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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Post STS-134 Evaluation of Main Flame Deflector Witness Materials

NASA and USA design engineers submitted witness materials from the solid rocket booster (SRB) main flame deflector for evaluation after the launch of STS-134. The following items were submitted for analysis: 1018 steel witness rods 304 stainless steel caps, tungsten pistons, and A-286 piston sleeves. All of the items were photographed in order to document their condition after the launch of STS-134. All of the items were dimensionally measured in order to determine the amount of material lost during launch. Microstructural changes were observed in the 1018 witness rod metallographic samples due to the heat of the launch

Long, Victoria↗
NASA NTRS2012

Sample Sealing Approaches for Mars Sample Return Caching

Objective ot this project was to investigate sealing methods for encapsulating samples in 1 cm diameter thin-walled sample tubes applicable to future proposed Mars Sample Return Techniques implemented include a spring energized Teflon sleeve plug, a crimped tube seal, a heat-activated shape memory alloy plug, a shape memory alloy activated cap, a solder-based plug, and a solder-based cap

Mars Sample Return (MSR) mission↗
NASA NTRS2014

NASA Tech Briefs, March 2014

Topics include: Data Fusion for Global Estimation of Forest Characteristics From Sparse Lidar Data; Debris and Ice Mapping Analysis Tool - Database; Data Acquisition and Processing Software - DAPS; Metal-Assisted Fabrication of Biodegradable Porous Silicon Nanostructures; Post-Growth, In Situ Adhesion of Carbon Nanotubes to a Substrate for Robust CNT Cathodes; Integrated PEMFC Flow Field Design for Gravity-Independent Passive Water Removal; Thermal Mechanical Preparation of Glass Spheres; Mechanistic-Based Multiaxial-Stochastic-Strength Model for Transversely-Isotropic Brittle Materials; Methods for Mitigating Space Radiation Effects, Fault Detection and Correction, and Processing Sensor Data; Compact Ka-Band Antenna Feed with Double Circularly Polarized Capability; Dual-Leadframe Transient Liquid Phase Bonded Power Semiconductor Module Assembly and Bonding Process; Quad First Stage Processor: A Four-Channel Digitizer and Digital Beam-Forming Processor; Protective Sleeve for a Pyrotechnic Reefing Line Cutter; Metabolic Heat Regenerated Temperature Swing Adsorption; CubeSat Deployable Log Periodic Dipole Array; Re-entry Vehicle Shape for Enhanced Performance; NanoRacks-Scale MEMS Gas Chromatograph System; Variable Camber Aerodynamic Control Surfaces and Active Wing Shaping Control; Spacecraft Line-of-Sight Stabilization Using LWIR Earth Signature; Technique for Finding Retro-Reflectors in Flash LIDAR Imagery; Novel Hemispherical Dynamic Camera for EVAs; 360 deg Visual Detection and Object Tracking on an Autonomous Surface Vehicle; Simulation of Charge Carrier Mobility in Conducting Polymers; Observational Data Formatter Using CMOR for CMIP5; Propellant Loading Physics Model for Fault Detection Isolation and Recovery; Probabilistic Guidance for Swarms of Autonomous Agents; Reducing Drift in Stereo Visual Odometry; Future Air-Traffic Management Concepts Evaluation Tool; Examination and A Priori Analysis of a Direct Numerical Simulation Database for High-Pressure Turbulent Flows; and Resource-Constrained Application of Support Vector Machines to Imagery.

