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At least 271 records · Page 15

Adventures in Low Disc Loading VTOL Design

This memoir covers the first eight years of my 37 year career in VTOL aircraft design. It starts with family and how I came to be an engineer with a passion for aviation and a desire to make a difference. At MIT I acquired a solid understanding of basic physics, learned the basics of the various engineering disciplines and gained design experience. After over a decade on the East Coast I was homesick for Northern California. I decided to take a chance on working for the government instead of industry in order to return home. I was hired by Dr. Richard M. Carlson in March 1975 and joined a wonderful Army/NASA technical environment. The Interservice Helicopter Commonality Study was an important introduction to Joint Service aircraft design. The Advanced Attack Helicopter Source Selection Evaluation Board was an opportunity to learn acquisition system fundamentals and to lead a small team in a major technical evaluation. The Advanced Scout Helicopter Concept Formulation was an opportunity to learn how an aircraft development program is created and it formed a partnership between Dr. Carlson's Labs and Charlie Crawford's Development and Qualification directorate. The Army was Executive Service for the first year (1982) of the Joint Services Advanced Vertical Lift Aircraft (JVX) program. The JVX Joint Technology Assessment concluded that there was at least one design configuration, the tilt rotor, which could satisfy all JVX mission requirements with a high degree of inter-service commonality. The Navy became Executive Service at the end of the year and promptly released a JVX RFP to industry. This RFP resulted in the V-22 Osprey tilt rotor as the third type of VTOL aircraft to enter production and service. I was very lucky to have a useful role early in this program.

VTOL Design↗

NDE Development for Inspection of the Ares I Crew Launch Vehicle

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. Another impact is the proposed usage of an aluminum face sheet, phenolic honeycomb sandwich structure for a common bulkhead between the fuel and oxidizer tanks. This design was used on the second stage of Saturn IB and the second and third stages of Saturn V, but both the manufacturing and subsequent inspection were very costly and time consuming so a more efficient inspection method is sought. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Richter, Joel↗

Development of Weld Inspection of the Ares I Crew Launch Vehicle Upper Stage

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges in inspection. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Russell, Sam↗

Investigation of Dive Brakes and a Dive-Recovery Flap on a High-Aspect-Ratio Wing in the Langley 8-Foot High-Speed Tunnel

The results of tests made to determine the aerodynamic characteristics of a solid brake, a slotted brake, and a dive-recovery flap mounted on a high aspect ratio wing at high Mach numbers are presented. The data were obtained in the Langley 8-foot high-speed tunnel for corrected Mach numbers up to 0.940. The results have been analyzed with regard to the suitability of dive-control devices for a proposed high-speed airplane in limiting the airplane terminal Mach number by the use of dive brakes and in achieving favorable dive-recovery characteristics by the use of a dive-recovery flap. The analysis of the results indicated that the slotted brake would limit the proposed airplane terminal Mach number to values below 0.880 for altitudes up to 35,000 feet and a wing loading of 80 pounds per square foot and the dive-recovery flap would produce trim changes required for controlled pull-outs at 25,000 feet for a Mach number range from 0.800 to 0.900. Basic changes in spanwise loading are presented to aid in the evaluation of the wing strength requirements.

Mattson, Axel T.↗

Solid rocket motor nozzles

The steps in the nozzle design process are examined. The nozzle designer's role in defining design requirements and constraints is included along with discussions of each of the three basic phases of the nozzle design process itself: (1) aerodynamic design, in which the gas-contacting surfaces are configured to produce the required performance within the envelope limits; (2) thermal design, in which termal liners and thermal insulators are selected and configured to maintain the surfaces as closely as practical against effects of erosion and to limit the structure temperature to acceptable levels; and (3) structural design, in which materials are selected and configured to support the thermal components and to sustain the predicted loads. Analytical techniques that are used to establish thermal and structural design integrity and to predict nozzle performance are discussed along with methods for nozzle quality assurance. Emphasis is placed on nozzle design and materials for modern high-temperature aluminized propellants. Recurring nozzle design problems of graphite cracking and ejection, differential erosion at material interfaces, lack of sufficient proven nondestructive testing (NDT) techniques, the uncertainty of adhesive bonding, and inadequate definition of material properties, particularly at high temperatures are considered.

