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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

Predicted and measured strain responses of isotropic panels to base excitation

The accuracy of classical linear theory for predicting acceleration and strain for cantilevered and Clamped-Free-Clamped-Free (C-F-C-F) panels excited through the base is studied. Aluminum, steel and titanium plates of various dimensions and thicknessess were vibration tested, using a broadband random signal applied through a shaker mounting fixture. The strains were measured at 9 locations on the cantilevered panels and at 5 locations on the C-F-C-F panels. Predictions were based on the Ritz method. The measured accelerations of the base were input to the analysis for the forcing function. Comparisons between predicted and measured strain acceleration spectra were within an average error of 20 percent for both the cantilevered and C-F-C-F panels.

Lyle, Karen H.↗

European Service Module - Structural Test Article (E-STA) Building Block Test Approach and Model Correlation Observations

The Orion European Service Module - Structural Test Article (E-STA) underwent sine vibration testing in 2016 using the Mechanical Vibration Facility (MVF) multi-axis shaker system at NASA Glenn Research Center’s (GRC) Plum Brook Station (PBS) Space Power Facility (SPF). The main objective was to verify the structural integrity of the European Service Module (ESM) under sine sweep dynamic qualification vibration testing. A secondary objective was to perform a fixed-base modal survey, while E-STA was still mounted to MVF, in order to achieve a test correlate the finite element model (FEM). To facilitate the E-STA system level correlation effort, a building block test approach was implemented. Modal tests were performed on two major subassemblies, the crew module/launch abort structure (CM/LAS) and the crew module adapter (CMA) mass simulators. These subassembly FEMs were individually correlated and then integrated into the E-STA FEM prior to the start of the E-STA sine vibration test. This paper summarizes the modal testing and model correlation efforts of both of these subassemblies and how the building block approach assisted in the overall correlation of the E-STA FEM. This paper will also cover modeling practices that should be avoided, recommended instrumentation positioning on complex structures, and the importance of the FEM geometrically matching CAD in sufficient detail in order to adequately replicate internal load paths. The goal of this paper is to inform the reader of the hard earned lessons learned and pitfalls to avoid when applying a building block test approach.

Winkel, James P.↗

Aeroelastic Tests of an Eight Percent Scale Saturn C-1 Block II

Buffet and flutter characteristics of Saturn Apollo mission were studied using a dynamically scaled model. The model was built around a central aluminum tube for scaled stiffness distribution and strength to resist loads imposed during testing. Styrofoam sections attached to the core provided the correct external contours. Lead weights were added for correct mass distribution. An electromagnetic shaker was used to excite the model in its flexible modes of vibration during portions of the test. The model was supported on a sting, mounted by leaf springs, cables and torsion bars. The support system provided for simulating the full scale rigid body pitch frequency with minimum restraint imposed on elastic deflections. Bending moments recorded by sensors on the aluminum tube. Several modified nose configurations were tested: The basic configuration was tested with and without a flow separator disk on the escape rocket motor, tests also were made with the escape tower and rocket motor removed completely. For the final test, the Apollo capsule was replaced with a Jupiter nose cone. The test program consisted of determining model response throughout the transonic speed range at angles of attack up to 6 degrees and measuring the aerodynamic damping over the same range for the basic model and the modified configurations. Signals from the model pickup were recorded on tape for later analysis. The data obtained were used to estimate bending moments that would be produced on the full-scale vehicle by aerodynamic forces due to buffeting.

EXPERIMENTS↗

Fail-safe hydraulic shaker protection

Nine channel system controls acceleration and force on structure undergoing vibration stress testing. System has automatic and manually operative abort feature.

Woodbury, R. C.↗

Magnetic Excitation for Spin Vibration Testing

The Dynamic Spin Rig Laboratory (DSRL) at the NASA Lewis Research Center is a facility used for vibration testing of structures under spinning conditions. The current actuators used for excitation are electromagnetic shakers which are configured to apply torque to the rig's vertical rotor. The rotor is supported radially and axially by conventional bearings. Current operation is limited in rotational speed, excitation capability, and test duration. In an effort to enhance its capabilities, the rig has been initially equipped with a radial magnetic bearing which provides complementary excitation and shaft support. The new magnetic feature has been used in actual blade vibration tests and its performance has been favorable. Due to the success of this initial modification further enhancements are planned which include making the system fully magnetically supported. This paper reports on this comprehensive effort to upgrade the DSRL with an emphasis on the new magnetic excitation capability.

