Problems of the theory of pneumatic shells
Determining geometrical shape of closed, singly connected pneumatic elastic shell of revolution under statically increasing internal pressure
INTERNAL PRESSURE↗
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Computational Simulation of Damage Progression of Composite Thin Shells Subjected to Mechanical Loads
Defect-free and defected composite thin shells with ply orientation (90/0/+/-75) made of graphite/epoxy are simulated for damage progression and fracture due to internal pressure and axial loading. The thin shells have a cylindrical geometry with one end fixed and the other free. The applied load consists of an internal pressure in conjunction with an axial load at the free end, the cure temperature was 177 C (350 F) and the operational temperature was 21 C (70 F). The residual stresses due to the processing are taken into account. Shells with defect and without defects were examined by using CODSTRAN an integrated computer code that couples composite mechanics, finite element and account for all possible failure modes inherent in composites. CODSTRAN traces damage initiation, growth, accumulation, damage propagation and the final fracture of the structure. The results show that damage initiation started with matrix failure while damage/fracture progression occurred due to additional matrix failure and fiber fracture. The burst pressure of the (90/0/+/- 75) defected shell was 0.092% of that of the free defect. Finally the results of the damage progression of the (90/0/+/- 75), defective composite shell was compared with the (90/0/+/- theta, where theta = 45 and 60, layup configurations. It was shown that the examined laminate (90/0/+/- 75) has the least damage tolerant of the two compared defective shells with the (90/0/+/- theta), theta = 45 and 60 laminates.
Gotsis, P. K.↗
Multiphase Transport in Porous Media: Gas-Liquid Separation Using Capillary Pressure Gradients International Space Station (ISS) Flight Experiment Development
Advances in the understanding of multiphase flow characteristics under variable gravity conditions will ultimately lead to improved and as of yet unknown process designs for advanced space missions. Such novel processes will be of paramount importance to the success of future manned space exploration as we venture into our solar system and beyond. In addition, because of the ubiquitous nature and vital importance of biological and environmental processes involving airwater mixtures, knowledge gained about fundamental interactions and the governing properties of these mixtures will clearly benefit the quality of life here on our home planet. The techniques addressed in the current research involving multiphase transport in porous media and gas-liquid phase separation using capillary pressure gradients are also a logical candidate for a future International Space Station (ISS) flight experiment. Importantly, the novel and potentially very accurate Lattice-Boltzmann (LB) modeling of multiphase transport in porous media developed in this work offers significantly improved predictions of real world fluid physics phenomena, thereby promoting advanced process designs for both space and terrestrial applications.This 3-year research effort has culminated in the design and testing of a zero-g demonstration prototype. Both the hydrophilic (glass) and hydrophobic (Teflon) media Capillary Pressure Gradient (CPG) cartridges prepared during the second years work were evaluated. Results obtained from ground testing at 1-g were compared to those obtained at reduced gravities spanning Martian (13-g), Lunar (16-g) and zero-g. These comparisons clearly demonstrate the relative strength of the CPG phenomena and the efficacy of its application to meet NASAs unique gas-liquid separation (GLS) requirements in non-terrestrial environments.LB modeling software, developed concurrently with the zero-g test effort, was shown to accurately reproduce observed CPG driven gas-liquid separation phenomena. The design and fabrication of a micropost plate-lamina Hele-Shaw (HS) cell was performed which served as a computationally attainable geometric structure facilitating direct comparison between physical phenomena observed in our laboratory and the LB software predictions.
Wheeler, Richard R., Jr.↗
Testing and Analysis of a Composite Non-Cylindrical Aircraft Fuselage Structure: Ultimate Design Loads - Part 1
The Environmentally Responsible Aviation Project aimed to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration were not sufficient to achieve the desired metrics. One airframe concept identified by the project as having the potential to dramatically improve aircraft performance was a composite-based hybrid wing body configuration. Such a concept, however, presented inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses finite element analysis and testing of a large-scale hybrid wing body center section structure developed and constructed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. Part I of the paper considers the five most critical load conditions, which are internal pressure only and positive and negative g-loads with and without internal pressure. Analysis results are compared with measurements acquired during testing. Performance of the test article is found to be closely aligned with predictions and, consequently, able to support the hybrid wing body design loads in pristine and barely visible impact damage conditions.
