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The concept of acoustic emission analysis is explained in scientific terms. The detection of acoustic events, their localization, damage discrimination, and event summation curves are discussed. A block diagram of the concept of damage-free testing of fiber-reinforced synthetic materials is depicted. Prospects for application of the concept are assessed.
A prototype 11.994 GHz, traveling-wave accelerating structure for the Compact Linear Collider has been built, using the novel technique of assembling the structure from milled halves. The use of milled halves has many advantages when compared to a structure made from individual disks. These include the potential for a reduction in cost, because there are fewer parts, as well as a greater freedom in choice of joining technology because there are no rf currents across the halves’ joint. Here we present the rf design and fabrication of the prototype structure, followed by the results of the high-power test and post-test surface analysis. During high-power testing the structure reached an unloaded gradient of 100 MV / m at a rf breakdown rate of less than 1.5×10 –5 breakdowns / pulse / m with a 200 ns pulse. Furthermore, this structure has been designed for the CLIC testing program but construction from halves can be advantageous in a wide variety of applications.
The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include various graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Keviar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.
The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Kevlar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.
The use of small laboratory specimens to predict the integrity of large, complex structures relies on the validity of single parameter fracture mechanics. Unfortunately, the constraint loss associated with large scale yielding, whether in a laboratory specimen because of its small size or in a structure because it contains shallow flaws loaded in tension, can cause the breakdown of classical fracture mechanics and the loss of transferability of critical, global fracture parameters. Although the issue of constraint loss can be eliminated by testing actual structural configurations, such an approach can be prohibitively costly. Hence, a methodology that can correct global fracture parameters for constraint effects is desirable. This research uses micromechanical analyses to define the relationship between global, ductile fracture initiation parameters and constraint in two specimen geometries (SECT and SECB with varying a/w ratios) and one structural geometry (circumferentially cracked pipe). Two local fracture criteria corresponding to ductile fracture micromechanisms are evaluated: a constraint-modified, critical strain criterion for void coalescence proposed by Hancock and Cowling and a critical void ratio criterion for void growth based on the Rice and Tracey model. Crack initiation is assumed to occur when the critical value in each case is reached over some critical length. The primary material of interest is A516-70, a high-hardening pressure vessel steel sensitive to constraint; however, a low-hardening structural steel that is less sensitive to constraint is also being studied. Critical values of local fracture parameters are obtained by numerical analysis and experimental testing of circumferentially notched tensile specimens of varying constraint (e.g., notch radius). These parameters are then used in conjunction with large strain, large deformation, two- and three-dimensional finite element analyses of the geometries listed above to predict crack initiation loads and to calculate the associated (critical) global fracture parameters. The loads are verified experimentally, and microscopy is used to measure pre-crack length, crack tip opening displacement (CTOD), and the amount of stable crack growth. Results for A516-70 steel indicate that the constraint-modified, critical strain criterion with a critical length approximately equal to the grain size (0.0025 inch) provides accurate predictions of crack initiation. The critical void growth criterion is shown to considerably underpredict crack initiation loads with the same critical length. The relationship between the critical value of the J-integral for ductile crack initiation and crack depth for SECT and SECB specimens has been determined using the constraint-modified, critical strain criterion, demonstrating that this micromechanical model can be used to correct in-plane constraint effects due to crack depth and bending vs. tension loading. Finally, the relationship developed for the SECT specimens is used to predict the behavior of circumferentially cracked pipe specimens.
Electromagnetic band gap (EBG) integrated monopole antenna is investigated in deformed cavity resonator in this study. The operation frequency is chosen as X band frequency regime and designs are completed for this frequency. Firstly, a square grounded monopole antenna is designed and analytically examined, then EBG grounded monopole is designed and tested. After that operation, an 8 cm × 8 cm × 8 cm cubic cavity resonator designed and antennas are examined in it. Moreover, a cuboid deformation is added in one corner of metallic cavity resonator to perturb rectangular eigenmodes. Also, tunability of this structure is tested by various resistive lumped elements, and according to results, resonance shifting and magnitude changes are obtained. This suggested structure is also an adjustable impedance surface and can be used in sensing, detection and microwave imaging applications.
