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NASA NTRS2007

Lunar In Situ Materials-Based Surface Structure Technology Development Efforts at NASA/MSFC

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As man's presence on these bodies expands, so must the structures to accommodate them, including habitats, laboratories, berms, radiation shielding for surface reactors, garages, solar storm shelters, greenhouses, etc. The use of in situ materials will significantly offset required launch upmass and volume issues. Under the auspices of the In Situ Fabrication & Repair (ISFR) Program at NASA/Marshall Space Flight Center (MSFC), the Surface Structures project has been developing materials and construction technologies to support development of these in situ structures. This paper will report on the development of several of these technologies at MSFC's Prototype Development Laboratory (PDL). These technologies include, but are not limited to, development of extruded concrete and inflatable concrete dome technologies based on waterless and water-based concretes, development of regolith-based blocks with potential radiation shielding binders including polyurethane and polyethylene, pressure regulation systems for inflatable structures, production of glass fibers and rebar derived from molten lunar regolith simulant, development of regolithbag structures, and others, including automation design issues. Results to date and lessons learned will be presented, along with recommendations for future activities.

Fiske, M. R.↗

NASA NTRS2008

Structural Definition and Mass Estimation of Lunar Surface Habitats for the Lunar Architecture Team Phase 2 (LAT-2) Study

The Lunar Architecture Team Phase 2 study defined and assessed architecture options for a Lunar Outpost at the Moon's South Pole. The Habitation Focus Element Team was responsible for developing concepts for all of the Habitats and pressurized logistics modules particular to each of the architectures, and defined the shapes, volumes and internal layouts considering human factors, surface operations and safety requirements, as well as Lander mass and volume constraints. The Structures Subsystem Team developed structural concepts, sizing estimates and mass estimates for the primary Habitat structure. In these studies, the primary structure was decomposed into a more detailed list of components to be sized to gain greater insight into concept mass contributors. Structural mass estimates were developed that captured the effect of major design parameters such as internal pressure load. Analytical and empirical equations were developed for each structural component identified. Over 20 different hard-shell, hybrid expandable and inflatable soft-shell Habitat and pressurized logistics module concepts were sized and compared to assess structural performance and efficiency during the study. Habitats were developed in three categories; Mini Habs that are removed from the Lander and placed on the Lunar surface, Monolithic habitats that remain on the Lander, and Habitats that are part of the Mobile Lander system. Each category of Habitat resulted in structural concepts with advantages and disadvantages. The same modular shell components could be used for the Mini Hab concept, maximizing commonality and minimizing development costs. Larger Habitats had higher volumetric mass efficiency and floor area than smaller Habitats (whose mass was dominated by fixed items such as domes and frames). Hybrid and pure expandable Habitat structures were very mass-efficient, but the structures technology is less mature, and the ability to efficiently package and deploy internal subsystems remains an open issue.

Dorsey, John T.↗

NASA NTRS2015

Advanced Composite Structures At NASA Langley Research Center

Dr. Eldred's presentation will discuss several NASA efforts to improve and expand the use of composite structures within aerospace vehicles. Topics will include an overview of NASA's Advanced Composites Project (ACP), Space Launch System (SLS) applications, and Langley's ISAAC robotic composites research tool.

Eldred, Lloyd B.↗

NASA NTRS1994

Computational simulation of composite structures with and without damage

A methodology is described which uses finite element analysis of various laminates to computationally simulate the effects of delamination damage initiation and growth on the structural behavior of laminated composite structures. The delamination area is expanded according to a set pattern. As the delamination area increases, how the structural response of the laminate changes with respect to buckling and strain energy release rate are investigated. Rules are presented for laminates of different configurations, materials and thickness. These results demonstrate that computational simulation methods can provide alternate methods to investigate the complex delamination damage mechanisms found in composite structures.

