A Study of Piston and Ring Friction
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DMA Modulus as a Screening Parameter for Compatibility of Polymeric Containment Materials with Various Solutions for use in Space Shuttle Microgravity Protein Crystal Growth (PCG) Experiments
Protein crystals are grown in microgravity experiments inside the Space Shuttle during orbit. Such crystals are basically grown in a five-component system containing a salt, buffer, polymer, organic and water. During these experiments, a number of different polymeric containment materials must be compatible with up to hundreds of different PCG solutions in various concentrations for durations up to 180 days. When such compatibility experiments are performed at NASA/MSFC (Marshall Space Flight Center) simultaneously on containment material samples immersed in various solutions in vials, the samples are rather small out of necessity. DMA4 modulus was often used as the primary screening parameter for such small samples as a pass/fail criterion for incompatibility issues. In particular, the TA Instruments DMA 2980 film tension clamp was used to test rubber O-rings as small in I.D. as 0.091 in. by cutting through the cross-section at one place, then clamping the stretched linear cord stock at each end. The film tension clamp was also used to successfully test short length samples of medical/surgical grade tubing with an O.D. of 0.125 in.
Wingard, Charles Doug↗
Evaluation of Stress Corrosion Cracking Susceptibility Using Fracture Mechanics Techniques, Part 1
Stress corrosion cracking (SSC) tests were performed on 13 aluminum alloys, 13 precipitation hardening stainless steels, and two titanium 6Al-4V alloy forgings to compare fracture mechanics techniques with the conventional smooth specimen procedures. Commercially fabricated plate and rolled or forged bars 2 to 2.5-in. thick were tested. Exposures were conducted outdoors in a seacoast atmosphere and in an inland industrial atmosphere to relate the accelerated tests with service type environments. With the fracture mechanics technique tests were made chiefly on bolt loaded fatigue precracked compact tension specimens of the type used for plane-strain fracture toughness tests. Additional tests of the aluminum alloy were performed on ring loaded compact tension specimens and on bolt loaded double cantilever beams. For the smooth specimen procedure 0.125-in. dia. tensile specimens were loaded axially in constant deformation type frames. For both aluminum and steel alloys comparative SCC growth rates obtained from tests of precracked specimens provide an additional useful characterization of the SCC behavior of an alloy.
Sprowls, D. O.↗
Slow Crack Growth Behavior and Life/Reliability Analysis of 96 wt % Alumina at Ambient Temperature With Various Specimen/Loading Configurations
Extensive constant stress-rate testing for 96 wt % alumina was conducted in room-temperature distilled water using four different specimen/loading configurations: rectangular beam test specimens under four-point uniaxial flexure, square plate test specimens in ring-on-ring biaxial flexure, square plate test specimens in ball-on-ring biaxial flexure, and dog-boned tensile test specimens in pure tension. The slow crack growth (SCG) parameter n was almost independent of specimen/loading configurations, in either four-point uniaxial flexure, ring-on-ring biaxial flexure, ball-on-ring biaxial flexure, or pure tension, ranging from n = 35 to 47 with an average value of n = 41.1 +/- 4.5. The prediction of fatigue strength/reliability based on the four-point uniaxial flexure data by using the CARES/Life design code as well as a simple PIA model was in good agreement with both the ring-on-ring biaxial and the ball-on-ring biaxial flexure data. A poor prediction using the PIA model was observed for the dog-boned tensile test specimens, presumably due to different flaw population involved in the tensile test specimens.
Choi, Sung R.↗
Silicon Nitride Creep Under Various Specimen-Loading Configurations
Extensive creep testing of a hot-pressed silicon nitride (NC 132) was performed at 1300 C in air using five different specimen-loading configurations: (1) pure tension, (2) pure compression, (3) four-point uniaxial flexure, (4) ball-on-ring biaxial flexure, and (5) ring-on-ring biaxial flexure. This paper reports experimental results as well as test techniques developed in this work. Nominal creep strain and its rate for a given nominal applied stress were greatest in tension, least in compression, and intermediate in uniaxial and biaxial flexure. Except for the case of compression loading, nominal creep strain generally decreased with time, resulting in a less-defined steady-state condition. Of the four creep formulations-power-law, hyperbolic sine, step, and redistribution--the conventional power-law formulation still provides the most convenient and reasonable estimation of the creep parameters of the NC 132 material. The data base to be obtained will be used to validate the NASA Glenn-developed design code CARES/Creep (ceramics analysis and reliability evaluation of structures and creep).