Source record↗
NASA NTRS2013

Acquisition and Retaining Granular Samples via a Rotating Coring Bit

This device takes advantage of the centrifugal forces that are generated when a coring bit is rotated, and a granular sample is entered into the bit while it is spinning, making it adhere to the internal wall of the bit, where it compacts itself into the wall of the bit. The bit can be specially designed to increase the effectiveness of regolith capturing while turning and penetrating the subsurface. The bit teeth can be oriented such that they direct the regolith toward the bit axis during the rotation of the bit. The bit can be designed with an internal flute that directs the regolith upward inside the bit. The use of both the teeth and flute can be implemented in the same bit. The bit can also be designed with an internal spiral into which the various particles wedge. In another implementation, the bit can be designed to collect regolith primarily from a specific depth. For that implementation, the bit can be designed such that when turning one way, the teeth guide the regolith outward of the bit and when turning in the opposite direction, the teeth will guide the regolith inward into the bit internal section. This mechanism can be implemented with or without an internal flute. The device is based on the use of a spinning coring bit (hollow interior) as a means of retaining granular sample, and the acquisition is done by inserting the bit into the subsurface of a regolith, soil, or powder. To demonstrate the concept, a commercial drill and a coring bit were used. The bit was turned and inserted into the soil that was contained in a bucket. While spinning the bit (at speeds of 600 to 700 RPM), the drill was lifted and the soil was retained inside the bit. To prove this point, the drill was turned horizontally, and the acquired soil was still inside the bit. The basic theory behind the process of retaining unconsolidated mass that can be acquired by the centrifugal forces of the bit is determined by noting that in order to stay inside the interior of the bit, the frictional force must be greater than the weight of the sample. The bit can be designed with an internal sleeve to serve as a container for granular samples. This tube-shaped component can be extracted upon completion of the sampling, and the bottom can be capped by placing the bit onto a corklike component. Then, upon removal of the internal tube, the top section can be sealed. The novel features of this device are: center dot A mechanism of acquiring and retaining granular samples using a coring bit without a closed door. center dot An acquisition bit that has internal structure such as a waffle pattern for compartmentalizing or helical internal flute to propel the sample inside the bit and help in acquiring and retaining granular samples. center dot A bit with an internal spiral into which the various particles wedge. center dot A design that provides a method of testing frictional properties of the granular samples and potentially segregating particles based on size and density. A controlled acceleration or deceleration may be used to drop the least-frictional particles or to eventually shear the unconsolidated material near the bit center.

Bar-Cohen, Yoseph↗
NASA NTRS2014

Thrust Measurement of Dielectric Barrier Discharge (DBD) Plasma Actuators: New Anti-Thrust Hypothesis, Frequency Sweeps Methodology, Humidity and Enclosure Effects

We discuss thrust measurements of Dielectric Barrier Discharge (DBD) plasma actuators devices used for aerodynamic active flow control. After a review of our experience with conventional thrust measurement and significant non-repeatability of the results, we devised a suspended actuator test setup, and now present a methodology of thrust measurements with decreased uncertainty. The methodology consists of frequency scans at constant voltages. The procedure consists of increasing the frequency in a step-wise fashion from several Hz to the maximum frequency of several kHz, followed by frequency decrease back down to the start frequency of several Hz. This sequence is performed first at the highest voltage of interest, then repeated at lower voltages. The data in the descending frequency direction is more consistent and selected for reporting. Sample results show strong dependence of thrust on humidity which also affects the consistency and fluctuations of the measurements. We also observed negative values of thrust, or "anti-thrust", at low frequencies between 4 Hz and up to 64 Hz. The anti-thrust is proportional to the mean-squared voltage and is frequency independent. Departures from the parabolic anti-thrust curve are correlated with appearance of visible plasma discharges. We propose the anti-thrust hypothesis. It states that the measured thrust is a sum of plasma thrust and anti-thrust, and assumes that the anti-thrust exists at all frequencies and voltages. The anti-thrust depends on actuator geometry and materials and on the test installation. It enables the separation of the plasma thrust from the measured total thrust. This approach enables more meaningful comparisons between actuators at different installations and laboratories. The dependence on test installation was validated by surrounding the actuator with a grounded large-diameter metal sleeve. Strong dependence on humidity is also shown; the thrust significantly increased with decreasing humidity, e.g., 44 percent increase as relative humidity changed from 18 percent and dew point 33 degF to 50 percent and dew point of 57 degF.

