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At least 253 records · Page 14

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NASA NTRS2000

Hall Propulsion Technology Development, NASA Glenn Research Center: 50 kW Thruster Technology EXPRESS Ground/Space Correlation

It is the goal of this activity to develop 50 kW class Hall thruster technology in support of cost and time critical mission applications such as orbit insertion. NASA Marshall Space Flight Center is tasked to develop technologies that enable cost and travel time reduction of interorbital transportation. Therefore, a key challenge is development of moderate specific impulse (2000-3000 s), high thrust-to-power electric propulsion. NASA Glenn Research Center is responsible for development of a Hall propulsion system to meet these needs. First-phase, sub-scale Hall engine development completed. A 10 kW engine designed, fabricated, and tested. Performance demonstrated >2400 s, >500 mN thrust over 1000 hours of operation documented.

Jankovsky, Robert↗

NASA NTRS2001

Structural Analysis of a 50 cm Diameter Open-back Triangular Cell Beryllium Mirror in a Cryogenic Environment

This paper discusses NASTRAN structural analysis of the Sub-Scale Beryllium Mirror Demonstrator (SBMD), which has been developed by Ball Aerospace as an experimental design concept for the Next Generation Space Telescope (NGST). The mirror was repeatedly subjected to 35 K environment in the large cryogenic test chamber at Marshall Space Flight Center. Deformations on the mirror surface were measured optically. The surface distortions predicted by NASTRAN are analyzed optically for comparison with the measured values. Model results compare favorably with measured results for ambient temperature validation cases. For the cryogenic environment case the influence of geometry and material property variations is being investigated to obtain closer correlation.

Craig, Larry↗

NASA NTRS2001

ODC-Free Solvent Implementation for Phenolics Cleaning

During phenolic liner manufacture, resin-impregnated (pre-preg) bias tape of silica, glass, or carbon cloth is tape-wrapped, cured, machined, and then wiped with 1,1,1 tri-chloroethane (TCA) to remove contaminants that may have been introduced during machining and handling. Following the TCA wipe, the machined surface is given a resin wet-coat and over-wrapped with more prepreg and cured. A TCA replacement solvent for these wiping operations must effectively remove both surface contaminants, and sub-surface oils and greases while not compromising the integrity of this interface. Selection of a TCA replacement solvent for phenolic over-wrap interface cleaning began with sub-scale compatibility tests with cured phenolics. Additional compatibility tests included assessment of solvent retention in machined phenolic surfaces. Results from these tests showed that, while the candidate solvent did not degrade the cured phenolics, it was retained in higher concentrations than TCA in phenolic surfaces. This effect was most pronounced with glass and silica cloth phenolics with steep ply angles relative to the wiped surfaces.

Wurth, Laura↗

NASA NTRS2001

Thermal Fault Tolerance Analysis of Carbon Fiber Rope Barrier Systems for Use in the Reusable Solid Rocket Motor ( RSRM) Nozzle Joints

Carbon Fiber Rope (CFR) thermal barrier systems are being considered for use in several RSRM (Reusable Solid Rocket Motor) nozzle joints as a replacement for the current assembly gap close-out process/design. This study provides for development and test verification of analysis methods used for flow-thermal modeling of a CFR thermal barrier subject to fault conditions such as rope combustion gas blow-by and CFR splice failure. Global model development is based on a 1-D (one dimensional) transient volume filling approach where the flow conditions are calculated as a function of internal 'pipe' and porous media 'Darcy' flow correlations. Combustion gas flow rates are calculated for the CFR on a per-linear inch basis and solved simultaneously with a detailed thermal-gas dynamic model of a local region of gas blow by (or splice fault). Effects of gas compressibility, friction and heat transfer are accounted for the model. Computational Fluid Dynamic (CFD) solutions of the fault regions are used to characterize the local flow field, quantify the amount of free jet spreading and assist in the determination of impingement film coefficients on the nozzle housings. Gas to wall heat transfer is simulated by a large thermal finite element grid of the local structure. The employed numerical technique loosely couples the FE (Finite Element) solution with the gas dynamics solution of the faulted region. All free constants that appear in the governing equations are calibrated by hot fire sub-scale test. The calibrated model is used to make flight predictions using motor aft end environments and timelines. Model results indicate that CFR barrier systems provide a near 'vented joint' style of pressurization. Hypothetical fault conditions considered in this study (blow by, splice defect) are relatively benign in terms of overall heating to nozzle metal housing structures.

