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NASA NTRS1994

Test plan. GCPS task 7, subtask 7.1: IHM development

The overall objective of Task 7 is to identify cost-effective life cycle integrated health management (IHM) approaches for a reusable launch vehicle's primary structure. Acceptable IHM approaches must: eliminate and accommodate faults through robust designs, identify optimum inspection/maintenance periods, automate ground and on-board test and check-out, and accommodate and detect structural faults by providing wide and localized area sensor and test coverage as required. These requirements are elements of our targeted primary structure low cost operations approach using airline-like maintenance by exception philosophies. This development plan will follow an evolutionary path paving the way to the ultimate development of flight-quality production, operations, and vehicle systems. This effort will be focused on maturing the recommended sensor technologies required for localized and wide area health monitoring to a technology readiness level (TRL) of 6 and to establish flight ready system design requirements. The following is a brief list of IHM program objectives: design out faults by analyzing material properties, structural geometry, and load and environment variables and identify failure modes and damage tolerance requirements; design in system robustness while meeting performance objectives (weight limitations) of the reusable launch vehicle primary structure; establish structural integrity margins to preclude the need for test and checkout and predict optimum inspection/maintenance periods through life prediction analysis; identify optimum fault protection system concept definitions combining system robustness and integrity margins established above with cost effective health monitoring technologies; and use coupons, panels, and integrated full scale primary structure test articles to identify, evaluate, and characterize the preferred NDE/NDI/IHM sensor technologies that will be a part of the fault protection system.

Greenberg, H. S.↗

NASA NTRS2018

Modeling the Effect of Damage on the Electrical Resistivity of Melt-Infiltrated SiC/SiC Composites

Electrical resistivity (ER) measurements are a possible health monitoring technique for CMC components in future aerospace applications. In order to use ER measurements to detect and identify damage, it is necessary to understand how each specific damage state will affect the ER response. In this paper, finite element models are developed and applied to quantify the effect of specific damage states on the electrical resistivity response in a melt-infiltrated silicon carbide (SiC) fiber-reinforced silicon carbide composite. The electrical resistivity of several damage states are calculated by simulating the electric current flow through the damaged micro-structure. This is achieved by performing the numerical solution of the steady-state conservation of charge density equation. Numerical results reveal that cracking of the inter-tow matrix has the most profound effect on the composite electrical resistivity. Also, fiber/matrix debonding at matrix cracks in the 0° tows (tows aligned with the loading direction) may cause a significant increase in the electrical resistivity, but only if the fiber coating resistivity is 1000 Ω-cm or less. Cracks in the 90° tows and the crack opening displacement have very little effect on the composite electrical resistivity.

finite element analysis↗

NASA NTRS2018

A Nonlocal Progressive Damage Model for Composite Materials

Fiber reinforced composite materials are widely used in aerospace structures due to their high specific stiffness and strength. These materials exhibit complex deformation, damage and failure mechanisms under high strain rate loading conditions. Many different failure criteria have been proposed in literature to describe the damage initiation and evolution of fiber reinforced composite materials. Most of these damage models are based on a local framework. In a local framework, the material behavior is based on a point-wise constitutive relation which is independent of the effect of the surrounding points. These models include stiffness degradation when damage initiates in the material, which within a local framework leads to a highly mesh dependent result. This could be overcome using a nonlocal finite element approach. In the current work, a nonlocal formulation based on the work by Andrade et al [1] is adapted to describe composite material behavior. The LS-DYNA rate dependent progressive damage model, MAT162 is employed to detect the initiation and evolution of damage in orthotropic composite materials. This model is developed as a FORTRAN user material subroutine in the LS-DYNA environment. The results of MAT162 with and without the nonlocal formulation are compared at different mesh densities to validate the model. The numerical analysis exhibits the advantages of the nonlocal formulation.

Kodagali, Karan↗

DOE OSTI2021

Unveiling damage mechanisms of chromium-coated zirconium-based fuel claddings at LWR operating temperature by in-situ digital image correlation

