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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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At least 127 records · Page 7

X-38 Bolt Retractor Subsystem Separation Demonstration

The Flight Robotics Laboratory FRL successfully demonstrated the X-38 bolt retractor subsystem (BRS). The BRS design was proven safe by testing in the Pyrotechnic Shock Facility (PSI) before being demonstrated in the FRL. This Technical Memorandum describes the BRS, FRL, PSF, and interface hardware. Bolt retraction time, spacecraft simulator acceleration, and a force analysis are also presented. The purpose of the demonstration was to show the FRL capability for spacecraft separation testing using pyrotechnics. Although a formal test was not performed due to schedule and budget constraints, the data will show that the BRS is a successful design concept and the FRL is suitable for future separation tests.

Rugless, Fedoria↗

Bolting Technology

With NERAC assistance, Raymond Engineering has developed a line of sophisticated tools for producing and controlling high torques that affect bolted joints in various applications. Information from NERAC was also useful in designing and presenting a series of Raymond Bolting Seminars. The new tools have increased sales and created jobs.

Source record↗

Analysis of a Preloaded Bolted Joint in a Ceramic Composite Combustor

This paper presents the detailed analysis of a preloaded bolted joint incorporating ceramic materials. The objective of this analysis is to determine the suitability of a joint design for a ceramic combustor. The analysis addresses critical factors in bolted joint design including preload, preload uncertainty, and load factor. The relationship between key joint variables is also investigated. The analysis is based on four key design criteria, each addressing an anticipated failure mode. The criteria are defined in terms of margin of safety, which must be greater than zero for the design criteria to be satisfied. Since the proposed joint has positive margins of safety, the design criteria are satisfied. Therefore, the joint design is acceptable.

Hissam, D. Andy↗

Design and Demonstration of Bolt Retractor Separation System for X-38 Deorbit Propulsion Stage

A separation system was designed for the X-38 experimental crew return vehicle program to allow the Deorbit Propulsion Stage (DPS) to separate from the X-38 lifting body during reentry operations. The configuration chosen was a spring-loaded plunger, known as the Bolt Retractor Subsystem (BRS), that retracts each of the six DPS-to-lifting body attachment bolts across the interface plane after being triggered by a separation nut mechanism. The system was designed to function on the ground in an atmospheric environment as well as in space. The BRS provides the same functionality as that of a completely pyrotechnic shear separation system that would normally be considered ideal for this application, but at a much lower cost. This system also could potentially be applied to future space station crew return vehicles. The design goal of 40 ms retraction time was successfully met in a series of demonstrations performed at the NASA Marshall Space Flight Center s Pyrotechnic Shock Facility (PSF) and Flight Robotics Laboratory (FRL). It must be emphasized that a full-scale test series was not performed on the BRS due to program schedule and cost constraints.

Ahmed, Raf↗

Small-Bolt Torque-Tension Tester

The device described here measures the torque-tension relationship for fasteners as small as #0. The small-bolt tester consists of a plate of high-strength steel into which three miniature load cells are recessed. The depth of the recess is sized so that the three load cells can be shimmed, the optimum height depending upon the test hardware. The three miniature load cells are arranged in an equilateral triangular configuration with the test bolt aligned with the centroid of the three. This is a kinematic arrangement.

Posey, Alan J.↗

Demonstration of a Pyrotechnic Bolt-Retractor System

A paper describes a demonstration of the X-38 bolt-retractor system (BRS) on a spacecraft-simulating apparatus, called the Large Mobility Base, in NASA's Flight Robotics Laboratory (FRL). The BRS design was proven safe by testing in NASA's Pyrotechnic Shock Facility (PSF) before being demonstrated in the FRL. The paper describes the BRS, FRL, PSF, and interface hardware. Information on the bolt-retraction time and spacecraft-simulator acceleration, and an analysis of forces, are presented. The purpose of the demonstration was to show the capability of the FRL for testing of the use of pyrotechnics to separate stages of a spacecraft. Although a formal test was not performed because of schedule and budget constraints, the data in the report show that the BRS is a successful design concept and the FRL is suitable for future separation tests.

Johnston, Nick↗

Ballistics Analysis of Orion Crew Module Separation Bolt Cover

NASA is currently developing a new crew module to replace capabilities of the retired Space Shuttles and to provide a crewed vehicle for exploring beyond low earth orbit. The crew module is a capsule-type design, which is designed to separate from the launch vehicle during launch ascent once the launch vehicle fuel is expended. The separation is achieved using pyrotechnic separation bolts, wherein a section of the bolt is propelled clear of the joint at high velocity by an explosive charge. The resulting projectile must be contained within the fairing structure by a containment plate. This paper describes an analytical effort completed to augment testing of various containment plate materials and thicknesses. The results help guide the design and have potential benefit for future similar applications.

