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NASA NTRS2012

Determining Damping Trends from a Range of Cable Harness Assemblies on a Launch Vehicle Panel from Test Measurements

The team of authors at Marshall Space Flight Center (MSFC) has been investigating estimating techniques for the vibration response of launch vehicle panels excited by acoustics and/or aero-fluctuating pressures. Validation of the approaches used to estimate these environments based on ground tests of flight like hardware is of major importance to new vehicle programs. The team at MSFC has recently expanded upon the first series of ground test cases completed in December 2010. The follow on tests recently completed are intended to illustrate differences in damping that might be expected when cable harnesses are added to the configurations under test. This validation study examines the effect on vibroacoustic response resulting from the installation of cable bundles on a curved orthogrid panel. Of interest is the level of damping provided by the installation of the cable bundles and whether this damping could be potentially leveraged in launch vehicle design. The results of this test are compared with baseline acoustic response tests without cables. Damping estimates from the measured response data are made using a new software tool that employs a finite element model (FEM) of the panel in conjunction with advanced optimization techniques. This paper will report on the \damping trend differences. observed from response measurements for several different configurations of cable harnesses. The data should assist vibroacoustics engineers to make more informed damping assumptions when calculating vibration response estimates when using model based analysis approach. Achieving conservative estimates that have more flight like accuracy is desired. The paper may also assist analysts in determining how ground test data may relate to expected flight response levels. Empirical response estimates may also need to be adjusted if the measured response used as an input to the study came from a test article without flight like cable harnesses.

Smith, Andrew↗

NASA NTRS2012

Detection Performance of Upgraded "Polished Panel" Optical Receiver Concept on the Deep-Space Network's 34 Meter Research Antenna

The development and demonstration of a "polished panel" optical receiver concept on the 34 meter research antenna of the Deep Space Network (DSN) has been the subject of recent papers. This concept would enable simultaneous reception of optical and microwave signals by retaining the original shape of the main reflector for microwave reception, but with the aluminum panels polished to high reflectivity to enable focusing of optical signal energy as well. A test setup has been installed on the DSN's 34 meter research antenna at Deep Space Station 13 (DSS-13) of NASA's Goldstone Communications Complex in California, and preliminary experimental results have been obtained. This paper describes the results of our latest efforts to improve the point-spread function (PSF) generated by a custom polished panel, in an attempt to reduce the dimensions of the PSF, thus enabling more precise tracking and improved detection performance. The design of the new mechanical support structure and its operation are described, and the results quantified in terms of improvements in collected signal energy and optical communications performance, based on data obtained while tracking the planet Jupiter with the 34 meter research antenna at DSS-13.

photon-bucket receiver↗

NASA NTRS2013

Testing and Analysis Validation of a Metallic Repair Applied to a PRSEUS Tension Panel

A design and analysis of a repair concept applicable to a stiffened composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure was recently completed. The damage scenario considered was a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. Advanced modeling techniques such as mesh-independent definition of compliant fasteners and elastic-plastic material properties for metal parts were utilized in the finite element analysis supporting the design effort. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from a tension panel test conducted to validate both the repair concept and finite element analysis techniques used in the design effort. The test proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. This conclusion enables upward revision of the stress allowables that had been kept at an overly-conservative level due to concerns associated with repairability of the panels. Correlation of test data with finite element analysis results is also presented and assessed.

Przekop, Adam↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment using Design of Experiments Methodology

This experimental study seeks to quantify the impact various composite parameters have on the structural response of a composite structure in a pyroshock environment. The prediction of an aerospace structure's response to pyroshock induced loading is largely dependent on empirical databases created from collections of development and flight test data. While there is significant structural response data due to pyroshock induced loading for metallic structures, there is much less data available for composite structures. One challenge of developing a composite pyroshock response database as well as empirical prediction methods for composite structures is the large number of parameters associated with composite materials. This experimental study uses data from a test series planned using design of experiments (DOE) methods. Statistical analysis methods are then used to identify which composite material parameters most greatly influence a flat composite panel's structural response to pyroshock induced loading. The parameters considered are panel thickness, type of ply, ply orientation, and pyroshock level induced into the panel. The results of this test will aid in future large scale testing by eliminating insignificant parameters as well as aid in the development of empirical scaling methods for composite structures' response to pyroshock induced loading.

