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This viewgraph presentation provides information on quality control standards in mechanical engineering. The presentation addresses safety, structural loads, nonmetallic composite structural elements, bonded structural joints, externally induced shock, random vibration, acoustic tests, and mechanical function.
Accurate finite element modeling (FEM) is a vital part of the modern aircraft design process. As aircraft become increasingly complex, the time-consuming nature of detailed FEM approaches comes at a significant cost to program timeline and budget. In an effort produce modeling efforts that are sufficiently accurate and minimally costly, a proposed FEM approach and optimization scheme for a composite aircraft is explored, including a discussion of the manufacturing constraints of a highly tailored composite panel design. A high-fidelity structural model of a transonic truss-braced wing (TTBW) is generated, and the components are sized by structural optimization to satisfy buckling and strength constraints while subjected to critical maneuver loads. The structural modeling approaches and sizing of a TTBW are discussed, including details for FEM approaches, verification of an approximated FEM approach, a sizing optimization using the optimization software LS-OPT, and a manufacturing trial of integrally stiffened composite panels conducted to explore the validity of highly tailored composites as a design consideration. The results of study discussed herein indicate that the proposed FEM approach is suitable for modeling composite-construction aircraft and for use in sizing optimization. Further efforts regarding integrally stiffened composite panels will indicate the suitability of this method for the integration of highly tailored composite panels into the design and optimization process, given the manufacturability of such panels as shown here.
Accurate finite element modeling (FEM) is a vital part of the modern aircraft design process. As aircraft become increasingly complex, the time-consuming nature of detailed FEM approaches comes at a significant cost to program timeline and budget. In an effort produce modeling efforts that are sufficiently accurate and minimally costly, a proposed FEM approach and optimization scheme for a composite aircraft is explored, including a discussion of the manufacturing constraints of a highly tailored composite panel design. A high-fidelity structural model of a transonic truss-braced wing (TTBW) is generated, and the components are sized by structural optimization to satisfy buckling and strength constraints while subjected to critical maneuver loads. The structural modeling approaches and sizing of a TTBW are discussed, including details for FEM approaches, verification of an approximated FEM approach, a sizing optimization using the optimization software LS-OPT, and a manufacturing trial of integrally stiffened composite panels conducted to explore the validity of highly tailored composites as a design consideration. The results of study discussed herein indicate that the proposed FEM approach is suitable for modeling composite-construction aircraft and for use in sizing optimization. Further efforts regarding integrally stiffened composite panels will indicate the suitability of this method for the integration of highly tailored composite panels into the design and optimization process, given the manufacturability of such panels as shown here.
Considerable efforts have been underway to develop multidisciplinary technologies for aeroshell structures that will significantly increase the allowable working temperature for the aeroshell components, and enable the system to operate at higher temperatures while sustaining performance and durability. As part of these efforts, high temperature polymer matrix composites and fabrication technologies are being developed for the primary load bearing structure (heat shield) of the spacecraft. New high-temperature resins and composite material manufacturing techniques are available that have the potential to significantly improve current aeroshell design. In order to qualify a polymer matrix composite (PMC) material as a candidate aeroshell structural material, its performance must be evaluated under realistic environments. Thus, verification testing of lightweight PMC's at aeroshell entry temperatures is needed to ensure that they will perform successfully in high-temperature environments. Towards this end, a test program was developed to characterize the mechanical properties of two candidate material systems, T650-35/AFR-PE-4 and T650-35/RP46. The two candidate high-temperature polyimide resins, AFR-PE-4 and RP46, were developed at the Air Force Research Laboratory and NASA Langley Research Center, respectively. This paper presents experimental methods, strength, and stiffness data of the T650-35/AFR-PE-4 material as a function of elevated temperatures. The properties determined during the research test program herein, included tensile strength, tensile stiffness, Poisson s ratio, compressive strength, compressive stiffness, shear modulus, and shear strength. Unidirectional laminates, a cross-ply laminate and two eight-harness satin (8HS)-weave laminates (4-ply and 10-ply) were tested according to ASTM standard methods at room and elevated temperatures (23, 316, and 343 C). All of the relevant test methods and data reduction schemes are outlined along with mechanical data. These data contribute to a database of material properties for high-temperature polyimide composites that will be used to identify the material characteristics of potential candidate materials for aeroshell structure applications.