Choi, Sung R.↗
Designing the Next Generation of Human Spacecraft
Lunar Space Station Common Module: A new concept for a module for a lunar space station attempts to reduce the module's mass by abandoning the traditional rack structure currently used on the ISS for the mounting of internal hardware and replacing it with a core structure. By using this design, the pressure shell will not have to carry the loads resulting from the internal mass. I worked with another intern to create the initial design for the module, with him focusing on the core and myself focusing on the pressure shell. To start, I was given the shell overall dimensions and material and tasked with sizing the wall thickness and placing stiffeners such that the shell could withstand the required loads. At the same time, I had to keep the mass to a minimum to keep the overall module within the allowable launch mass. Once I had done initial sizing based on pressure loads, I combined the pressure shell with the inner core to perform optimization of the design. Currently, the design involves circumferential stiffeners along the entire length of the pressure shell with longitudinal stiffeners on either end. In addition, extra wall thickness was added around each of the hatches. At this stage, the design shows a comparable mass to a more traditional design, but we are hopeful that, through optimization, we will be able to reduce the mass even further. There is currently a patent pending for the module design, for which I am listed as a co-inventor. ALON Material Testing: I was given samples of aluminum oxynitride (ALON) that had been impacted by a previous intern on which to perform residual strength tests as part of a plan to approve them for space use. Before testing, I measured the pucks and their damages using a ruler and optical micrometer in order to verify that the puck dimensions were within the tolerances set by the test guidelines and that the damages had not grown when the pucks were thinned. The test was a ring-ring test, which used two concentric rings to place the ring in axisymmetric bending, with the puck set up so that the damaged side was always in tension. Though I was unable to do the setup of the test or run the load machine due to a period of changing test procedures, I was able to observe the testing and perform the data collection. The pucks behaved as expected, breaking at the damage, as did the strengths calculated from the data, being lower than for the unimpacted pucks and having less scatter between the puck values. The attached image is of myself during the ALON strength testing. Over the course of my internship, I was able to learn much more about real-life structural analysis and about the behavior of materials, and it confirmed my previous interest in structural analysis. At the same time, due to the opportunities offered to interns, I was able to learn a lot about mission control, and, in doing so, I developed a second interest in working in mission control. In addition, being able to meet the people here and learn about the type of work NASA does made me want to come back to work for NASA full time.
Simmons, Emily↗
Ball Bearings Equipped for In Situ Lubrication on Demand
In situ systems that provide fresh lubricants to ball/race contacts on demand have been developed to prolong the operational lives of ball bearings. These systems were originally intended to be incorporated into ball bearings in mechanisms that are required to operate in outer space for years, in conditions in which lubricants tend to deteriorate and/or evaporate. These systems may also be useful for similarly prolonging bearing lifetimes on Earth. Reservoirs have been among the means used previously to resupply lubricants. Lubricant- resupply reservoirs are bulky and add complexity to bearing assemblies. In addition, such a reservoir cannot be turned on or off as needed: it supplies lubricant continuously, often leading to an excess of lubricant in the bearing. A lubricator of the present type includes a porous ring cartridge attached to the inner or the outer ring of a ball bearing (see Figure 1). Oil is stored in the porous cartridge and is released by heating the cartridge: Because the thermal expansion of the oil exceeds that of the cartridge, heating causes the ejection of some oil. A metal film can be deposited on a face of the cartridge to serve as an electrical-resistance heater. The heater can be activated in response to a measured increase in torque that signals depletion of oil from the bearing/race contacts. Because the oil has low surface tension and readily wets the bearing-ring material, it spreads over the bearing ring and eventually reaches the ball/race contacts. The Marangoni effect (a surface-tension gradient associated with a temperature gradient) is utilized to enhance the desired transfer of lubricant to the ball/race contacts during heating. For a test, a ball bearing designed for use at low speed was assembled without lubricant and equipped with a porous-ring lubricator, the resistance heater of which consumed a power of less than 1 W when triggered on by a torque-measuring device. In the test, a load of 20 lb (.89 N) was applied and the bearing was turned at a rate of 200 RPM. The lubricator control was turned on at the beginning of the test, turned off for about 800 seconds, then turned on again. As shown in Figure 2, the controlled lubricator stabilized the torque in a low range, starting immediately after initial turn-on and immediately after resumption of the lubricator control.