Ellis, R. A.↗

Sandwich Composite, Syntactic Foam Core Based, Application for Space Structures

The current Solid Rocket Booster (SRB) launch vehicle has several metal based components that require a Thermal Protective System (TPS) be applied to the exterior surface to ensure its structural integrity and to protect the interior hardware from aerodynamic heating. TPS materials have distinct disadvantages associated with their use. One disadvantage to the application of TPS is that it can act as a debris source to the Space Shuttle Orbiter during flight and it also adds weight to the system without directly contributing any structural strength. One of the specific areas examined under this program was to replace a metal/TPS system with polymer based composites. A polymer matrix based sandwich composite was developed which had both structural and insulative properties to meet the high aerodynamic structural and heating load survival requirements. The SRB Nose Cap was selected as a candidate for this application. The sandwich system being qualified for this application is a carbon/epoxy outer and inner skin with a high strength-low thermal conductivity syntactic foam core.

Hodge, Andrew J.↗

Development of Gas-Lubricated Pistons for Heavy Duty Diesel Engine Technology Program

Static testing of a segmented, gas-lubricated, piston-ring was accomplished. The ring utilizes high-pressure gas generated during the diesel cycle to energize a hydrostatic gas film between the piston and cylinder liner. The configuration was deficient in overall performance, because all segments of a ring set failed to form a fluid-film simultaneously, when exposed to internal preload. The difficulty was traced to the moment balance required to prevent the segments from overturning and contacting the cylinder walls. Some individual sectors formed a film and performed well in every respect including load capability to 6,000 N. These results produce optimism as to the ultimate feasibility of hydrostatic, gas-lubricated piston rings. In addition to test results, the principles of operation, and theoretical developments are presented. Breathable liner concepts are suggested for future consideration. In these configurations, solid hydrostatic pistons are coupled with flexible liners that elastically deform to form a gas-film under hydrostatic pressurization. Breathable liners afford the mechanical simplicity required for mass produced engines, and initial examination indicates satisfactory operation.

Shapiro, W.↗

Aerodynamic Evaluation of Two Compact Radial-Inflow Turbine Rotors

The aerodynamic evaluation of two highly loaded compact radial turbine rotors was conducted at the NASA Lewis Research Center Small Engine Component Test Facility (SECTF). The experimental results were used for proof-of-concept, for modeling radial inflow turbine rotors, and for providing data for code verification. Two rotors were designed to have a shorter axial length, up to a 10-percent reduced diameter, a lighter weight, and equal or higher efficiencies with those of conventional radial inflow turbine rotors. Three configurations were tested: rotor 1, having a 40-percent shorter axial length, with the design stator (stator 1); rotor 1 with the design stator vanes closed down (stator 2); and rotor 2, slightly shorter axially and having higher loading, with stator 2. The stator had 36 vanes and the rotors each had 14 solid blades. Although presently uncooled, the rotor blades were designed for thicknesses which would allow cooling passages to be added. The overall stage performance measurements and the rotor and stator exit flow field surveys were obtained. Measurements of steady state temperatures, pressures, mass flow rates, flow angles, and output power were made at various operating conditions. Data were obtained at corrected speeds of 80, 90, 100, 110, and 120 percent of design over a range of equivalent inlet-to-exit pressure ratios of 3.5, 4.0, 4.5, and 5.0, the maximum pressure ratio achieved. The test showed that the configuration of rotor 1 with stator 1 running at the design pressure ratio produced a flow rate which was 5.6 percent higher than expected. This result indicated the need to close down the stator flow area to reduce the flow. The flow area reduction was accomplished by restaggering the vanes. Rotor 1 was retested with the closed-down stator vanes and achieved the correct mass flow. Rotor 2 was tested only with the restaggered vanes. The test results of the three turbine configurations were nearly identical. Although the measured efficiencies of the compact designs fell 2 to 3 points below the predicted efficiency of 91 percent, they did meet and exceed by up to 2.5 percentage points the efficiences of state-of-the-art turbines found in the literature.

Simonyi, P. Susan↗

A performance application study of a jet-flap helicopter rotor

A performance study was made of the application of a jet-flap to a reaction-drive rotor for a heavy-lift helicopter mission and for a high-speed-helicopter maneuverability (200 knots, 2g) mission. The results of the study are as follows: As a result of the increase in maximum airfoil lift coefficient achieved by the jet-flap, rotor solidity is reduced with the jet-flap to approximately 59% of a nonjet-flap rotor. As a result of the saving in rotor solidity, and hence in rotor weight, the jet-flap configuration had a 21% higher productivity than a nonjet-flap configuration. Of the three propulsion systems studied utilizing a jet-flap (hot cycle, warm cycle, cold cycle) the hot cycle gave the largest increase in productivity. The 200 knot 2g mission is performed best with a warm cycle propulsion system. The jet-flap permits designing for a rotor blade loading coefficient C sub T/sigma = .170 at 2g without encountering blade stall. The jet-flap rotor permits a 200 knot 2g maneuver without suffering the penalty of an unreasonable rotor solidity that would be required by a nonjet-flap rotor.