Johnson, Dexter↗

Measurement of damping of graphite expoxy materials

During this period damping measurements were made on the cylindrical graphite epoxy specimen using the forced-vibration test method. The specimen was carefully mounted directly on the shaker through the supporting ring and the impedance head. This was done to simulate an idealized free-free boundary condition at the two edges. The damping ratio value and the natural frequency (first mode) obtained in this experiment were 0.13% and 508.75 Hz respectively. In order to check the damping induced by the supporting ring, measurements were made with the top half of the ring removed. The specimen then was supported only by the bottom half of the ring (half ring). It was observed that the natural frequency of the specimen (first mode) increased of a value of 552.5 Hz due to the influence of the reduced mass of the supporting ring. But the damping ratio value obtained was the same as that obtained with full supporting ring, namely 0.13%.

Crocker, M. J.↗

Bearing Failure Detection

Shaker Research Corporation, under a contract with NASA, produced a test vehicle that measures resonant frequency of railroad roller bearings to identify source of bearings defects. Marshall scientists have developed a detection concept based on fact that bearing defects themselves excite resonant frequency of rolling elements of bearing as they impact the defect. By detecting resonant frequency and subsequently analyzing character of the signal, bearing defects may be detected and identified as to source. The bearing fault detector will help eliminate this cause of derailments.

Source record↗

Solder Joint Health Monitoring Testbed

A method of monitoring the health of selected solder joints, called SJ-BIST, has been developed by Ridgetop Group Inc. under a Small Business Innovative Research (SBIR) contract. The primary goal of this research program is to test and validate this method in a flight environment using realistically seeded faults in selected solder joints. An additional objective is to gather environmental data for future development of physics-based and data-driven prognostics algorithms. A test board is being designed using a Xilinx FPGA. These boards will be tested both in flight and on the ground using a shaker table and an altitude chamber.

Delaney, Michael M.↗

Characterization and Comparison of Vibration Transfer Paths in a Helicopter Gearbox and a Fixture Mounted Gearbox

Health monitoring of rotorcraft components, currently being performed by Health and Usage Monitoring Systems through analyses of vibration signatures of dynamic mechanical components, is very important for their safe and economic operation. HUMS analyze vibration signatures associated with faults and quantify them as condition indicators to predict component behavior. Vibration transfer paths are characterized by frequency response functions derived from the input/output relationship between applied force and dynamic response through a structure as a function of frequency. With an objective to investigate the differences in transfer paths, transfer path measurements were recorded under similar conditions in the left and right nose gearboxes of an AH-64 helicopter and in an isolated left nose gearbox in a test fixture at NASA Glenn Research Center. The test fixture enabled the application of measured torques-common during an actual operation. An impact hammer as well as commercial and lab piezo shakers, were used in conjunction with two types of commercially available accelerometers to collect the vibration response under various test conditions. The frequency response functions measured under comparable conditions of both systems were found to be consistent. Measurements made on the fixture indicated certain real-world installation and maintenance issues, such as sensor alignments, accelerometer locations and installation torques, had minimal effect. However, gear vibration transfer path dynamics appeared to be somewhat dependent on the presence of oil, and the transfer path dynamics were notably different if the force input was on the internal ring gear rather than on the external gearbox case.

