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Space Suit Portable Life Support System Fastener and Insert Summary, Issues, and Testing Results

Fasteners are included in every assembly on the Exploration External Mobility Unity Portable Life Support System (xEMU PLSS). However, fasteners and inserts have been the cause of many issues seen on the PLSS during development; furthermore, inserts with thermoplastics are not very well understood. The materials used in the PLSS are sometimes softer and lighter weight metals or thermoplastics which require the installation of inserts to improve the interface strength. In addition, space flight requirements call out the need for an additional running/locking torque, so they do not detach in case of failure of the final torque. The xEMU PLSS has experienced various issues with fasteners and inserts, from the bolt binding in an insert or the running torque failing prematurely. A study has been completed to address the running torque life problem. This study compares the insert and locking feature combinations to determine the combination which maximizes life. The study found that using a locking patch with an insert fails after the first installation. Therefore, it is no longer recommended to use a locking patch fastener with an insert for future installments. For the bolt binding issue, inserts have been installed too deep and have caused the bolt to bind near the final threads of the inserts where the hole is not tapped deep enough. Thermoplastics, on the other end, can either use standard helical inserts or heat set inserts. Another study was performed using tangless inserts and heat inserts installed in thermoplastics to quantify the expected pull-out strength for various insert installation parameters (insert type, temperature, and pressure). This paper will review the issues and lessons learned with fasteners on the xEMU PLSS, provide results of a locking feature study, and provide results and recommended installation settings from a heat insert study.

Ryan Ogilvie↗

NASA NTRS1992

Quick-connect fasteners for assembling devices in space

A quick-connect fastener of a relatively-simple straightforward design is arranged with a tubular body adapted to be engaged against an attachment fitting in coincidental alignment with an opening in that fitting. A tubular collet having flexible finger projecting from its forward end is arranged in the fastener body to be shifted forwardly by an elongated expander member coaxially arranged within the tubular collet for advancing the collet fingers into the opening in the attachment fitting. Biasing means are arranged between the elongated expander member and a rotatable actuator which is threadedly mounted within the tubular collet so as to be rotated for urging the expander member into engagement with the collet fingers. A first coupling member is arranged on the rotatable actuator to be accessible from outside of the fastener so that a second coupling member on the distal end of a flexible shaft can be introduced into the fastener body and coupled to the first coupling member to enable a typical actuating tool coupled to the shaft outside of the fastener body to be operated for advancing the outwardly-enlarged ends of the collet fingers into the opening in the attachment fitting and thereafter rotating the actuator member to expand the fingers to that attachment fitting. Upon expansion of the collet fingers, the biasing means impose a biasing force on the expander to releasably retain the fingers in their latching positions.

Wesselski, Clarence J.↗

NASA NTRS1993

Quick-connect fasteners for assembling devices in space

A quick-connect fastener of a relatively-simple straightforward design is arranged with a tubular body adapted to be engaged against an attachment fitting in coincidental alignment with an opening in that fitting. A tubular collet having flexible fingers projecting from its forward end is arranged in the fastener body to be shifted forwardly by an elongated expander member coaxially arranged within the tubular collet for advancing the collet fingers into the opening in the attachment fitting. Biasing means are arranged between the elongated expander member and a rotatable actuator which is threadedly mounted within the tubular collet so as to be rotated for urging the expander member into engagement with the collet fingers. A first coupling member is arranged on the rotatable actuator to be accessible from outside of the fastener so that a second coupling member on the distal end of a flexible shaft can be introduced into the fastener body and coupled to the first coupling member to enable a typical actuating tool coupled to the shaft outside of the fastener body to be operated for advancing the outwardly-enlarged ends of the collet fingers into the opening in the attachment fitting and thereafter rotating the actuator member to expand the fingers within the opening for releasably latching the fastener to that attachment fitting. Upon expansion of the collet fingers, the biasing means impose a biasing force on the expander to releasably retain the fingers in their latching positions.

Evenson, Erik E.↗

NASA NTRS1997

Fastener Design Course

Richard T. Barrett, Senior Aerospace Engineer of NASA Lewis Research Center presents a comprehensive course on fastener design. A recognized expert in the field of fastener technology Mr. Barrett combines lecture, charts, illustrations with real-world experiences. Topics covered include: materials, plantings and coatings, locking methods threads, joint stiffness, rivets, inserts, nut plates, thread lubricants, design criteria, etc. A workbook accompanies the DVD.

