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At least 19 records

Control Surface Seals Investigated for Re- Entry Vehicles

Re-entry vehicles generally use control surfaces (e.g., rudders, body flaps, and elevons) to steer or guide them as they pass into and through the Earth s atmosphere. High temperature seals are required around control surfaces both along hinge lines and in areas where control surface edges seal against the vehicle body to limit hot gas ingestion and the transfer of heat to underlying low-temperature structures. Working with the NASA Johnson Space Center, the Seals Team at the NASA Glenn Research Center completed a series of tests on the baseline seal design for the rudder/fin control surface interfaces of the X-38 vehicle. This seal application was chosen as a case study to evaluate a currently available control surface seal design for applications in future re-entry vehicles. The structures of the rudder/fin assembly and its associated seals are shown in the following illustration.

Dunlap, Patrick H.↗

Investigations of Control Surface Seals for Re-entry Vehicles

Re-entry vehicles generally require control surfaces (e.g., rudders, body flaps) to steer them during flight. Control surface seals are installed along hinge lines and where control surface edges move close to the vehicle body. These seals must operate at high temperatures and limit heat transfer to underlying structures to prevent them from overheating and causing possible loss of vehicle structural integrity. This paper presents results for thermal analyses and mechanical testing conducted on the baseline rudder/fin seal design for the X-38 re-entry vehicle. Exposure of the seals in a compressed state at the predicted peak seal temperature of 1900 F resulted in loss of seal resiliency. The vertical Inconel rudder/fin rub surface was re-designed to account for this loss of resiliency. Room temperature compression tests revealed that seal unit loads and contact pressures were below limits set to protect Shuttle thermal tiles on the horizontal sealing surface. The seals survived an ambient temperature 1000 cycle scrub test over sanded Shuttle tiles and were able to disengage and re-engage the tile edges during testing. Arc jet tests confirmed the need for seals in the rudder/fin gap location because a single seal caused a large temperature drop (delta T = 1710 F) in the gap.

Dunlap, Patrick H., Jr.↗

Advances in Hot-Structure Development

The National Aeronautics and Space Administration has actively participated in the development of hot structures technology for application to hypersonic flight systems. Hot structures have been developed for vehicles including the X-43A, X-37, and the Space Shuttle. These trans-atmospheric and atmospheric entry flight systems that incorporate hot-structures technology are lighter weight and require less maintenance than those that incorporate parasitic, thermal-protection materials that attach to warm or cool substructure. The development of hot structures requires a thorough understanding of material performance in an extreme environment, boundary conditions and load interactions, structural joint performance, and thermal and mechanical performance of integrated structural systems that operate at temperatures ranging from 1500 C to 3000 C, depending on the application. This paper will present recent advances in the development of hot structures, including development of environmentally durable, high temperature leading edges and control surfaces, integrated thermal protection systems, and repair technologies. The X-43A Mach-10 vehicle utilized carbon/carbon (C/C) leading edges on the nose, horizontal control surface, and vertical tail. The nose and vertical and horizontal tail leading edges were fabricated out of a 3:1 biased, high thermal conductivity C/C. The leading edges were coated with a three-layer coating comprised of a SiC conversion of the C/C, followed by a CVD layer of SiC, followed by a thin CVD layer of HfC. Work has also been performed on the development of an integrated structure and was focused on both hot and warm (insulated) structures and integrated fuselage/tank/TPS systems. The objective was to develop integrated multifunctional airframe structures that eliminate fragile external thermal-protection systems and incorporate the insulating function within the structure. The approach taken to achieve this goal was to develop candidate hypersonic airframe concepts, including structural arrangement, load paths, thermal-structural wall design, thermal accommodation features, and integration of major components, optimize thermalstructural configurations, and validate concepts through a building block test program and generate data to improve and validate analytical and design tools.

