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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System↗
NASA NTRS2005

Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗
NASA NTRS2020

Modal Test of the NASA Mobile Launcher at Kennedy Space Center

The NASA Mobile Launcher (ML), located at Kennedy Space Center (KSC), has recently been modified to support the launch of the new NASA Space Launch System (SLS). The ML is a massive structure—consisting of a 345-foot tall tower attached to a two-story base, weighing approximately 10.5 million pounds—that will secure the SLS vehicle as it rolls to the launch pad on a Crawler Transporter, as well as provide a launch platform at the pad. The ML will also provide the boundary condition for an upcoming SLS Integrated Modal Test (IMT). To help correlate the ML math models prior to this modal test, and allow focus to remain on updating SLS vehicle models during the IMT, a ML-only experimental modal test was performed in June 2019. Excitation of the tower and platform was provided by five uniquely-designed test fixtures, each enclosing a hydraulic shaker, capable of exerting thousands of pounds of force into the structure. For modes not that were not sufficiently excited by the test fixture shakers, a specially-designed mobile drop tower provided impact excitation at additional locations of interest. The response of the ML was measured with a total of 361 accelerometers. Following the random vibration, sine sweep vibration, and modal impact testing, frequency response functions were calculated and modes were extracted for three different configurations of the ML in 0 Hz to 12 Hz frequency range. This paper will provide a case study in performing modal tests on large structures by discussing the Mobile Launcher, the test strategy, an overview of the test results, and recommendations for meeting a tight test schedule for a large-scale modal test.

Hydraulic shakers↗
NASA NTRS2003

High-Frequency Testing of Composite Fan Vanes With Erosion-Resistant Coating Conducted

The mechanical integrity of hard, erosion-resistant coatings were tested using the Structural Dynamics Laboratory at the NASA Glenn Research Center. Under the guidance of Structural Mechanics and Dynamics Branch personnel, fixturing and test procedures were developed at Glenn to simulate engine vibratory conditions on coated polymer-matrix- composite bypass vanes using a slip table in the Structural Dynamics Laboratory. Results from the high-frequency mechanical bench testing, along with concurrent erosion testing of coupons and vanes, provided sufficient confidence to engine-endurance test similarly coated vane segments. The knowledge gained from this program will be applied to the development of oxidation- and erosion-resistant coatings for polymer matrix composite blades and vanes in future advanced turbine engines. Fan bypass vanes from the AE3007 (Rolls Royce America, Indianapolis, IN) gas turbine engine were coated by Engelhard (Windsor, CT) with compliant bond coatings and hard ceramic coatings. The coatings were developed collaboratively by Glenn and Allison Advanced Development Corporation (AADC)/Rolls Royce America through research sponsored by the High-Temperature Engine Materials Technology Project (HITEMP) and the Higher Operating Temperature Propulsion Components (HOTPC) project. High-cycle fatigue was performed through high-frequency vibratory testing on a shaker table. Vane resonant frequency modes were surveyed from 50 to 3000 Hz at input loads from 1g to 55g on both uncoated production vanes and vanes with the erosion-resistant coating. Vanes were instrumented with both lightweight accelerometers and strain gauges to establish resonance, mode shape, and strain amplitudes. Two high-frequency dwell conditions were chosen to excite two strain levels: one approaching the vane's maximum allowable design strain and another near the expected maximum strain during engine operation. Six specimens were tested per dwell condition. Pretest and posttest inspections were performed optically at up to 60 magnification and using a fluorescent-dye penetrant. Accumulation of 10 million cycles at a strain amplitude of two to three times that expected in the engine (approximately 670 Hz and 20g) led to the development of multiple cracks in the coating that were only detectable using fluorescent-dye penetrant inspection. Cracks were prevalent on the trailing edge and on the convex side of the midsection. No cracking or spalling was evident using standard optical inspection at up to 60 magnification. Further inspection may reveal whether these fine cracks penetrated the coating or were strictly on the surface. The dwell condition that simulated actual engine conditions produced no obvious surface flaws even after up to 80 million cycles had been accumulated at strain amplitudes produced at approximately 1500 Hz and 45g.

