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NASA NTRS2007

Structural Analysis Methods for Structural Health Management of Future Aerospace Vehicles

Two finite element based computational methods, Smoothing Element Analysis (SEA) and the inverse Finite Element Method (iFEM), are reviewed, and examples of their use for structural health monitoring are discussed. Due to their versatility, robustness, and computational efficiency, the methods are well suited for real-time structural health monitoring of future space vehicles, large space structures, and habitats. The methods may be effectively employed to enable real-time processing of sensing information, specifically for identifying three-dimensional deformed structural shapes as well as the internal loads. In addition, they may be used in conjunction with evolutionary algorithms to design optimally distributed sensors. These computational tools have demonstrated substantial promise for utilization in future Structural Health Management (SHM) systems.

Tessler, Alexander↗

NASA NTRS2007

Characterizing the Superconducting-to-Normal Transition in Mo/Au Transition-Edge Sensor Bilayers

We are developing arrays of Mo/Au bilayer transition-edge sensors (TES's) for applications in future X-ray astronomy missions such as NASA's Constellation-X. The physical properties of the superconducting-to-normal transition in our TES bilayers, while often reproducible and characterized, are not well understood. The addition of normal metal features on top of the bilayer are found to change the shape and temperature of the transition, and they typically reduce the unexplained 'excess' noise. In order to understand and potentially optimize the properties of the transition, we have been studying the temperature, widths and current dependence of these transitions. We report on the characterization of devices both deposited on silicon substrates and suspended on thin silicon nitride membranes. This includes key device parameters such as the logarithmic resistance sensitivity with temperature alpha, and the logarithmic resistance sensitivity with current beta, of the phase-transition. We investigate alpha and beta as a function of current, both at fixed and varying bias points in the transition. Using Ginzburg-Landau theory for the current dependence of the superconducting transition temperature, we investigate the relationship between alpha and beta and compare our measured and theoretical estimates.

Smith, Stephen J.↗

NASA NTRS2013

Design and Application of Hybrid Magnetic Field-Eddy Current Probe

The incorporation of magnetic field sensors into eddy current probes can result in novel probe designs with unique performance characteristics. One such example is a recently developed electromagnetic probe consisting of a two-channel magnetoresistive sensor with an embedded single-strand eddy current inducer. Magnetic flux leakage maps of ferrous materials are generated from the DC sensor response while high-resolution eddy current imaging is simultaneously performed at frequencies up to 5 megahertz. In this work the design and optimization of this probe will be presented, along with an application toward analysis of sensory materials with embedded ferromagnetic shape-memory alloy (FSMA) particles. The sensory material is designed to produce a paramagnetic to ferromagnetic transition in the FSMA particles under strain. Mapping of the stray magnetic field and eddy current response of the sample with the hybrid probe can thereby image locations in the structure which have experienced an overstrain condition. Numerical modeling of the probe response is performed with good agreement with experimental results.

Wincheski, Buzz↗

NASA NTRSDate not supplied

Thin-Ply: Exploration and Manufacturing with Automated Fiber Placement

Abstract Highly repeatable and nearly defect-free fabrication of composite parts is critical to the success and widespread acceptance of composite materials. Through optimization using thin-ply materials, composite parts can be manufactured to be lighter and tailored more specifically to anticipated design loads than with standard prepreg materials alone. However, defects arising from the thin-ply manufacturing process are not always similar to defects found with standard tows. These new defects warrant evaluation. At NASA Langley Research Center, the manufacturing process parameters associated with automated fiber placement (AFP), a slit tape-based composite manufacturing process, were optimized for the use of a thin-ply prepreg carbon-epoxy material. Carbon-epoxy tows with areal weights of 30 g/m2 and 70 g/m2 were used in these manufacturing trials. The AFP process parameters of heater output, compaction force, tow feed rate, and tow tension were adjusted and optimized for successful manufacturing. This article documents an exploration of thin-ply fabrication on both flat and complex-shaped surfaces. Ultimately, aerospace-quality laminates were made from the 70-g/m2 material, but imperfections in the 30-g/m2 material itself and the fact that the AFP machine was not designed for such a thin material meant that more research and trials are required to obtain flight-quality 30-g/m2 laminates.

