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NASA NTRS2017

NASA's Robotics Mining Competition Provides Undergraduates Full Life Cycle Systems Engineering Experience

NASA has held an annual robotic mining competition for teams of university/college students since 2010. This competition is yearlong, suitable for a senior university engineering capstone project. It encompasses the full project life cycle from ideation of a robot design to actual tele-operation of the robot in simulated Mars conditions mining and collecting simulated regolith. A major required element for this competition is a Systems Engineering Paper in which each team describes the systems engineering approaches used on their project. The score for the Systems Engineering Paper contributes 25% towards the team's score for the competition's grand prize. The required use of systems engineering on the project by this competition introduces the students to an intense practical application of systems engineering throughout a full project life cycle.

Stecklein, Jonette↗
NASA NTRS2017

NASA's Robotic Mining Competition Provides Undergraduates Full Life Cycle Systems Engineering Experience

NASA has held an annual robotic mining competition for teams of university/college students since 2010. This competition is yearlong, suitable for a senior university engineering capstone project. It encompasses the full project life cycle from ideation of a robot design, through tele-operation of the robot collecting regolith in simulated Mars conditions, to disposal of the robot systems after the competition. A major required element for this competition is a Systems Engineering Paper in which each team describes the systems engineering approaches used on their project. The score for the Systems Engineering Paper contributes 25% towards the team’s score for the competition’s grand prize. The required use of systems engineering on the project by this competition introduces the students to an intense practical application of systems engineering throughout a full project life cycle.

Stecklein, Jonette↗
NASA NTRS2016

Preliminary Results From a Heavily Instrumented Engine Ice Crystal Icing Test in a Ground Based Altitude Test Facility

Preliminary results from the Heavily Instrumented ALF503R-5 Engine test conducted in the NASA Glenn Research Center Propulsion Systems Laboratory will be discussed. The effects of ice crystal icing on a full scale engine is examined and documented. This model engine, serial number LF01, was used during the inaugural icing test in the PSL facility. The reduction of thrust (rollback) events experienced by this engine in flight were replicated in the facility. Limited instrumentation was used to detect icing. Metal temperature on the exit guide vanes and outer shroud and the load measurement were the only indicators of ice formation. The current study features a similar engine, serial number LF11, which is instrumented to characterize the cloud entering the engine, detect characterize ice accretion, and visualize the ice accretion in the region of interest.

enigine icing↗
NASA NTRS2017

Digital Model-Based Engineering: Expectations, Prerequisites, and Challenges of Infusion

Digital model-based engineering (DMbE) is the use of digital artifacts, digital environments, and digital tools in the performance of engineering functions. DMbE is intended to allow an organization to progress from documentation-based engineering methods to digital methods that may provide greater flexibility, agility, and efficiency. The term 'DMbE' was developed as part of an effort by the Model-Based Systems Engineering (MBSE) Infusion Task team to identify what government organizations might expect in the course of moving to or infusing MBSE into their organizations. The Task team was established by the Interagency Working Group on Engineering Complex Systems, an informal collaboration among government systems engineering organizations. This Technical Memorandum (TM) discusses the work of the MBSE Infusion Task team to date. The Task team identified prerequisites, expectations, initial challenges, and recommendations for areas of study to pursue, as well as examples of efforts already in progress. The team identified the following five expectations associated with DMbE infusion, discussed further in this TM: (1) Informed decision making through increased transparency, and greater insight. (2) Enhanced communication. (3) Increased understanding for greater flexibility/adaptability in design. (4) Increased confidence that the capability will perform as expected. (5) Increased efficiency. The team identified the following seven challenges an organization might encounter when looking to infuse DMbE: (1) Assessing value added to the organization. Not all DMbE practices will be applicable to every situation in every organization, and not all implementations will have positive results. (2) Overcoming organizational and cultural hurdles. (3) Adopting contractual practices and technical data management. (4) Redefining configuration management. The DMbE environment changes the range of configuration information to be managed to include performance and design models, database objects, as well as more traditional book-form objects and formats. (5) Developing information technology (IT) infrastructure. Approaches to implementing critical, enabling IT infrastructure capabilities must be flexible, reconfigurable, and updatable. (6) Ensuring security of the single source of truth (7) Potential overreliance on quantitative data over qualitative data. Executable/ computational models and simulations generally incorporate and generate quantitative vice qualitative data. The Task team also developed several recommendations for government, academia, and industry, as discussed in this TM. The Task team recommends continuing beyond this initial work to further develop the means of implementing DMbE and to look for opportunities to collaborate and share best practices.