Here, we investigate the coupled thermomechanical fracture mechanisms of coated nuclear fuel claddings at Light Water Reactor (LWR) operating temperatures. These coated claddings are a highly attractive, near-term solution, which addresses the demands for accident-tolerant fuel systems and provide greater oxidation resistance. However, the fracture mechanisms of these coatings, which may create channels for oxidation ingression, must be fully understood prior to implementation. Thus, high-temperature expanding plug experiments were conducted on coated cladding specimens at a temperature of 315 °C, consistent with the operating environment of LWRs. Furthermore, in-situ thermomechanical deformation was measured with stereo digital image correlation during heating and mechanical testing to separately resolve contributions of thermal and mechanical strain. Digital image correlation, supported by acoustic emissions (AE) detection, was also leveraged to track cracking activity during loading. Coating fracture was found to initiate at total hoop strains of 0.34%. The thermal deformation of the coated claddings was investigated via finite element simulations, revealing a bidirectional stress-state within the coating with axial and circumferential strains of 0.026 and 0.031%. This bidirectional stress-state was attributed with the generation of off-axis fracture pattern within the coating as identified via post-experiment scanning electron microscopy. Thus, this study unveiled critical, coupled thermomechanical mechanisms governing the coating fracture of coated claddings at LWR temperatures.

36 MATERIALS SCIENCE↗

NASA NTRS2017

Structural Health Management of Damaged Aircraft Structures Using the Digital Twin Concept

The development of multidisciplinary integrated Structural Health Management (SHM) tools will enable accurate detection, and prognosis of damaged aircraft under normal and adverse conditions during flight. As part of the digital twin concept, methodologies are developed by using integrated multiphysics models, sensor information and input data from an in-service vehicle to mirror and predict the life of its corresponding physical twin. SHM tools are necessary for both damage diagnostics and prognostics for continued safe operation of damaged aircraft structures. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern in these structures is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable, catastrophic propagation of damage during a flight, load levels must be maintained that are below a reduced load-carrying capacity for continued safe operation of an aircraft. Hence, a capability is needed for accurate real-time predictions of damage size and safe load carrying capacity for structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size, location, and orientation is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size, location, and orientation is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries, and sizes.

Seshadri, Banavara R.↗

NASA NTRS2006

NASA Tech Briefs, January 2006

Topics covered include: Semiautonomous Avionics-and-Sensors System for a UAV; Biomimetic/Optical Sensors for Detecting Bacterial Species; System Would Detect Foreign-Object Damage in Turbofan Engine; Detection of Water Hazards for Autonomous Robotic Vehicles; Fuel Cells Utilizing Oxygen From Air at Low Pressures; Hybrid Ion-Detector/Data-Acquisition System for a TOF-MS; Spontaneous-Desorption Ionizer for a TOF-MS; Equipment for On-Wafer Testing From 220 to 325 GHz; Computing Isentropic Flow Properties of Air/R-134a Mixtures; Java Mission Evaluation Workstation System; Using a Quadtree Algorithm To Assess Line of Sight; Software for Automated Generation of Cartesian Meshes; Optics Program Modified for Multithreaded Parallel Computing; Programs for Testing Processor-in-Memory Computing Systems; PVM Enhancement for Beowulf Multiple-Processor Nodes; Ion-Exclusion Chromatography for Analyzing Organics in Water; Selective Plasma Deposition of Fluorocarbon Films on SAMs; Water-Based Pressure-Sensitive Paints; System Finds Horizontal Location of Center of Gravity; Predicting Tail Buffet Loads of a Fighter Airplane; Water Containment Systems for Testing High-Speed Flywheels; Vapor-Compression Heat Pumps for Operation Aboard Spacecraft; Multistage Electrophoretic Separators; Recovering Residual Xenon Propellant for an Ion Propulsion System; Automated Solvent Seaming of Large Polyimide Membranes; Manufacturing Precise, Lightweight Paraboloidal Mirrors; Analysis of Membrane Lipids of Airborne Micro-Organisms; Noninvasive Diagnosis of Coronary Artery Disease Using 12-Lead High-Frequency Electrocardiograms; Dual-Laser-Pulse Ignition; Enhanced-Contrast Viewing of White-Hot Objects in Furnaces; Electrically Tunable Terahertz Quantum-Cascade Lasers; Few-Mode Whispering-Gallery-Mode Resonators; Conflict-Aware Scheduling Algorithm; and Real-Time Diagnosis of Faults Using a Bank of Kalman Filters.

