The structural efficiency of carbon-epoxy tapered struts is considered through trade studies, detailed analysis, manufacturing and experimentation. Since some of the lunar lander struts are more highly loaded than struts used in applications such as satellites and telescopes, the primary focus of the effort is on these highly loaded struts. Lunar lander requirements include that the strut has to be tapered on both ends, complicating the design and limiting the manufacturing process. Optimal stacking sequences, geometries, and materials are determined and the sensitivity of the strut weight to each parameter is evaluated. The trade study results indicate that the most efficient carbon-epoxy struts are 30 percent lighter than the most efficient aluminum-lithium struts. Structurally efficient, highly loaded struts were fabricated and loaded in tension and compression to determine if they met the design requirements and to verify the accuracy of the analyses. Experimental evaluation of some of these struts demonstrated that they could meet the greatest Altair loading requirements in both tension and compression. These results could be applied to other vehicles requiring struts with high loading and light weight.

In recent years, fiber-reinforced composites have become more accepted for aerospace applications. Specifically, during NASA's recent efforts to develop new launch vehicles, composite materials were considered and baselined for a number of structures. Because of mass and stiffness requirements, sandwich composites are often selected for many applications. However, there are a number of manufacturing and in-service concerns associated with traditional honeycomb-core sandwich composites that in certain instances may be alleviated through the use of other core materials or construction methods. Flutedcore, which consists of integral angled web members with structural radius fillers spaced between laminate face sheets, is one such construction alternative and is considered herein. Two different fluted-core designs were considered: a subscale design and a full-scale design sized for a heavy-lift-launch-vehicle interstage. In particular, axial compression of flutedcore composites was evaluated with experiments and finite-element analyses (FEA); axial compression is the primary loading condition in dry launch-vehicle barrel sections. Detailed finite-element models were developed to represent all components of the fluted-core construction, and geometrically nonlinear analyses were conducted to predict both buckling and material failures. Good agreement was obtained between test data and analyses, for both local buckling and ultimate material failure. Though the local buckling events are not catastrophic, the resulting deformations contribute to material failures. Consequently, an important observation is that the material failure loads and modes would not be captured by either linear analyses or nonlinear smeared-shell analyses. Compression-after-impact (CAI) performance of fluted-core composites was also investigated by experimentally testing samples impacted with 6 ft.-lb. impact energies. It was found that such impacts reduced the ultimate load carrying capability by approximately 40% on the subscale test articles and by less than 20% on the full-scale test articles. Nondestructive inspection of the damage zones indicated that the detectable damage was limited to no more than one flute on either side of any given impact. More study is needed, but this may indicate that an inherent damagearrest capability of fluted core could provide benefits over traditional sandwich designs in certain weight-critical applications.

The primary loading condition in launch-vehicle barrel sections is axial compression, and it is therefore important to understand the compression behavior of any structures, structural concepts, and materials considered in launch-vehicle designs. This understanding will necessarily come from a combination of test and analysis. However, certain potentially beneficial structures and structural concepts do not lend themselves to commonly used simplified analysis methods, and therefore innovative analysis methodologies must be developed if these structures and structural concepts are to be considered. This paper discusses such an analysis technique for the fluted-core sandwich composite structural concept. The presented technique is based on commercially available finite-element codes, and uses shell elements to capture behavior that would normally require solid elements to capture the detailed mechanical response of the structure. The shell thicknesses and offsets using this analysis technique are parameterized, and the parameters are adjusted through a heuristic procedure until this model matches the mechanical behavior of a more detailed shell-and-solid model. Additionally, the detailed shell-and-solid model can be strategically placed in a larger, global shell-only model to capture important local behavior. Comparisons between shell-only models, experiments, and more detailed shell-and-solid models show excellent agreement. The discussed analysis methodology, though only discussed in the context of fluted-core composites, is widely applicable to other concepts.

The structural efficiency of carbon-epoxy tapered struts is considered through trade studies, detailed analysis, manufacturing and experimentation. Since some of the lunar lander struts are more highly loaded than struts used in applications such as satellites and telescopes, the primary focus of the effort is on these highly loaded struts. Lunar lander requirements include that the strut has to be tapered on both ends, complicating the design and limiting the manufacturing process. Optimal stacking sequences, geometries, and materials are determined and the sensitivity of the strut weight to each parameter is evaluated. The trade study results indicate that the most efficient carbon-epoxy struts are 30 percent lighter than the most efficient aluminum-lithium struts. Structurally efficient, highly loaded struts were fabricated and loaded in tension and compression to determine if they met the design requirements and to verify the accuracy of the analyses. Experimental evaluation of some of these struts demonstrated that they could meet the greatest Altair loading requirements in both tension and compression. These results could be applied to other vehicles requiring struts with high loading and light weight.

Generation Orbit (GO) is developing the GO Launcher-1 (GO-1), a single stage liquid rocket that is launched from a Gulfstream III carrier aircraft platform. The vehicle is designed as the next generation platform for hypersonic flight testing and suborbital microgravity research. To reduce mass and increase payload, GO partnered with NASA Langley Research Center to design, analyze, optimize, and fabricate a tow-steered manufacturing development unit of a cylindrical section of a liquid oxygen tank. The fabrication process of using the ISAAC (Integrated Structural Assembly of Advanced Composites) system is described. The structural design challenges and the concept design solutions are also presented to provide the context for the fabrication process. The in-situ nondestructive evaluation supporting the effort is also described.