Current Projects List

*STS-107 Columbia Accident Investigation

Applied high-fidelity computational fluid dynamics (CFD), thermal and structural analyses to simulate the

initiation and propagation of thermal/structural failure in the Shuttle’s left wing during atmospheric reentry. 

Key Accomplishments: Multiple failure mechanisms were treated including insulation material and failure of RCC panels.

*Honeywell Engine Combustor Development

Centered on enhancement of GENOA to simulate 2D/3D-braided/woven CMC materials.

Key Accomplishments: Verification of GENOA predictions were made relative to CMC strength, stiffness, and creep rupture. 

*Optimizing Composite Rocket Motor Development Using Advanced Evolutionary Algorithms

Developed advanced software suite for analysis and optimization of filament-wound composite rocket motors. 

Key Accomplishments: Optimized high fidelity manufacturing and structural design modules. The process included Geometry, Thermal Analysis,

and Manufacturing Simulation.

*Army Composite Assault Bridge Repair

Identified a number of potential repair procedures. The Army TARDEC sponsored program - SBIR

Key Accomplishments: GENOA Modeling and Simulation for progressive failure analysis was performed on the Composite Army Bridge (CAB) design.

Through the analysis, several extreme-loading conditions were considered; locations and modes of failure were identified.

*Navy -Simplified Analytical Procedure for Prediction of Fracture Damage in Composite Structures

Alpha Star developed a simplified composite analytical life prediction procedure (SAPGEN).

Key Accomplishments:  Completed the development of Material Constituent Analysis (MCA), Material Uncertainty Analysis (MUA), and Fracture Damage modules.

*Design of X-37 Orbital Vehicle

Accurate design and safety margins were the scope of this project.   

Key Accomplishments: Identified potential mission-critical failure modes.  Improved safety by targeting predicted premature failures.

*Collaborative Virtual Testing & Space Shuttle Columbia Accident Investigation

The Boeing Company and Alpha STAR utilized the Collaborative Virtual Testing (CVT) to simulate the STS-107 Space Shuttle Columbia accident.

Key Accomplishments: Collaboration of ASC and Boeing engineers through the CVT program was successfully accomplished.

Past Projects List

*Boeing/NASA Space Launch Initiative: (SLI)

Metallic Tank Analysis

Key Accomplishments: Manufacturing simulation and accelerated testing of metallic tank were performed.

Composite Fuel Tank Analysis

 Key Accomplishments: Composite tank leakage was simulated under cryogenic conditions including test data verification.

 Accelerated Testing

 Key Accomplishments:  Utilized alternative thermo-mechanical loads to minimize mission cycle test subject to maximum damage during 

   test.

 *Aerodynamic loads

 Key Accomplishments: Configuration trade study, aerodynamic support of Computational Fluid Dynamics (CFD) was completed.

*Crew Escape, Recovery, and Survivability

Key Accomplishments:  Impact and survivability analysis was performed.

*Boeing-X-37 Mini-Space Plane Life Prediction and Certification Process

Key Accomplishments: X37 full-scale model including C/Sic flaperon and manufacturing process simulation of C/SIC panels were successfully simulated.

*Static and Fatigue Life Predictions for X-37 under 3g Loading Condition

Key Accomplishments:  X-37 full-scale model was simulated for fatigue and life prediction.

 *Simulation of B-52 Drop Test

 Key Accomplishments: X-37 full-scale model was simulated. Power spectrum density loading condition, multi-site damage initiation,

 and damage propagation to final life were analyzed.

 *C/SiC T-joint Analysis

 Key Accomplishments: The effect of stitch on damage initiation and propagation determined delay of damage initiation. Sensitivity of the

 damage response to design variables was identified.

 *NASA Langley Carbon/SiC Flaperon

 Key Accomplishments: Determined the fractional contribution of failure modes to the failure mechanisms for critical damage events

 (Damage initiation, damage propagation, fracture initiation, fracture propagation, final failure). 

 *C/SiC Manufacturing Cool Down Process

 Key Accomplishments:  Test showed that the composite properties were reduced during manufacturing process. The degradation of composite properties

 (strength, and stiffness) was simulated and matched  favorably with test data.

*NASA/HQ Collaborative Virtual Testing Partnerships (ASC/Boeing/NASA LaRC)    

 Boeing Anaheim

 Key Accomplishments:  Predicted GPS transmission failure under random vibration and thermal environment. 