Carbon-expoxy↗

NASA NTRSDate not supplied

Exploration and Manufacturing with Automated Fiber Placement

Highly repeatable and nearly defect-free fabrication of composite parts is critical to the success and widespread acceptance of composite materials. Through optimization using thin-ply materials, composite parts can be manufactured to be lighter and tailored more specifically to anticipated design loads than with standard prepreg materials alone. However, defects arising from the thin-ply manufacturing process are not always similar to defects found with standard tows. These new defects warrant evaluation. At NASA Langley Research Center, the manufacturing process parameters associated with automated fiber placement (AFP), a slit tape-based composite manufacturing process, were optimized for the use of a thin-ply prepreg carbon-epoxy material. Carbon-epoxy tows with areal weights of 30 g/m2 and 70 g/m2 were used in these manufacturing trials. The AFP process parameters of heater output, compaction force, tow feed rate, and tow tension were adjusted and optimized for successful manufacturing. This article documents an exploration of thin-ply fabrication on both flat and complex-shaped surfaces. Ultimately, aerospace-quality laminates were made from the 70-g/m2 material, but imperfections in the 30-g/m2 material itself and the fact that the AFP machine was not designed for such a thin material meant that more research and trials are required to obtain flight-quality 30-g/m2 laminates.

carbon-epoxy↗

NASA NTRSDate not supplied

Tessellation and Numerical Simulation of the in-Space Assembled Telescope (iSAT) Reflector

A novel tessellation method has been developed to allow the use of uniform truss modules to form curved or doubly curved surfaces. To illustrate the method, the structural support for the doubly curved in-Space Assembled Telescope primary reflector is developed. The method intentionally leaves gaps at the nodes between identical connecting modules; the gaps are relatively small, on the order of 0.5% of the lattice characteristic cell size. Uniquely shaped nodal connectors called multi-nuts are generated to fill in the nodal gaps and connect adjacent modules. With optimization techniques, the size of these nodal gaps can be minimized to thereby minimize the incurred structural efficiency losses. Finite element analyses of the primary reflector were performed, and the structural efficiency losses amounted to a natural frequency reduction of 5%. The benefits of having uniform truss modules outweigh the structural penalties as it will greatly simplify assembly and lower manufacturing costs.

Tessellation↗

NASA NTRSDate not supplied

Tessellation and Numerical Simulation of the in-Space Assembled Telescope (iSAT) Reflector

Tessellation↗

NASA NTRS1999

A Neural Network Aero Design System for Advanced Turbo-Engines

An inverse design method calculates the blade shape that produces a prescribed input pressure distribution. By controlling this input pressure distribution the aerodynamic design objectives can easily be met. Because of the intrinsic relationship between pressure distribution and airfoil physical properties, a Neural Network can be trained to choose the optimal pressure distribution that would meet a set of physical requirements. Neural network systems have been attempted in the context of direct design methods. From properties ascribed to a set of blades the neural network is trained to infer the properties of an 'interpolated' blade shape. The problem is that, especially in transonic regimes where we deal with intrinsically non linear and ill posed problems, small perturbations of the blade shape can produce very large variations of the flow parameters. It is very unlikely that, under these circumstances, a neural network will be able to find the proper solution. The unique situation in the present method is that the neural network can be trained to extract the required input pressure distribution from a database of pressure distributions while the inverse method will still compute the exact blade shape that corresponds to this 'interpolated' input pressure distribution. In other words, the interpolation process is transferred to a smoother problem, namely, finding what pressure distribution would produce the required flow conditions and, once this is done, the inverse method will compute the exact solution for this problem. The use of neural network is, in this context, highly related to the use of proper optimization techniques. The optimization is used essentially as an automation procedure to force the input pressure distributions to achieve the required aero and structural design parameters. A multilayered feed forward network with back-propagation is used to train the system for pattern association and classification.