Rivers, H. Kevin↗

Nonlinear lift control at high speed and high angle of attack using vortex flow technology

Nonlinear lift control at subsonic, transonic and low supersonic speeds owes its origin to the separated but organized vortical flows interacting with the wing upper surface. Since most of this flow originates near the wing or control-surface leading edge, a variety of devices has been studied experimentally which interact with and/or control this flow in order to gain a beneficial effect. The benefits (effects) originally studied were associated only with lift enhancement. Whereas, now the studied benefits encompass performance increase, attention to changes in trimmed conditions and longitudinal stability, improvements in lateral stability, and the attendant variation with changing Mach number. For those devices that can be theoretically modeled, state-of-the-art computer codes have been used for device design and/or analysis. Comparisons at design and off-design conditions are presented for validation purposes.

Lamar, John E.↗

Some data on the static longitudinal stability and control of airplanes : design of control surfaces

In the solution of a number of problems on the stability and controllability of airplanes, there arises the necessity for knowing the characteristics of the tail surfaces of the types in common use today. Of those characteristics, the most important are the effectiveness and hinge moments of the tail surfaces. As has been shown in the present paper, there exists the possibility of determining these characteristics by the formulas obtained with a degree of accuracy sufficient for the purposes of preliminary computation. These formulas take into account a number of fundamental tail characteristics such as tail cut-outs on the control surface and the form of the control surface leading edge.

Martinov, A↗

Reduction of computer usage costs in predicting unsteady aerodynamic loadings caused by control surface motion. Addendum to computer program description

Changes to be made that provide increased accuracy and increased user flexibility in prediction of unsteady loadings caused by control surface motions are described. Analysis flexibility is increased by reducing the restrictions on the location of the downwash stations relative to the leading edge and the edges of the control surface boundaries. Analysis accuracy is increased in predicting unsteady loading for high Mach number analysis conditions through use of additional chordwise downwash stations. User guideline are presented to enlarge analysis capabilities of unusual wing control surface configurations. Comparative results indicate that the revised procedures provide accurate predictions of unsteady loadings as well as providing reductions of 40 to 75 percent in computer usage cost required by previous versions of this program.

Rowe, W. S.↗

Nonlinear lift control at high speed and high angle of attack using vortex flow technology

Nonlinear lift control at subsonic, transonic and low supersonic speeds owes its origin to the separated but organized vortical flows interacting with the wing upper surface. Since most of this flow originates near the wing or control-surface leading-edge, a variety of devices have been studied experimentally which interact with and/or control this flow in order to gain a beneficial effect. The benefits (effects) originally studied were only associated with lift enhancement. Whereas, now the studied benefits encompass performance increase, attention to changes in trimmed conditions and longitudinal stability, improvements in lateral stability, and the attendant variation with changing Mach number. For those devices that can be theoretically modeled, state-of-the-art computer codes have been used for device design and/or analysis. Comparisons at design and off-design conditions are presented for validation purposes.

Lamar, J. E.↗

Real-time edge tracking using a tactile sensor

Object recognition through the use of input from multiple sensors is an important aspect of an autonomous manipulation system. In tactile object recognition, it is necessary to determine the location and orientation of object edges and surfaces. A controller is proposed that utilizes a tactile sensor in the feedback loop of a manipulator to track along edges. In the control system, the data from the tactile sensor is first processed to find edges. The parameters of these edges are then used to generate a control signal to a hybrid controller. Theory is presented for tactile edge detection and an edge tracking controller. In addition, experimental verification of the edge tracking controller is presented.

Berger, Alan D.↗

Third Generation RLV Structural Seal Development Programs at NASA GRC

NASA is currently developing technologies for the 3rd Generation Reusable Launch Vehicle (RLV) that is being designed to enter service around the year 2025. In particular, NASA's Glenn Research Center (GRC) is working on advanced high temperature structural seal designs including propulsion system and control surface seals. Propulsion system seals are required along the edges of movable panels in advanced engines, while control surface seals seal the edges and hinge lines of movables flaps and elevons on the vehicle. The overall goal is to develop reusable, resilient seals capable of operating at temperatures up to 2000 F. High temperature seal preloading devices (e.g., springs) are also being evaluated as a means of improving seal resiliency. In order to evaluate existing and potential new seal designs, GRC has designed and is installing several new test rigs capable of simulating the types of conditions that the seals would endure during service including temperatures, pressures, and scrubbing. Two new rigs, the hot compression test rig and the hot scrub test rig, will be used to perform seal compression and scrub tests for many cycles at temperatures up to 3000 F. Another new test rig allows simultaneous flow and scrub tests to be performed on the seals at room temperature to evaluate how the flow blocking performance of the seals varies as they accumulate damage during scrubbing. This presentation will give an overview of these advanced seal development efforts.