Ashpis, David E.↗
NASA NTRS2014

Human Performance in Simulated Reduced Gravity Environments

NASA is currently designing a new space suit capable of working in deep space and on Mars. Designing a suit is very difficult and often requires trade‐offs between performance, cost, mass, and system complexity. Our current understanding of human performance in reduced gravity in a planetary environment (the moon or Mars) is limited to lunar observations, studies from the Apollo program, and recent suit tests conducted at JSC using reduced gravity simulators. This study will look at our most recent reduced gravity simulations performed on the new Active Response Gravity Offload System (ARGOS) compared to the C‐9 reduced gravity plane. Methods: Subjects ambulated in reduced gravity analogs to obtain a baseline for human performance. Subjects were tested in lunar gravity (1.6 m/sq s) and Earth gravity (9.8 m/sq s) in shirt‐sleeves. Subjects ambulated over ground at prescribed speeds on the ARGOS, but ambulated at a self‐selected speed on the C‐9 due to time limitations. Subjects on the ARGOS were given over 3 minutes to acclimate to the different conditions before data was collected. Nine healthy subjects were tested in the ARGOS (6 males, 3 females, 79.5 +/- 15.7 kg), while six subjects were tested on the C‐9 (6 males, 78.8 +/- 11.2 kg). Data was collected with an optical motion capture system (Vicon, Oxford, UK) and was analyzed using customized analysis scripts in BodyBuilder (Vicon, Oxford, UK) and MATLAB (MathWorks, Natick, MA, USA). Results: In all offloaded conditions, variation between subjects increased compared to 1‐g. Kinematics in the ARGOS at lunar gravity resembled earth gravity ambulation more closely than the C‐9 ambulation. Toe‐off occurred 10% earlier in both reduced gravity environments compared to earth gravity, shortening the stance phase. Likewise, ankle, knee, and hip angles remained consistently flexed and had reduced peaks compared to earth gravity. Ground reaction forces in lunar gravity (normalized to Earth body weight) were 0.4 +/- 0.2 on the ARGOS, but only 0.2 +/- 0.1 on the C‐9. Discussion: Gait analysis showed differences in joint kinematics and temporal‐spatial parameters between the reduced gravity simulators and with respect to earth gravity. Although most of the subjects chose a somewhat unique ambulation style as a result of learning to ambulate in a new environment, all but two were consistent with keeping an Earth‐like gait. Learning how reduced gravity affects ambulation will help NASA to determine optimal suit designs, influence mission planning, help train crew, and may shed light on the underlying methods the body uses to optimize gait for energetic efficiency. Conclusion: Kinematic and kinetic analysis demonstrated noteworthy differences between an offloaded environment and 1‐g, as would be expected. The analysis showed a trend to change the ambulation style in an offloaded environment to a rolling‐loping walk (resembling crosscountry skiing) with increased swing time. This ambulation modification, particularly in the ARGOS, indicated that the relative kinetic energy of the subject was increased, on average, per the static body weight compared to the 1‐g condition. How much of this was influenced by the active offloading of the ARGOS system is unknown.

Cowley, Matthew↗
NASA NTRS2014

Dielectric Barrier Discharge (DBD) Plasma Actuators Thrust-Measurement Methodology Incorporating New Anti-Thrust Hypothesis

