Laboratory Testing and Analysis through GSA

Jacobs provides engineering, construction, and operations services for the world's most complex testing, research, and development centers. Our experience includes five decades of support to the aerospace industry including the United States Department of Defense (DoD), National Aeronautics and Space Administration (NASA), Department of Energy (DoE), and commercial clients delivering and operating world class facilities to develop and test next generation technology. In addition, we have three decades of experience supporting the automotive industry in the United States , Europe , and Asia . Our experience base encompasses virtually every type of aerospace, including engine test stands, sea-level engine test cells, aerodynamic wind tunnels, arc heater facilities, acoustic enclosures, and transmission/gearbox test stands. Likewise, our automotive test facility experience encompasses climatic wind tunnels, driveability test cells, aerodynamic, acoustic, and thermodynamic wind tunnels, emissions test rooms, soak rooms, altitude chambers, engine and powertrain test cells, and electromagnetic compatibility chambers.

This experience provides us with intensive, hands-on mechanical testing experience in the evaluation and analysis of various types of equipment – ranging from the performance of full-scale aircraft and automobiles in simulation environmental conditions to the calibration of the equipment and systems utilized to execute testing activities.

Material Strength Testing – At Wright-Patterson Air Force Base, we are currently responsible for the operations and maintenance of the Landing Gear Test Facility where landing gear assemblies and components are tested. Likewise, we perform structural analysis on the various test units, including model aircraft, weapons, and engines, which undergo testing at various DoD and NASA sites where Jacobs is responsible for test operations. These sites include, but are not limited to Arnold Engineering Development Center , Aberdeen Test Center (ATC), Stennis Space Center (SSC), and Marshall Space Flight Center (MSFC). For example, at AEDC Jacobs performed analyses to determine fatigue life expended on mission critical facility components. The analyses performed in these investigations include determination of loads and cyclic stresses, and fracture and fatigue analysis to determine FLE, remaining life, and structural stability. These analyses are performed on pressure systems (i.e., piping and ducting), rotating equipment components (i.e., compressor rotors and blades) and general structural components subjected to heavy acoustic and flow turbulence conditions. We then document vibration environment and system conditions regularly. At MSFC, NASA has entrusted Jacobs to define the standard for fracture analysis, including a source for damage tolerance analysis methods. For example, Jacobs is the primary author of the NASA Fracture Control Implementation Handbook for Payloads, Experiments, and Similar Hardware. Jacobs has been tasked to assist in the development of the NASA/MSFC Fracture Control Guidelines for Composite Structures.

Mechanical Equipment Calibration/Testing – We perform calibration and testing of mechanical equipment at various sites where we are responsible for test operations. For example, at AEDC an IG inspection identified the need to improve management of the test measurement and diagnostic equipment (TMDE) under Jacobs control. We worked with fellow support contractor ACS to identify and implement all changes required to ensure AEDC was complaint with AF Technical Order 00-20-14 before AFMETCAL certification inspection in June 2002. Specifically, Jacobs implemented an IPT, provided coordinator training, ensured that all incoming TMDE was sent to PMEL for inspection, and completed the initial inventory of non-system items. Jacobs completed 39 Calibration Measurement Summaries covering 20,479 items, excessed 9,655 items, and brought 8,979 non-system items into compliance. We developed a “lights out” calibration concept to reduce costs of maintaining intermittently used test capabilities. In addition, we are also responsible for the calibration of all test equipment used at the Driveability Test Facility, where we provide test operations for two climatic wind tunnels, an aero-acoustic wind tunnel, six chassis dynamometer cells, and the associated soak rooms, garages, prep areas, and controls rooms.

Metrology – From our Metrology Laboratory in Southfield , MI , Jacobs provides a proven disciplined approach to managing, maintaining and calibrating instrumentation assets. Our A2LA scope of accreditation and certification are ISO/IEC 17025 and ISO 9001. Test and measurement equipment, sensors, and complete systems are repaired and calibrated in accordance with National Institute of Standards and Technology regulations. Measurement uncertainty analysis is also performed in this laboratory along with the development and maintenance of instrumentation ancillary equipment. We use this experience to help ensure measured results are within acceptable standards/tolerances for your application. We understand the relationship between the precision of calibrations and the precision of measurements. We have pioneered measurement uncertainty concepts and have presented numerous short courses on measurement systems throughout the aerospace and automotive industries. In fact, we co-authored NASA's 1994 Handbook of Metrology (Ref. Pub. 1342).

Acoustic/Vibration Testing – Jacobs brings extensive experience in acoustic and vibration testing for both the aerospace and automotive industries. At Aberdeen Test Center (ATC), we conduct laboratory shock, acoustic, vibration, rough handling and climatic test on various types of ammunition for combat vehicle, mortar systems, individual/crew weapons, electronic systems, and shelter systems. At Eglin Air Force Base, Jacobs personnel have developed and implemented tests techniques to capture and characterize seismic, and acoustic measurements from military vehicles operated in open air test ranges. At AEDC, we preformed Impact (shock), Vibration, and Acceleration (IVA) testing on Minuteman Stage 3 engines prior to propulsion testing in support of the Minuteman reliability program. Vibration data are also acquired and analyzed during engine tests conducted at propulsion test facilities operated by Jacobs personnel at AEDC, and the NASA facilities at Johnson Space Center , Stennis Space Center , Marshall Space Flight Center, Glenn Research Center , Langley Research Center , and Ames Research Center .