Marchetti, Mario↗
Advanced Manufacturing of the SLS Block 1B Payload Adapter: Engineering Development Unit
The Payload Adapter (PLA) for the Space Launch System Block 1B configuration (SLS B1B) is a structural frustum that interfaces with the Exploration Upper Stage (EUS) and the Universal Stage Adapter (USA) or the cargo fairing at the aft end and interfaces with the primary or co-manifested payload at the forward end. The primary structure is composed of a single piece aluminum forward ring, a segmented aluminum aft ring, eight carbon composite sandwich panels, and composite bonded longitudinal joints. The PLA is designed and fabricated in-house at MSFC. Development and flight article builds are joint efforts between the Materials & Processes Laboratory (EM), the Spacecraft & Vehicle Systems Department (EV), the Space Systems Department (ES), and the Test Laboratory (ET). The large-scale manufacturing efforts associated with this task include the fabrication of pathfinder panels; the fabrication and assembly of a full-scale Manufacturing Demonstration Article (MDA); the fabrication, assembly, and test of an Engineering Demonstration Unit (EDU); the fabrication, assembly, and test of a qualification Article; and the fabrication, assembly, and proof test of subsequent flight articles. The PLA team recently completed assembly of the EDU. The final assembly included the instillation of the co-manifested secondary payload, NEST, and the instillation and tensioning of the Payload Separation System (PSS). This poster will detail the assembly process which includes: (1) composite panel to ring assembly, (2) adhesive bonding for the longitudinal joints, and (3) instillation of the NEST and PSS. The PLA EDU is prepared to undergo modal and static load testing.
Monique Wallace↗
TO252: Parabolic Flight Demonstration of Fluid Dispensing Tube Performance Limits for Drop Delivery
Ring Shear Drop (RSD) ISS flight hardware failed to pin sample fluid drops between two rings, likely due to dynamic instability inherent to the dispensing tube (D-Tube) design. The first parabolic flight tested 5 D-tube tip designs with two bounding surface tension fluids, enabling an engineering design decision. D-tube Tip Cage Design was selected based on the November 2020 parabolic flight test data. Flight Operations Program (FOP) approved a reflight proposal to include 2 parabolic flight days during the April/May 2021 campaign with following objectives: • Validate ISS hardware flight design with actual flight fluids (test as you fly), demonstrating the ability to deliver 1” fluid drops in near-microgravity conditions. • Demonstrate pinning of 1” flight fluid drops: a secondary pinning ring is planned to be installed in the parabolic flight hardware to meet this objective. Fluid flow rates will also be varied as needed and as possible. • Provide data to validate computational models used to guide ISS operational deployment decisions and demonstrate the viability of the redesigned hardware to accommodate a range of future flight investigations. This presentation introduces highlights and lessons learned during this recent flight campaign for discussion in the Flight Opportunities Program Panel, “Leveraging Suborbital Flight Tests to Advance Science and Technology."
Sridhar Gorti↗
Development of circumferential seal for helicopter transmissions: Results of bench and flight tests
A modified circumferential segmented ring seal was designed for direct replacement of a helicopter transmission elastomeric lip seal operating on a shaft diameter of 13.91 centimeters (5.481 in.) at sliding velocities to 52.48 m/sec (10 330 ft/min). The modifications involved the garter spring tension, shaft roundness, seal housing flatness, and pumping grooves to inhibit leakage. Operation of the seals in bench tests under simulated helicopter transmission conditions revealed that the seal leakage rate was within acceptable limits and that the wear rate was negligible. The low leakage and wear rates were confirmed in flight tests of 600 and 175 hours (sliding speed, 48.11 m/sec (9470 ft/min)). An additional 200 hours of air worthiness qualification testing (aircraft tie down) demonstrated that the seal can operate at the advanced sliding conditions of 52.48 m/sec (10 330 ft/min).
Strom, T. N.↗
Developments in fracture mechanics test methods standardization; Proceedings of the Symposium, St. Louis, Mo., May 4, 1976
Experience in plane-strain fracture toughness testing per ASTM Method E 399 is considered along with fracture toughness testing using the C-shaped specimen, an analysis of radially cracked ring segments subject to forces and couples, compliance calibration of specimens used in the R-curve practice, heavy-section fracture toughness screening specimen, and sharply notched cylindrical tension specimens for screening plane-strain fracture toughness. Attention is also given to an investigation of some problems in developing standards for precracked Charpy specimen strength ratios, fracture testing with surface crack specimens, and the estimation of plane strain fracture toughness values from slow bend precracked Charpy specimen strength ratios.
