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NASA NTRS2011

Ground Vibration Testing Options for Space Launch Vehicles

New NASA launch vehicles will require development of robust systems in a fiscally-constrained environment. NASA, Department of Defense (DoD), and commercial space companies routinely conduct ground vibration tests as an essential part of math model validation and launch vehicle certification. Although ground vibration testing must be a part of the integrated test planning process, more affordable approaches must also be considered. A study evaluated several ground vibration test options for the NASA Constellation Program flight test vehicles, Orion-1 and Orion-2, which concluded that more affordable ground vibration test options are available. The motivation for ground vibration testing is supported by historical examples from NASA and DoD. The approach used in the present study employed surveys of ground vibration test subject-matter experts that provided data to qualitatively rank six test options. Twenty-five experts from NASA, DoD, and industry provided scoring and comments for this study. The current study determined that both element-level modal tests and integrated vehicle modal tests have technical merits. Both have been successful in validating structural dynamic math models of launch vehicles. However, element-level testing has less overall cost and schedule risk as compared to integrated vehicle testing. Future NASA launch vehicle development programs should anticipate that some structural dynamics testing will be necessary. Analysis alone will be inadequate to certify a crew-capable launch vehicle. At a minimum, component and element structural dynamic tests are recommended for new vehicle elements. Three viable structural dynamic test options were identified. Modal testing of the new vehicle elements and an integrated vehicle test on the mobile launcher provided the optimal trade between technical, cost, and schedule.

Patterson, Alan↗

NASA NTRS1994

Residual flexibility test method for verification of constrained structural models

A method is described for deriving constrained modes and frequencies from a reduced model based on a subset of the free-free modes plus the residual effects of neglected modes. The method involves a simple modification of the MacNeal and Rubin component mode representation to allow development of a verified constrained (fixed-base) structural model. Results for two spaceflight structures having translational boundary degrees of freedom show quick convergence of constrained modes using a measureable number of free-free modes plus the boundary partition of the residual flexibility matrix. This paper presents the free-free residual flexibility approach as an alternative test/analysis method when fixed-base testing proves impractical.

Admire, John R.↗

NASA NTRS1989

How gravity and joint scaling affect dynamics response

If a scale model of a space structure is ground tested to establish dynamic characteristics of full-scale space structure, two factors need to be taken into consideration: the joint tolerances may not be scaled, and joint preloads (from gravity) may be present. In some situations, these differences may significantly affect dynamic response so that the model is not representative of the structure in space. In this study, joint effects are investigated by considering the response of a single-degree-of-freedom system that is restrained by a joint linkage. The joint is characterized by its initial stiffness, the load at which it slips, its hardening rate, and the distance it can slip (joint 'slop' or gap). The steady-state response of the system is calculated using a harmonic balance approach. It is found that the system response is multivalued for certain ranges of gap dimensions. When this is the case, small changes in system properties can lead to large differences in dynamic response and make it difficult to obtain meaningful results directly from model testing.

Hsu, S. T.↗

NASA NTRS1997

Independent Analysis of the Space Station Node Modal Test Data

With complex structures, comparison of independently derived sets of experimental modal parameters is an excellent way to increase confidence in the results. This paper presents modal identification results using the Eigensystem Realization Algorithm (ERA) on frequency response functions from the modal test of the Space Station Resource Node. The Resource Node is the first U.S.-built structure for the International Space Station. The modal test was conducted by the NASA Marshall Space Flight Center (MSFC) in January 1997 for the Boeing Company, who designed and built the Node. The ERA-calculated parameters are compared with independent results obtained by the MSFC test team using commercial software. There was excellent correlation of mode shapes between the two sets of results for the first 21 vibration modes of the structure up to 35 Hz. From 35 to 50 Hz, about 60 percent of 25 additional modes had excellent correlation. Natural frequencies and damping factors of most modes agreed within 0.1 Hz and 0.2 percent, respectively.

