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NASA NTRS2004

Numerical, Analytical, Experimental Study of Fluid Dynamic Forces in Seals: Description of Seal Dynamics Code DYSEAL and Labyrinth Seals Code KTK - Volume 5

The objectives of the program were to develop computational fluid dynamics (CFD) codes and simpler industrial codes for analyzing and designing advanced seals for air-breathing and space propulsion engines. The CFD code SCISEAL is capable of producing full three-dimensional flow field information for a variety of cylindrical configurations. An implicit multidomain capability allow the division of complex flow domains to allow optimum use of computational cells. SCISEAL also has the unique capability to produce cross-coupled stiffness and damping coefficients for rotordynamic computations. The industrial codes consist of a series of separate stand-alone modules designed for expeditious parametric analyses and optimization of a wide variety of cylindrical and face seals. Coupled through a Knowledge-Based System (KBS) that provides a user-friendly Graphical User Interface (GUI), the industrial codes are PC based using an OS/2 operating system. These codes were designed to treat film seals where a clearance exists between the rotating and stationary components. Leakage is inhibited by surface roughness, small but stiff clearance films, and viscous pumping devices. The codes have demonstrated to be a valuable resource for seal development of future air-breathing and space propulsion engines

Shapiro, Wilbur↗

NASA NTRS1986

Load cell verification of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

Beatty, R. F.↗

NASA NTRS2007

Circuit for Full Charging of Series Lithium-Ion Cells

An advanced charger has been proposed for a battery that comprises several lithium-ion cells in series. The proposal is directed toward charging the cells in as nearly an optimum manner as possible despite unit-to-unit differences among the nominally identical cells. The particular aspect of the charging problem that motivated the proposal can be summarized as follows: During bulk charging (charging all the cells in series at the same current), the voltages of individual cells increase at different rates. Once one of the cells reaches full charge, bulk charging must be stopped, leaving other cells less than fully charged. To make it possible to bring all cells up to full charge once bulk charging has been completed, the proposed charger would include a number of top-off chargers one for each cell. The top-off chargers would all be powered from the same DC source, but their outputs would be DC-isolated from each other and AC-coupled to their respective cells by means of transformers, as described below. Each top-off charger would include a flyback transformer, an electronic switch, and an output diode. For suppression of undesired electromagnetic emissions, each top-off charger would also include (1) a resistor and capacitor configured to act as a snubber and (2) an inductor and capacitor configured as a filter. The magnetic characteristics of the flyback transformer and the duration of its output pulses determine the energy delivered to the lithium-ion cell. It would be necessary to equip the cell with a precise voltage monitor to determine when the cell reaches full charge. In response to a full-charge reading by this voltage monitor, the electronic switch would be held in the off state. Other cells would continue to be charged similarly by their top-off chargers until their voltage monitors read full charge.

Ott, William E.↗

NASA NTRS2016

Tool for Generation of MAC/GMC Representative Unit Cell for CMC/PMC Analysis

This document describes a recently developed analysis tool that enhances the resident capabilities of the Micromechanics Analysis Code with the Generalized Method of Cells (MAC/GMC) 4.0. This tool is especially useful in analyzing ceramic matrix composites (CMCs), where higher fidelity with improved accuracy of local response is needed. The tool, however, can be used for analyzing polymer matrix composites (PMCs) as well. MAC/GMC 4.0 is a composite material and laminate analysis software developed at NASA Glenn Research Center. The software package has been built around the concept of the generalized method of cells (GMC). 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 thermomechanical 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 primary focus of the current effort is to provide a graphical user interface (GUI) capability that generates a number of different user-defined repeating unit cells (RUCs). In addition, the code has provisions for generation of a MAC/GMC-compatible input text file that can be merged with any MAC/GMC input file tailored to analyze composite materials. Although the primary intention was to address the three different constituents and phases that are usually present in CMCs-namely, fibers, matrix, and interphase-it can be easily modified to address two-phase polymer matrix composite (PMC) materials where an interphase is absent. Currently, the tool capability includes generation of RUCs for square packing, hexagonal packing, and random fiber packing as well as RUCs based on actual composite micrographs. All these options have the fibers modeled as having a circular cross-sectional area. In addition, a simplified version of RUC is provided where the fibers are treated as having a square cross section and are distributed randomly. This RUC facilitates a speedy analysis using the higher fidelity version of GMC known as HFGMC. The first four mentioned options above support uniform subcell discretization. The last one has variable subcell sizes due to the primary intention of keeping the RUC size to a minimum to gain the speed ups using the higher fidelity version of MAC. The code is implemented within the MATLAB (The Mathworks, Inc., Natick, MA) developmental framework; however, a standalone application that does not need a priori MATLAB installation is also created with the aid of the MATLAB compiler.