We discuss thrust measurements of Dielectric Barrier Discharge (DBD) plasma actuators devices used for aerodynamic active flow control. After a review of our experience with conventional thrust measurement and significant non-repeatability of the results, we devised a suspended actuator test setup, and now present a methodology of thrust measurements with decreased uncertainty. The methodology consists of frequency scans at constant voltages. The procedure consists of increasing the frequency in a step-wise fashion from several Hz to the maximum frequency of several kHz, followed by frequency decrease back down to the start frequency of several Hz. This sequence is performed first at the highest voltage of interest, then repeated at lower voltages. The data in the descending frequency direction is more consistent and selected for reporting. Sample results show strong dependence of thrust on humidity which also affects the consistency and fluctuations of the measurements. We also observed negative values of thrust or "anti-thrust", at low frequencies between 4 Hz and up to 64 Hz. The anti-thrust is proportional to the mean-squared voltage and is frequency independent. Departures from the parabolic anti-thrust curve are correlated with appearance of visible plasma discharges. We propose the anti-thrust hypothesis. It states that the measured thrust is a sum of plasma thrust and anti-thrust, and assumes that the anti-thrust exists at all frequencies and voltages. The anti-thrust depends on actuator geometry and materials and on the test installation. It enables the separation of the plasma thrust from the measured total thrust. This approach enables more meaningful comparisons between actuators at different installations and laboratories. The dependence on test installation was validated by surrounding the actuator with a large diameter, grounded, metal sleeve.

Ashpis, David E.↗
NASA NTRS2011

A Dual-Chamber Hybrid Inflatable Suitlock (DCIS) for Planetary Surfaces or Deep Space

The Habitat Demonstration Unit (HDU) Project in conjunction with the NASA Extravehicular Activity (EVA) team has identified a need for a hybrid inflatable and hard shell suitlock that can be used for planetary surface and deep space human exploration missions. Through ongoing analog studies at NASA Desert Research and Technologies Studies (D-RATS) and in NASA's Prototyping Testbed Facility, it has been determined that a compactly stowed, deployable suitlock unit is needed to accommodate advanced EVA egress and ingress operations for various environments with only minor modification.The Dual-Chamber Inflatable Suitlock (DCIS) consists of three hard in-line bulkheads, separating two cylindrical membrane-walled compartments. A dual-compartment suitlock will allow for dust and contaminant control, suit maintenance, and efficient egress / ingress; and the inflatable aspect of the design will allow the unit to stow in a compact package for transport. This paper describes the DCIS functionality, subsystems, and operational scenarios.The novel concepts included in the DCIS are the triple bulkhead, dual-chamber that has one compartment that is continuously pressurized (either at cabin pressure, or may be used for transitional pressure from high-pressure habitats), and a nominal unpressurized second compartment where the suits will be kept for normal operations. The advantages include quicker egress / ingress, capacity for 'shirt sleeve' suit maintenance, and portability of the entire unit.

habitat demonstration unit (HUD)↗
NASA NTRS2013

Gesture-Based Robot Control with Variable Autonomy from the JPL Biosleeve

This paper presents a new gesture-based human interface for natural robot control. Detailed activity of the user's hand and arm is acquired via a novel device, called the BioSleeve, which packages dry-contact surface electromyography (EMG) and an inertial measurement unit (IMU) into a sleeve worn on the forearm. The BioSleeve's accompanying algorithms can reliably decode as many as sixteen discrete hand gestures and estimate the continuous orientation of the forearm. These gestures and positions are mapped to robot commands that, to varying degrees, integrate with the robot's perception of its environment and its ability to complete tasks autonomously. This flexible approach enables, for example, supervisory point-to-goal commands, virtual joystick for guarded teleoperation, and high degree of freedom mimicked manipulation, all from a single device. The BioSleeve is meant for portable field use; unlike other gesture recognition systems, use of the BioSleeve for robot control is invariant to lighting conditions, occlusions, and the human-robot spatial relationship and does not encumber the user's hands. The BioSleeve control approach has been implemented on three robot types, and we present proof-of-principle demonstrations with mobile ground robots, manipulation robots, and prosthetic hands.

