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NASA NTRS2003

New Tools Being Developed for Engine- Airframe Blade-Out Structural Simulations

One of the primary concerns of aircraft structure designers is the accurate simulation of the blade-out event. This is required for the aircraft to pass Federal Aviation Administration (FAA) certification and to ensure that the aircraft is safe for operation. Typically, the most severe blade-out occurs when a first-stage fan blade in a high-bypass gas turbine engine is released. Structural loading results from both the impact of the blade onto the containment ring and the subsequent instantaneous unbalance of the rotating components. Reliable simulations of blade-out are required to ensure structural integrity during flight as well as to guarantee successful blade-out certification testing. The loads generated by these analyses are critical to the design teams for several components of the airplane structures including the engine, nacelle, strut, and wing, as well as the aircraft fuselage. Currently, a collection of simulation tools is used for aircraft structural design. Detailed high-fidelity simulation tools are used to capture the structural loads resulting from blade loss, and then these loads are used as input into an overall system model that includes complete structural models of both the engines and the airframe. The detailed simulation (shown in the figure) includes the time-dependent trajectory of the lost blade and its interactions with the containment structure, and the system simulation includes the lost blade loadings and the interactions between the rotating turbomachinery and the remaining aircraft structural components. General-purpose finite element structural analysis codes are typically used, and special provisions are made to include transient effects from the blade loss and rotational effects resulting from the engine s turbomachinery. To develop and validate these new tools with test data, the NASA Glenn Research Center has teamed with GE Aircraft Engines, Pratt & Whitney, Boeing Commercial Aircraft, Rolls-Royce, and MSC.Software.

Lawrence, Charles↗

NASA NTRS2001

Simulation of Aircraft Engine Blade-Out Structural Dynamics

A primary concern of aircraft structure designers is the accurate simulation of the blade-out event and the subsequent windmilling of the engine. Reliable simulations of the blade-out event are required to insure structural integrity during flight as well as to guarantee successful blade-out certification testing. The system simulation includes the lost blade loadings and the interactions between the rotating turbomachinery and the remaining aircraft structural components. General-purpose finite element structural analysis codes such as MSC NASTRAN are typically used and special provisions are made to include transient effects from the blade loss and rotational effects resulting from the engine's turbomachinery. The present study provides the equations of motion for rotordynamic response including the effect of spooldown speed and rotor unbalance and examines the effects of these terms on a cantilevered rotor. The effect of spooldown speed is found to be greater with increasing spooldown rate. The parametric term resulting from the mass unbalance has a more significant effect on the rotordynamic response than does the spooldown term. The parametric term affects both the peak amplitudes as well as the resonant frequencies of the rotor.

Lawrence, Charles↗

NASA NTRS2001

Simulation of Aircraft Engine Blade-Out Structural Dynamics

Lawrence, Charles↗

NASA NTRS2012

Examining Individual Differences in Temporal Profiles of Cardiovascular Responses to the Head Down Tilt during Fluid Loading

Upon returning to Earth after an extended exposure to micro-gravity in space many astronauts have experienced symptoms of light headedness and fainting associated with post-flight orthostatic intolerance (low blood pressure). The main reason for this condition is the reduced fluid volume in the body while in space. A preventative treatment was proposed to prevent this condition by fluid loading to restore lost plasma volume by giving crew members salt tablets and water prior to re-entry. In order to simulate micro-gravity effects on earth test subjects are placed in a supine position with their head below the level of their heart (6 head down tilt-HDT). The purpose of the present study is to define individual differences in the time course of cardiac stroke volume responses to HDT (6 hours) and the effectiveness of fluid loading for mitigating orthostatic intolerance when standing . Echocardiography and impedance cardiography data will be collected on 8 men and 8 women to examine heart function to HDT. A second objective is to determine if the effects of fluid loading vary due to individual differences (e.g., age, gender, height, weight, physical fitness, etc.).