In addition, we have provided 10+ aerodynamic, aeroacoustic, and motorsports wind tunnels during the past 15 years. The aero-acoustic wind tunnel in Node 8 at the Driveability Test Facility provides aerodynamic, acoustic, and climatic powertrain testing capabilities to increase vehicle quality while decreasing design validation and production time. The Node 8 Aero-Acoustic Wind Tunnel's combination of wind speed capability and aerodynamic flow quality rank it among the elite aerodynamic wind tunnels in the world, while its operating noise levels establish it as one of the world's quietest wind tunnels for acoustic development of automobiles.

Hydraulic/Pneumatic Testing – Jacobs supplies numerous hydraulic and pneumatic systems as part of our aerospace test stand and launch facility design/build projects. The vessels and pipelines provided as part of these systems undergo stringent testing in compliance with codes and regulations to ensure that they perform in accordance with specifications. For instance, Jacobs designed and constructed the NASA X-33 Launch Facility at Edwards AFB, CA. The X-33 Launch Facility ground support systems included various pneumatic systems (i.e., high pressure GN 2 and GHe systems, GN 2 inerting and dry air purging of vehicle, gaseous oxygen, gaseous hydrogen). For the California Spaceport Commercial Launch Complex, we designed provisions for 6,000, 2,200, and 150 psig GN 2 and GH 2 distribution, LOX and RP-1 distribution, hypergolic fuel and oxidizer distribution, and breathing air distribution.

Non-Destructive Evaluation – As a major operations and maintenance support provider, non-destructive testing, leak detection and repair are essential skills in the maintenance of DoD and NASA test and launch facility. Jacobs supports the maintenance of numerous gas, hydraulic and cryogenic handling system at nine Major Range and Test Facility Bases (MRTFB), eight NASA centers, and numerous commercial test facilities, and petroleum and pharmaceutical plants. For instance, at AEDC and Eglin AFB we use x-ray systems to evaluate and inspect packaged items, and components. We also use x-rays to inspect parts and materials for defects such as cracks and void. High power pulsed x-rays are used to capture stop motion imagery of collisions and impact events. At Eglin AFB, we use x-rays for our initial evaluation of foreign weapon systems, and warhead characterization.

Environmental Simulation/Climatic Testing – Jacobs has extensive environmental simulation/climatic testing experience for both the aerospace and automotive industries. At Eglin AFB, we support climatic testing of military hardware in the McKinley Climatic chamber. At AEDC, we support space system testing at extreme temperatures and pressures in the space simulation chambers. At ATC, we operate and maintain fixed and portable environmental chambers, such as temperature and humidity, altitude, solar, salt fog, corrosion and sand/dust facilities. In the automotive industry, our experience designing and constructing environmental test facilities is unmatched as we have provided 30+ facilities in the past 15 years alone. In addition, we are currently providing test operations for wind tunnels in the United States and Germany .

Our test facilities consistently provide conditions that simulate any environmental extreme that can be found on the planet with temperatures ranging from -40°F to +140°F, wind speeds up to 155 mph, humidity from 5% to 95%, and altitudes from 700 ft below to 12,500 ft above sea level. In addition, these facilities provide road simulation via chassis dynamometers, under car simulation, solar light/heat simulation, and rain, snow, and ice simulation. Similarly, the vehicle testing capabilities vary from facility to facility, encompassing passenger cars, vans, light trucks, buses, and Class 8 heavy trucks.

Failure Analysis – In support of our operations and maintenance contracts at sites such as AEDC, we perform analyses to determine the fatigue life remaining for systems and structures subjected to dynamic and cyclic loads. We also perform failure investigations and structural repairs, modifications, and upgrades to existing structures and systems, and design of new systems. Routinely, we perform investigations of fatigue related failures in pressure systems, rotating equipment components (i.e., cracks in the compressor rotors and blades). In these cases, fatigue is the driving mechanism leading to premature failure. The analysis performed in these investigations includes determination of loads and cyclic stresses, fracture and fatigue analysis to determine expanded structural life, and remaining life and structural stability of components. These require rigorous fatigue life analyses to balance the need for maximum economic life against the high cost of failure (i.e., a failure can take a critical test capability off line for months or even years). In these cases, rigorous analyses using external load spectra converted to local stress intensities are performed to compute crack lengths. Structural finite element analysis is performed to design structures such as pressure vessels, propulsion and aerodynamic test cells, equipment support systems, and special purpose structural systems. We perform analyses using metallic and composite materials.