Pappa, Richard S.↗

NASA NTRS2018

A Summary of Results from Two Full-Scale Fokker F28 Fuselage Section Drop Tests

During 2017, two vertical drop tests were conducted on two partial sections removed from a Fokker F28 MK4000 aircraft as a part of a joint NASA / Federal Aviation Administration (FAA) effort to investigate the crashworthiness characteristics of Transport Category Aircraft, as defined by 14 Code of Federal Regulations, Part 25. The first test was a pure vertical drop test of a relatively uniform forward section, which included an underfloor area for luggage. The second test was a canted drop test onto a sloped surface of a portion of the fuselage representing the wingbox stiffened structure. In both tests, accelerometers were installed on the floor, seat track, luggage, and overhead bin to measure responses in the two airframe sections. In addition, ten Anthropomorphic Test Devices (ATDs, a.k.a. crash test dummies) were included in each test to measure the potential of onboard occupant injury. Self-contained data recorders, logging accelerations and rotational rates, were also used on the seat tracks and lower structure for evaluation as potential crash recording devices in future tests. Finally, the starboard side of each section was painted with a stochastic black and white speckle pattern for use in full field photogrammetric imaging techniques. The results collected show notable differences in the Forward and Wingbox Section responses. The Forward Section floor accelerations showed a relatively uniform response of approximately 7 g throughout the impact event. This section exhibited large amounts of subfloor crushing, floor stiffener failures and seat deformation upon impact. These results are contrasted by the Wingbox Section accelerations, which showed large differences when comparing accelerations recorded from either the rear or the front portion of the section reaching peaks of 39 g in some locations. Additionally, the Wingbox Section test induced a forward motion caused from the rotation at impact. With the exception of the lower cavity, there was minimal deformation in the Wingbox Section, and ATD responses were consistently higher than those for the Forward Section. A complete set of results are presented for the airframe, seat, ATD, overhead bin, and subfloor regions for each section. The ATD results are compared to current injury criteria, and determinations will be made on the likelihood of injury. Additional results for cargo-hold stored luggage are presented in an attempt to provide a component-level characterization for better understanding of under-floor loading. Finally, a discussion of the relevance of the results for a proposed airframe level crashworthiness guideline are presented.

Littell, Justin D.↗

NASA NTRS1983

Testing and error analysis of a real-time controller

Inexpensive ways to organize and conduct system testing that were used on a real-time satellite network control system are outlined. This system contains roughly 50,000 lines of executable source code developed by a team of eight people. For a small investment of staff, the system was thoroughly tested, including automated regression testing, before field release. Detailed records were kept for fourteen months, during which several versions of the system were written. A separate testing group was not established, but testing itself was structured apart from the development process. The errors found during testing are examined by frequency per subsystem by size and complexity as well as by type. The code was released to the user in March, 1983. To date, only a few minor problems found with the system during its pre-service testing and user acceptance has been good.

Savolaine, C. G.↗

NASA NTRS2004

Development of a Low Data Event Timer for Monitoring an Advancing Crack in Fracture

Monitoring the crack position and velocity in a fracture specimen can be difficult and laborious. In addition, the data storage requirements can be considerable depending upon the testing conditions. A low data event timer was developed to alleviate these problems. The test apparatus was applied to cantilever beams bonded with a structural epoxy and tested under different conditions such as stable to unstable transitions and different temperature extremes. The results indicate that the approach eliminates problems associated with other types of crack measurement and greatly simplifies the measuring process.

Macon, D. J.↗

NASA NTRS1998

Space Suit Survivability Enhancement NASA Research Announcement 96-OLMSA-01B: Advanced Life Support and Environmental Technologies for Human Exploration and Development of Space

Conducted two meetings to review the project scope and develop concepts for self-sealing material compositions, Focus has been on developing concepts that would seal a penetration enough to allow the astronauts to re-enter the spacecraft within the window provided by the emergency air supply. Concepts discussed include: quilted fabrics containing a viscous flow material in the quilted cells which would seal the bladder breach when forced to flow by the internal suit pressure; a sealant impregnated felt liner which acts similar to above; and a "blousy" fibrous layer which would mechanically plug a rupture under pressure. Illustrations of the above concepts are included in the attached viewgraphs, which were used in a presentation. The most promising of these concepts will be made into prototypes for testing. ILC has developed a test fixture to test the scaling characteristics of various material layups by measuring real-time changes in pressure and make-up flow in a pressurized cylinder. Candidate viscous sealing compounds such as silicones and urethanes have been identified. These compounds will be coated on existing bladder cloth for initial tests. The most promising compounds will be integrated into the above material structures for final testing. Design and analysis of fabric weaves to improve cut and puncture resistance of the suit TMG layers is underway. Philadelphia Textile is developing a mathematical model to correlate yarn type and weave structure to cut and tear resistance. The computer mathematical modeling of the fabric failure mechanisms by Cornell University, as originally proposed, will be replaced with the above model and empirical testing methods, due to the loss of key Cornell personnel.

