Static Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for A 1.4 MW Electric Machine in A Thermal Vacuum Chamber
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electrified aircraft propulsion↗
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X-57 Structural Analysis, Wing Design, & Testing (Statics)
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Jeffrey Viken↗
An Experimental Investigation of Transverse Tension Fatigue Characterization of IM6/3501-6 Composite Materials Using a Three-Point Bend Test
As composites are introduced into more complex structures with out-of-plane loadings, a better understanding is needed of the out-of-plane, matrix-dominated failure mechanisms. This work investigates the transverse tension fatigue characteristics of IM6/3501 composite materials. To test the 90 degree laminae, a three-point bend test was chosen, potentially minimizing handling and gripping issues associated with tension tests. A finite element analysis was performed of a particular specimen configuration to investigate the influence of specimen size on the stress distribution for a three-point bend test. Static testing of 50 specimens of 9 different sized configurations produced a mean transverse tensile strength of 61.3 Mpa (8.0 ksi). The smallest configuration (10.2 mm wide, Span-to-thickness ratio of 3) consistently exhibited transverse tensile failures. A volume scale effect was difficult to discern due to the large scatter of the data. Static testing of 10 different specimens taken from a second panel produced a mean transverse tensile strength of 82.7 Mpa (12.0 ksi). Weibull parameterization of the data was possible, but due to variability in raw material and/or manufacturing, more replicates are needed for greater confidence. Three-point flex fatigue testing of the smallest configuration was performed on 59 specimens at various levels of the mean static transverse tensile strength using an R ratio of 0.1 and a frequency of 20 Hz. A great deal of scatter was seen in the data. The majority of specimens failed near the center loading roller. To determine whether the scatter in the fatigue data is due to variability in raw material and/or the manufacturing process, additional testing should be performed on panels manufactured from different sources.
Peck, Ann W.↗
Instrumentation for measuring the dynamic pressure on rotating compressor blades
To establish the capability for measurement of oscillatory pressure on rotating blades, miniature fast response semiconductor strain gage pressure transducers (2mm x 0.33mm) were mounted in several configurations on thin titanium and steel compressor blades and subjected to pressure cycles from 1 to 310 kPa during static tests and spin tests. Static test conditions included 20 C to 150 C, 0 to 3000 tensile microstrain, -1000 to +1000 bending microstrain and + or - 650G vibration. The spin test conditions included 20 C to 82 C at 0 to 90,000G. Durability was excellent. Pressure transducer sensitivity changed by only a few percent over this range of environmental conditions. Noise signal due to oscillatory acceleration normal to the diaphragm was acceptable (0.33Pa/G). Noise signal due to oscillatory strain was acceptable (0.5 Pa/microstrain) when the transducer was mounted on a 0.05mm rubber pad, with a total buildup of 0.38mm on the measure surface. Back mounting or partial recessing to eliminate buildup, increased the strain effect to 1.2 Pa/microstrain. Flush mounting within the blade to eliminate buildup reduced the strain effect, but required development of a special transducer shape. This transducer was not available in time for spin tests. Unpredictable zero drift + or - 14 kPa ruled out the use of these mounting arrangements for accurate steady-state (D.C.) measurements on rotating blades. The two best configurations fully developed and spin tested were then successfully applied in the NAS3-20606 rotating fan flutter program for quantitative measurement of oscillatory pressure amplitudes.
Grant, H. P.↗
Aerodynamic characteristics of a large-scale semispan model with a swept wing and an augmented jet flap with hypermixing nozzles
The aerodynamic characteristics of the augmentor wing concept with hypermixing primary nozzles were investigated. A large-scale semispan model in the Ames 40- by 80-Foot Wind Tunnel and Static Test Facility was used. The trailing edge, augmentor flap system occupied 65% of the span and consisted of two fixed pivot flaps. The nozzle system consisted of hypermixing, lobe primary nozzles, and BLC slot nozzles at the forward inlet, both sides and ends of the throat, and at the aft flap. The entire wing leading edge was fitted with a 10% chord slat and a blowing slot. Outboard of the flap was a blown aileron. The model was tested statically and at forward speed. Primary parameters and their ranges included angle of attack from -12 to 32 degrees, flap angles of 20, 30, 45, 60 and 70 degrees, and deflection and diffuser area ratios from 1.16 to 2.22. Thrust coefficients ranged from 0 to 2.73, while nozzle pressure ratios varied from 1.0 to 2.34. Reynolds number per foot varied from 0 to 1.4 million. Analysis of the data indicated a maximum static, gross augmentation of 1.53 at a flap angle of 45 degrees. Analysis also indicated that the configuration was an efficient powered lift device and that the net thrust was comparable with augmentor wings of similar static performance. Performance at forward speed was best at a diffuser area ratio of 1.37.
