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Activities in the development of advanced high pressure oxygen-hydrogen stage combustion rocket engines are reported. Particular emphasis is given to the Space Shuttle main engine. The areas of engine technology discussed include fracture and fatigue in engine components, manufacturing and producibility engineering, materials, bearing technology, structure dynamics, fluid dynamics, and instrumentation technology.
Lewis Structures Div. performs and disseminates results of research conducted in support of aerospace engine structures. These results have a wide range of applicability to practitioners of structural engineering mechanics beyond the aerospace arena. The engineering community was familiarized with the depth and range of research performed by the division and its academic and industrial partners. Sessions covered vibration control, fracture mechanics, ceramic component reliability, parallel computing, nondestructive evaluation, constitutive models and experimental capabilities, dynamic systems, fatigue and damage, wind turbines, hot section technology (HOST), aeroelasticity, structural mechanics codes, computational methods for dynamics, structural optimization, and applications of structural dynamics, and structural mechanics computer codes.
The charter of the Structures Division is to perform and disseminate results of research conducted in support of aerospace engine structures. These results have a wide range of applicability to practioners of structural engineering mechanics beyond the aerospace arena. The specific purpose of the symposium was to familiarize the engineering structures community with the depth and range of research performed by the division and its academic and industrial partners. Sessions covered vibration control, fracture mechanics, ceramic component reliability, parallel computing, nondestructive evaluation, constitutive models and experimental capabilities, dynamic systems, fatigue and damage, wind turbines, hot section technology (HOST), aeroelasticity, structural mechanics codes, computational methods for dynamics, structural optimization, and applications of structural dynamics, and structural mechanics computer codes.
The contents include: 1) Mission Accomplished; 2) Resource Report: Marshall Space Flight Center; 3) NASA 1995 Software of the Year Award; 4) Microbolometers Based on Epitaxial YBa2Cu3O(sub 7-x) Thin Films; 5) Garnet Random-Access Memory; 6) Fabrication of SNS Weak Links on SOS Substrates; 7) High-Voltage MOSFET Switching Circuit; 8) Asymmetric Switching for a PWM H-Bridge Power Circuit; 9) Better Ohmic Contacts for InP Semiconductor Devices; 10) Low-Bandgap Thermovoltaic Materials and Devices; 11) Digital Frequency-Differencing Circuit; 12) Imaging Magnetometer; 13) Computer-Assisted Monitoring of a Complex System; 14) Buffered Telemetry Demodulator; 15) Compact Multifunction Inspection Head; 16) Optical Detection of Fractures in Ceramic Diaphragms; 17) Eddy-Current Detection of Cracks in Reinforced Carbon/Carbon; 18) Apparent Thermal Conductivity of Multilayer Insulation; 19) Optimizing Misch-Metal Compositions in Metal Hydride Anodes; 20) Device for Sampling Surface Contamination; 21) Probabilistic Failure Assessment for Fatigue; 22) Probabilistic Fatigue and Flaw-Propagation Analysis; 23) Windows Program for Driving the TDU-850 Printer; 24) Subband/Transform MATLAB Functions for Processing Images; 25) Computing Equilibrium Chemical Compositions; 26) Program Processes Thermocouple Readings; 27) ICAN-Second-Generation Integrated Composite Analyzer; 28) Integrated Composite Analyzer with Damping Capabilities; 29) Computing Efficiency of Transfer of Microwave Power; 30) Program Calculates Power Demands of Electronic Designs; 31) Cost-Estimation Program; 32) Program Estimates Areas Required by Electronic Designs; 33) Program to Balance Mapped Turbopump Assemblies; 34) BiblioTech; 35) Controlling Mirror Tilt With a Bimorph Actuator; 36) Burst-Disk Device Simulates