Source record↗

NASA NTRS1970

Evaluation of nonmetallic thermal protection materials for the manned space shuttle. Volume 1, task 1: Assessment of technical risks associated with utilization of nonmetallic thermal protection system

Technical problems of design and flight qualification of the proposed classes of surface insulation materials and leading edge materials were reviewed. A screening test plan, a preliminary design data test plan and a design data test plan were outlined. This program defined the apparent critical differences between the surface insulators and the leading edge materials, structuring specialized screening test plans for each of these two classes of materials. Unique testing techniques were shown to be important in evaluating the structural interaction aspects of the surface insulators and a separate task was defined to validate the test plan. In addition, a compilation was made of available information on proposed material (including metallic TPS), previous shuttle programs, pertinent test procedures, and other national programs of merit. This material was collected and summarized in an informally structured workbook.

Wilkinson, W. H.↗

NASA NTRS1960

Tests of Aerodynamically Heated Multiweb Wing Structures in a Free Jet at Mach Number 2: Five Aluminum-Alloy Models of 20-Inch Chord with 0.064-Inch-Thick Skin, 0.025-Inch-Thick Webs, and Various Chordwise Stiffening at 2 deg Angle of Attack

An experimental study was made on five 2024-T3 aluminum-alloy multiweb wing structures (MW-2-(4), MW-4-(3), mw-16, MW-17, and MW-18), at a Mach number of 2 and an angle of attack of 2 deg under simulated supersonic flight conditions. These models, of 20-inch chord and semi-span and 5-percent-thick circular-arc airfoil section, were identical except for the type and amount of chordwise stiffening. One model with no chordwise ribs between root and tip bulkhead fluttered and failed dynamically partway through its test. Another model with no chordwise ribs (and a thinner tip bulkhead) experienced a static bending type of failure while undergoing flutter. The three remaining models with one, two, or three chordwise ribs survived their tests. The test results indicate that the chordwise shear rigidity imparted to the models by the addition of even one chordwise rib precludes flutter and subsequent failure under the imposed test conditions. This paper presents temperature and strain data obtained from the tests and discusses the behavior of the models.

Trussell, Donald H.↗

NASA NTRS1974

Damping synthesis from substructure tests

A new method is proposed for synthesizing structural damping from substructure test data. It utilizes the off-diagonal coupling terms in the substructure modal damping matrices as well as the diagonal terms which correspond to uncoupled modal damping. The coupling terms are evaluated from complex resonant response measured at each substructure mode. Both analytical and experimental verification of the method have been made. Accuracy requirements on experimental data and data reduction have been established.

Hasselman, T. K.↗

NASA NTRS1987

On sine dwell or broadband methods for modal testing

For large, complex spacecraft structural systems, the objectives of the modal test are outlined. Based on these objectives, the comparison criteria for the modal test methods, namely, the broadband excitation and the sine dwell methods are established. Using the Galileo spacecraft modal test and the Centaur G Prime upper stage vehicle modal test as examples, the relative advantages or disadvantages of each method are examined. The usefulness or shortcoming of the methods are given from a practicing engineer's view point.

Chen, Jay-Chung↗

NASA NTRS1991

Development of structural composite mirror technology for submillimeter space telescopes

The technical approach to the design, manufacturing, testing, and analytical simulation of lightweight graphite/epoxy mirrors is described. The precision segmented reflector (PSR) program has produced (1) 1.0-m graphite/epoxy panels with areal densities of 7 kg/sq m as-manufactured surface precision near 1 micron rms, (2) 0.5-m panels with figure changes less than 1 micron rms for temperature reductions of 100 K, (3) analytical performance-prediction capability with submicron accuracy relative to panel thermal distortion, and (4) a unique thermal vacuum test facility for structural composite mirrors.