Source record↗

NASA NTRSDate not supplied

TPSAS-NF1676L-17800-DND

Currently, there are two national challenge problems that guide much of the research in durability and damage tolerance at NASA Langley. The first, Airframe Digital Twin, is a concept that combines as-built vehicle components, as-experienced loads and environments, and other vehicle-specific characteristics to enable ultrahigh fidelity modeling of aircraft and spacecraft throughout their service lives. The second, Materials Genome Initiative, is an analog to the Human Genome Project, and is intended to improve the rate at which materials scientists can discover, understand fundamental physics, and improve material systems. This presentation will highlight several research projects ongoing at NASA Langley that are in support of the above challenge problems. Two of those topics will be the subject of detailed discussion. First, investigations of microstructurally-small fatigue cracking (MSFC) in Al-2Cu and Al-4Cu, fabricated in-house, will be presented. Single- and oligo-crystals of Al-Cu specimens were loaded in uniaxial fatigue, while high-resolution in-situ measurements of deformation were made using image correlation (IC) in a scanning-electron microscope (SEM). The Al-Cu specimens were then replicated as crystal plasticity finite element models (CPFEM), where evolution of slip localization near grain boundaries was computed. Comparison among experiment and CPFEM is made. In addition, XRay diffraction measurements of the as-fabricated specimens were carried out, where direct measurements of the embedded copper precipitates were made, and their influence on growing MSFCs were directly observed. The second main topic will illustrate ongoing work in the area of so-called damage-sensing particles. In this work, shape-memory alloys are embedded in an aluminum alloy matrix. Upon the propagation of a fatigue crack, these particles undergo a strain-induced phase transformation which is detected using an acoustic sensor, providing real-time information on propagating cracks. Experiments and simulations regarding the development of this system will also be detailed.

Jacob Hochhalter↗

DOE OSTI2020

Illumination of Damage in Intact Rocks by Ultrasonic Transmission-Reflection and Digital Image Correlation

aboratory-scale experiments on intact rocks are critical to the development of physics-based fundamental understanding of various geophysical phenomena. In this work, the capability of ultrasonic wave transmission (T-mode) and reflection (R-mode) to monitor damage progression in uniaxially loaded prismatic intact rock specimens has been analyzed, as it is imperative to study the observations and document the capabilities of these techniques in a controlled environment. This study is novel in the sense that the R-mode linear ultrasonic testing (LUT) has been rarely employed in studying intact rock damage processes in a laboratory setting, with most of the studies utilizing a direct transmission (T-mode) approach or focusing on macroscopically fractured material. The two-dimensional digital image correlation (2-D DIC) full-field strain measurement approach was also used in-sync with the LUT monitoring to explicitly correlate the stress-induced damage in the specimens with the changes observed in the ultrasonic (T-mode and R-mode) signals. The results show that both the T-mode and R-mode LUT approaches are sensitive to detect the evolution of tensile and shear damage in the specimens, with the R-mode ultrasonic signals showing higher degree of sensitivity to the damage in the rocks, immediately following the initiation of damage in the rock volume.

58 GEOSCIENCES↗

NASA NTRS2018

A Versatile Simulation Framework for Elastodynamic Modeling of Structural Health Monitoring

Structural health monitoring (SHM) has the capacity to reduce failure by detecting damage during service life, by periodic, automated monitoring. Guided Wave (GW) Ultrasound is a common SHM approach for aerospace structures. Modelling the physics of GW SHM systems provides a route for understanding system dependencies, capabilities and limitations as damage evolves during service life. Such a toolset can strengthen the understanding of the connection between GW SHM results and the true material state. The most useful modelling tools are those that provide versatile solutions with respect to the simulated component geometry and computational grid connectivity. This work details a versatile application programming interface (API) for the elastodynamic finite integration technique for modelling GW SHM of metals. The custom code implementation, EFIT-CompCell, allows for the modelling of diverse geometries by automatically balancing the message passing interface parallelization layout. The user provides the basic parameters of the simulation and the software automatically performs an initial balancing based on anticipated computational loads, and establishes the CPU communication patterns for any geometry. This work describes the programming philosophy and code structure used to create EFIT-CompCell and compares its performance and capacity to simulation tools that are more specialized for specific architectures. Results are presented for a simulation of GW SHM of an aluminum fuselage section being tested by the FAA. The simulation consists of 733M voxels which took approximately 70 hours to complete 25000 time steps using 40 Intel Xeon E5-4650v2 Ivy Bridge processor cores.