Przekop, Adam↗
Pressure-volume properties of metallic bellows
Metallic bellows are commonly used as segments of propellant feedlines for rocket-propelled vehicles to accommodate temperature-induced length variations, manufacturing tolerances, and gimbaling of the engines. These bellows sections deform radially and change volume when internal pressure varies, and the magnitude of such deformation is much higher than that for the straight, cylindrical segments of the line. The greater flexibility, or lesser stiffness, of the bellows, decreases the frequency of acoustic oscillations in the line. These acoustic oscillations are a major factor in the so-called POGO phenomena which have plagued most of the larger liquid rocket-propelled vehicles for many years. A method is developed to calculate the change in volume of a bellows due to a change in internal pressure. Results of an experiment are also presented along with a test-analysis comparison. The computer code is included.
Kiefling, Larry↗
High strain rate properties of unidirectional composites, part 1
Experimental methods were developed for testing and characterization of composite materials at strain rates ranging from quasi-static to over 500 s(sup -1). Three materials were characterized, two graphite/epoxies and a graphite/S-glass/epoxy. Properties were obtained by testing thin rings 10.16 cm (4 in.) in diameter, 2.54 cm (1 in.) wide, and six to eight plies thick under internal pressure. Unidirectional 0 degree, 90 degree, and 10 degree off-axis rings were tested to obtain longitudinal, transverse, and in-plane shear properties. In the dynamic tests internal pressure was applied explosively through a liquid and the pressure was measured with a calibrated steel ring. Strains in the calibration and specimen rings were recorded with a digital processing oscilloscope. The data were processed and the equation of motion solved numerically by the mini-computer attached to the oscilloscope. Results were obtained and plotted in the form of dynamic stress-strain curves. Longitudinal properties which are governed by the fibers do not vary much with strain rate with only a moderate (up to 20 percent) increase in modulus. Transverse modulus and strength increase sharply with strain rate reaching values up to three times the static values. The in-plane shear modulus and shear strength increase noticeably with strain rate by up to approximately 65 percent. In all cases ultimate strains do not vary significantly with strain rates.
Daniel, I. M.↗
A computational parametric study of three-dimensional sidewall compression scramjet inlets at Mach 10
A computational parametric study of three-dimensional sidewall compression scramjet inlets has been performed. The parameters considered for the study include the leading edge sweep angle, varied between 30 and 60 degrees, and the cowl position, located at the throat and at two forward positions. Additionally, the effects of laminar and turbulent boundary layers as well as adiabatic and cold wall boundary conditions are assessed. The parametric study is performed for a Mach number of 10 and a unit freestream Reynolds number of 2 x 10 to the 6th/ft at a geometric contraction ratio of 5. Comparisons among the various configurations are made in terms of the gross parameters of mass capture, throat Mach number, total pressure recovery, and area weighted internal pressure ratios, as well as more detailed flow field phenomena comparisons. The inclusion of one 0-deg sweep computation indicates that the leading edge may be swept by up to 30 deg before significant changes in the gross flow field parameters occur. It is found that a 45-deg sweep configuration provides a good compromise of mass capture, total pressure recovery, and internal compression.
Holland, Scott D.↗
Hermetically sealed aluminum electrolytic capacitor
Aluminum electrolytic capacitors are presently not allowed on NASA missions because they outgas water and organic vapors, as well as H2. As a consequence, much larger and heavier packages of tantalum capacitors are used. A hermetically sealed aluminum capacitor has been developed under NASA-MSFC SBIR contracts. This capacitor contains a nongassing electrolyte that was developed for this application so internal pressure would remain low. Capacitors rated at 250 to 540 V have been operated under full load for thousands of hours at 85 and 105 C with good electrical performance and low internal pressure. Electrolyte chemistry and seal engineering concepts will be discussed.
