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NASA NTRSDate not supplied

Undue Conservatisim in Structural Designs

Assuming that dynamic (transient/vibratory) loads are static in the design of structures is a long-standing engineering practice. The assumption is conservative for hardware that will have limited exposure to the specified dynamic environment and fatigue is not a concern. This is the case for most space flight hardware. Once out of the Earth’s atmosphere, significant vibrations are non-existent for most hardware and vibration cycles are limited. Mass is, and has always been, a concern with respect to flight hardware design. How much unnecessary mass due to the subject assumption may be in structural designs was questioned and numerous tests have been performed to qualitatively address that. Tests have been performed on simple aluminum beams, beams with bolted joints and beams with welded joints. Results of those tests are reported in this paper. The objective of these efforts was to demonstrate the order of magnitude of conservatism associated with this engineering process via comparing static to dynamic tests and the longer term endgame is to develop a new or modified quick turnaround structural design process that circumvents assuming dynamic loads are static and results in lighter structural designs. Test results qualitatively demonstrate notable conservatism. Activities to devise the new method are underway.

conservative loads↗
NASA NTRS1973

Benefits of advanced propulsion technology for the advanced supersonic transport

Future supersonic transports will have to provide improvement in the areas of economics, range, and emissions relative to the present generation of supersonic transports, as well as meeting or improving upon FAR 36 noise goals. This paper covers the promising propulsion systems including variable-cycle engine concepts for long-range supersonic commercial transport application. The benefits of applying advanced propulsion technology to solve the economic and environmental problems are reviewed. The advanced propulsion technologies covered are in the areas of structures, materials, cooling techniques, aerodynamics, variable engine geometry, jet noise suppressors, acoustic treatment, and low-emission burners. The results of applying the advanced propulsion technology are presented in terms of improvement in overall system takeoff gross weight and return on investment.

Hines, R. W.↗
NASA NTRS1993

Coupled multi-disciplinary composites behavior simulation

The capabilities of the computer code CSTEM (Coupled Structural/Thermal/Electro-Magnetic Analysis) are discussed and demonstrated. CSTEM computationally simulates the coupled response of layered multi-material composite structures subjected to simultaneous thermal, structural, vibration, acoustic, and electromagnetic loads and includes the effect of aggressive environments. The composite material behavior and structural response is determined at its various inherent scales: constituents (fiber/matrix), ply, laminate, and structural component. The thermal and mechanical properties of the constituents are considered to be nonlinearly dependent on various parameters such as temperature and moisture. The acoustic and electromagnetic properties also include dependence on vibration and electromagnetic wave frequencies, respectively. The simulation is based on a three dimensional finite element analysis in conjunction with composite mechanics and with structural tailoring codes, and with acoustic and electromagnetic analysis methods. An aircraft engine composite fan blade is selected as a typical structural component to demonstrate the CSTEM capabilities. Results of various coupled multi-disciplinary heat transfer, structural, vibration, acoustic, and electromagnetic analyses for temperature distribution, stress and displacement response, deformed shape, vibration frequencies, mode shapes, acoustic noise, and electromagnetic reflection from the fan blade are discussed for their coupled effects in hot and humid environments. Collectively, these results demonstrate the effectiveness of the CSTEM code in capturing the coupled effects on the various responses of composite structures subjected to simultaneous multiple real-life loads.

Singhal, Surendra N.↗
NASA NTRS2014

Aeroelastic Modeling of a Nozzle Startup Transient

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development during test. While three-dimensional, transient, turbulent, chemically reacting computational fluid dynamics methodology has been demonstrated to capture major side load physics with rigid nozzles, hot-fire tests often show nozzle structure deformation during major side load events, leading to structural damages if structural strengthening measures were not taken. The modeling picture is incomplete without the capability to address the two-way responses between the structure and fluid. The objective of this study is to develop a tightly coupled aeroelastic modeling algorithm by implementing the necessary structural dynamics component into an anchored computational fluid dynamics methodology. The computational fluid dynamics component is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, while the computational structural dynamics component is developed under the framework of modal analysis. Transient aeroelastic nozzle startup analyses at sea level were performed, and the computed transient nozzle fluid-structure interaction physics presented,