Bowman, Cheryl L.↗
DOE OSTI2020

TRUST Testing Procedure Documentation

The TRUST testbed was designed and fabricated to conduct vibration testing and validate the behavior of hyper-elastic foams in a pre-loaded condition. The main goals of this testbed design were to ensure symmetry, proper instrumentation alignment and mounting, simplified geometry to make the data analysis validation process more straightforward, and to apply and monitor the applied pre-load. Based off of the test parameters, a shaker system was purchased. The baseplate was designed to mount directly to the bolt holes provided on the top of the shaker table. It was determined that the specimens will be cylindrical and vary in thickness from 2-10mm. The baseplate riser, center-mass, and testbed cap were designed to be cylindrical to make alignment about the center axis more straightforward. It was determined to fabricate the parts previously mentioned using Aluminum 6061-T6 due to its stiffness in order to reduce the likelihood of the stiff material impacting the data being collected for the foam specimens. The design concept used to apply the pre-load to the testbed was a through bolt/nut configuration. A through hole was included in each piece of the testbed, specimens, and instrumentation large enough to allow for 1/8” clearance between the through bolt and each of these pieces. This was imperative to avoid causing friction and complicating the validation model. A load cell was then purchased and used to measure the pre-load being applied to the testbed. It was also required to collect data for 3 axes at 3 different locations 120° apart on the center-mass. This configuration was required to be placed on the cylindrical face and toward the top and bottom of the center-mass. Slots were milled out in the middle of each sensor block with tight tolerances for mounting each of the accelerometers at 120° apart. This same approach was taken to mount 2 accelerometers on the baseplate at 180° apart. Holes were milled out of the corners of each accelerometer mounting slot to relieve the corner and allow for a flat edge at the back of each slot. Sensor blocks were mounted into the center-mass using 6-32 bolts at the required locations. This initial testbed design was fabricated at the TA53 machine shop.

42 ENGINEERING↗
NASA NTRS2018

Comparing Free-Free and Shaker Table Model Correlation Methods Using Jim Beam

Finite element model correlation as part of a spacecraft program has always been a challenge. For any NASA mission, the coupled system response of the spacecraft and launch vehicle can be determined analytically through a Coupled Loads Analysis (CLA), as it is not possible to test the spacecraft and launch vehicle coupled system before launch. The value of the CLA is highly dependent on the accuracy of the frequencies and mode shapes extracted from the spacecraft model. NASA standards require the spacecraft model used in the final Verification Loads Cycle to be correlated by either a modal test or by comparison of the model with Frequency Response Functions (FRFs) obtained during the environmental qualification test. Due to budgetary and time constraints, most programs opt to correlate the spacecraft dynamic model during the environmental qualification test, conducted on a large shaker table. For any model correlation effort, the key has always been finding a proper definition of the boundary conditions. This paper is a correlation case study to investigate the difference in responses of a simple structure using a free-free boundary, a fixed boundary on the shaker table, and a base-drive vibration test, all using identical instrumentation. The NAVCON Jim Beam test structure, featured in the IMAC round robin modal test of 2009, was selected as a simple, well recognized and well characterized structure to conduct this investigation. First, a free-free impact modal test of the Jim Beam was done as an experimental control. Second, the Jim Beam was mounted to a large 20,000 lbf shaker, and an impact modal test in this fixed configuration was conducted. Lastly, a vibration test of the Jim Beam was conducted on the shaker table. The free-free impact test, the fixed impact test, and the base-drive test were used to assess the effect of the shaker modes, evaluate the validity of fixed-base modeling assumptions, and compare final model correlation results between these boundary conditions.

Modal Test↗
DOE OSTI2023

Electrodynamic Shaker Capability Estimation Through Experimental Dynamic Substructuring [Thesis]

Electrodynamic shaker systems are an essential tool in shock and vibration testing of dynamic environments. However, the specific performance capability of these systems is difficult to characterize. The dynamics of the shaker itself, the device under test and the specific test configuration used all couple to create a dynamic response unique to each test. Poorly predicted limitations in shaker capability affect the ability to achieve test specifications, delay testing schedules, and create difficulties for choosing test equipment. To predict shaker capability for a specific test configuration prior to setup, a lumped parameter model of the shaker system and a modal model of a device under test was developed. These models were then analytically coupled using LaGrange multiplier frequency based substructuring to estimate their coupled frequency response functions. The coupled frequency response functions were used to predict electrical inputs required to meet a given test specification. These input requirements were finally compared to a validation test using the specification and setup. Input requirements estimated using the substructuring estimated frequency response functions showed significant error. However, results using an ideal frequency response function showed very little error. These results indicate that with a better method of experimental dynamic substructuring employed it would be possible to accurately predict shaker capability for a given test configuration prior to setup.

42 ENGINEERING↗
NASA NTRSDate not supplied

Challenges Associated with In-Situ Calibration of Load Cells in Force Limited Vibration Testing

The difference in mounting configuration between flight and test can significantly impact the effectiveness of the test in environmental vibration testing. Many tests are performed with large electrodynamic shakers, which utilize interfaces that seek to replicate a fixed base, such as slip tables and head expanders. This fixed base configuration is rarely seen in flight configurations; rather a more realistic configuration would include a flexible mounting structure with its own compliance and dynamics. This causes significant over and under tests in various frequency bands depending on the differences between the test article and fixture dynamics. The traditional way of avoiding these high loads is to limit the acceleration responses at multiple locations on the test article. However, the effectiveness of this approach is highly dependent upon the validity of the test article’s analytical in order to derive accurate acceleration response limit specifications. Also this technique requires limiting the acceleration responses at many locations throughout the test article, which may not be implementable due to such things as access and cleanliness issues An improved environmental vibration testing technique known as force limiting incorporates measurements of the forces between the test article and shaker system interface and limiting them to a specification that more accurately replicates the interface impedance of the structure the test article will be mounted to in flight. In effect this transforms the high mechanical impedance at the test article to shaker interface to more closely match the mechanical impedance of the flight interface, which avoids producing the unrealistically high interface loads. Typically force gauges or load cells are used to measure these interface forces. However, utilizing load cells can present a multitude of challenges depending upon such things as their installation method, geometric layout, and test fixture setup. Regardless, it is extremely important to perform an in-situ calibration of the load cells prior to vibration testing at any significant levels. This paper will discuss the challenges associated with utilizing load cells during the NASA Evolutionary Xenon Thruster – Commercial (NEXT-C) gridded ion thruster proto-flight vibration test performed at the NASA Glenn Research Center’s Structural Dynamics Laboratory.

