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At least 145 records · Page 8

Strain Gage Loads Calibration Testing of the Active Aeroelastic Wing F/A-18 Aircraft

This report describes strain-gage calibration loading through the application of known loads of the Active Aeroelastic Wing F/A-18 airplane. The primary goal of this test is to produce a database suitable for deriving load equations for left and right wing root and fold shear; bending moment; torque; and all eight wing control-surface hinge moments. A secondary goal is to produce a database of wing deflections measured by string potentiometers and the onboard flight deflection measurement system. Another goal is to produce strain-gage data through both the laboratory data acquisition system and the onboard aircraft data system as a check of the aircraft system. Thirty-two hydraulic jacks have applied loads through whiffletrees to 104 tension-compression load pads bonded to the lower wing surfaces. The load pads covered approximately 60 percent of the lower wing surface. A series of 72 load cases has been performed, including single-point, double-point, and distributed load cases. Applied loads have reached 70 percent of the flight limit load. Maximum wingtip deflection has reached nearly 16 in.

Lokos, William A.↗

Graphite-epoxy panel compression strength reduction due to local impact

A review of results from on-going research to investigate the effects of low-velocity impact on the compressive strength of graphite-epoxy structures is presented. Extensive tests have been conducted on sandwich beams, laminated plates and stiffened panels. Conditions for failures were investigated by impact tests on statically loaded test specimens. The effects of compression load intensity were such that lightly loaded graphite structures (such as aircraft secondary structure) were insensitive to impact damage. In more heavily loaded structures, (such as wing panels), however, appreciable reductions in compressive strength occurred. The implications of the tests for structural design are discussed by comparing panel masses for designs where ultimate strains have been reduced due to impact considerations with the masses of designs with higher ultimate strains. Finally, preliminary test data is presented to show the possibility of improvements in damage tolerance achievable by using an alternate matrix material.

Card, M. P.↗

MSAT boom joint testing and load absorber design

Through a series of component and system-level tests, the torque margin for the MSAT booms is being determined. The verification process has yielded a number of results and lessons that can be applied to many other types of deployable spacecraft mechanisms. The MSAT load absorber has proven to be an effective way to provide high energy dissipation using crushable honeycomb. Using two stages of crushable honeycomb and a fusible link, a complex crush load profile has been designed and implemented. The design features of the load absorber lend themselves to use in other spacecraft applications.

Klinker, D. H.↗

Unsteady environments and responses of the shuttle combined loads orbiter test

Both separate and combined wind tunnel and vibration shaker tests were conducted on two structural panels representative of the Shuttle orbiter in the NASA LaRC 8-foot transonic pressure tunnel (TPT) to determine the effects of combined loads on the thermal protection system (TPS). The primary objective of this test was to provide a combined full-scale load environment and realistic time history of the dynamic pressures, Mach numbers (through transonic), and dynamic structural responses of these panels. The panels were selected from orbiter locations where interactive load sources such as aerodynamic shock waves, turbulent boundary layers, strut-induced vorticity, and substrate deformation combined to provide high bonding loads between the TPS and the orbiter structure. The test panels for this program were highly instrumented with static and dynamic pressure gages, accelerometers, deflectometers, strain gages, Schileren and high-speed photography, and special instrumentation necessary to determine TPS/structure interface loads and tile motions. Two test specimens of each orbiter panel were utilized. Both were high-fidelity representations of the selected orbiter location. The first panel (calibration panel) for each test was utilized to calibrate the tunnel and shaker system as well as provide a data-gathering source for applied static and dynamic loads. The second panel (test panel) for each test was subjected to flight time exposures only so that TPS characteristics as a function of flight mission exposure could be determined. These tests were the last in a series that was suce6ssfully completed and necessary to certify the TPS prior to the first launching of the Shuttle.

