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NASA NTRS2001

Pulse Detonation Engine Modeled

Pulse Detonation Engine Technology is currently being investigated at Glenn for both airbreathing and rocket propulsion applications. The potential for both mechanical simplicity and high efficiency due to the inherent near-constant-volume combustion process, may make Pulse Detonation Engines (PDE's) well suited for a number of mission profiles. Assessment of PDE cycles requires a simulation capability that is both fast and accurate. It should capture the essential physics of the system, yet run at speeds that allow parametric analysis. A quasi-one-dimensional, computational-fluid-dynamics-based simulation has been developed that may meet these requirements. The Euler equations of mass, momentum, and energy have been used along with a single reactive species transport equation, and submodels to account for dominant loss mechanisms (e.g., viscous losses, heat transfer, and valving) to successfully simulate PDE cycles. A high-resolution numerical integration scheme was chosen to capture the discontinuities associated with detonation, and robust boundary condition procedures were incorporated to accommodate flow reversals that may arise during a given cycle. The accompanying graphs compare experimentally measured and computed performance over a range of operating conditions for a particular PDE. Experimental data were supplied by Fred Schauer and Jeff Stutrud from the Air Force Research Laboratory at Wright-Patterson AFB and by Royce Bradley from Innovative Scientific Solutions, Inc. The left graph shows thrust and specific impulse, Isp, as functions of equivalence ratio for a PDE cycle in which the tube is completely filled with a detonable hydrogen/air mixture. The right graph shows thrust and specific impulse as functions of the fraction of the tube that is filled with a stoichiometric mixture of hydrogen and air. For both figures, the operating frequency was 16 Hz. The agreement between measured and computed values is quite good, both in terms of trend and magnitude. The error is under 10 percent everywhere except for the thrust value at an equivalence ratio of 0.8 in the left figure, where it is 14 percent. The simulation results shown were made using 200 numerical cells. Each cycle of the engine, approximately 0.06 sec, required 2.0 min of CPU time on a Sun Ultra2. The simulation is currently being used to analyze existing experiments, design new experiments, and predict performance in propulsion concepts where the PDE is a component (e.g., hybrid engines and combined cycles).

Paxson, Daniel E.↗

NASA NTRS2011

Creep Behavior of Hafnia and Ytterbium Silicate Environmental Barrier Coating Systems on SiC/SiC Ceramic Matrix Composites

Environmental barrier coatings will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability and stability of SiC/SiC ceramic matrix composite (CMC) engine components, thus improving the engine performance. In order to develop high performance, robust coating systems for engine components, appropriate test approaches simulating operating temperature gradient and stress environments for evaluating the critical coating properties must be established. In this paper, thermal gradient mechanical testing approaches for evaluating creep and fatigue behavior of environmental barrier coated SiC/SiC CMC systems will be described. The creep and fatigue behavior of Hafnia and ytterbium silicate environmental barrier coatings on SiC/SiC CMC systems will be reported in simulated environmental exposure conditions. The coating failure mechanisms will also be discussed under the heat flux and stress conditions.

Zhu, Dongming↗

NASA NTRS2017

A Compilation of MATLAB Scripts and Functions for MACGMC Analyses

The primary aim of the current effort is to provide scripts that automate many of the repetitive pre- and post-processing tasks associated with composite materials analyses using the Micromechanics Analysis Code with the Generalized Method of Cells. This document consists of a compilation of hundreds of scripts that were developed in MATLAB (The Mathworks, Inc., Natick, MA) programming language and consolidated into 16 MATLAB functions. (MACGMC). MACGMC is a composite material and laminate analysis software code developed at NASA Glenn Research Center. The software package has been built around the generalized method of cells (GMC) family of micromechanics theories. The computer code is developed with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated to increase the user friendliness, as well as to make it more robust in terms of input preparation and code execution. Finally, classical lamination theory has been implemented within the software, wherein GMC is used to model the composite material response of each ply. Thus, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. The pre-processing tasks include generation of a multitude of different repeating unit cells (RUCs) for CMCs and PMCs, visualization of RUCs from MACGMC input and output files and generation of the RUC section of a MACGMC input file. The post-processing tasks include visualization of the predicted composite response, such as local stress and strain contours, damage initiation and progression, stress-strain behavior, and fatigue response. In addition to the above, several miscellaneous scripts have been developed that can be used to perform repeated Monte-Carlo simulations to enable probabilistic simulations with minimal manual intervention. This document is formatted to provide MATLAB source files and descriptions of how to utilize them. It is assumed that the user has a basic understanding of how MATLAB scripts work and some MATLAB programming experience.