Sanz, Jose M.↗

NASA NTRS2020

Multiple Shaker Placement for Ground Vibration Test of X-59 Aircraft Using Topology Optimization

A multiple shaker placement methodology is developed and tested using a topology optimization technique. Current multiple shaker placement methodology requires optimum accelerometer placement and optimum single-shaker placement techniques. The proposed methodology is tested using a finite element model of the X-59 Low Boom Flight Demonstrator aircraft. The effective independence and the driving point acceleration transfer function (DPATF) methods are used for the accelerometer placement study. In this study, four shakers are used to excite each mode more effectively during the ground vibration test; all the modes of interest thus are separated into four groups. Each shaker takes care of a separate group of modes. Grouping the modes of interest is performed utilizing topology optimization. The number of modes for each group therefore will be automatically decided during grouping. For each group of modes, perform the following two steps to determine optimal location of four shakers: 1) At each accelerometer location, compare the magnitude of DPATF values at natural frequencies, select the minimum value, and make a vector with these minimum values of the DPATF magnitudes for each group; and 2) Select the degrees of freedom corresponding to the maximum value of this vector. The objective function value is the maximum value of the vector with minimum value of the magnitude of the superposed acceleration transfer function. This objective function value is maximized by changing the modes for each group. Forty accelerometers are enough to have good correlation between mode shapes obtained from the reduced order model and the simulated ground vibration test.

Optimization Analysis↗

NASA NTRS2009

Reliability-Based Design Optimization of a Composite Airframe Component

A stochastic design optimization methodology (SDO) has been developed to design components of an airframe structure that can be made of metallic and composite materials. The design is obtained as a function of the risk level, or reliability, p. The design method treats uncertainties in load, strength, and material properties as distribution functions, which are defined with mean values and standard deviations. A design constraint or a failure mode is specified as a function of reliability p. Solution to stochastic optimization yields the weight of a structure as a function of reliability p. Optimum weight versus reliability p traced out an inverted-S-shaped graph. The center of the inverted-S graph corresponded to 50 percent (p = 0.5) probability of success. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure that corresponds to unity for reliability p (or p = 1). Weight can be reduced to a small value for the most failure-prone design with a reliability that approaches zero (p = 0). Reliability can be changed for different components of an airframe structure. For example, the landing gear can be designed for a very high reliability, whereas it can be reduced to a small extent for a raked wingtip. The SDO capability is obtained by combining three codes: (1) The MSC/Nastran code was the deterministic analysis tool, (2) The fast probabilistic integrator, or the FPI module of the NESSUS software, was the probabilistic calculator, and (3) NASA Glenn Research Center s optimization testbed CometBoards became the optimizer. The SDO capability requires a finite element structural model, a material model, a load model, and a design model. The stochastic optimization concept is illustrated considering an academic example and a real-life raked wingtip structure of the Boeing 767-400 extended range airliner made of metallic and composite materials.

Patnaik, Surya N.↗

NASA NTRS1985

Disturbance-accommodating tracking maneuvers of flexible spacecraft

In this paper the problem of maneuvering a flexible spacecraft through a large angle is considered, where the disturbance-accommodating feedback control tracks a desired output state. The desired output state is provided from an open-loop solution for the linear system model. The components of the disturbance vector are assumed to be represented in terms of Fourier series. Closed-form solutions are provided for the Ricati, prefilter, state trajectory, and residual state trajectory equations which define the optimal control. Example maneuvers are presented where control-rate penalties have been included in the performance index for frequency-shaping, in order to smooth both the open- and closed-loop control commands.

Turner, J. D.↗

NASA NTRS1993

Trajectory optimization for the national aerospace plane

During the past six months the research objectives outlined in the last semi-annual report were accomplished. Specifically, these are: three-dimensional (3-D) fuel-optimal ascent trajectory of the aerospace plane and the effects of thrust vectoring control (TVC) on the fuel consumption and trajectory shaping were investigated; the maximum abort landing area (footprint) was studied; preliminary assessment of simultaneous design of the ascent trajectory and the vehicle configuration for the aerospace plane was also conducted. The work accomplished in the reporting period is summarized.