Wilt, Thomas F.↗

NASA NTRS1995

Displacement based multilevel structural optimization

Multidisciplinary design optimization (MDO) is expected to play a major role in the competitive transportation industries of tomorrow, i.e., in the design of aircraft and spacecraft, of high speed trains, boats, and automobiles. All of these vehicles require maximum performance at minimum weight to keep fuel consumption low and conserve resources. Here, MDO can deliver mathematically based design tools to create systems with optimum performance subject to the constraints of disciplines such as structures, aerodynamics, controls, etc. Although some applications of MDO are beginning to surface, the key to a widespread use of this technology lies in the improvement of its efficiency. This aspect is investigated here for the MDO subset of structural optimization, i.e., for the weight minimization of a given structure under size, strength, and displacement constraints. Specifically, finite element based multilevel optimization of structures (here, statically indeterminate trusses and beams for proof of concept) is performed. In the system level optimization, the design variables are the coefficients of assumed displacement functions, and the load unbalance resulting from the solution of the stiffness equations is minimized. Constraints are placed on the deflection amplitudes and the weight of the structure. In the subsystems level optimizations, the weight of each element is minimized under the action of stress constraints, with the cross sectional dimensions as design variables. This approach is expected to prove very efficient, especially for complex structures, since the design task is broken down into a large number of small and efficiently handled subtasks, each with only a small number of variables. This partitioning will also allow for the use of parallel computing, first, by sending the system and subsystems level computations to two different processors, ultimately, by performing all subsystems level optimizations in a massively parallel manner on separate processors. It is expected that the subsystems level optimizations can be further improved through the use of controlled growth, a method which reduces an optimization to a more efficient analysis with only a slight degradation in accuracy. The efficiency of all proposed techniques is being evaluated relative to the performance of the standard single level optimization approach where the complete structure is weight minimized under the action of all given constraints by one processor and to the performance of simultaneous analysis and design which combines analysis and optimization into a single step. It is expected that the present approach can be expanded to include additional structural constraints (buckling, free and forced vibration, etc.) or other disciplines (passive and active controls, aerodynamics, etc.) for true MDO.

Striz, Alfred G.↗

NASA NTRS1999

Control Design Strategies to Enhance Long-Term Aircraft Structural Integrity

Over the operational lifetime of both military and civil aircraft, structural components are exposed to hundreds of thousands of low-stress repetitive load cycles and less frequent but higher-stress transient loads originating from maneuvering flight and atmospheric gusts. Micro-material imperfections in the structure, such as cracks and debonded laminates, expand and grow in this environment, reducing the structural integrity and shortening the life of the airframe. Extreme costs associated with refurbishment of critical load-bearing structural components in a large fleet, or altogether reinventoring the fleet with newer models, indicate alternative solutions for life extension of the airframe structure are highly desirable. Increased levels of operational safety and reliability are also important factors influencing the desirability of such solutions. One area having significant potential for impacting crack growth/fatigue damage reduction and structural life extension is flight control. To modify the airframe response dynamics arising from command inputs and gust disturbances, feedback loops are routinely applied to vehicles. A dexterous flight control system architecture senses key vehicle motions and generates critical forces/moments at multiple points distributed throughout the airframe to elicit the desired motion characteristics. In principle, these same control loops can be utilized to influence the level of exposure to harmful loads during flight on structural components. Project objectives are to investigate and/or assess the leverage control has on reducing fatigue damage and enhancing long-term structural integrity, without degrading attitude control and trajectory guidance performance levels. In particular, efforts have focused on the effects inner loop control parameters and architectures have on fatigue damage rate. To complete this research, an actively controlled flexible aircraft model and a new state space modeling procedure for crack growth have been utilized. Analysis of the analytical state space model for crack growth revealed the critical mathematical factors, and hence the physical mechanism they represent, that influenced high rates of airframe crack growth. The crack model was then exercised with simple load inputs to uncover and expose key crack growth behavior. To characterize crack growth behavior, both "short-term" laboratory specimen test type inputs and "long-term" operational flight type inputs were considered. Harmonic loading with a single overload revealed typical exponential crack growth behavior until the overload application, after which time the crack growth was retarded for a period of time depending on the overload strength. An optimum overload strength was identified which leads to maximum retardation of crack growth. Harmonic loading with a repeated overload of varying strength and frequency again revealed an optimum overload trait for maximizing growth retardation. The optimum overload strength ratio lies near the range of 2 to 3 with dependency on frequency. Experimental data was found to correlate well with the analytical predictions.

