are open-circuit devices comprised of conductive trace spiral patterns sans (without) electrical connections. The SansEC sensor is an electromagnetic resonator having specific resonant parameters (frequency, amplitude, bandwidth & phase) which when electromagnetically coupled with a composite substrate will indicate the electrical impedance of the composite through a change in its resonant response. Any measureable shift in the resonant characteristics can be an indication of damage to the composite caused by a lightning strike or from other means. The SansEC sensor method is intended to diagnose damage for both in-situ health monitoring or ground inspections. In this paper, the theoretical mathematical framework is established for the use of open circuit sensors to perform damage detection and diagnosis on carbon fiber composites. Both computational and experimental analyses were conducted to validate this new method and system for aircraft composite damage detection and diagnosis. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. This paper also presents the shielding effectiveness along with the lightning direct effect test results from several different SansEC LSP and baseline protected and unprotected carbon fiber reinforced polymer (CFRP) test panels struck at 40 and 100 kiloamperes following a universal common practice test procedure to enable damage comparisons between SansEC LSP configurations and common practice copper mesh LSP approaches. The SansEC test panels were mounted in a LSP test bed during the lightning test. Electrical, mechanical and thermal parameters were measured during lightning attachment and are presented with post test nondestructive inspection comparisons. The paper provides correlational results between the SansEC sensors computed electric field distribution and the location of the lightning attachment on the sensor trace and visual observations showing the SansEC sensor's affinity for dispersing the lightning attachment.

Szatkowski, George N.↗

Three-Dimensional, Transgenic Cell Models to Quantify Space Genotoxic Effects

The space environment contains radiation and chemical agents known to be mutagenic and carcinogenic to humans. Additionally, microgravity is a complicating factor that may modify or synergize induced genotoxic effects. Most in vitro models fail to use human cells (making risk extrapolation to humans more difficult), overlook the dynamic effect of tissue intercellular interactions on genotoxic damage, and lack the sensitivity required to measure low-dose effects. Currently a need exists for a model test system that simulates cellular interactions present in tissue, and can be used to quantify genotoxic damage induced by low levels of radiation and chemicals, and extrapolate assessed risk to humans. A state-of-the-art, three-dimensional, multicellular tissue equivalent cell culture model will be presented. It consists of mammalian cells genetically engineered to contain multiple copies of defined target genes for genotoxic assessment,. NASA-designed bioreactors were used to coculture mammalian cells into spheroids, The cells used were human mammary epithelial cells (H184135) and Stratagene's (Austin, Texas) Big Blue(TM) Rat 2 lambda fibroblasts. The fibroblasts were genetically engineered to contain -a high-density target gene for mutagenesis (60 copies of lacl/LacZ per cell). Tissue equivalent spheroids were routinely produced by inoculation of 2 to 7 X 10(exp 5) fibroblasts with Cytodex 3 beads (150 micrometers in diameter). at a 20:1 cell:bead ratio, into 50-ml HARV bioreactors (Synthecon, Inc.). Fibroblasts were cultured for 5 days, an equivalent number of epithelial cells added, and the fibroblast/epithelial cell coculture continued for 21 days. Three-dimensional spheroids with diameters ranging from 400 to 600 micrometers were obtained. Histological and immunohistochemical Characterization revealed i) both cell types present in the spheroids, with fibroblasts located primarily in the center, surrounded by epithelial cells; ii) synthesis of extracellular matrix; and iii,, mitotic cells located throughout the spheroids. Spheroidal integrity and cell viability were retained for the 30-day test period after removal of spheroids from the bioreactor. Potential utility of this three-dimensional, transgenic model for genotoxicity was initially assessed by exposure of spheroids to 0-2 Gy neon at dose rates of 0.3 to 1.5 Gy/min (National Institute of Radiological Sciences, Chiba, Japan). Quantification of mutation at the lacl gene revealed a linear dose response for mutation induction. Limited sequencing analysis of mutant clones revealed higher frequencies of deletions and multiple base sequence changes with increasing dose. These results suggest that our three-dimensional, transgenic model is applicable to a wide variety of studies involving the quantification, identification, and characterization of genotoxicity incurred in space and on Earth. This model uniquely allows investigation of the interaction of relevant factors, namely cell-to-cell interactions and the mechanistic interaction of microgravity with radiation insults and DNA repair. Using this three-dimensional model will allow us to obtain dual genotoxic information (i.e., mutation rate plus chromosome aberration data) from the same system so that one endpoint can be used to reference the other, thereby increasing the fidelity of the data set. Moreover, the tissue-equivalent nature of the three-dimensional model provides high confidence for relevance of risk assessment, i.e., the establishment of quality factors directly applicable to the microgravity environment.