Parsons, David S.↗

NASA NTRS2013

Designing, Modeling, Constructing, and Testing a Flat Panel Speaker and Sound Diffuser for a Simulator

The goal of this project was to design, model, build, and test a flat panel speaker and frame for a spherical dome structure being made into a simulator. The simulator will be a test bed for evaluating an immersive environment for human interfaces. This project focused on the loud speakers and a sound diffuser for the dome. The rest of the team worked on an Ambisonics 3D sound system, video projection system, and multi-direction treadmill to create the most realistic scene possible. The main programs utilized in this project, were Pro-E and COMSOL. Pro-E was used for creating detailed figures for the fabrication of a frame that held a flat panel loud speaker. The loud speaker was made from a thin sheet of Plexiglas and 4 acoustic exciters. COMSOL, a multiphysics finite analysis simulator, was used to model and evaluate all stages of the loud speaker, frame, and sound diffuser. Acoustical testing measurements were utilized to create polar plots from the working prototype which were then compared to the COMSOL simulations to select the optimal design for the dome. The final goal of the project was to install the flat panel loud speaker design in addition to a sound diffuser on to the wall of the dome. After running tests in COMSOL on various speaker configurations, including a warped Plexiglas version, the optimal speaker design included a flat piece of Plexiglas with a rounded frame to match the curvature of the dome. Eight of these loud speakers will be mounted into an inch and a half of high performance acoustic insulation, or Thinsulate, that will cover the inside of the dome. The following technical paper discusses these projects and explains the engineering processes used, knowledge gained, and the projected future goals of this project

Dillon, Christina↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment Using Design of Experiments Methodology

Parsons, David S.↗

NASA NTRS2013

Characterizing the Response of Composite Panels to a Pyroshock Induced Environment Using Design of Experiments Methodology

This experimental study seeks to quantify the impact various composite parameters have on the structural response of a composite structure in a pyroshock environment. The prediction of an aerospace structure's response to shock induced loading is largely dependent on empirical databases created from collections of development and flight test data. While there is significant structural response data due to shock induced loading for metallic structures, there is much less data available for composite structures. One challenge of developing a composite shock response database as well as empirical prediction methods for composite structures is the large number of parameters associated with composite materials. This experimental study uses data from a test series planned using design of experiments (DOE) methods. Statistical analysis methods are then used to identify which composite material parameters most greatly influence a flat composite panel's structural response to shock induced loading. The parameters considered are panel thickness, type of ply, ply orientation, and shock level induced into the panel. The results of this test will aid in future large scale testing by eliminating insignificant parameters as well as aid in the development of empirical scaling methods for composite structures' response to shock induced loading.

Parsons, David↗

NASA NTRS2014

Evaluation of a Metallic Repair on a Rod-Stiffened Composite Panel

A design and analysis of a repair concept applicable to a stiffened composite panel based on the pultruded rod stitched efficient unitized structure was recently completed.The damage scenario considered was a midbay-to-midbay saw-cut with a severed stiffener, flange, and skin. Advanced modeling techniques such as mesh-independent definition of compliant fasteners and elastic-plastic material properties for metal parts were used in the finite-element analysis supporting the design effort. A bolted metallic repair was selected so that it could be easily applied in the operational environment. The present work describes results obtained from a tension panel test conducted to validate both the repair concept and finite element analysis techniques used in the design effort. The test proved that the proposed repair concept is capable of sustaining load levels that are higher than those resulting from the current working stress allowables. This conclusion enables upward revision of the stress allowables that had been kept at an overly conservative level due to concerns associated with repairability of the panels. Correlation of test data with finite-element analysis results is also presented and assessed.