Newman, Brett A.↗

NASA NTRS1975

Spinning mode sound propagation in ducts with acoustic treatment

Recent acoustic data show larger noise attenuations than predicted for acoustically treated aircraft engine inlets without splitter rings. A theoretical study of the acoustic propagation of spinning modes in acoustically treated open circular ducts is presented, and a suppressor with splitter rings was modeled by using the rectangular approximation to the annular duct. Theoretical models were used to determine optimum impedance and maximum attenuation for several spinning lobe numbers from 0 to 50. Results of the analysis indicate that for circular ducts the maximum possible attenuation and the optimum wall impedance are strong functions of the lobe number, and for annular ducts the attenuation and optimum wall impedance are insensitive to the spinning lobe number for well cut-on modes. These results explain why suppressors with splitter rings were quite effective in spite of the lack of detailed information on the noise source modal structure. Conversely, effective use of outer wall treatment alone will require expanded knowledge of the noise source structure. Approximate solutions are presented to help interpret the more exact theoretical results.

Rice, E. J.↗

NASA NTRS1998

Tooling Foam for Structural Composite Applications

Tooling technology applications for composite structures fabrication have been expanded at MSFC's Productivity Enhancement Complex (PEC). Engineers from NASA/MSFC and Lockheed Martin Corporation have developed a tooling foam for use in composite materials processing and manufacturing that exhibits superior thermal and mechanical properties in comparison with other tooling foam materials. This tooling foam is also compatible with most preimpregnated composite resins such as epoxy, bismaleimide, phenolic and their associated cure cycles. MARCORE tooling foam has excellent processability for applications requiring either integral or removable tooling. It can also be tailored to meet the requirements for composite processing of parts with unlimited cross sectional area. A shelf life of at least six months is easily maintained when components are stored between 50F - 70F. The MARCORE tooling foam system is a two component urethane-modified polyisocyanurate, high density rigid foam with zero ozone depletion potential. This readily machineable, lightweight tooling foam is ideal for composite structures fabrication and is dimensionally stable at temperatures up to 350F and pressures of 100 psi.

DeLay, Tom↗

NASA NTRS1994

Software for continuum modeling of controls-structures interactions

It is clear that computer software is needed to assist in the generation of the equations of motion for complex, flexible spacecraft. Daniel Poelaert of ESTEC has developed the software DISTEL with which he has modeled the structural dynamics for different satellites. He is interested in expanding the capabilities of DISTEL to include structural damping and control systems. Unfortunately, the software has not been released. The author has developed similar software, PDEMOD, which has been used to model the Spacecraft control Laboratory Experiment (SCOLE), the Solar Array Flight Experiment (SAFE), the Mini-MAST truss, and the LACE satellite. PDEMOD has been used also for optimal parameter estimation and integrated control-structures design. PDEMOD is also being extended to include structural damping and control systems which are imbedded into the same equations for the structural dynamics. This paper will address the formulation of the equations for the structural dynamics of spacecraft structures which are constructed of a 3-dimensional arrangement of rigid bodies and flexible beam elements. Control system dynamics are imbedded into the same equations so that model order reduction approximations are not necessary. The input data consists of the physical data of the elements and the topological information describing how the elements are connected. PDEMOD accomplishes the following: (1) automatically assembles the equations of motion for the entire structural model; (2) calculates the modal frequencies; (3) calculates the mode shapes; (4) generates perspective views of the mode shapes; and (5) forms selected transfer functions. The software PDEMOD continues to be developed to provide additional features to assist in analyzing and synthesizing control and structural systems for flexible spacecraft.

Taylor, Lawrence W., Jr.↗

NASA NTRS2009

Testing Large Structures in the Field

Field testing large structures creates unique challenges such as limited choices for boundary conditions and the fact that natural excitation sources cannot be removed. Several critical developments in field testing of large structures are reviewed, including: step relaxation testing which has been developed into a useful technique to apply large forces to operational systems by careful windowing; the capability of large structures testing with free support conditions which has been expanded by implementing modeling of the support structure; natural excitation which has been developed as a viable approach to field testing; and the hybrid approach which has been developed to allow forces to be estimated in operating structures. These developments have increased the ability to extract information from large structures and are highlighted in this presentation.

