Composite Payload Fairing Structural Architecture Assessment and Selection

This paper provides a summary of the structural architecture assessments conducted and a recommendation for an affordable high performance composite structural concept to use on the next generation heavy-lift launch vehicle, the Space Launch System (SLS). The Structural Concepts Element of the Advanced Composites Technology (ACT) project and its follow on the Lightweight Spacecraft Structures and Materials (LSSM) project was tasked with evaluating a number of composite construction technologies for specific Ares V components: the Payload Shroud, the Interstage, and the Core Stage Intertank. Team studies strived to address the structural challenges, risks and needs for each of these vehicle components. Leveraging off of this work, the subsequent Composites for Exploration (CoEx) effort is focused on providing a composite structural concept to support the Payload Fairing for SLS. This paper documents the evaluation and down selection of composite construction technologies and evolution to the SLS Payload Fairing. Development of the evaluation criteria (also referred to as Figures of Merit or FOMs), their relative importance, and association to vehicle requirements are presented. A summary of the evaluation results, and a recommendation of the composite concept to baseline in the Composites for Exploration (CoEx) project is presented. The recommendation for the SLS Fairing is a Honeycomb Sandwich architecture based primarily on affordability and performance with two promising alternatives, Hat stiffened and Fiber Reinforced Foam (FRF) identified for eventual program block upgrade

Evaluation of Separation Mechanism Design for the Orion/Ares Launch Vehicle

As a part of the preliminary design work being performed for the Orion vehicle, the Orion to Spacecraft Adaptor (SA) separation mechanism was analyzed and sized, with findings presented here. Sizing is based on worst case abort condition as a result of an anomaly driving the launch vehicle engine thrust vector control hard-over causing a severe vehicle pitch over. This worst case scenario occurs just before Upper Stage Main Engine Cut-Off (MECO) when the vehicle is the lightest and the damping effect due to propellant slosh has been reduced to a minimum. To address this scenario and others, two modeling approaches were invoked. The first approach was a detailed Simulink model to quickly assess the Service Module Engine nozzle to SA clearance for a given separation mechanism. The second approach involved the generation of an Automatic Dynamic Analysis of Mechanical Systems (ADAMS) model to assess secondary effects due to mass centers of gravity that were slightly off the vehicle centerline. It also captured any interference between the Solar Arrays and the Spacecraft Adapter. A comparison of modeling results and accuracy are discussed. Most notably, incorporating a larger SA flange diameter allowed for a natural separation of the Orion and it's engine nozzle even at relatively large pitch rates minimizing the kickoff force. Advantages and disadvantages of the Simulink model vs. a full geometric ADAMS model are discussed as well

A Numerical Study on the Effect of Facesheet-Core Disbonds on the Buckling Load of Curved Honeycomb Sandwich Panels

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance approach for the next-generation Space Launch System heavy lift vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method. Facesheet and core nodes in a predetermined circular region were detached to simulate a disbond induced via low-speed impact between the outer mold line facesheet and honeycomb core. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. A significant change in the slope of the edge load-deflection response was used to determine the onset of global buckling and corresponding buckling load

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: Comparison of In- and Out-of-Autoclave Facesheet Configurations

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10-m diameter barrel section of the Heavy Lift Launch Vehicle, were manufactured and tested under the NASA Composites for Exploration and the NASA Constellation Ares V programs. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.0 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: in-autoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3 ft. by 5 ft. panels were cut from the 1/16th barrel sections and tested under compressive loading. Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of each 3 ft. by 5 ft. panel. To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yielded good qualitative and quantitative predictions. Additionally, it was correctly predicted that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber angle misalignments, and three-dimensional effects on the compressive response of the panel

Position and momentum mapping of vibrations in graphene nanostructures in the electron microscope