Hale, J. P.↗
NASA NTRS2016

Expanded Guidance for NASA Systems Engineering. Volume 2: Crosscutting Topics, Special Topics, and Appendices

Historically, most successful NASA projects have depended on effectively blending project management, systems engineering, and technical expertise among NASA, contractors, and third parties. Underlying these successes are a variety of agreements (e.g., contract, memorandum of understanding, grant, cooperative agreement) between NASA organizations or between NASA and other Government agencies, Government organizations, companies, universities, research laboratories, and so on. To simplify the discussions, the term "contract" is used to encompass these agreements. This section focuses on the NASA systems engineering activities pertinent to awarding a contract, managing contract performance, and completing a contract. In particular, NASA systems engineering interfaces to the procurement process are covered, since the NASA engineering technical team plays a key role in the development and evaluation of contract documentation. Contractors and third parties perform activities that supplement (or substitute for) the NASA project technical team accomplishment of the NASA common systems engineering technical process activities and requirements outlined in this guide. Since contractors might be involved in any part of the systems engineering life cycle, the NASA project technical team needs to know how to prepare for, allocate or perform, and implement surveillance of technical activities that are allocated to contractors.

Steven R Hirshorn↗
NASA NTRS2017

JANNAF "Test and Evaluation Guidelines for Liquid Rocket Engines": Status and Application

For many decades, the U.S. rocket propulsion industrial base has performed remarkably in developing complex liquid rocket engines that can propel critical payloads into service for the nation, as well as transport people and hardware for missions that open the frontiers of space exploration for humanity. This has been possible only at considerable expense given the lack of detailed guidance that captures the essence of successful practices and knowledge accumulated over five decades of liquid rocket engine development. In an effort to provide benchmarks and guidance for the next generation of rocket engineers, the Joint Army Navy NASA Air Force (JANNAF) Interagency Propulsion Committee published a liquid rocket engine (LRE) test and evaluation (T&E) guideline document in 2012 focusing on the development challenges and test verification considerations for liquid rocket engine systems. This document has been well received and applied by many current LRE developers as a benchmark and guidance tool, both for government-driven applications as well as for fully commercial ventures. The USAF Space and Missile Systems Center (SMC) has taken an additional near-term step and is directing activity to adapt and augment the content from the JANNAF LRE T&E guideline into a standard for potential application to future USAF requests for proposals for LRE development initiatives and launch vehicles for national security missions. A draft of this standard was already sent out for review and comment, and is intended to be formally approved and released towards the end of 2017. The acceptance and use of the LRE T&E guideline is possible through broad government and industry participation in the JANNAF liquid propulsion committee and associated panels. The sponsoring JANNAF community is expanding upon this initial baseline version and delving into further critical development aspects of liquid rocket propulsion testing at the integrated stage level as well as engine component level, in order to advance the state of the practice. The full participation of the entire U.S. rocket propulsion industrial base is invited and expected at this opportune moment in the continuing advancement of spaceflight technology.

