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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Revisiting Building-Block Approaches for Structures

The building-block approach is a method for building confidence in designs, working from lower-level components to more complex assemblies, using knowledge gained at each step to inform higher fidelity representations. The goals of this paper are to revisit the basic techniques of the building-block approach as it applies to structural design and analysis and illustrate some best practices that should be considered when developing structural analysis models. The paper demonstrates the process of leveraging existing information to build confidence in the design/development of analysis models, followed by examples of how the building-block approach for analysis was used in NASA hardware and spacecraft development efforts. The paper will also discuss virtual testing and hybrid simulation techniques, which are showing promise for more efficient/cost-effective verification of aerospace structures.

Kenneth R. Hamm Jr.↗
NASA NTRS2005

Utilization of the Building-Block Approach in Structural Mechanics Research

In the last 20 years NASA has worked in collaboration with industry to develop enabling technologies needed to make aircraft safer and more affordable, extend their lifetime, improve their reliability, better understand their behavior, and reduce their weight. To support these efforts, research programs starting with ideas and culminating in full-scale structural testing were conducted at the NASA Langley Research Center. Each program contained development efforts that (a) started with selecting the material system and manufacturing approach; (b) moved on to experimentation and analysis of small samples to characterize the system and quantify behavior in the presence of defects like damage and imperfections; (c) progressed on to examining larger structures to examine buckling behavior, combined loadings, and built-up structures; and (d) finally moved to complicated subcomponents and full-scale components. Each step along the way was supported by detailed analysis, including tool development, to prove that the behavior of these structures was well-understood and predictable. This approach for developing technology became known as the "building-block" approach. In the Advanced Composites Technology Program and the High Speed Research Program the building-block approach was used to develop a true understanding of the response of the structures involved through experimentation and analysis. The philosophy that if the structural response couldn't be accurately predicted, it wasn't really understood, was critical to the progression of these programs. To this end, analytical techniques including closed-form and finite elements were employed and experimentation used to verify assumptions at each step along the way. This paper presents a discussion of the utilization of the building-block approach described previously in structural mechanics research and development programs at NASA Langley Research Center. Specific examples that illustrate the use of this approach are included from recent research and development programs for both subsonic and supersonic transports.

Rouse, Marshall↗
NASA NTRS2019

A Composite Damage Tolerance Simulation Technique to Augment the Building Block Approach

Aerospace structures comprised of composite materials are traditionally certified empirically via the Building Block Approach (BBA). While this approach has been performed successfully in the past, it is expensive and time consuming. One means to improve the overall efficiency of composite structural certification is to reduce the cost of the BAA by eliminating the need for some tests by incorporating damage analysis tools. For an analysis to replace a given test, the tool must first be validated using other similar test data. The subject of this paper is a description of an analysis technique for simulating compression after damage strength of a solid laminate. The analysis technique is one that is practical for use in an applied engineering context due to efforts to minimize necessary computational resources and complexity of the model.

McElroy, Mark↗
NASA NTRS2019

A Composite Damage Tolerance Simulation Technique to Augment the Building Block Approach

Aerospace structures comprised of composite materials are traditionally certified empirically via the Building Block Approach (BBA). While this approach has been performed successfully in the past, it is expensive and time-consuming. One means to improve the overall efficiency of composite structural certification is to reduce the cost of the BBA by eliminating the need for some tests by incorporating damage analysis tools. For an analysis to replace a given test, the tool must first be validated using other similar test data. The subject of this paper is a description of an efficient analysis technique for simulating compression after damage strength of a solid laminate. The analysis technique is one that is practical for use in an applied engineering context due to efforts to minimize necessary computational resources and complexity of the model.

McElroy, Mack↗
NASA NTRS1974

Reusable Agena study. Volume 1: Executive summary

The shuttle Agena upper stage interim tug concept is based on a building block approach. These building block concepts are extensions of existing ascent Agena configurations. Several current improvements, have been used in developing the shuttle/Agena upper stage concepts. High-density acid is used as the Agena upper stage oxidizer. The baffled injector is used in the main engine. The DF-224 is a fourth generation computer currently in development and will be flight proven in the near future. The Agena upper stage building block concept uses the current Agena as a baseline, adds an 8.5-inch (21.6 cm) extension to the fuel tank for optimum mixture ratio, uses monomethyl hydrazine as fuel, exchanges a 150:1 nozzle extension for the existing 45:1, exchanges an Autonetics DF-224 for the existing Honeywell computer, and adds a star sensor for guidance update. These modifications to the current Agena provide a 5-foot (1.52m) diameter shuttle/Agena upper stage that will fly all Vandenberg Air Force Base missions in the reusable mode without resorting to a kick motor. The delta V velocity of the Agena is increased by use of a strap-on propellant tank option. This option provides a shuttle/Agena upper stage with the capability to place almost 3900 pounds (1769 kg) into geosynchronous orbit (24 hour period) without the aid of kick motors.