Przekop, Adam↗

NASA NTRS2015

New York City Panel on Climate Change 2015 Report Introduction

The climate of the New York City metropolitan region is changing annual temperatures are hotter, heavy downpours are increasingly frequent, and the sea is rising. These trends, which are also occurring in many parts of the world, are projected to continue and even worsen in the coming decades because of higher concentrations of greenhouse gases in the atmosphere caused by burning of fossil fuels and clearing of forests for agriculture. These changing climate hazards increase the risks for the people, economy, and infrastructure of New York City. As was demonstrated by Hurricane Sandy, coastal and low-lying areas, the elderly and very young, and lower-income neighborhoods are highly vulnerable. In response to these climate challenges, New York City is developing a broad range of climate resiliency policies and programs, as well as the knowledge base to support them. The knowledge base includes up-to-date climate, sea level rise, and coastal flooding projections; a Climate Resiliency Indicators and Monitoring System; and resiliency studies. A special attribute of the New York City response to these challenges is the recognition that both the knowledge base and the programs and policies it supports need to evolve through time as climate risks unfold in the coming decades. In early September 2012, just weeks before Hurricane Sandy hit, the New York City Council passed Local Law 42 that established the New York City Panel on Climate Change (NPCC) as an ongoing body serving the City of New York. The NPCC is required to meet at least twice each calendar year to review recent scientific data on climate change and its potential impacts, and to make recommendations on climate projections for the coming decades to the end of the century. These projections are due within one year of the publication of the Intergovernmental Panel on Climate Change Assessment Reports (http:www.ipcc.ch), or at least every three years. The NPCC also advises the Mayor's Office of Sustainability and the Mayor's Office of Recovery and Resiliency (ORR) on the development of a community- or borough-level communications strategy intended to ensure that the public is informed about the findings of the panel, including the creation of a summary of the climate change projections for dissemination to city residents.

hurricanes↗

NASA NTRS2015

A Numerical Study on the Effect of Facesheet-Core Disbonds on the Buckling Load of Curved Honeycomb Sandwich Panels

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance approach for the next-generation Space Launch System heavy lift vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method. Facesheet and core nodes in a predetermined circular region were detached to simulate a disbond induced via low-speed impact between the outer mold line facesheet and honeycomb core. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. A significant change in the slope of the edge load-deflection response was used to determine the onset of global buckling and corresponding buckling load.

structural failure↗

NASA NTRS2016

Post-Buckling Analysis of Curved Honeycomb Sandwich Panels Containing Interfacial Disbonds

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance plan for the next-generation Space Launch System heavy lift launch vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method incorporating geometric nonlinearity. In a predetermined circular region, facesheet and core nodes were detached to simulate a disbond, between the outer mold line facesheet and honeycomb core, induced via low-speed impact. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements and obtain realistic stresses in the core. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. Significant changes in the slope of the edge load-deflection response were used to determine the onset of global buckling and corresponding buckling load. Finally, several studies were conducted to determine the sensitivity of the numerical predictions to refinement in the finite element mesh.

elastic buckling↗

NASA NTRS2015

Electrostatic Discharge Testing of Carbon Composite Solar Array Panels for Use in the Jovian Environment