BioSleeve↗
NASA NTRS2015

Reducing the Effect of Transducer Mount Induced Noise on Aeroacoustic Wind Tunnel Testing Data with a New Transducer Mount Design

Characterization of launch vehicle unsteady aerodynamics is a field best studied through experimentation, which is often carried out in the form of large scale wind tunnel testing. Measurement of the fluctuating pressures induced by the boundary layer noise is customarily made with miniature pressure transducers installed into a model of the vehicle of interest. Literature shows that noise level increases between two to five decibels (dB referenced to 20 micropascal) can be induced when the transducer surface is not mounted perfectly flush with the model outer surface. To reduce this artificially induced noise, special transducer holders have been used for aeroacoustic wind tunnel testing by NASA. This holder is a sleeve into which the transducer fits, with a cap that allows it to be mounted in a recessed hole in the model. A single hole in the holder allows the transport of the tunnel medium so the transducer can discriminate the fluctuating pressure due to the turbulent boundary layer noise. The holder is first dry fitted into the model and any difference in height between the holder and the model surface can be sanded flush. The holder is then removed from the model, the transducer glued inside the holder, and the holder replaced in the model, secured also with glue, thus eliminating the problem of noise level increases due to lack of flushness. In order to work with this holder design, special transducers have been ordered with their standard screen removed and the diaphragm moved as close to the top of the casing as possible to minimize any cavity volume. Although this greatly reduces induced noise due to the transducers being out of flush, the holders can also induce a cavity resonance that is usually at a very high frequency. This noise is termed transducer mount induced noise (XMIN). The peak of the mode can vary with the cavity depth, boundary layer noise that can excite the mode, tunnel flow medium, and the build of the transducers. Because the boundary layer flow interaction with the microphone holder seems to have some effect on the cavity resonance response, the NASA/Marshall Space Flight Center (MSFC) aeroacoustic team postulated that changing the design of the holder might reduce the cavity resonance response. An experiment was performed at the MSFC Trisonic Wind Tunnel comparing a new holder design with the traditional MSFC holder. The new holder design is intended to mimic the Kulite Semiconductors, Inc. B-screen, where the single hole of the traditional MSFC holder is replaced by a series of ten 0.007 inch diameter holes. This particular design serves to protect the transducer diaphragm as in the manufacturer's B-screen, but also increases the frequency of the XMIN such that it is not apparent in the data collected from aeroacoustic wind tunnel tests. MSFC compared the two holder designs by installing two transducers in standard holders on one side of a ten inch long ten degree cone, and two transducers in B-screen holders on the opposite side for a series of runs at different conditions. Over 11-13 February, 2013, the model was run at Mach numbers between 0.80 and 1.96 at angles of attack at 0 deg, plus or minus 1 deg, plus or minus 2 deg, plus or minus 4 deg, and plus or minus 8 deg. Model roll attitudes at 0 deg, 90 deg, and 180 deg were tested to isolate potential tunnel bias. This paper presents results from the test showing that the proposed holder design significantly reduces the influence of XMIN on measured fluctuating pressure levels.

Herron, A. J.↗
NASA NTRS2015

Grasp Assist Device with Shared Tendon Actuator Assembly

A grasp assist device includes a glove with first and second tendon-driven fingers, a tendon, and a sleeve with a shared tendon actuator assembly. Tendon ends are connected to the respective first and second fingers. The actuator assembly includes a drive assembly having a drive axis and a tendon hook. The tendon hook, which defines an arcuate surface slot, is linearly translatable along the drive axis via the drive assembly, e.g., a servo motor thereof. The flexible tendon is routed through the surface slot such that the surface slot divides the flexible tendon into two portions each terminating in a respective one of the first and second ends. The drive assembly may include a ball screw and nut. An end cap of the actuator assembly may define two channels through which the respective tendon portions pass. The servo motor may be positioned off-axis with respect to the drive axis.

Ihrke, Chris A.↗
NASA NTRS2017

Structural Joint with Multi-Axis Load Carrying Capability

A structural joint is formed of a mandrel having a plurality of bumps and dimples formed thereon which is fitted into a sleeve. The bumps and dimples form a non-circular geometry at all points along the length of the mandrel. The bumps are defined by surfaces which have 1st and 2nd derivatives which are continuous.

