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NASA NTRS1999

The Human Powered Submarine Team of Virginia Tech Propulsion System Design Final Report

The Human Powered Submarine Team has been in existence at Virginia Tech since its conception in 1993. Since then, it has served as a way for engineering students from many different disciplines to implement design conception and realization. The first submarine built was Phantom 1, a two-man submarine made of fiberglass. After construction was complete, Phantom 1 was ready for racing, but, unfortunately, suffered fatal problems come race time. The submarine team slowed down a bit after experiencing racing problems, but was revived in 1995 when design efforts for a new two-man submarine, the Phantom 2 commence. The propulsion system consisted of a chain and gear drive system using an ultra-light helicopter tail rotor for a propeller. Although the team learned valuable lessons as a result of Phantom 1's problems, Phantom 2 still experiences problems at races. After various parts of Phantom 2 are redesigned, it is once again ready for racing and proves that the redesign was well worth the time and effort. In 1997, Phantom 2 not only finishes its first race, held in San Diego, California, but comes in third. This success sparks yet another revival of the submarine team and design for the team's current project, the Phantom 3, a one-man submarine, is started. In 1998, the plug for Phantom 3 is built and the hull is constructed. With so many past problems from which to learn, Phantom 3 promises to be the fastest and best-designed submarine the team has developed thus far. The current speed world-record is 7 knots.

An, Eric↗

NASA NTRS2000

On Flowfield Periodicity in the NASA Transonic Flutter Cascade: Numerical Study - Part 2

The transonic flutter cascade facility at NASA Glenn Research Center was redesigned based on a combined program of experimental measurements and numerical analyses. The objectives of the redesign were to improve the periodicity of the cascade in steady operation, and to better quantify the inlet and exit flow conditions needed for CFD predictions. Part I of this paper describes the experimental measurements, which included static pressure measurements on the blade and endwalls made using both static taps and pressure sensitive paints, cobra probe measurements of the endwall boundary layers and blade wakes, and shadowgraphs of the wave structure. Part II of this paper describes three CFD codes used to analyze the facility, including a multibody panel code, a quasi-three-dimensional viscous code, and a fully three-dimensional viscous code. The measurements and analyses both showed that the operation of the cascade was heavily dependent on the configuration of the sidewalls. Four configurations of the sidewalls were studied and the results are described. For the final configuration, the quasi-three-dimensional viscous code was used to predict the location of mid-passage streamlines for a perfectly periodic cascade. By arranging the tunnel sidewalls to approximate these streamlines, sidewall interference was minimized and excellent periodicity was obtained.

Chima, Rodrick V.↗

NASA NTRS2001

System Accommodation of Propylene Loop Heat Pipes For The Geoscience Laser Altimeter System (GLAS) Instrument

Loop Heat Pipes (LHP) are used for precise temperature control for NASA Goddard Space Flight Center's Geoscience Laser Altimeter System (GLAS) Instrument in a widely varying LEO thermal environment. Two propylene LHPs are utilized to provide separate thermal control for the Nd:YAG Lasers and the remaining avionics/detector components suite. Despite a rigorous engineering development and test plan to demonstrate the performance in the restrictive GLAS design, the flight units failed initial thermal vacuum acceptance testing at GSFC. Subsequent investigation revealed that compromises in the mechanical packaging of these systems resulted in inadequate charge levels for a concentric wick LHP. The redesign effort included larger compensation chambers that provide more fluid to the wick for start-up scenarios and highlighted the need to fully understand the limitations and accommodation requirements of new technologies in a system design application. Once again, seemingly minor departures from heritage configurations and limited resources led to performance and operational issues. This paper provides details into the GLAS LHP engineering development program and acceptance testing of the flight units, including the redesign effort.

Grob, Eric W.↗

NASA NTRS1999

Improving the Unsteady Aerodynamic Performance of Transonic Turbines using Neural Networks

A recently developed neural net-based aerodynamic design procedure is used in the redesign of a transonic turbine stage to improve its unsteady aerodynamic performance. The redesign procedure used incorporates the advantages of both traditional response surface methodology and neural networks by employing a strategy called parameter-based partitioning of the design space. Starting from the reference design, a sequence of response surfaces based on both neural networks and polynomial fits are constructed to traverse the design space in search of an optimal solution that exhibits improved unsteady performance. The procedure combines the power of neural networks and the economy of low-order polynomials (in terms of number of simulations required and network training requirements). A time-accurate, two-dimensional, Navier-Stokes solver is used to evaluate the various intermediate designs and provide inputs to the optimization procedure. The procedure yielded a modified design that improves the aerodynamic performance through small changes to the reference design geometry. These results demonstrate the capabilities of the neural net-based design procedure, and also show the advantages of including high-fidelity unsteady simulations that capture the relevant flow physics in the design optimization process.