NASA is currently considering a mission to investigate the moons of Jupiter. When designing a spacecraft for this type of mission, there are a number of engineering challenges, especially if the mission chooses to utilize solar arrays to provide the spacecraft power. In order for solar arrays to be feasible for the mission, their total mass needed to fit within the total budget for the mission, which strongly suggested the use of carbon composite facesheets on an aluminum core for the panel structure. While these composite structures are a good functional substitution for the metallic materials they replace, they present unique challenges when interacting with the harsh Jovian space environment. As a composite material, they are composed of more than one material and can show different base properties depending in differing conditions. Looking at the electrical properties, in an Earth-based environment the carbon component of the composite dominates the response of the material to external stimulus. Under these conditions, the structures strongly resembles a conductor. In the Jovian environment, with temperatures reaching 50K and under the bombardment from energetic electrons, the non-conducting pre-preg binding materials may come to the forefront and change the perceived response. Before selecting solar arrays as the baseline power source for a mission to Jupiter, the response of the carbon composites to energetic electrons while held at cryogenic temperatures needed to be determined. A series of tests were devised to exam the response of a sample solar array panel composed of an M55J carbon weave layup with an RS-3 pre-preg binder. Test coupons were fabricated and exposed to electrons ranging from 10 keV to 100 keV, at 1 nA/cm2, while being held at cryogenic temperatures. While under electron bombardment, electrical discharges were observed and recorded with the majority of discharges occurring with electron energies of 25 keV. A decrease in temperature to liquid nitrogen temperatures showed a marked increase in the magnitude of these discharges. The results indicate that dielectric discharges are primarily produced due to the presence of large regions of the non-conductive pre-preg on the surface of the carbon sheets. The frequency and magnitude of discharges decreased when layers of the pre-preg material were removed from the composite surface. These tests indicate that solar array panels may be used in the Jovian environment, but that electrostatic discharges can be expected on the carbon composite solar arrays.

Jupiter↗

NASA NTRS2018

Integrated Solar-Panel Antenna Array for CubeSats

The goal of the Integrated Solar-Panel Antenna Array for CubeSats (ISAAC) project is to design and demonstrate an effective optically transparent, high-gain, lightweight, conformal X band antenna array that is integrated with the solar panels of a CubeSat. The targeted demonstration is for a Near Earth Network (NEN) radio at X-band, but the design can be easily scaled to other network radios for higher frequencies. ISAAC is a less expensive and more flexible design for communication systems compared to a deployed dish antenna or the existing integrated solar panel antenna designs.

Baktur, Reyhan↗

NASA NTRS2019

Hypervelocity Impact Performance of 3D Printed Aluminum Panels

With the continued development of additive manufacturing methods, control over the shape of ligaments, cell regularity, and macroscopic shape can all be easily tuned. This capability allows for tailoring of component architecture and promotes potential mass savings in a space vehicle structure. Additionally, it allows one the flexibility of combining structural elements such as MMOD protection and vehicle stiffness for launch loads for an overall mass reduction. At NASA JSC this technology is being explored in many different ways with the goal being a multifunctional structural component. For this study, four different types of aluminum panels have been 3D printed for testing, three being of a body centric cubic (BCC) lattice structure core and one being kelvin cell structure core. All samples have a 5.33 cm (0.05”) nominally thick aluminum face sheet printed on the front and back side of each panel, with all core materials having a 5.08 cm (2.0”) nominal thickness (see Table 1 for test sample summary and Figures 1 – 2 for sample illustrations). These tests will evaluate the performance of 3D printed aluminum panels under hypervelocity impact (HVI) conditions. The hypervelocity impact tests are being conducted at the JSC White Sands Test Facility (WSTF) Remote Hypervelocity Test Laboratory (RHTL), located in Las Cruces, New Mexico. All tests will be conducted with a 3.4mm Al 2017-T4 sphere at 6.8 km/s impacting at 0° to surface normal (i.e., impacting with no obliquity). Each sample will be trapped between two metal frames, with gasket material residing between the sample and frame, which will be the shipping and testing configuration for all tests. There will be an Al 2017-T4 witness plate staged 5.08 cm (2.0”) from each sample to capture signature of debris, if the rear face sheet of the sample were to perforate from the HVI test event.