orthostatic intolerance↗

NASA NTRS1999

Preparing for Mars: the physiologic and medical challenges

As the twentieth century closes, retrospectives cite the Apollo moon missions as one of the important events of the past 100 years. A trip to Mars, however, would be even more challenging and significant. A round-trip Mars journey would require nearly three years away from Earth, a significant leap in complexity compared to the two week long Moon trips or the record-breaking fourteen-month flight on Mir. What would be the physiologic and medical challenges of a Mars flight? Two key areas of physiology present the greatest potential problems--calcium metabolism and radiation exposure. Data from Mir missions show that bone loss continues in space despite an aggressive countermeasure program. Average losses were 0.35% per month, but some load bearing areas lost >1% per month. A 1% loss rate, if it continued unabated for 30 months, could produce osteoporosis. Smaller losses could still increase fracture risk. Some bone loss can be well tolerated, particularly if the bone can be regained after the mission. But the effectiveness of post-flight rehabilitation to restore the density and quality of bone after spaceflight is not well known. Bone loss estimates are based on continuous weightlessness exposure, but this is not a requirement for a Mars trip. Most of the time on a Mars trip will be spent in the 1/3 Earth's gravity environment on Mars, and either intermittent or continuous artificial gravity can be provided for the transit between planets (although at an engineering cost). The dosing of the gravity exposure (e.g. the level and duration), however, has not been established. Radiation protection also requires a balance between engineering cost and human health. Excessive shielding could add billions of dollars to the cost of a mission. Trips in interplanetary space, however, expose the crew to heavy high-energy particles from cosmic rays (HZE particles), which have a high linear energy transfer. This high energy leads to significant biological damage (e.g. chromosomal aberrations, cancer induction). A recent report from the Committee on Space Biology and Medicine notes that only one systematic study of cancer induction from high-energy particles has been conducted (using the mouse Harderian gland). Predictions of cancer risk and acceptable radiation exposure in space are extrapolated from minimal data. Other areas of physiology also present problems, such as muscle loss, cardiovascular deconditioning, and vestibular adaptation. Despite all the issues, however, a focussed, aggressive research program that uses the resources of the International Space Station should pave the way for mankind's greatest adventure--a trip to Mars.

STS-90 Shuttle Project↗

NASA NTRS1947

Calculation of Wing Bending Moments and Tail Loads Resulting from the Jettison of Wing Tips During a Symmetrical Pull-Up

A preliminary analytical investigation was made to determine the feasibility of the basic idea of controlled failure points as safety valves for the primary airplane structure. The present analysis considers the possibilities of the breakable wing tip which, in failing as a weak link, would relieve the bending moments on the wing structure. The analysis was carried out by computing the time histories of the wing and stabilizer angle of attack in a 10g pull-up for an XF8F airplane with tips fixed and comparing the results with those for the same maneuver, that is, elevator motion but with tips jettisoned at 8g. The calculations indicate that the increased stability accompanying the loss of the wing tips reduces the bending moment an additional amount above that which would be expected from the initial loss in lift and the inboard shift in load. The vortex shed when the tips are lost may induce a transient load requiring that the tail be made stronger than otherwise.

Boshar, John↗

NASA NTRS2012

A Proposed Study Examining Individual Differences in Temporal Profiles of Cardiovascular Responses to Head Down Tilt During Fluid Loading

Susceptibility of healthy astronauts to orthostatic hypotension and presyncope is exacerbated upon return from spaceflight. The effect of altered gravity during space flight and planetary transition on human cardiovascular function is of critical importance to maintenance of astronaut health and safety. Hypovolemia, reduced plasma volume, is suspected to play an important role in cardiovascular deconditioning following exposure to spaceflight, which may lead to increased peripheral resistance, attenuated arterial baroreflex, and changes in cardiac function. A promising countermeasure for post-flight orthostatic intolerance is fluid loading used to restore lost plasma volume by giving crew salt tablets and water prior to re-entry. The main purpose of the proposed study is to define the temporal profile of cardiac responses to simulated 0-G conditions before and following a fluid loading countermeasure. 8 men and 8 women will be tested during 4 hour exposures at 6o head down tilt (HDT). Each subject will be given two exposures to HDT on separate days, one with and one without fluid loading (one liter of 0.9% saline solution). Stand tests (orthostatic stress) will be done before and after each HDT. Cardiac measures will be obtained with both impedance cardiography and echo ultrasound