Wang, Ten-See↗
NASA NTRS2013

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development. Currently there is no fully coupled computational tool to analyze this fluid/structure interaction process. The objective of this study was to develop a fully coupled aeroelastic modeling capability to describe the fluid/structure interaction process during the transient nozzle operations. The aeroelastic model composes of three components: the computational fluid dynamics component based on an unstructured-grid, pressure-based computational fluid dynamics formulation, the computational structural dynamics component developed in the framework of modal analysis, and the fluid-structural interface component. The developed aeroelastic model was applied to the transient nozzle startup process of the Space Shuttle Main Engine at sea level. The computed nozzle side loads and the axial nozzle wall pressure profiles from the aeroelastic nozzle are compared with those of the published rigid nozzle results, and the impact of the fluid/structure interaction on nozzle side loads is interrogated and presented.

Wang, Ten-See↗
NASA NTRS2001

Working Toward Nanotube Composites

One of the most attractive applications of single-wall carbon nanotubes (SWNT) is found in the area of structural materials. Nanotubes have a unique combination of high strength, modulus, and elongation to failure, and therefore have potential to significantly enhance the mechanical properties of today's composites. This is especially attractive for the aerospace industry looking for any chance to save weight. This is why NASA has chosen to tackle this difficult application of SWNT. Nanotube properties differ significantly from that of conventional carbon fibers, and a whole new set of problems, including adhesion and dispersion in the adhesive polymer matrix, must be resolved in order to engineer superior composite materials. From recent work on a variety of applications it is obvious that the wide range of research in nanotubes will lead to advances in physics, chemistry, and engineering. However, the possibility of ultralightweight structures is what causes dreamers to really get excited. One of the important issues in composite engineering is aspect ratio of the fibers, since it affects load transfer in composites. Nanotube length was a gray area for years, since they are formed in bundles, making it impossible to monitor individual nanotube length. Even though bundles are observed to be tens and hundreds of microns long, they can be built of relatively short tubes weakly bound by Van der Waals forces. Nanotube length can be affected by subsequent purification and ultrasound processing, which has been necessary in order to disperse nanotubes and introduce them into a polymer matrix. Some calculations show that nanotubes with 10(exp 5) aspect ratio may be necessary to achieve good load transfer. We show here that nanotubes produced in our laser system are as much as tens of microns long and get cut into lengths of hundreds of nanometers during ultrasound processing. Nanotube length was measured by AFM on pristine nanotube specimens as well, as after sonication. In each case great care was taken to measure individual nanotubes, rather than bundles. Pristine nanotubes were collected on quartz substrates placed directly in the laser oven and exposed for 0.5 s. This results in an equal mix of bundles and individual nanotubes. Nanotube length measurements were limited practically by the lateral span of the AFM scanner, but nanotube length is certainly in excess of 20 micrometers.

Arepalli, Sivaram↗
NASA NTRS1983

ADS-1 - A new general-purpose optimization program

Today, numerous programs are available which may be coupled with finite element analysis or other analysis techniques to perform the optimization function in the solution of structural synthesis problems. However, most of these codes include only one or two algorithms and many have not been tested on problems of significant size and complexity. There is, therefore, a need for a reliable, general-purpose, publicly available code, containing a variety of modern algorithms for use in structural synthesis as well as general engineering design. The ADS-1 program (Automated Design Synthesis: Version 1) was written in response to this need. The present investigation has the objective to present the capabilities of the ADS program and to demonstrate its application to structural synthesis. The ADS program solves the general nonlinear constrained optimization problem in the standard form. At each level of the optimization process, several options are available.

Vanderplaats, G. N.↗
NASA NTRS1978

Quiet Clean Short-haul Experimental Engine (QCSEE) composite fan frame design report

An advanced composite frame which is flight-weight and integrates the functions of several structures was developed for the over the wing (OTW) engine and for the under the wing (UTW) engine. The composite material system selected as the basic material for the frame is Type AS graphite fiber in a Hercules 3501 epoxy resin matrix. The frame was analyzed using a finite element digital computer program. This program was used in an iterative fashion to arrive at practical thicknesses and ply orientations to achieve a final design that met all strength and stiffness requirements for critical conditions. Using this information, the detail design of each of the individual parts of the frame was completed and released. On the basis of these designs, the required tooling was designed to fabricate the various component parts of the frame. To verify the structural integrity of the critical joint areas, a full-scale test was conducted on the frame before engine testing. The testing of the frame established critical spring constants and subjected the frame to three critical load cases. The successful static load test was followed by 153 and 58 hours respectively of successful running on the UTW and OTW engines.