At Eglin AFB, Jacobs uses classical fatigue analysis techniques as well as fracture mechanics-based damage tolerance analysis on various air-carried missile components and carriage hardware to determine fatigue life. Our experience includes performing and reviewing fracture mechanics-based fatigue life analysis of various structural components of the JSOW weapon, and then reporting this data to the user community. We have also used crack growth analysis to perform failure analysis, including the determination of fatigue life expended relative to life expected on AGM-142 lug plates.

For our Design and Engineering Support Program contract at Hill AFB , Jacobs performs complete structural analyses, including static strength analyses on Navy and USAF aircraft for structural repair and modification projects involving both metallic and composite aircraft structures. Some analyses are performed using closed-form methods; however, most projects involve modeling the structure using finite element analysis. We work with provided loads – either measured or calculated – to ensure structural adequacy of the repaired component to meet the ultimate load conditions. Where observed failures are to be duplicated for failure analysis and redesign, loads may be derived through an iterative process that involves modeling the structure and duplicating the observed failure modes. This approach determines internal loads and component stresses and strains. Jacobs then uses this data to design repairs and modification and determine the margins of safety of our designs. Where warranted, we augment analytical results with representative component testing. We have experience performing structural analysis using classical, closed form techniques as well as FEA of aircraft structures to model the structure and calculate loads and stresses. We perform fatigue/crack growth analyses to predict service life of modifications.

For our Naval Air Warfare Systems Weapons Division (NAWCWD) contract, these data include a global finite element model, structural load conditions, structural concept/ configuration, structural sizing, structural stiffness, flutter results, and mass properties of the structural elements. The task of designing an air vehicle capable of hypersonic velocities is a significant challenge, because the effects of a hypersonic environment are so great and complex. The Structural Module performs sub-optimization on the designated structure design and then provides improved structural design data back to an overarching system, which uses the data in conjunction with other subsystem data for overall vehicle optimization. Structural design improvements include optimum weight, size, and stiffness of the structure while maintaining material property constraints (stress/strain limits), volume and buckling constraints, modal frequency constraints, and displacement goals. The Structural Module uses off-the-shelf codes where possible, such as NASTRAN (SOL144, SOL145, and SOL200) for much of the analysis. We were responsible for the design, development, and implementation of the IHAT system that provides the structural subsystem data associated with the overall air vehicle.

At MSFC, we have extensive experience in the structural analysis of NASA space vehicles and their components, including the Space Shuttle Main Engine Turbopump components, the Solid Rocket Booster components, Space Shuttle and Space Station payloads, rocket engine turbopumps, composite rocket engine nozzles, metallic and composite cryogenic fuel tanks, and the X-37 composite test vehicle. Jacobs has conducted structural analyses that have included determining the component-level margins of safety such as the effects of static and dynamic loads (i.e., static accelerations, random accelerations, rotational loading, crew-induced loading, external forces and pressures, and thermal environments). These analyses have ranged from classical hand analyses of critical fasteners and welds, to very detailed, highly nonlinear (i.e., large deflection, contact, material plasticity) finite element models. Our expertise includes the extensive use of PATRAN, NASTRAN, ANSYS, and ABACUS finite element software as well as Unigraphics and Pro-Engineer CAD software in executing these tasks. We have performed fracture disposition (i.e., contained, fail-safe, low-risk, or fracture critical) and fatigue analysis of both the Space Shuttle engine and primary structure components, and Space Shuttle and Space Station experiments and payloads. Fracture analyses are performed using NASGRO. Our engineers were deeply involved in the development of the friction stir weld technique for the Aluminum Lithium external tank for the Space Shuttle.

Building and Welding Inspection – We perform building and welding inspection at our operations and maintenance sites, including AEDC and Langley Research Center (LaRC). As part of our Research Operations, Maintenance, and Engineering contract, we perform site monitoring, field surveys, quality assurance, certification, and related training for modifications and upgrades to the existing buildings and test facilities at LaRC. We also performed these tasks under the predecessor Systems Engineering for Research Facility Integrated Systems (SERFIS) and Multi-Discipline Architect/Engineer Services (MAES) contracts for LaRC. For the SERFIS contract, we provided complete systems engineering of mechanical, fluid, and automation systems for research facilities, including design, development, fabrication, installation, integration and activation. For the MAES contract, we provided complete professional architectural and engineering design support, construction management and inspection services, general drafting, surveying, SPECSINTACT system support and engineering library support.

Quality Assurance – In 1995, shortly after the release of ISO 9001:1994, Jacobs chose to seek ISO registration as a method to instill greater discipline into the systems used to manage the business as a method to improve the effectiveness of our business management systems. Our corporate home office in Tullahoma , TN achieved registration in June 1998, and several additional segments of the company were ISO-certified in the immediate years following – including sites at Cape Canaveral , NASA Marshall Space Flight Center , and our Technology Group sites in Tullahoma and Detroit . Most recently, Jacobs led the ISO 9001:2000 registration effort for the Aerospace Testing Alliance (ATA) at the Arnold Engineering Development Center (AEDC).

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