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At least 19 records

Structural attachments for large space structures

The feasibility of fabricating beams in space and using them as components of a large, crew assembled structure, was investigated. Two projects were undertaken: (1) design and development of a ground version of an automated beam builder capable of producing triangular cross section aluminum beams; and (2) design and fabrication of lap joints to connect the beams orthogonally and centroidal end caps to connect beams end to end at any desired angle. The first project produced a beam building machine which fabricates aluminum beams suitable for neutral buoyancy evaluation. The second project produced concepts for the lap joint and end cap. However, neither of these joint concepts was suitable for use by a pressure suited crew member in a zero gravity environment. It is concluded that before the beams can be evaluated the joint designs need to be completed and sufficient joints produced to allow assembly of a complex structure.

Pruett, E. C.↗

Supersonic loads due to shuttle-orbiter/external-tank attachment structures

A large variety of tests were conducted during development of the Space Shuttle to determine the strength, fatigue, and thermal characteristics of the thermal-protection system of the orbiter. The research and analysis carried out to accurately define and simulate the flow characteristics immediately ahead of the external tank attachment structures are described. The highest known acoustic pressure loads occur in these regions and tests to insure the ability of the titles to withstand these acoustic loads, plus those due to pressure gradient, were thought necessary. First flight-critical wind tunnel tests were therefore conducted in the Langley 8-Foot Transonic Pressure Tunnel (8-Ft. TPT), which simulated the time histories of Shuttle ascent loads on tile arrays bonded to structures which accurately duplicated those of the Shuttle. The time-varying free stream conditions were provided by controlling the deflection angle history of diffuser spoiler flaps in an automated way. Time histories of the critical load parameters imposed on the tile arrays in the tunnel are compared with those expected in flight.

Edwards, C. L. W.↗

Elastomeric Structural Attachment Concepts for Aircraft Flap Noise Reduction - Challenges and Approaches to Hyperelastic Structural Modeling and Analysis

Airframe noise is a significant part of the overall noise of transport aircraft during the approach and landing phases of flight. Airframe noise reduction is currently emphasized under the Environmentally Responsible Aviation (ERA) and Fixed Wing (FW) Project goals of NASA. A promising concept for trailing-edge-flap noise reduction is a flexible structural element or link that connects the side edges of the deployable flap to the adjacent main-wing structure. The proposed solution is distinguished by minimization of the span-wise extent of the structural link, thereby minimizing the aerodynamic load on the link structure at the expense of increased deformation requirement. Development of such a flexible structural link necessitated application of hyperelastic materials, atypical structural configurations and novel interface hardware. The resulting highly-deformable structural concept was termed the FLEXible Side Edge Link (FLEXSEL) concept. Prediction of atypical elastomeric deformation responses from detailed structural analysis was essential for evaluating feasible concepts that met the design constraints. The focus of this paper is to describe the many challenges encountered with hyperelastic finite element modeling and the nonlinear structural analysis of evolving FLEXSEL concepts. Detailed herein is the nonlinear analysis of FLEXSEL concepts that emerged during the project which include solid-section, foamcore, hollow, extended-span and pre-stressed concepts. Coupon-level analysis performed on elastomeric interface joints, which form a part of the FLEXSEL topology development, are also presented.

Sreekantamurthy, Thammaiah↗

Analysis of the effects of firing Orbiter primary reaction control system jets with an attached truss structure

A study was conducted to determine the dynamic effects of firing the orbiter primary reaction control jets during assembly of protoflight space station structure. Maximum longeron compressive load was calculated as a function of jet pulse time length, number of jet pulses, and total torque imposed by the reaction control jets. The study shows that it is possible to fire selected jets to achieve a pitch maneuver without causing failure of the attached structure.

Kaszubowski, M.↗

Self-locking mechanical center joint

A device for connecting, rotating and locking together a pair of structural half columns is described. The device is composed of an identical pair of cylindrical hub assemblies connected at their inner faces by a spring loaded hinge; each hub assembly having a structural half column attached to its outer end. Each hub assembly has a spring loading locking ring member movably attached adjacent to its inner face and includes a latch member for holding the locking ring in a rotated position subject to the force of its spring. Each hub assembly also has a hammer member for releasing the latch on the opposing hub assembly when the hub assemblies are rotated together. The spring loaded hinge connecting the hub assemblies rotates the hub assemblies and attached structural half columns together bringing the inner faces of the opposing hub assemblies into contact with one another.

Bush, H. G.↗

Aerodynamic characteristics of MSFC model 454 of the 142 inch solid rocket booster tested in the LeRC 10 foot SWT at Mach numbers of 2.0 and 2.7 (SA6F)

A 2.112 percent scale Space Shuttle Solid Rocket Booster (SRB) was tested in a ten foot, supersonic wind tunnel. The test Mach numbers were 2.0 and 2.7. Test angles of attack were from minus 5 degrees to plus 185 degrees. The Reynolds numbers ranged from 0.514 to 2.81 million per foot. Test roll angles were 0, 22.5, 45, 90, and 135 degrees. The following configurations were tested: (1) SRB without external protuberances, (2) SRB with an electrical tunnel and a thrust attachment structure, (3) SRB with two engine shroud strakes, (4) SRB with eight engine shroud strakes, and (5) SRB with an electrical tunnel, thrust attachment structure, eight engine shroud strakes, and separation motors.