Mitchell, S. C.↗
NASA NTRS1981

The 15th Aerospace Mechanisms Symposium

The purpose of the symposium was to provide a forum for the interchange of information among those active in the field of mechanism technology. To that end, 27 papers were presented on aeronautics and space flight, with special emphasis on actuators and aerospace applications for pointing systems, latches, connectors, and other mechanisms for large space structures. The papers were authored by engineers from a broad aerospace spectrum including the U. S. aerospace industry, NASA, and several European participants. Technological areas covered include: aerospace propulsion; aerodynamic devices; crew safety; space vehicle control; spacecraft deployment, positioning, and pointing; deployable antennas/reflectors; and large space structures. Devices for payload deployment, payload retention, and crew extravehicular activities on the space shuttle orbiter are also described.

Actuators↗
NASA NTRS2000

Aerospace Systems Design in NASA's Collaborative Engineering Environment

Past designs of complex aerospace systems involved an environment consisting of collocated design teams with project managers, technical discipline experts, and other experts (e.g., manufacturing and systems operation). These experts were generally qualified only on the basis of past design experience and typically had access to a limited set of integrated analysis tools. These environments provided less than desirable design fidelity, often lead to the inability of assessing critical programmatic and technical issues (e.g., cost, risk, technical impacts), and generally derived a design that was not necessarily optimized across the entire system. The continually changing, modern aerospace industry demands systems design processes that involve the best talent available (no matter where it resides) and access to the the best design and analysis tools. A solution to these demands involves a design environment referred to as collaborative engineering. The collaborative engineering environment evolving within the National Aeronautics and Space Administration (NASA) is a capability that enables the Agency's engineering infrastructure to interact and use the best state-of-the-art tools and data across organizational boundaries. Using collaborative engineering, the collocated team is replaced with an interactive team structure where the team members are geographical distributed and the best engineering talent can be applied to the design effort regardless of physical location. In addition, a more efficient, higher quality design product is delivered by bringing together the best engineering talent with more up-to-date design and analysis tools. These tools are focused on interactive, multidisciplinary design and analysis with emphasis on the complete life cycle of the system, and they include nontraditional, integrated tools for life cycle cost estimation and risk assessment. NASA has made substantial progress during the last two years in developing a collaborative engineering environment. NASA is planning to use this collaborative engineering engineering infrastructure to provide better aerospace systems life cycle design and analysis, which includes analytical assessment of the technical and programmatic aspects of a system from "cradle to grave." This paper describes the recent NASA developments in the area of collaborative engineering, the benefits (realized and anticipated) of using the developed capability, and the long-term plans for implementing this capability across Agency.

Monell, Donald W.↗
NASA NTRS1999

Aerospace Systems Design in NASA's Collaborative Engineering Environment

Past designs of complex aerospace systems involved an environment consisting of collocated design teams with project managers, technical discipline experts, and other experts (e.g. manufacturing and systems operations). These experts were generally qualified only on the basis of past design experience and typically had access to a limited set of integrated analysis tools. These environments provided less than desirable design fidelity, often lead to the inability of assessing critical programmatic and technical issues (e.g., cost risk, technical impacts), and generally derived a design that was not necessarily optimized across the entire system. The continually changing, modern aerospace industry demands systems design processes that involve the best talent available (no matter where it resides) and access to the best design and analysis tools. A solution to these demands involves a design environment referred to as collaborative engineering. The collaborative engineering environment evolving within the National Aeronautics and Space Administration (NASA) is a capability that enables the Agency's engineering infrastructure to interact and use the best state-of-the-art tools and data across organizational boundaries. Using collaborative engineering, the collocated team is replaced with an interactive team structure where the team members are geographically distributed and the best engineering talent can be applied to the design effort regardless of physical location. In addition, a more efficient, higher quality design product is delivered by bringing together the best engineering talent with more up-to-date design and analysis tools. These tools are focused on interactive, multidisciplinary design and analysis with emphasis on the complete life cycle of the system, and they include nontraditional, integrated tools for life cycle cost estimation and risk assessment. NASA has made substantial progress during the last two years in developing a collaborative engineering environment. NASA is planning to use this collaborative engineering infrastructure to provide better aerospace systems life cycle design and analysis, which includes analytical assessment of the technical and programmatic aspects of a system from "cradle to grave." This paper describes the recent NASA developments in the area of collaborative engineering, the benefits (realized and anticipated) of using the developed capability, and the long-term plans for implementing this capability across the Agency.