Rai, Man Mohan↗

NASA NTRS2002

Space Shuttle Main Engine (SSME) Options for the Future Shuttle

The main engines for the Future Shuttle will focus on improved safety and operability. Performance enhancements may also be required for vehicle safety purposes to achieve more desirable abort scenarios. This paper discusses the potential improvements that will be considered for implementation into the Future Shuttle. Integrated engine and vehicle health management systems will achieve additional system-level reliability improvements over those currently in development. Advanced instrumentation for detecting leaks, analyzing component wear and degradation, and providing sophisticated operational data will be used for reliable engine control and scheduling maintenance operations. A new nozzle and main combustion chamber (MCC) will reduce failure probability by 50% and allow for higher thrust capability without requiring the entire engine to be redesigned. Turbopump improvements may range from minor component improvements to using 3rd-generation pumps built on the advanced concepts demonstrated by the Integrated Powerhead Development (IPD) program and the Space Launch Initiative (SLI) prototype engines.The main engines for the Future Shuttle will focus on improved safety and operability. Performance enhancements may also be required for vehicle safety purposes to achieve more desirable abort scenarios. This paper discusses the potential improvements that will be considered for implementation into the Future Shuttle. Integrated engine and vehicle health management systems will achieve additional system-level reliability improvements over those currently in development. Advanced instrumentation for detecting leaks, analyzing component wear and degradation, and providing sophisticated operational data will be used for reliable engine control and scheduling maintenance operations. A new nozzle and main combustion chamber (MCC) will reduce failure probability by 50% and allow for higher thrust capability without requiring the entire engine to be redesigned. Turbopump improvements may range from minor component improvements to using 3rd-generation pumps built on the advanced concepts demonstrated by the Integrated Powerhead Development (IPD) program and the Space Launch Initiative (SLI) prototype engines.

Jue, Fred↗

NASA NTRS2002

Active Control Analysis for Aeroelastic Instabilities in Turbomachines

Turbomachines onboard aircraft operate in a highly complex and harsh environment. The unsteady flowfield inherent to turbomachines leads to several problems associated with safety, stability, performance and noise. In-flight surge or flutter incidents could be catastrophic and impact the safety and reliability of the aircraft. High-Cycle-Fatigue (HCF), on the other hand, can significantly impact safety, readiness and maintenance costs. To avoid or minimize these problems generally a more conservative design method must be initiated which results in thicker blades and a loss of performance. Actively controlled turbomachines have the potential to reduce or even eliminate the instabilities by impacting the unsteady aerodynamic characteristics. By modifying the unsteady aerodynamics, active control may significantly improve the safety and performance especially at off-design conditions, reduce noise, and increase the range of operation of the turbomachine. Active control can also help improve reliability for mission critical applications such as the Mars Flyer. In recent years, HCF has become one of the major issues concerning the cost of operation for current turbomachines. HCF alone accounts for roughly 30% of maintenance cost for the United States Air-Force. Other instabilities (flutter, surge, rotating-stall, etc.) are generally identified during the design and testing phase. Usually a redesign overcomes these problems, often reducing performance and range of operation, and resulting in an increase in the development cost and time. Despite a redesign, the engines do not have the capabilities or means to cope with in-flight unforeseen vibration, stall, flutter or surge related instabilities. This could require the entire fleet worldwide to be stood down for expensive modifications. These problems can be largely overcome by incorporating active control within the turbomachine and its design. Active control can help in maintaining the integrity of the system in unforeseen events and provide for more aggressive designs to reduce the weight and improve efficiency of the turbomachine. Another area where active control can be useful is in controlling and suppressing rotating stall and surge in compressors, thereby increasing its operating range. Although some of these benefits will be offset by the added cost and weight penalty of the control system, the potential benefits in safety, reliability, performance, and noise characteristics are significant enough to warrant research in the area of active control of turbomachines. There is renewed interest within industry to understand unsteady aerodynamic behavior. This improved understanding not only leads to better design of turbomachines, which avoid instabilities but also which helps in understanding the controllability of the instabilities. The proliferation of micro-electro-mechanical-system (MEMS) devices has made available new tools to designers for employing feedback controls at reasonable costs. MEMS have also made the control devices small and unobtrusive enough to be implemented within the turbomachine without significant obstruction to the flow path. This has made active-control very attractive especially for systems requiring extreme confidence.