Materials Engineering↗

NASA NTRS2018

Why Space Technology Needs More Non-Traditional Chemical Engineers – From the Perspective of a NASA Chemical Engineering Student

Final document is attached. With planetary missions and deep space gateway on the horizon, humankind is entering a new era of space exploration. Manned mission durations will be longer than any previous flight, resupply capabilities are limited, and system robustness is more imperative than ever. Traditional space systems, especially in the realm of carbon dioxide removal and water remediation, are large in size, mass, energy consumption, and number of mechanical moving parts prone to failure. Non-traditional space exploration needs non-traditional technology solutions. Organizational psychologist Adam Grant is well-known for his studies on originality and how non-conformists can move the world. In the words of Adam Grant, "to become original, you have to try something new, which means accepting some measure of risk." As chemical engineers, we shouldn't let that measure of risk stop us from considering ingenious technology. As a part of the new generation of engineers at NASA, I believe we need a paradigm shift in space technology for this new era of exploration.

Rogers, Tanya↗

NASA NTRS2012

Laser Ablation Surface Preparation of Ti-6A1-4V for Adhesive Bonding

Adhesive bonding offers many advantages over mechanical fastening, but requires certification before it can be incorporated in primary structures for commercial aviation without disbond-arrestment features or redundant load paths. Surface preparation is widely recognized as the key step to producing robust and predictable bonds. Laser ablation imparts both topographical and chemical changes to a surface which can lead to increased bond durability. A laser based process provides an alternative to chemical-dip, manual abrasion and grit blast treatments which are expensive, hazardous, polluting, and less precise. This report documents preliminary testing of a surface preparation technique using laser ablation as a replacement for the chemical etch and abrasive processes currently applied to Ti-6Al-4V alloy adherends. Failure mode, surface roughness, and chemical makeup were analyzed using fluorescence enhanced visualization, microscopy, and X-ray photoelectron spectroscopy, respectively. Single lap shear tests were conducted on bonded and aged specimens to observe bond strength retention and failure mode. Some promising results showed increasing strength and durability of lap shear specimens as laser ablation coverage area and beam intensity increased. Chemical analyses showed trends for surface chemical species which correlated with improved bond strength and durability. Combined, these results suggest that laser ablation is a viable process for inclusion with or/and replacement of one or more currently used titanium surface treatments. On-going work will focus on additional mechanical tests to further demonstrate improved bond durability.

Palmieri, Frank L.↗

NASA NTRSDate not supplied

Materials for Extreme Environments: Paving the Way for Lunar Exploration

As humanity expands its ventures into lunar and planetary exploration, the demand intensifies for resilient materials capable of enduring extreme environmental and service conditions. The Moon’s surface presents numerous challenges, including ultra-high vacuum exposure, temperature extremes and intense radiation. Additionally, lunar regolith poses a significant threat to component durability and reusability due to its abrasive nature. Lunar dust particles scoring, adhering, or embedding into surfaces and within device-confined geometries, such as bearings, drive mechanisms and connectors, can cause premature component wear or failure. Furthermore, the interaction between the rocket plume and the surface during vehicle landings and ascents creates severe erosive conditions near critical vehicle components and adjacent infrastructure. A key barrier hindering materials discovery for lunar dust tolerant applications is a lack of standard laboratory methods to evaluate material properties and performance under representative operating conditions. A case will be presented for research activities supporting identification, processing and characterization of candidate materials in conjunction with innovations in standardized testing and qualification. Results will highlight current and emerging test methods for simulating lunar dust exposure and component degradation, paving the way for a new generation of robust materials and coatings for space exploration.

Lunar dust↗

NASA NTRS2016

Robust Thermal Control of Propulsion Lines for Space Missions

In spacecraft that have propulsion lines that are located externally with open bus architecture, the lines are typically insulated by Multi Layer Insulation (MLI) blankets to protect them thermally from the cold space environment. In addition to heat loss through the insulation, mechanical supports used to attach the lines to the spacecraft structure also create heat leaks from the lines. These lines typically have very low thermal conduction in the axial direction, so the heat balance in the lines tends to be very local without much heat spreading. The typical allowable temperature range for hydrazine-based lines is +15/+50°C. This tight temperature range has to be maintained for every location on these lines. For typical spacecraft, these lines can be several meters long. Temperature control is typically achieved by closed loop monitoring of temperatures along the lines and the corresponding powering of the heaters in a bang-bang approach to maintain the temperatures within the dead band of the control loop. The temperatures of propulsion lines are a function of several parameters with heat loss characteristics of the MLI being the key one. Unfortunately, this same key characteristic (MLI effective emittance) has a large variation along its length due to its dependence on workmanship, which in turn leads to large uncertainties in the propulsion lines’ local temperatures. Because of the poor conduction along the axial direction, heat balance along the length varies dramatically from one location to the next, even few inches apart, depending on the combination of the controlling parameters. This paper describes various robust design and implementation approaches that have been investigated to greatly reduce the randomness associated with predicting the temperature of these propulsion lines.