Effect of Pyrotechnic Device; 37) Bearing-Mounting Concept Accommodates Thermal Expansion; 38) Parallel-Plate Acoustic Absorbers for Hot Environments; 39) Adjustable-Length Strut Withstands Large Cyclic Loads; 40) Tool Indicates Contact Angles in Bearing Raceways; 41) Gravity Slides With Magnetic Braking; 42) High-Torque, Lightweight, Pneumatically Driven Wrench for Small Spaces; 43) Device for Testing Compatibility of an O-Ring; 44) Magnetic Heat Pump Containing Flow Diverters; 45) Variable-Tilt Helicopter Rotor Mast; 46) "Beach-Ball" Robotic Rovers; 47) Apparatus Would Measure Temperatures of Ball Bearings; 48) Flexible Borescope for Inspecting Ducts; 49) Texturing Copper To Reduce Secondary Emission of Electrons; 50) Automated Laser Cutting in Three Dimensions; 51) Algorithm Helps Monitor Engine Operation; 52) Flexible Revision of Data-Processing Communications; 53) Software for Managing the Use of Land; 54) Thermal Strap Increases Cryocooling Efficiency; 55) Reversible Nut With Engagement Indication; 56) Control Algorithms for Kinematically Redundant Manipulators; 57) Computed Hydrogen-Flow Splits in a Rocket Engine; 58) Pressure and Thermal Modeling of Rocket Launches; 59) Field of View of a Spacecraft Antenna: Analysis and Software; 60) Digital Controller for Laser-Beam-Steering Subsystem; 61) More About Beam-Steering Subsystem for Laser Communication; 62) Digital Controller for Laser-Beam-Steering Subsystem: Part 2; 63) Interface Circuit Board for Space-Shuttle Communications; 64) Automated Planning of Spacecraft Telecommunications; 65) Artifacts of Spectral Analysis of Instrument Readings; 66) Neural-Network Controller for Vibration Suppression; 67) Adaptive Finite-Element Computation in Fracture Mechanics; 68) Attitude Control for the Cassini Spacecraft; 69) Analytical Model for Fluid Dynamics in a Microgravity Environment; 70) Study of Rocket-Engine Joints Bonded by NVCU/NARloy-Z; 71) Improved Silicon Nitride for Advanced Heat Engines; 72) Parameters for Welding Aluminum/Lithium Alloys; 73) Lightweight Composite Intertank Structure; 74) Foil Patches Seal Small Vacuum Leaks; 75) Data Base on Cables and Connectors; 76) Effect of Clock Mode on Radiation Hardnessf an ADC; and 77) Fault-Tolerant Control for a Robotic Inspection System.
Bone minerals decline in microgravity, and bone mineral density (BMD) losses of approximately -1 to -1.5% per month were calculated for astronauts serving on long-duration missions prior to 2009. It is unclear whether BMD losses will stabilize with time in space, or continue to diminish with time. In addition, it is unknown if fractional gravity, present on the moon and Mars, will mitigate the mineral loss. Clinicians diagnose osteoporosis in premenopausal females and males younger than 50 years on the basis of BMD T-scores < -2.5 (hip and lumbar spine) accompanied by clinical evidence of a fragility fracture. If mission-related changes to the skeleton cannot be corrected by rehabilitation after the mission, crewmembers could be at risk for premature osteoporosis-related fractures in later life. To mitigate this risk it is necessary to understand the dynamics underlying the BMD changes that occur in microgravity, to monitor for the persistence of changes after space flight, and to evaluate if and how current and future osteoporosis treatments might be used to mitigate the risk of long-term skeletal problems in astronauts.
To assess the stress corrosion susceptibility of a machinable glass-ceramic, its dynamic fatigue behavior was investigated by measuring its strength as a function of stress rate. Fracture mechanics techniques were used to analyse the results for the purpose of making lifetime predictions for components of this material. This material was concluded to have only moderate resistance to stress in ambient conditions. The effects of specimen size on strength were assessed for the material used in this study: it was concluded that the Weibull edge-flaw scaling law adequately describes the observed strength-size relationship.