Gonda, S. R.↗

Broadband, 920-nm mirror thin film damage competition

This year’s competition proposed to survey the state-of-the-art broadband, near-IR multilayer dielectric (MLD) mirrors designed for ultra-short, pulsed laser applications. The requirements for the coatings were a minimum reflection of 99.5% at 45-degree incidence angle for S-polarization from 830 nm to 1010 nm and group delay dispersion (GDD) < ± 50 fs 2 . The participants in this effort selected the coating materials, coating design, and deposition method. Samples were damage tested at a single testing facility to enable direct comparison among the participants using a 25 ± 5 fs OPCPA laser system operating at 5 Hz. A double blind test assured sample and submitter anonymity. The damage performance results, sample rankings, details of the deposition processes, coating materials and substrate cleaning methods are shared here. We found that multilayer coatings using tantala and/or hafnia as high index materials were top performers within several coating deposition groups. Specifically, dense coatings by ion-beam sputtering (IBS), magnetron sputtering (MS), and electron-beam ion assisted deposition (e-beam IAD) exhibited highest damage initiation onset (LIDT) while e-beam coatings were low performers. In addition, damage growth onset (LDGT) was also examined and the results are reported here for all samples as this performance metric plays an important role in establishing the safe operational conditions for larger aperture, ultrashort pulsed lasers. As a result, not all coating samples in the survey met the GDD requirements stated above and associated measurements are discussed in the context of the present and past competitions focused on similar broadband, near-IR MLD coatings.

42 ENGINEERING↗

Imparting Barely Visible Impact Damage to a Stitched Composite Large-Scale Pressure Box

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a concept that was developed by The Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration, which has been a focus of the NASA Environmentally Responsible Aviation Project. The NASA-Boeing structural development for the HWB aircraft culminated in testing of the multi-bay box, which is an 80%-scale representation of the pressurized center-body section. This structure was tested in the NASA Langley Research Center Combined Loads Test System facility. As part of this testing, barely visible impact damage was imparted to the interior and exterior of the test article to demonstrate compliance with a condition representative of the requirements for Category 1 damaged composite structure as defined by the Federal Aviation Regulations. Interior impacts were imparted using an existing spring-loaded impactor, while the exterior impacts were imparted using a newly designed, gravity-driven impactor. This paper describes the impacts to the test article, and the design of the gravitydriven guided-weight impactor. The guided-weight impactor proved to be a very reliable method to impart barely visible impact damage in locations which are not easily accessible for a traditional drop-weight impactor, while at the same time having the capability to be highly configurable for use on other aircraft structures.

Lovejoy, Andrew E.↗

Lightning Protection

Lightning Technologies, Inc., Pittsfield, MA, - a spinoff company founded by president J. Anderson Plumer, a former NASA contractor employee who developed his expertise with General Electric Company's High Voltage Laboratory - was a key player in Langley Research Center's Storm Hazards Research Program. Lightning Technologies used its NASA acquired experience to develop protective measures for electronic systems and composite structures on aircraft, both of which are particularly susceptible to lightning damage. The company also provides protection design and verification testing services for complete aircraft systems or individual components. Most aircraft component manufacturers are among Lightning Technologies' clients.