Clayton, J. Louie↗

NASA NTRS2001

ODC-Free Solvent Implementation Issues for Vulcanized Rubber and Bond Systems

Thiokol Propulsion has worked extensively to replace 1,1,1-trichloroethane (TCA) with ozone depleting chemicals (ODC)-free solvents for use in the manufacture of the Reusable Solid Rocket Motor (RSRM) for the Space Shuttle Program. As Thiokol has transitioned from sub-scale to full-scale testing and implementation of these new solvents, issues have been discovered which have required special attention. The original intent of Thiokol's solvent replacement strategy was to replace TCA with a single drop-in solvent for all equivalent applications. We have learned that a single candidate does not exist for replacing TCA. Solvent incompatibility with process materials has caused us to seek for niche solvents and/or processing changes that provide an ODC-free solution for special applications. This paper addresses some of the solvent incompatibilities, which have lead to processes changes and possible niche solvent usage. These incompatibilities were discovered during full-scale testing of ODC-free solvents and relate to vulcanized rubber and bond systems in the RSRM. Specifically, the following items are presented: (1) Cure effects of d-limonene based solvents on Silica Filled Ethylene Propylene Diene Monomer (SF-EPDM) rubber. During full-scale test operations, Thiokol discovered that d-limonene (terpene) based solvents inhibit the cure of EPDM rubber. Subsequent testing showed the same issue with Nitrile Butadiene Rubber (NBR). Also discussed are efforts to minimize uncured rubber exposure to solvents; and (2) Cured bond system sensitivity to ODC-free solvents. During full scale testing it was discovered that a natural rubber to steel vulcanized bond could degrade after prolonged exposure to ODC-free solvents. Follow on testing showed that low vapor pressure and residence time seemed to be most likely cause for failure.

Hodgson, James R.↗

NASA NTRS2002

Status of NASA Mirror Technology Development for Large Space Telescopes

This paper presents the current status of several NASA technology development activities, including: Sub-scale Beryllium Mirror Demonstrator (SBMD), NGST (Next Generation Space Telescope) Mirror System Demonstrator (NMSD), Advanced Mirror System Demonstrator (AMSD), etc.. It also describes how these activities map into future NASA mission requirements, including: Next Generation Space Telescope (NGST), Single Aperture Far Infrared Observatory (SAFIR), Space Ultraviolet/Optical Observatory (SUVO), etc..

Stahl, H. Philip↗

NASA NTRS2002

Ball Aerospace SBMD Coating Test Results

The Sub-scale Beryllium Mirror Demonstrator that was successfully tested to demonstrate cryogenic figuring of a bare mirror has been coated with a protected gold reflective surface and retested at cryogenic temperatures. Results showing less than 9 nm rms surface distortion attributable to the added coating are presented.

Brown, Robert↗

NASA NTRS2003

A Collection of Nonlinear Aircraft Simulations in MATLAB

Nonlinear six degree-of-freedom simulations for a variety of aircraft were created using MATLAB. Data for aircraft geometry, aerodynamic characteristics, mass / inertia properties, and engine characteristics were obtained from open literature publications documenting wind tunnel experiments and flight tests. Each nonlinear simulation was implemented within a common framework in MATLAB, and includes an interface with another commercially-available program to read pilot inputs and produce a three-dimensional (3-D) display of the simulated airplane motion. Aircraft simulations include the General Dynamics F-16 Fighting Falcon, Convair F-106B Delta Dart, Grumman F-14 Tomcat, McDonnell Douglas F-4 Phantom, NASA Langley Free-Flying Aircraft for Sub-scale Experimental Research (FASER), NASA HL-20 Lifting Body, NASA / DARPA X-31 Enhanced Fighter Maneuverability Demonstrator, and the Vought A-7 Corsair II. All nonlinear simulations and 3-D displays run in real time in response to pilot inputs, using contemporary desktop personal computer hardware. The simulations can also be run in batch mode. Each nonlinear simulation includes the full nonlinear dynamics of the bare airframe, with a scaled direct connection from pilot inputs to control surface deflections to provide adequate pilot control. Since all the nonlinear simulations are implemented entirely in MATLAB, user-defined control laws can be added in a straightforward fashion, and the simulations are portable across various computing platforms. Routines for trim, linearization, and numerical integration are included. The general nonlinear simulation framework and the specifics for each particular aircraft are documented.

