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  • NASA/TM-2004-212039

    Combined Loads Test Fixture for Thermal-Structural Testing Aerospace Vehicle Panel Concepts

    Roger A. FieldsAnalytical Services and Materials, Inc.Edwards, California

    W. Lance RichardsNASA Dryden Flight Research CenterEdwards, California

    Michael V. DeAngelisPAT Projects, Inc.Lancaster, California

    February 2004

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  • NASA/TM-2004-212039

    Combined Loads Test Fixture for Thermal-Structural Testing Aerospace Vehicle Panel Concepts

    Roger A. FieldsAnalytical Services and Materials, Inc.Edwards, California

    W. Lance RichardsNASA Dryden Flight Research CenterEdwards, California

    Michael V. DeAngelisPAT Projects, Inc.Lancaster, California

    February 2004

    National Aeronautics andSpace Administration

    Dryden Flight Research CenterEdwards, California 93523-0273

  • NOTICE

    Use of trade names or names of manufacturers in this document does not constitute an official endorsementof such products or manufacturers, either expressed or implied, by the National Aeronautics andSpace Administration.

    Available from the following:

    NASA Center for AeroSpace Information (CASI) National Technical Information Service (NTIS)7121 Standard Drive 5285 Port Royal RoadHanover, MD 21076-1320 Springfield, VA 22161-2171(301) 621-0390 (703) 487-4650

  • iii

    CONTENTS

    Page

    ABSTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    SIDE SHEAR PANEL TEST REQUIREMENTS

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    SIDE SHEAR PANEL TEST ARTICLE

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    DETAILED TEST FIXTURE DESIGN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Mechanical Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

    Test Article . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Vertical Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Self-Reacting Load Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    Thermal Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Requirement and Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

    TEST FIXTURE FABRICATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Outer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Axial Load Alignment Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Vertical Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

    TEST FIXTURE DESIGN VALIDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Structural Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Thermal Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

    RESULTS AND DISCUSSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

    CONCLUDING REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

    REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

  • iv

    TABLES

    1. Instrumentation summary for the side shear panel test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

    2. Test sequence for the side shear panel program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

    3. Average percent differences between finite-element analyses and test data . . . . . . . . . . . . . . . . . . . 32

    4. Minimum (min) and maximum (max) principal strains (p-strain) and directions (angle) for four test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

    5. Measured shear strain for four test conditions compared to data from room temperature analyses. . . 51

    FIGURES

    1. Side shear panel location on the X-30 concept vehicle illustrating a positive shear load (N

    xy

    ) combined with a comprehensive axial load (N

    x

    ) relative to the x-y coordinate system. . . . . . . . . . . . 2

    2. Exploded view of the titanium matrix composite (TMC) side shear panel assembly . . . . . . . . . . . . . 4

    3. Sketch of the side shear panel test article assembly, viewed from the hat-stiffened side. . . . . . . . . . . 4

    4. Side shear panel test article assembly, viewed from the hat-stiffened side . . . . . . . . . . . . . . . . . . . . . 5

    5. Test article assembly, viewed from the hat-stiffened side, with combined positive shear and positive axial loads illustrated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

    6. Test article assembly mounted in the test fixture, viewed from the hat-stiffened side (drawing not to scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

    7. Combined loads test fixture details of the out-of-plane motion constraints (with the test fixture removed for clarity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

    8. Attachment point K (fig. 6) detail for a