Overview of NASA’s Impact Testing of Energy Storage Systems Research: A Summary of Phase 1 and 2 Results
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energy storage systems↗
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Overview of NASA’s Impact Testing of Energy Storage Systems Research with a Partial Summary of Phase 1 Results
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Energy Storage Module↗
Methods for data reduction and loads analysis of Space Shuttle Solid Rocket Booster model water impact tests
The methodology used to predict full scale space shuttle solid rocket booster (SRB) water impact loads from scale model test data is described. Tests conducted included 12.5 inch and 120 inch diameter models of the SRB. Geometry and mass characteristics of the models were varied in each test series to reflect the current SRB baseline configuration. Nose first and tail first water entry modes were investigated with full-scale initial impact vertical velocities of 40 to 120 ft/sec, horizontal velocities of 0 to 60 ft/sec., and off-vertical angles of 0 to plus or minus 30 degrees. The test program included a series of tests with scaled atmospheric pressure.
Source record↗
A Study of the "toss Factor" in the Impact Testing of Cermets by the Izod Pendulum Test
The test method presented shows that the "toss energy" contributed by the apparatus for brittle materials is negligible. The total toss energy is considered to consist of two components. (a) recovered stored elastic energy and (b) kinetic energy contributed directly by the apparatus. The results were verified by high-speed motion pictures of the test in operation. From these photographs, velocities of tossed specimens were obtained and toss energy computed. In addition, impact energies of some titanium carbide base cermets and high-temperature alloys, as measured by the low-capacity Izod pendulum test, compare well with impact energies measured by the NACA drop test.
ALLOYS, HEAT-RESISTING↗
Apollo pad abort land impact tests at Kennedy Space Center
Drop test data from Apollo pad abort land impact study
Reese, T. G.↗
Hypervelocity impact testing of non-metallic materials
A comparative analysis of impact damage in composite and ceramic specimens and in geometrically similar aluminum specimens is performed to determine the advantages and disadvantages of employing certain composite and ceramic materials in the design of structural wall systems for long-duration spacecraft. A similar analysis of the damage in single panel lexan and multi-plane glass windows shows that glass window systems are rather resilent under hypervelocity impact loadings. It is concluded that thin Kevlar 49, IM6/3501-6 graphite/epoxy, and alumina panels offer no advantage over equivalent aluminum 6061-T6 panels in reducing the penetration threat of hypervelocity projectiles.
Schonberg, William P.↗
Low-velocity impact tests on fibrous composite sandwich structures
The effect of low-velocity projectile impact on the load-carrying ability of the composite sandwich structural components is investigated experimentally, the impact simulating the damage caused by runway debris and the accidental dropping of hand tools during servicing on secondary aircraft structures made with composites. The sandwich-type beam specimens were fabricated with graphite/epoxy face sheets, aluminum honeycomb core, and a steel (back) plate. A four-point beam-loading apparatus was used, and the ultimate strength, ultimate strain, and residual strength of the composites were determined. A faired curve is presented indicating the lower bound of the failure threshold for each of the laminate configurations tested in compression and tension as a function of the projectile impact energy. It is shown that strength degradation due to impact is dependent on the laminate configuration and the fiber/matrix combination. The laminates having more angle plies near the impact surface and unidirectional plies elsewhere seem to show extensive interply and intraply fiber delaminations at failure relative to the laminates with a cross-ply on the impact surface.
Sharma, A. V.↗
Multi-Terrain Impact Testing and Simulation of a Composite Energy Absorbing Fuselage Section
Comparisons of the impact performance of a 5-ft diameter crashworthy composite fuselage section were investigated for hard surface, soft soil, and water impacts. The fuselage concept, which was originally designed for impacts onto a hard surface only, consisted of a stiff upper cabin, load bearing floor, and an energy absorbing subfloor. Vertical drop tests were performed at 25-ft/s onto concrete, soft-soil, and water at NASA Langley Research Center. Comparisons of the peak acceleration values, pulse durations, and onset rates were evaluated for each test at specific locations on the fuselage. In addition to comparisons of the experimental results, dynamic finite element models were developed to simulate each impact condition. Once validated, these models can be used to evaluate the dynamic behavior of subfloor components for improved crash protection for hard surface, soft soil, and water impacts.
