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At least 1,189 records · Page 66

Corrugated Rollable Tubular Booms

A promising candidate for a new class of deployable composite boom is the COrrugated ROllable TUbular Boom (COROTUB), which is to be employed on future large space structures by the National Aeronautics and Space Administration (NASA). This is due to its two corrugated thin-shells forming a closed-section,which yields high bending and torsion stiffness, allowing for high dimensional stability. The corrugation geometry that dictates the boom cross-section shape is completely defined by closed-form analytical equations given a set of key input parameters available to the designer. Parametric studies changing two geometric variables are used to evaluate which parameters most influence the cross-section’s area moment of inertia and torsional constant. The number of corrugations, flattened height of the boom, and concave and convex corrugation radii are varied to study the complete boom design space. Deeper corrugations increase the local buckling loads (crimpling) of the thin-shell boom but reduce the area moment of inertia and therefore the global Euler buckling load of the compressive member,and thus a fine balance is sought. Finite element analyses of pure bending and compression load cases for 1.22 m boom specimens were carried out to study this design trade-off in detail. Based on previous work, several thin-ply composite laminates have been selected for the different shells that form the cross-section. Feasible boom designs with a maximized stiffness and load-carrying capacity will be manufactured to study their rollability and for experimental characterization. Structural characterization tests and additional numerical analyses will provide guidelines towards future corrugated boom designs and adequate boundary conditions to maximize the boom bending strength.

Deployable Booms↗

Static stability of the Space Station solar array FASTMast structure

The combined loads test of the 3-Bay FASTMast marks the end of the Lewis Research Center (LeRC) effort to characterize the behavior of the principal Space Station solar array support structure. The primary objective of this test and analysis effort was to develop a method to predict structural stability failure modes under flight-like applied loads. Included at the beginning of this report is a brief historical perspective of the hardware design development and FASTMast structural stability problem evolution. Once an understanding of the solution process has been established, test and analysis details are presented and related to the postulated failure theories. The combined load test series subjected the structure to a combination of transverse, moment, and torsion loads similar to that expected in the service environment. Nonlinear finite element (FE) models were developed and large displacement analyses were performed to support the test effort and failure mode predictions. Details of the test configuration as well as test and analysis results are presented. The results were then critiqued to establish valid and successful support of the failure mode assessments. Finally, study conclusions are drawn and recommendations for safe operation of the FASTMast structure are presented for consideration.

Shaker, John F.↗

Thermomechanical Multiaxial Fatigue Testing Capability Developed

Structural components in aeronautical gas turbine engines typically experience multiaxial states of stress under nonisothermal conditions. To estimate the durability of the various components in the engine, one must characterize the cyclic deformation and fatigue behavior of the materials used under thermal and complex mechanical loading conditions. To this end, a testing protocol and associated test control software were developed at the NASA Lewis Research Center for thermomechanical axial-torsional fatigue tests. These tests are to be performed on thin-walled, tubular specimens fabricated from the cobalt-based superalloy Haynes 188. The software is written in C and runs on an MS-DOS based microcomputer.

Source record↗

Preparation for foam composites

Methods were developed for the fabrication of fire resistant panels utilizing polybenzimidazole (PBI) and Kerimid 601 resins along with glass, quartz, and Kevlar reinforcements. Stitched truss structure, both unfilled and filled with PBI foam, were successfully fabricated and tested. Second generation structures were then selected, fabricated, and tested, with a PBI/glass skin/PBI foam sandwich structure emerging as the optimum panel concept. Mechanical properties, smoke generation, and fire resistance were determined for the candidate panels.

Maximovich, M. G.↗

High-Temperature Modal Survey of a Hot-Structure Control Surface

NASA Dryden is directing a program to test a Carbon-Silicon Carbide (C/SiC) Ruddervator Subcomponent Test Article (RSTA). The RSTA is a truncated version of the full-scale X-37 hot-structure control surface incorporating all major features including the metallic spindle and five major C/SiC quasi isotropic lay-up components secured with C/SiC fasteners. As part of NASA's Aeronautics Research Mission Directorate Hypersonics program, the RSTA will undergo thermal-structural testing to develop an extensive database for future structural design and analysis methodology validation. Ground Vibration Tests (GVTs) are routinely conducted for model validation in supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, GVT techniques are not well-established. New fabrication technologies, high-temperature materials systems, and sensors offer new opportunities to develop techniques for performing GVTs at elevated temperatures. The RSTA is comprised of materials whose stiffness both increases and decreases with increasing temperature. The impact of this type of material system interaction must be understood as it will ultimately affect hypersonic flutter analysis. The test objectives are to perform room-temperature GVTs, develop the capability to conduct high-temperature GVTs and to compare and generate an understanding of the modal characteristics which capture RSTA's material interaction when subjected to temperature varying conditions.