Source record↗

Investigating Biological Responses to Space-like Radiation using the yeast Saccharomyces cerevisiae

As we plan crewed missions to the Moon, Mars, and beyond, it is essential to understand how persistent exposure to space radiation affects biology. Unlike on the International Space Station, where crew support and sample return are possible, experiments for long-duration missions require autonomous systems with no sample return. Human cells would be ideal biosensors, but limitations in culture methods, extended prelaunch storage, and long flight durations make it very difficult to keep human cells alive. Unlike other model systems, yeast can survive the constraints of long-duration spaceflight. Despite a billion years of evolution separating yeast from humans, we share homology in hundreds of genes important for basic cell function, including responses to DNA damage. Thus, yeast are excellent biosensors for detecting types/extent of damage induced by space radiation. BioSentinel is NASA’s latest biological CubeSat, and first interplanetary space bioscience mission. BioSentinel is manifested on Artemis 1, the first test flight of NASA’s Space Launch System, in the coming year. The BioSensor payload within BioSentinel contains two yeast strains. The wild type serves as a control for health and “normal” DNA damage repair (DDR). The rad51 deletion mutant is defective for DDR and will undergo alterations to growth and metabolism as it accumulates radiation damage. Changes in growth and metabolic activity will be measured using a 3-color LED detection system and the metabolic redox dye alamarBlue®. Preliminary tests indicate a significant change in alamarBlue response to space-like, low-dose ionizing radiation. We will discuss these findings in four parts – Introduction to biological CubeSats and the BioSentinel mission (presented by Sergio Santa Maria), preliminary responses to space-like ionizing radiation (presented here), a deeper dive into tracking metabolic changes after exposure to ionizing radiation (presented by Diana Gentry), and a look into methods for correcting flight optical data (presented by Abbey Kim). This work is funded by NASA’s Advanced Exploration Systems.

CubeSat↗

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗

Damage tolerant composite wing panels for transport aircraft

Commercial aircraft advanced composite wing surface panels were tested for durability and damage tolerance. The wing of a fuel-efficient, 200-passenger airplane for 1990 delivery was sized using grahite-epoxy materials. The damage tolerance program was structured to allow a systematic progression from material evaluations to the optimized large panel verification tests. The program included coupon testing to evaluate toughened material systems, static and fatigue tests of compression coupons with varying amounts of impact damage, element tests of three-stiffener panels to evaluate upper wing panel design concepts, and the wing structure damage environment was studied. A series of technology demonstration tests of large compression panels is performed. A repair investigation is included in the final large panel test.

Smith, Peter J.↗

Intelligent fault management for the Space Station active thermal control system

The Thermal Advanced Automation Project (TAAP) approach and architecture is described for automating the Space Station Freedom (SSF) Active Thermal Control System (ATCS). The baseline functionally and advanced automation techniques for Fault Detection, Isolation, and Recovery (FDIR) will be compared and contrasted. Advanced automation techniques such as rule-based systems and model-based reasoning should be utilized to efficiently control, monitor, and diagnose this extremely complex physical system. TAAP is developing advanced FDIR software for use on the SSF thermal control system. The goal of TAAP is to join Knowledge-Based System (KBS) technology, using a combination of rules and model-based reasoning, with conventional monitoring and control software in order to maximize autonomy of the ATCS. TAAP's predecessor was NASA's Thermal Expert System (TEXSYS) project which was the first large real-time expert system to use both extensive rules and model-based reasoning to control and perform FDIR on a large, complex physical system. TEXSYS showed that a method is needed for safely and inexpensively testing all possible faults of the ATCS, particularly those potentially damaging to the hardware, in order to develop a fully capable FDIR system. TAAP therefore includes the development of a high-fidelity simulation of the thermal control system. The simulation provides realistic, dynamic ATCS behavior and fault insertion capability for software testing without hardware related risks or expense. In addition, thermal engineers will gain greater confidence in the KBS FDIR software than was possible prior to this kind of simulation testing. The TAAP KBS will initially be a ground-based extension of the baseline ATCS monitoring and control software and could be migrated on-board as additional computation resources are made available.

Hill, Tim↗