Fasanella, Edwin L.↗
Multi-Terrain Impact Testing and Simulation of a Composite Energy Absorbing Fuselage Section
Comparisons of the impact performance of a 5-ft diameter crashworthy composite fuselage section were investigated for hard surface, soft soil, and water impacts. The fuselage concept, which was originally designed for impacts onto a hard surface only, consisted of a stiff upper cabin, load bearing floor, and an energy absorbing subfloor. Vertical drop tests were performed at 25-ft/s onto concrete, soft-soil, and water at NASA Langley Research Center. Comparisons of the peak acceleration values, pulse durations, and onset rates were evaluated for each test at specific locations on the fuselage. In addition to comparisons of the experimental results, dynamic finite element models were developed to simulate each impact condition. Once validated, these models can be used to evaluate the dynamic behavior of subfloor components for improved crash protection for hard surface, soft soil, and water impacts.
Fasanella, Edwin L.↗
Mechanical impact tests of materials in oxygen effects of contamination
The effect of contaminants on the mechanical impact sensitivity of Teflon, stainless steel, and aluminum in a high-pressure oxygen environment was investigated. Uncontaminated Teflon did not ignite under the test conditions. The liquid contaminants - cutting oil, motor lubricating oil, and toolmaker dye - caused Teflon to ignite. Raising the temperature lowered the impact energy required for ignition. Stainless steel was insensitive to ignition under the test conditions with the contaminants used. Aluminum appeared to react without contaminants under certain test conditions; however, contamination with cutting oil, motor lubricating oil, and toolmakers dye increased the sensitivity of aluminum to mechanical impact. The grit contaminants silicon dioxide and copper powder did not conclusively affect the sensitivity of aluminum.
Ordin, P. M.↗
Permeability After Impact Testing of Composite Laminates
Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a non-linear fashion for almost all of the specimens tested.
Nettles, A.T.↗
Permeability After Impact Testing of Composite Laminates
Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a non-linear fashion for almost all of the specimens tested.
Nettles, Alan T.↗
Water Impact Test and Simulation of a Composite Energy Absorbing Fuselage Section
In March 2002, a 25-ft/s vertical drop test of a composite fuselage section was conducted onto water. The purpose of the test was to obtain experimental data characterizing the structural response of the fuselage section during water impact for comparison with two previous drop tests that were performed onto a rigid surface and soft soil. For the drop test, the fuselage section was configured with ten 100-lb. lead masses, five per side, that were attached to seat rails mounted to the floor. The fuselage section was raised to a height of 10-ft. and dropped vertically into a 15-ft. diameter pool filled to a depth of 3.5-ft. with water. Approximately 70 channels of data were collected during the drop test at a 10-kHz sampling rate. The test data were used to validate crash simulations of the water impact that were developed using the nonlinear, explicit transient dynamic codes, MSC.Dytran and LS-DYNA. The fuselage structure was modeled using shell and solid elements with a Lagrangian mesh, and the water was modeled with both Eulerian and Lagrangian techniques. The fluid-structure interactions were executed using the fast general coupling in MSC.Dytran and the Arbitrary Lagrange-Euler (ALE) coupling in LS-DYNA. Additionally, the smooth particle hydrodynamics (SPH) meshless Lagrangian technique was used in LS-DYNA to represent the fluid. The simulation results were correlated with the test data to validate the modeling approach. Additional simulation studies were performed to determine how changes in mesh density, mesh uniformity, fluid viscosity, and failure strain influence the test-analysis correlation.
Fasanella, Edwin L.↗
Simulated hail impact testing of photovoltaic solar panels
Techniques used to simulate and study the effect of hail on photovoltaic solar panels are described. Simulated hail stones (frozen ice spheres projected at terminal velocity) or steel balls were applied by air guns, gravity drop, or static loading. Tests with simulated hail and steel balls yielded different results. The impact strength of 10 commercially available flat-plate photovoltaic modules was tested. It was found that none of the six panel designs incorporating clear potting silicone material as the outermost layer remained undamaged by 1-in. simulated hailstones, while a photovoltaic module equipped with a 0.188-in.-thick acrylic cover sheet would be able to withstand the impact of a 2-in.-diameter hailstone.