Aiken, T. N.↗
Keynote address
The Space Shuttle test program is described. Consideration is given to thermal vacuum testing, static testing, ground vibration testing, high temperature testing, propulsion system testing, etc. Emphasis is placed on the Shuttle test philosophy and how it differs from that of past programs.
Yardley, J. F.↗
A Comparison of Quasi-Static Indentation Testing to Low Velocity Impact Testing
The need for a static test method for modeling low-velocity foreign object impact events to composites would prove to be very beneficial to researchers since much more data can be obtained from a static test than from an impact test. In order to examine if this is feasible, a series of static indentation and low velocity impact tests were carried out and compared. Square specimens of many sizes and thickness were utilized to cover the array of types of low velocity impact events. Laminates with a n/4 stacking sequence were employed since this is by the most common type of engineering laminate. Three distinct flexural rigidities under two different boundary conditions were tested in order to obtain damage due to large deflections, contact stresses and both to examine if the static indentation-impact comparisons are valid under the spectrum of damage modes that can be experienced. Comparisons between static indentation and low velocity impact tests were based on the maximum applied transverse load. The dependent parameters examined included dent depth, back surface crack length, delamination area and to a limited extent, load-deflection behavior. Results showed that no distinct differences could be seen between the static indentation tests and the low velocity impact tests, indicating that static indentation can be used to represent a low velocity impact event.
Nettles, Alan T.↗
Over-the-wing model thrust reverser noise tests
Static acoustic tests were conducted on a 1/12 scale model over-the-wing target type thrust reverser. The model configuration simulates a design that is applicable to the over-the-wing short-haul advanced technology engine. Aerodynamic screening tests of a variety of reverser designs identified configurations that satisfied a reverse thrust requirement of 35 percent of forward thrust at a nozzle pressure ratio of 1.29. The variations in the reverser configuration included, blocker door angle, blocker door lip angle and shape, and side skirt shape. Acoustic data are presented and compared for the various configurations. The model data scaled to a single full size engine show that peak free field perceived noise (PN) levels at a 152.4 meter sideline distance range from 98 to 104 PNdb.
Goodykoontz, J.↗
Large-scale Advanced Prop-fan (LAP) static rotor test report
Discussed is Static Rotor Testing of the SR-7L Large Scale Advanced Prop-Fan (LAP). The LAP is an advanced 9 foot diameter, 8 bladed propeller designed and built by Hamilton Standard under contract to the NASA Lewis Research Center. The Prop-Fan employs thin swept blades to provide efficient propulsion at flight speeds up to Mach .85. Static Testing was conducted on a 10,000 HP whirl rig at Wright Patterson Air Force Base. The test objectives were to investigate the Prop-Fan static aerodynamic and structural dynamic performance, determine the blade steady state stressers and deflections and to measure steady and unsteady pressures on the SR-7L blade surface. The measured performance of the LAP correlated well with analytical predictions at blade pitch angles below 30 deg. A stall buffet phenomenon was observed at blade pitch angles above 30 deg. This phenomenon manifested itself by elevated blade vibratory stress levels and lower than expected thrust produced and power absorbed by the Prop-Fan for a given speed and blade angle.