P. H. Schuetz↗

Optical Fiber Distributed Sensing Structural Health Monitoring (SHM) Strain Measurements Taken During Cryotank Y-Joint Test Article Load Cycling at Liquid Helium Temperatures

This paper outlines cryogenic Y-joint testing at Langley Research Center (LaRC) to validate the performance of optical fiber Bragg grating strain sensors for measuring strain at liquid helium temperature (-240 C). This testing also verified survivability of fiber sensors after experiencing 10 thermal cool-down, warm-up cycles and 400 limit load cycles. Graphite composite skins bonded to a honeycomb substrate in a sandwich configuration comprised the Y-joint specimens. To enable SHM of composite cryotanks for consideration to future spacecraft, a light-weight, durable monitoring technology is needed. The fiber optic distributed Bragg grating strain sensing system developed at LaRC is a viable substitute for conventional strain gauges which are not practical for SHM. This distributed sensing technology uses an Optical Frequency Domain Reflectometer (OFDR). This measurement approach has the advantage that it can measure hundreds of Bragg grating sensors per fiber and the sensors are all written at one frequency, greatly simplifying fiber manufacturing. Fiber optic strain measurements compared well to conventional strain gauge measurements obtained during these tests. These results demonstrated a high potential for a successful implementation of a SHM system incorporating LaRC's fiber optic sensing system on the composite cryotank and other future cryogenic applications.

Allison, Sidney G.↗

Fracture characteristics of structural aerospace alloys containing deep surface flaws

Conditions controlling the growth and fracture of deep surface flaws in aerospace alloys were investigated. Static fracture tests were performed on 7075-T651 and 2219-T87 aluminum, and 6Ai-4V STA titanium . Cyclic flaw growth tests were performed on the two latter alloys, and sustain load tests were performed on the titanium alloy. Both the cyclic and the sustain load tests were performed with and without a prior proof overload cycle to investigate possible growth retardation effects. Variables included in all test series were thickness, flaw depth-to-thickness ratio, and flaw shape. Results were analyzed and compared with previously developed data to determine the limits of applicability of available modified linear elastic fracture solutions.

Masters, J. N.↗

X-37 C/SiC Ruddervator Subcomponent Test Program

Completed thermal-mechanical and mechanical load testing: a) 6 re-entry heating tests (3 with loading to 50% DLL), 3 hypersonic cruise tests with loading to 50% DLL and 4 high-temperature modal survey tests. b) 9 tests to 100% DLL. High-temperature modal survey results were inconclusive due to exceeding capability of some accelerometers. Overall good correlation between analysis and measured results for windward and leeward surface temperatures. Generally poor correlation between analysis and measured results for spindle area temperatures. Excellent test-to-test repeatability in strain and deflection data for 100% DLL testing. In-situ thermography images taken before and after thermal testing showed only minor changes in initial defects. Final detailed thermography tests scheduled for completion in Oct 09. In process of completing test documentation and test data analysis. Final reports complete by Dec 09. All analysis, test data, test plans, reports, photos, etc. will be made available to the technical community via the CMC Wiki.

Hudson, Larry D.↗

Determination of Stress-Corrosion Cracking in Aluminum-Lithium Alloy ML377

The use of aluminum-lithium alloys for aerospace applications is currently being studied at NASA Langley Research Center's Metallic Materials Branch. The alloys in question will operate under stress in a corrosive environment. These conditions are ideal for the phenomena of Stress-Corrosion Cracking (SCC) to occur. The test procedure for SCC calls for alternate immersion and breaking load tests. These tests were optimized for the lab equipment and materials available in the Light Alloy lab. Al-Li alloy ML377 specimens were then subjected to alternate immersion and breaking load tests to determine residual strength and resistance to SCC. Corrosion morphology and microstructure were examined under magnification. Data shows that ML377 is highly resistant to stress-corrosion cracking.

Valek, Bryan C.↗

Dynamic Regulation of Sub-Atmospheric Pressure for Constant and Cyclic Gas Loads During Testing of Spacesuit Components

New iterations of the various subsystems within the spacesuit will benefit from a new sorbent technology. For example, sorbents used in the Trace Contaminant Control (TCC) and the Rapid Cycle Amine (RCA) systems within the Exploration Portable Life Support System (xPLSS), part of the Extra-Vehicular Mobility Unit (xEMU). For proper validation, the sub-atmospheric pressure needs to be maintained within a simulated 2 ft 3 spacesuit volume. The traditional approach, which involves placing the entire vent loop within a hypobaric chamber, is not practical for the widespread testing of components and prototypes, as these specialized chambers are costly and not widely available. A two-stage regulator based sub-atmospheric pressure system is presented in this work. The method regulates the pressure based on pressure differentials between the pressure regulation pump, the test system, and the ambient environment. The performance of this system is demonstrated using data collected during a 150+ hour non-regenerative TCC sorbent evaluation, several 24-hour regenerative TCC sorbent evaluations with different regeneration cycles, and an 8-hour RCA sorbent evaluation, all under xEMU operating conditions. For regulation, the inlet regulator was set to propagate a small leak to increase the stability of the system as the gas load from the testing system changes. It was also found that controlling the input flow rate that replaces the material lost during regeneration is critical for ensuring the stability of the system. This system provided excellent pressure regulation, without adjustments, for constant loads during shorter time evaluations (hours), while longer time evaluations (days) are easily obtainable with periodic regulator adjustments. A second method is under development to address longer-term stability and to automate pressure regulation. It will incorporate flow and pressure measurements to dynamically control a set of electronically controlled proportional valves for adjusting the pumping speed and air bleed supply.