Alwitt, Robert S.↗
ORION Environmental Control and Life Support Systems Suit Loop and Pressure Control Analysis
Under NASA's ORION Multi-Purpose Crew Vehicle (MPCV) Environmental Control and Life Support System (ECLSS) Project at Johnson Space Center's (JSC), the Crew and Thermal Systems Division has developed performance models of the air system using Thermal Desktop/FloCAD. The Thermal Desktop model includes an Air Revitalization System (ARS Loop), a Suit Loop, a Cabin Loop, and Pressure Control System (PCS) for supplying make-up gas (N2 and O2) to the Cabin and Suit Loop. The ARS and PCS are designed to maintain air quality at acceptable O2, CO2 and humidity levels as well as internal pressures in the vehicle Cabin and during suited operations. This effort required development of a suite of Thermal Desktop Orion ECLSS models to address the need for various simulation capabilities regarding ECLSS performance. An initial highly detailed model of the ARS Loop was developed in order to simulate rapid pressure transients (water hammer effects) within the ARS Loop caused by events such as cycling of the Pressurized Swing Adsorption (PSA) Beds and required high temporal resolution (small time steps) in the model during simulation. A second ECLSS model was developed to simulate events which occur over longer periods of time (over 30 minutes) where O2, CO2 and humidity levels, as well as internal pressures needed to be monitored in the cabin and for suited operations. Stand-alone models of the PCS and the Negative Pressure relief Valve (NPRV) were developed to study thermal effects within the PCS during emergency scenarios (Cabin Leak) and cabin pressurization during vehicle re-entry into Earth's atmosphere. Results from the Orion ECLSS models were used during Orion Delta-PDR (July, 2014) to address Key Design Requirements (KDR's) for Suit Loop operations for multiple mission scenarios.
Eckhardt, Brad↗
Fracture of cylindrical and spherical shells containing a crack.
Fatigue and fracture of cylindrical and spherical shells containing a through crack and subjected to internal pressure or torsion are considered. The stress intensity factor ratios giving the effect of curvature are obtained as functions of a dimensionless shell parameter. By using the conventional plastic strip model the plastic zone size around the crack tip and the crack opening displacement are calculated. The calculated COD values are shown to be in good agreement with the experimental results. The fracture criterion of critical COD is verified by using the results of the burst tests in titanium and aluminum alloy cryogenic pressure vessels. Modified fatigue crack propagation models taking into account the bending effect in shells are introduced and are applied to the analysis of experimental data obtained from flat plates, and cylindrical shells under axial tension, internal pressure, and torsion. Finally, the paper includes the effect of humidity on the crack growth rate and the effect of load biaxiality on the rupture strength.
Erdogan, F.↗
The response of the Space Shuttle Orbiter graphite/epoxy sandwich panels to exposure to moisture and heat
The Shuttle Orbiter Payload Bay Door is covered with graphite/epoxy sandwich panels. Their interaction with ground environments causes a moisture absorption of approximately 1.0% by weight at the time of launch. During the reentry phase the temperature of the outer facesheets rises to 177 C and their moisture content diminishes to 0.65%. In this condition the facesheet strength deteriorates significantly. Also, desorption of moisture produces an internal pressure in the panels of ca. 345 kPa. The paper discusses the prediction of expected moisture levels in the constituent parts of the sandwich panels. It describes further the test program necessary to assess the residual strength of the facesheets and the internal pressure capability of the sandwich panels.
Zigrang, D. J.↗
Composite fuselage shell structures research at NASA Langley Research Center
Fuselage structures for transport aircraft represent a significant percentage of both the weight and the cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and the cost of transport fuselage structures, but only limited studies of the response and failure of composite fuselage structures have been conducted for transport aircraft. The behavior of these important primary structures must be understood, and the structural mechanics methodology for analyzing and designing these complex stiffened shell structures must be validated in the laboratory. The effects of local gradients and discontinuities on fuselage shell behavior and the effects of local damage on pressure containment must be thoroughly understood before composite fuselage structures can be used for commercial aircraft. This paper describes the research being conducted and planned at NASA LaRC to help understand the critical behavior or composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested at Langley to study critical fuselage shell behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient-producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full-scale and subscale behavior of composite fuselage shells. Failure mechanisms are being identified and advanced designs will be developed based on what is learned from early results from the LaRC research activities. Results from combined load tests will be used to validate analytical models of critical nonlinear response mechanisms as well as shell scaling laws.
Starnes, James H., Jr.↗
Damaged stiffened shell research at NASA. Langley Research Center
The structural behavior of stiffened fuselage shells with local cracks is influenced by the local deformations and stress gradients near the cracks, and this behavior must be understood to predict fuselage structural integrity and residual strength. As a crack grows, the stiffness and internal load distributions in a stiffened shell change, affecting the local deformations and stress gradients near the crack. Transport fuselage shells are designed to support internal pressure and mechanical loads which cause a geometrically nonlinear response. Research is being conducted at NASA LaRC to develop and demonstrate a verified nonlinear stiffened shell analysis methodology for accurately predicting the global and local behavior of nonlinear stiffened fuselage shells with local cracks and with combined internal pressure and mechanical loads. The nonlinear structural analysis methodology being developed and planned at NASA LaRC for damaged stiffened fuselage shells and the experiments being planned to verify this analysis methodology are summarized in the present paper.
