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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

Artemis Internal Science Team Update: Artemis Science Flight Operations

The Artemis Internal Science Team (AIST) is positioned across NASA to provide crossmission Science leadership across the Agency and Artemis. To prepare for the next generation of planetary surface exploration-based extravehicular activities (EVAs), we draw heavily from experience with Apollo, SkyLab, Space Shuttle, International Space Station (ISS), and analog tests to design the structure by which science will be integrated in the Plan, Train, and Fly phases of Artemis missions. AIST members have been working for years to integrate science into the Artemis flight operations structure, most notably through a tight collaboration with the NASA JSC Flight Operations Directorate (FOD). This abstract describes several examples of this integration, including Structure of RealTime Science Integration, the development of the EVA Science Officer Flight Controller Position, the development and testing of the Science Evaluation Room, and the development of Training for Artemis Science Teams.

K E Young↗
NASA NTRS2008

Compression After Impact Testing of Sandwich Structures Using the Four Point Bend Test

For many composite laminated structures, the design is driven by data obtained from Compression after Impact (CAI) testing. There currently is no standard for CAI testing of sandwich structures although there is one for solid laminates of a certain thickness and lay-up configuration. Most sandwich CAI testing has followed the basic technique of this standard where the loaded ends are precision machined and placed between two platens and compressed until failure. If little or no damage is present during the compression tests, the loaded ends may need to be potted to prevent end brooming. By putting a sandwich beam in a four point bend configuration, the region between the inner supports is put under a compressive load and a sandwich laminate with damage can be tested in this manner without the need for precision machining. Also, specimens with no damage can be taken to failure so direct comparisons between damaged and undamaged strength can be made. Data is presented that demonstrates the four point bend CAI test and is compared with end loaded compression tests of the same sandwich structure.

Nettles, Alan T.↗
NASA NTRS1996

Braided Composites for Aerospace Applications. (Latest citations from the Aerospace Database)

The bibliography contains citations concerning the design, fabrication, and testing of structural composites formed by braiding machines. Topics include computer aided design and associated computer aided manufacture of braided tubular and flat forms. Applications include aircraft and spacecraft structures, where high shear strength and stiffness are required.

COMPOSITE STRUCTURES↗
NASA NTRS2012

Space Evaporator-Absorber-Radiator (SEAR)

A system for non-venting thermal control for spacesuits was built by integrating two previously developed technologies, namely NASA s Spacesuit Water Membrane Evaporator (SWME), and Creare s flexible version of the Lithium Chloride Absorber Radiator (LCAR). This SEAR system was tested in relevant thermal vacuum conditions. These tests show that a 1 m2 radiator having about three times as much absorption media as in the test article would be required to support a 7 hour spacewalk. The serial flow arrangement of the LCAR of the flexible version proved to be inefficient for venting non-condensable gas (NCG). A different LCAR packaging arrangement was conceived wherein the Portable Life Support System (PLSS) housing would be made with a high-strength carbon fiber composite honeycomb, the cells of which would be filled with the chemical absorption media. This new packaging reduces the mass and volume impact of the SEAR on the Portable Life Support System (PLSS) compared to the flexible design. A 0.2 sq m panel with flight-like honeycomb geometry is being constructed and will be tested in thermal and thermal vacuum conditions. Design analyses forecast improved system performance and improved NCG control. A flight-like regeneration system also is also being built and tested. Design analyses for the structurally integrated prototype as well as the earlier test data show that SEAR is not only practical for spacesuits but also has useful applications in spacecraft thermal control.

Bue, Grant C.↗
NASA NTRS2013

Multifunctional Space Evaporator-Absorber-Radiator (SEAR)

A system for non-venting thermal control for spacesuits was built by integrating two previously developed technologies, namely NASA's Spacesuit Water Membrane Evaporator (SWME), and Creare's flexible version of the Lithium Chloride Absorber Radiator (LCAR). This SEAR system was tested in relevant thermal vacuum conditions. These tests show that a 1 sq m radiator having about three times as much absorption media as in the test article would be required to support a 7 hour spacewalk. The serial flow arrangement of the LCAR of the flexible version proved to be inefficient for venting non-condensable gas (NCG). A different LCAR packaging arrangement was conceived wherein the Portable Life Support System (PLSS) housing would be made with a high-strength carbon fiber composite honeycomb, the cells of which would be filled with the chemical absorption media. This new packaging reduce the mass and volume impact of the SEAR on the Portable Life Support System (PLSS) compared to the flexible design. A 0.2 sq m panel with flight-like honeycomb geometry is being constructed and will be tested in thermal and thermal vacuum conditions. Design analyses forecast improved system performance and improved NCG control. A flight-like regeneration system also is also being built and tested. Design analyses for the structurally integrated prototype as well as the earlier test data show that SEAR is not only practical for spacesuits but also has useful applications in spacecraft thermal control.