structures↗

Electrodynamic Dust Shield (EDS) Preparation for MISSE-11 Launch

The dusty surfaces of the Moon, Mars, and various asteroids present a significant challenge to NASA’s manned and unmanned space exploration efforts. The fine, electrostatically charged dust is difficult to remove and has resulted in vision obscuration, false instrument readings, contamination, elevated temperatures, performance reduction, and equipment failure. To alleviate these problems, NASA KSC’s Electrostatics and Surface Physics Laboratory (ESPL) is developing active dust mitigation systems for solar system exploration and in situ resource utilization (ISRU). Part of KSC’s Swamp Works system, the lab emphasizes fast-paced, hands-on, cost-effective, and collaborative innovation. The Electrodynamic Dust Shield (EDS) is an ESPL technology being developed to prevent dust accumulation on space components. It consists of a dielectric substrate embedded with parallel electrodes which, when applied with high voltage out-of-phase waveforms, produce a traveling electric field wave that scatters dust particles from its surface via dielectrophoretic and electrostatic forces. The EDS is currently fully functional and has been tested for scalability and endurance in reduced gravity/pressure flight. Next, it will be part of the May 2019 Materials International Space Station Experiment-11 (MISSE-11) payload, which will test small shield samples for performance durability with exposure to the harsh space environment. The summer objective was to test EDS functionality before active and passive dust shield samples launch on MISSE-11, in order to screen for good flight/control samples as well as to compare pre-flight and post-flight clearing efficiencies. I imaged glass and Kapton shields of 2-phase and 3-phase electrode configurations with the Keyence VHX-5000 digital microscope to check for damage before and after all testing for a qualitative pre-flight baseline; helped with vacuum testing of high-voltage shield breakdown; assembled shields and wires using Electrobond 004 silver epoxy; and helped with vacuum and cryogenic dust clearance testing of assembled EDS systems. I learned CAD (computer-aided design) and 3D printing skills to create parts for a shaker table/motor assembly, which will allow for repeatable experiments by evening out EDS dust distribution in a consistent manner prior to dust scattering testing. I will also be improving the interfacing with Alpha Space’s prototype Data Communications Unit (DCU), a payload component to control power to the EDS and store data, by mapping the DCU structure upon power-up and writing shell scripts to improve various processes. Finally, I also CADed and 3D-printed plastic supports for three different geometries of the Electrostatic Precipitator (ESP), a project that aims to use high voltage electrodes to charge and filter out dust from the Martian atmosphere drawn for ISRU devices. This work on dust mitigation technologies will help to support future robotic and human space exploration missions, including NASA’s Journey to Mars; the EDS has especially significant applications to spacecraft solar panels, thermal radiators, viewports, and astronaut visors. This opportunity has also allowed me to become more familiar with various lab equipment and hardware testing, develop key modeling skills in SolidWorks, explore past and present components critical to America’s space program, work with inspiring peers and mentors, and ascertain my dream of working permanently for NASA.

space↗

TPSAS-NF1676L-31853-DND

Risk that Orion arrives later than Space Launch System (SLS). MSO mitigates this risk by using a mass simulator for SLS’ tests. An Orion simulator for the Integrated Modal Test (IMT) and Umbilical Release and Retraction Tests (URRT) mitigates schedule risk by significant timeframe. A clean sheet alternate being pursued - analysis shows matching modal characteristics unnecessary; rigid simulator is acceptable wrt existing SLS accelerometer locations and shaker placement/size. Key Simulator Requirements: Representative mass, CG, rigid modal characteristics, high fidelity interface at MSA. Pre-test analyses show that MSO vertical CG could be up to 40” low without affecting IMT.

Steve Cutright↗

A novel triaxial vibration test technique

The present work examines the circumstances under which simultaneous multiaxial vibration testing may be desirable, the testing techniques and equipment required to make it feasible, and the type of results that may be obtained together with some practical limitations to the techniques. Two schemes for performing vibration testing simultaneously or sequentially along three mutually perpendicular axes are considered and the most promising, involving a 'floating' technique, is presented in some detail. Practical problems associated with jig design and system resonances, cross-coupling between the various degrees of freedom, secondary loads on shaker elements, and system drift, are considered and workable solutions proposed. A simple simulation of multiaxial testing of a 1.1-pound inertia-simulated model of an Apollo command module is presented.