Parkinson, Douglas↗
NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗
NASA NTRS2017

Control Design for an Advanced Geared Turbofan Engine

This paper describes the design process for the control system of an advanced geared turbofan engine. This process is applied to a simulation that is representative of a 30,000 pound-force thrust class concept engine with two main spools, ultra-high bypass ratio, and a variable area fan nozzle. Control system requirements constrain the non-linear engine model as it operates throughout its flight envelope of sea level to 40,000 feet and from 0 to 0.8 Mach. The purpose of this paper is to review the engine control design process for an advanced turbofan engine configuration. The control architecture selected for this project was developed from literature and reflects a configuration that utilizes a proportional integral controller with sets of limiters that enable the engine to operate safely throughout its flight envelope. Simulation results show the overall system meets performance requirements without exceeding operational limits.

system modeling↗
NASA NTRS2016

Analysis of a Radioisotope Thermal Rocket Engine

The Triton Hopper is a concept for a global hopper vehicle which uses a radioisotope rocket engine and In-situ propellant acquisition to explore the surface of Neptune's moon, Triton. The current Triton Hopper concept stores heated Nitrogen in a spherical tank to be used as the propellant. The aim of the research was to investigate the benefits of storing propellant at ambient temperature and heating it through the use of a thermal block during engine operation, as opposed to storing gas at a high temperature. Lithium, Lithium Fluoride and Beryllium were considered as possible materials for the thermal block. A heat energy analysis indicated that a lithium thermal mass would provide the highest heat energy for a temperature change from 900 Celsius to -100 Celsius. A heat transfer analysis was performed for Nitrogen at -100 Celsius flowing through 1000 passages inside a 1kg lithium thermal block at a temperature of 900 Celsius. The system was analyzed as turbulent flow through a tube with constant surface temperature. The analysis indicated that the propellant reached a maximum temperature of 877 Celsius before entering the nozzle. At this exit temperature, the average specific impulse [I(sub sp)] of the engine was determined to be 157s. Previous studies for the stored heated gas concept suggest that the engine would have an average I(sub sp) of approximately 52s. Thus, the use of a thermal block concept results in a 200 percent engine performance increase. In addition, a tank sizing study was performed to determine if the concept is feasible in terms of mass requirements. The mass for a spherical carbon fiber COPV storing 35kg of nitrogen at an initial temperature of -100 Celsius and a pressure of 1000psia, was determined to be 7.2kg. The specific impulse analysis indicated that the maximum engine performance is obtained for a mass ratio of 5kg of Nitrogen per every 1kg of lithium thermal mass. Thus for 35kg of Nitrogen the total thermal mass would be 7kg. This brings the total mass of the system to 49.2.kg which is less than the 56kg landing payload capacity of the Triton Hopper. Finally, an insulation analysis using 10mm of MLI insulation indicated that a total of 22 watts of heat are lost to the environment. With the heat loss known, the power required to heat the thermal mass to 900 Celsius in 24 days was determined to be 2.15 watts. The study's results allowed us to conclude that the thermal mass concept is the better option due to the performance increase provided, the low power requirement and its compliance with the landing mass requirement of the Triton Hopper.

Radioisotope↗
NASA NTRS2017

Practical Application of Sociology in Systems Engineering

Systems engineering involves both the integration of the system and the integration of the disciplines which develop and operate the system. Integrating the disciplines is a sociological effort to bring together different groups, who often have different terminology, to achieve a common goal, the system. The focus for the systems engineer is information flow through the organization, between the disciplines, to ensure the system is developed and operated will all relevant information informing system decisions. The practical application of the sociology in systems engineering brings in various organizational development concepts including the principles of planned renegotiation and the application of principles to address information barriers created by organizational culture. Concepts such as specification of ignorance, consistent terminology, opportunity structures, role-sets, and the reclama (reconsideration) process are all important sociological approaches that help address the organizational social structure (culture). In bringing the disciplines together, the systems engineer must also be wary of social ambivalence, social anomie, social dysfunction, and insider-outsider behavior. Unintended consequences can result when these social issues are present. These issues can occur when localized subcultures shift from the overarching organizational culture, or when the organizational culture prevents achievement of system goals. These sociological principles provide the systems engineer with key approaches to manage the information flow through the organization as the disciplines are integrated and share their information and provides key sociological barriers to information flow through the organization. This paper will discuss the practical application of sociological principles to systems engineering.