Bue, Grant C.↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot tall rocket assembly—consisting primarily of two fuel tanks, an engine section, and four RS-25 rocket engines—capable of sending crew and large payloads to the moon and beyond with 1.6 million pounds of thrust. Currently, the Core Stage is in the B2 Test Stand at Stennis Space Center, undergoing a series of structural and functional tests, designated the Green Run test series. The ultimate goal of Green Run is to verify analytical models and confirm proper subsystem operation of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test performed by the Marshal Space Flight Center modal test team. The desired free boundary condition of the Core Stage was achieved by suspending the massive spacecraft from the B2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound impact hammer for impact testing. Modal response was measured with 550 accelerometers channels distributed on both the Core Stage and the B2 Test Stand crane. Following one very long night of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 2.5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully extracted. The case-study presented in this paper will discuss the SLS Core Stage, the modal test setup and procedure, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Green Run↗
NASA NTRS1982

Design, ancillary testing, analysis and fabrication data for the advanced composite stabilizer for Boeing 737 aircraft, volume 2

Results of tests conducted to demonstrate that composite structures save weight, possess long term durability, and can be fabricated at costs competitive with conventional metal structures are presented with focus on the use of graphite-epoxy in the design of a stabilizer for the Boeing 737 aircraft. Component definition, materials evaluation, material design properties, and structural elements tests are discussed. Fabrication development, as well as structural repair and inspection are also examined.

Aniversario, R. B.↗
NASA NTRSDate not supplied

Simplified Applied Loads of a Transonic Truss-Braced Wing Derived from Computational Fluid Dynamics

The transonic truss-braced wing (TTBW) concept is under consideration by the NASA Advanced Air Transport Technology (AATT) project due to its potential to reduce fuel consumption of transport aircraft. To properly evaluate the TTBW concept, detailed structural modeling and subsequent test planning is underway, which requires a simplified set of discrete applied loads that simulate the distributed aerodynamic pressures. Given the unique architecture of the TTBW and its intended operation in the transonic regime, computational fluid dynamics (CFD) is the ideal approach to employ to ensure the aerodynamics of this configuration are sufficiently captured. To convert aerodynamic results into input for structural models, application of a data transfer tool, Discrete Data Transfer Between Dissimilar Meshes (DDTBDM), is presented to resolve aerodynamic pressures from CFD into single load vectors at hardpoints along both the wing and the strut. Evaluation of mapping the aerodynamic forces to hardpoints at rib and spar intersections in a structural model is performed, and the results are also compared with a linear static aeroelastic analysis. The structural responses indicate that distributing forces along only the wing and strut forward spars is insufficient for simulating the distributed aerodynamic loads. Adding moments along the forward spars improved the global response of the wing, but the point moments created unrealistic local rotations within the structure. When distributing loads along both the forward and aft spars of the wing and strut, the global response was less sensitive to the inclusion of point moments, which indicated the arrangement of point forces alone was sufficient input for structural design work and testing and provided a more continuous loading profile.

Finite Element↗
NASA NTRSDate not supplied

Simplified Applied Loads of a Transonic Truss-Braced Wing Derived from Computational Fluid Dynamic

The transonic truss-braced wing (TTBW) concept is under consideration by the NASA Advanced Air Transport Technology (AATT) project due to its potential to reduce fuel consumption of transport aircraft. To properly evaluate the TTBW concept, detailed structural modeling and subsequent test planning is underway, which requires a simplified set of discrete applied loads that simulate the distributed aerodynamic pressures. Given the unique architecture of the TTBW and its intended operation in the transonic regime, computational fluid dynamics (CFD) is the ideal approach to employ to ensure the aerodynamics of this configuration are sufficiently captured. To convert aerodynamic results into input for structural models, application of a data transfer tool, Discrete Data Transfer Between Dissimilar Meshes (DDTBDM), is presented to resolve aerodynamic pressures from CFD into single load vectors at hardpoints along both the wing and the strut. Evaluation of mapping the aerodynamic forces to hardpoints at rib and spar intersections in a structural model is performed, and the results are also compared with a linear static aeroelastic analysis. The structural responses indicate that distributing forces along only the wing and strut forward spars is insufficient for simulating the distributed aerodynamic loads. Adding moments along the forward spars improved the global response of the wing, but the point moments created unrealistic local rotations within the structure. When distributing loads along both the forward and aft spars of the wing and strut, the global response was less sensitive to the inclusion of point moments, which indicated the arrangement of point forces alone was sufficient input for structural design work and testing and provided a more continuous loading profile.