Kenneth J Pederson↗
NASA NTRSDate not supplied

Challenges Associated with In-Situ Calibration of Load Cells in Force Limited Vibration Testing

The difference in mounting configuration between flight and test can significantly impact the effectiveness of the test in environmental vibration testing. Many tests are performed with large electrodynamic shakers, which utilize interfaces that seek to replicate a fixed base, such as slip tables and head expanders. This fixed base configuration is rarely seen in flight configurations; rather a more realistic configuration would include a flexible mounting structure with its own compliance and dynamics. This causes significant over and under tests in various frequency bands depending on the differences between the test article and fixture dynamics. The traditional way of avoiding these high loads is to limit the acceleration responses at multiple locations on the test article. However, the effectiveness of this approach is highly dependent upon the validity of the test article’s analytical in order to derive accurate acceleration response limit specifications. Also this technique requires limiting the acceleration responses at many locations throughout the test article, which may not be implementable due to such things as access and cleanliness issues An improved environmental vibration testing technique known as force limiting incorporates measurements of the forces between the test article and shaker system interface and limiting them to a specification that more accurately replicates the interface impedance of the structure the test article will be mounted to in flight. In effect this transforms the high mechanical impedance at the test article to shaker interface to more closely match the mechanical impedance of the flight interface, which avoids producing the unrealistically high interface loads. Typically force gauges or load cells are used to measure these interface forces. However, utilizing load cells can present a multitude of challenges depending upon such things as their installation method, geometric layout, and test fixture setup. Regardless, it is extremely important to perform an in-situ calibration of the load cells prior to vibration testing at any significant levels. This paper will discuss the challenges associated with utilizing load cells during the NASA Evolutionary Xenon Thruster – Commercial (NEXT-C) gridded ion thruster proto-flight vibration test performed at the NASA Glenn Research Center’s Structural Dynamics Laboratory.

K. J. Pederson↗
DOE OSTI2025

Automated shaker placement and regularized input estimation for MIMO testing.

Multi-input, multi-output (MIMO) testing is used in component qualification to reproduce operational responses in the laboratory. It is often preferred to single-input and base-shake testing because of the potential for equivalent or better tests using smaller actuators and shorter test suites. Given a target response, two key steps in MIMO test design are selecting actuator locations and solving for input loads. Actuator locations are often manually selected using expert judgment. If an automatic method is used, locations are usually determined by simulating the vibration control problem and minimizing a combination of the input energy and control residuals. To select a configuration, the relative importance of input energy and residuals must be specified. Specifying relative weights is, in general, a manual and subjective process. This paper develops an objective function that compares actuator configurations based on control accuracy and required input energy without any manual parameter tuning. The objective function uses an optimally selected tradeoff parameter for each candidate configuration. To choose actuator locations using the new objective function, a pivoting algorithm for integer programming problems is developed. Starting with an initial configuration (such as the one generated by a greedy algorithm), the pivoting algorithm guarantees an objective function decrease in each iteration until convergence is reached. In a simulation featuring a structure excited by a diffuse acoustic field, electrodynamic shaker locations and regularized inputs are solved for without any analyst-specified parameters. Simulations are performed in MIMO configurations where the number of target responses is less than, equal to, and greater than the number of actuators.

Multi-input multi-output↗
NASA NTRS1990

Three-dimensional random vibration testing definition and simulation

An approach is presented for the definition of 3D random vibration test requirements for multiaxial shaker systems. In particular, it is shown that, by utilizing coherence functions for cross-correlation effects, test requirements can be defined in a simple way and provide a more realistic environmental simulation. The method is applicable to the simulation of all field environments and can be similarly employed to develop laboratory test requirements based on field data. Example problems are presented to demonstrate the approach.

Chang, Kurng Y.↗
NASA NTRS2015

Coupled Facility/Payload Vibration Modeling Improvements

A major phase of aerospace hardware verification is vibration testing. The standard approach for such testing is to use a shaker to induce loads into the payload. In preparation for vibration testing at NASA/GSFC there is an analysis to assess the responses of the payload. A new method of modeling the test is presented that takes into account dynamic interactions between the facility and the payload. This dynamic interaction has affected testing in the past, but been ignored or adjusted for during testing. By modeling the combination of the facility and test article (payload) it is possible to improve the prediction of hardware responses. Many aerospace test facilities work in similar way to those at NASA Goddard Space Flight Center. Lessons learned here should be applicable to other test facilities with similar setups.

Finite Element Analysis↗