Brown, W. F., Jr.↗
Verification of the SRB motor case pin retainer band tips
The pin retainer band is a 1-1/4 in. wide by about 1/32 in. thick steel band that is stretched over the pins circumferentially at the joints of the solid rocket booster (SRB) motor case segments. Its purpose is to hold the retaining pins in place during flight. Since the band is thin and is mounted stretched, or under tension, over the pins which are greased in place, it is necessary to protect it thermally. Three typical areas of the band location on the SRB motor case joints were chosen for verifying the cork thermal prection system (TPS) performance on the band: the joint in front of the attach ring, at the aft skirt joint in front of the kick ring and in an unperturbed area at the forward segments of the SRB motor cases. The kick ring area pin retainer band cork TPS passed the test requirements in the region where there are no phenolic splice caps. In the splice cap areas where the band TPS is closed out around the splice with K5NA, additional amounts of K5NA material is required to adequately protect the steel band. TPS requirements were easily met in the one location where the ends of the steel band are joined together after installation and tensioning. The attack ring area pin retainer band TPS did not quite pass the heat load requirements with the .375 in. thick cork TPS as used for the kick ring area band. It is recommended that the cork thickness here be increased to .50 in. The unperturbed area band TPS presented no problems.
Karu, Z. S.↗
Dynamic and thermal response finite element models of multi-body space structural configurations
Presented is structural dynamics modeling of two multibody space structural configurations. The first configuration is a generic space station model of a cylindrical habitation module, two solar array panels, radiator panel, and central connecting tube. The second is a 15-m hoop-column antenna. Discussed is the special joint elimination sequence used for these large finite element models, so that eigenvalues could be extracted. The generic space station model aided test configuration design and analysis/test data correlation. The model consisted of six finite element models, one of each substructure and one of all substructures as a system. Static analysis and tests at the substructure level fine-tuned the finite element models. The 15-m hoop-column antenna is a truss column and structural ring interconnected with tension stabilizing cables. To the cables, pretensioned mesh membrane elements were attached to form four parabolic shaped antennae, one per quadrant. Imposing thermal preloads in the cables and mesh elements produced pretension in the finite element model. Thermal preload variation in the 96 control cables was adjusted to maintain antenna shape within the required tolerance and to give pointing accuracy.
Edighoffer, Harold H.↗
Biaxial and uniaxial data for statistical comparisons of a ceramic's strength
The uniaxial and equibiaxial tensile strengths of a brittle material were measured in bending. Equibiaxial tension was attained by concentric ring loading of disks and uniaxial tension by four-point line loading of plates. The two specimen designs give equal volumes, surface areas, and stress gradients. Ground surfaces and lapped surfaces were tested. The equibiaxial tensile strength of a dense alumina was lower than the uniaxial tensile strengths for both ground and lapped surfaces, 8.5 and 8.1%, respectively. The Batdorf theory of flaw statistics, in which biaxial tensile strengths can be predicted from the statistical distribution of uniaxial tensile strength measurements, agreed with the data.
Giovan, M. N.↗
Creep of a Silicon Nitride Under Various Specimen/Loading Configurations
Extensive creep testing of a hot-pressed silicon nitride (NC132) was performed at 1300 C in air using five different specimen/loading configurations, including pure tension, pure compression, four-point uniaxial flexure, ball-on-ring biaxial flexure, and ring-on-ring biaxial flexure. Nominal creep strain and its rate for a given nominal applied stress were greatest in tension, least in compression, and intermediate in uniaxial and biaxial flexure. Except for the case of compressive loading, nominal creep strain generally decreased with time, resulting in less-defined steady-state condition. Of the four different creep formulations - power-law, hyperbolic sine, step, redistribution models - the conventional power-law model still provides the most convenient and reasonable means to estimate simple, quantitative creep parameters of the material. Predictions of creep deformation for the case of multiaxial stress state (biaxial flexure) were made based on pure tension and compression creep data by using the design code CARES/Creep.