Spivey, Natalie D.↗

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗

High Fidelity Modeling of Evolutionary Structures in IMOS

A methodology is proposed for testing, modal identification, and model correlation of structures which are assembled in an evolutionary manner. The methodology prescribes initial testing of a base structure without any attached components. The experimental modal properties are used to update the physical properties of the base structure finite element model using a Bayesian Estimation Technique (BET). The BET is implemented in METLAB using IMOS functions. As components are added to the base structure, additional tests are performed. Three testing options are proposed, all of which enable estimation of the physical parameters of the components alone. Furthermore, improvements to the original BET implementation have been made, which contribute to higher fidelity models and more efficient computational times.

structures testing assembling modeling BET Bayesia↗

Residual flexibility test method for verification of constrained structural models

A method is presented for deriving constrained modes and frequencies from a model correlated to a set of free-free test modes and a set of measured residual flexibilities. The method involves a simple modification of the MacNeal and Rubin component mode representation to allow verification of a constrained structural model. Results for two spaceflight structures show quick convergence of constrained modes using an easily measurable set of free-free modes plus the residual flexibility matrix or its boundary partition. This paper further validates the residual flexibility approach as an alternative test/analysis method when fixed-base testing proves impractical.

Admire, John R.↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading. The structure is able to sustain design limit load (DLL). Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions.

Eric M. Roberts↗

Mass-additive modal test method for verification of constrained structural models

A method for deriving constrained or fixed-base modes and frequencies from free-free modes of a structure with mass-loaded boundaries is developed. Problems associated with design and development of test fixtures can be avoided with such an approach. The analytical methodology presented is used to assess applicability of the mass-additive method for three types of structures and to determine the accuracy of derived constrained modes and frequencies. Results show that mass loading of the boundaries enables local interface modes to be measured within a desired frequency bandwidth, thus allowing constrained modes to be derived with considerably fewer free-free modes than for unloaded boundaries. Good convergence was obtained for a simple beam and a truss-like Shuttle payload, both of which had well-spaced modes and stiff interface support structures. Slow convergence was obtained for a space station module prototype, a shell-like structure having high modal density.

Admire, John R.↗

Structural evaluation of Marman V-band coupling and flange with conoseal gasket

Results are described of a development test program directed at evaluating the structural capabilities of the Marman V-band coupling and flange with conoseal gasket. The intended end use was for the 75K NERVA flight engine propellant lines. Of major importance in the structural evaluation was the ability to predict stresses throughout the assembly for a variety of loading conditions. Computer finite element analysis was used to predict these stresses but, for the subject configuration, large uncertainties were introduced in modeling the complex geometry and boundary conditions. The purpose of the structural tests was to obtain actual stresses and deflections for correlation with, and updating of the finite element model. Results of the incomplete test program are inconclusive with respect to determining suitability for use on the NERVA engine.

Oates, J. H.↗

A hybrid approach to test-analysis-model development for large space structures

The present FEM reduction method for the generation of test-analysis-models (TAMs) in test-analysis correlation addresses contentions that the current modal TAM is hypersensitive to differences between test model shapes and analysis mode shapes, thereby generating large off-diagonal terms within the orthogonality and cross-orthogonality matrices employed in test-analysis mode-shape correlation. A hybrid TAM methodology is accordingly developed which combines the exact representation of the FEM target modes from the modal TAM with the more accurate TAM representation of the residual modes; the superior residual dynamics representation of the hybrid TAM is demonstrated for a detailed representation of a large space structure.