To assess the stress-corrosion susceptibility of a machinable glass-ceramic, its dynamic fatigue behavior was investigated by measuring its strength as a function of stress rate. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions for components of this material. This material was concluded to have only moderate resistance (N = 30) to stress corrosion in ambient conditions. The effects of specimen size on strength were assessed for the material used in this study; it was concluded that the Weibull edge-flaw scaling law adequately describes the observed strength-size relation.
This paper gives an overview of safety requirements related to structural design and verificationof payloads to be launched and/or retrieved by the Space Shuttle. To demonstrate the generalapproach used to implement these requirements in the development of a typical Shuttle payload, theWide Field/Planetary Camera II, a second generation science instrument currently being developed bythe Jet Propulsion Laboratory (JPL) for the Hubble Space Telescope is used as an example. Inaddition to verification of strength and dynamic characteristics, special emphasis is placed upon thefracture control implementation process, including parts classification and fracture controlacceptability.
Many optical MEMS device designs involve large arrays of thin (0.5 to 1 micron components subjected to high stresses due to cyclic loading. These devices are fabricated from a variety of materials, and the properties strongly depend on size and processing. Our objective is to develop standard and convenient test methods that can be used to measure the properties of large numbers of witness samples, for every device we build. In this work we explore a variety of fracture test configurations for 0.5 micron thick silicon nitride membranes machined using the Reactive Ion Etching (RIE) process. Testing was completed using an FEI 620 dual focused ion beam milling machine. Static loads were applied using a probe. and dynamic loads were applied through a piezo-electric stack mounted at the base of the probe. Results from the tests are presented and compared, and application for predicting fracture probability of large arrays of devices are considered.
In the present work, the behavior of composite-fastener joints in bearing failure at dynamic stroke rates of 500 in/s, 300 in/s and 100 in/s has been evaluated through progressive damage analysis (PDA) material model in LS-DYNA, namely MAT162. Two joint types: titanium pin and Hi-Lok® fastener were analyzed to identify the differences between without and with preload conditions. A meso-level approach where each lamina was modeled separately was employed and a contact definition based on fracture toughness data was defined to represent composite delamination behavior. Test fixture had been modeled in a detailed manner to account for the dynamic effects and the simulation results were validated against experimental data. Preliminary test-analysis correlation indicated that MAT162 predicted results conservatively when compared to tests. Debris accumulation were observed to greatly affect the test results which were not considered in the current modelling strategies.
In an attempt to understand the mechanical interaction of a growing lithosphere containing fracture zones with small and large scale mantle convection, which gives rise to geoid anomalies in oceanic regions, a series of fluid dynamical experiments is in progress to investigate: (1) the influence of lithosphere structure, fluid depth and viscosity field on the onset, scale, and evolution of sublithospheric convection; (2) the role of this convection in determining the rate of growth of lithosphere, especially in light of the flattening of the lithosphere bathymetry and heat flow at late times; and (3) combining the results of both numerical and laboratory experiments to decide the dominate factors in producing geoid anomalies in oceanic regions through the thermo-mechanical interaction of the lithosphere and subjacent mantle. The clear existence of small scale convection associated with a downward propagating solidification front (i.e., the lithosphere) and a larger scale flow associated with a discontinuous upward heat flux (i.e., a fracture zone) has been shown. The flows exist simultaneously and each may have a significant role in deciding the thermal evolution of the lithosphere and in understanding the relation of shallow mantle convection to deep mantle convection. This overall process is reflected in the geoid, gravity, and topographic anomalies in the north-central Pacific. These highly correlated fields of intermediate wavelength (approx. 200 to 2000 km) show isostatic compensation by a thin lithosphere for shorter (less than or equal to approx. 500 km), but not the longer, wavelengths. The ultimate, dynamic origin of this class of anomalies is being investigated.
A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.