James, George↗

NASA NTRS1974

Quasi-perfect FIFO: Synchronous or asynchronous with application in controller design for the UNICON laser memory

The first-in-first-out memory buffer (FIFO), is an elastic digital memory whose main application is in data buffering between devices operating at different rates. Data written into the top is moved autonomously down toward the bottom of the FIFO to the lowest unoccupied location, and data read from the bottom of the FIFO will cause data from the top to move autonomously down toward the bottom. The FIFO is available in MOS LSI asynchronous form with data rate in the 1 MHz region. The FIFO described yields a simple high-speed iterative implementation, either synchronous of asynchronous. Because of this simple iterative structure, the FIFO is expandable in both number of words and bits per word, and it is attractive from the viewpoint of integrated-circuit production. For the synchronous FIFO, a model was built and successfully used in the controller for the UNICON laser memory. For the asynchronous FIFO, a model was built and also successfully used in a high-performance magnetic tape controller.

Lim, R. S.↗

NASA NTRS1976

Stellar convection theory. I - The anelastic modal equations

Methods are developed for dealing with the various dynamical problems that arise because of convective zones in stars. A system of equations for stellar convection is derived from the full equations of compressible fluid dynamics with the aid of two major approximations. The first of these is the anelastic approximation, which involves both the filtering out of acoustic waves and a suitable linearization of the fluctuating thermodynamic variables. The second one approximates the horizontal structure of convection by expanding the motion in a set of horizontal cellular platforms and severely truncating the expansion. The resulting system of partial differential equations, referred to as the anelastic modal equations, is outlined along with suggested boundary conditions and techniques for solving the equations. Ways of assessing the overall validity of the present treatment are discussed.

Latour, J.↗

NASA NTRS1981

Structural requirements and technology needs of geostationary platforms

To identify structural requirements and technology needs of the geostationary platforms, two design alternatives are analyzed with respect to utilities accommodation, interface, and strength and stiffness requirements. Alternative 1 is comprised of 6,800 kg (15,000 lb) platform modules, each delivered to low earth orbit (LEO) with an attached orbit transfer vehicle (OTV) in a single Shuttle flight, deployed, and transferred to a geostationary constellation of platforms. Alternative 2 is made up of 16,800 kg (37,000 lb) platform modules, each delivered to LEO, deployed, mated to a 2 stage OTV (delivered to LEO in two additional Shuttle flights) and transferred to GEO for docking with other modules to form a single large platform. The top candidates for deployable structure elements are the expandable truss beam and the Astromast. The beam, fabricated of graphite/epoxy with a designed coefficient of thermal expansion of zero, provides good packaging density and high strength and stiffness per unit weight. The Astromast provides the best packaging density, but lacks the strength and stiffness required for the platform payloads. A graphite/epoxy mast with the Astromast packaging density is an advancement in technology needed for optimizing the geostationary platform designs.

Stone, G. R.↗

NASA NTRS1981

Primary propulsion/large space system interaction study

An interaction study was conducted between propulsion systems and large space structures to determine the effect of low thrust primary propulsion system characteristics on the mass, area, and orbit transfer characteristics of large space systems (LSS). The LSS which were considered would be deployed from the space shuttle orbiter bay in low Earth orbit, then transferred to geosynchronous equatorial orbit by their own propulsion systems. The types of structures studied were the expandable box truss, hoop and column, and wrap radial rib each with various surface mesh densities. The impact of the acceleration forces on system sizing was determined and the effects of single point, multipoint, and transient thrust applications were examined. Orbit transfer strategies were analyzed to determine the required velocity increment, burn time, trip time, and payload capability over a range of final acceleration levels. Variables considered were number of perigee burns, delivered specific impulse, and constant thrust and constant acceleration modes of propulsion. Propulsion stages were sized for four propellant combinations; oxygen/hydrogen, oxygen/methane, oxygen/kerosene, and nitrogen tetroxide/monomethylhydrazine, for pump fed and pressure fed engine systems. Two types of tankage configurations were evaluated, minimum length to maximize available payload volume and maximum performance to maximize available payload mass.