Bhandari, Pradeep↗

NASA NTRSDate not supplied

Dragonfly Entry and Descent Flight Mechanics Modeling and Analysis

Dragonfly is a New Frontiers Program mission that will deliver a rotorcraft lander to Saturn’s moon, Titan [1]. The focus of this work is to analyze the trajectory from cruise stage separation until lander separation. This analysis is done by the NASA Langley (LaRC) EDL team using Program to Optimize Trajectories II (POST2)[2]. This poster provides an overview of the current design and the robustness of the overall entry sequence as assessed using a Monte Carlo uncertainty analysis. This mission is led by Johns Hopkins Applied Physics Laboratory (APL), presented here is the design and analysis as of the Dragonfly EDL Assembly Preliminary Design Review (PDR).

Modeling↗

NASA NTRS1994

Robust 300 C wire insulation system

The objective of this program is to identify, develop, and demonstrate an optimum wire insulation system that is capable of continuous operation at 300 C. The system is to possess a combination of superior electrical (AC or DC), mechanical, and physical properties over the KAPTON (trademark) derived insulations described in MIL-W-81381 and those hybrid constructions identified in Air Force contract F33615-89-C-5606, commonly known as TKT constructions.

Nairus, John G.↗

NASA NTRS1988

Viscous flow computations using a second-order upwind differencing scheme

In the present computations of a wide range of fluid flow problems by means of the primitive variables-incorporating Navier-Stokes equations, a mixed second-order upwinding scheme approximates the convective terms of the transport equations and the scheme's accuracy is verified for convection-dominated high Re number flow problems. An adaptive dissipation scheme is used as a monotonic supersonic shock flow capture mechanism. Many benchmark fluid flow problems, including the compressible and incompressible, laminar and turbulent, over a wide range of M and Re numbers, are presently studied to verify the accuracy and robustness of this numerical method.

Chen, Y. S.↗

NASA NTRS2016

Microstructure Evolution and Durability of Advanced Environmental Barrier Coating Systems for SiC/SiC Ceramic Matrix Composites

Environmental barrier coated SiC-SiC ceramic matrix composites (CMCs) systems will play a crucial role in next generation turbine engines for hot-section component applications because of their ability to significantly increase engine operating temperatures with improved efficiency, reduce engine weight and cooling requirements. Advanced HfO2 and rare earth silicate environmental barrier coatings (EBCs), along with multicomponent hafnium and rare earth silicide EBC bond coats have been developed. The coating degradation mechanisms in the laboratory simulated engine thermal cycling, and fatigue-creep operating environments are also being investigated. This paper will focus on the microstructural and compositional evolutions of an advanced environmental barrier coating system on a SiC-SiC CMC substrate during the high temperature simulated durability tests, by using a Field Emission Gun Scanning Electron Microscopy, Energy Dispersive Spectroscopy (EDS) and Wavelength Dispersive Spectroscopy (WDS). The effects of Calcium-Magnesium-Alumino-Silicate (CMAS) from road sand or volcano-ash deposits on the degradation mechanisms of the environmental barrier coating systems will also be discussed. The detailed analysis results help understand the EBC-CMC system performance, aiming at the durability improvements to achieve more robust, prime-reliant environmental barrier coatings.

ceramic matrix composites↗

NASA NTRSDate not supplied

Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy

Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.

Rodolfo Ledesma↗

NASA NTRSDate not supplied

Closed-Loop Control of Laser Surface Treatment via Laser Induced Breakdown Spectroscopy

Rodolfo Ledesma↗

NASA NTRSDate not supplied

Parallelized Carbon Oxidation and Surface Recession Model in Direct-Simulation Monte Carlo Code, SPARTA

Ablative thermal protection system (TPS) materials for spacecraft are composites that often consist of a carbon-based reinforcement and a polymeric matrix. During Earth re-entry, they endure high-temperature oxidation and surface recession. Oxidation is an important mechanism for ablation, sometimes leading to the weakening, spallation, or failure of the oxidized fibers at the surface and in the char layer. However, more details are required including accurate material properties of the fiber microstructure, whether the fibers recede homogenously or localized at pits, and the role of pyrolysis outgassing in order to evaluate the role oxidation plays in the degradation and failure mechanisms of these materials. In this work, we demonstrate a parallelizable oxidation-driven ablation model developed for detailed, large-scale simulations in the DSMC code SPARTA. We also develop robust algorithms which handle the conservation of the surface state after an ablation step. Finally, we verify our model for both simple and more complex chemistry as well as microstructures with reaction statistics, oxidation depth calculations, and detailed visualization of oxidation-induced material recession at the microscale.