An attempt was made to determine elevated-temperature, 'ultra'-fast fracture strengths of one alumina, two silicon nitrides and one silicon carbide by using constant stress-rate ('dynamic fatigue') testing with a series of 'ultra'-fast test rates. Of the materials tested, the alumina exhibited a convergence of strength at stress rates below 3.3 x 10(exp 4) MPa/s. The strength approached approximately the room-temperature inert strength. By contrast, the silicon nitrides and silicon carbide did not reveal a strength approach, but exhibited elevated-temperature strengths 10 and 20% lower than their respective room-temperature strengths. Although the analytical results imply that the elevated-temperature 'inert' strength of a ceramic material can be obtained by using sufficiently high stress rates, the experimental testing rates were only sufficient to demonstrate convergence for the alumina.
The Human System Risk Board (HSRB) has the overall responsibility for tracking the evolution of the top ~30 human system risks that it has identified to be associated with human spaceflight. As part of this process, the Board is charged with maintaining a consistent, integrated process to mitigate those risks, and developing evidence-based risk posture recommendations. Risks are re-evaluated in a Continuous Risk Management (CRM) process. This session will summarize the risk posture changes that have occurred in the last year and what high level research, performance, and epidemiologic data have informed those changes. Human System Risks updated in 2021 include: Dynamic Loads, Sensorimotor, EVA, Crew Egress, Behavioral Medicine, Electrical Shock, Human System Integration Architecture (HSIA), Toxic Exposure, Bone Fracture, Cardiovascular, Medical Conditions, Renal Stone, CO2 Exposure, and Pharmacology.
Molecular dynamics simulations of carbon nanotube (CNT) composites, in which the CNTs are continuous across the periodic boundary, overestimate the experimentally measured mechanical properties of CNT composites along the fiber direction. Since the CNTs in these composites are much shorter than the composite dimensions, load must be transferred either directly between CNTs or through the matrix, a mechanism that is absent in simulations of effectively continuous CNTs. In this study, the elastic and fracture properties of high volume fraction discontinuous carbon nanotube/amorphous carbon composite systems were compared to those of otherwise equivalent continuous CNT composites using ReaxFF reactive molecular dynamics simulations. These simulations were used to show how the number of nanotube-matrix interfacial covalent bonds affect composite mechanical properties. Furthermore, the mechanical impact of interfacial bonding was decomposed to reveal its effect on the properties of the CNTs, the interfacial layer of matrix, and the bulk matrix. For the composites with continuous reinforcement, it was found that any degree of interfacial bonding has a negative impact on axial tensile strength and stiffness. This is due to disruption of the structure of the CNTs and interfacial matrix layer by the interfacial bonds. For the discontinuous composites, the modulus was maximized between 4%-7% interfacial bonding and the strength continues to increase up to the highest levels of interfacial bonding studied. Areas of low stress and voids were observed in the simulated discontinuous composites at the ends of the tubes, from which fracture was observed to initiate. Experimental carbon nanotube yarn composites were fabricated and tested. The results were used to illustrate knockdown factors relative to the mechanical performance of the tubes themselves.
We have experimentally investigated liquid metal segregation from a solid silicate matrix under conditions of applied stress. Liquid moves in fractures and formation of fayalitic olivine from orthopyroxene by migrating Fe-Ni-S-O liquids is observed. Additional information is contained in the original extended abstract.
In this paper, recent studies concerning path independent integrals, of relevance in the fracture of solids, and the applications of these integrals, are critically summarized. Specific topics dealt with include: (1) unsteady dynamic crack-propagation in (nonlinear) elastic solids and (2) slow stable, as well as fast crack propagation in elastic-plastic materials, which are characterized by an (incremental) flow theory of plasticity, and which are subject to arbitrary loading (and unloading) histories.
Over the last five years BEM has been developed into a very effective tool for micromechanical studies of composites. The analyses developed range from static elastic analysis, steady state heat transfer, steady state and transient thermoelastic analysis, periodic and transient dynamic analysis. Currently some of these analyses are being extended to nonlinear micromechanical analyses involving viscoplasticity, elastoplasticity, combined plasticity fracture and creep. The paper describes some of the results for elastic analysis, heat transfer and thermoelastic analyses.