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.

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. REPORT DOCUMENTATION PAGE REPORT DATE SECURITY CLASSIFICATION OF ABSTRACT SECURITY CLASSIFICATION OF THIS PAGEPublic reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503.

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