Aging Aircraft↗
Composite fuselage shell structures research at NASA Langley Research Center
Fuselage structures for transport aircraft represent a large portion of both the weight and cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and cost of these structures, but only limited studies of the response and failure of composite fuselage structures have been conducted. The research is described which is being conducted and planned at NASA Langley to understand the critical behavior of composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested to study critical fuselage behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full scale and subscale behavior of composite fuselage shells.
Starnes, James H., Jr.↗
Biaxial fatigue loading of notched composites
Thin walled, 2.54-cm (1-in.) diameter tubular specimens of T300/934 graphite/epoxy were fabricated and fatigue cycled in combinations of axial, torsional, and internal pressure loading. Two different four-ply layup configurations were tested: (0/90)S and (+ or - 45)S; all tubes contained a 0.48-cm (3/16-in.) diameter circular hole penetrating one wall midway along the tube length. S-N curves were developed to characterize fatigue behavior under pure axial, torsional, or internal pressure loading, as well as combined loading fatigue. A theory was developed based on the Hill plane stress model which enabled the S-N curve for combined stress states to be predicted from the S-N data for the uniaxial loading modes. Correlation of the theory with the experimental data proved to be remarkably good.
Francis, P. H.↗
Biaxial fatigue loading of notched composites
Thin-walled, 2.54-cm diameter tubular specimens of graphite/epoxy were fatigue cycled in combinations of axial, torsional, and internal pressure loading. Two different four-ply layup configurations were tested: (0-90)s and (+ or- 45)s; each tube contained a 0.48-cm diameter circular hole penetrating one wall midway along the tube length. S-N curves were developed to characterize fatigue behavior under pure axial, torsional, or internal pressure loading, as well as combined loading fatigue. A theory was developed based on a plane stress model which enabled the S-N curve for combined stress states to be predicted from the S-N data for the uniaxial loading modes. Correlation of the theory with the experimental data proved to be remarkably good.
Francis, P. H.↗
Probabilistic analysis of a materially nonlinear structure
A probabilistic finite element program is used to perform probabilistic analysis of a materially nonlinear structure. The program used in this study is NESSUS (Numerical Evaluation of Stochastic Structure Under Stress), under development at Southwest Research Institute. The cumulative distribution function (CDF) of the radial stress of a thick-walled cylinder under internal pressure is computed and compared with the analytical solution. In addition, sensitivity factors showing the relative importance of the input random variables are calculated. Significant plasticity is present in this problem and has a pronounced effect on the probabilistic results. The random input variables are the material yield stress and internal pressure with Weibull and normal distributions, respectively. The results verify the ability of NESSUS to compute the CDF and sensitivity factors of a materially nonlinear structure. In addition, the ability of the Advanced Mean Value (AMV) procedure to assess the probabilistic behavior of structures which exhibit a highly nonlinear response is shown. Thus, the AMV procedure can be applied with confidence to other structures which exhibit nonlinear behavior.
Millwater, H. R.↗
Facesheet Delamination of Composite Sandwich Materials at Cryogenic Temperatures
The next generation of space transportation vehicles will require advances in lightweight structural materials and related design concepts to meet the increased demands on performance. One potential source for significant structural weight reduction is the replacement of traditional metallic cryogenic fuel tanks with new designs for polymeric matrix composite tanks. These new tank designs may take the form of thin-walled sandwich constructed with lightweight core and composite facesheets. Life-time durability requirements imply the materials must safely carry pressure loads, external structural loads, resist leakage and operate over an extremely wide temperature range. Aside from catastrophic events like tank wall penetration, one of the most likely scenarios for failure of a tank wall of sandwich construction is the permeation of cryogenic fluid into the sandwich core and the subsequent delamination of the sandwich facesheet due to the build-up of excessive internal pressure. The research presented in this paper was undertaken to help understand this specific problem of core to facesheet delamination in cryogenic environments and relate this data to basic mechanical properties. The experimental results presented herein provide data on the strain energy release rate (toughness) of the interface between the facesheet and the core of a composite sandwich subjected to simulated internal pressure. A unique test apparatus and associated test methods are described and the results are presented to highlight the effects of cryogenic temperature on the measured material properties.
Gates, Thomas S.↗