Kammer, D. C.↗

High-Frequency Testing of Composite Fan Vanes With Erosion-Resistant Coating Conducted

The mechanical integrity of hard, erosion-resistant coatings were tested using the Structural Dynamics Laboratory at the NASA Glenn Research Center. Under the guidance of Structural Mechanics and Dynamics Branch personnel, fixturing and test procedures were developed at Glenn to simulate engine vibratory conditions on coated polymer-matrix- composite bypass vanes using a slip table in the Structural Dynamics Laboratory. Results from the high-frequency mechanical bench testing, along with concurrent erosion testing of coupons and vanes, provided sufficient confidence to engine-endurance test similarly coated vane segments. The knowledge gained from this program will be applied to the development of oxidation- and erosion-resistant coatings for polymer matrix composite blades and vanes in future advanced turbine engines. Fan bypass vanes from the AE3007 (Rolls Royce America, Indianapolis, IN) gas turbine engine were coated by Engelhard (Windsor, CT) with compliant bond coatings and hard ceramic coatings. The coatings were developed collaboratively by Glenn and Allison Advanced Development Corporation (AADC)/Rolls Royce America through research sponsored by the High-Temperature Engine Materials Technology Project (HITEMP) and the Higher Operating Temperature Propulsion Components (HOTPC) project. High-cycle fatigue was performed through high-frequency vibratory testing on a shaker table. Vane resonant frequency modes were surveyed from 50 to 3000 Hz at input loads from 1g to 55g on both uncoated production vanes and vanes with the erosion-resistant coating. Vanes were instrumented with both lightweight accelerometers and strain gauges to establish resonance, mode shape, and strain amplitudes. Two high-frequency dwell conditions were chosen to excite two strain levels: one approaching the vane's maximum allowable design strain and another near the expected maximum strain during engine operation. Six specimens were tested per dwell condition. Pretest and posttest inspections were performed optically at up to 60 magnification and using a fluorescent-dye penetrant. Accumulation of 10 million cycles at a strain amplitude of two to three times that expected in the engine (approximately 670 Hz and 20g) led to the development of multiple cracks in the coating that were only detectable using fluorescent-dye penetrant inspection. Cracks were prevalent on the trailing edge and on the convex side of the midsection. No cracking or spalling was evident using standard optical inspection at up to 60 magnification. Further inspection may reveal whether these fine cracks penetrated the coating or were strictly on the surface. The dwell condition that simulated actual engine conditions produced no obvious surface flaws even after up to 80 million cycles had been accumulated at strain amplitudes produced at approximately 1500 Hz and 45g.

Bowman, Cheryl L.↗

Bi-axial Strain Measurement of Woven-Webbing Inflatable Structures Using Digital Image Correlation with RGB Filtering

Crewed inflatable softgoods structures can significantly reduce launch volume for habitable pressure vessels. To ensure the operational safety of these structures, NASA has developed an extensive testing program to evaluate the structural capability on ground test articles. This paper will discuss a current challenge faced by test engineers evaluating the strain of large-scale inflatable space structures during ground testing. Namely, the difficulty that arises using monochrome digital image correlation (DIC) to evaluate bi-axial strain for woven-webbing restraint layers. This report provides insight into a novel method of photogrammetry using red-green-blue (RGB) filtering in conjunction with DIC to evaluate the strain in each direction on a test article experiencing bi-directional strain. To evaluate this concept, a uniaxial tensile test was performed that represented a biaxial woven architecture using orthogonally interfaced straps. The resulting analysis demonstrates promise for this novel approach for isolating a specific region and direction of strain, reducing the effects of straps not in the area of interest, while allowing for a larger region of analysis. Moreover, it was shown that the application of a white basecoat prior to applying photogrammetry patterns significantly reduced data loss while performing RGB filtered DIC.

inflatable↗

Integral Airframe Structures (IAS): Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

The Integral Airframe Structures (IAS) program investigated the feasibility of using "integrally stiffened" construction for commercial transport fuselage structure. The objective of the program was to demonstrate structural performance and weight equal to current "built-up" structure with lower manufacturing cost. Testing evaluated mechanical properties, structural details, joint performance, repair, static compression, and two-bay crack residual strength panels. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511x extrusion, and 7475-T7351 plate. Structural performance was evaluated with a large 7475-T7351 pressure test that included the arrest of a two-bay longitudinal crack, and a measure of residual strength for a two-bay crack centered on a broken frame. Analysis predictions for the two-bay longitudinal crack panel correlated well with the test results. Analysis activity conducted by the IAS team strongly indicates that current analysis tools predict integral structural behavior as accurately as built-up structure. The cost study results indicated that, compared to built-up fabrication methods, high-speed machining structure from aluminum plate would yield a recurring cost savings of 61%. Part count dropped from 78 individual parts on a baseline panel to just 7 parts for machined IAS structure.

Munroe, J.↗