Barrett, Richard T.↗

NASA NTRS1997

Fastener Design Course [Workbook]

Barrett, Richart T.↗

NASA NTRS1986

Quick-Connect Heavy-Duty Fastener

Attaching device combines fast connection and disconnection with high strength. T-shaped stud engages groove in receptacle after one-quarter turn. Further turning tightens nut on receptacle. Like quarter-turn attaching devices, connected and disconnected quickly. Like threaded devices, adjusted to desired preload, withstand high loads, and accommodate wide range of grip lengths.

Moore, D. M.↗

NASA NTRS1983

Tool for Guiding An Auger

Auger and Ram have same pitch, which minimizes damage to workpiece and load carried by auger. Auger firmly fastened onto ram shaft by screw and kept from rotating on shaft by slot machined into end of stem and male driving lug that engages slot. Used to install threaded studs in plastic or rubber where impractical to mold them in.

Wesselski, C. J.↗

NASA NTRS1993

Connector systems for structures

A releasable coupling device for connecting two members to one another where a collet type fastener has normally retracted latching fingers insertable into a latching recess and a longitudinally movable expander for activating the fastener is described. The longitudinal movement is retained with a paraffin actuated system which can reset. The longitudinal movement of the expander in one direction is through a one way threaded ratchet system which provides an automatic locking action and the expander is movable in either direction by an independently operated threaded action.

Lupo, Christian↗

NASA NTRS1995

Connector systems for structures

Evenson, Erik E.↗

NASA NTRS1987

Fastener apparatus

A fastening apparatus is adapted to be inserted and removed from one side of a work piece having an opposite side which is substantially inaccessible to a worker. A first, externally threaded member is threadingly engaged with a receiving structure, and a second member is inserted within corresponding seats or grooves for interlocking the two members. In the preferred embodiment diverting seats are provided for forming the second member into locking engagement between the receiving structure and the first member. In one embodiment, seat structures are provided for engaging frangible panels or the like for high temperature applications.

While, Donald M.↗

NASA NTRS2011

Cryogenic-Compatible Winchester Connector Mount and Retaining System for Composite Tubes

A connector retainer and mounting system has been designed to replace screw-mounting of Winchester connectors. Countersunk screws are normally used to secure connectors to structures, and to keep them from coming apart. These screws are normally put into threaded or through-holes in metallic structures. This unique retainer is designed such that integral posts keep the connector halves retained, and a groove permits a cable tie to be fastened around the retainer and composite tube, thus securing the connector to the structure. The system is compatible for use on cryogenic (and conventional) bonded composite tube assemblies. Screws and tapped/through-holes needed to retain and mount Winchester connectors cannot be used on blind-access composite tubes. This system allows for rapid installation, removal, low-molecular-outgassing materials, and particulate-free installation and removal. Installation and/or changes late in the integration, and test flow with limited access in a cleanroom environment are possible. No sanding or bonding is needed.

Pontius, James↗

NASA NTRS1973

Fastener stretcher

A description is given of a fastener stretcher used to apply a substantial pure axial tensile force to a structural bolt or similar fastening element. The system is comprised of a pair of telescoping elements, one of which is temporarily secured to the bolt. By spreading the telescoping elements axially, the bolt is tensioned axially to permit a nut or the like to be threaded with a minimum of torque; when the elements are then removed from the bolt, the axial forces on the bolt are taken up by the nut to retain the bolt in its stressed state.

Oconnor, J. W.↗

NASA NTRS2016

Z-2 Threaded Insert Design and Testing Abstract

The Z-2 Prototype Planetary Extravehicular Space Suit Assembly is a continuation of NASA's Z series of spacesuits. The Z-2 is another step in the NASA's technology development roadmap leading to human exploration of the Martian surface. To meet a more challenging set of requirements than previous suit systems standard design features, such as threaded inserts, have been re-analyzed and improved. NASA's Z-2 prototype space suit contains several components fabricated from an advanced hybrid composite laminate consisting of IM10 carbon fiber and fiber glass. One requirement NASA levied on the suit composites was the ability to have removable, replaceable helicoil inserts to which other suit components would be fastened. An approach utilizing bonded in inserts with helicoils inside of them was implemented. The design of the interface flanges of the composites allowed some of the inserts to be a "T" style insert that was installed through the entire thickness of the laminate. The flange portion of the insert provides a mechanical lock as a redundancy to the adhesive aiding in the pullout load that the insert can withstand. In some locations it was not possible to utilize at "T" style insert and a blind insert was used instead. These inserts rely completely on the bond strength of the adhesive to resist pullout. It was determined during the design of the suit that the inserts did not need to withstand loads induced from pressure cycling but instead tension induced from torqueing the screws to bolt on hardware which creates a much higher stress on them. Bolt tension is determined by dividing the torque on the screw by a k value multiplied by the thread diameter of the bolt. The k value is a factor that accounts for friction in the system. A common value used for k for a non-lubricated screw is 0.2. The k value can go down by as much as 0.1 if the screw is lubricated which means for the same torque, a much larger tension could be placed on the bolt and insert. This paper summarizes testing that was performed to determine a k value for helicoil inserts in the Z2 suit and how the insert design was modified to resist a higher pull out tension.