Davis, B. A.↗

NASA NTRSDate not supplied

Testing of a Multi-Stringer Post-Buckled Panel with Incremental Damage Detection

A multi-stringer panel was designed and tested to produce a failure mode of skin-stiffener delamination due to compression loading of a post-buckled skin to support the validation of high-fidelity progressive damage failure analysis modeling. The test procedure included multiple methods of data acquisition ranging from multiple strain gages, front and back digital image correlation, passive thermography, acoustic emission, and ultrasonic inspection to capture key events and damage progression prior to catastrophic failure. Detailed data showing the initial stiffness, onset of skin buckling, buckled mode shape, damage initiation load, damage propagation morphology, and peak load was captured. Two panel configurations were tested. The first had a Teflon insert placed in the interface between the skin and the stiffener flanges adjacent to the center skin bay. The second was subjected to impact damage to the skin-stiffener flange. In each case, continuously-loaded-to-failure tests were conducted first with passive thermography being used exclusively to determine key damage events. Then, incrementally loaded tests were completed where ultrasonic inspections were conducted between each increment. The amount of load applied between each increment was determined based on the in-situ damage detection provided by the passive thermography system. The results of the testing showed a complex delamination growth pattern which migrated between ply interfaces through matrix splits in the upper skin ply of the panel. The result of the testing produced very detailed data which will prove to be useful for validation of delamination growth and migration predictions from progressive damage failure analysis methods.

Jason Action↗

NASA NTRS1994

On-Orbit Thermal Performance of a Submillimeter Telescope Primary Reflector Panel

A detailed thermal analysis has been performed for a panel of a segmented primary mirror which is closest to the high side of the telescope sunshade. This panel was selected because the spatial temperature distribution was expected to be the worst. The JPL90-10 primary reflector panel configuration was investigated because of its superior figure error performance in ground-based testing.

SMILS↗

NASA NTRS2021

AIAA Ascend 2021 Conference On Demand Manufacturing of Electronics Panel Abstract

1. Session Proposal o Session Title NASA’s In Space Manufacturing and the On Demand Manufacturing of Electronics o Session Topic Primary -- Space Logistics, Autonomy, and Robotics; Secondary – Transformative Research and Technologies o Session Format: Panel Discussion. o Requested Session Duration: 60 minutes o Short Session Description: The goal of NASA’s On Demand Manufacturing of Electronics project is to develop and demonstrate the feasibility of a low-gravity, on-demand manufacturing system for flexible hybrid electronic devices on the International Space Station. This panel will feature several key collaborators and team members from the commercial sector, academia, and internal to NASA, each of which are contributing an unique and vital role to the design and implementation of this new technology system. o Extended Session Description (Please describe in detail the activity proposed, including how you intend to use the requested session duration. This session description will be provided to the reviewers for consideration and will not be displayed in the online agenda.): The session will be moderated by Curtis Hill, the Project Lead for the On Demand Manufacturing of Electronics (ODME), and he will start by giving a brief introduction to the ODME project which is working to produce a demo system for the manufacturing of electronic devices on the International Space Station. Panelists consisting of collaborators and team members to the ODME project will then give a brief (~5 min) introduction highlighting their contributions to the project, followed by time for Q&A from the audience. The panel will consist of: 1. Kenneth Church, nScrypt. nScrypt is a leader in multi-material printing with a modular system that incorporates a direct write thick film print head, a polymer fused filament fabrication print head, a laser sintering attachment, a drill head attachment for milling, and a pick and place. The system can print a layer and scan for accuracy of prints. The combination of multiple print heads and scanning allows for the on-demand production of intricate electronic components. 2. Andy Kurk, TechShot, Inc. Techshot, Inc. has collaborated extensively with NASA on the in space manufacturing of both printed electronics and fused metal materials. They are currently working to develop and integrate a test system for printed electronics, and a flight demonstration on the International Space Station is anticipated in 2024. 3. Ed Hendricks, NextFlex. NextFlex has the goal of advancing the manufacture of flexible hybrid electronics in the U.S. They are working with ODME on the development of AstroSense, an additively manufactured, wireless, flexible, and wearable health sensor. 4. Dr. Pradeep Lall, Auburn University. Professor Lall is the MacFarlane Endowed Distinguished Professor in the Department of Mechanical Engineering with a Courtesy Joint Appointment in the Department of Electrical and Computer Engineering and a Courtesy Joint Appointment in the Department of Finance. He is collaborating with NASA’s ODME project to develop multilayer printable devices and to develop techniques to test the quality of a printed electronic device. 5. Dr. Wei Gao, California Institute of Technology. Professor Gao is an Assistant Professor of Medical Engineering. His group is developing fully printed, flexible, and wearable biosensors for crew health monitoring in collaboration with NASA’s ODME project. In addition, they are working on using sweat to power biofuel cells for wearable, self-powered electronic devices. 6. Beth Paquette, NASA Goddard. The ODME branch at NASA Goddard is spearheading a sounding rocket flight demo to prove the capability of a printed electronic device with multiple sensors. In addition, they focus on thin film and flexible energy storage evaluations. o Session Goal(s)/Outcome(s): Please list the learning objectives and/or tangible outcomes (technical paper or other publication). The goal of this session is to highlight the internal and collaborative efforts of NASA’s On Demand Manufacturing of Electronics project to develop a system for printing electronics that will be tested on the International Space Station in 2024. In addition, the session with facilitate discussion with the community on the state of the art of printable electronics, current challenges, and new avenues for collaboration.