Frederico R Garza↗

NASA NTRS2003

Wind Tunnel Database Development using Modern Experiment Design and Multivariate Orthogonal Functions

A wind tunnel experiment for characterizing the aerodynamic and propulsion forces and moments acting on a research model airplane is described. The model airplane called the Free-flying Airplane for Sub-scale Experimental Research (FASER), is a modified off-the-shelf radio-controlled model airplane, with 7 ft wingspan, a tractor propeller driven by an electric motor, and aerobatic capability. FASER was tested in the NASA Langley 12-foot Low-Speed Wind Tunnel, using a combination of traditional sweeps and modern experiment design. Power level was included as an independent variable in the wind tunnel test, to allow characterization of power effects on aerodynamic forces and moments. A modeling technique that employs multivariate orthogonal functions was used to develop accurate analytic models for the aerodynamic and propulsion force and moment coefficient dependencies from the wind tunnel data. Efficient methods for generating orthogonal modeling functions, expanding the orthogonal modeling functions in terms of ordinary polynomial functions, and analytical orthogonal blocking were developed and discussed. The resulting models comprise a set of smooth, differentiable functions for the non-dimensional aerodynamic force and moment coefficients in terms of ordinary polynomials in the independent variables, suitable for nonlinear aircraft simulation.

Morelli, Eugene A.↗

NASA NTRS2003

Experimental Performance Evaluation of a Supersonic Turbine for Rocket Engine Applications

In order to mitigate the risk of rocket propulsion development, efficient, accurate, detailed fluid dynamics analysis and testing of the turbomachinery is necessary. To support this requirement, a task was developed at NASA Marshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. These tools were applied to optimize a supersonic turbine design suitable for a reusable launch vehicle (RLV). The hot gas path and blading were redesigned-to obtain an increased efficiency. The goal of the demonstration was to increase the total-to- static efficiency of the turbine by eight points over the baseline design. A sub-scale, cold flow test article modeling the final optimized turbine was designed, manufactured, and tested in air at MSFC s Turbine Airflow Facility. Extensive on- and off- design point performance data, steady-state data, and unsteady blade loading data were collected during testing.

Snellgrove, Lauren M.↗

NASA NTRS2003

StarBooster Demonstrator Cluster Configuration Analysis/Verification Program

In order to study the flight dynamics of the cluster configuration of two first stage boosters and upper-stage, flight-testing of subsonic sub-scale models has been undertaken using two glideback boosters launched on a center upper-stage. Three high power rockets clustered together were built and flown to demonstrate vertical launch, separation and horizontal recovery of the boosters. Although the boosters fly to conventional aircraft landing, the centerstage comes down separately under its own parachute. The goal of the project has been to collect data during separation and flight for comparison with a six degree of freedom simulation. The configuration for the delta wing canard boosters comes from a design by Starcraft Boosters, Inc. The subscale rockets were constructed of foam covered in carbon or fiberglass and were launched with commercially available solid rocket motors. The first set of boosters built were 3-ft tall with a 4-ft tall centerstage, and two additional sets of boosters were made that were each over 5-ft tall with a 7.5 ft centerstage. The rocket cluster is launched vertically, then after motor bum out the boosters are separated and flown to a horizontal landing under radio-control. An on-board data acquisition system recorded data during both the launch and glide phases of flight.

DeTurris, Dianne J.↗

NASA NTRS2004

Experimental and Numerical Correlation of Gravity Sag in Solar Sail Quality Membranes

Solar sails are among the most studied members of the ultra-lightweight and inflatable (Gossamer) space structures family due to their potential to provide propellentless propulsion. They are comprised of ultra-thin membrane panels that, to date, have proven very difficult to experimentally characterize and numerically model due to their reflectivity and flexibility, and the effects of gravity sag and air damping. Numerical models must be correlated with experimental measurements of sub-scale solar sails to verify that the models can be scaled up to represent full-sized solar sails. In this paper, the surface shapes of five horizontally supported 25 micron thick aluminized Kapton membranes were measured to a 1.0 mm resolution using photogrammetry. Several simple numerical models closely match the experimental data, proving the ability of finite element simulations to predict actual behavior of solar sails.