Watson, Michael D.↗
NASA NTRS2019

Development and Characterization of Hot-Pressed Matrices for Engineered Ceramic Matrix Composites (E-CMCs)

The present research effort was undertaken to develop a new generation of SiC fiber-reinforced engineered ceramic matrix composites (E-CMCs). In contrast to traditional CMCs with a brittle SiC matrix, an E-CMC is designed to consist of a matrix engineered to possess sufficient high temperature plasticity to minimize crack propagation, relatively high fracture toughness, and self-healing capabilities to prevent oxygen ingress to the BN-coated fibers through surface-connected cracks. The present paper discusses the bend strength, isothermal oxidation, microstructures and self-healing properties of several silicide-behaved engineered matrices. Based on the oxidation tests, where it was observed that some of the matrices exhibited either catastrophic oxidation ("pesting") or spalling of the oxide scale, two engineered matrices, CrSi2/SiC/Si3N4 and CrMoSi/SiC/Si3N4, were down-selected for further investigation. Four-point bend tests were conducted on these two engineered matrices between room temperature and 1698 degrees Kelvin. Although these matrices were brittle at low temperatures, it was observed that the bend strengths and bend ductility increased at high temperatures as the silicide particles became more ductile, which was qualitatively consistent with the theoretically expected behavior that crack blunting at these particles should increase the matrix strength. Additional studies were conducted to study the effects of different additives on the self-healing properties of the engineered matrices, which helped to identify the most effective additives.

Composite Materials↗
NASA NTRS2017

Take-off Engine Particle Emission Indices for In-Service Aircraft at Los Angeles International Airport

We present ground‐based, advected aircraft engine emissions from flights taking off at Los Angeles International Airport. 275 discrete engine take‐off plumes were observed on 18 and 25 May 2014 at a distance of 400 m downwind of the runway. CO2 measurements are used to convert the aerosol data into plume‐average emissions indices that are suitable for modelling aircraft emissions. Total and non‐volatile particle number EIs are of order 1016‐1017 kg‐1 and 1014‐1016 kg‐1, respectively. Black‐carbon‐equivalent particle mass EIs vary between 175‐941 mg kg‐1 (except for the GE GEnx engines at 46 mg kg‐1). Aircraft tail numbers recorded for each take‐off event are used to incorporate aircraft‐ and engine‐specific parameters into the data set. Data acquisition and processing follow standard methods for quality assurance. A unique aspect of the data set is the mapping of aerosol concentration time series to integrated plume EIs, aircraft and engine specifications, and manufacturer‐reported engine emissions certifications. The integrated data enable future studies seeking to understand and model aircraft emissions and their impact on air quality.

Richard H Moore↗
NASA NTRS2019

Predicted Ice Shape Formations on a Boundary Layer Ingesting Engine Inlet

Computational ice shapes were generated on the boundary layer ingesting engine nacelle of the D8 Double Bubble aircraft. The computations were generated using LEWICE3D, a well-known CFD icing post processor. A 50-bin global drop diameter discretization was used to capture the collection efficiency due to the direct impingement of water onto the engine nacelle. These discrete results were superposed in a weighted fashion to generate six drop size distributions that span the Appendix C and O regimes. Due to the presence of upstream geometries, i.e. the fuselage nose, the trajectories of the water drops are highly complex. Since the ice shapes are significantly correlated with the collection efficiency, the upstream fuselage nose has a significant impact on the ice accretion on the engine nacelle. These complex trajectories are caused by the ballistic nature of the particles and are thus exacerbated as particle size increases. Shadowzones are generated on the engine nacelle, and due to the curvature of the nose of the aircraft the shadowzone boundary moves from lower inboard to upper outboard as particle size increases. The largest particle impinging one the engine nacelle from the 50-bin discretization was the 47 um drop diameter. As a result, the MVD greater than 40 um Appendix O conditions were characterized by extremely low collection efficiency on the engine nacelle for these direct impingement simulations.