Sullivan, R. J.↗

Fully Coupled Aero-Thermochemical-Elastic Simulations of an Eroding Graphite Nozzle

A multiphysics simulation capability has been developed that incorporates mutual interactions between aerodynamics, structural response from aero/thermal loading, ablation/pyrolysis, heating, and surface-to-surface radiation to perform high-fidelity, fully coupled aerothermoelastic ablation simulations, which to date had been unattainable. The multiphysics framework couples CHAR (a 3-D implicit charring ablator solver), Loci/CHEM (a computational fluid dynamics solver for high-speed chemically reacting flows), and Abaqus (a nonlinear structural dynamics solver) to create a fully coupled aerothermoelastic charring ablative solver. The solvers are tightly coupled in a fully integrated fashion to resolve the effects of the ablation pyrolysis and charring process and chemistry products upon the flow field, the changes in surface geometry due to recession upon the flow field, and thermal-structural analysis of the body from the induced aerodynamic heating from the flow field. The multiphysics framework was successfully demonstrated on a solid rocket motor graphite nozzle erosion application. Comparisons were made with available experimental data that measured the throat erosion during the motor firing. The erosion data is well characterized, as the test rig was equipped with a windowed nozzle section for real-time X-ray radiography diagnostics of the instantaneous throat variations for deducing the instantaneous erosion rates. The nozzle initially undergoes a nozzle contraction due to thermal expansion before ablation effects are able to widen the throat. A series of parameters studies were conducted using the coupled simulation capability to determine the sensitivity of the nozzle erosion to different parameters. The parameter studies included the shape of the nozzle throat (flat versus rounded), the material properties, the effect of the choice of turbulence model, and the inclusion or exclusion of the mechanical thermal expansion. Overall, the predicted results match the experiment very well, and the predictions were able to bound the data within acceptable limits.

Blades, E. L.↗

Launch Vehicle Performance for Bipropellant Propulsion Using Atomic Propellants With Oxygen

Atomic propellants for bipropellant launch vehicles using atomic boron, carbon, and hydrogen were analyzed. The gross liftoff weights (GLOW) and dry masses of the vehicles were estimated, and the 'best' design points for atomic propellants were identified. Engine performance was estimated for a wide range of oxidizer to fuel (O/F) ratios, atom loadings in the solid hydrogen particles, and amounts of helium carrier fluid. Rocket vehicle GLOW was minimized by operating at an O/F ratio of 1.0 to 3.0 for the atomic boron and carbon cases. For the atomic hydrogen cases, a minimum GLOW occurred when using the fuel as a monopropellant (O/F = 0.0). The atomic vehicle dry masses are also presented, and these data exhibit minimum values at the same or similar O/F ratios as those for the vehicle GLOW. A technology assessment of atomic propellants has shown that atomic boron and carbon rocket analyses are considered to be much more near term options than the atomic hydrogen rockets. The technology for storing atomic boron and carbon has shown significant progress, while atomic hydrogen is not able to be stored at the high densities needed for effective propulsion. The GLOW and dry mass data can be used to estimate the cost of future vehicles and their atomic propellant production facilities. The lower the propellant's mass, the lower the overall investment for the specially manufactured atomic propellants.

Palaszewski, Bryan↗

Impact Simulation of Composite Panels for Aerospace Applications

The aerospace research community has been working towards the development of a comprehensive framework for the design of composite structures at the component, subassembly, assembly, and system levels. Such a framework requires accurate, efficient and easy-to-use mathematical and computational models that are in sync with physical reality. The research work in this paper is designed to help an aerospace structural engineer move towards this goal by simulating dynamic impact to composite panels. First, the existing orthotropic visco-elastic visco-plastic material model in LS-DYNA commercial finite element program, MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE (MAT_213) is enhanced with the development and use of rate-dependent damage data. Using state-of-the-art experimental procedures, impact validation test data are created. Second, the versatility of the constitutive model is examined by its ability to simulate a low velocity (27 ft/s, 8 m/s) impact test, and two high velocity impact tests (385–417 ft/s, 117–127 m/s) that straddle the ballistic limit of the projectile and the composite panels. Third, these impact events are modeled using three different finite element types – under-integrated and fully-integrated solid elements, and fully-integrated thin shell elements. Insight into accuracy versus numerical efficiency is gained by comparing the performance of solid versus thin shell elements. The numerical results show that accurate predictions of these impact events can be obtained with reasonable effort and care.