Black, Jonathan T.↗

NASA NTRS2004

High-speed Imaging of Global Surface Temperature Distributions on Hypersonic Ballistic-Range Projectiles

The NASA-Ames ballistic range provides a unique capability for aerothermodynamic testing of configurations in hypersonic, real-gas, free-flight environments. The facility can closely simulate conditions at any point along practically any trajectory of interest experienced by a spacecraft entering an atmosphere. Sub-scale models of blunt atmospheric entry vehicles are accelerated by a two-stage light-gas gun to speeds as high as 20 times the speed of sound to fly ballistic trajectories through an 24 m long vacuum-rated test section. The test-section pressure (effective altitude), the launch velocity of the model (flight Mach number), and the test-section working gas (planetary atmosphere) are independently variable. The model travels at hypersonic speeds through a quiescent test gas, creating a strong bow-shock wave and real-gas effects that closely match conditions achieved during actual atmospheric entry. The challenge with ballistic range experiments is to obtain quantitative surface measurements from a model traveling at hypersonic speeds. The models are relatively small (less than 3.8 cm in diameter), which limits the spatial resolution possible with surface mounted sensors. Furthermore, since the model is in flight, surface-mounted sensors require some form of on-board telemetry, which must survive the massive acceleration loads experienced during launch (up to 500,000 gravities). Finally, the model and any on-board instrumentation will be destroyed at the terminal wall of the range. For these reasons, optical measurement techniques are the most practical means of acquiring data. High-speed thermal imaging has been employed in the Ames ballistic range to measure global surface temperature distributions and to visualize the onset of transition to turbulent-flow on the forward regions of hypersonic blunt bodies. Both visible wavelength and infrared high-speed cameras are in use. The visible wavelength cameras are intensified CCD imagers capable of integration times as short as 2 ns. The infrared camera uses an Indium Antimonide (InSb) sensor in the 3 to 5 micron band and is capable of integration times as short as 500 ns. The projectiles are imaged nearly head-on using expendable mirrors offset slightly from the flight path. The proposed paper will discuss the application of high-speed digital imaging systems in the NASA-Ames hypersonic ballistic range, and the challenges encountered when applying these systems. Example images of the thermal radiation from the blunt nose of projectiles flying at nearly 14 times the speed of sound will be given.

Wilder, Michael C.↗

NASA NTRS2004

Experimental, Theoretical, and Computational Investigation of Separated Nozzle Flows

A detailed experimental, theoretical, and computational study of separated nozzle flows has been conducted. Experimental testing was performed at the NASA Langley 16-Foot Transonic Tunnel Complex. As part of a comprehensive static performance investigation, force, moment, and pressure measurements were made and schlieren flow visualization was obtained for a sub-scale, non-axisymmetric, two-dimensional, convergent- divergent nozzle. In addition, two-dimensional numerical simulations were run using the computational fluid dynamics code PAB3D with two-equation turbulence closure and algebraic Reynolds stress modeling. For reference, experimental and computational results were compared with theoretical predictions based on one-dimensional gas dynamics and an approximate integral momentum boundary layer method. Experimental results from this study indicate that off-design overexpanded nozzle flow was dominated by shock induced boundary layer separation, which was divided into two distinct flow regimes; three- dimensional separation with partial reattachment, and fully detached two-dimensional separation. The test nozzle was observed to go through a marked transition in passing from one regime to the other. In all cases, separation provided a significant increase in static thrust efficiency compared to the ideal prediction. Results indicate that with controlled separation, the entire overexpanded range of nozzle performance would be within 10% of the peak thrust efficiency. By offering savings in weight and complexity over a conventional mechanical exhaust system, this may allow a fixed geometry nozzle to cover an entire flight envelope. The computational simulation was in excellent agreement with experimental data over most of the test range, and did a good job of modeling internal flow and thrust performance. An exception occurred at low nozzle pressure ratios, where the two-dimensional computational model was inconsistent with the three-dimensional separation observed in the experiment. In general, the computation captured the physics of the shock boundary layer interaction and shock induced boundary layer separation in the nozzle, though there were some differences in shock structure compared to experiment. Though minor, these differences could be important for studies involving flow control or thrust vectoring of separated nozzles. Combined with other observations, this indicates that more detailed, three-dimensional computational modeling needs to be conducted to more realistically simulate shock-separated nozzle flows.

Hunter, Craig A.↗

NASA NTRS1998

Recent Dynamic Measurements and Considerations for Aerodynamic Modeling of Fighter Airplane Configurations

As airplane designs have trended toward the expansion of flight envelopes into the high angle of attack and high angular rate regimes, concerns regarding modeling the complex unsteady aerodynamics for simulation have arisen. Most current modeling methods still rely on traditional body axis damping coefficients that are measured using techniques which were intended for relatively benign flight conditions. This paper presents recent wind tunnel results obtained during large-amplitude pitch, roll and yaw testing of several fighter airplane configurations. A review of the similitude requirements for applying sub-scale test results to full-scale conditions is presented. Data is then shown to be a strong function of Strouhal number - both the traditional damping terms, but also the associated static stability terms. Additionally, large effects of sideslip are seen in the damping parameter that should be included in simulation math models. Finally, an example of the inclusion of frequency effects on the data in a simulation is shown.