Wu, K. Chauncey↗
NASA NTRS2017

An Alternative Approach to Human Servicing of Crewed Earth Orbiting Spacecraft

As crewed spacecraft have grown larger and more complex, they have come to rely on spacewalks, or Extravehicular Activities (EVA), for assembly and to assure mission success. Typically, these spacecraft maintain all of the hardware and trained personnel needed to perform an EVA on-board at all times. Maintaining this capability requires up-mass, volume for storage of EVA hardware, crew time for ground and on-orbit training, and on-orbit maintenance of EVA hardware. This paper proposes an alternative methodology, utilizing either launch-on-need hardware and crew or regularly scheduled missions to provide EVA capability for space stations in low Earth orbit after assembly complete. Much the same way that one would call a repairman to fix something at their home these EVAs are dedicated to maintenance and upgrades of the orbiting station. For crew safety contingencies it is assumed the station would be designed such the crew could either solve those issues from inside the spacecraft or use the docked Earth to Orbit vehicles as a return lifeboat, in the same manner as the International Space Station (ISS) which does not rely on EVA for crew safety related contingencies. This approach would reduce ground training requirements for long duration crews, save Intravehicular Activity (IVA) crew time in the form of EVA hardware maintenance and on-orbit training, and lead to more efficient EVAs because they would be performed by specialists with detailed knowledge and training stemming from their direct involvement in the development of the EVA. The on-orbit crew would then be available to focus on the immediate response to any failures such as IVA systems reconfiguration or jumper installation as well as the day-to-day operations of the spacecraft and payloads. This paper will look at how current unplanned EVAs are conducted on ISS, including the time required for preparation, and offer an alternative for future spacecraft. As this methodology relies on the on-time and on-need launch of spacecraft, any space station that utilized this approach would need a robust transportation system, possibly including more than one launch vehicle capable of carrying crew. In addition, the fault tolerance of the future space station would be an important consideration in how much time was available for EVA preparation after the failure. Ideally the fault tolerance of the station would allow for the maintenance tasks to be grouped such that they could be handled by regularly scheduled maintenance visits and not contingency launches. Each future program would have to weigh the risk of on-time launch against the increase in available crew time for the main objective of the spacecraft. This is only one of several ideas that could be used to reduce or eliminate a station's reliance on rapid turnaround EVAs using on-board crew. Others could include having shirt-sleeve access to critical systems or utilizing low pressure temporarily pressurized equipment bays.

Mularski, John R.↗
NASA NTRS2017

Development of Augmented Spark Impinging Igniter System for Methane Engines

The Lunar Cargo Transportation and Landing by Soft Touchdown (Lunar CATALYST) program is establishing multiple no-funds-exchanged Space Act Agreement (SAA) partnerships with U.S. private sector entities. The purpose of this program is to encourage the development of robotic lunar landers that can be integrated with U.S. commercial launch capabilities to deliver payloads to the lunar surface. NASA can share technology and expertise under the SAA for the benefit of the CATALYST partners. MSFC seeking to vacuum test Augmented Spark Impinging (ASI) igniter with methane and new exciter units to support CATALYST partners and NASA programs. ASI has previously been used/tested successfully at sea-level, with both O2/CH4 and O2/H2 propellants. Conventional ignition exciter systems historically experienced corona discharge issues in vacuum. Often utilized purging or atmospheric sealing on high voltage lead to remedy. Compact systems developed since PCAD could eliminate the high-voltage lead and directly couple the exciter to the spark igniter. MSFC developed Augmented Spark Impinging (ASI) igniter. Successfully used in several sea-level test programs. Plasma-assisted design. Portion of ox flow is used to generate hot plasma. Impinging flows downstream of plasma. Additional fuel flow down torch tube sleeve for cooling near stoichiometric torch flame. Testing done at NASA GRC Altitude Combustion Stand (ACS) facility 2000-lbf class facility with altitude simulation up to around 100,000 ft. (0.2 psia [10 Torr]) via nitrogen driven ejectors. Propellant conditioning systems can provide temperature control of LOX/CH4 up to test article.