Source record↗
NASA NTRS1986

Fault-free performance validation of avionic multiprocessors

This paper describes the application of a portion of a validation methodology to NASA's Fault-Tolerant Multiprocessor System (FTMP) and the Software Implemented Fault-Tolerance (SIFT) computer system. The methodology entails a building block approach, starting with simple baseline experiments and building to more complex experiments. The goal of the validation methodology is to thoroughly test and characterize the performance and behavior of ultrareliable computer systems. The validation methodology presented in this paper showed that the methodology is not machine specific and can be used in lieu of life testing approaches. By applying a building block approach at the systems level, the machine complexity was broken down to manageable levels independent of system implementation.

Czeck, Edward W.↗
NASA NTRS2019

European Service Module - Structural Test Article (E-STA) Building Block Test Approach and Model Correlation Observations

The Orion European Service Module - Structural Test Article (E-STA) underwent sine vibration testing in 2016 using the Mechanical Vibration Facility (MVF) multi-axis shaker system at NASA Glenn Research Center’s (GRC) Plum Brook Station (PBS) Space Power Facility (SPF). The main objective was to verify the structural integrity of the European Service Module (ESM) under sine sweep dynamic qualification vibration testing. A secondary objective was to perform a fixed-base modal survey, while E-STA was still mounted to MVF, in order to achieve a test correlate the finite element model (FEM). To facilitate the E-STA system level correlation effort, a building block test approach was implemented. Modal tests were performed on two major subassemblies, the crew module/launch abort structure (CM/LAS) and the crew module adapter (CMA) mass simulators. These subassembly FEMs were individually correlated and then integrated into the E-STA FEM prior to the start of the E-STA sine vibration test. This paper summarizes the modal testing and model correlation efforts of both of these subassemblies and how the building block approach assisted in the overall correlation of the E-STA FEM. This paper will also cover modeling practices that should be avoided, recommended instrumentation positioning on complex structures, and the importance of the FEM geometrically matching CAD in sufficient detail in order to adequately replicate internal load paths. The goal of this paper is to inform the reader of the hard earned lessons learned and pitfalls to avoid when applying a building block test approach.

Winkel, James P.↗
NASA NTRS2001

Fabrication and Testing of Ceramic Matrix Composite Rocket Propulsion Components

NASA has established goals for Second and Third Generation Reusable Launch Vehicles. Emphasis has been placed on significantly improving safety and decreasing the cost of transporting payloads to orbit. Ceramic matrix composites (CMC) components are being developed by NASA to enable significant increases in safety and engineer performance, while reducing costs. The development of the following CMC components are being pursued by NASA: (1) Simplex CMC Blisk; (2) Cooled CMC Nozzle Ramps; (3) Cooled CMC Thrust Chambers; and (4) CMC Gas Generator. These development efforts are application oriented, but have a strong underpinning of fundamental understanding of processing-microstructure-property relationships relative to structural analyses, nondestructive characterization, and material behavior analysis at the coupon and component and system operation levels. As each effort matures, emphasis will be placed on optimizing and demonstrating material/component durability, ideally using a combined Building Block Approach and Build and Bust Approach.

Effinger, M. R.↗
NASA NTRS2012

The Building Blocks for JWST I and T (Integrations and Test) to Operations - From Simulator to Flight Units

The James Webb Space Telescope (JWST) Project has an extended integration and test (I&T) phase due to long procurement and development times of various components as well as recent launch delays. The JWST Ground Segment and Operations group has developed a roadmap of the various ground and flight elements and their use in the various JWST I&T test programs. The JWST Project s building block approach to the eventual operational systems, while not new, is complex and challenging; a large-scale mission like JWST involves international partners, many vendors across the United States, and competing needs for the same systems. One of the challenges is resource balancing so simulators and flight products for various elements congeal into integrated systems used for I&T and flight operations activities. This building block approach to an incremental buildup provides for early problem identification with simulators and exercises the flight operations systems, products, and interfaces during the JWST I&T test programs. The JWST Project has completed some early I&T with the simulators, engineering models and some components of the operational ground system. The JWST Project is testing the various flight units as they are delivered and will continue to do so for the entire flight and operational system. The JWST Project has already and will continue to reap the value of the building block approach on the road to launch and flight operations.