Lu, Ping↗

NASA NTRS2000

Improving Jet Reactor Configuration for Production of Carbon Nanotubes

The jet mixing reactor has been proposed for the industrial production of fullerene carbon nanotubes. Here we study the flowfield of this reactor using the SIMPLER algorithm. Hot peripheral jets are used to enhance heating of the central jet by mixing with the ambiance of reactor. Numerous configurations of peripheral jets with various number of jets, distance between nozzles, angles between the central jet and a peripheral jets, and twisted configuration of nozzles are considered. Unlike the previous studies of jet mixing, the optimal configuration of peripheral jets produces strong non-uniformity of the central jet in a cross-section. The geometrical shape of reactor is designed to obtain a uniform temperature of a catalyst.

Povitsky, Alex↗

NASA NTRS2014

Extravehicular Activity Asteroid Exploration and Sample Collection Capability

One of the challenging primary objectives associated with NASA's Asteroid Redirect Crewed Mission (ARCM) is to demonstrate deep space Extravehicular Activity (EVA) and tools and to obtain asteroid samples to return to Earth for further study. Prior Shuttle and International Space Station (ISS) spacewalks have benefited from engineered EVA interfaces which have been designed and manufactured on Earth. Rigid structurally mounted handrails, and tools with customized interfaces and restraints optimize EVA performance. For ARCM, EVA complexity increases due to the uncertainty of the asteroid properties. The variability of rock size, shape and composition, as well as behavior of the asteroid capture mechanism will complicate EVA translation, tool restraint, and body stabilization. The unknown asteroid hardness and brittleness will complicate tool use. The rock surface will introduce added safety concerns for cut gloves and debris control. Feasible solutions to meet ARCM EVA objectives were identified using experience gained during Apollo, Shuttle, and ISS EVAs, terrestrial mountaineering practices, NASA Extreme Environment Mission Operations (NEEMO) 16 mission, and during Neutral Buoyancy Laboratory testing in the Modified Advanced Crew Escape Suit (MACES) suit. This paper will summarize the overall operational concepts for conducting EVAs for the ARCM mission including translation paths and body restraint methods, potential tools used to extract the samples, design implications for the Asteroid Redirect Vehicle (ARV) for EVA, and the results of early development testing of potential EVA tasks.

Sipila, Stephanie A.↗

NASA NTRS2014

Extravehicular Activity Asteroid Exploration and Sample Collection Capability

Sipila, Stephanie A.↗

NASA NTRS2015

Main Oxidizer Valve Design

A developmental Main Oxidizer Valve (MOV) was designed by NASA-MSFC using additive manufacturing processes. The MOV is a pneumatically actuated poppet valve to control the flow of liquid oxygen to an engine's injector. A compression spring is used to return the valve to the closed state when pneumatic pressure is removed from the valve. The valve internal parts are cylindrical in shape, which lends itself to traditional lathe and milling operations. However, the valve body represents a complicated shape and contains the majority of the mass of the valve. Additive manufacturing techniques were used to produce a part that optimized mass and allowed for design features not practical with traditional machining processes.

Addona, Brad↗

NASA NTRS2016

Inlet Trade Study for a Low-Boom Aircraft Demonstrator

Propulsion integration for low-boom supersonic aircraft requires careful inlet selection, placement, and tailoring to achieve acceptable propulsive and aerodynamic performance, without compromising vehicle sonic boom loudness levels. In this investigation, an inward-turning streamline-traced and axisymmetric spike inlet are designed and independently installed on a conceptual low-boom supersonic demonstrator aircraft. The airframe was pre-shaped to achieve a target ground under-track loudness of 76.4 PLdB at cruise using an adjoint-based design optimization process. Aircraft and inlet performance characteristics were obtained by solution of the steady-state Reynolds-averaged Navier-Stokes equations. Isolated cruise inlet performance including total pressure recovery and distortion were computed and compared against installed inlet performance metrics. Evaluation of vehicle near-field pressure signatures, along with under- and off-track propagated loudness levels is also reported. Results indicate the integrated axisymmetric spike design offers higher inlet pressure recovery, lower fan distortion, and reduced sonic boom. The vehicle with streamline-traced inlet exhibits lower external wave drag, which translates to a higher lift-to-drag ratio and increased range capability.