Chemical Propulsion↗
NASA NTRS2018

Measurements of Parachute Dynamics in the World's Largest Wind Tunnel by Stereo Photogrammetry

Between 2012 and 2017, parachutes for four NASA Projects were tested in the 80- by 120-Ft test section of the National Full-Scale Aerodynamic Complex (NFAC) at NASA Ames Research Center. These projects were: (1) Low-Density Supersonic Decelerator (LDSD); (2) Capsule Parachute Assembly System (CPAS, for Orion); (3) Interior Exploration using Seismic Investigations, Geodesy and Heat Transport (InSight, a Mars mission); and (4) Mars 2020. In all tests stereo photogrammetry was used to measure time-dependent positions of features on the canopies. For the LDSD and CPAS tests, where the purpose was to study the trade-off between stability and drag of different parachute designs, the pendulum motion of the canopies about the riser attachment point was measured by calibrated cameras in the diffuser. The CPAS test also included static measurements where the inflated parachutes were pulled to the side by a system of tethers. The Insight tests were structural qualification tests where each canopy was packed in a bag and launched from a mortar. Cameras in the diffuser measured the trajectory of the bag and the stripping of the bag from the canopy. The Mars 2020 test was a workmanship verification test where the canopies were either launched from a mortar or deployed from a sleeve stretched along the tunnel axis. The deployments were recorded from many directions by thirteen high-speed cameras distributed in the diffuser and test section. Photogrammetry was not planned; however, after a tunnel-related accident ended the test prematurely, photogrammetric measurements were bootstrapped from the images to support the accident investigations. This paper describes how the photogrammetry measurements were made in each test and presents typical results.

Schairer, Edward T.↗
NASA NTRS2018

Performance, Stability and Compatibility of Oxygen/RP-1 Multi-Element Oxidizer-Rich Staged-Combustion Injectors

In 2015 and 2016, the National Aeronautics and Space Administration Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/RP-1 propellant multi-element oxidizer-rich staged-combustion test article. The main objective was to provide thrust chamber combustion stability data as part of the Combustion Stability Tool Development program, although demonstration of performance and compatibility of oxidizer-rich main injectors was also important. Funding was provided by the Air Force Space and Missile Systems Center. Five configurations of main injectors were designed and fabricated, using conventional gas-centered swirl coaxial injector element designs generally similar to those used in oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines. Variations of element features included element size, recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. Ablative combustion chambers were fabricated based on hardware previously used at the NASA MSFC for testing at similar size and pressure. Existing oxygen/RP-1 oxidizer-rich subscale preburner injectors and hot gas ducts from a previous NASA-funded program were modified for use to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Testing of the resulting integrated test article - which included the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was conducted at Test Stand 116 at the East Test Area of the NASA MSFC. The test article was well instrumented with static and dynamic pressure, temperature, and vibration sensors. This paper presents and discusses all the hot-fire test results of the integrated test article thrust chamber. Eighteen successful hot-fire tests of the integrated rig were conducted. Testing was accomplished with all five of the injector element concepts. Main combustion chamber pressures ranged from 710 to 2350 psia, and main combustion chamber mixture ratios ranged from 2.47 to 2.87. A chamber barrier fuel film coolant of about 2% to 4% of the total fuel flow was used for most tests. Characteristic exhaust velocity efficiency excluding the influence of the fuel film cooling ranged from 91% to 98% of theoretical. All tests of the thrust chamber exhibited stable combustion, even down to 40% of nominal operating pressures. Compatibility of the injector face and combustion chamber walls was acceptable. This paper is a follow-on to publication of preliminary test data presented at the 2016 JANNAF Liquid Propulsion Subcommittee meeting.