Howard, Samuel A.↗

Secondary Side Considerations for the BOLT Flight Experiment

The Boundary Layer Transition (BOLT) Flight Experiment is preparing for launch in the Spring of 2020. Final designs decisions have been made to allow fabrication of hardware. The secondary side experiment, which was initially proposed to be a roughness experiment, was selected instead to be an investigation of step effects to provide better synergy with the primary side. Numerous design decisions have influenced the decision to revise and refine the goal of the secondary side, which is now to investigate the effects of rearward-facing steps. The present paper focused on the BOLT secondary side flight experiment, providing details of the key inputs and decisions made to finalize the flight vehicle and instrumentation.

Scott A Berry↗

A Computational Analysis of Boundary Layer Instability over the BOLT Configuration

The complex boundary layer flow over the BOLT flight configuration is known to exhibit multiple and potentially interacting instability mechanisms. This paper represents a continuation of our numerical investigation of the flow instabilities over the main test surface of the BOLT configuration by using state-of-the-art tools in multidimensional instability analysis. Specifically, the paper extends our previous computations by considering the separate effects of a nonzero angle-of-attack and a nonzero yaw on the modal instability characteristics of the boundary layer streaks adjacent to the minor-axis symmetry plane. At a selected condition from the ascent part of the anticipated flight trajectory, either type of departure from the design condition is shown to have a considerable impact on the structure of the laminar basic state and, hence, also on the amplification characteristics of the instability waves. A broader set of computations, including N-factor predictions for the relevant instabilities, will be presented in the final paper.

Boundary layer transition↗

A Computational Analysis of Boundary Layer Instability over the BOLT Configuration

The complex boundary layer flow over the BOLT flight configuration is known to exhibit multiple and potentially interacting instability mechanisms. This paper represents a continuation of our numerical investigation of the flow instabilities over the main test surface of the BOLT configuration by using state-of-the-art tools in multidimensional instability analysis. Specifically, the paper extends our previous computations by considering the separate effects of a nonzero angle of attack and a nonzero yaw on the modal instability characteristics of the boundary layer streaks adjacent to the minor-axis symmetry plane, specifically near both ends of the azimuthal region of a thick boundary layer in the middle, where this region rapidly changes to a thinner boundary layer on either side. At the t = 28.8767 s condition from the ascent part of the anticipated flight trajectory with a flight Mach number of M ∞ = 5.53 and unit Reynolds number of 4.25 x 10 6 /m, either type of departure from the design condition is shown to have a considerable impact on the structure of the basic state rollup within the region of interest and, hence, also on the amplification characteristics of instability waves within the resulting streaks. Yet, for a yaw angle of β = 4 degrees, the computations indicate only a slight reduction with respect to the peak N-factor of nearly 11 at the design condition of zero degrees yaw and zero degrees angle of attack. In contrast, an angle of attack equal to α = 4 degrees, the peak N-factor decreases to nearly 6 on the leeward side and increases above 16 on the windward side, making the onset of transition highly likely on the windward side. Computations also highlight the role of streak instabilities that originate as Mack mode disturbances and also demonstrate the potential pitfalls in using surface pressure sensors alone to gauge the magnitude of instability amplification.

Boundary layer transition↗

A Computational Analysis of Boundary Layer Instability over the BOLT Configuration (Effect of Nonzero AoA and Yaw)

The complex boundary layer flow over the BOLT flight configuration is known to exhibit multiple and potentially interacting instability mechanisms. This paper represents a continuation of our numerical investigation of the flow instabilities over the main test surface of the BOLT configuration by using state-of-the-art tools in multidimensional instability analysis. Specifically, the paper extends our previous computations by considering the separate effects of a nonzero angle of attack and a nonzero yaw on the modal instability characteristics of the boundary layer streaks adjacent to the minor-axis symmetry plane, specifically near both ends of the azimuthal region of a thick boundary layer in the middle, where this region rapidly changes to a thinner boundary layer on either side. At the t = 28.8767 s condition from the ascent part of the anticipated flight trajectory with a flight Mach number of M ∞ = 5.53 and unit Reynolds number of 4.25 x 10 6 /m, either type of departure from the design condition is shown to have a considerable impact on the structure of the basic state rollup within the region of interest and, hence, also on the amplification characteristics of instability waves within the resulting streaks. Yet, for a yaw angle of β = 4 degrees, the computations indicate only a slight reduction with respect to the peak N-factor of nearly 11 at the design condition of zero degrees yaw and zero degrees angle of attack. In contrast, an angle of attack equal to α = 4 degrees, the peak N-factor decreases to nearly 6 on the leeward side and increases above 16 on the windward side, making the onset of transition highly likely on the windward side. Computations also highlight the role of streak instabilities that originate as Mack mode disturbances and also demonstrate the potential pitfalls in using surface pressure sensors alone to gauge the magnitude of instability amplification.