Design studies are presented which consider the important parameters in providing 200 knot test velocities at the landing loads and traction facility. Two major components of this facility, the hydraulic jet catapult and the test carriage structure, are considered. Suitable factors are determined to correlate analytical data for characteristics of the hydraulic jet catapult with data measured from the existing catapult system. The resulting equations are used to calculate test velocities for a range of jet nozzle diameters and carriage masses with both the current 122 m and an increased 183 m catapult stroke. Using the catapult characteristics, a target design point is selected and a carriage structure is sized to meet the target point strength requirements.
With the privatization of the space industry, NASA has entered a new era. To explore deeper parts of the solar system, NASA is developing a new spacecraft, the Space Launch System (SLS), capable of reaching these destinations, such as an asteroid or Mars. However, the test stand that is capable of testing the stage has been unused for many years. In addition to the updating/repair of the stand, more steel is being added to fully support the SLS. With all these modifications, the lightning protection system must be brought up to code to assure the protection of all personnel and assets. Structural bonding is a part of the lightning protection system. The focus of this project was to assure proper structural bonding. To begin, all relevant technical standards and the construction specifications were reviewed. This included both the specifications for the lightning protection and for general construction. The drawings were reviewed as well. From the drawings, bolted structural joints were reviewed to determine whether bonding was necessary. Several bolted joints were determined to need bonding according to the notes in the drawings. This exceeds the industry standards. The bolted joints are an electrically continuous joint. During tests, the stand experiences heavy vibration that may weaken the continuity of the bolted joint. Therefore, the secondary bonding is implemented to ensure that the structural joint has low resistance. If the structural joint has a high resistance because of corrosion, a potential gradient can occur that can cause a side flash. Damage, injury, or death can occur from a side flash so they are to be prevented. A list of the identified structural joints was compiled and sent to the contractor to be bonded. That covers the scope of this project.
An inventory of test facilities for conducting acceleration, environmental, impact, structural shock, load, heat, vibration, and noise tests is presented. The facility is identified with a description of the equipment, the testing capabilities, and cost of operation. Performance data for the facility are presented in charts and tables.
The crash dynamics and energy absorption of composite sailplane fuselage segments undergoing nose-down impact were investigated. More than 10 quarter-scale structurally similar test articles, typical of high-performance sailplane designs, were tested. Fuselages segments were fabricated of combinations of fiberglass, graphite, Kevlar, and Spectra fabric materials. Quasistatic and dynamic tests were conducted. The quasistatic tests were found to replicate the strain history and failure modes observed in the dynamic tests. Failure modes of the quarter-scale model were qualitatively compared with full-scale crash evidence and quantitatively compared with current design criteria. By combining material and structural improvements, substantial increases in crashworthiness were demonstrated.
A simple method for an unsteady aerodynamic model tuning is proposed in this study. This method is based on the direct modification of the aerodynamic influence coefficient matrices. The aerostructures test wing 2 flight-test data is used to demonstrate the proposed model tuning method. The flutter speed margin computed using only the test validated structural dynamic model can be improved using the additional unsteady aerodynamic model tuning, and then the flutter speed margin requirement of 15 % in military specifications can apply towards the test validated aeroelastic model. In this study, unsteady aerodynamic model tunings are performed at two time invariant flight conditions, at Mach numbers of 0.390 and 0.456. When the Mach number for the unsteady model tuning approaches to the measured fluttering Mach number, 0.502, at the flight altitude of 9,837 ft, the estimated flutter speed is approached to the measured flutter speed at this altitude. The minimum flutter speed difference between the estimated and measured flutter speed is -.14 %.
A flight test campaign of a supersonic natural laminar flow airfoil has been recently completed. The test surface was an 80-inch (203 cm) chord and 40-inch (102 cm) span article mounted on the centerline store location of an F-15B airplane. The wing was designed with a leading edge sweep of effectively 0 deg to minimize boundary layer crossflow. The test article surface was coated with an insulating material to avoid significant heat transfer to and from the test article structure to maintain a quasi-adiabatic wall. An aircraft-mounted infrared camera system was used to determine boundary layer transition and the extent of laminar flow. The tests were flown up to Mach 2.0 and chord Reynolds numbers in excess of 30 million. The objectives of the tests were to determine the extent of laminar flow at high Reynolds numbers and to determine the sensitivity of the flow to disturbances. Both discrete (trip dots) and 2-D disturbances (forward-facing steps) were tested. A series of oblique shocks, of yet unknown origin, appeared on the surface, which generated sufficient crossflow to affect transition. Despite the unwanted crossflow, the airfoil performed well. The results indicate the sensitivity of the flow to the disturbances, which can translate into manufacturing tolerances, were similar to that of subsonic natural laminar flow wings.
