On the Use of 3dB Qualification Margin for Structural Parts on Expendable Launch Vehicles

The standard random vibration qualification test used for Expendable Launch Vehicle components is Maximum Predicted Environment (MPE) + 6dB for a duration of 4 times the service life of the part. This can be a severe qualification test for these fatigue-sensitive structures. This paper uses flight data from several launch vehicles to establish that reducing the qualification approach to MPE+3dB for the duration of the peak environment (1x life) is valid for fatigue-sensitive structural components. Items that can be classified as fatigue-sensitive are probes, ducts, tubing, bellows, hoses, and any non-functional structure. Non-functional structure may be flight critical or carry fluid, but it cannot include any moving parts or electronics. This reduced qualification approach does not include primary or secondary structure which would be exclusively designed by peak loads, either transient or quasi-static, that are so large and of so few cycles as to make fatigue a moot point

The application of structural reliability techniques to plume impingement loading of the Space Station Freedom Photovoltaic Array

A new aerospace application of structural reliability techniques is presented, where the applied forces depend on many probabilistic variables. This application is the plume impingement loading of the Space Station Freedom Photovoltaic Arrays. When the space shuttle berths with Space Station Freedom it must brake and maneuver towards the berthing point using its primary jets. The jet exhaust, or plume, may cause high loads on the photovoltaic arrays. The many parameters governing this problem are highly uncertain and random. An approach, using techniques from structural reliability, as opposed to the accepted deterministic methods, is presented which assesses the probability of failure of the array mast due to plume impingement loading. A Monte Carlo simulation of the berthing approach is used to determine the probability distribution of the loading. A probability distribution is also determined for the strength of the array. Structural reliability techniques are then used to assess the array mast design. These techniques are found to be superior to the standard deterministic dynamic transient analysis, for this class of problem. The results show that the probability of failure of the current array mast design, during its 15 year life, is minute

Use of Flexible Body Coupled Loads in Assessment of Day of Launch Flight Loads

A Day of Launch flight loads assessment technique that determines running loads calculated from flexible body coupled loads was developed for the Ares I-X Flight Test Vehicle. The technique was developed to quantify DOL flight loads in terms of structural load components rather than the typically used q-alpha metric to provide more insight into the DOL loads. In this technique, running loads in the primary structure are determined from the combination of quasi-static aerodynamic loads and dynamic loads. The aerodynamic loads are calculated as a function of time using trajectory parameters passed from the DOL trajectory simulation and are combined with precalculated dynamic loads using a load combination equation. The potential change in aerodynamic load due to wind variability during the countdown is included in the load combination. In the event of a load limit exceedance, the technique allows the identification of what load component is exceeded, a quantification of how much the load limit is exceeded, and where on the vehicle the exceedance occurs. This technique was used to clear the Ares I-X FTV for launch on October 28, 2009. This paper describes the use of coupled loads in the Ares I-X flight loads assessment and summarizes the Ares I-X load assessment results