Materials Engineering↗

NASA NTRS1981

High performance silicon solar arrays employing advanced structures

Specific design features to reduce cell mass, lower panel operating temperatures, and improve power to mass ratios for silicon solar cell arrays in space applications are presented. Because mass constraints limit payload capacity for launch into GEO, graphite/epoxy structures combined with high performance Si cells are needed to deliver a power/mass ratio of 265 W/kg, notably for Solar Electric Propulsion systems, compared with existing level of 65 W/kg. Shallow diffusion and back surface field cell technology have raised cell efficiencies to 15%, with a back emissivity of 1.64. Structural design requirements comprise Shuttle interface compatibility, full ground test capability, low mass, and high stiffness. Three array alternatives are discussed, and the STACBEAM configuration, which consists of a triangular truss and a piston deployer with folding accomplished on simple hinges, provides 0.2 Hz stiffness and achieves the design power/mass goals.

Rockey, D. E.↗

NASA NTRS2024

NESC Ceramic Oxygen Generator (COG) Technology Development

The NASA Engineering and Safety Center (NESC) sponsored a project to accelerate the pace of technology development of a ceramic oxygen generator (COG), for NASA and COVID related medical use. NASA applications for this technology include spacesuit oxygen tank recharge, medical applications include providing medical oxygen in remote and low resource settings. During this project, five full-scale (i.e., 30 wafer) cell stacks were built and tested in prototype systems capable of producing pressurized oxygen. System testing measured oxygen product purity, delivery pressure, production rate, and energy use. This report describes ion transport membrane mechanisms, cell stack configuration, and test results.

Oxygen↗

NASA NTRS1990

Latest developments in the Advanced Photovoltaic Solar Array Program

In 1985, the Advanced Photovoltaic Solar Array (APSA) Program was established to demonstrate a producible array system with a specific power greater than 130 W/kg at a 10-kW (BOL) power level. The latest program phase completed fabrication and initial functional testing of a prototype wing representative of a full-scale 5-kW (BOL) wing (except truncated in length to about 1 kW), with weight characteristics that could meet the 130-W/kg (BOL) specific power goal using thin silicon solar cell modules and weight-efficient structural components. The wing configuration and key design details are reviewed, along with results from key component-level and wing-level tests. Projections for future enhancements that may be expected through the use of advanced solar cells and structural components are shown. Performance estimates are given for solar electric propulsion orbital transfer missions through the Van Allen radiation belts. The latest APSA program plans are presented.

Stella, Paul M.↗

NASA NTRS2016

Periodic Orbit-Attitude Solutions in the Planar Elliptic Restricted Three-Body Problem

The pitch motion of a spacecraft in the planar elliptic restricted three-body system is studied. Previous studies laid the foundation for spacecraft stability analysis with a small perturbation to the zero pitch motion. In this study, a cell mapping approach that combines analytical and numerical techniques is used to study the global behavior of the full nonlinear spacecraft attitude in which coupling between orbital dynamics and attitude occurs. The effect of gravity gradient torques, orbital eccentricity, and the spacecraft configuration at different Lagrangian points is analyzed. Multiple-period periodic solutions and invariant surfaces are presented for different cases. Reference trajectories around the Lagrangian points are also considered to study coupled dynamics.

Koh, Dayung↗

NASA NTRS2012

ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays

The objective of this work was to develop a new class of readout integrated circuit (ROIC) arrays to be operated with Geiger avalanche photodiode (GPD) arrays, by integrating multiple functions at the pixel level (smart-pixel or active pixel technology) in 250-nm CMOS (complementary metal oxide semiconductor) processes. In order to pack a maximum of functions within a minimum pixel size, the ROIC array is a full, custom application-specific integrated circuit (ASIC) design using a mixed-signal CMOS process with compact primitive layout cells. The ROIC array was processed to allow assembly in bump-bonding technology with photon-counting infrared detector arrays into 3-D imaging cameras (LADAR). The ROIC architecture was designed to work with either common- anode Si GPD arrays or common-cathode InGaAs GPD arrays. The current ROIC pixel design is hardwired prior to processing one of the two GPD array configurations, and it has the provision to allow soft reconfiguration to either array (to be implemented into the next ROIC array generation). The ROIC pixel architecture implements the Geiger avalanche quenching, bias, reset, and time to digital conversion (TDC) functions in full-digital design, and uses time domain over-sampling (vernier) to allow high temporal resolution at low clock rates, increased data yield, and improved utilization of the laser beam.