Cowings, Patricia↗

NASA NTRS1991

Combined thermal and bending fatigue of high-temperature metal-matrix composites: Computational simulation

The nonlinear behavior of a high-temperature metal-matrix composite (HT-MMC) was simulated by using the metal matrix composite analyzer (METCAN) computer code. The simulation started with the fabrication process, proceeded to thermomechanical cyclic loading, and ended with the application of a monotonic load. Classical laminate theory and composite micromechanics and macromechanics are used in METCAN, along with a multifactor interaction model for the constituents behavior. The simulation of the stress-strain behavior from the macromechanical and the micromechanical points of view, as well as the initiation and final failure of the constituents and the plies in the composite, were examined in detail. It was shown that, when the fibers and the matrix were perfectly bonded, the fracture started in the matrix and then propagated with increasing load to the fibers. After the fibers fractured, the composite lost its capacity to carry additional load and fractured.

Gotsis, Pascal K.↗

NASA NTRS1992

Combined bending and thermal fatigue of high-temperature metal-matrix composites - Computational simulation

Gotsis, Pascal K.↗

NASA NTRS2000

Numerical Simulation of Non-Rotating and Rotating Coolant Channel Flow Fields

Future generations of ultra high bypass-ratio jet engines will require far higher pressure ratios and operating temperatures than those of current engines. For the foreseeable future, engine materials will not be able to withstand the high temperatures without some form of cooling. In particular the turbine blades, which are under high thermal as well as mechanical loads, must be cooled. Cooling of turbine blades is achieved by bleeding air from the compressor stage of the engine through complicated internal passages in the turbine blades (internal cooling, including jet-impingement cooling) and by bleeding small amounts of air into the boundary layer of the external flow through small discrete holes on the surface of the blade (film cooling and transpiration cooling). The cooling must be done using a minimum amount of air or any increases in efficiency gained through higher operating temperature will be lost due to added load on the compressor stage. Turbine cooling schemes have traditionally been based on extensive empirical data bases, quasi-one-dimensional computational fluid dynamics (CFD) analysis, and trial and error. With improved capabilities of CFD, these traditional methods can be augmented by full three-dimensional simulations of the coolant flow to predict in detail the heat transfer and metal temperatures. Several aspects of turbine coolant flows make such application of CFD difficult, thus a highly effective CFD methodology must be used. First, high resolution of the flow field is required to attain the needed accuracy for heat transfer predictions, making highly efficient flow solvers essential for such computations. Second, the geometries of the flow passages are complicated but must be modeled accurately in order to capture all important details of the flow. This makes grid generation and grid quality important issues. Finally, since coolant flows are turbulent and separated the effects of turbulence must be modeled with a low Reynolds number turbulence model to accurately predict details of heat transfer.

Rigby, David L.↗

NASA NTRS2012

Flexible Architecture for FPGAs in Embedded Systems

Commonly, field-programmable gate arrays (FPGAs) being developed in cPCI embedded systems include the bus interface in the FPGA. This complicates the development because the interface is complicated and requires a lot of development time and FPGA resources. In addition, flight qualification requires a substantial amount of time be devoted to just this interface. Another complication of putting the cPCI interface into the FPGA being developed is that configuration information loaded into the device by the cPCI microprocessor is lost when a new bit file is loaded, requiring cumbersome operations to return the system to an operational state. Finally, SRAM-based FPGAs are typically programmed via specialized cables and software, with programming files being loaded either directly into the FPGA, or into PROM devices. This can be cumbersome when doing FPGA development in an embedded environment, and does not have an easy path to flight. Currently, FPGAs used in space applications are usually programmed via multiple space-qualified PROM devices that are physically large and require extra circuitry (typically including a separate one-time programmable FPGA) to enable them to be used for this application. This technology adds a cPCI interface device with a simple, flexible, high-performance backend interface supporting multiple backend FPGAs. It includes a mechanism for programming the FPGAs directly via the microprocessor in the embedded system, eliminating specialized hardware, software, and PROM devices and their associated circuitry. It has a direct path to flight, and no extra hardware and minimal software are required to support reprogramming in flight. The device added is currently a small FPGA, but an advantage of this technology is that the design of the device does not change, regardless of the application in which it is being used. This means that it needs to be qualified for flight only once, and is suitable for one-time programmable devices or an application specific integrated circuit (ASIC). An application programming interface (API) further reduces the development time needed to use the interface device in a system.

