Stress Analysis and Testing at the Marshall Space Flight Center to Study Cause and Corrective Action of Space Shuttle External Tank Stringer Failures

After the launch scrub of Space Shuttle mission STS-133 on November 5, 2010, large cracks were discovered in two of the External Tank intertank stringers. The NASA Marshall Space Flight Center, as managing center for the External Tank Project, coordinated the ensuing failure investigation and repair activities with several organizations, including the manufacturer, Lockheed Martin. To support the investigation, the Marshall Space Flight Center formed an ad-hoc stress analysis team to complement the efforts of Lockheed Martin. The team undertook six major efforts to analyze or test the structural behavior of the stringers. Extensive finite element modeling was performed to characterize the local stresses in the stringers near the region of failure. Data from a full-scale tanking test and from several subcomponent static load tests were used to confirm the analytical conclusions. The analysis and test activities of the team are summarized. The root cause of the stringer failures and the flight readiness rationale for the repairs that were implemented are discussed

Releasable locking mechanisms

In the aerospace field spacecraft components are held together by separation systems until a specific time when they must be separated or deployed. Customarily a threaded joining bolt engages one of the components to be joined, and a threaded nut is placed on that bolt against the other component so they can be drawn together by a releasable locking assembly. The releasable locking assembly herein includes a plunger having one end coupled to one end of a plunger bolt. The other end is flanged to abut and compress a coil spring when the plunger is advanced toward the interface plane between the two components. When the plunger is so advanced toward the interface plane, the end of the plunger bolt can be connected to the joining bolt. Thus during retraction the joining bolt is drawn to one side of the interface plane by the force of the expanding spring

Seal Joint Analysis and Design for the Ares-I Upper Stage LOX Tank

The sealing capability of the Ares-I Upper Stage liquid oxygen tank-to-sump joint is assessed by analyzing the deflections of the joint components. Analyses are performed using three-dimensional symmetric wedge finite element models and the ABAQUS commercial finite element software. For the pressure loads and feedline interface loads, the analyses employ a mixed factor of safety approach to comply with the Constellation Program factor of safety requirements. Naflex pressure-assisted seals are considered first because they have been used successfully in similar seal joints in the Space Shuttle External Tank. For the baseline sump seal joint configuration with a Naflex seal, the predicted joint opening greatly exceeds the seal design specification. Three redesign options of the joint that maintain the use of a Naflex seal are studied. The joint openings for the redesigned seal joints show improvement over the baseline configuration; however, these joint openings still exceed the seal design specification. RACO pressure-assisted seals are considered next because they are known to also be used on the Space Shuttle External Tank, and the joint opening allowable is much larger than the specification for the Naflex seals. The finite element models for the RACO seal analyses are created by modifying the models that were used for the Naflex seal analyses. The analyses show that the RACO seal may provide sufficient sealing capability for the sump seal joint. The results provide reasonable data to recommend the design change and plan a testing program to determine the capability of RACO seals in the Ares-I Upper Stage liquid oxygen tank sump seal joint

Seal Analysis for the Ares-I Upper Stage Fuel Tank Manhole Cover

Techniques for studying the performance of Naflex pressure-assisted seals in the Ares-I Upper Stage liquid hydrogen tank manhole cover seal joint are explored. To assess the feasibility of using the identical seal design for the Upper Stage as was used for the Space Shuttle External Tank manhole covers, a preliminary seal deflection analysis using the ABAQUS commercial finite element software is employed. The ABAQUS analyses are performed using three-dimensional symmetric wedge finite element models. This analysis technique is validated by first modeling a heritage External Tank liquid hydrogen tank manhole cover joint and correlating the results to heritage test data. Once the technique is validated, the Upper Stage configuration is modeled. The Upper Stage analyses are performed at 1.4 times the expected pressure to comply with the Constellation Program factor of safety requirement on joint separation. Results from the analyses performed with the External Tank and Upper Stage models demonstrate the effects of several modeling assumptions on the seal deflection. The analyses for Upper Stage show that the integrity of the seal is successfully maintained

Test Analysis Correlation of the Single Stringer Bending Tests for the Space Shuttle ET-137 Intertank Stringer Crack Investigation