Vasile, Stefan↗

NASA NTRS2017

Cart3D Simulations for the Second AIAA Sonic Boom Prediction Workshop

Simulation results are presented for all test cases prescribed in the Second AIAA Sonic Boom Prediction Workshop. For each of the four nearfield test cases, we compute pressure signatures at specified distances and off-track angles, using an inviscid, embedded-boundary Cartesian-mesh flow solver with output-based mesh adaptation. The cases range in complexity from an axisymmetric body to a full low-boom aircraft configuration with a powered nacelle. For efficiency, boom carpets are decomposed into sets of independent meshes and computed in parallel. This also facilitates the use of more effective meshing strategies - each off-track angle is computed on a mesh with good azimuthal alignment, higher aspect ratio cells, and more tailored adaptation. The nearfield signatures generally exhibit good convergence with mesh refinement. We introduce a local error estimation procedure to highlight regions of the signatures most sensitive to mesh refinement. Results are also presented for the two propagation test cases, which investigate the effects of atmospheric profiles on ground noise. Propagation is handled with an augmented Burgers' equation method (NASA's sBOOM), and ground noise metrics are computed with LCASB.

Prediction↗

NASA NTRS1981

Design, evaluation, and fabrication of low-cost composite blades for intermediate-size wind turbines

Low cost approaches for production of 60 ft long glass fiber/resin composite rotor blades for the MOD-OA wind turbine were identified and evaluated. The most cost-effective configuration was selected for detailed design. Subelement and subscale specimens were fabricated for testing to confirm physical and mechanical properties of the composite blade materials, to develop and evaluate blade fabrication techniques and processes, and to confirm the structural adequacy of the root end joint. Full-scale blade tooling was constructed and a partial blade for tool and process tryout was built. Then two full scale blades were fabricated and delivered to NASA-LeRC for installation on a MOD-OA wind turbine at Clayton, New Mexico for operational testing. Each blade was 60 ft. long with 4.5 ft. chord at root end and 2575 lbs weight including metal hub adapter. The selected blade configuration was a three cell design constructed using a resin impregnated glass fiber tape winding process that allows rapid wrapping of primarily axially oriented fibers onto a tapered mandrel, with tapered wall thickness. The ring winder/transverse filament tape process combination was used for the first time on this program to produce entire rotor blade structures. This approach permitted the complete blade to be wound on stationary mandrels, an improvement which alleviated some of the tooling and process problems encountered on previous composite blade programs.

Weingart, O.↗

NASA NTRSDate not supplied

The NASA Space Radiation Laboratory

The Space Radiation Element (SRE) of the Human Research Program (HRP) aims to establish a robust biospecimen and tissue sharing collection (BTSC) to improve sample collection, tracking, access, distribution, and usability to maximize scientific return with intention. Future missions to the Moon, Mars, and beyond will require the appropriate characterization and mitigation of the many of the health risks associated with cosmic radiation exposure. An ongoing partnership between the National Aeronautics and Space Agency (NASA) and the Office of Science for the U.S. Department of Energy (DOE) has established the NASA Space Radiation Laboratory (NSRL) at the DOE Brookhaven National Laboratory (BNL) to create a space radiation ground-analog. NSRL provides the capability to use simulated space radiation with high energy ion beams for assessment of biological outcomes relevant space radiation risks as well as electronics testing for avionics safety. Current NSRL irradiation capabilities include a variety of exposure variables available for experimental needs: - Up to approximately 10 Gy/min dose-rates with a 20 × 20 cm 2 beam area. - Down to several hundred particles within a 60 × 60 cm 2 beam area. - Dose fractionation across multiple days is also possible. - For most radiobiology experiments the exposure structure, referred to as “spills”, has a 4 second repetition time where ions are extracted uniformly during a 0.3-0.4 second spill, followed by a ~3.6 second recovery time when the beam is off. - Both single or mixed-beam field irradiations are possible including a full 33-beam GCRSim and 6-beam SimGCRSim. Biological experiment capabilities: Two labs for Cell/tissue culture procedures can be conducted in two lab spaces with a separate lab available for sample processing that contains two chemical fume hoods. Sixteen fully equipped cell culture laboratories are available in the NSRL’s Long Term Support area in the Medical Building. The current vivarium configuration can support approximately 8,000 rodents/year for animal-based experiments. The NSRL area animal husbandry system includes five caging racks with 48 spaces in each coupled to a ventilation/filtration system in largest room, and two smaller rooms with conventional caging systems. Schedule: The NSRL is nominally open for experiment scheduling during three runs per year; Spring (March – May), Summer (May - June), and Fall (Sept – Nov). NASA funding is not required for biological and electronic testing experiments at the NSRL.