V Arias↗

NASA NTRS2013

Chemical Microsensor Development for Aerospace Applications

Numerous aerospace applications, including low-false-alarm fire detection, environmental monitoring, fuel leak detection, and engine emission monitoring, would benefit greatly from robust and low weight, cost, and power consumption chemical microsensors. NASA Glenn Research Center has been working to develop a variety of chemical microsensors with these attributes to address the aforementioned applications. Chemical microsensors using different material platforms and sensing mechanisms have been produced. Approaches using electrochemical cells, resistors, and Schottky diode platforms, combined with nano-based materials, high temperature solid electrolytes, and room temperature polymer electrolytes have been realized to enable different types of microsensors. By understanding the application needs and chemical gas species to be detected, sensing materials and unique microfabrication processes were selected and applied. The chemical microsensors were designed utilizing simple structures and the least number of microfabrication processes possible, while maintaining high yield and low cost. In this presentation, an overview of carbon dioxide (CO2), oxygen (O2), and hydrogen/hydrocarbons (H2/CxHy) microsensors and their fabrication, testing results, and applications will be described. Particular challenges associated with improving the H2/CxHy microsensor contact wire-bonding pad will be discussed. These microsensors represent our research approach and serve as major tools as we expand our sensor development toolbox. Our ultimate goal is to develop robust chemical microsensor systems for aerospace and commercial applications.

hydrogen sensors↗

NASA NTRS2013

Surface-Enhanced Raman Scattering Using Silica Whispering-Gallery Mode Resonators

The motivation of this work was to have robust spectroscopic sensors for sensitive detection and chemical analysis of organic and molecular compounds. The solution is to use silica sphere optical resonators to provide surface-enhanced spectroscopic signal. Whispering-gallery mode (WGM) resonators made from silica microspheres were used for surface-enhanced Raman scattering (SERS) without coupling to a plasmonic mechanism. Large Raman signal enhancement is observed by exclusively using 5.08-micron silica spheres with 785-nm laser excitation. The advantage of this non-plasmonic approach is that the active substrate is chemically inert silica, thermally stable, and relatively simple to fabricate. The Raman signal enhancement is broadly applicable to a wide range of molecular functional groups including aliphatic hydrocarbons, siloxanes, and esters. Applications include trace organic analysis, particularly for in situ planetary instruments that require robust sensors with consistent response.

Anderson, Mark S.↗

NASA NTRS2002

Turbopump Performance Improved by Evolutionary Algorithms

The development of design optimization technology for turbomachinery has been initiated using the multiobjective evolutionary algorithm under NASA's Intelligent Synthesis Environment and Revolutionary Aeropropulsion Concepts programs. As an alternative to the traditional gradient-based methods, evolutionary algorithms (EA's) are emergent design-optimization algorithms modeled after the mechanisms found in natural evolution. EA's search from multiple points, instead of moving from a single point. In addition, they require no derivatives or gradients of the objective function, leading to robustness and simplicity in coupling any evaluation codes. Parallel efficiency also becomes very high by using a simple master-slave concept for function evaluations, since such evaluations often consume the most CPU time, such as computational fluid dynamics. Application of EA's to multiobjective design problems is also straightforward because EA's maintain a population of design candidates in parallel. Because of these advantages, EA's are a unique and attractive approach to real-world design optimization problems.

Oyama, Akira↗

NASA NTRS2005

Strategies and Approaches to TPS Design

Thermal protection systems (TPS) insulate planetary probes and Earth re-entry vehicles from the aerothermal heating experienced during hypersonic deceleration to the planet s surface. The systems are typically designed with some additional capability to compensate for both variations in the TPS material and for uncertainties in the heating environment. This additional capability, or robustness, also provides a surge capability for operating under abnormal severe conditions for a short period of time, and for unexpected events, such as meteoroid impact damage, that would detract from the nominal performance. Strategies and approaches to developing robust designs must also minimize mass because an extra kilogram of TPS displaces one kilogram of payload. Because aircraft structures must be optimized for minimum mass, reliability-based design approaches for mechanical components exist that minimize mass. Adapting these existing approaches to TPS component design takes advantage of the extensive work, knowledge, and experience from nearly fifty years of reliability-based design of mechanical components. A Non-Dimensional Load Interference (NDLI) method for calculating the thermal reliability of TPS components is presented in this lecture and applied to several examples. A sensitivity analysis from an existing numerical simulation of a carbon phenolic TPS provides insight into the effects of the various design parameters, and is used to demonstrate how sensitivity analysis may be used with NDLI to develop reliability-based designs of TPS components.

Paul Kolodziej↗