Brandon, Jay M.↗

NASA NTRS1997

Fluidic Thrust Vectoring of an Axisymmetric Exhaust Nozzle at Static Conditions

A sub-scale experimental static investigation of an axisymmetric nozzle with fluidic injection for thrust vectoring was conducted at the NASA Langley Jet Exit Test Facility. Fluidic injection was introduced through flush-mounted injection ports in the divergent section. Geometric variables included injection-port geometry and location. Test conditions included a range of nozzle pressure ratios from 2 to 10 and a range of injection total pressure ratio from no-flow to 1.5. The results indicate that fluidic injection in an axisymmetric nozzle operating at design conditions produced significant thrust-vector angles with less reduction in thrust efficiency than that of a fluidically-vectored rectangular jet. The axisymmetric geometry promoted a pressure relief mechanism around the injection slot, thereby reducing the strength of the oblique shock and the losses associated with it. Injection port geometry had minimal effect on thrust vectoring.

Wing, David J.↗

NASA NTRS2004

Epoxy Adhesives for Stator Magnet Assembly in Stirling Radioisotope Generators (SRG)

As NASA seeks to fulfill its goals of exploration and understanding through missions planned to visit the moons of Saturn and beyond, a number of challenges arise from the idea of deep space flight. One of the first problems associated with deep space travel is electrical power production for systems on the spacecraft. Conventional methods such as solar power are not practical because efficiency decreases substantially as the craft moves away from the Sun. The criterion for power generation during deep space missions are very specific, the main points requiring high reliability, low mass, minimal vibration and a long lifespan. A Stirling generator, although fairly old in concept, is considered to be a potential solution for electrical power generation for deep space flight. A Stirling generator works on the same electromagnetic principles of a standard generator, using the linear motion of the alternator through the stationary stator which produces electric induction. The motion of the alternator, however, is produced by the heating and cooling dynamics of pressurized gases. Essentially heating one end and cooling another of a contained gas will cause a periodic expansion and compression of the gas from one side to the other, which a displacer translates into linear mechanical motion. NASA needs to confirm that the materials used in the generator will be able to withstand the rigors of space and the life expectancy of the mission. I am working on the verification of the epoxy adhesives used to bond magnets to the steel lamination stack to complete the stator; in terms of in-service performance and durability under various space environments. Understanding the proper curing conditions, high temperature properties, and degassing problems as well as production difficulties are crucial to the long term success of the generator. system and steel substrate used in the stator. To optimize the curing conditions of the epoxies, modulated differential scanning calorimetry analysis was done as a function of cure time and temperatures. Adhesion bond strength was tested at various temperatures with lap shear samples using Hiperco 50 substrate to ensure that the proper adhesive is being used. To try and solve the problem of bondline thickness, micro glass beads of 0.0017" in diameter were investigated to see if any other physical properties of the epoxy were affected. Efforts will be made to develop a standard, optimized, fabrication process/procedure of sub-scale magnet-stator assemblies for various adhesive performance evaluation studies under simulated generator conditions. Also, accelerated aging testing will be done in a pressurized canister with stator assembly samples for three years to verify if any degassing or thermal degradation of the epoxy occurs. The necessity of verifying the correct epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself. My work involves specimen fabrications, testing, and data analyses of the epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself.

Cater, George M.↗

NASA NTRS2005

Thermal and Mechanical Property Characterization of the Advanced Disk Alloy LSHR

A low solvus, high refractory (LSHR) powder metallurgy disk alloy was recently designed using experimental screening and statistical modeling of composition and processing variables on sub-scale disks to have versatile processing-property capabilities for advanced disk applications. The objective of the present study was to produce a scaled-up disk and apply varied heat treat processes to enable full-scale demonstration of LSHR properties. Scaled-up disks were produced, heat treated, sectioned, and then machined into specimens for mechanical testing. Results indicate the LSHR alloy can be processed to produce fine and coarse grain microstructures with differing combinations of strength and time-dependent mechanical properties, for application at temperatures exceeding 1300 F.

Gabb, Timothy P.↗