Jason M Weeks↗

NASA NTRS2024

Mock Truss-Braced Wing Loads Calibration Research Utilizing Fiber-Optic Sensors

In support of the National Aeronautics and Space Administration Advanced Air Transonic Transport Truss-Braced Wing structural research, the Armstrong Flight Research Center Flight Loads Laboratory is performing pathfinder tests on a small, scaled test article (dubbed the mock Truss-Braced Wing) to study the application of a loads calibration on a truss-braced wing structure. The addition of a truss to the wing structure, as opposed to a purely cantilever beam setup, changes the strain-gage-based loads calibration techniques. In a truss-braced configuration, the internal shear and moments, inboard of the truss-wing connection, are not directly representative of the external aerodynamic loading as is the case for a traditional cantilever configuration. A 3-axis load cell was used at the wing-to-strut interface to estimate the load sharing between the two structural members. Crosstalk within the 3-axis load cell is added to the measurement uncertainties of the calibration effort, and the results, including crosstalk uncertainties, are presented. The calibration tests presented in this report are used as a pathfinder for developing an understanding how to perform loads calibration on a truss-braced wing structural configuration. The use of distributed fiber-optic strain sensors is leveraged to provide a near-full-span strain profile along the leading and trailing edge of the wing structure for strain-based loads calibration.

Francisco Peña↗

NASA NTRS1993

Lithium D-cell study

The purpose of this contract is to evaluate parametrically the effects of various factors including the electrolyte type, electrolyte concentration, depolarizer type, and cell configuration on lithium cell electrical performance and safety. This effort shall allow for the selection and optimization of cell design for future NASA applications while maintaining close ties with WGL's continuous improvements in manufacturing processes and lithium cell design. Taguchi experimental design techniques are employed in this task, and allow for a maximum amount of information to be obtained while requiring significantly less cells than if a full factorial design were employed. Acceptance testing for this task is modeled after the NASA Document EP5-83-025, Revision C, for cell weights, OCV's and load voltages. The performance attributes that are studied in this effort are fresh capacity and start-up characteristics evaluated at two rates and two temperatures, shelf-life characteristics including start-up and capacity retention, and iterative microcalorimetry measurements. Abuse testing includes forced over discharge at two rates with and without diode protection, temperature tolerance testing, and shorting tests at three rates with the measurement of heat generated during shorting conditions.

Size, P.↗

NASA NTRS2015

Multi-Level Experimental and Analytical Evaluation of Two Composite Energy Absorbers

Two composite energy absorbers were developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research program. A conical-shaped energy absorber, designated the conusoid, was evaluated that consisted of four layers of hybrid carbon-Kevlar plain weave fabric oriented at [+45 deg/-45 deg/-45 deg/+45 deg] with respect to the vertical, or crush, direction. A sinusoidal-shaped energy absorber, designated the sinusoid, was developed that consisted of hybrid carbon-Kevlar plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical direction and a closed-cell ELFOAM P200 polyisocyanurate (2.0-lb/cu ft) foam core. The design goal for the energy absorbers was to achieve average floor-level accelerations of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in both designs were assessed through dynamic crush testing of component specimens. Once the designs were finalized, subfloor beams of each configuration were fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorbers prior to retrofit into TRACT 2. The retrofitted airframe was crash tested under combined forward and vertical velocity conditions onto soil, which is characterized as a sand/clay mixture. Finite element models were developed of all test articles and simulations were performed using LS-DYNA, a commercial nonlinear explicit transient dynamic finite element code. Test-analysis results are presented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading for each evaluation level.

Jackson, Karen E.↗

NASA NTRS2015

The Development of Two Composite Energy Absorbers for Use in a Transport Rotorcraft Airframe Crash Testbed (TRACT 2) Full-Scale Crash Test

Two composite energy absorbers were developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research program. A conical-shaped energy absorber, designated the conusoid, was evaluated that consisted of four layers of hybrid carbon-Kevlar plain weave fabric oriented at [+45deg/-45deg/-45deg/+45deg] with respect to the vertical direction. A sinusoidal-shaped energy absorber, designated the sinusoid, was developed that consisted of hybrid carbon-Kevlar plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical direction, and a closed-cell ELFOAM P200 polyisocyanurate (2.0-lb/cu ft) foam core. The design goal for the energy absorbers was to achieve average floor-level accelerations of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in both designs were assessed through dynamic crush testing of component specimens. Once the designs were finalized, subfloor beams of each configuration were fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorbers prior to retrofit into TRACT 2. The retrofitted airframe was crash tested under combined forward and vertical velocity conditions onto soft soil. Finite element models were developed of all test articles and simulations were performed using LS-DYNA, a commercial nonlinear explicit transient dynamic finite element code. Test-analysis results are presented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading for each evaluation level.