Degeorge, Charles L.↗
Effect of Installation of Mixer/Ejector Nozzles on the Core Flow Exhaust of High-Bypass-Ratio Turbofan Engines
The aerospace industry is currently investigating the effect of installing mixer/ejector nozzles on the core flow exhaust of high-bypass-ratio turbofan engines. This effort includes both full-scale engine tests at sea level conditions and subscale tests in static test facilities. Subscale model tests are to be conducted prior to full-scale testing. With this approach, model results can be analyzed and compared with analytical predications. Problem areas can then be identified and design changes made and verified in subscale prior to committing to any final design configurations for engine ground tests. One of the subscale model test programs for the integrated mixer/ejector development was a joint test conducted by the NASA Lewis Research Center and Pratt & Whitney Aircraft. This test was conducted to study various mixer/ejector nozzle configurations installed on the core flow exhaust of advanced, high-bypass-ratio turbofan engines for subsonic, commercial applications. The mixer/ejector concept involves the introduction of largescale, low-loss, streamwise vortices that entrain large amounts of secondary air and rapidly mix it with the primary stream. This results in increased ejector pumping relative to conventional ejectors and in more complete mixing within the ejector shroud. The latter improves thrust performance through the efficient energy exchange between the primary and secondary streams. This experimental program was completed in April 1997 in Lewis' CE-22 static test facility. Variables tested included the nozzle area ratio (A9/A8), which ranged from 1.6 to 3.0. This ratio was varied by increasing or decreasing the nozzle throat area, A8. Primary nozzles tested included both lobed mixers and conical primaries. These configurations were tested with and without an outer shroud, and the shroud position was varied by inserting spacers in it. In addition, data were acquired with and without secondary flow.
Harrington, Douglas E.↗
Some observations on loss of static strength due to fatigue cracks
Static tensile tests were performed on simple notched specimens containing fatigue cracks. Four types of aluminum alloys were investigated: 2024-T3(formerly 24S-T3) and 7075-T6(formerly 75S-T6) in sheet form, and 2024-T4(formerly 24S-T4) and 7075-T6(formerly 75S-T6) in extruded form. The cracked specimens were tested statically under four conditions: unmodified and with reduced eccentricity of loading by three methods. Results of static tests on C-46 wings containing fatigue cracks are also reported.
MATERIALS, PROPERTIES - FATIGUE↗
Technical Evaluation Motor no. 5 (TEM-5)
Technical Evaluation Motor No. 5 (TEM-5) was static test fired at the Thiokol Corporation Static Test Bay T-97. TEM-5 was a full scale, full duration static test fire of a high performance motor (HPM) configuration solid rocket motor (SRM). The primary purpose of TEM static tests is to recover SRM case and nozzle hardware for use in the redesigned solid rocket motor (RSRM) flight program. Inspection and instrumentation data indicate that the TEM-5 static test firing was successful. The ambient temperature during the test was 41 F and the propellant mean bulk temperature (PMBT) was 72 F. Ballistics performance values were within the specified requirements. The overall performance of the TEM-5 components and test equipment was nominal. Dissembly inspection revealed that joint putty was in contact with the inner groove of the inner primary seal of the ignitor adapter-to-forward dome (inner) joint gasket; this condition had not occurred on any previous static test motor or flight RSRM. While no qualification issues were addressed on TEM-5, two significant component changes were evaluated. Those changes were a new vented assembly process for the case-to-nozzle joint and the installation of two redesigned field joint protection systems. Performance of the vented case-to-nozzle joint assembly was successful, and the assembly/performance differences between the two field joint protection system (FJPS) configurations were compared.
Cook, M.↗
Data acquisition during static rocket testing.
Data acquisition of acoustic, vibration and heat flux during static rocket testing, using balloon rigging arrangement
SOUND MEASUREMENT↗
Space Shuttle Flight Support Motor no. 1 (FSM-1)
Space Shuttle Flight Support Motor No. 1 (FSM-1) was static test fired on 15 Aug. 1990 at the Thiokol Corporation Static Test Bay T-24. FSM-1 was a full-scale, full-duration static test fire of a redesigned solid rocket motor. FSM-1 was the first of seven flight support motors which will be static test fired. The Flight Support Motor program validates components, materials, and manufacturing processes. In addition, FSM-1 was the full-scale motor for qualification of Western Electrochemical Corporation ammonium perchlorate. This motor was subjected to all controls and documentation requirements CTP-0171, Revision A. Inspection and instrumentation data indicate that the FSM-1 static test firing was successful. The ambient temperature during the test was 87 F and the propellant mean bulk temperature was 82 F. Ballistics performance values were within the specified requirements. The overall performance of the FSM-1 components and test equipment was nominal.
