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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2

All sources NASA NTRS DOE OSTI

NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.

Shah, Sandeep↗

NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗

NASA NTRS2023

Find My Astronaut Photo

An automated localization and georectification pipeline for astronaut photography

Machine Learning↗

NASA NTRS1982

Wire EDM for Refractory Materials

In an attempt to reduce fabrication time and costs, Wire Electrical Discharge Machine (Wire EDM) method was investigated as tool for fabricating matched blade roots and disk slots. Eight high-strength nickel-base superalloys were used. Computer-controlled Wire EDM technique provided high quality surfaces with excellent dimensional tolerances. Wire EDM method offers potential for substantial reductions in fabrication costs for "hard to machine" alloys and electrically conductive materials in specific high-precision applications.

Zellars, G. R.↗

NASA NTRS1986

Matching Vibration Testing to "Real-World" Conditions

Vibration spectrum of test machine adjusted to that observed in operation. Test specimen placed in test fixture and attached to shaker. Shaker initially operated at one-quarter full level of input spectrum to prevent overloading. Short vibration test run, and specimen response compared to control spectrum. Imput spectrum then adjusted until response resembles control spectrum.

Olsen, Albert D., Jr.↗

NASA NTRSDate not supplied

Machine Learning Algorithms for Alignment Verification of the Roman Space Telescope

The Nancy Grace Roman Telescope is a NASA observatory designed to unravel the secrets of dark energy and dark matter, search for and image exoplanets, and explore many topics in infrared optics. Scheduled to launch no earlier than October 2026, this 2.4 meter aperture telescope has a field of view 100 times greater than the Hubble Space Telescope. The mission is currently in its construction phase, where the telescope and its two instruments will soon be aligned together to ensure proper pupil matching. To help verify this alignment, multiple point sources above the entrance pupil of the telescope will illuminate the optical path through the telescope-instrument system, and shadows of various obstructions in the system will be analyzed using machine learning algorithms to determine the pupil matching error. This presentation discusses the test approach and the machine learning algorithms employed, as well as our uncertainty predictions based on a modeled Monte-Carlo analysis of the test.

Telescope↗

NASA NTRS1983

Evaluation of human exposure to the noise from large wind turbine generators

The human perception of a nuisance level of noise was quantified in tests and attempts were made to define criteria for acceptable sound levels from wind turbines. Comparisons were made between the sound necessary to cause building vibration, which occurred near the Mod-1 wind turbine, and human perception thresholds for building noise and building vibration. Thresholds were measured for both broadband and impulsive noise, with the finding that noise in the 500-2000 Hz region, and impulses with a 1 Hz fundamental, were most noticeable. Curves were developed for matching a receiver location with expected acoustic output from a machine to determine if the sound levels were offensive. In any case, further data from operating machines are required before definitive criteria can be established.

Shepherd, K. P.↗

NASA NTRS1991

Sensor fusion III: 3-D perception and recognition; Proceedings of the Meeting, Boston, MA, Nov. 5-8, 1990

The volume on data fusion from multiple sources discusses fusing multiple views, temporal analysis and 3D motion interpretation, sensor fusion and eye-to-hand coordination, and integration in human shape perception. Attention is given to surface reconstruction, statistical methods in sensor fusion, fusing sensor data with environmental knowledge, computational models for sensor fusion, and evaluation and selection of sensor fusion techniques. Topics addressed include the structure of a scene from two and three projections, optical flow techniques for moving target detection, tactical sensor-based exploration in a robotic environment, and the fusion of human and machine skills for remote robotic operations. Also discussed are K-nearest-neighbor concepts for sensor fusion, surface reconstruction with discontinuities, a sensor-knowledge-command fusion paradigm for man-machine systems, coordinating sensing and local navigation, and terrain map matching using multisensing techniques for applications to autonomous vehicle navigation.

Schenker, Paul S.↗

NASA NTRS2024

Additively Manufactured Plastic Plasma Spectrometer

We report results in development and testing of a low resource top hat electrostatic analyzer (ESA) for space plasma measurements. This device has been additively manufactured (3D-printed) using fused deposition modeling. The classic top hat design is composed of four plastic pieces, without any surface coatings. The three conducting electrodes are printed from carbon nanotube infused polyether ether ketone (CNT-PEEK). The fourth piece, an insulating electrode support, uses pure PEEK. This ESA is designed to detect electrons in space from 10eV up to 30 keV. We demonstrate that the printed CNT-PEEK is sufficiently electrically conductive to support the fast high voltage slewing often required for high time resolution measurements. The plastic ESA has been successfully vibrated beyond standard pre-flight levels, tested under keV electron beam illumination over a wide range of temperatures, and tested under UV illumination, simulating the solar Ly-α flux. In comparison with an identical machined aluminum ESA, our CNT-PEEK ESA provides nominal energy/angle band passes, closely matching simulation. These band passes imply minimal impact from surface charging at beam energies of 2-3 keV, although more investigation is needed. We also find that the CNT-PEEK ESA provides far superior out-of-band electron rejection and UV photon rejection compared to the machined aluminum ESA. We do not detect any problems with trapped gases or outgassing. This development offers potential for significant mass savings, implementation of otherwise unattainable geometric configurations, and dramatic simplification in manufacturing and assembly processes required for development of space plasma instruments.