Simulations↗

The Characterization of the Selected Materials for Space Shuttle

The harsh conditions to which the Space Shuttles are exposed during flight required the development and use of many unique materials. These materials were specially designed to withstand extreme temperatures, in some cases over 1600 C, while other material must withstand the cryogenic conditions of -253 C, and others must operate while under extreme loads. All of these materials must not only operate in the harsh condition but they must be light weight as well. The Space Shuttle is composed of three major components when configured for launch, Figure 1; the Shuttle, solid rocket boosters, and external tank (ET). The different heat shields of the Shuttle make up the thermal protection system (TPS); this system consists of many different types of components designed to operate on various parts of the vehicle. The body of the Shuttle and ET are composed mainly of aluminum alloy and graphite epoxy. The TPS consists of reinforced carbon-carbon (RCC) used on the wing leading edges and nose cap areas while the upper forward fuselage areas, the entire underside of the Shuttle, the Orbiter maneuvering system, and reaction control system utilize blacc high temperature reusable surface insulation (HRSI) tiles, Figure 2. Other areas of the Orbiter are protected by fibrous refractory composite insulation (FRCI) tiles. Areas where the temperature stays below 649 C, such as the forward fuselage, mid-fuselage, aft fuselage, vertical tail, and upper wing, are protected by other material such as, white low temperature reusable surface insulation (LRSI) tiles, advanced flexible reusable surface insulation (AFRSI) blankets, and felt reusable surface insulation (FRSI) white blankets. The RCC is a pyrolized laminated carbon with the outer surface converted to silicon carbide to prevent oxidation. The FiRST tiles are made of a low-density, high purity silica 99.8-percent amorphous fiber insulation that is made rigid by ceramic bonding resulting in 90-percent void and 10-percent materials. The RCC and HRSI are used in areas where the temperature rises above 1260 T. The FRCI tiles are high strength tiles derived by adding alumina-bososilicate fiber to the pure silica tile slurry that welds the micron-sizes fibers of pure silica into a rigid structure during sintering. The FRCI is composed of 20-percent alumina-borosilicate fibers and 80-percent silica fibers, and provided improved strength, durability and resistance to coating cracking and weight reduction than HRSI.

Kim, Hae-Soo↗

Oil-Free Turbomachinery Research Enhanced by Thrust Bearing Test Capability

NASA Glenn Research Center s Oil-Free Turbomachinery research team is developing aircraft turbine engines that will not require an oil lubrication system. Oil systems are required today to lubricate rolling-element bearings used by the turbine and fan shafts. For the Oil-Free Turbomachinery concept, researchers combined the most advanced foil (air) bearings from industry with NASA-developed high-temperature solid lubricant technology. In 1999, the world s first Oil-Free turbocharger was demonstrated using these technologies. Now we are working with industry to demonstrate Oil-Free turbomachinery technology in a small business jet engine, the EJ-22 produced by Williams International and developed during Glenn s recently concluded General Aviation Propulsion (GAP) program. Eliminating the oil system in this engine will make it simpler, lighter (approximately 15 percent), more reliable, and less costly to purchase and maintain. Propulsion gas turbines will place high demands on foil air bearings, especially the thrust bearings. Up until now, the Oil-Free Turbomachinery research team only had the capability to test radial, journal bearings. This research has resulted in major improvements in the bearings performance, but journal bearings are cylindrical, and can only support radial shaft loads. To counteract axial thrust loads, thrust foil bearings, which are disk shaped, are required. Since relatively little research has been conducted on thrust foil air bearings, their performance lags behind that of journal bearings.

Bauman, Steven W.↗

1KW Power Transmission Using Wireless Acoustic-Electric Feed-Through (WAEF)

A variety of space applications require the delivery of power into sealed structures. Since the structural integrity can be degraded by holes for cabling we present an alternative method of delivering power and information using stress waves to the internal space of a sealed structure. One particular application of this technology is in sample return missions where it is critical to preserve the sample integrity and to prevent earth contamination. Therefore, the container has to be hermetically sealed and the integrity of the seal must be monitored in order to insure to a high degree of reliability the integrity of the sample return vessel. In this study we investigated the use of piezoelectric acoustic-electric power feed-through devices to transfer electric power wirelessly through a solid wall by using elastic or acoustic waves. The technology is applicable to a range of space and terrestrial applications where power is required by electronic equipment inside sealed containers, vacuum or pressure vessels, etc., where holes in the wall are prohibitive or may result in significant structural performance degradation or unnecessarily complex designs. To meet requirements of higher power applications, the feasibility to transfer kilowatts level power was investigated. Pre-stressed longitudinal piezoelectric feed-through devices were analyzed by finite element models and an equivalent circuit model was developed to predict the power transfer characteristics to different electric loads. Based on the results of the analysis a prototype device was designed, fabricated and a demonstration of the transmission of electric power up to 1.068-kW was successfully conducted. Efficiencies in the 80-90% range were also demonstrated and methods to increase the efficiency further are currently being considered.