Fatig, Curtis↗
NASA NTRS2020

Space Launch System Mobile Launcher Modal Pretest Analysis

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation from the Vehicle Assembly Building out to the launch pad, and provides the launch platform at the launch pad. The previous Saturn/Apollo and Space Shuttle programs had integrated vehicle ground vibration tests of their integrated launch vehicles performed with simulated free-free boundary conditions to experimentally anchor and validate structural and flight controls analysis models. For the Space Launch System program, the Mobile Launcher will be used as the modal test fixture for the ground vibration test of the first Space Launch System flight vehicle, Exploration Mission ? 1( now referred to as Artemis 1), programmatically referred to as the Integrated vehicle modal test. The Integrated vehicle modal test of the Exploration Mission - 1 integrated launch vehicle will have its core and second stages unfueled while mounted to the ML while inside the Vehicle Assembly Building, which is currently scheduled for the late spring or early summer of 2020. The Space Launch System program has implemented a building block approach for dynamic model validation. The modal test of the Mobile Launcher is an important part of this building block approach in supporting the integrated vehicle modal test since the Mobile Launcher will serve as a structurally dynamic test fixture whose modes will couple with the modes of the Exploration Mission ? 1 test vehicle. The Mobile Launcher modal test will further support understanding the structural dynamics of the Mobile Launcher and SLS during rollout to the launch pad, which will play a key role in better understanding and prediction of the rollout forces acting on the launch vehicle. The Mobile Launcher modal test is currently scheduled for the summer of 2019. Due to a very tight modal testing schedule, this Mobile Launcher modal pretest analysis has been performed to ensure there is a high likelihood of being able to successfully complete the modal test (i.e. identify the primary target modes) using the planned instrumentation, shakers, and excitation types. This paper will discuss this Mobile Launcher modal pretest analysis and the unique challenges faced due to the Mobile Launcher's size and weight, which are typically not faced when modal testing aerospace structures.

Akers, James C.↗
NASA NTRS2020

Space Launch System Mobile Launcher Modal Pretest Analysis

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation from the Vehicle Assembly Building out to the launch pad, and provides the launch platform at the launch pad. The previous Saturn/Apollo and Space Shuttle programs had integrated vehicle ground vibration tests of their integrated launch vehicles performed with simulated free-free boundary conditions to experimentally anchor and validate structural and flight controls analysis models. For the Space Launch System program, the Mobile Launcher will be used as the modal test fixture for the ground vibration test of the first Space Launch System flight vehicle, Artemis 1, programmatically referred to as the integrated vehicle modal test. The integrated vehicle modal test of the Artemis 1 integrated launch vehicle will have its core and second stages unfueled while mounted to the Mobile Launcher while inside the Vehicle Assembly Building, which is currently scheduled for the summer of 2020. The Space Launch System program has implemented a building block approach for dynamic model validation. The modal test of the Mobile Launcher is an important part of this building block approach in supporting the integrated vehicle modal test since the Mobile Launcher will serve as a structurally dynamic test fixture whose modes will couple with the modes of the Artemis 1 integrated vehicle. The Mobile Launcher modal test will further support understanding the structural dynamics of the Mobile Launcher and Space Launch System during rollout to the launch pad, which will play a key role in better understanding and prediction of the rollout forces acting on the launch vehicle. The Mobile Launcher modal test is currently scheduled for the summer of 2019. Due to a very tight modal testing schedule, this independent Mobile Launcher modal pretest analysis has been performed to ensure there is a high likelihood of successfully completing the modal test (i.e. identify the primary target modes) using the planned instrumentation, shakers, and excitation types. This paper will discuss this Mobile Launcher modal pretest analysis for its three test configurations and the unique challenges faced due to the Mobile Launcher’s size and weight, which are typically not faced when modal testing aerospace structures.

Akers, James C.↗
NASA NTRS1991

Effects of scale in predicting global structural response

Analytical techniques for scale-up effects were reviewed. The advantages and limitations of applying the principles of similitude to composite structures is summarized and illustrated by simple examples. An analytical procedure was formulated to design scale models of an axially compressed composite cylinder. A building-block approach was outlined where each structural detail is analyzed independently and the probable failure sequence of a selected component is predicted, taking into account load redistribution subsequent to first element failure. Details of this building-block approach are under development.