Dunlap, Patrick H., Jr.↗

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗

Inert Welding/Brazing Gas Filters and Dryers

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heat-flux environments (150 W/sq cm) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading-edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same "pick" location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cu cm in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Goudy, Jerry↗

Method for a Leading Edge Slat on a Wing of an Aircraft

A method for managing a flight control surface system. A leading edge device is moved on a leading edge from an undeployed position to a deployed position. The leading edge device has an outer surface, an inner surface, and a deformable fairing attached to the leading edge device such that the deformable fairing covers at least a portion of the inner surface. The deformable fairing changes from a deformed shape to an original shape when the leading edge device is moved to the deployed position. The leading edge device is then moved from the deployed position to the undeployed position, wherein the deformable fairing changes from the original shape to the deformed shape.

Pitt, Dale M.↗

Stiffened Carbon/Carbon Compression Panels

Panels with integral stiffeners made with woven fabric in two-dimensional, cross-ply layups. Local skin buckling does not cause collapse of panels, and ultimate failure occurs at loads 10 to 20 percent above buckling loads. For panels subjected to in-plane loading, separation of stiffeners from panel skins was not problem. High-temperature structural applications on advanced aircraft and spacecraft include leading edges, fairings, and control surfaces.

Sawyer, James W.↗

Method and Apparatus for a Leading Edge Slat on a Wing of an Aircraft

A method and apparatus for managing a flight control surface system. A leading edge device is moved on a leading edge from an undeployed position to a deployed position. The leading edge device has an outer surface, an inner surface, and a deformable fairing attached to the leading edge device such that the deformable fairing covers at least a portion of the inner surface. The deformable fairing changes from a deformed shape to an original shape when the leading edge device is moved to the deployed position. The leading edge device is then moved from the deployed position to the undeployed position, wherein the deformable fairing changes from the original shape to the deformed shape.

Pitt, Dale M.↗

Rolling flow wind tunnel tests of F-18 aircraft

The lateral directional characteristics of an F-18 aircraft was investigated. Aerodynamic derivatives associated with pure roll rate, or the 'p' derivatives were obtained. The model is described and the procedures used to obtain and correct the data, and a graphical presentation of the results are presented. These results include graphs of the lateral directional static stability derivatives versus angle of attack, and the lateral directional force and moment coefficients versus nondimensional roll rate. Results are presented for several configurations including complete, complete without vertical tails, complete without horizontal tails, fuselage wing and fuselage alone. Each of these configuations was tested with and without wing leading edge extensions. The basic control surfaces were deflected and the results were investigated.

Lutze, F. H.↗

Ceramic Matrix Composite (CMC) Thermal Protection Systems (TPS) and Hot Structures for Hypersonic Vehicles

Thermal protection systems (TPS) and hot structures are required for a range of hypersonic vehicles ranging from ballistic reentry to hypersonic cruise vehicles, both within Earth's atmosphere and non-Earth atmospheres. The focus of this paper is on air breathing hypersonic vehicles in the Earth's atmosphere. This includes single-stage to orbit (SSTO), two-stage to orbit (TSTO) accelerators, access to space vehicles, and hypersonic cruise vehicles. This paper will start out with a brief discussion of aerodynamic heating and thermal management techniques to address the high heating, followed by an overview of TPS for rocket-launched and air-breathing vehicles. The argument is presented that as we move from rocket-based vehicles to air-breathing vehicles, we need to move away from the insulated airplane approach used on the Space Shuttle Orbiter to a wide range of TPS and hot structure approaches. The primary portion of the paper will discuss issues and design options for CMC TPS and hot structure components, including leading edges, acreage TPS, and control surfaces. The current state-of-the-art will be briefly discussed for some of the components. The two primary technical challenges impacting the use of CMC TPS and hot structures for hypersonic vehicles are environmental durability and fabrication, and will be discussed briefly.

Glass, David E.↗