The Lunar Atmosphere Dust Environment Explorer (LADEE) mission will orbit the moon in order to measure the density, composition and time variability of the lunar dust environment. The ground-side and onboard flight software for the mission is being developed using a Model-Based Software methodology. In this technique, models of the spacecraft and flight software are developed in a graphical dynamics modeling package. Flight Software requirements are prototyped and refined using the simulated models. After the model is shown to work as desired in this simulation framework, C-code software is automatically generated from the models. The generated software is then tested in real time Processor-in-the-Loop and Hardware-in-the-Loop test beds. Travelling Road Show test beds were used for early integration tests with payloads and other subsystems. Traditional techniques for verifying computational sciences models are used to characterize the spacecraft simulation. A lightweight set of formal methods analysis, static analysis, formal inspection and code coverage analyses are utilized to further reduce defects in the onboard flight software artifacts. These techniques are applied early and often in the development process, iteratively increasing the capabilities of the software and the fidelity of the vehicle models and test beds.
Noise characteristics of advanced composite material fuselages were discussed from the standpoints of applicable research programs and noise transmission theory. Experimental verification of the theory was also included.
The author has identified the following significant results. Eucalyptus tree stands killed by low temperatures in December 1972 were outlined by image enhancement of two separate dates of ERTS-1 images (January 22, 1973-I.D. 1183-18175 and April 22, 1973-I.D. 1273-18183). Three stands larger than 500 meters in size were detected very accurately. In Colorado, range and grassland communities were analyzed by visual interpretation of color composite scene I.D. 1028-17135. It was found that mixtures of plant litter, amount and kind of bare soil, and plant foliage cover made classification of grasslands very difficult. Changes in forest land use were detected on areas as small as 5 acres when ERTS-1 color composite scene 1264-15445 (April 13, 1973) was compared with 1966 ASCS index mosaics (scale 1:60,000). Verification of the changes were made from RB-57 underflight CIR transparencies (scale 1:120,000).
The through-the-thickness properties of three-dimensionally (3D) woven carbon/epoxy composites have been studied. The investigation aimed at the evaluation and development of test methodologies for the property characterization in the thickness direction, and the establishment of fiber architectures were studied: layer-to-layer Angle Interlock, through-the-thickness Orthogonal woven preform with surface pile was also designed and manufactured for the fabrication of tensile test coupons with integrated grips. All the preforms were infiltrated by the resin transfer molding technique. The microstructures of the composites were characterized along the warp and fill (weft) directions to determine the degree of yarn undulations, yarn cross-sectional shapes, and microstructural dimensions. These parameters were correlated to the fiber architecture. Specimens were designed and tested for the direct measurement of the through-the-thickness tensile, compressive and shear properties of the composites. Design optimization was conducted through the analysis of the stress fields within the specimen coupled with experimental verification. The experimentally-derived elastic properties in the thickness direction compared well with analytical predictions obtained from a volume averaging model.
The development of benchmark examples for assessing growth prediction capabilities is presented and demonstrated for a commercial code. The examples are based on finite element models of Mixed-Mode Bending (MMB) specimens for three different mode ratios. The examples are independent of the analysis software used and allow the assessment of the automated delamination propagation, onset and growth prediction capabilities in commercial finite element codes based on the virtual crack closure technique (VCCT). First, based on existing results for delamination propagation under static loading, new benchmark examples for delamination growth under fatigue loading were created. Second, starting from an initially straight front, the delamination was allowed to grow under fatigue loading. The number of cycles to delamination onset and the number of cycles during delamination growth for each growth increment were obtained from the automated analysis and compared to the benchmark examples. Good agreement between the results obtained from the growth analysis and the benchmark results could be achieved by selecting the appropriate input parameters. The benchmarking procedure proved valuable by highlighting the issues associated with choosing the input parameters of the particular implementation. Overall the results from automatic propagation are encouraging, however, selecting the appropriate input parameters was not straightforward and often required an iterative procedure.
Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.