Boundary layer transition↗

Development of Optical Step Height Measurement Capability for the BOLT Flight Vehicle

This paper presents details on the development of testing procedures to evaluate two different optical step height sensors that were intended for use on the first and second Boundary Layer Transition (BOLT and BOLT II) flight vehicle as well as other flight vehicles. The accurate and precise measurement of step height at the interface of different sections of a flight vehicle is important, as small changes in the step height (in some instances < 10 microns) at such locations can have a significant influence on the development of a boundary layer over the outer surface of the vehicle, which in turn can significantly impact aeroheating (among other things). In this paper, testing procedures have been developed, and test hardware assembled, to determine the capabilities of two optical step height sensor candidates. The first candidate is a miniaturized camera sensor that would be embedded into the body of a flight vehicle and would image the interface between two sections of that vehicle. The second candidate is a small fiber-based optical sensor that would also be embedded into the body of the flight vehicle, but projects light onto the interface between two sections of the flight vehicle, and then monitors any reflected/scattered light from that interface. Preliminary data from these two sensor candidates are presented, and a discussion of improvements that will be made in the testing procedures and to the test hardware is provided.

Brett F Bathel↗

BOLT II Roughness-Side Flight Results

An initial review of the roughness data from the BOLT II flight is provided. The BOLT II roughness experiment was designed to investigate discrete trips in flight based on the diamond configuration, which has been shown to be an efficient vortex generator and boundary layer trip from extensive ground-based testing. There were three trip locations chosen for the flight test and their size (height and width) were tailored to the local boundary layer thickness, but all three were expected to trip at the same time or flight condition. Details about the flight vehicle design, instrumentation, and best estimated trajectory are discussed. The present paper is limited to only a review and analysis of the thermocouple data. Boundary layer transition onset times are derived from the thermocouple analysis, thus allowing an initial assessment of the performance of these discrete trips. Since the three trips were sized to trip the boundary layer at the same time, based on a previous wind tunnel study, the present analysis indicates that they performed as expected.

Hypersonic↗

Effect of Roughness on Transition on the BOLT-1a Geometry in Supersonic Flow

Infrared thermography measurements on an 8.8% scale BOLT-1a model were made in the NASA Langley Probe Calibration Tunnel for freestream unit Reynolds numbers from 7.7 × 10^ -6 /m to 30.7 × 10^ -6 /m, a freestream Mach number of 3.5, and nominal angle of attack of 0 degrees. The model was printed from polycarbonate and tested before and after fine-grit sanding to evaluate the effect of surface roughness on transition. Global surface roughness measurements were obtained using a 3D optical profilometer. The temperature distributions on the upper and lower experimental surfaces of the test article were simultaneously captured using two infrared cameras. Prior to testing, the facility’s freestream environment was characterized. At a freestream unit Reynolds number of approximately 17 × 10^ -6 /m, the nozzle-wall boundary layer began to transition non-uniformly, inducing transition on the model. The boundary-layer state was determined by analyzing Stanton number distributions computed from the surface temperature measurements. The present supersonic conditions that were examined on BOLT-1a were found to display both similarities and disparities in comparison to previous hypersonic experiments.

boundary layer transition↗

Investigation of Bolt Preload Relaxation for JWST Thermal Heat Strap Assembly Joints with Aluminum-1100 and Indium Gaskets

Accurately predicting fastener preload relaxation in the James Webb Space Telescope (JWST) heat strap assemblies is essential to insure adequate thermal performance during its mission lifecycle. The mechanisms for preload relaxation in the strap joints include Al-1100 material creep, indium gasket flow-out, and embedment of the joint faying surfaces. This report documents the results from a bolted joint relaxation test, including analysis and curve fitting of the test data for predicting preloads five years after initial torque application. The report also includes the derivation of a preload uncertainty factor enveloping both torque/preload application scatter and expected preload relaxation at the end of mission life.

Joint↗

Investigation of Bolt Preload Relaxation for JWST Thermal Heat Strap Assembly Joints with Aluminum-1100 and Indium Gaskets

Accurately predicting fastener preload relaxation in the James Webb Space Telescope (JWST) heat strap assemblies is essential to insure adequate thermal performance during its mission lifecycle. The mechanisms for preload relaxation in the strap joints include Al-1100 material creep, indium gasket flow-out, and embedment of the joint faying surfaces. This report documents the results from a bolted joint relaxation test, including analysis and curve fitting of the test data for predicting preloads five years after initial torque application. The report also includes the derivation of a preload uncertainty factor enveloping both torque/preload application scatter and expected preload relaxation at the end of mission life.

Preload↗