Nicholas F Materer↗

Installation of TVC Actuators in a Two Axis Inertial Load Simulator Test Stand

This paper is about the installation of Space Shuttle Main Engines (SSME) actuators in the new Two Axis Inertial Load Simulator (ILS) at MSFC. The new test stand will support the core stage of the Space Launch System (SLS). Because of the unique geometry of the new test stand standard actuator installation procedures will not work. I have been asked to develop a design on how to install the actuators into the new test stand. After speaking with the engineers and technicians I have created a possible design solution. Using Pro Engineer design software and running my own stress calculations I have proven my design is feasible. I have learned how to calculate the stresses my design will see from this task. From the calculations I have learned I have over built the apparatus. I have also expanded my knowledge of Pro Engineer and was able to create a model of my idea.

Dziubanek, Adam↗

Highly Loaded Composite Strut Test Results

Highly loaded composite struts from a proposed truss-based Altair lunar lander descent stage concept were selected for development under NASA's Advanced Composites Technology program. Predicted compressive member forces during launch and ascent of over -100,000 lbs were much greater than the tensile loads. Therefore, compressive failure modes, including structural stability, were primary design considerations. NASA's industry partner designed and built highly loaded struts that were delivered to NASA for testing. Their design, fabricated on a washout mandrel, had a uniform-diameter composite tube with composite tapered ends. Each tapered end contained a titanium end fitting with facing conical ramps that are overlaid and overwrapped with composite materials. The highly loaded struts were loaded in both tension and compression, with ultimate failure produced in compression. Results for the two struts tested are presented and discussed, along with measured deflections, strains and observed failure mechanisms.

Wu, K. C.↗

Recognizing defects in carbon-fiber reinforced plastics

The damage tolerance of structures made of carbon-fiber-reinforced plastic is tested under various loads. Test laminate (73/1/1, 24/9/1, 1465 A) specimens of thickness 1.5-3.2 mm with various defects were subjected to static and dynamic loads. Special attention was given to delamination, and ultrasonic C-scans were made on the specimens. It was shown that cracks from even small defects are detected with great accuracy. The same probes were also X rayed; defects that could not be detected under ordinary X rays were bored and studied under vacuum by a contrast technique. The nondestructive ultrasonic and X ray tests were controlled by partially destructive tests, and good agreement was observed.

Schuetze, R.↗

Preparation for Testing a Multi-Bay Box Subjected to Combined Loads

The COmbined Loads Test System (COLTS) facility at NASA Langley Research Center provides a test capability to help develop validated structures technologies. The test machine was design to accommodate a range of fuselage structures and wing sections and subject them to both quasistatic and cyclic loading conditions. The COLTS facility is capable of testing fuselage barrels up to 4.6 m in diameter and 13.7 m long with combined mechanical, internal pressure, and thermal loads. The COLTS facility is currently being prepared to conduct a combined mechanical and pressure loading for a multi-bay pressure box to experimentally verify the structural performance of a composite structure which is 9.1 meters long and representative of a section of a hybrid wing body fuselage section in support of the Environmentally Responsible Aviation Project at NASA. This paper describes development of the multi-bay pressure box test using the COLTS facility. The multi-bay test article will be subjected to mechanical loads and internal pressure loads up to design ultimate load. Mechanical and pressure loads will be applied independently in some tests and simultaneously in others.

Rouse, Marshall↗

Testing Machine for Biaxial Loading

Standard tensile-testing machine applies bending and tension simultaneously. Biaxial-loading test machine created by adding two test fixtures to commercial tensile-testing machine. Bending moment applied by substrate-deformation fixture comprising yoke and anvil block. Pneumatic tension-load fixture pulls up on bracket attached to top surface of specimen. Tension and deflection measured with transducers. Modified test apparatus originally developed to load-test Space Shuttle surface-insulation tiles and particuarly important for composite structures.