Keith, Theo G., Jr.↗

NASA NTRS2002

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

This presentation provides an overview of the effort by Metal Matrix Cast Composites, Inc. to redesign turbopump housing joints using metal matrix composite material and a toolless net-shape pressure infiltration casting technology. Topics covered include: advantage of metal matrix composites for propulsion components, baseline pump design and analysis, advanced toolless pressure infiltration casting process, subscale pump housing, preform splicing and joining for large components, and fullscale pump housing redesign.

Shah, Sandeep↗

NASA NTRS1980

Equipment Failure Analysis

Tennessee Eastman uses NASTRAN to minimize lost production by pinpointing the causes of equipment failures and preventing recurrences. An example of the program's utility involves a large centrifugal fan which developed cracks during start-ups and shutdowns. This information prompted redesign of the fan. Tennessee Eastman has made extensive use of NASTRAN, both as failure analysis tool and as an aid in redesigning production hardware.

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NASA NTRS2003

Hybrid Residual Flexibility/Mass-Additive Method for Structural Dynamic Testing

A large fixture was designed and constructed for modal vibration testing of International Space Station elements. This fixed-base test fixture, which weighs thousands of pounds and is anchored to a massive concrete floor, initially utilized spherical bearings and pendulum mechanisms to simulate Shuttle orbiter boundary constraints for launch of the hardware. Many difficulties were encountered during a checkout test of the common module prototype structure, mainly due to undesirable friction and excessive clearances in the test-article-to-fixture interface bearings. Measured mode shapes and frequencies were not representative of orbiter-constrained modes due to the friction and clearance effects in the bearings. As a result, a major redesign effort for the interface mechanisms was undertaken. The total cost of the fixture design, construction and checkout, and redesign was over $2 million. Because of the problems experienced with fixed-base testing, alternative free-suspension methods were studied, including the residual flexibility and mass-additive approaches. Free-suspension structural dynamics test methods utilize soft elastic bungee cords and overhead frame suspension systems that are less complex and much less expensive than fixed-base systems. The cost of free-suspension fixturing is on the order of tens of thousands of dollars as opposed to millions, for large fixed-base fixturing. In addition, free-suspension test configurations are portable, allowing modal tests to be done at sites without modal test facilities. For example, a mass-additive modal test of the ASTRO-1 Shuttle payload was done at the Kennedy Space Center launch site. In this Technical Memorandum, the mass-additive and residual flexibility test methods are described in detail. A discussion of a hybrid approach that combines the best characteristics of each method follows and is the focus of the study.

Tinker, M. L.↗

NASA NTRS2003

Design and Analysis of Turbines for Space Applications

In order to mitigate the risk of rocket propulsion development, efficient, accurate, detailed fluid dynamics analysis of the turbomachinery is necessary. This analysis is used for component development, design parametrics, performance prediction, and environment definition. To support this requirement, a task was developed at NASAh4arshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. There are four major objectives of this task: 1) to develop, enhance, and integrate advanced turbine aerodynamic design and analysis tools; 2) to develop the methodology for application of the analytical techniques; 3) to demonstrate the benefits of the advanced turbine design procedure through its application to a relevant turbine design point; and 4) to verify the optimized design and analysis with testing. The turbine chosen on which to demonstrate the procedure was a supersonic design suitable for a reusable launch vehicle (RLV). The hot gas path and blading were redesigned to obtain an increased efficiency. The redesign of the turbine was conducted with a consideration of system requirements, realizing that a highly efficient turbine that, for example, significantly increases engine weight, is of limited benefit. Both preliminary and detailed designs were considered. To generate an improved design, one-dimensional (1D) design and analysis tools, computational fluid dynamics (CFD), response surface methodology (RSM), and neural nets (NN) were used.

Griffin, Lisa W.↗

NASA NTRS2002

Air Traffic Control Response to Delays: A System Study of Newark International Airport

