Results for “Staging” — Page 22

NASA NTRSDate not supplied

Space Launch System Core Stage Green Run Base Heating: Anomaly, Mitigation and Flight Redesign

The NASA Space Launch System (SLS) vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the Core Stage (CS). The SLS Core Stage went through Green Run hot-fire testing at NASA Stennis Space Center’s B-2 test facility in 2021. The main goal of this testing was to confirm Core Stage tanking, propulsion and thrust vector control systems operations and performance to verify with predicted models. Two hot-fire (HF) test sequences were performed with the first one (HF1) in January for a test duration of 70 seconds and the second (HF2) testing completed in March for a test duration of 500 seconds. This paper focuses on the base heating anomalies observed during HF1 and HF2 where an extensive fire was observed along the Core Stage base heat shield during test operations. This environment was not anticipated and led to extensive unplanned damage to the thermal protection system which was augmented for flight. Green Run observations also led to a reassessment of flight environments for Artemis I. This paper discusses the potential cause of the anomalies, the flow physics, the reconstructed base environments, and mitigation plans for HF2 and flight.

aerothermodynamics↗

NASA NTRSDate not supplied

Space Launch System Core Stage Green Run Base Heating: Anomaly, Mitigation and Flight Redesign

The NASA Space Launch System (SLS) vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the Core Stage (CS). The SLS Core Stage went through Green Run hotfire testing at NASA Stennis Space Center’s B-2 test facility in 2021. The main goal of this testing was to confirm Core Stage tanking, propulsion and thrust vector control systems operations and performance to verify with predicted models. Two hot-fire (HF) test sequences were performed with the first one (HF1) in January for a test duration of 70 seconds and the second (HF2) testing completed in March for a test duration of 500 seconds. This paper focuses on the base heating anomalies observed during HF1 and HF2 where an extensive fire was observed along the Core Stage base heat shield during test operations. This environment was not anticipated and led to extensive unplanned damage to the thermal protection system which was augmented for flight. Green Run observations also led to a reassessment of flight environments for Artemis I. This paper discusses the potential cause of the anomalies, the flow physics, the reconstructed base environments, and mitigation plans for HF2 and flight.

aerothermodynamics↗

NASA NTRSDate not supplied

Overview of the SLS Core Stage Thrust Vector Control System Design

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.

Thrust Vector Control↗

NASA NTRSDate not supplied

Overview of the SLS Core Stage Thrust Vector Control System Design

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.

Thrust Vector Control↗

NASA NTRSDate not supplied

A Four-Stage Continuous ADR for Space Missions

The cryogenics group at NASA-Goddard has provided adiabatic demagnetization refrigerators (ADRs) for cooling detectors to sub-Kelvin temperatures in space. These ADRs were single-shot devices that produced cooling at 0.05 K for tens of hours before needing to be recycled. Our group also developed a four-stage laboratory ADR system which holds one stage continuously at 0.05K, or colder, while using the other stages to pump heat from the continuous stage up to a heat sink near 4K. This continuous ADR (CADR) provides a useful cooling power that is more than 10 times greater at 0.050 K than what was required by the single-shot space systems. Over the past several years, this system was updated so that it can withstand the rigors of a launch into space. We describe this development process and report its final results.

Continuous ADR↗

NASA NTRSDate not supplied

A Four-Stage Continuous ADR for Space Missions

The cryogenics group at NASA-Goddard has provided adiabatic demagnetization refrigerators (ADRs) for cooling detectors to sub-Kelvin temperatures in space. These ADRs were single-shot devices that produced cooling at 0.05 K for tens of hours before needing to be recycled. Our group also developed a four-stage laboratory ADR system which holds one stage continuously at 0.05K, or colder, while using the other stages to pump heat from the continuous stage up to a heat sink near 4K. This continuous ADR (CADR) provides a useful cooling power that is more than 10 times greater at 0.050 K than what was required by the single-shot space systems. Over the past several years, this system was updated so that it can withstand the rigors of a launch into space. We describe this development process and report its final results.

Continuous ADR↗

NASA NTRSDate not supplied

Numerical Investigation of Combustor-Turbine Interactions with a Two-Stage High-Pressure Turbine Including Cooling Airflows

Combustor–turbine interactions (CTIs) are investigated by performing three-dimensional unsteady simulations using a realistic combustor and high-pressure turbine (HPT) configurations from the Energy Efficient Engine (E3) program. To understand CTIs, we compare the numerically predicted flow fields from single-component simulations (Step 1: the combustor + the first-stage stator of turbine; Step 2: the two-stage HPT imposing the time-averaged flow solution from Step 1 as the inflow boundary condition) and a fully coupled combustor–turbine simulation (Step 3) at the sea-level takeoff (SLTO) condition. In addition to three previous simulations where the cooling airflows inside the HPT had been neglected for all Step 1, Step 2, and Step 3, two new simulations of Step 2 and Step 3 take into account the cooling airflows using the source team approach. In this approach, to mimic the cooling airflows, we impose the source term at a specific area of a cooling airflow hole at the solid surfaces without making a mesh of each hole. The objective of this study is twofold. One is to investigate the effect of the presence of the cooling airflows on the aerodynamics of the combustor and HPT as well as the HPT performance. The second is to perform a detailed comparison among the calculated flowfields by two different numerical schemes, the central-difference with the standard Jameson–Schmidt–Turkel (CD-JST) scheme and the AUSM scheme. There is a noticeable difference in the hot-streak distributions at the first-stage stator. In addition, depending on the choice of the numerical scheme and the presence of the cooling airflows, an occurrence of shock waves appearing at the first-stage stator is greatly influenced. Thus, this has a noticeable impact on the HPT performance. It is shown that the estimated turbine efficiencies from Step 3 are about 7 % less than the ones from Step 2.