Littell, Justin D.↗

NASA NTRS2000

Orbiter Capability for Providing Water to the International Space Station according to the Most Probable Flight Attitudes

Water to be generated by, delivered to, and processed by the International Space Station (ISS) is a critical Environmental Control and Life Support (ECLS) element, especially for the early ISS missions. A significant portion of the water required by the ISS shall be provided by the Shuttle Transportation System (STS) Orbiter. The balance of water generated by the Orbiter Fuel Cells (FC), minus that water consumed by the Orbiter Flash Evaporator System (FES) and crew, is available for transfer to the ISS. During later missions, crew respired and perspired water, as well as effluent water from the Orbiter LiOH canisters, will be collected as condensate and available for transfer to the ISS. Orbiter radiator performance provides the most variance in determining the amount of net Orbiter water available for transfer to the ISS. As radiator performance decreases, the dependence upon the FES (and FC water) increases for rejecting Orbiter waste heat. Generally, radiator performance decreases as the ISS assembly size increases (especially as solar arrays are added), and also as beta angle increases. ISS solar array deployment necessitates the use of models with articulating solar arrays (for Earth local-vertical attitudes), as array position dramatically affects Orbiter radiator performance. Recent developments in the relaxation of beta angle limitations have also increased the complexity and difficulty of providing water to the ISS. Other factors that may hinder the ability to transfer water are the number of empty Contingency Water Containers (CWCs) available, duration of open-hatch time, crew activity timeline, and full CWC storage capability. A parametric study has been accomplished that provides a quick-reference table for determining expected water generation rates for ISS missions 2A.2 through 7A.1. An hourly Orbiter water generation rate is reported according to a matrix that consists of: (1) (six) significant changes in ISS assembly configuration; (2) (four) beta angles (0 deg. , +37 deg., +53 deg. , and +75 deg.); (3) the (three) most representative ISS attitudes (XPOP-O, XPOP-180 and +XVV); (4) (four) Orbiter radiator configurations (both stowed, starboard deployed, port deployed, and both deployed) and (5) the (two) conditions (radiator inlet temperatures and fuel cell power) most consistent with sleep and wake periods. Those permutations of higher probability of occurrence than others have been identified. Another parametric study has been accomplished that provides a quick-reference table for determining expected water generation rates for ISS assembly complete missions. An hourly Orbiter water generation rate is reported according to a matrix that consists of: (1) (seven) beta angles (-75 deg., -60 deg., -30 deg., 0 deg., +30 deg., +60 deg., and +75 deg.); (2) the (nine) PYR angles that define the corners of the envelope; (3) (four) Orbiter radiator configurations (both stowed, starboard deployed, port deployed, and both deployed) and (4) the (two) conditions (radiator inlet temperatures and fuel cell power) most consistent with sleep and wake periods.

Dunaway, Brian↗

NASA NTRS2007

High Altitude Long Endurance UAV Analysis of Alternatives and Technology Requirements Development

An Analysis of Alternatives and a Technology Requirements Study were conducted for two mission areas utilizing various types of High Altitude Long Endurance (HALE) Unmanned Aerial Vehicles (UAV). A hurricane science mission and a communications relay mission provided air vehicle requirements which were used to derive sixteen potential HALE UAV configurations, including heavier-than-air (HTA) and lighter-than-air (LTA) concepts with both consumable fuel and solar regenerative propulsion systems. A HTA diesel-fueled wing-body-tail configuration emerged as the preferred concept given near-term technology constraints. The cost effectiveness analysis showed that simply maximizing vehicle endurance can be a sub-optimum system solution. In addition, the HTA solar regenerative configuration was utilized to perform both a mission requirements study and a technology development study. Given near-term technology constraints, the solar regenerative powered vehicle was limited to operations during the long days and short nights at higher latitudes during the summer months. Technology improvements are required in energy storage system specific energy and solar cell efficiency, along with airframe drag and mass reductions to enable the solar regenerative vehicle to meet the full mission requirements.

Nickol, Craig L.↗