On November 5, 2010, Space Shuttle mission STS-133 was scrubbed due to a hydrogen leak at the Ground Umbilical Carrier Plate (GUCP). After the scrub, a crack in the foam thermal protection system (TPS) was observed on the External Tank (ET) near the interface between the liquid oxygen (LOX) tank and the Intertank. When the damaged foam was removed, two 9-in. long cracks were found on the feet of Intertank stringer S7-2, and the stringer failure was the cause of the TPS crack. An investigation was conducted to determine the root cause of the cracks, establish a remedy/repair for the stringers, and provide flight rationale for the damaged tank, ET-137. The Space Transportation System (STS) Super Lightweight ET (SLWT) is comprised of two propellant tanks (an aft liquid hydrogen (LH2) tank and a forward LOX tank) and an Intertank. The Intertank serves as the structural connection between the two propellant tanks and also functions to receive and distribute all thrust loads from the solid rocket boosters . The Intertank is a stiffened cylinder structure consisting of eight mechanically joined panels (two integrally-stiffened, machined thrust panels to react the booster loads and six stringer-stiffened skin panels). There are one main ring frame, four intermediate ring frames, and forward and aft flange chords that mate to the respective propellant tanks.. The skin/stringer panels utilize external hat-section stringers that are mechanically attached with rivets along most of their length and with specialty fasteners, such as GP Lockbolts and Hi-Loks, at the forward and aft ends where the stringers attach to the flange chords. During the STS-133 Intertank stringer crack investigation, cracks were found on a total of five stringers. All of the cracks were at the LOX end, in the feet of the stringers, and near the forward fasteners (GP Lockbolts). Video of tanking for the November 5 launch attempt was used to determine that the TPS failure, and thus the stringer failure, occurred as the LOX liquid level crossed the LOX tank / Intertank interface ring frame. Hence, cryogenically-induced displacements were suspected as a contributing cause of the stringer cracks. To study the behavior of Intertank stringers subjected to similar displacements, static load tests of individual stringers, colloquially known as "single stringer bending tests" were performed. Approximately thirty stringers were tested, many of which were cut from the partially completed Intertank for what would have been ET-139. In addition to the tests, finite element (FE) analyses of the test configuration were also performed. In this paper, the FE analyses and test-analysis correlation for stringer test S6-8 are presented. Stringer S6-8 is a "short chord" configuration with no doubler panels

Stringer Bending Test Helps Diagnose and Prevent Cracks in the Space Shuttle's External Tank

Space Shuttle Discovery's last mission, STS-133, was scheduled to launch on November 5, 2010. Just hours before liftoff, a hydrogen leak at an umbilical connection scrubbed the launch attempt. After the scrub, further inspection revealed a large crack in the foam insulation covering the External Tank, ET-137. Video replay of the launch attempt confirmed the crack first appeared as cryogenic propellants were being loaded into the ET. When the cracked foam was removed, technicians found the underlying stringer had two 9-inch-long cracks. Further inspection revealed a total of 5 of the 108 ET stringers had cracked. NASA and Lockheed Martin immediately launched an aggressive campaign to understand the cracks and repair the stringers in ET-137, targeting February 2011 as the new launch date for STS-133. Responsibilities for the various aspects of the investigation were widely distributed among NASA centers and organizations. This paper will focus on lab testing at Marshall Space Flight Center (MSFC) in Huntsville, Alabama that was intended to replicate the stringer failure and gauge the effect of proposed countermeasures

Folding and Hydrodynamics of a DNA i-Motif from the c-MYC Promoter Determined by Fluorescent Cytidine Analogs

AbstractThe four-stranded i-motif (iM) conformation of cytosine-rich DNA has importance to a wide variety of biochemical systems that range from their use in nanomaterials to potential roles in oncogene regulation. The iM structure is formed at slightly acidic pH, where hemiprotonation of cytosine results in a stable C-C+ basepair. Here, we performed fundamental studies to examine iM formation from a C-rich strand from the promoter of the human c-MYC gene. We used a number of biophysical techniques to characterize both the hydrodynamic properties and folding kinetics of a folded iM. Our hydrodynamic studies using fluorescence anisotropy decay and analytical ultracentrifugation show that the iM structure has a compact size in solution and displays the rigidity of a double strand. By studying the rates of circular dichroism spectral changes and quenching of fluorescent cytidine analogs, we also established a mechanism for the folding of a random coil oligo into the iM. In the course of determining this folding pathway, we established that the fluorescent dC analogs tC° and PdC can be used to monitor individual residues of an iM structure and to determine the pKa of an iM. We established that the C-C+ hydrogen bonding of certain bases initiates the folding of the iM structure. We also showed that substitutions in the loop regions of iMs give a distinctly different kinetic signature during folding compared with bases that are intercalated. Our data reveal that the iM passes through a distinct intermediate form between the unfolded and folded forms. Taken together, our results lay the foundation for using fluorescent dC analogs to follow structural changes during iM formation. Our technique may also be useful for examining folding and structural changes in more complex iMs

Autism Spectrum Disorder Among US Children (2002–2010): Socioeconomic, Racial, and Ethnic Disparities

Objectives. To describe the association between indicators of socioeconomic status (SES) and the prevalence of autism spectrum disorder (ASD) in the United States during the period 2002 to 2010, when overall ASD prevalence among children more than doubled, and to determine whether SES disparities account for ongoing racial and ethnic disparities in ASD prevalence

Fermion Masses and Mixing in Extended Technicolor Models

We study fermion masses and mixing angles, including the generation of a seesaw mechanism for the neutrinos, in extended technicolor (ETC) theories. We formulate an approach to these problems that relies on assigning right-handed $Q=-1/3$ quarks and charged leptons to ETC representations that are conjugates of those of the corresponding left-handed fermions. This leads to a natural suppression of these masses relative to the $Q=2/3$ quarks, as well as the generation of quark mixing angles, both long-standing challenges for ETC theories. Standard-model-singlet neutrinos are assigned to ETC representations that provide a similar suppression of neutrino Dirac masses, as well as the possibility of a realistic seesaw mechanism with no mass scale above the highest ETC scale of roughly $10^3$ TeV. A simple model based on the ETC group SU(5) is constructed and analyzed. This model leads to non-trivial, but not realistic mixing angles in the quark and lepton sectors. It can also produce sufficiently light neutrinos, although not simultaneously with a realistic quark spectrum. We discuss several aspects of the phenomenology of this class of models.Comment: 74 pages, revtex with embedded figure