Hughes, Phil D.↗
Static vibration tests of sailplane with electronic measuring instruments
Static vibration tests of sailplanes with electronic measuring apparatus
VIBRATION TESTING↗
Summary of static load test of the Mod-0 blade
A static load test was performed on the spare Mod-0 wind turbine blade to define load transfer at the root end of the blade, and to validate stress analysis of this particular type of blade construction (frame and stringer). Analysis of the load transfer from the airfoil skin to the shank tube predicted a step change in spanwise stress in the airfoil skin at station 81.5 inches (STA 81.5). For flatwise bending a 40% reduction in spanwise stress was predicted, and for edgewise bending a 6% reduction. Experimental results verified the 40% reduction for flatwise bending, but indicated about a 30% reduction for edgewise bending.
Miller, D. R.↗
Ares Launch Vehicles Development Awakens Historic Test Stands at NASA's Marshall Space Flight Center
This paper chronicles the rebirth of two national rocket testing assets located at NASA's Marshall Space Flight Center: the Dynamic Test Stand (also known as the Ground Vibration Test Stand) and the Static Test Stand (also known as the Main Propulsion Test Stand). It will touch on the historical significance of these special facilities, while introducing the requirements driving modifications for testing a new generation space transportation system, which is set to come on line after the Space Shuttle is retired in 2010. In many ways, America's journey to explore the Moon begins at the Marshall Center, which is developing the Ares I crew launch vehicle and the Ares V cargo launch vehicle, along with managing the Lunar Precursor Robotic Program and leading the Lunar Lander descent stage work, among other Constellation Program assignments. An important component of this work is housed in Marshall's Engineering Directorate, which manages more than 40 facilities capable of a full spectrum of rocket and space transportation technology testing - from small components to full-up engine systems. The engineers and technicians who operate these test facilities have more than a thousand years of combined experience in this highly specialized field. Marshall has one of the few government test groups in the United States with responsibility for the overall performance of a test program from conception to completion. The Test Laboratory has facilities dating back to the early 1960s, when the test stands needed for the Apollo Program and other scientific endeavors were commissioned and built along the Marshall Center's southern boundary, with logistics access by air, railroad, and barge or boat on the Tennessee River. NASA and its industry partners are designing and developing a new human-rated system based on the requirements for safe, reliable, and cost-effective transportation solutions. Given below are summaries of the Dynamic Test Stand and the Static Test Stand capabilities, along with an introduction to the new missions that these sleeping giants will be fulfilling as NASA readies the Ares I for service in the 2015 timeframe, and plans the development work for fielding the Ares V late next decade (fig. 1). Validating modern computer design models and techniques requires the sorts of data that can only be generated by these one-of-a-kind facilities.
Dumbacher, Daniel L.↗
Static Torsion Testing and Modeling of a Variable Thickness Hybrid Composite Bull Gear
Torsional strength of a variable thickness hybrid gear web was measured by performing static testing on the part in a large torsion test frame. The outer rim of the hybrid gear web was fixed to the bottom of the test frame and loading was applied to the web through a shaft. The test setup included the installation of digital image correlation (DIC) systems to obtain deformation and strain measurements from the surfaces of the hybrid gear web and the mechanical test equipment to ensure reliability of the test. The results indicated that the variable thickness hybrid gear web achieved approximately twice the torsional strength compared to that of previous hybrid gear designs. The DIC analysis showed significantly more straining of the loading shaft than the actual test article. Additionally, the results demonstrated the importance and affect that the metallic, lobed interlock features had on the principal strain and out-of-plane displacement fields. The analysis revealed that the fixed outer rim was in fact rotating and a rigid body motion compensation (RBMC) function was computed to determine the actual rotation of the hub and composite web relative to the outer rim. Modeling simulations were performed for the variable thickness hybrid gear web and correlated well with the RBMC rotational deformation seen in the DIC analysis. In addition to benchmarking the load capacity of the hybrid gear web, measuring its strength is useful information to define the parameters needed for dynamic, endurance, and other testing of the part.
Johnston, Joel P.↗