Monell, Donald W.↗
NASA NTRS1993

Development of hypersonic engine seals - Flow effects of preload and engine pressures

A new type of engine seal is being developed to meet the needs of advanced hypersonic engines. A seal braided of emerging high temperature ceramic fibers comprised of a sheath-core construction has been selected for study based on its low leakage rates. Flexible, low-leakage, high-temperature seals are required to seal the movable engine panels of advanced ramjet-scramjet engines either preventing potentially dangerous leakage into backside engine cavities or limiting the purge coolant flow rates through the seals. To predict the leakage through these flexible, porous seal structures as a function of preload and engine pressures, new analytical flow models are required. An empirical leakage resistance/preload model is proposed to characterize the observed decrease in leakage with increasing preload. Empirically determined compression modulus and preload factor are used to correlate experimental leakage data for a wide range of seal architectures. Good agreement between measured and predicted values are observed over a range of engine pressures and seal preload.

Cai, Zhong↗
NASA NTRS1993

Development of hypersonic engine seals: Flow effects of preload and engine pressures

A new type of engine seal is being developed to meet the needs of advanced hypersonic engines. A seal braided of emerging high temperature ceramic fibers comprised of a sheath-core construction was selected for study based on its low leakage rates. Flexible, low-leakage, high temperature seals are required to seal the movable engine panels of advanced ramjet-scramjet engines either preventing potentially dangerous leakage into backside engine cavities or limiting the purge coolant flow rates through the seals. To predict the leakage through these flexible, porous seal structures as a function of preload and engine pressures, new analytical flow models are required. An empirical leakage resistance/preload model is proposed to characterize the observed decrease in leakage with increasing preload. Empirically determined compression modulus and preload factor are used to correlate experimental leakage data for a wide range of seal architectures. Good agreement between measured and predicted values are observed over a range of engine pressures and seal preloads.

Cai, Zhong↗
NASA NTRS2001

Large structural, thin-wall castings made of metals subject to hot tearing, and their fabrication

An article, such as a gas turbine engine mixer, is made by providing a mold structure defining a thin-walled, hollow article, and a base metal that is subject to hot tear cracking when cast in a generally equiaxed polycrystalline form, such as Rene' 108 and Mar-M247. The article is fabricated by introducing the molten base metal into the mold structure, and directionally solidifying the base metal in the mold structure to form a directionally oriented structure. The directionally oriented structure may be formed of a single grain or oriented multiple grains.

Smashey, Russell W.↗
NASA NTRS1987

Structural design options for the new 34 meter beam waveguide antenna

In addition to the successful network of 34 m High Efficiency antennas recently built by JPL, the Deep Space Network (DSN) is embarking on the construction of a 34 m high performance, research and development antenna with beam waveguide optics at the Venus site. The construction of this antenna presents many engineering challenges in the area of structural, mechanical, RF, and pointing system design. A set of functional and structural design requirements is outlined to guide analysts in the final configuration selection. Five design concepts are presented covering both the conventional center-fed beam optics as well as the nonconventional, by-pass beam configuration. The merits of each concept are discussed with an emphasis on obtaining a homologous design. The preliminary results of structural optimization efforts, currently in progress, are promising, indicating the feasibility of meeting, as a minimum, all X-band (8.4 GHz) requirements, with a goal towards meeting Ka-band (32 GHz) quality performance, at the present budget constraints.

Katow, S.↗