Coyner, J. V.↗

NASA NTRS1985

Optical observations of the AMPTE artificial comet and magnetotail barium releases

The first AMPTE artificial comet was observed with a low light level television camera operated aboard the NASA CV990 flying out of Moffett Field, California. The comet head, neutral cloud, and comet tail were all observed for four minutes with an unifiltered camera. Brief observations at T + 4 minutes through a 4554A Ba(+) filter confirmed the identification of the structures. The ion cloud expanded along with the neutral cloud at a rate of 2.3 km/sec (diameter) until it reached a final diameter of approx. 170 km at approx. T + 90 s. It also drifted with the neutral cloud until approx. 165 s. By T + 190 s it had reached a steady state velocity of 5.4 km/sec southward. A barium release in the magnetotail was observed from the CV990 in California, Eagle, Alaska, and Fairbanks, Alaska. Over a twenty-five minute period, the center of the barium streak drifted southward (approx. 500 m/sec), upward (24 km/sec) and eastward (approx 1 km/sec) in a nonrotating reference frame. An all-sky TV at Eagle showed a single auroral arc in the far North during this period.

Hallinan, T. J.↗

NASA NTRS1987

A high temperature fatigue and structures testing facility

As man strives for higher levels of sophistication in air and space transportation, awareness of the need for accurate life and material behavior predictions for advanced propulsion system components is heightened. Such sophistication will require complex operating conditions and advanced materials to meet goals in performance, thrust-to-weight ratio, and fuel efficiency. To accomplish these goals will require that components be designed using a high percentage of the material's ultimate capabilities. This serves only to complicate matters dealing with life and material behavior predictions. An essential component of material behavior model development is the underlying experimentation which must occur to identify phenomena. To support experimentation, the NASA Lewis Research Center's High Temperature Fatigue and Structures Laboratory has been expanded significantly. Several new materials testing systems have been added, as well as an extensive computer system. The intent of this paper is to present an overview of the laboratory, and to discuss specific aspects of the test systems. A limited discussion of computer capabilities will also be presented.

Bartolotta, Paul A.↗

NASA NTRS1987

Sunspot observations from the SOUP instrument on Spacelab 2

A series of white light images obtained by the SOUP instrument on Spacelab 2 of active region 4682 on August 5, 1985 were analyzed in the area containing sunspots. Although the umbra of the spot is underexposed, the film is well exposed in the penumbral regions. These data were digitally processed to remove noise and to separate p-mode oscillations from low velocity material motions. The results of this preliminary investigation include: (1) proper motion measurements of a radial outflow in the photospheric granulation pattern just outside the penumbra; (2) discovery of occasional bright structures (streakers) that appear to be ejected outward from the penumbra; (3) broad dark clouds moving outward in the penumbra in addition to the well known bright penumbral grains moving inward; (4) apparent extensions and contractions of penumbral filaments over the photosphere; and (5) observation of a faint bubble or loop-like structure which seems to expand from two bright penumbral filaments into the photosphere.

Shine, R. A.↗

NASA NTRS1987

White light sunspot observations from the Solar Optical Universal Polarimeter on Spacelab-2

The flight of the Solar Optical Universal Polarimeter on Spacelab-2 provided the opportunity for the collection of time sequences of diffraction-limited (0.5 arcsec) solar images with excellent pointing stability (0.003 arcsec) and with freedom from the distortion that plagues ground-based images. A series of white-light images of active region 4682 were obtained on August 5, 1985, and the area containing the sunspot has been analyzed. These data have been digitally processed to remove noise and to separate waves from low-velocity material motions. The results include: (1) proper motion measurements of a radial outflow in the photospheric granulation pattern just outside the penumbra; (2) discovery of occasional bright structures ('streakers') that appear to be ejected outward from the penumbra; (3) broad dark 'clouds' moving outward in the penumbra, in addition to the well-known bright penumbral grains moving inward; (4) apparent extensions and contractions of penumbral filaments over the photosphere; and (5) observation of a faint bubble or looplike structure that seems to expand from two bright penumbral filaments into the photosphere.

Shine, R. A.↗