Evolution of the structural and fracture design of the ISS payloads due to the new launchers, specifically applied to Biolab IEC-2 projects

The relatively young discipline of astronautics represents one of the scientifically most fascinating and technologically advanced achievements of our time. The human exploration in space does not offer only extraordinary research possibilities but also demands high requirements from man and technology. The space environment provides a lot of attractive experimental tools towards the understanding of fundamental mechanism in natural sciences. It has been shown that especially reduced gravity and elevated radiation, two distinctive factors in space, influence the behavior of biological systems significantly. For this reason one of the key objectives on board of an earth orbiting laboratory is the research in the field of life sciences, covering the broad range from botany, human physiology and crew health up to biotechnology. The Columbus Module is the only European low gravity platform that allows researchers to perform ambitious experiments in a continuous time frame up to several months. Biolab is part of the initial outfitting of the Columbus Laboratory; it is a multi-user facility supporting research in the field of biology, e.g. effect of microgravity and space radiation on cell cultures, micro-organisms, small plants and small invertebrates. The Biolab IEC are projects designed to work in the automatic part of Biolab. In this moment in the TO-53 department of Airbus Defence & Space (formerly Astrium) there are two experiments that are in phase C/D of the development and they are the subject of this thesis: CELLRAD and CYTOSKELETON. They will be launched in soft configuration, that means packed inside a block of foam that has the task to reduce the launch loads on the payload. Until 10 years ago the payloads which were launched in soft configuration were supposed to be structural safe by themselves and a specific structural analysis could be waived on them; with the opening of the launchers market to private companies (that are not under the direct control of the international space agencies), the requirements on the verifications of payloads are changed and they have become much more conservative. In 2012 a new random environment has been introduced due to the new Space-X launch specification that results to be particularly challenging for the soft launched payloads. The last ESA specification requires to perform structural analysis on the payload for combined loads (random vibration, quasi-steady acceleration and pressure). The aim of this thesis is to create FEM models able to reproduce the launch configuration and to verify that all the margins of safety are positive and to show how they change because of the new Space-X random environment. In case the results are negative, improved design solution are implemented. Based on the FEM result a study of the joins has been carried out and, when needed, a crack growth analysis has been performed.

Structural failures due to lack of bracing

The goal of the research is to provide an overview of those factors that play a major role in structural failures and also to focus on the importance that bracing has in construction accidents. A temporary bracing system is important to construction safety, yet it is often neglected. Structural collapses often occur due to the insufficient support of loads that are applied at the time of failure. The structural load is usually analyzed by conceiving the whole structure as a completed entity, and there is frequently a lack of design or proper implementation of systems that can provide stability during construction. Often, the specific provisions and requirements of temporary bracing systems are left to the workers on the job site that may not have the qualifications or expertise for proper execution. To effectively see if bracing design should get more attention in codes and standards, failures which could have been avoided with the presence and/or the correct design of a bracing system were searched and selected among a variety of cases existing in the engineering literature. Eleven major cases were found, which span in a time frame of almost 70 years, clearly showing that the topic should get more attention. The case studies are presented in chronological order and in a systematic way. The failed structure is described in its design components and the sequence of failure is reconstructed. Then, the causes and failure mechanism are presented. Advice on how to avoid similar failures from happening again and hypothetic solutions which could have prevented the collapses are identified. The findings shows that insufficient or nonexistent bracing mainly results from human negligence or miscalculation of the load analysis and show that time has come to fully acknowledge that temporary structures should be more accounted for in design and not left to contractors' means and methods of construction.