Jennifer McInnis Jones↗

NASA NTRSDate not supplied

A Flat-Panel 8x8 Sequentially Rotated Wideband Microstrip Patch Phased Array Antenna for K/Ka-band 6U CubeSat Communications Applications

Flat-panel electronically-scanned phased arrays have recently become a mainstream technology in the areas of radar and satellite applications, particularly due to their low profile and not having to steer the beams mechanically, both of which helps in realizing a lightweight phased array solution that also occupies a smaller volume. Typically for satellite applications, circularly polarized element radiators are often employed in order to deal with the signal fading problem. In this project, the main objective was to design a flat-panel phased array solution for 6U CubeSat communication applications. As for the required specifications, the array should have two operating bands: 22.55–23.55 GHz and 25.5–27.5 GHz, which span part of the K and Ka bands. For both these bands, the panel should be able to radiate dual circular polarization, in both transmit and receive modes, and with a stable gain performance. Since the individual bands are very closely spaced, it was realized that a single wideband design would be a better solution than a closely spaced dual-band design. Thus, a stacked microstrip patch configuration was selected for the element radiator design, which is known to be wideband. Now, it is rather difficult to realize both wide impedance and axial ratio bandwidths simultaneously, and at high frequencies, without complicating the element stacked patch design.. As a result, a sequential rotation technique wasemployed to significantly improves the axial ratio bandwidth and circular polarization purity of an array, all the while improving the pattern symmetry (P. S. Hall, “Application of Sequential Feeding to Wide Bandwidth, Circularly Polarised Microstrip Patch Arrays,” IEE Proc. H (Microw., Antennas Propag.), vol. 136, no. 5, pp. 390–398, Oct. 1989). The designed element radiator is a circularly-polarized probe-fed stacked patch antenna, which has a 10-dB matching bandwidth of 22.3– 30 GHz, with only a 5.14% axial ratio bandwidth around the center frequency of the required band, i.e., ~25 GHz. However, the resulting array demonstrates a very low axial ratio (≪ 3 dB) over the entire bandwidth, due to the application of the sequential rotation technique. The 8×8 array was able to scan up to ±51° and ±40° at frequencies 23.05 GHz and 26.5 GHz (center frequencies of the lower and upper bands), respectively, while maintaining a ≤ 3 dB axial ratio and a ≤ 3 dB gain drop from the corresponding peak broadside value at both the principle and the diagonal radiation planes. The designed layout for the 8×8 phased array prototype is shown in Fig. 1, which is currently undergoing fabrication and RF assembly. The antenna will be tested in the far-field anechoic chambers of the Antenna and Microwave Laboratory (AML) at San Diego State University and at NASA Glenn Research Center (GRC).

5G↗