Wignot, J. E.↗

Dry wind tunnel system

This invention is a ground flutter testing system without a wind tunnel, called Dry Wind Tunnel (DWT) System. The DWT system consists of a Ground Vibration Test (GVT) hardware system, a multiple input multiple output (MIMO) force controller software, and a real-time unsteady aerodynamic force generation software, that is developed from an aerodynamic reduced order model (ROM). The ground flutter test using the DWT System operates on a real structural model, therefore no scaled-down structural model, which is required by the conventional wind tunnel flutter test, is involved. Furthermore, the impact of the structural nonlinearities on the aeroelastic stability can be included automatically. Moreover, the aeroservoelastic characteristics of the aircraft can be easily measured by simply including the flight control system in-the-loop. In addition, the unsteady aerodynamics generated computationally is interference-free from the wind tunnel walls. Finally, the DWT System can be conveniently and inexpensively carried out as a post GVT test with the same hardware, only with some possible rearrangement of the shakers and the inclusion of additional sensors.

Chen, Ping-Chih↗

Shake test results of the MDHC test stand in the 40- by 80-foot wind tunnel

A shake test was conducted to determine the modal properties of the MDHC (McDonnell Douglas Helicopter Company) test stand installed in the 40- by 80- Foot Wind Tunnel at Ames Research Center. The shake test was conducted for three wind-tunnel balance configurations with and without balance dampers, and with the snubber engagement to lock the balance frame. A hydraulic shaker was used to apply random excitation at the rotor hub in the longitudinal and lateral directions. A GenRad 2515 computer-aided test system computed the frequency response functions at the rotor hub and support struts. From these response functions, the modal properties, including the natural frequency, damping ratio, and mode shape were calculated. The critical modes with low damping ratios are identified as the test-stand second longitudinal mode for the dampers-off configuration, the test-stand yaw mode for the dampers-on configuration, and the test stand first longitudinal mode for the balance-frame locked configuration.

Lau, Benton H.↗

Dynamic testing of complex structures

Response of structure is determined under impulses large enough to create severe strains. Electrodynamic shaker can provide impulses to nearly any point on structure and can deliver repeated pulses of varying force and duration.

Birs, C.↗

Calculation of Dynamic Loads Due to Random Vibration Environments in Rocket Engine Systems

An important part of rocket engine design is the calculation of random dynamic loads resulting from internal engine "self-induced" sources. These loads are random in nature and can greatly influence the weight of many engine components. Several methodologies for calculating random loads are discussed and then compared to test results using a dynamic testbed consisting of a 60K thrust engine. The engine was tested in a free-free condition with known random force inputs from shakers attached to three locations near the main noise sources on the engine. Accelerations and strains were measured at several critical locations on the engines and then compared to the analytical results using two different random response methodologies.

Christensen, Eric R.↗

Data-Driven Method for Nonlinear Modal Interaction Identification in Fighter Aircraft

The purpose of this paper is to report a new data-driven analysis methodology for identifying nonlinear modal interactions and its application to aeroelastic wind-tunnel data from a generic fighter configuration, which reveals global modal interactions in this system caused by multiple resonance capture events initiated by local nonlinearities. It is shown that during supersonic testing at the Transonic Dynamics Tunnel, vibro-impacts at the embedded external fuel tank shakers on the inboard underwing stations of the generic fighter introduce strong nonlinearity that gives rise to nonlinear modal interactions. Specifically, time–frequency analysis of the acceleration data demonstrates that 6∶5 and 7∶6 transient resonance captures occur across the aircraft exclusively during this vibro-impact forcing window. Further analysis suggests that these resonance captures are dependent on Mach number. These results show experimentally that local vibro-impacts can cause global nonlinear effects in an aeroelastic system and that these effects can be identified using the new methodology herein. The data-driven analysis scheme employed shows applicability to full-aircraft flight test data for identifying nonlinear modal interactions without knowledge of the precise nonlinear contributors.

nonlinear dynamics↗

Dual control vibration tests of flight hardware

A vibration retest of a spacecraft flight instrument, the Mars Observer Camera (MOC), was conducted using extremal dual control to automatically limit the shaker force and notch the shaker acceleration at resonances. This was the first application of extremal dual control with flight hardware at JPL. The retest was successful in that the environment was representative of flight plus some margin, the instrument survived without any structural or performance degradation, and the force limiting worked very well. The test set-up, force limiting procedure, and test results are described herein. It is concluded that dual control should be utilized when there is a concern about overtesting in hard-base-drive tests and the instrumentation for force measurement and control is available. Recommendations for improving the implementation of dual control are provided as a result of this first experience.

Scharton, Terry D.↗