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November 4, 2009: Full scale static test of the NASA Composite Crew Module tested today at Langley Research Center. HyperSizer predictions match all test measurements. HyperSizer was used by NASA team to perform structural analysis and margins-of-safety predictions for test.
“Since the structure is designed to minimum margins in many areas, the ultimate test exercised the structure close to the minimum material properties and I assure you there was celebration amongst the team when we achieved that critical milestone!” Mike Kirsch, CCM Project Manager
This is a milestone achievement for HyperSizer software, the NASA Composite Crew Module design team, and the nation’s plans for future use of composites in space vehicles. Over the last 3 years, HyperSizer has been used as a primary tool by NASA to design and analyze the composite variant of the metallic Orion crew module which is to house the astronauts throughout the flight mission from launch to ocean splashdown. The CCM constructed of honeycomb sandwich panels and solid laminates is weight optimized to over fifty loading scenarios. Three of these loadings were selected for test validation: internal pressurization, parachute pull, and abort launch system thrust force. Today’s test conducted at Langley pushed the envelope to the highest design-to loads that the CCM will ever experience, ultimate pressure of 31.1 psi, which is 200% of the limit pressure. In every load case tested to date, HyperSizer accurately predicted the structural response strain gage readings of the composite material under loading – and more importantly achieved the required loading without structural failure.
Partners: Led by the NASA Engineering and Safety Center’s (NESC), the project team is a partnership between NASA and industry, including design, manufacturing, and tooling expertise. Partners are civil servants from nine NASA Centers - ARC, DFRC, GRC, GSFC, JSC, JPL, KSC, LaRC, and MSFC; the Air Force Research Laboratories; and contractors from Alcore, ATK, Bally Ribbon Mills, Collier Research Corporation (HyperSizer), Genesis Engineering, Janicki Industries, Lockheed Martin, and Northrop Grumman. The CCM team operates in a virtual environment, electronically connecting participants across the country.
The "as manufactured" full scale Composite Crew Module primary structure with fiber optic and traditional strain gauges attached. Additional test data instrumentation included optical and acoustic.
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