Clark, Duane I.↗

NASA NTRS2003

Toward an Improved Hypersonic Engine Seal

High temperature, dynamic seals are required in advanced engines to seal the perimeters of movable engine ramps for efficient, safe operation in high heat flux environments at temperatures from 2000 to 2500 F. Current seal designs do not meet the demanding requirements for future engines, so NASA s Glenn Research Center (GRC) is developing advanced seals to overcome these shortfalls. Two seal designs and two types of seal preloading devices were evaluated in a series of compression tests at room temperature and 2000 F and flow tests at room temperature. Both seals lost resiliency with repeated load cycling at room temperature and 2000 F, but seals with braided cores were significantly more flexible than those with cores composed of uniaxial ceramic fibers. Flow rates for the seals with cores of uniaxial fibers were lower than those for the seals with braided cores. Canted coil springs and silicon nitride compression springs showed promise conceptually as potential seal preloading devices to help maintain seal resiliency.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Physiology of a microgravity environment invited review: microgravity and skeletal muscle

Spaceflight (SF) has been shown to cause skeletal muscle atrophy; a loss in force and power; and, in the first few weeks, a preferential atrophy of extensors over flexors. The atrophy primarily results from a reduced protein synthesis that is likely triggered by the removal of the antigravity load. Contractile proteins are lost out of proportion to other cellular proteins, and the actin thin filament is lost disproportionately to the myosin thick filament. The decline in contractile protein explains the decrease in force per cross-sectional area, whereas the thin-filament loss may explain the observed postflight increase in the maximal velocity of shortening in the type I and IIa fiber types. Importantly, the microgravity-induced decline in peak power is partially offset by the increased fiber velocity. Muscle velocity is further increased by the microgravity-induced expression of fast-type myosin isozymes in slow fibers (hybrid I/II fibers) and by the increased expression of fast type II fiber types. SF increases the susceptibility of skeletal muscle to damage, with the actual damage elicited during postflight reloading. Evidence in rats indicates that SF increases fatigability and reduces the capacity for fat oxidation in skeletal muscles. Future studies will be required to establish the cellular and molecular mechanisms of the SF-induced muscle atrophy and functional loss and to develop effective exercise countermeasures.

short duration↗

NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗

NASA NTRS2010

Simulation of Propellant Loading System Senior Design Implement in Computer Algorithm

Propellant loading from the Storage Tank to the External Tank is one of the very important and time consuming pre-launch ground operations for the launch vehicle. The propellant loading system is a complex integrated system involving many physical components such as the storage tank filled with cryogenic fluid at a very low temperature, the long pipe line connecting the storage tank with the external tank, the external tank along with the flare stack, and vent systems for releasing the excess fuel. Some of the very important parameters useful for design purpose are the prediction of pre-chill time, loading time, amount of fuel lost, the maximum pressure rise etc. The physics involved for mathematical modeling is quite complex due to the fact the process is unsteady, there is phase change as some of the fuel changes from liquid to gas state, then conjugate heat transfer in the pipe walls as well as between solid-to-fluid region. The simulation is very tedious and time consuming too. So overall, this is a complex system and the objective of the work is student's involvement and work in the parametric study and optimization of numerical modeling towards the design of such system. The students have to first become familiar and understand the physical process, the related mathematics and the numerical algorithm. The work involves exploring (i) improved algorithm to make the transient simulation computationally effective (reduced CPU time) and (ii) Parametric study to evaluate design parameters by changing the operational conditions