A flight-test campaign of a supersonic natural laminar flow airfoil has been recently completed. The test surface was an 80-inch (203 cm) chord and 40-inch (102 cm) span article mounted on the centerline store location of an F-15B airplane (McDonnell Douglas Corporation, now The Boeing Company, Chicago, Illinois). The test article was designed with a leading edge sweep of effectively 0 deg to minimize boundary layer crossflow. The test article surface was coated with an insulating material to avoid significant heat transfer to and from the test article structure to maintain a quasi-adiabatic wall. An aircraft-mounted infrared camera system was used to determine boundary layer transition and the extent of laminar flow. The tests were flown up to Mach 2.0 and chord Reynolds numbers in excess of 30 million. The objectives of the tests were to determine the extent of laminar flow at high Reynolds numbers and to determine the sensitivity of the flow to disturbances. Both discrete (trip dots) and 2-D disturbances (forward-facing steps) were tested. A series of oblique shocks, of yet unknown origin, appeared on the surface, which generated sufficient crossflow to affect transition. Despite the unwanted crossflow, the airfoil performed well. The results indicate the sensitivity of the flow to the disturbances, which can translate into manufacturing tolerances, were similar to that of subsonic natural laminar flow wings.
Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.
The failure of the NSTX-U PF1A upper coil suspended plasma operations during the project's first operational campaign after commissioning. Initial nondestructive testing and examination of the failed coil was followed by extensive nondestructive radiography. Destructive testing facilitated visual borescope/videoscope inspection through the cooling path, vacuum testing, and electrical testing of every conductor segment. One conductor cooling path visually evidenced a void through the sidewall of the cooling path in a layer-to-layer region. The identified void in the conductor cooling path was not proximal to a braze or joggle. Electrical testing indicated that the voided conductor segment was a member of a group of 14 conductor segments that evidenced low-resistance connectivity. Four braze joints and two lead segments were subjected to 400-lbf/in 2 hydrostatic pressure testing followed by helium leak testing and evidenced that there were no detectable leaks in the tested cooling path segments. The faulted region was proximal to the center of the coil pack and evidenced historical electrical pitting and molten conductor debris. Samples of the epoxy resin insulation system were extracted and analyzed with dynamic mechanical analysis and differential scanning calorimetry techniques. Epoxy resin insulation samples were subjected to immersion testing per ASTM D570. Metallurgical samples were extracted from the coil pack conductors and subjected to hardness testing and grain structure analysis. The base material testing results indicated no abnormalities. In conclusion, the coil incipient failure was determined to most likely have resulted from conductive material located between conductor and insulation layers.
X 15 flight tests showing structure, powerplant, and auxiliary systems problems, and emphasizing pilots boost, entry, and landing techniques
The need for a standardized battery of human performance tests to measure the effects of various treatments is pointed out. Progress in such a program is reported. Three batteries are available which differ in length and the number of tests in the battery. All tests are implemented on a portable, lap held, briefcase size microprocessor. Performances measured include: information processing, memory, visual perception, reasoning, and motor skills, programs to determine norms, reliabilities, stabilities, factor structure of tests, comparisons with marker tests, apparatus suitability. Rationale for the battery is provided.
The purpose of the Solar Array Flight Dynamic Experiment (SAFDE) is to demonstrate the feasibility of on-orbit measurement and ground processing of large space structures dynamic characteristics. Test definition or verification provides the dynamic characteristic accuracy required for control systems use. An illumination/measurement system was developed to fly on space shuttle flight STS-31D. The system was designed to dynamically evaluate a large solar array called the Solar Array Flight Experiment (SAFE) that had been scheduled for this flight. The SAFDE system consisted of a set of laser diode illuminators, retroreflective targets, an intelligent star tracker receiver and the associated equipment to power, condition, and record the results. In six tests on STS-41D, data was successfully acquired from 18 retroreflector targets and ground processed, post flight, to define the solar array's dynamic characteristic. The flight experiment proved the viability of on-orbit test definition of large space structures dynamic characteristics. Future large space structures controllability should be greatly enhanced by this capability.