Johnson, J. D.↗

Pyrotechnic shock at the orbiter/external tank forward attachment

During the initial certification test of the forward structural attachment of the space shuttle orbiter to the external tank, pyrotechnic shock from actuation of the separation device resulted in structural failure of the thermal protection tiles surrounding the attachment. Because of the high shock associated with the separation bolt, the development of alternative low shock separation designs was initiated. Two concepts that incorporate a 5.08 centimeter frangible nut as the release device were developed and tested.

Rogers, W. F.↗

Method of determining shear stress employing a monomer-polymer laminate structure

A laminate structure attached to the test surface of an article is presented. The laminate structure is comprised of a liquid crystal polymer substrate. A light absorbing coating is applied to the substrate and is thin enough to permit bonding steric interaction between the liquid crystal polymer substrate and an overlying liquid crystal monomer thin film. Light is directed through and reflected by the liquid crystal monomer thin film and unreflected light is absorbed by the underlying coating. The wavelength of the reflected light is indicative of the shear stress experienced by the test surface.

Singh, Jag J.↗

Trade study plan for Graphite Composite Primary Structure (GCPS)

This TA 2 document (with support from TA 1) describes the trade study plan that will identify the most suitable structural configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 degree inclination For this most suitable configuration the structural attachment of the wing, and the most suitable GCPS composite materials for intertank, wing, tail and thrust structure are identified. This trade study analysis uses extensive information derived in the TA 1 trade study plan and is identified within the study plan. In view of this, for convenience, the TA 1 study plan is included as an appendix to this document.

Greenberg, H. S.↗

The Flying Diamond: A joined aircraft configuration design project, volume 1

The results of the analysis conducted on the Joined Wing Configuration study are presented. The joined wing configuration employs a conventional fuselage and incorporates two wings joined together near their tips to form a diamond shape in both plan view and front view. The arrangement of the lifting surfaces uses the rear wing as a horizontal tail and as a forward wing strut. The rear wing has its root at the tip of the vertical stabilizer and is structurally attached to the trailing edge of the forward wing. This arrangement of the two wings forms a truss structure which is inherently resistant to the aerodynamic bending loads generated during flight. This allows for a considerable reduction in the weight of the lifting surfaces. With smaller internal wing structures needed, the Joined Wing may employ thinner wings which are more suitable for supersonic and hypersonic flight, having less induced drag than conventional cantilever winged aircraft. Inherent in the Joined Wing is the capability of the generation of direct lift and side force which enhance the performance parameters.

Ball, Chris↗

Hybrid deployable support truss designs for LDR

Concepts for a 20-meter diameter Large Deployable Reflector (LDR) deployable truss backup structure, and analytical predictions of its structural characteristics are discussed. The concept shown is referred to as the SIXPAC; It is a combination of the PACTRUSS concept and a single-fold beam, which would make up the desired backup structure. One advantage of retaining the PACTRUSS concept is its packaging density and its capability for synchronous deployment. Various 2-meter hexagonal panel arrangements are possible for this Hybrid PACTRUSS structure depending on the panel-to-structure attachment strategies used. Static analyses of the SIXPAC using various assumptions for truss designs and panel masses of 10 kg sq meters were performed to predict the tip displacement of the structure when supported at the center. The tip displacement ranged from 0.20 to 0.44 mm without the panel mass, and from 0.9 to 3.9 mm with the panel mass (in a 1-g field). The data indicate that the structure can be adequately ground tested to validate its required performance in space, assuming the required performance in space is approximately 100 microns. The static displacement at the tip of the structure when subjected to an angular acceleration of 0.001 rad/sec squared were estimated to range from 0.8 to 7.5 microns, depending on the type of truss elements.

Hedgepeth, J.↗

3D Woven Composite End Ring Structure: Design Development and Verification Testing

The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing composite technologies for exploration missions. The Composite Technology for Exploration (CTE) project goal is to advance lightweight joint concepts for Space Launch System (SLS) class structures. To this end CTE is developing and demonstrating a 3D woven carbon /epoxy composite joint design co-bonded in a circumferential end ring configuration, applied to a SLS sized conceptual payload attachment structure. This joint is a lightweight alternative to heavy and costly metallic joints. The 3D woven joint development advances lightweight joint technologies through material and structural design, material and joint analyses, and fabrication, as well as demonstration through building block testing. Prior limited building block tests are mentioned. In this paper, new sub-element-scale test results are described that demonstrate the structural capability well beyond design limit load. Then, results for a sub-component test article with a 889 mm joint subjected to combined loads are presented.