Hulka, J. R.↗
NASA NTRS2018

Comparison of Single-Element and Multi-Element Oxygen/RP-1 Oxidizer-Rich Staged-Combustion Injector Hot-Fire Test Results

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/hydrocarbon propellant multi-element integrated test article that included an oxidizer-rich oxygen/hydrocarbon propellant preburner and a staged-combustion main injector. Also as part of this project, the Air Force Research Laboratory fabricated single-element main injectors of the same designs as used in the NASA multi-element injectors, and tested them in a staged-combustion integrated test article that used an oxidizer-rich oxygen/hydrogen propellant preburner. Final results of the multi-element and single-element staged-combustion main injector test programs are described in companion papers at this JANNAF meeting. The design, development, and preliminary test results of these main injectors have also been described in previous JANNAF papers. The main injector element designs were all based on relatively conventional gas-centered swirl coaxial injector element configurations such as used in Russian RD-170 and NK-33 engines, and planned for use in future U.S.-built experimental engine systems such as the Hydrocarbon Boost program demonstration engine. Four different elements were tested in both the multi-element and single-element main injectors, at similar combustion chamber pressures, chamber contraction ratios, and mixture ratios. Variations of the element features included recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. This paper compares the hydraulics, combustion performance, stability, and compatibility characteristics of the single-element and multi-element injectors operated at similar conditions. The single-element hardware is shown to have captured a significant level of the operability of the multi-element hardware.

Hulka, J. R.↗
NASA NTRS2017

Non-Linear Analysis of the NASA Super Pressure Balloons: Whole Flight Simulations

Tensys have a long-established background in the shape generation and load analysis of architectural stressed membrane structures. Founded upon their inTENS finite element analysis suite, these activities have broadened to encompass 'lighter than air' structures such as aerostats, airships, hybrid air vehicles and stratospheric balloons. Tensys have acted as consultants to the NASA Super Pressure Balloon (SPB) Program since 2004. Previous papers have focussed upon the application of inTENS to the overall structural and stability analysis of pumpkin type balloons as used in the SPB Program. Particular emphasis has been placed upon the ability to study both stress and stability at all stages of a flight. As the program has developed, increasing modelling fidelity has been introduced as design refinement has moved emphasis from the overall shape to the performance of individual details. Examples include the introduction of a contact capability into inTENS to better represent the separate cap layer of film. Localised investigations have considered the consequence of local geometric anomalies introduced during fabrication and the effects of debonding of the PBO tendon within its sleeve. Analysis to date has used a material model for the polyethylene shell film developed by Dr Rand of Winzen Engineering, supported by a program of fine resolution material tests at the Balloon Research and Development Laboratory (BRDL) at the GSFC Wallops Island Facility. Based upon work first reported by Schapery, this model has been incorporated into so-called 'snapshot' analyses within inTENS. For a given elapsed time point and temperature distribution, non-linear material properties are iteratively updated for the current stress state in each individual element until changes in those material properties are insignificant. This process has to be iterative as the film stresses and material properties are interdependent. Attempts to derive a time-stepping incremental viscoelastic capability using the Schapery Rand model encountered problems when dealing with the varying temperatures associated with balloon deployment, pressurisation and diurnal behaviour. An alternative approach has been developed by Pellegrino et al at Caltech, again with support from the NASA Balloon Program Office. This is a large strain non-linear viscoelastic model that includes film out-of-plane mechanical and thermal effects. Working from a unified base, this model can be utilised for time-stepping analyses in both a modulus or compliance mode, or a combination of both. This new capability is intended to enhance the current NASA balloon design process. This paper presents the implementation of the Caltech model into a specialist finite element suite, inTENS and its application to whole flight simulations.

Wakefield, David↗