Quetzal Larrick↗

NASA NTRS2021

Machine Vision based Sample-Tube Localization for Mars Sample Return

A potential Mars Sample Return (MSR) architecture is being jointly studied by NASA and ESA. As currently envisioned, the MSR campaign consists of a series of 3 missions: sample cache, fetch and return to Earth. In this paper, we focus on the fetch part of the MSR, and more specifically the problem of autonomously detecting and localizing sample tubes deposited on the Martian surface. Towards this end, we study two machine-vision based approaches: First, a geometrydriven approach based on template matching that uses hardcoded filters and a 3D shape model of the tube; and second, a data-driven approach based on convolutional neural networks (CNNs) and learned features. Furthermore, we present a large benchmark dataset of sample-tube images, collected in representative outdoor environments and annotated with ground truth segmentation masks and locations. The dataset was acquired systematically across different terrain, illumination conditions and dust-coverage; and benchmarking was performed to study the feasibility of each approach, their relative strengths and weaknesses, and robustness in the presence of adverse environmental conditions.

Detry, R.↗

NASA NTRSDate not supplied

Initial Development of A Digital Twin Model for an Electrified Aircraft Propulsion Emulation Rig

In support of aviation fuel burn and emission reduction goals, NASA is pursing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP), which relies on the generation, storage, transmission, and use of electrical power for producing thrust and optimizing propulsion system efficiency. Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes advances in propulsion controls, which will be vital for ensuring coordinated efficient operation of the complex integrated subsystems that comprise EAP architectures. To support EAP controls research, the NASA Glenn Research Center has developed the Hybrid Propulsion Emulation Rig (HyPER). The HyPER laboratory hardware includes shaft-mounted electric machines, power converters, power supplies, power distribution cables, and an energy storage device that can be reconfigured to represent a variety of EAP architectures. It also includes an integrated real-time computer system that hosts developed EAP control software and turbomachinery simulations. This enables the electrical system and rotating shafts of EAP designs to be implemented in actual hardware and integrated with turbomachinery simulations and system-level EAP control logic implemented in software. In this form, the HyPER laboratory provides a partially simulated, partially hardware-in-the-loop test environment enabling the initial development and evaluation of EAP control technology. A prerequisite for the development of EAP control designs is the availability of a system model that accurately reflects the operation of the electrical system hardware. To support this need, a digital twin model of the HyPER electrical system hardware is under development. This model is being coded in the MATLAB Simulink environment and uses the NASA-developed Electrical Modeling and Thermal Analysis Toolbox (EMTAT) to construct a digital twin framework. EMTAT contains generic electrical component building blocks that are simulated at turbomachinery timescales. Associated inputs and outputs allow the blocks to be combined to model complete electrical systems. The EMTAT blocks also contain adjustable internal maps and parameters that can be set to reflect the operation of a specific electrical component. For the HyPER digital twin, the settings of these EMTAT block internal maps and parameters is determined through machine learning approaches applied to characterization run data collected from the laboratory. During characterization runs the laboratory electrical system hardware is subjected to a full range of torque, speed, and power settings. Acquired data is then used to estimate EMTAT block parameters using a variety of machine learning techniques. The resulting digital twin model is found to match the operation of actual HyPER hardware with an accuracy suitable for control development purposes. It also holds promise for other applications including modeling the performance of HyPER laboratory reconfigurations and model-based anomaly detection. Planned follow-on work to automate post-processing of acquired laboratory data to update the HyPER digital twin model will also be presented and discussed.

Electrified Aircraft Propulsion↗

NASA NTRS1977

Adaptive supervisory control of remote manipulation

The command language by which an operator exerts supervisory control over a general purpose remote manipulator should be designed to accommodate certain characteristics of human performance if there is to be effective communication between the operator and the machine. Some of the ways in which people formulate tasks, use language, learn and make errors are discussed and design implications are drawn. A general approach to command language design is suggested, based on the notion matching the operator's current task schema or context by appropriate program structures or 'frames' in the machine.

Ferrell, W. R.↗

NASA NTRS1974

Fractional watt Vuillemier cryogenic refrigerator program engineering notebook. Volume 1: Thermal analysis

The cryogenic refrigerator thermal design calculations establish design approach and basic sizing of the machine's elements. After the basic design is defined, effort concentrates on matching the thermodynamic design with that of the heat transfer devices (heat exchangers and regenerators). Typically, the heat transfer device configurations and volumes are adjusted to improve their heat transfer and pressure drop characteristics. These adjustments imply that changes be made to the active displaced volumes, compensating for the influence of the heat transfer devices on the thermodynamic processes of the working fluid. Then, once the active volumes are changed, the heat transfer devices require adjustment to account for the variations in flows, pressure levels, and heat loads. This iterative process is continued until the thermodynamic cycle parameters match the design of the heat transfer devices. By examing several matched designs, a near-optimum refrigerator is selected.