Gregory, Elizabeth D.↗

NASA NTRS2009

Health Monitoring of a Rotating Disk Using a Combined Analytical-Experimental Approach

Rotating disks undergo rigorous mechanical loading conditions that make them subject to a variety of failure mechanisms leading to structural deformities and cracking. During operation, periodic loading fluctuations and other related factors cause fractures and hidden internal cracks that can only be detected via noninvasive types of health monitoring and/or nondestructive evaluation. These evaluations go further to inspect material discontinuities and other irregularities that have grown to become critical defects that can lead to failure. Hence, the objectives of this work is to conduct a collective analytical and experimental study to present a well-rounded structural assessment of a rotating disk by means of a health monitoring approach and to appraise the capabilities of an in-house rotor spin system. The analyses utilized the finite element method to analyze the disk with and without an induced crack at different loading levels, such as rotational speeds starting at 3000 up to 10 000 rpm. A parallel experiment was conducted to spin the disk at the desired speeds in an attempt to correlate the experimental findings with the analytical results. The testing involved conducting spin experiments which, covered the rotor in both damaged and undamaged (i.e., notched and unnotched) states. Damaged disks had artificially induced through-thickness flaws represented in the web region ranging from 2.54 to 5.08 cm (1 to 2 in.) in length. This study aims to identify defects that are greater than 1.27 cm (0.5 in.), applying available means of structural health monitoring and nondestructive evaluation, and documenting failure mechanisms experienced by the rotor system under typical turbine engine operating conditions.

Abdul-Aziz, Ali↗

NASA NTRS2008

The Summer of Hydrogen

Ground crew veterans at Kennedy Space Center still talk about what they call "the summer of hydrogen"-the long, frustrating months in 1990 when the shuttle fleet was grounded by an elusive hydrogen leak that foiled our efforts to fill the orbiter's external fuel tank. Columbia (STS-35) was on Launch Pad A for a scheduled May 30 launch when we discovered the hydrogen leak during - tanking. The external fuel tank is loaded through the orbiter. Liquid hydrogen flows through a 17-inch umbilical between the orbiter and the tank. During fueling, we purge the aft fuselage with gaseous nitrogen to reduce the risk of fire, and we have a leak-detection system in the mobile launch platform, which samples (via tygon tubing) the atmosphere in and around the vehicle, drawing it down to a mass spectrometer that analyzes its composition. When we progressed to the stage of tanking where liquid hydrogen flows through the vehicle, the concentration of hydrogen approached four percent-the limit above which it would be dangerously flammable. We had a leak. We did everything we could think of to find it, and the contractor who supplied the flight hardware was there every day, working alongside us. We did tanking tests, which involved instrumenting the suspected leak sources, and cryo-loaded the external tank to try to isolate precisely where the leak originated. We switched out umbilicals; we replaced the seals between the umbilical and the orbiter. We inspected the seals microscopically and found no flaws. We replaced the recirculation pumps, and we found and replaced a damaged teflon seal in a main propulsion system detent cover, which holds the prevalve-the main valve supplying hydrogen to Space Shuttle Main Engine 3 -in the open position. The seal passed leak tests at ambient temperature but leaked when cryogenic temperatures were applied. We added new leak sensors-up to twenty at a time and tried to be methodical in our placements to narrow down the possible sources of the problem. We even switched orbiters, sending Columbia back to the Vehicle Assembly Building and bringing out Atlantis, scheduled to fly as STS-38. Two shuttles on their mobile launchers passing in the night was a majestic sight, but not one you want to see if you're trying to get an orbiter launched. None of this told us where the leak was, or if we were dealing with more than one leak source.

Weber, Philip↗

NASA NTRS2014

Coupling Damage-Sensing Particles to the Digitial Twin Concept

The research presented herein is a first step toward integrating two emerging structural health management paradigms: digital twin and sensory materials. Digital twin is an emerging life management and certification paradigm whereby models and simulations consist of as-built vehicle state, as-experienced loads and environments, and other vehicle-specific history to enable high-fidelity modeling of individual aerospace vehicles throughout their service lives. The digital twin concept spans many disciplines, and an extensive study on the full domain is out of the scope of this study. Therefore, as it pertains to the digital twin, this research focused on one major concept: modeling specifically the as-manufactured geometry of a component and its microstructure (to the degree possible). The second aspect of this research was to develop the concept of sensory materials such that they can be employed within the digital twin framework. Sensory materials are shape-memory alloys that undergo an audible phase transformation while experiencing sufficient strain. Upon embedding sensory materials with a structural alloy, this audible transformation helps improve the reliability of crack detection especially at the early stages of crack growth. By combining these two early-stage technologies, an automated approach to evidence-based inspection and maintenance of aerospace vehicles is sought.