Demonet, R. J.↗

Liquid Oxygen Propellant Densification Production and Performance Test Results With a Large-Scale Flight-Weight Propellant Tank for the X33 RLV

This paper describes in-detail a test program that was initiated at the Glenn Research Center (GRC) involving the cryogenic densification of liquid oxygen (LO2). A large scale LO2 propellant densification system rated for 200 gpm and sized for the X-33 LO2 propellant tank, was designed, fabricated and tested at the GRC. Multiple objectives of the test program included validation of LO2 production unit hardware and characterization of densifier performance at design and transient conditions. First, performance data is presented for an initial series of LO2 densifier screening and check-out tests using densified liquid nitrogen. The second series of tests show performance data collected during LO2 densifier test operations with liquid oxygen as the densified product fluid. An overview of LO2 X-33 tanking operations and load tests with the 20,000 gallon Structural Test Article (STA) are described. Tank loading testing and the thermal stratification that occurs inside of a flight-weight launch vehicle propellant tank were investigated. These operations involved a closed-loop recirculation process of LO2 flow through the densifier and then back into the STA. Finally, in excess of 200,000 gallons of densified LO2 at 120 oR was produced with the propellant densification unit during the demonstration program, an achievement that s never been done before in the realm of large-scale cryogenic tests.

Tomsik, Thomas M.↗

Current Activities in the Advanced Exploration Systems ISRU Project

Media Filter MOXIE support: completed flow performance tests and initial dust loading tests of the MOXIE HEPA filter in the Mars Flow Loop Designed and fabricated prototype full-scale scroll filter for testing of renewable filter performance Mars Flow Loop upgrades: installed more sensitive instrumentation, improved imaging, and increased run duration capability Electrostatic Precipitator (ESP) Plasma-physics based model predicts particle charge and trajectory Characterizing dust environment from fluidized-bed injection dust environment using laser sheet visualization and Fine Particle Analyzer Sabatier Design Study Defined the Sabatier design space, including reactor type, thermal management, gas recycling/separation Modeled Sabatier systems with one or two reactors with different types of thermal management Adding thermal management schemes and recycling and gas separation to model Catalyst Screening Performing compression testing on new and used catalyst pellets Performing vibration testing on different catalyst pellet types under different load conditions Preparing to test catalysts for performance and degradation

In-Situ Resource Utilization↗

Investigation of Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears

An investigation of the low-cycle bending fatigue of spur gears made from AISI 9310 gear steel was completed. Tests were conducted using the single-tooth bending method to achieve crack initiation and propagation. Tests were conducted on spur gears in a fatigue test machine using a dedicated gear test fixture. Test loads were applied at the highest point of single tooth contact. Gear bending stresses for a given testing load were calculated using a linear-elastic finite element model. Test data were accumulated from 1/4 cycle to several thousand cycles depending on the test stress level. The relationship of stress and cycles for crack initiation was found to be semilogarithmic. The relationship of stress and cycles for crack propagation was found to be linear. For the range of loads investigated, the crack propagation phase is related to the level of load being applied. Very high loads have comparable crack initiation and propagation times whereas lower loads can have a much smaller number of cycles for crack propagation cycles as compared to crack initiation.

Handschuh, Robert F.↗

Investigation of Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears

An investigation of the low-cycle bending fatigue of spur gears made from AISI 9310 gear steel was completed. Tests were conducted using the single-tooth bending method to achieve crack initiation and propagation. Tests were conducted on spur gears in a fatigue test machine using a dedicated gear test fixture. Test loads were applied at the highest point of single tooth contact. Gear bending stresses for a given testing load were calculated using a linear-elastic finite element model. Test data were accumulated from 1/4 cycle to several thousand cycles depending on the test stress level. The relationship of stress and cycles for crack initiation was found to be semi-logarithmic. The relationship of stress and cycles for crack propagation was found to be linear. For the range of loads investigated, the crack propagation phase is related to the level of load being applied. Very high loads have comparable crack initiation and propagation times whereas lower loads can have a much smaller number of cycles for crack propagation cycles as compared to crack initiation.

Handschuh, Robert F.↗