Finite Element↗
NASA NTRS1976

Performance of a mullite reusable surface insulation system in a hypersonic stream

The thermal and structural performance of a large panel of mullite reusable surface insulation (RSI) tiles was determined by a series of aerothermal tests in the Langley 8-foot high-temperature structures tunnel. The test panel was designed to represent a portion of the surface structure on a space shuttle orbiter fuselage along a 1,150 K isotherm with the mullite tile system bonded directly to the primary structure. Aerothermal tests were conducted at a free-stream Mach number of 6.7, a total temperature of 1,880 K, a unit Reynolds number of 4.6 million per meter, and dynamic pressure of 62 kPa. The thermal response of the mullite tile was as predicted, and the bond-line temperature did not exceed the design level of 570 K during a typical entry-heat cycle. Geometric irregularities of the tile gaps affected the tile edge temperatures when exposed to hypersonic flow. The tile coating demonstrated good toughness to particle impacts, but the coating cracked and flaked with thermal cycles. The gap filler of woven silica fibers appeared to hinder flow penetration into the gaps and withstood the flow shear of the present tests.

Hunt, L. R.↗
NASA NTRS1984

Optimization applications in aircraft engine design and test

Starting with the NASA-sponsored STAEBL program, optimization methods based primarily upon the versatile program COPES/CONMIN were introduced over the past few years to a broad spectrum of engineering problems in structural optimization, engine design, engine test, and more recently, manufacturing processes. By automating design and testing processes, many repetitive and costly trade-off studies have been replaced by optimization procedures. Rather than taking engineers and designers out of the loop, optimization has, in fact, put them more in control by providing sophisticated search techniques. The ultimate decision whether to accept or reject an optimal feasible design still rests with the analyst. Feedback obtained from this decision process has been invaluable since it can be incorporated into the optimization procedure to make it more intelligent. On several occasions, optimization procedures have produced novel designs, such as the nonsymmetric placement of rotor case stiffener rings, not anticipated by engineering designers. In another case, a particularly difficult resonance contraint could not be satisfied using hand iterations for a compressor blade, when the STAEBL program was applied to the problem, a feasible solution was obtained in just two iterations.

Pratt, T. K.↗
DOE OSTI2024

Effect of Part Size, Displacement Rate, and Aging on Compressive Properties of Elastomeric Parts of Different Unit Cell Topologies Formed by Vat Photopolymerization Additive Manufacturing

Due to its ability to achieve geometric complexity at high resolution and low length scales, additive manufacturing (AM) has increasingly been used for fabricating cellular structures (e.g., foams and lattices) for a variety of applications. Specifically, elastomeric cellular structures offer tunability of compliance as well as energy absorption and dissipation characteristics. However, there are limited data available on compression properties for printed elastomeric cellular structures of different designs and testing parameters. In this work, the authors evaluate how unit cell topology, part size, the rate of compression, and aging affect the compressive response of polyurethane-based simple cubic, body-centered, and gyroid structures formed by vat photopolymerization AM. Finite element simulations incorporating hyperelastic and viscoelastic models were used to describe the data, and the simulated results compared well with the experimental data. Of the designs tested, only the parts with the body-centered unit cell exhibited differences in stress–strain responses at different part sizes. Of the compression rates tested, the highest displacement rate (1000 mm/min) often caused stiffer compressive behavior, indicating deviation from the quasi-static assumption and approaching the intermediate rate response. The cellular structures did not change in compression properties across five weeks of aging time, which is desirable for cushioning applications. This work advances knowledge on the structure–property relationships of printed elastomeric cellular materials, which will enable more predictable compressive properties that can be traced to specific unit cell designs.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Prediction of hail damage to aircraft.

Description of a hailstone impact simulator, a valuable laboratory apparatus which can be used for such hailstone research as the testing of prospective structural designs or generating data to compare with theory. The simulator consists of a launcher and a velocity-measuring system. It has been successfully used to obtain deformation data on flat sheets and spherical caps of various sizes impacted by hailstones at typical flight velocities. A computer program is described which adequately predicts the damage to a simple structure when impacted by a hailstone.

Hayduk, R. J.↗
NASA NTRS1979

Graphite/Polyimide Composites

Technology developed under the Composites for Advanced Space Transportation System Project is reported. Specific topics covered include fabrication, adhesives, test methods, structural integrity, design and analysis, advanced technology developments, high temperature polymer research, and the state of the art of graphite/polyimide composites.

Dexter, H. B.↗