Airport delays are a significant problem in the United States air transportation system. Between 1999 and 2000 the number of flights delayed increased by 20 percent despite only a 0.4% increase in total operations. Newark International Airport (EWR), one of New York City's primary airports, is one of the airports in the United States most impacted by delays. Newark had the highest percentage of operations delayed in 1999, and was second only to LaGuardia Airport in 2000. Nearly 85% of delays at Newark are caused by adverse weather impacting an airport that may be characterized as having limited capacity and a very full schedule. Although Newark is heavily impacted by weather, delays have not increased significantly since 1998. This indicates that the airlines, air traffic control (ATC), and the Port Authority of New York and New Jersey have successfully adapted. On June 29, 2000, a research team from MIT visited Newark airport to assess the effectiveness of any adaptations made, and to collect data on airline and ATC departure operations, and of the national and local weather affecting the airport. Airline and ATC personnel were also interviewed. Results of this study indicate that airspace capacity limitations downstream of the airport are a primary flow constraint at the airport, and that these constraints are the source of most surface delays. A number of tactical ATC responses to delays were examined, including the application of restrictions, re-routing with the help of the National Playbook, and the use of decision-aiding tools such as the Dynamic Spacing Program (DSP) and the Integrated Terminal Weather System (ITWS). Improved interfacility communications and further utilization of runway 11-29 were identified as other tactical responses to delays, whilst the formation of the Air Traffic Control System Command Center and the New York Airspace redesign were identified as thekey strategic ATC responses to delays. Particularly the New York airspace redesign has great potential to reduce delays at the airport. Because delays at Newark are caused by downstream flow constraints, the responses at the airport can be applied to other airports as delays from downstream constraints increase. Such an increase in delays system wide from downstream constraints is inevitable as the system becomes more congested.

Evans, Antony D.↗

NASA NTRS2004

Laboratory Astrophysics using a Microcalorimeter and Bragg Crystal Spectrometer on an Electron Beam Ion Trap

When we last reported, our new microcalorimeter system was being prepared for delivery and permanent installation at the NIST EBIT. This occurred in June 2003 and check-out with the internal calibration source and EBIT plasma x-rays took place over the next several months during which time we modified several component parts to improve the performance. These changes included: 1) A redesign of the x-ray calibration source from a direct electron impact source to one that irradiates the microcalorimeter with fluorescent x-rays. The resulting calibration lines are free of bremsstrahlung background; 2) The microcalorimeter electronic circuit has been significantly improved to ensure long-term stability for the lengthy upcoming runs of the EBIT. Both the preamplifier feedback resistors were changed and the first stage of the preamplifier redesigned. Several photos of the new system are shown in slides 3 and 4. This microcalorimeter spectrometer only requires helium refills every three days (as opposed to every 24 hours in our earlier system) and it will hold a temperature of 65 mK for up to 48 hours (as opposed to 8 hours). Consequently, the efficiency of data acquisition will improve dramatically. The first x-ray spectra of the new calibration source made with the 4-element detector array is shown. An example of the temperature control capabilities of the ADR for a 23 hour interval is shown. The horizontal line shows the temperature stability (about +/- 3 micro kelvin). There are a few short-lived heating excursions caused by technical staff working on the EBIT machine simultaneously. During actual experimental runs these are absent. This temporal profile was interrupted to test additional components of the system; otherwise, the temperature controlling would have continued for another 24 hours.

Silver, Eric↗

NASA NTRS2005

Design and Testing of a Blended Wing Body With Boundary Layer Ingestion Nacelles at High Reynolds Numbers

A knowledge-based aerodynamic design method coupled with an unstructured grid Navier-Stokes flow solver was used to improve the propulsion/airframe integration for a Blended Wing Body with boundary-layer ingestion nacelles. A new zonal design capability was used that significantly reduced the time required to achieve a successful design for each nacelle and the elevon between them. A wind tunnel model was built with interchangeable parts reflecting the baseline and redesigned configurations and tested in the National Transonic Facility (NTF). Most of the testing was done at the cruise design conditions (Mach number = 0.85, Reynolds number = 75 million). In general, the predicted improvements in forces and moments as well as the changes in wing pressures between the baseline and redesign were confirmed by the wind tunnel results. The effectiveness of elevons between the nacelles was also predicted surprisingly well considering the crudeness in the modeling of the control surfaces in the flow code. A novel flow visualization technique involving pressure sensitive paint in the cryogenic nitrogen environment used in high-Reynolds number testing in the NTF was also investigated.

Campbell, Richard L.↗

NASA NTRS2000

FACET: Future ATM Concepts Evaluation Tool

FACET (Future ATM Concepts Evaluation Tool) is an Air Traffic Management research tool being developed at the NASA Ames Research Center. This paper describes the design, architecture and functionalities of FACET. The purpose of FACET is to provide E simulation environment for exploration, development and evaluation of advanced ATM concepts. Examples of these concepts include new ATM paradigms such as Distributed Air-Ground Traffic Management, airspace redesign and new Decision Support Tools (DSTs) for controllers working within the operational procedures of the existing air traffic control system. FACET is currently capable of modeling system-wide en route airspace operations over the contiguous United States. Airspace models (e.g., Center/sector boundaries, airways, locations of navigation aids and airports) are available from databases. A core capability of FACET is the modeling of aircraft trajectories. Using round-earth kinematic equations, aircraft can be flown along flight plan routes or great circle routes as they climb, cruise and descend according to their individual aircraft-type performance models. Performance parameters (e.g., climb/descent rates and speeds, cruise speeds) are obtained from data table lookups. Heading, airspeed and altitude-rate dynamics are also modeled. Additional functionalities will be added as necessary for specific applications. FACET software is written in Java and C programming languages. It is platform-independent, and can be run on a variety of computers. FACET has been designed with a modular software architecture to enable rapid integration of research prototype implementations of new ATM concepts. There are several advanced ATM concepts that are currently being implemented in FACET airborne separation assurance, dynamic density predictions, airspace redesign (re-sectorization), benefits of a controller DST for direct-routing, and the integration of commercial space transportation system operations into the U.S. National Airspace System (NAS).