Flooding, severe weather, and drought are key forecasting challenges for the Kenya Meteorological Department (KMD), based in Nairobi, Kenya. Atmospheric processes leading to convection, excessive precipitation and/or prolonged drought can be strongly influenced by land cover, vegetation, and soil moisture content, especially during anomalous conditions and dry/wet seasonal transitions. It is thus important to represent accurately land surface state variables (green vegetation fraction, soil moisture, and soil temperature) in Numerical Weather Prediction (NWP) models. The NASA SERVIR and the Short-term Prediction Research and Transition (SPoRT) programs in Huntsville, AL have established a working partnership with KMD to enhance its regional modeling capabilities. SPoRT and SERVIR are providing experimental land surface initialization datasets and model verification capabilities for capacity building at KMD. To support its forecasting operations, KMD is running experimental configurations of the Weather Research and Forecasting (WRF; Skamarock et al. 2008) model on a 12-km/4-km nested regional domain over eastern Africa, incorporating the land surface datasets provided by NASA SPoRT and SERVIR. SPoRT, SERVIR, and KMD participated in two training sessions in March 2014 and June 2015 to foster the collaboration and use of unique land surface datasets and model verification capabilities. Enhanced regional modeling capabilities have the potential to improve guidance in support of daily operations and high-impact weather and climate outlooks over Eastern Africa. For enhanced land-surface initialization, the NASA Land Information System (LIS) is run over Eastern Africa at ~3-km resolution, providing real-time land surface initialization data in place of interpolated global model soil moisture and temperature data available at coarser resolutions. Additionally, real-time green vegetation fraction (GVF) composites from the Suomi-NPP VIIRS instrument is being incorporated into the KMD-WRF runs, using the product generated by NOAA/NESDIS. Model verification capabilities are also being transitioned to KMD using NCAR's Model *Corresponding author address: Jonathan Case, ENSCO, Inc., 320 Sparkman Dr., Room 3008, Huntsville, AL, 35805. Email: Jonathan.Case-1@nasa.gov Evaluation Tools (MET; Brown et al. 2009) software in conjunction with a SPoRT-developed scripting package, in order to quantify and compare errors in simulated temperature, moisture and precipitation in the experimental WRF model simulations. This extended abstract and accompanying presentation summarizes the efforts and training done to date to support this unique regional modeling initiative at KMD. To honor the memory of Dr. Peter J. Lamb and his extensive efforts in bolstering weather and climate science and capacity-building in Africa, we offer this contribution to the special Peter J. Lamb symposium. The remainder of this extended abstract is organized as follows. The collaborating international organizations involved in the project are presented in Section 2. Background information on the unique land surface input datasets is presented in Section 3. The hands-on training sessions from March 2014 and June 2015 are described in Section 4. Sample experimental WRF output and verification from the June 2015 training are given in Section 5. A summary is given in Section 6, followed by Acknowledgements and References.
This paper reports stress rupture testing of Kevlar(TradeMark) composite overwrapped pressure vessels (COPVs) at NASA White Sands Test Facility. This 6-year test program was part of the larger effort to predict and extend the lifetime of flight vessels. Tests were performed to characterize control parameters for stress rupture testing, and vessel life was predicted by statistical modeling. One highly instrumented 102-cm (40-in.) diameter Kevlar(TradeMark) COPV was tested to failure (burst) as a single-point model verification. Significant data were generated that will enhance development of improved NDE methods and predictive modeling techniques, and thus better address stress rupture and other composite durability concerns that affect pressure vessel safety, reliability and mission assurance.
The recently-completed NASA Advanced Composites Project (ACP) successfully developed several new technologies aimed at reducing the timeline to design and certify composite aircraft structures. Advancements in the areas of manufacturing simulation, nondestructive inspection and advanced structural design and analysis methodologies were completed in late 2019 under the Advanced Composites Consortium (ACC) public/private partnership as well as NRA-funded university contracts. In the area of Structures, the ACC made significant improvements in rapid design tools for preliminary sizing of structure, along with developing detailed static and fatigue strength prediction methods and methods for modeling high energy impact events in composite structures. These new methodologies and toolsets were validated against a range of representative test data using a comprehensive verification and validation approach which has been published and is now used extensively on other programs. Specific new tool improvements supported by ACC include NASA’s CompDam code and Floating Node Method code. CompDam is now available from NASA as open source code. The team alsoworked on improved impact modeling using LS-Dyna™ and improved delamination modeling using Abaqus™. Rapid design tool improvements are available through Hypersizer. The ACC team released well over 50 publications documenting these method improvements, and the ACP recently received the prestigious NASA Group Achievement Award for their work.Typical Hat Stiffened Panel Test Article Used for Method Validation
Turbulent boundary layer effects on chemical and kinetic measurements of gas mixture composition from nonuniform shock tube flow
Lightning Technologies, Inc., Pittsfield, MA, - a spinoff company founded by president J. Anderson Plumer, a former NASA contractor employee who developed his expertise with General Electric Company's High Voltage Laboratory - was a key player in Langley Research Center's Storm Hazards Research Program. Lightning Technologies used its NASA acquired experience to develop protective measures for electronic systems and composite structures on aircraft, both of which are particularly susceptible to lightning damage. The company also provides protection design and verification testing services for complete aircraft systems or individual components. Most aircraft component manufacturers are among Lightning Technologies' clients.