Hochhalter, Jacob↗

DOE OSTI2025

Self-Sensing Composites via an Embedded 3D-Printed PVDF-MoS 2 Nanosensor for Structural Health Monitoring

Carbon fiber (CF)-reinforced epoxy composites are widely used in vehicle applications, where early damage detection is crucial for reliability and safety. To address this need, we developed a self-sensing epoxy/CF composite by embedding a PVDF-MoS 2 nanosensor via an embedded 3D printing method. By harnessing the intrinsic curing kinetics of epoxy, we tailored its rheological properties to optimize the embedded printing process, enabling precise and reliable support for sensor filaments without compromising the composite’s structural and functional integrity. Through comprehensive rheological and kinetic analysis, we established a quantitative relationship among curing temperature, conversion rate, and resulting yield modulus─defining a narrow processing window essential for successful sensor integration. Specifically, we identified that an epoxy yield modulus range of 180–294 Pa and a conversion rate below 10% are critical to support the PVDF-MoS 2 filament architecture. Here, this embedded 3D printing method produces complex and multimaterial PVDF-MoS 2 sensors within an epoxy matrix with minimal deformation and reduced postprocessing, which is scalable and adaptable for industrial applications. Under cyclic loading, the embedded sensors exhibited stable signals under constant loads and increased voltage signals in response to crack formation (17–35% higher) and catastrophic failure (1 order of magnitude higher), effectively capturing structural changes in real time. This study demonstrates the potential of PVDF-MoS 2 nanocomposite sensor materials for real-time structural health monitoring in epoxy–CF composite systems, enabling early detection of defects and stress anomalies, significantly reducing the risk of unexpected failures, and enhancing structural reliability.

PVDF-MoS2 sensor↗

DOE OSTI2025

Tensile and fatigue characterization of multifunctional composites

This research is part of a larger effort to develop advanced self-sensing multifunctional polymer composites that are both lightweight and high-strength, while also enabling structural damage detection, fatigue cycle monitoring, and service life prediction. These multifunctional composites are particularly sought after in the automotive industry for their potential to significantly reduce vehicle weight and simultaneously provide additional functionality like condition monitoring to enhance safety. This study examines the tensile and fatigue properties of a composite material composed of acrylonitrile butadiene styrene (ABS) polymer embedded with piezoelectric barium titanate (BaTiO3) nanoparticles. The integration of BaTiO3 nanoparticles not only supplies the material with self-sensing capabilities but also influences its mechanical properties. While a high content of BaTiO3 nanoparticles is desired to enhance sensing capacity, the brittle nature of such materials causes concerns of decreased strength characteristics. To explore this, various composite samples were fabricated with nanoparticle contents ranging from 0 wt% to 20 wt%. These samples underwent tensile testing to measure their ultimate tensile strengths and Young’s moduli. Following this, fatigue tests were conducted to generate S-N curves, which are essential for understanding the material's durability under cyclic loading. The findings from these tests assess the impact of nanoparticle content on the composite’s tensile strength and fatigue life, providing essential insights that can guide the optimization and design of future self-sensing multifunctional composites. The results suggest that 5 wt% BaTiO3 provides an optimal balance between mechanical properties and nanoparticle concentration, making it a promising composition for semi-structural applications.

Bowland, Christopher [ORNL] (ORCID:000000021229431↗

DOE OSTI2021

The impact of simultaneous inoculation of Pseudomonas aeruginosa, Staphylococcus aureus , and Candida albicans on rodent burn wounds

Burn wound infection often involves a diverse combination of bacterial and fungal pathogens. In this study, we characterize the mixed species burn wound infection by inoculating the burn surface with 1 × 10 3/4/5 CFU of Pseudomonas aeruginosa, Staphylococcus aureus, and Candida albicans in a 1:1:1 ratio. Using the revised Walker–Mason scald burn rat model, 168 male Sprague-Dawley rats (350–450 g) subject to ~10% TBSA burn injury, with or without inoculation, were evaluated for 11 days after burn. In the wound, P. aeruginosa and S. aureus formed robust biofilms as determined by the bacterial tissue load, ~1 × 10 9 CFU/g, and expression of key biofilm genes. Interestingly, within 3 days C. albicans achieved tissue loads of ~1 × 10 6 CFU/g, but its numbers were significantly reduced beyond the limit of detection in the burn wound by day 7 in partial-thickness injuries and by day 11 in full-thickness injuries. The pathogenic biofilms contributed to burn depth progression, increased release of HMGB-1 into circulation from injured tissue, and significantly elevated the numbers of circulating innate immune cells (Neutrophils, Monocytes, and Basophils). This robust model of multi-species burn wound infection will serve as the basis for the development of new antimicrobials for combating biofilm-based wound infections.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

Feasibility of an Accelerometer-Based Structural Health Monitoring System for the LANL Blast Tube