Choi, Sung R.↗
Effects of hindlimb unweighting on the mechanical and structure properties of the rat abdominal aorta
Previous studies have shown that hindlimb unweighting of rats, a model of microgravity, reduces evoked contractile tension of peripheral conduit arteries. It has been hypothesized that this diminished contractile tension is the result of alterations in the mechanical properties of these arteries (e.g., active and passive mechanics). Therefore, the purpose of this study was to determine whether the reduced contractile force of the abdominal aorta from 2-wk hindlimb-unweighted (HU) rats results from a mechanical function deficit resulting from structural vascular alterations or material property changes. Aortas were isolated from control (C) and HU rats, and vasoconstrictor responses to norepinephrine (10(-9)-10(-4) M) and AVP (10(-9)-10(-5) M) were tested in vitro. In a second series of tests, the active and passive Cauchy stress-stretch relations were determined by incrementally increasing the uniaxial displacement of the aortic rings. Maximal Cauchy stress in response to norepinephrine and AVP were less in aortic rings from HU rats. The active Cauchy stress-stretch response indicated that, although maximum stress was lower in aortas from HU rats (C, 8.1 +/- 0.2 kPa; HU, 7.0 +/- 0.4 kPa), it was achieved at a similar hoop stretch. There were also no differences in the passive Cauchy stress-stretch response or the gross vascular morphology (e.g., medial cross-sectional area: C, 0.30 +/- 0.02 mm(2); HU, 0.32 +/- 0.01 mm(2)) between groups and no differences in resting or basal vascular tone at the displacement that elicits peak developed tension between groups (resting tension: C, 1.71 +/- 0.06 g; HU, 1.78 +/- 0.14 g). These results indicate that HU does not alter the functional mechanical properties of conduit arteries. However, the significantly lower active Cauchy stress of aortas from HU rats demonstrates a true contractile deficit in these arteries.
Non-NASA Center↗
Miniature Piezoelectric Shaker for Distribution of Unconsolidated Samples to Instrument Cells
The planned Mars Science Laboratory mission requires inlet funnels for channeling unconsolidated powdered samples from the sampling and sieving mechanisms into instrument test cells, which are required to reduce cross-contamination of the samples and to minimize residue left in the funnels after each sample transport. To these ends, a solid-state shaking mechanism has been created that requires low power and is lightweight, but is sturdy enough to survive launch vibration. The funnel mechanism is driven by asymmetrically mounted, piezoelectric flexure actuators that are out of the load path so that they do not support the funnel mass. Each actuator is a titanium, flextensional piezoelectric device driven by a piezoelectric stack. The stack has Invar endcaps with a half-spherical recess. The Invar is used to counteract the change in stress as the actuators are cooled to Mars ambient temperatures. A ball screw is threaded through the actuator frame into the recess to apply pre-stress, and to trap the piezoelectric stack and endcaps in flexure. During the vibration cycle of the flextensional actuator frame, the compression in the piezoelectric stack may decrease to the point that it is unstressed; however, because the ball joint cannot pull, tension in the piezoelectric stack cannot be produced. The actuators are offset at 120 . In this flight design, redundancy is required, so three actuators are used though only one is needed to assist in the movement. The funnel is supported at three contact points offset to the hexapod support contacts. The actuator surface that does not contact the ring is free to expand. Two other configurations can be used to mechanically tune the vibration. The free end can be designed to drive a fixed mass, or can be used to drive a free mass to excite impacts (see figure). Tests on this funnel mechanism show a high density of resonance modes between 1 and 20 kHz. A subset of these between 9 and 12 kHz was used to drive the CheMin actuators at 7 V peak to peak. These actuators could be driven by a single resonance, or swept through a frequency range to decrease the possibility that a portion of the funnel surface was not coincident with a nodal line (line of no displacement). The frequency of actuation can be electrically controlled and monitored and can also be mechanically tuned by the addition of tuning mass on the free end of the actuator. The devices are solid-state and can be designed with no macroscopically moving parts. This design has been tested in a vacuum at both Mars and Earth ambient temperatures ranging from 30 to 25 C
Sherrit, Stewart↗
Experimental Stress Analysis of Stiffened Cylinders with Cutouts : Shear Load
A cylindrical semimonocoque shell of circular cross section was mounted as a cantilever and loaded by a direct shear at the tip. The cylinder was tested with no cutout, with a rectangular cutout on the tension side, and with the cutout centered on the neutral axis on one side of the cylinder. The cutout was successively enlarged through six sizes varying from 30 degrees to 130 degrees in circumference and from 1 and 2 bays in length. Strain measurements were made with resistance-type wire strain gages near the cutout on the stringers, the skin, and the rings for each case, and the stresses obtained are presented in tables. (author)
Rosecrans, Richard↗