Miller, W. S.↗

NASA NTRS1997

Low Cost Manufacturing Approach of High Temperature PMC Components

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Kannmacher, Kevin↗

NASA NTRSDate not supplied

Comparing Low-Cost Sensors with Ground-Based and Airborne In-Situ and Column Observations of NO2 and HCHO during the FRAPPE Field Campaign in Colorado, USA

Even in the presence of more reliable air quality tools, low-cost sensors have the benefit of recording data on highly localized spatial and temporal scales, allowing for multiple measurements within a single satellite pixel and on pixel boundaries. However, they are less accurate than their regulatory-grade counterparts, requiring regular co-locations with accepted instruments to ensure their validity. Thus, the addition of low-cost sensors to a field campaign – where reference-grade air quality instruments are abundant – not only provides ample opportunities for low-cost sensor co-location and calibration, but also allows the low-cost instruments to be used for sub-pixel validation, covering more surface area than the regulatory instruments alone with a network of sensors. During the summer of 2014, our low-cost sensor network was deployed during the Front Range Air Pollution and Photochemistry Experiment (FRAPPÉ) campaign conducted to sample the composition of air at and above ground level in northeastern Colorado, USA. The low-cost sensor platform included a suite of gas-phase sensors, notably NO2 and two generalized volatile organic compound (VOC) sensors, which were leveraged together to quantify speciated hydrocarbons such as formaldehyde. These key pollutants were chosen for their impacts on human health and climate change, as well as their inclusion on the TEMPO satellite launching this year. Airborne campaign measurements included slant column optical observations of formaldehyde (HCHO), nitrogen dioxide (NO2), and ozone (O3). Myriad additional in-situ instruments described chemical composition up to approximately 5 km above surface level. Ground-based instrumentation included both stationary and mobile regulatory-grade instruments, which were used for sensor calibration. Machine learning techniques such as artificial neural networks (ANNs) were used to match the low-cost signals to that of the reference-grade instruments. Here, we compare calibrated low-cost sensor data collected at ground level in a variety of locations along Colorado’s Front Range to various data sources from the FRAPPÉ campaign to better understand how well airborne and regulatory ground-based measurements can be extrapolated to other locations. Further, as the slant column measurements act as satellite simulators, we explore how low-cost instruments can be used for satellite validation purposes. Comparisons among these different data types also have important implications in data fusion.

Kristen Okorn↗

NASA NTRS1995

Scalability of Parallel Spatial Direct Numerical Simulations on Intel Hypercube and IBM SP1 and SP2

The implementation and performance of a parallel spatial direct numerical simulation (PSDNS) approach on the Intel iPSC/860 hypercube and IBM SP1 and SP2 parallel computers is documented. Spatially evolving disturbances associated with the laminar-to-turbulent transition in boundary-layer flows are computed with the PSDNS code. The feasibility of using the PSDNS to perform transition studies on these computers is examined. The results indicate that PSDNS approach can effectively be parallelized on a distributed-memory parallel machine by remapping the distributed data structure during the course of the calculation. Scalability information is provided to estimate computational costs to match the actual costs relative to changes in the number of grid points. By increasing the number of processors, slower than linear speedups are achieved with optimized (machine-dependent library) routines. This slower than linear speedup results because the computational cost is dominated by FFT routine, which yields less than ideal speedups. By using appropriate compile options and optimized library routines on the SP1, the serial code achieves 52-56 M ops on a single node of the SP1 (45 percent of theoretical peak performance). The actual performance of the PSDNS code on the SP1 is evaluated with a "real world" simulation that consists of 1.7 million grid points. One time step of this simulation is calculated on eight nodes of the SP1 in the same time as required by a Cray Y/MP supercomputer. For the same simulation, 32-nodes of the SP1 and SP2 are required to reach the performance of a Cray C-90. A 32 node SP1 (SP2) configuration is 2.9 (4.6) times faster than a Cray Y/MP for this simulation, while the hypercube is roughly 2 times slower than the Y/MP for this application. KEY WORDS: Spatial direct numerical simulations; incompressible viscous flows; spectral methods; finite differences; parallel computing.

Joslin, Ronald D.↗

NASA NTRS1988

Dynamically allocating sets of fine-grained processors to running computations

Researchers explore an approach to using general purpose parallel computers which involves mapping hardware resources onto computations instead of mapping computations onto hardware. Problems such as processor allocation, task scheduling and load balancing, which have traditionally proven to be challenging, change significantly under this approach and may become amenable to new attacks. Researchers describe the implementation of this approach used by the FFP Machine whose computation and communication resources are repeatedly partitioned into disjoint groups that match the needs of available tasks from moment to moment. Several consequences of this system are examined.

Middleton, David↗