Propagating atomic vibrational waves, phonons, rule important thermal, mechanical, optoelectronic and transport characteristics of materials. Thus the knowledge of phonon dispersion, namely the dependence of vibrational energy on momentum is a key ingredient to understand and optimize the material's behavior. However, despite its scientific importance in the last decade, the phonon dispersion of a freestanding monolayer of two dimensional (2D) materials such as graphene and its local variations has still remained elusive because of experimental limitations of vibrational spectroscopy. Even though electron energy loss spectroscopy (EELS) in transmission has recently been shown to probe the local vibrational charge responses, these studies are yet limited to polar materials like boron nitride or oxides, in which huge signals induced by strong dipole moments are present. On the other hand, measurements on graphene performed by inelastic x-ray (neutron) scattering spectroscopy or EELS in reflection do not have any spatial resolution and require large microcrystals. Here we provide a new pathway to determine the phonon dispersions down to the scale of an individual freestanding graphene monolayer by mapping the distinct vibration modes for a large momentum transfer. The measured scattering intensities are accurately reproduced and interpreted with density functional perturbation theory (DFPT). Additionally, a nanometre-scale mapping of selected momentum (q) resolved vibration modes using graphene nanoribbon structures has enabled us to spatially disentangle bulk, edge and surface vibrations

Design and Fabrication of the ISTAR Direct-Connect Combustor Experiment at the NASA Hypersonic Tunnel Facility

The Integrated Systems Test of an Airbreathing Rocket (ISTAR) project was a flight demonstration project initiated to advance the state of the art in Rocket Based Combined Cycle (RBCC) propulsion development. The primary objective of the ISTAR project was to develop a reusable air breathing vehicle and enabling technologies. This concept incorporated a RBCC propulsion system to enable the vehicle to be air dropped at Mach 0.7 and accelerated up to Mach 7 flight culminating in a demonstration of hydrocarbon scramjet operation. A series of component experiments was planned to reduce the level of risk and to advance the technology base. This paper summarizes the status of a full scale direct connect combustor experiment with heated endothermic hydrocarbon fuels. This is the first use of the NASA GRC Hypersonic Tunnel facility to support a direct-connect test. The technical and mechanical challenges involved with adapting this facility, previously used only in the free-jet configuration, for use in direct connect mode will be also described

Lessons Learned from the Construction of Upgrades to the NASA Glenn Icing Research Tunnel and Re-activation Testing

Major upgrades were made in 1999 to the 6- by 9-Foot (1.8- by 2.7-m) Icing Research Tunnel (IRT) at the NASA Glenn Research Center. These included replacement of the electronic controls for the variable-speed drive motor, replacement of the heat exchanger, complete replacement and enlargement of the leg of the tunnel containing the new heat-exchanger, the addition of flow-expanding and flow-contracting turning vanes upstream and downstream of the heat exchanger, respectively, and the addition of fan outlet guide vanes (OGV's). This paper presents an overview of the construction and reactivation testing phases of the project. Important lessons learned during the technical and contract management work are documented

Three-dimensional Imaging Reveals New Compartments and Structural Adaptations in Odontoblasts

In organized tissues, the precise geometry and the overall shape are critical for the specialized functions that the cells carry out. Odontoblasts are major matrix-producing cells of the tooth and have also been suggested to participate in sensory transmission. However, refined morphologic data on these important cells are limited, which hampers the analysis and understanding of their cellular functions. We took advantage of fluorescent color-coding genetic tracing to visualize and reconstruct in 3 dimensions single odontoblasts, pulp cells, and their assemblages. Our results show distinct structural features and compartments of odontoblasts at different stages of maturation, with regard to overall cellular shape, formation of the main process, orientation, and matrix deposition. We demonstrate previously unanticipated contacts between the processes of pulp cells and odontoblasts. All reported data are related to mouse incisor tooth. We also show that odontoblasts express TRPM5 and Piezo2 ion channels. Piezo2 is expressed ubiquitously, while TRPM5 is asymmetrically distributed with distinct localization to regions proximal to and within odontoblast processes