Rhodes, RIchard↗

NASA NTRS1991

Consolidation of graphite thermoplastic textile preforms for primary aircraft structure

The use of innovative cost effective material forms and processes is being considered for fabrication of future primary aircraft structures. Processes that have been identified as meeting these goals are textile preforms that use resin transfer molding (RTM) and consolidation forming. The Novel Composites for Wing and Fuselage Applications (NCWFA) program has as its objective the integration of innovative design concepts with cost effective fabrication processes to develop damage-tolerant structures that can perform at a design ultimate strain level of 6000 micro-inch/inch. In this on-going effort, design trade studies were conducted to arrive at advanced wing designs that integrate new material forms with innovative structural concepts and cost effective fabrication methods. The focus has been on minimizing part count (mechanical fasteners, clips, number of stiffeners, etc.), by using cost effective textile reinforcement concepts that provide improved damage tolerance and out-of-plane load capability, low-cost resin transfer molding processing, and thermoplastic forming concepts. The fabrication of representative Y spars by consolidation methods will be described. The Y spars were fabricated using AS4 (6K)/PEEK 150g commingled angle interlock 0/90-degree woven preforms with +45-degree commingled plies stitched using high strength Toray carbon thread and processed by autoclave consolidation.

Suarez, J.↗

NASA NTRS1978

Test evaluation of space station ECLSS maintenance concepts

The Space Station Prototype (SSP) Environmental Control and Life Support System (ECLSS) hardware was designed and built to be maintainable by the flight crew. To achieve this goal, subsystems were designed for ease of component removal and installation, which included accessibility to component fasteners and connectors, adequate tool clearance, minimum fluid loss during changeout, positive capture of loose parts during changeout, replacement by one crewman, and protection of adjacent parts during maintenance. During testing of this hardware, many day-to-day problems arose which allowed the evaluation of the maintenance concepts under actual maintenance conditions. This paper briefly discusses the maintenance objectives of the hardware design. Specific maintenance designs and their test evaluations are discussed. A removable cartridge valve concept for liquid line components and threaded mechanical fittings and V-band couplings for gaseous line components are critiqued. Other maintenance devices are also evaluated.

Reysa, R. P.↗

NASA NTRS1984

Fastener load tests and retention systems tests for cryogenic wind-tunnel models

A-286 stainless steel screws were tested to determine the tensile load capability and failure mode of various screw sizes and types at both cryogenic and room temperature. Additionally, five fastener retention systems were tested by using A-286 screws with specimens made from the primary metallic alloys that are currently used for cryogenic models. The locking system effectiveness was examined by simple no-load cycling to cryogenic temperatures (-275 F) as well as by dynamic and static loading at cryogenic temperatures. In general, most systems were found to be effective retention devices. There are some differences between the various devices with respect to ease of application, cleanup, and reuse. Results of tests at -275 F imply that the cold temperatures act to improve screw retention. The improved retention is probably the result of differential thermal contraction and/or increased friction (thread-binding effects). The data provided are useful in selecting screw sizes, types, and locking devices for model systems to be tested in cryogenic wind tunnels.

Wallace, J. W.↗

NASA NTRS2003

Fastener starter tool

A fastener starter tool includes a number of spring retention fingers for retaining a small part, or combination of parts. The tool has an inner housing, which holds the spring retention fingers, a hand grip, and an outer housing configured to slide over the inner housing and the spring retention fingers toward and away from the hand grip, exposing and opening, or respectively, covering and closing, the spring retention fingers. By sliding the outer housing toward (away from) the hand grip, a part can be released from (retained by) the tool. The tool may include replaceable inserts, for retaining parts, such as screws, and configured to limit the torque applied to the part, to prevent cross threading. The inner housing has means to transfer torque from the hand grip to the insert. The tool may include replaceable bits, the inner housing having means for transferring torque to the replaceable bit.

Chandler, Faith T.↗

NASA NTRS1994

Experimental analysis of thread movement in bolted connections due to vibrations

The objective of this study was to identify the main design parameters contributing to loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Ramey, G. ED↗