Kenneth N Segal↗

Inflatable Re-Entry Vehicle Experiment (IRVE) Design Overview

Inflatable aeroshells offer several advantages over traditional rigid aeroshells for atmospheric entry. Inflatables offer increased payload volume fraction of the launch vehicle shroud and the possibility to deliver more payload mass to the surface for equivalent trajectory constraints. An inflatable s diameter is not constrained by the launch vehicle shroud. The resultant larger drag area can provide deceleration equivalent to a rigid system at higher atmospheric altitudes, thus offering access to higher landing sites. When stowed for launch and cruise, inflatable aeroshells allow access to the payload after the vehicle is integrated for launch and offer direct access to vehicle structure for structural attachment with the launch vehicle. They also offer an opportunity to eliminate system duplication between the cruise stage and entry vehicle. There are however several potential technical challenges for inflatable aeroshells. First and foremost is the fact that they are flexible structures. That flexibility could lead to unpredictable drag performance or an aerostructural dynamic instability. In addition, durability of large inflatable structures may limit their application. They are susceptible to puncture, a potentially catastrophic insult, from many possible sources. Finally, aerothermal heating during planetary entry poses a significant challenge to a thin membrane. NASA Langley Research Center and NASA's Wallops Flight Facility are jointly developing inflatable aeroshell technology for use on future NASA missions. The technology will be demonstrated in the Inflatable Re-entry Vehicle Experiment (IRVE). This paper will detail the development of the initial IRVE inflatable system to be launched on a Terrier/Orion sounding rocket in the fourth quarter of CY2005. The experiment will demonstrate achievable packaging efficiency of the inflatable aeroshell for launch, inflation, leak performance of the inflatable system throughout the flight regime, structural integrity when exposed to a relevant dynamic pressure and aerodynamic stability of the inflatable system. Structural integrity and structural response of the inflatable will be verified with photogrammetric measurements of the back side of the aeroshell in flight. Aerodynamic stability as well as drag performance will be verified with on board inertial measurements and radar tracking from multiple ground radar stations. The experiment will yield valuable information about zero-g vacuum deployment dynamics of the flexible inflatable structure with both inertial and photographic measurements. In addition to demonstrating inflatable technology, IRVE will validate structural, aerothermal, and trajectory modeling techniques for the inflatable. Structural response determined from photogrammetrics will validate structural models, skin temperature measurements and additional in-depth temperature measurements will validate material thermal performance models, and on board inertial measurements along with radar tracking from multiple ground radar stations will validate trajectory simulation models.

Hughes, Stephen J.↗

Validation of Shadowgraph Spectral Analysis using an SLS Block 2 Wind-Tunnel Model

A flow quantification method has previously been developed that uses high-speed shadowgraph images to extract frequency content of a transonic flow field around a wind-tunnel model. In this method, a classical spectral analysis is performed on a set of shadowgraph image pixels to identify their intensity fluctuation frequencies. The spatial change of the image intensity is related to the second derivative of the density gradient. Examining the change of the density gradient as a function of time can be used to understand the flow field pressure fluctuations. Pressure measurements collected during a Booster Obsolescence Life Extension Forward Attachment Structure Trade Study Test are used to calibrate the shadowgraph-based measurements. The test was performed at the NASA Ames Research Center Unitary Plan Wind Tunnel 11- by 11-foot test section and investigated aerodynamic environment downstream of various booster forward attachment hardware geometries of the Space Launch System Block 2 Cargo configuration. Time-correlated shadowgraph video and model surface pressure measurements were acquired during the test and served as an ideal opportunity to calibrate and validate the shadowgraph image intensity method.

Shadowgraph↗

Dynamic assessment of B-52B-008 carrier aircraft for the revised Space Shuttle solid rocket booster decelerator subsystem drop test vehicle

The structural integrity of B-52B-008, pylon, and hooks for the drop test missions was determined by theoretical analysis. The results of the analysis and conclusions are presented in this document. The major modification to the drop test vehicle was shortening it about 54 inches, which resulted in the forward hook attach structure being located at the base of the nosecone. The shims that are located in the aft hook structures are increased from two inches to three inches. Airspeed, aerodynamic configuration, and load charts are included.

Doty, L. J.↗

Swing-arm beam erector (SABER) concept for single astronaut assembly of space structure

Results are presented of tests conducted to evaluate a mobile work station/assembly fixture concept that would mechanically assist an astronaut in the on-orbit manual assembly of erectable truss-beams. The concept eliminates astronaut manual translation by use of a motorized work platform with foot restraints. The tests involved assembly of a tetrahedral truss-beam by a test subject in simulated zero gravity (neutral bouyancy in water). A three-bay truss-beam was assembled from 30 aluminum struts with quick-attachment structural joints. The results show that average on-orbit assembly rates of 2.1 struts per minute can be expected for struts of the size employed in these tests.

Watson, J. J.↗