Porter, Christopher↗
NASA NTRS2019

Aerojet Engineering Corporation: Stimulation and Creation, 1935-1942

There are multiple published accounts of the stimulation and creation of the Aerojet Engineering Corporation that are inconsistent, incomplete, or erroneous in significant details, describing principals involved, timing, and funding of the creation process. This paper corrects the record and offers a well-documented and reliable history of the creation of the Aerojet Engineering Corporation. A small group of academic researchers and technicians, joined by an attorney, working at the California Institute of Technology (Caltech), accomplished the formation and creation of the corporation. The group of six men incorporated and served as initial officers of the Aerojet Engineering Corporation—Dr. Theodore von Karman; Dr. Frank Malina; Dr. Martin Summerfield; John Parsons; Edward Forman; and a Washington, DC, attorney, Andrew Haley. A government-funded program definition study at Caltech generated a proposal to produce a means of providing superior aircraft performance capabilities using rocketry, often referred to as jet propulsion, due to engineering disrepute of “rocketry" prior to WWII. Caltech successfully conducted flight demonstrations at March Field (Riverside, California) in the summer of 1941, leading Drs. von Karman and Malina to discuss and explore the best method to provide for production of jet-assisted takeoff (JATO) rockets with established industrial leaders, as well as industrial organizational alternatives. Von Karman, Malina, Summerfield, Parsons, and Forman continued these discussions until von Karman decided, in early 1942, to solicit the legal advice of Andrew Haley on how to proceed. After meetings at von Karman's home in Pasadena, on Haley's recommendation and using his volunteered initial corporate funding, it was agreed to incorporate the group. Articles of incorporation were drawn up by Haley and on 19 March 1942 were formally filed with the Delaware Secretary of State, establishing the Aerojet Engineering Corporation. Many accounts previously published have distorted or misreported many of the details of the process followed by the group that created the company. It is intended that this paper will be regarded as a fully researched historical account of the creation of the Aerojet Engineering Corporation. Included are the historical environment, the industrial motivations, descriptions of key players, the role of government, and the ultimate confluence of these factors with the motivation of a champion and the availability of the required resources.

Doyle, Stephen E.↗
NASA NTRS2019

Extreme-Temperature Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

The United States (US) National Aeronautics and Space Administration (NASA) and its US industry partners are developing extreme-temperature composite nozzle extensions for a variety of cryogenic liquid rocket engine propulsion systems. Applications under consideration at the NASA Marshall Space Flight Center (MSFC) include launch vehicle (upper stage), in-space, and lunar lander descent/ascent propulsion systems. Composite material systems of interest include carbon-carbon (C-C) and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Missions addressed include access to low Earth orbit, the lunar surface, and more distant destinations. Cryogenic upper-stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. As a result of the large size of such nozzles, and the related engine performance requirements, composite nozzle extensions are being considered to reduce mass impacts. Currently, metallic and foreign composite nozzle extensions used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles represent the state-of-the-art. Such extensions are limited to use at or slightly above 2000°F (1093°C). Materials under development by MSFC and its industry partners have the potential to operate at temperatures up to (or above) 4250°F (2343°C). Marshall Space Flight Center efforts are aimed at (a) further developing the technology and databases needed to enable the use of composite nozzle extensions on cryogenic liquid rocket engines, (b) developing and demonstrating low-cost capabilities for testing and qualifying such nozzle extensions, and (c) advancing the US domestic supply chain for nozzle extensions. Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs, low-level internal MSFC research projects, and teaming arrangements with domestic industry partners, composite material design, development, hot-fire test, and evaluation efforts are progressing. Hot- fire engine tests of subscale hardware have been conducted using oxygen/hydrogen (LOX/H2), oxygen/methane (LOX/CH4), and oxygen/kerosene (LOX/RP-1) propellants. These engine tests at MSFC have enabled the evaluation of both heritage and state-of-the-art material systems, demonstrating the initial capabilities of the extreme temperature materials and their fabrication methods. Recent, ongoing, and potential future work supporting cryogenic propulsion systems development will be presented. The composite nozzle extension technology and test capabilities being developed are intended to support both NASA and US Department of Defense requirements, as well as those of the broader Commercial Space industry.

