Research achievements review series no. 10
Improvements in space vehicle stage checkout, structural nondestructive testing, and electronic component testing within quality control program
CHECKOUT EQUIPMENT↗
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Results for “Structural Testing”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Simulation studies for surfaces and materials strength
From intermolecular force studies, it is now known that the overall non-additive contribution to the lattice enegy is positive so that analysis based on only pairwise additivity suggests a shallower intermolecular potential than the true value. Two body contributions alone are also known to be categorically unable to even qualitatively describe some configurations of molecular clusters in the gas phase or the general relaxation and reconstruction of fcc crystal surfaces. In addition, the many-body contribution was shown to play a key role in the stability of certain crystal structures. In these recent analyses, a relatively simple potential energy function (PEF), comprising only a two-body Mie-type potential plus a three-body Axilrod-Teller-type potential, was found to be extremely effective. This same parametric PEF is applied to describe the bulk stability and surface energy for the diamond cubic structure. To test the stability condition, the FCC, BCC, diamond cubic, graphite and beta-tin structures were considered.
Halicioglu, T.↗
Space Station Freedom - Accommodation for technology R&D
The paper examines the features of the accommodation equipment designed for the candidate technology payloads of the Space Station, which include magnetic plasma thruster systems and a hypothetical advanced electromagnetic propulsion system utilizing high-temperature superconductivity materials. The review of the accommodation-equipment concepts supports the assumption that some propulsion technologies can be tested on the Space Station while being attached externally to the station's truss structure. For testing technologies with inherent operation or performance hazards, space platforms and smaller free-flyers coordinated with the Space Station can be used. Diagrams illustrating typical accommodation equipment configurations are included.
Holt, Alan C.↗
(abstract) Overview of NASA's Adaptive Structures Program
NASA's research program in Adaptive Structures was initiated seven years ago to provide the technology required for large (20-50 meters in dimension) precision (submicron) structures for observations from space. The current approach of designing thermally stable passive structures cannot meet the requirements and moreover the systems cannot be validated by ground tests. Adaptive Structures provides the capability to adjust the quasistatic dimensions of the structures, preload joints, add active damping, and provide the actuation forces necessary to attenuate the undesired dynamic motions. The technology is applicable to space platforms with various pointing instruments as well as for microspacecraft. This technology has been incorporated as part of a small Active Fold Mirror on the Wide Field Planetary Camera to be flown within the year to correct the optical errors in the Hubble Telescope. Highlights of NASA's Adaptive Structures research and applications will be presented along with future technology and research requirements for both small inexpensive spacecraft and large precision systems.
adaptive↗
Temperature Effects on Adhesive Bond Strengths and Modulus for Commonly Used Spacecraft Structural Adhesives
A study was performed to observe how changes in temperature and substrate material affected the strength and modulus of an adhesive bondline. Seven different adhesives commonly used in aerospace bonded structures were tested. Aluminum, titanium and Invar adherends were cleaned and primed, then bonded using the manufacturer's recommendations. Following surface preparation, the coupons were bonded with the adhesives. The single lap shear coupons were then pull tested per ASTM D 1002 Standard Test Method for Apparent Shear Strength of Single- Lap-Joint over a temperature range from -150 deg C up to +150 deg C. The ultimate strength was calculated and the resulting data were converted into B-basis design allowables. Average and Bbasis results were compared. Results obtained using aluminum adherends are reported. The effects of using different adherend materials and temperature were also studied and will be reported in a subsequent paper. Dynamic Mechanical Analysis (DMA) was used to study variations in adhesive modulus with temperature. This work resulted in a highly useful database for comparing adhesive performance over a wide range of temperatures, and has facilitated selection of the appropriate adhesive for spacecraft structure applications.
structural adhesives testing↗
Dynamic assessment of B-52B-008 carrier aircraft for the revised Space Shuttle solid rocket booster decelerator subsystem drop test vehicle
The structural integrity of B-52B-008, pylon, and hooks for the drop test missions was determined by theoretical analysis. The results of the analysis and conclusions are presented in this document. The major modification to the drop test vehicle was shortening it about 54 inches, which resulted in the forward hook attach structure being located at the base of the nosecone. The shims that are located in the aft hook structures are increased from two inches to three inches. Airspeed, aerodynamic configuration, and load charts are included.
Doty, L. J.↗
Approach for Structurally Clearing an Adaptive Compliant Trailing Edge Flap for Flight
The Adaptive Compliant Trailing Edge (ACTE) flap was flown on the National Aeronautics and Space Administration (NASA) Gulfstream GIII testbed at the NASA Armstrong Flight Research Center. This smoothly curving flap replaced the existing Fowler flaps creating a seamless control surface. This compliant structure, developed by FlexSys Inc. in partnership with the Air Force Research Laboratory, supported NASA objectives for airframe structural noise reduction, aerodynamic efficiency, and wing weight reduction through gust load alleviation. A thorough structures airworthiness approach was developed to move this project safely to flight. A combination of industry and NASA standard practice require various structural analyses, ground testing, and health monitoring techniques for showing an airworthy structure. This paper provides an overview of compliant structures design, the structural ground testing leading up to flight, and the flight envelope expansion and monitoring strategy. Flight data will be presented, and lessons learned along the way will be highlighted.
flight test↗
Ballpoint probe gives optimum results in ultrasonic testing
Ballpoint-type ultrasonic probe assembly focuses its beam precisely on the bond lines of a composite thin face sheet structure when testing for bond integrity. It can scan in any direction, and eliminate external couplant spray.