Bilmoria, Karl D.↗

NASA NTRS2005

F119 Nozzle Flaps Tested at Lewis' CE-22 Facility

The next generation of aircraft fighters requires higher engine performance and enhanced stealth characteristics for air superiority. A Lockheed-Martin/Boeing aircraft with a Pratt & Whitney F119 engine was selected by the Air Force for the next advanced tactical fighter (ATF). As part of this program, the NASA Lewis Research Center entered into a cooperative test program with Pratt & Whitney along with the Air Force to study the performance for various advanced nozzle concepts for the F119 engine. The area of interest was to measure the internal performance (both thrust and flow coefficients) of nozzle flaps redesigned for low observability with minimal performance loss. The experimental program was successfully completed May 1995 in Lewis' CE-22 facility. The models were tested over a wide range of geometric variations and nozzle pressure ratios. Results confirmed that the redesigned nozzle flaps had an insignificant effect on the thrust performance and that the resulting flow patterns should not be a problem in the cooling flow design. The results also agreed well with Pratt & Whitney's computational fluid dynamics analysis. The data obtained from this test were added to the current data base to help validate other performance prediction methodology.

Source record↗

NASA NTRS2001

Multimillion Dollar Construction Project Completed in Glenn's Icing Research Tunnel

Over the last year, the Glenn Research Center's Icing Research Tunnel (IRT) underwent a major $5.2 million rehabilitation project as part of the Construction of Facilities program. The scope of the project included redesign and replacement of the 55-yr-old heat exchanger, the addition of fan outlet guide vanes for flow conditioning downstream of the 25-ft-diameter fan, and redesign and replacement of the C and D corner-turning vanes. The purpose of the rehabilitation was to replace old portions of the infrastructure and to improve the aerodynamic flow quality in the tunnel.

Kevdzija, Susan L.↗

NASA NTRS2005

NESC Peer-Review of the Flight Rationale for Expected Debris Report

Since the loss of Columbia on February 1, 2003, the Space Shuttle Program (SSP) has significantly improved the understanding of launch and ascent debris, implemented hardware modifications to reduce debris, and conducted tests and analyses to understand the risks associated with expected debris. The STS-114 flight rationale for expected debris relies on a combination of all three of these factors. A number of design improvements have been implemented to reduce debris at the source. The External Tank (ET) thermal protection system (TPS) foam has been redesigned and/or process improvements have been implemented in the following locations: the bipod closeout, the first ten feet of the liquid hydrogen (LH2) tank protuberance air load (PAL) ramp, and the LH2 tank-to-intertank flange closeout. In addition, the forward bipod ramp has been eliminated and heaters have been installed on the bipod fittings and the liquid oxygen (LO2) feedline forward bellows to prevent ice formation. The Solid Rocket Booster (SRB) bolt catcher has been redesigned. The Orbiter reaction control system (RCS) thruster cover "butcher paper" has been replaced with a material that sheds at a low velocity. Finally, the pad area has been cleaned to reduce debris during lift-off.

Harris, Charles E.↗

NASA NTRS2001

Highly Loaded Low Pressure Turbine (LPT)

The goal of this study is to evaluate aspirated and non-aspirated aerodynamics on highly loaded LPT design. The objective is to increase stage loading by 30 to 50 percent without loss of efficiency for an existing low pressure turbine design. A study conducted on a NASA highly loaded multistage fan drive turbine (NASA CR-1964) indicated that end-wall bleed at the hub is a more significant parameter compared to aspirated airfoil. Based on this study, a 3-stage LPT is redesigned to 2-stage LIT with and without end-wall bleed. Both aerodynamic design and mechanical design are completed. In addition to end-wall bleed, exit guide vanes are designed with aspirated airfoils to reduce the losses. The LPT is redesigned with all constraints necessary for practical application. The benefit of the high-performance, highly loaded LPT shows up in reduced stage and part count, reduced size and weight, and reduced cost.

Ortiz, Milt↗