Valentine, Peter G.↗
NASA NTRS2019

Space Research Project Management Can Benefit from Engineering Technology Selection Methods

Many engineering methods have been developed to help management select technology for a system design or further research. The simplest way to compare technologies is to use a checklist containing all the more or less important selection criteria, so that nothing is overlooked. The criteria usually include cost, safety, reliability and maintainability, and potential problems such as noise generation and microgravity sensitivity. The next step typically is to weight and score all the criteria. The process of weighting and scoring is helpful in bringing out different priorities and reaching a shared point of view. Group technology selection methods are designed to highlight initial disagreements and produce a shared consensus. Often a frank discussion led by management rather than decision analysts can be more effective. The final selection depends on management and engineering judgment and may include programmatic and organizational factors that are beyond the engineering checklist. The objective of engineering technology selection methods is to provide engineering information to assist management in making sound decisions. Project management and technology selection are assumed to use rational engineering analytic methods, but they often do not. The reason is that human insight, intuition, and “gut feel,” rather than logic, more frequently determine our decisions. Project selection and management are strongly influenced by nonrational psychological influences, which can produce unjustified confidence and determination. Nevertheless, there is a strong need for space projects to do rational project analysis and selection. Demonstrating a rational spirit is necessary for a scientific and technical organization. Professional ethics at its best requires an open, honest, and fair process, without damaging politics. Rational analysis can help improve good projects and avoid selecting bad ones. A sanity check using rational analysis guided by a checklist can help avoid egregious and damaging errors.

Jones, Harry W.↗
NASA NTRS2019

Interference Drag Associated with Engine Locations for Multidisciplinary Design Optimization

This research aims to quantify the interference drag for various engine locations on a traditional “tube and wing,” 150-passenger commercial aircraft flying at 35,000 ft and Mach 0.8. Engine locations are varied in the chord wise, span wise, and vertical directions near the wing, both under and above the wing, as well as along the fuselage. Euler simulations are performed with representative powered modern engines. The results are intended to supplement empirical drag estimates suitable for multidisciplinary design environments. Large interference drag increases, as compared to the isolated air frame and engine geometry, are found to occur when the engine is placed directly above or below the wing. Interference effects are significantly reduced, and in some instances result in benefits compared to the isolated bodies, when the engines are placed fore or aft of the wing. Interference drag increases are partially explained by flow channels leading to choked flow and shock interactions between bodies.

Blaesser, Nathaniel J.↗
NASA NTRS2020

Strategic Perspectives on the Future of Systems Engineering at NASA

NASA’s Model-Based Systems Engineering (MBSE) Infusion and Modernization Initiative (MIAMI) chartered a strategy group comprising early to mid-career NASA subject matter experts with diverse experiences to look into the future of systems engineering at NASA. The purpose of the group was to provide a vision for the future state of systems engineering practices and to develop a strategic plan to enable the evolution of the art up to 20 years in the future. The group used a design thinking approach to gather ideas and obtained insight into current engineering processes and domain outlook by interviewing engineers of varying expertise and experiences who had worked on teams of different sizes for missions large and small. The group built a roadmap to highlight future needs, projected capabilities, and technology and competency gaps and developed a strategic plan to ensure the expedient introduction of these capabilities. The resulting strategic plan recommends capability development and workforce strategies and provides guidance for Agency-wide SE policy. Artifacts, details, and raw data from the strategy team’s work are contained in NASA/TM-20205002911/SUPPL, Strategic Perspectives on the Future of Systems Engineering at NASA: Supplemental Information: Appendixes A to K.

Anupa R Bajwa↗

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