engine airframe integration↗

NASA NTRS2014

Quantification of In-flight Physical Changes: Anthropometry and Neutral Body Posture

Currently, NASA does not have sufficient in-flight anthropometric data gathered to assess the impact of physical body shape and size changes on suit sizing. For developing future planetary and reduced gravity suits, NASA needs to quantify the impacts of microgravity on anthropometry, body posture, and neutral body postures (NBP) to ensure optimal crew performance, fit, and comfort. To obtain these impacts, anthropometric data, circumference, length, height, breadth, and depth for body segments (i.e. chest, waist, bicep, thigh, calf) from astronauts for pre, in-, and postflight conditions needs to be collected. Once this data has been collected, a comparison between pre, in-, and postflight anthropometric values will be analyzed, yielding microgravity factors. The NBP will be used to determined body posture (joint angle) changes between subjects throughout the duration of a mission. Data collection, starting with Increments 37/38, is still in progress with the completion of 3 out of 12 subjects. NASA suit engineers and NASA's Extravehicular Activity (EVA) Project Office have identified that suit fit in microgravity could become an issue. It has been noted that crewmembers often need to adjust their suit sizing once they are in orbit. This adjustment could be due to microgravity effects on anthropometry and postural changes, and is necessary to ensure optimal crew performance, fit, and comfort in space. To date, the only data collected to determine the effects of microgravity on physical human changes have been during Skylab, STS-57, and a recent HRP study on seated height changes due to spinal elongation (Spinal Elongation, Master Task List [MTL] #221). The Skylab and the STS-57 studies found that there is a distinct neutral body posture (NBP) based on photographs. The still photographs showed that there is a distinguishable posture with the arms raised and the shoulder abducted; and, in addition, the knees were flexed with noticeable hip flexion and the foot plantar flexed [1,2]. This is the one standard set of body joint angles for a NBP in microgravity. A recent simulated microgravity NBP study [3] has shown an individual variability and inconsistencies in defining NBP. This variation may be influenced by spinal growth, the type of suit fit, and other potential anthropometry factors such as spinal curvature, age, and gender. The variation aspect of this essential data is required for all kinds of space device designs (e.g. suits, habitat, mobility aids, etc.). The method proposed considers the dynamic nature of body movement and will use a measurement technique to continually monitor posture and develop a probability likelihood of the natural posture and how the NBP postures are affected by anthropometry. Additionally, Skylab studies found that crewmembers experienced a stature growth of up to 3%. The data included 3 crewmembers that showed that there is a bi-phasic stature growth once the crew enters into weightlessness. However, the Spinal Elongation study identified that the crewmembers could experience about a 6% growth in seated height and a 3% stature growth, when exposed to microgravity. The results prove that not all anthropometric measurements have the same microgravity percent growth factor. For EVA and suit engineers to properly update the sizing protocol for microgravity, they need additional anthropometric data from space missions. Hence, this study is aimed to gather additional in-flight anthropometric measurements, such as length, depth, breadth, and circumference, to determine the changes to body shape and size due to microgravity effects. It is anticipated that by recording the potential changes to body shape and size, a better suit sizing protocol will be developed for ISS and other space missions. In essence, this study will help NASA quantify the impacts of microgravity on anthropometry to ensure optimal crew performance, fit, and comfort. This study will use simplistic data collection techniques, 3D laser scanning, digital still, and video data, and perform photogrammetric analyses to determine the changes that occur to the body shape, size, and NBP when exposed to a microgravity environment.

Young, K. S.↗