pressure vessels↗

Coherence Analysis of the Space Launch System using Unsteady Pressure Sensitive Paint

Transonic buffet forces are a major source of unsteady loading on launch vehicles, thus requiring accurate estimation for efficient vehicle design. The state of the art in modeling these unsteady loads utilizes wind-tunnel tests where the fluctuating pressures are measured by pressure transducers (PTs) at discrete locations on a rigid buffet model. These pressures are then integrated over the surface of the vehicle to yield a series of orthogonal centerline loads called buffet forcing functions (BFFs). Typically, the PT layout aims at resolving the pressure correlation along the longitudinal axis of the vehicle. As a result, the distribution of azimuthal correlation and its impact on the estimated BFFs are not well known. To fill these gaps, extremely high-spatial-resolution uPSP data were collected for three different configurations of the Space Launch System in the NASA Ames Research Center 11-Foot Transonic Unitary Plan Wind Tunnel. The spatio-temporal behavior of the pressure correlation on these vehicles is analyzed and flow features of interest are investigated. It is shown that terminal shocks interacting with turbulence are a source of increased azimuthal coherence, especially when the shock develops at a junction. Vortex shedding off the forward attachment hardware that connects the core stage to the solid rocket boosters (SRBs) is the most severe buffet environment on the vehicle. The associated fluctuating pressures are shown to be highly coherent as far as the vehicle tail and up to 40 degrees away from the boosters. For selected areas of the vehicle, factoring the azimuthal coherence into the attenuation of discrete-measurements-based BFFs results in under prediction relative to the BFFs obtained from full integration of the uPSP data.

buffet↗

Aerospace technology development of three types of solid state remote power controllers for 120VDC with current ratings of five, and thirty amperes, one type having current limiting

The first generation of remote power controllers (RPC) developed included: a 5-ampere design (Type 1), capable of limiting maximum overload current to 15 amperes for .1 sec; and 5-ampere noncurrent (Type 2) and 30-ampere noncurrent (Type 3) limiting designs, both with selectable instant trip levels for high-current overload. Each design provides overcurrent protection through an inverse I squared T trip-out function with an automatic reset option and demonstrates step-applied fault capability with a 4000-ampere surge, fast-risetime (low-inductance) power source. They also meet MIL - STD - 461A specification for electromagnetic interference. The second generation RPCs traded off specification compliance for reduction in cost and complexity for the Type 1 and 2 designs and give comparable or improved performance in most areas. The noncurrent limiting RPC proved to be a more economical and feasible method of overload protection for certain load types.

Baker, D. E.↗

Notch Sensitivity of Woven Ceramic Matrix Composites Under Tensile Loading: An Experimental, Analytical, and Finite Element Study

The stress concentrations associated with circular notches and subjected to uniform tensile loading in woven ceramic matrix composites (CMCs) have been investigated for high-efficient turbine engine applications. The CMC's were composed of Nicalon silicon carbide woven fabric in SiNC matrix manufactured through polymer impregnation process (PIP). Several combinations of hole diameter/plate width ratios and ply orientations were considered in this study. In the first part, the stress concentrations were calculated measuring strain distributions surrounding the hole using strain gages at different locations of the specimens during the initial portion of the stress-strain curve before any microdamage developed. The stress concentration was also calculated analytically using Lekhnitskii's solution for orthotropic plates. A finite-width correction factor for anisotropic and orthotropic composite plate was considered. The stress distributions surrounding the circular hole of a CMC's plate were further studied using finite element analysis. Both solid and shell elements were considered. The experimental results were compared with both the analytical and finite element solutions. Extensive optical and scanning electron microscopic examinations were carried out for identifying the fracture behavior and failure mechanisms of both the notched and notched specimens. The stress concentration factors (SCF) determined by analytical method overpredicted the experimental results. But the numerical solution underpredicted the experimental SCF. Stress concentration factors are shown to increase with enlarged hole size and the effects of ply orientations on stress concentration factors are observed to be negligible. In all the cases, the crack initiated at the notch edge and propagated along the width towards the edge of the specimens.

Haque, A.↗