Moore, D.↗
Hypervelocity Impact Test Facility: A gun for hire
An affordable technique has been developed to duplicate the types of impacts observed on spacecraft, including the Shuttle, by use of a certified Hypervelocity Impact Facility (HIF) which propels particulates using capacitor driven electric gun techniques. The fully operational facility provides a flux of particles in the 10-100 micron diameter range with a velocity distribution covering the space debris and interplanetary dust particle environment. HIF measurements of particle size, composition, impact angle and velocity distribution indicate that such parameters can be controlled in a specified, tailored test designed for or by the user. Unique diagnostics enable researchers to fully describe the impact for evaluating the 'targets' under full power or load. Users regularly evaluate space hardware, including solar cells, coatings, and materials, exposing selected portions of space-qualified items to a wide range of impact events and environmental conditions. Benefits include corroboration of data obtained from impact events, flight simulation of designs, accelerated aging of systems, and development of manufacturing techniques.
Johnson, Calvin R.↗
Hypervelocity impact testing of tethers
An experimental test program has been conducted to ascertain the strength losses to which representative space tether materials may be prone upon impact by hypervelocity particles of known size, density, and velocity, when the tether is under tensile loading typical of flight design loads. Twelve hypervelocity impacts were followed by tensile tests to failure to determine residual strength; relationships are established between particle velocity and strength loss due to impact damage, as well as between tether strength loss and the relationship between particle and tether diameters. Tentative design criteria are formulated in terms of a design factor allowing for strength degradation by impact.
Woodis, William R.↗
Micro-Satellite Impact Tests to Investigate Multi-Layer Insulation Fragments
This paper summarizes two satellite impact experiments completed in 2008. The objective of the experiments is to investigate the physical properties of satellite fragments, including those originated from Multi-Layer Insulation (MLI) and solar panels. The ultimate goal is to use the results to improve the NASA Standard Breakup Model. The targets were two cubic micro-satellites, 20 cm by 20 cm by 20 cm in size, and approximately 1,500 g in mass. The main structure of each micro-satellite was composed of five layers; the top and bottom layers and three internal layers parallel to the top and bottom layers, plus four side panels. The top layer was equipped with solar cells that was mounted to an aluminum honeycomb sandwich panel with CFRP face sheets. The four side panels and the bottom layer are all covered with MLI. The two satellite impact experiments were conducted using the two-stage light gas gun at the Kyushu Institute of Technology in Kitakyusyu, Japan. For the first experiment (labeled Shot F), the satellite was oriented in such a way that the solar panel was facing the incoming projectile, a 39.3 g aluminum alloy solid sphere. For the second experiment (labeled Shot R), the satellite was oriented so that the solar panel was on the opposite side of the impact surface. The projectile used in the second shot was a 39.2 g aluminum alloy solid sphere. The impact speeds of Shot F and Shot R were 1.74 km/s and 1.78 km/s, respectively. The ratio of the impact kinetic energy to satellite mass for the two experiments was about 40 J/g. Both target satellites were completely fragmented, although there were noticeable differences in the characteristics of the fragments. Approximately 1,800 fragments were collected from Shot F but only 1,000 fragments were collected from Shot R. This difference primarily comes from the number of needle-like CFRP and MLI fragments. The difference in CFRP pieces depends on how the CFRP panels were fragmented. Regarding the MLI pieces, a significant difference in size and number can be observed. The largest MLI pieces in Shot F are almost of the same size as the side panels, whereas those in Shot R are larger by about a factor of two. The collected fragments and MLI pieces will be measured and analyzed using the same method as described in the NASA Standard Breakup Model. This paper will present: (1) the area-to-mass ratio, size, and mass distributions of the fragments, and (2) the differences in fragment properties between Shot F and Shot R.
Liou, J.C.↗
Dynamic Open-Rotor Composite Shield Impact Test Report
The Federal Aviation Administration (FAA) is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the aircraft. NASA Glenn and Naval Air Warfare Center (NAWC) China Lake collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test a shield that would protect the aircraft passengers and critical systems from a released blade that could impact the fuselage. This report documents the live-fire test from a full-scale rig at NAWC China Lake. NASA provided manpower and photogrammetry expertise to document the impact and damage to the shields. The test was successful: the blade was stopped from penetrating the shield, which validates the design analysis method and the parameters used in the analysis. Additional work is required to implement the shielding into the aircraft.
Shielding↗