Bandyopadhyay, Alak↗

NASA NTRS1973

Evaluation of a high response electrohydraulic digital control valve

The application is described of a digital control valve on an electrohydraulic servo actuator. The digital control problem is discussed in general as well as the design and evaluation of a breadboard actuator. The evaluation revealed a number of problems associated with matching the valve to a hydraulic load. The problems were related to lost motion resulting from bulk modulus and leakage. These problems were effectively minimized in the breadboard actuator by maintaining a 1000 psi back pressure on the valve circuit and thereby improving the effective bulk modulus.

Anderson, R. L.↗

NASA NTRS2003

The impact of skeletal unloading on bone formation

Skeletal unloading leads to decreased bone formation and decreased bone mass. Bone resorption is uncoupled from bone formation, contributing to the bone loss. During space flight bone is lost principally from the bones most loaded in the 1 g environment. Determining the mechanism(s) by which loading of bone is sensed and translated into a signal(s) controlling bone formation remains the holy grail in this field. It seems likely that matrix/cell interactions will underlie much of the mechanocoupling. Integrins are a prime mediator of such interactions. The role for systemic hormones such as PTH, GH and 1,25(OH)2D compared to locally produced factors such as IGF-I, PTHrP, BMPs and TGF beta in modulating the cellular response to load remains unclear. Our studies demonstrate that skeletal unloading leads to resistance to the anabolic actions of IGF-I on bone as a result of failure of IGF-I to activate its own signaling pathways. This is associated with a reduction in integrin expression, suggesting crosstalk between these two pathways. As the mechanism(s) by which bone responds to changes in mechanical load with changes in bone formation is further elucidated, applications of this knowledge to other etiologies of osteoporosis are likely to develop. Skeletal unloading provides a perturbation in bone mineral homeostasis that can be used to understand the mechanisms by which bone mineral homeostasis is maintained, and that such understanding will lead to effective treatment for disuse osteoporosis in addition to preventive measures for the bone loss that accompanies space travel.

NASA Discipline Musculoskeletal↗

NASA NTRS1999

The response of bone to unloading

Skeletal unloading leads to decreased bone formation and decreased bone mass. Bone resorption is uncoupled from bone formation, contributing to the bone loss. During spaceflight bone is lost principally from the bones most loaded in the 1-g environment, and some redistribution of bone from the lower extremities to the head appears to take place. Although changes in calcitropic hormones have been demonstrated during skeletal unloading (PTH and 1,25(OH)2D decrease), it remains unclear whether such changes account for or are in response to the changes in bone formation and resorption. Bed rest studies with human volunteers and hindlimb elevation studies with rats have provided useful data to help explain the changes in bone formation during spaceflight. These models of skeletal unloading reproduce a number of the conditions associated with microgravity, and the findings from such studies confirm many of the observations made during spaceflight. Determining the mechanism(s) by which loading of bone is sensed and translated into a signal(s) controlling bone formation remains the holy grail in this field. Such investigations couple biophysics to biochemistry to cell and molecular biology. Although studies with cell cultures have revealed biochemical responses to mechanical loads comparable to that seen in intact bone, it seems likely that matrix-cell interactions underlie much of the mechanocoupling. The role for systemic hormones such as PTH, GH, and 1,25(OH)2D compared to locally produced factors such as IGF-I, PTHrP, BMPs, and TGF-beta in modulating the cellular response to load remains unclear. As the mechanism(s) by which bone responds to mechanical load with increased bone formation are further elucidated, applications of this knowledge to other etiologies of osteoporosis are likely to develop. Skeletal unloading provides a perturbation in bone mineral homeostasis that can be used to understand the mechanisms by which bone mineral homeostasis is maintained, with the expectation that such understanding will lead to effective treatment for disuse osteoporosis.

NASA Program Fundamental Space Biology↗