Melton, R. E.↗
Generic characterization of electrical test benches for AC- and HVDC-connected wind power plants
The electrical test and assessment of wind turbines go hand in hand with standards and network connection requirements. In this paper, the generic structure of advanced electrical test benches, including grid emulator or controllable grid interface, wind torque emulator, and device under test, is proposed to harmonize state-of-the-art test sites. On the other hand, modern wind turbines are under development towards new features, concerning grid-forming, black-start, and frequency support capabilities as well as harmonic stability and control interaction considerations, to secure the robustness and stability of renewable-energy-based power systems. Therefore, it is necessary to develop new and revised test standards and methodologies to address the new features of wind turbines. This paper proposes a generic test structure within two main groups, including open-loop and closed-loop tests. The open-loop tests include the IEC 61400-21-1 standard tests as well as the additional proposed test options for the new capabilities of wind turbines, which replicate grid connection compliance tests using open-loop references for the grid emulator. In addition, the closed-loop tests evaluate the device under test as part of a virtual wind power plant and perform real-time simulations considering the grid dynamics. The closed-loop tests concern grid connection topologies consisting of AC and HVDC, as well as different electrical characteristics, including impedance, short-circuit ratio, inertia, and background harmonics. The proposed tests can be implemented using available advanced test benches by adjusting their control systems. The characteristics of a real power system can be emulated by a grid emulator coupled with real-time digital simulator systems through a high-bandwidth power-hardware-in-the-loop interface.
17 WIND ENERGY↗
Vibration response of Apollo shell structures to acoustic and aerodynamic noise.
Vibration response of Apollo shell structures to acoustic and aerodynamic noise
VIBRATION TESTING↗
Electro-impulse deicing - Structural dynamic studies, icing tunnel tests and applications
This paper contains a discussion of the comparison of analytical and experimental results of the dynamic response of a flat rectangular plate subjected to electro-impulse type deicing forces. Early attempts in this correlation have been hampered by the complex leading edge geometries of the airfoils tested to date. The lack of a suitable analytical model for a typical leading edge structure has prompted these preliminary investigations of simple geometries, beginning with a flat plate and to be followed by a semi-cylindrical leading edge representation. The comparisons reported herein are thus limited to rectangular plate models. Project plans and icing tunnel results are given.
Bernhart, W. D.↗
Test-Anchored Vibration Response Predictions for an Acoustically Energized Curved Orthogrid Panel with Mounted Components
rich body of vibroacoustic test data was recently generated at Marshall Space Flight Center for component-loaded curved orthogrid panels typical of launch vehicle skin structures. The test data were used to anchor computational predictions of a variety of spatially distributed responses including acceleration, strain and component interface force. Transfer functions relating the responses to the input pressure field were generated from finite element based modal solutions and test-derived damping estimates. A diffuse acoustic field model was applied to correlate the measured input sound pressures across the energized panel. This application quantifies the ability to quickly and accurately predict a variety of responses to acoustically energized skin panels with mounted components. Favorable comparisons between the measured and predicted responses were established. The validated models were used to examine vibration response sensitivities to relevant modeling parameters such as pressure patch density, mesh density, weight of the mounted component and model form. Convergence metrics include spectral densities and cumulative root-mean squared (RMS) functions for acceleration, velocity, displacement, strain and interface force. Minimum frequencies for response convergence were established as well as recommendations for modeling techniques, particularly in the early stages of a component design when accurate structural vibration requirements are needed relatively quickly. The results were compared with long-established guidelines for modeling accuracy of component-loaded panels. A theoretical basis for the Response/Pressure Transfer Function (RPTF) approach provides insight into trends observed in the response predictions and confirmed in the test data. The software developed for the RPTF method allows easy replacement of the diffuse acoustic field with other pressure fields such as a turbulent boundary layer (TBL) model suitable for vehicle ascent. Structural responses using a TBL model were demonstrated, and wind tunnel tests have been proposed to anchor the predictions and provide new insight into modeling approaches for this environment. Finally, design load factors were developed from the measured and predicted responses and compared with those derived from traditional techniques such as historical Mass Acceleration Curves and Barrett scaling methods for acreage and component-loaded panels.