Freeland, R. E.↗

NASA NTRS1990

Development and fabrication of structural components for a scramjet engine

A program broadly directed toward design and development of long-life (100 hours and 1,000 cycles with a goal of 1,000 hours and 10,000 cycles) hydrogen-cooled structures for application to scramjets is presented. Previous phases of the program resulted in an overall engine design and analytical and experimental characterization of selected candidate materials and concepts. The latter efforts indicated that the basic life goals for the program can be reached with available means. The main objective of this effort was an integrated, experimental evaluation of the results of the previous program phases. The fuel injection strut was selected for this purpose, including fabrication development and fabrication of a full-scale strut. Testing of the completed strut was to be performed in a NASA-Langley wind tunnel. In addition, conceptual designs were formulated for a heat transfer test unit and a flat panel structural test unit. Tooling and fabrication procedures required to fabricate the strut were developed, and fabrication and delivery to NASA of all strut components, including major subassemblies, were completed.

Buchmann, O. A.↗

NASA NTRS2001

NASTRAN DMAP Fuzzy Structures Analysis: Summary of Research

The main proposed tasks of Cooperative Agreement NCC1-382 were: (1) developing MSC/NASTRAN DMAP language scripts to implement the Soize fuzzy structures approach for modeling the dynamics of complex structures; (2) benchmarking the results of the new code to those for a cantilevered beam in the literature; and (3) testing and validating the new code by comparing the fuzzy structures results to NASA Langley experimental and conventional finite element results for two model test structures representative of aircraft fuselage sidewall construction: (A) a small aluminum test panel (SLP, single longeron panel) with a single longitudinal stringer attached with bolts; and (B) a 47 by 72 inch flat aluminum fuselage panel (AFP, aluminum fuselage panel) including six longitudinal stringers and four frame stiffeners attached with rivets.

Sparrow, Victor W.↗

NASA NTRS1990

Design, Evaluation and Experimental Effort Toward Development of a High Strain Composite Wing for Navy Aircraft

This design development effort addressed significant technical issues concerning the use and benefits of high strain composite wing structures (Epsilon(sub ult) = 6000 micro-in/in) for future Navy aircraft. These issues were concerned primarily with the structural integrity and durability of the innovative design concepts and manufacturing techniques which permitted a 50 percent increase in design ultimate strain level (while maintaining the same fiber/resin system) as well as damage tolerance and survivability requirements. An extensive test effort consisting of a progressive series of coupon and major element tests was an integral part of this development effort, and culminated in the design, fabrication and test of a major full-scale wing box component. The successful completion of the tests demonstrated the structural integrity, durability and benefits of the design. Low energy impact testing followed by fatigue cycling verified the damage tolerance concepts incorporated within the structure. Finally, live fire ballistic testing confirmed the survivability of the design. The potential benefits of combining newer/emerging composite materials and new or previously developed high strain wing design to maximize structural efficiency and reduce fabrication costs was the subject of subsequent preliminary design and experimental evaluation effort.

Bruno, Joseph↗

NASA NTRS1986

The development of the 15-Meter Hoop Column deployable antenna system with structural and electromagnetic performance results

This paper presents the technical results obtained during the development and engineering tests of a 15-Meter Hoop Column deployable antenna system. An important element of the 15-meter antenna program was the structural tests and the characterization of the surface accuracy of the deployed mesh surface. The overall system performance of the 15-meter antenna was obtained during radio frequency tests conducted in the Martin Marietta Near Field Test Laboratory in Denver, CO. The near field tests verified the electromagnetic performance of the structure which exhibited a surface accuracy of 0.061 in (RMS). Radio frequency tests were conducted at 2.3, 4.3, 7.7, and 11.6 GHz. The experiment and analytical results obtained through the 15-meter antenna program will provide new opportunities for the application of large space antennas for future missions.

Campbell, T. G.↗

NASA NTRS1992

Active member vibration control for a 4 meter primary reflector support structure

The design and testing of a new low voltage piezoelectric active member with integrated load cell and displacement sensor is described. This active member is intended for micron level vibration and structural shape control of the Precision Segmented Reflector test-bed. The test-bed is an erectable 4 meter diameter backup support truss for a 2.4 meter focal length parabolic reflector. Active damping of the test-bed is then demonstrated using the newly developed active members. The control technique used is referred to as bridge feedback. With this technique the internal sensors are used in a local feedback loop to match the active member's input impedance to the structure's load impedance, which then maximizes vibrational energy dissipation. The active damping effectiveness is then evaluated from closed loop frequency responses.

Umland, J. W.↗