 Boeing Space Huntington Beach

 Key Accomplishments: Simulated failure of Delta II tank and Delta II rocket manufacturing anomalies.

 Boeing Space Huntington Beach

 Key Accomplishments:  Determined metallic material fracture toughness and fatigue crack growth.  

 Predicted material uncertainty effect on fatigue crack growth and fracture toughness.  

 *NASA/LaRC and Boeing Commercial (Long Beach) Static/Fatigue Analysis

 Key Accomplishments: Static/Fatigue analysis of Integrally Assembled Structure (IAS) Aluminum Panel Lap Joint was verified against NASA test

 Data.  Moreover, Boeing 747 Fuselage Crown Panel static and fatigue analyses were compared to Boeing test data for damage

 predication and design modification. 

 *Boeing St. Louis (Phantom works)  - Coupon Test Reduction and Life Assessment

 Key Accomplishments:  Used aluminum coupon simulations to predict the simple shape of coupons to complex wing failure under fatigue.

*Air Force /Wright Lab

Key Accomplishments: A one-inch wide IM-7/5250 laminated coupon with 0/90/0 lay-up under unidirectional tension was simulated. Damage initiation was compared with test data.  The analyses results matched test data. 

*Boeing (Long Beach) and NASA/LaRC - Analysis of DSD in S/RFI Commercial Aircraft

Key Accomplishments:  Software verification against eight three stringer tension, and compression tests, building block verification strategy (from coupon, element, panel), prediction of critical damage events.

*STI-Optronics/DOD- AirBorne Laser Reactor Housing

Key Accomplishments: GENOA durability and damage tolerance (D&DT) simulation was successfully used to predict susceptibility to damage under service loading. Design modifications to prevent structural failure were accomplished.

*Boeing Military (Seattle) - Fracture Toughness Simulation of Un-reinforced Composite Beam

Key Accomplishments: Conducted fracture toughness analysis simulating the un-reinforced DCB test specimen to determine the fracture toughness of composite material and to compare with available experimental results.

*Boeing Space Huntington Beach Delta IV Impact and Compression after Impact

Key Accomplishments: A foam core sandwich panel that was experimentally impacted prior to testing in compression was subsequently analyzed by GENOA.

The impact module in GENOA was used to simulate the impacting processes and the damage caused.

*Allied Signal Engine Combustor Development 

Key Accomplishments:  Centered on enhancement of GENOA to simulate 2D/3D-braided/woven Ceramic Matrix Composite materials with respect to:  3D woven/braided fiber architecture and tracking micro/macro damage (initiation, accumulation, stable growth, and fracture) for life prediction under fatigue and creep loading.

*NASA/LaRC - Composite Material Characterizations Under Cryogenic Conditions

Key Accomplishments: Evaluated the property changes in coefficient of thermal expansion (CTE), Poisson’s ratio, and fatigue degradation under various temperature and pressure loads.

*NASA/LaRC - Composite Satellite Solar Sail Wrinkling

Key Accomplishments: Predicted wrinkling as the result of radiation or various temperature changes. Predicted out-of-plane displacements under load, and determined loads configuration that would significantly reduce and eliminate wrinkling. 

*Honeywell/NASA (GRC) - High Temperature Composite Engine Life Prediction

Key Accomplishments: Predicted Honeywell Engine systems ceramic (SiC/SiC) combustor life at high temperatures. Predicted combustor life under RIG/engine conditions (creep test) and life uncertainty predictions for material variations (strength & moduli).

*NASA/LaRC, and Boeing Jet Cruiser - 21st Century Wing

Key Accomplishments: Predicted reliability increase by a factor of 100.  Reduced the weight by changing internal structure (i.e spar, height, width, skin thickness).

*US Army/Navy Composite Pre-form Pressure tube Testing

Key Accomplishments: Predicted durability and displacement of preform air pressurized beam tube under bending test and snow load. 

*Boeing - High Speed Civil Transport

Key Accomplishments: Performed trade study of aerodynamic CFD Canard configuration. Structural optimization of several wing/fuselage configurations were performed and compared with test data. 

*Department of Transportation (CALTRANS) – Long Beach Composite Bridge Deck

Key Accomplishments: Simulated fatigue and life prediction under thermal and traffic loading conditions.