A modeling- and simulation-based study was conducted on the feasibility of implementing an accelerometer-based SHM system on the Los Alamos National Laboratory blast tube. A blast tube experiment was modeled using the Abaqus explicit finite element solver. A custom user subroutine was written to apply test-like pressure loading to the inside surface of the blast tube. The subroutine applies analytically defined pressure loads derived from tracer output taken from a Compressible Flow Computational Fluid Dynamics Solver model of the blast tube. Five unique versions of the model were created: an undamaged reference model at 65°F was used as the baseline and compared to equivalent models at 10°F and 100°F. These three models were compared to models with small damage at the reference temperature. The two types of damage considered were a radial (circumferential) crack in the main tube body and a longitudinal crack in the supports. Acceleration outputs were extracted from accelerometer bodies included in the model and were post processed using a variety of standard SHM techniques. Different potential features signaling failure were extracted and compared using statistical methods in the time and frequency domains. A method was identified that clearly shows that differences in structural response resulting from the modeled damage can be differentiated from the structural response resulting from changing environmental conditions. However, the amount of damage applied to create observable differences in the accelerometer data was so large that simpler methods of damage detection would be more cost effective in locating damage.

42 ENGINEERING↗

NASA NTRS2001

Detection and Characterization of Imperfections in Composite Pressure Vessels

The thermographic evaluation of composite structures for delaminations, disbonds, inclusions, porosity and microcracking has proven to be a valuable asset in the field of nondestructive testing. Coupling large area coverage, variable sensitivity and minimal surface contact with a photographic type image representation of structural anomalies; thermography has become a primary inspection method for composite structures. Thermography works well for locating both surface and subsurface defects in most composite systems ranging in thickness of up to 0.25 inch (0.64 cm) or more. The thermographic method for inspection of composite structures typically involves applying an external source of heat to the structure and then recording the changes in the surface heat profile manifested by embedded defects or by material property variations. If these temperature variations are large enough and an infrared camera with sufficient sensitivity is used, then the material or structural abnormality can be detected and referred back to its source. Interpreting the information given in a thermogram, can be a difficult task under ideal circumstances and extremely challenging in a real world setting. Variables including depth, thermal conductivity, orientation and size of the abnormality can all have a great influence on how its heat pattern will be seen by the imager. The work discussed in this paper illustrates how the microstructure of several commonly found defects in composite structures relate to their thermographic image counterpart. Two test cases are studied herein, including a large graphite/epoxy RP-1 fuel tank and a graphite composite cryogenic fuel feedline. The structures used in this study were designed to serve as manufacturing proof of concept specimens and to undergo hydroburst testing to verify manufacturing practices and structural design. Prior to hydrostatic testing the structures underwent 100% thermographic evaluation to ensure that no manufacturing or handling damage was present. Due to a large inclusion found in the feedline, it was pulled from service and dissected without performing the hydroproof The thermographic indications found in the RP-1 tank were below critical limits so it underwent a complete hydroproof loading series and finally a hydroburst. Following the hydroburst samples were cut from the tank in regions where thermography had located damage before the test. These regions were thermographically and then were cross-sectioned and photomicrographed.

Walker, James L.↗

NASA NTRS2012

International Space Station 2A Array Modal Analysis

On December 9th 2009, the International Space Station (ISS) 2A solar array mast experienced prolonged longeron shadowing during a Soyuz undocking. Analytical reconstruction of induced thermal and dynamic structural loads showed an exceedance of the mast buckling limit. Possible structural damage to the solar array mast could have occurred during this event. A Low fidelity video survey of the 2A mast showed no obvious damage of the mast longerons or battens. The decision was made to conduct an on-orbit dynamic test of the 2A array on December 18th, 2009. The test included thruster pluming on the array while photogrammetry data was recorded. The test was similar to other Dedicated Thruster Firings (DTFs) that were performed to measure structural frequency and damping of a solar array. Results of the DTF indicated lower frequency mast modes than model predictions, thus leading to speculation of mast damage. A detailed nonlinear analysis was performed on the 2A array model to assess possible solutions to modal differences. The setup of the parametric nonlinear trade study included the use of a detailed array model and the reduced mass and stiffness matrices of the entire ISS being applied to the array interface. The study revealed that the array attachment structure is nonlinear and thus was the source of error in the model prediction of mast modes. In addition, a detailed study was performed to determine mast mode sensitivity to mast longeron damage. This sensitivity study was performed to assess if the ISS program has sufficient instrumentation for mast damage detection.

Laible, Michael↗