Frady, Gregory P.↗
Static and damage tolerance tests of an advanced composite vertical fin for L-1011 aircraft
This paper recounts the significant events which took place during the structural verification testing of two graphite/epoxy material, full-size vertical stabilizers. The ground test articles were tested to a high bending dynamic lateral gust condition. The first unit failed during static testing at 98 percent Design Ultimate Load. Failure began within the front spar cap. A detailed review of the failure was performed to identify all possible modes. This review resulted in a 'production line' type fix being designed for incorporation in the second ground test article prior to installation in the test fixture. The modified second unit sustained 106 percent of Design Ultimate Load without incident. One lifetime (36,000 flights) of damage tolerance testing was accomplished with the specimen purposely damaged at five locations. A fail-safe loading was performed successfully after simulating lightning strike damage to the fin box cover. A large area repair was substantiated by completing a second lifetime of spectrum loadings. The residual static strength was determined to be 119.7 percent of Design Ultimate Load.
Dorward, F.↗
Mechanism Design and Testing of a Self-Deploying Structure Using Flexible Composite Tape Springs
The detailed mechanical design of a novel deployable support structure that positions and tensions a membrane optic for space imagining applications is presented. This is a complex three-dimensional deployment using freely deploying rollable composite tape spring booms that become load bearing structural members at full deployment. The deployment tests successfully demonstrate a new architecture based on rolled and freely deployed composite tape spring members that achieve simultaneous deployment without mechanical synchronization. Proper design of the flexible component mounting interface and constraint systems, which were critical in achieving a functioning unit, are described. These flexible composite components have much potential for advancing the state of the art in deployable structures, but have yet to be widely adopted. This paper demonstrates the feasibility and advantages of implementing flexible composite components, including the design details on how to integrate with required traditional mechanisms.
Footdale, Joseph N.↗
Rapid Inspection of Aerospace Structures - Is It Autonomous Yet?
The trend to increase the usage of aging aircraft added a great deal of urgency to the ongoing need for low-cost, rapid, simple-to-operate, reliable and efficient NDE methods for detection and characterization of flaws in aircraft structures. In many cases, the problem of inspection is complex due to the limitation of current technology and the need to disassemble aircraft structures and testing them in lab conditions. To overcome these limitations, reliable field inspection tools are being developed for rapid NDE of large and complex-shape structures, that can operate at harsh, hostal and remote conditions with minimum human interface. In recent years, to address the need for rapid inspection in field conditions, numerous portable scanners were developed using NDE methods, including ultrasonics, shearography, thermography. This paper is written with emphasis on ultrasonic NDE scanners, their evolution and the expected direction of growth.
Crawling System autonomous robotics↗
Development of iterative techniques for the solution of unsteady compressible viscous flows
During the past two decades, there has been significant progress in the field of numerical simulation of unsteady compressible viscous flows. At present, a variety of solution techniques exist such as the transonic small disturbance analyses (TSD), transonic full potential equation-based methods, unsteady Euler solvers, and unsteady Navier-Stokes solvers. These advances have been made possible by developments in three areas: (1) improved numerical algorithms; (2) automation of body-fitted grid generation schemes; and (3) advanced computer architectures with vector processing and massively parallel processing features. In this work, the GMRES scheme has been considered as a candidate for acceleration of a Newton iteration time marching scheme for unsteady 2-D and 3-D compressible viscous flow calculation; from preliminary calculations, this will provide up to a 65 percent reduction in the computer time requirements over the existing class of explicit and implicit time marching schemes. The proposed method has ben tested on structured grids, but is flexible enough for extension to unstructured grids. The described scheme has been tested only on the current generation of vector processor architecture of the Cray Y/MP class, but should be suitable for adaptation to massively parallel machines.
Hixon, Duane↗
Optics-Only Calibration of a Neural-Net Based Optical NDE Method for Structural Health Monitoring
A calibration process is presented that uses optical measurements alone to calibrate a neural-net based NDE method. The method itself detects small changes in the vibration mode shapes of structures. The optics-only calibration process confirms previous work that the sensitivity to vibration-amplitude changes can be as small as 10 nanometers. A more practical value in an NDE service laboratory is shown to be 50 nanometers. Both model-generated and experimental calibrations are demonstrated using two implementations of the calibration technique. The implementations are based on previously published demonstrations of the NDE method and an alternative calibration procedure that depends on comparing neural-net and point sensor measurements. The optics-only calibration method, unlike the alternative method, does not require modifications of the structure being tested or the creation of calibration objects. The calibration process can be used to test improvements in the NDE process and to develop a vibration-mode-independence of damagedetection sensitivity. The calibration effort was intended to support NASA s objective to promote safety in the operations of ground test facilities or aviation safety, in general, by allowing the detection of the gradual onset of structural changes and damage.
Decker, Arthur J.↗
Impact tests on fibrous composite sandwich structures
The effect of low velocity impact on the strength of laminates fabricated from graphite/epoxy and Kevlar 49/epoxy composite materials was studied. The test laminates were loaded statically either in uniaxial tension or compression when impact occurred to evaluate the effect of loading on the initiation of damage and/or failure. Typical aircraft service conditions such as runway debris encountered during landing were simulated by impacting 1.27-cm-diameter projectiles normal to the plane of the test laminates at velocities between 5.2 and 48.8 m/s.
Rhodes, M. D.↗