The advantageous structural uses of advanced filamentary composites are demonstrated by design, fabrication, and test of three boron-epoxy reinforced C-130 center wing boxes. The advanced development work necessary to support detailed design of a composite reinforced C-130 center wing box was conducted. Activities included the development of a basis for structural design, selection and verification of materials and processes, manufacturing and tooling development, and fabrication and test of full-scale portions of the center wing box. Detailed design drawings, and necessary analytical structural substantiation including static strength, fatigue endurance, flutter, and weight analyses are considered. Some additional component testing was conducted to verify the design for panel buckling, and to evaluate specific local design areas. Development of the cool tool restraint concept was completed, and bonding capabilities were evaluated using full-length skin panel and stringer specimens.
Over the past few years,studies at the Short-term Prediction Research and Transition (SPoRT) Center have suggested that the use of Moderate Resolution Imaging Spectroradiometer (MODIS) composite sea-surface temperature (SST) products in regional weather forecast models can have a significant positive impact on short-term numerical weather prediction in coastal regions. The recent paper by LaCasse et al. (2007, Monthly Weather Review) highlights lower atmospheric differences in regional numerical simulations over the Florida offshore waters using 2-km SST composites derived from the MODIS instrument aboard the polar-orbiting Aqua and Terra Earth Observing System satellites. To help quantify the value of this impact on NWS Weather Forecast Offices (WFOs), the SPoRT Center and the NWS WFO at Miami, FL (MIA) are collaborating on a project to investigate the impact of using the high-resolution MODIS SST fields within the Weather Research and Forecasting (WRF) prediction system. The scientific hypothesis being tested is: More accurate specification of the lower-boundary forcing within WRF will result in improved land/sea fluxes and hence, more accurate evolution of coastal mesoscale circulations and the associated sensible weather elements. The NWS MIA is currently running the WRF system in real-time to support daily forecast operations, using the National Centers for Environmental Prediction Nonhydrostatic Mesoscale Model dynamical core within the NWS Science and Training Resource Center's Environmental Modeling System (EMS) software; The EMS is a standalone modeling system capable of downloading the necessary daily datasets, and initializing, running and displaying WRF forecasts in the NWS Advanced Weather Interactive Processing System (AWIPS) with little intervention required by forecasters. Twenty-seven hour forecasts are run daily with start times of 0300,0900, 1500, and 2100 UTC on a domain with 4-km grid spacing covering the southern half of Florida and the far western portions of the Bahamas, the Florida Keys, the Straights of Florida, and adjacent waters of the Gulf of Mexico and Atlantic Ocean. Each model run is initialized using the Local Analysis and Prediction System (LAPS) analyses available in AWIPS, invoking the diabatic. "hot-start" capability. In this WRF model "hot-start", the LAPS-analyzed cloud and precipitation features are converted into model microphysics fields with enhanced vertical velocity profiles, effectively reducing the model spin-up time required to predict precipitation systems. The SSTs are initialized with the NCEP Real-Time Global (RTG) analyses at l/12 degree resolution (approx. 9 km); however, the RTG product does not exhibit fine-scale details consistent with its grid resolution. SPoRT is conducting parallel WRF EMS runs identical to the operational runs at NWS MIA in every respect except for the use of MODIS SST composites in place of the RTG product as the initial and boundary conditions over water. The MODIS SST composites for initializing the SPoRT WRF runs are generated on a 2-km grid four times daily at 0400, 0700, 1600, and 1900 UTC, based on the times of the overhead passes of the Aqua and Terra satellites. The incorporation of the MODIS SST composites into the SPoRTWRF runs is staggered such that the 0400UTC composite initializes the 0900 UTC WRF, the 0700 UTC composite initializes the 1500 UTC WRF, the 1600 UTC composite initializes the 2100 UTC WRF, and the 1900 UTC composite initializes the 0300 UTC WRF. A comparison of the SPoRT and Miami forecasts is underway in 2007, and includes quantitative verification of near-surface temperature, dewpoint, and wind forecasts at surface observation locations. In addition, particular days of interest are being analyzed to determine the impact of the MODIS SST data on the development and evolution of predicted sea/land-breeze circulations, clouds, and precipitation. This paper will present verification results comparing the NWS MIA forecasts the SPoRT experimental WRF forecasts, and highlight any substantial differences noted in the predicted mesoscale phenomena.
The design and evaluation of built-up attachments and bonded joint concepts for use at elevated temperatures is documented. Joint concept screening, verification of GR/PI material, fabrication of design allowables panels, definition of test matrices, and analysis of bonded and bolted joints are among the tasks completed. The results provide data for the design and fabrication of lightly loaded components for advanced space transportation systems and high speed aircraft.