Deo, R. B.↗
NASA NTRS2015

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and facesheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Damage↗
NASA NTRS2015

Failure Predictions of Out-of-Autoclave Sandwich Joints with Delaminations Under Flexure Loads

An analysis and a test program was conducted to investigate the damage tolerance of composite sandwich joints. The joints contained a single circular delamination between the face-sheet and the doubler. The coupons were fabricated through out-of-autoclave (OOA) processes, a technology NASA is investigating for joining large composite sections. The four-point bend flexure test was used to induce compression loading into the side of the joint where the delamination was placed. The compression side was chosen since it tends to be one of the most critical loads in launch vehicles. Autoclave cure was used to manufacture the composite sandwich sections, while the doubler was co-bonded onto the sandwich face-sheet using an OOA process after sandwich panels were cured. A building block approach was adopted to characterize the mechanical properties of the joint material, including the fracture toughness between the doubler and face-sheet. Twelve four-point-bend samples were tested, six in the sandwich core ribbon orientation and six in sandwich core cross-ribbon direction. Analysis predicted failure initiation and propagation at the pre-delaminated location, consistent with experimental observations. A building block approach using fracture analyses methods predicted failure loads in close agreement with tests. This investigation demonstrated a small strength reduction due to a flaw of significant size compared to the width of the sample. Therefore, concerns of bonding an OOA material to an in-autoclave material was mitigated for the geometries, materials, and load configurations considered.

Tolerance↗
NASA NTRS1974

Appendices for the Space Applications program, 1974

To achieve truly low cost system design with direct evolution for inorbit shuttle resupply, a modular building block approach has been adopted. The heart of the modular building block concept lies in the ability to use a common set of nonoptimized subsystems in such a way that a wide variety of missions can be flown with no detrimental impact on performance. By standardizing the mechanical configurations and electrical interfaces of the subsystem modules, and by designing each of them to be structurally and thermally independent entities, it is possible to cluster these building blocks or modules about an instrument system so as to adequately perform the mission without the need for subsystem redevelopments for each mission. This system concept offers the following capabilities: (1) the ability to launch and orbit the observatory by either the Delta, the Titan, or the space shuttle. (2) the ability to completely reconfigure the spacecraft subsystems for different launch vehicles, and (3) the ability to perform in-orbit resupply and/or emergency retrieval of the observatory.

Source record↗
NASA NTRS1983

Large space structures controls research and development at Marshall Space Flight Center: Status and future plans

Work performed in Large Space Structures Controls research and development program at Marshall Space Flight Center is described. Studies to develop a multilevel control approach which supports a modular or building block approach to the buildup of space platforms are discussed. A concept has been developed and tested in three-axis computer simulation utilizing a five-body model of a basic space platform module. Analytical efforts have continued to focus on extension of the basic theory and subsequent application. Consideration is also given to specifications to evaluate several algorithms for controlling the shape of Large Space Structures.

Buchanan, H. J.↗
NASA NTRSDate not supplied

Operational Modal Analysis of the Artemis I Dynamic Rollout Test and Wet Dress Rehearsal

NASA has developed an expendable heavy lift launch vehicle capability, the Space Launch System (SLS), to support lunar and deep space exploration. The uncrewed Artemis I was the first flight of this new launch vehicle and tested critical systems for the upcoming crewed Artemis II flight to the moon. Accelerations were recorded at a multitude of locations on Artemis, the Mobile Launcher (ML), and the Crawler Transporter (CT)during the rollout of Artemis I from the Vehicle Assembly Building (VAB) to Launch Pad 39B March 2022 and is referred to as the Artemis I Dynamic Rollout Test (DRT). While Artemis I was at Launch Pad 39B, the Wet Dress Rehearsal (WDR) was performed to demonstrate launch readiness and acceleration measurements were also recorded. Finally, Artemis I rolled back from Launch Pad 39B to the VAB in April 2022, where acceleration measurements were also recorded and is referred to as the rollback portion of DRT. Because the forces during rollout and at the launch pad acting on Artemis I, the ML, and the CT are not directly measurable, Operational Modal Analysis (OMA) techniques, instead of traditional Experimental Modal Analysis (EMA) techniques, were used to identify modal characteristics. The OMA analysis of DRT and WDR directly builds upon the lessons learned from the OMA analysis of an earlier rollout of the ML from the VAB. DRT and WDR dynamic characteristics will be used to support SLS Integrated Modal Test finite element model correlation efforts and Exploration Ground System ML and CT finite element model verification and validation, which are part of the Building Block approach the Space Launch System program has implemented. The dynamic characteristics extracted from DRT as well as the rollout acceleration time histories themselves will be used in the development of generic rollout forcing functions that will provide refined estimates of the Artemis IV rollout forces, which will have the heavier and larger SLS Block 1B launch vehicle and Mobile Launcher 2 (ML-2). This paper briefly describes Artemis I, the ML, and the CT physical characteristics, DRT rollout/rollback and WDR data collection, the challenges in implementing OMA techniques due in part to the CT harmonics, and how these challenges were overcome to obtain the Artemis I DRT configuration and WDR configuration modal characteristics.

Apollo↗