Combustor-turbine interaction↗

NASA NTRS2014

Reflections on Centaur Upper Stage Integration by the NASA Lewis (Glenn) Research Center

The NASA Glenn (then Lewis) Research Center (GRC) led several expendable launch vehicle (ELV) projects from 1963 to 1998, most notably the Centaur upper stage. These major, comprehensive projects included system management, system development, integration (both payload and stage), and launch operations. The integration role that GRC pioneered was truly unique and highly successful. Its philosophy, scope, and content were not just invaluable to the missions and vehicles it supported, but also had significant Agencywide benefits. An overview of the NASA Lewis Research Center (now the NASA Glenn Research Center) philosophy on ELV integration is provided, focusing on Atlas/Centaur, Titan/Centaur, and Shuttle/Centaur vehicles and programs. The necessity of having a stable, highly technically competent in-house staff is discussed. Significant depth of technical penetration of contractor work is another critical component. Functioning as a cohesive team was more than a concept: GRC senior management, NASA Headquarters, contractors, payload users, and all staff worked together. The scope, content, and history of launch vehicle integration at GRC are broadly discussed. Payload integration is compared to stage development integration in terms of engineering and organization. Finally, the transition from buying launch vehicles to buying launch services is discussed, and thoughts on future possibilities of employing the successful GRC experience in integrating ELV systems like Centaur are explored.

Launch Vehicle↗

NASA NTRS2015

Reflections on Centaur Upper Stage Integration by the NASA Lewis (Glenn) Research Center

The NASA Glenn (then Lewis) Research Center (GRC) led several expendable launch vehicle (ELV) projects from 1963 to 1998, most notably the Centaur upper stage. These major, comprehensive projects included system management, system development, integration (both payload and stage), and launch operations. The integration role that GRC pioneered was truly unique and highly successful. Its philosophy, scope, and content were not just invaluable to the missions and vehicles it supported, but also had significant Agency-wide benefits. An overview of the NASA Lewis Research Center (now the NASA Glenn Research Center) philosophy on ELV integration is provided, focusing on Atlas/Centaur, Titan/Centaur, and Shuttle/Centaur vehicles and programs. The necessity of having a stable, highly technically competent in-house staff is discussed. Significant depth of technical penetration of contractor work is another critical component. Functioning as a cohesive team was more than a concept: GRC senior management, NASA Headquarters, contractors, payload users, and all staff worked together. The scope, content, and history of launch vehicle integration at GRC are broadly discussed. Payload integration is compared to stage development integration in terms of engineering and organization. Finally, the transition from buying launch vehicles to buying launch services is discussed, and thoughts on future possibilities of employing the successful GRC experience in integrating ELV systems like Centaur are explored.

Centaur↗

NASA NTRS2024

Intrastep, Stage-Value Predictors for Diagonally-Implicit Runge-Kutta Methods

To better identify the necessary attributes of good stage-value predictors (SVPs), numerous SVPs are designed for an existing: ESDIRK4(3)7L[2]SA [26] and a new: ESDIRK4(3)8L[2]SA scheme.1 Both are stifflyaccurate, stage-order two, explicit, singly-diagonally implicit Runge–Kutta (ESDIRK) schemes. Tradeoffs are studied in the parameter spaces enforcing the constraints on accuracy, linear stability, nonlinear stability and coefficient size to determine which objectives correlate with effective predictors. The SVPs are tested on three challenging external aerodynamics problems [107 − 108 degrees of freedom (DoFs)], each with a different level of stiffness. The problems include two 3D airfoils simulations and one canonical turbulence simulation. All simulations use the compressible Navier-Stokes equations (CNSE). An entropy stable spectral collocation formulation is used for discretizing the spatial terms in the equations. Simulations are performed at a wide variety of temporal error tolerances. Problems that are sufficiently stiff (e.g., lax temporal error tolerances) benefit from SVPs designed with second-order accuracy and stability properties: A-stability, and L-stability, rather than high accuracy constraints. Simulations with modest stiffness (e.g., strict error tolerances) are better suited for SVPs designed using high accuracy constraints. Designing SVPs with enhanced stability properties is tedious but worthwhile. Simulation times are reduced with optimal SVPs by as much as 100% on some stages, with combined stepwise improvements of between 50 − 100% for both methods. A comparative study is performed with the two aforementioned methods as well as four other ESDIRKs. The newly designed ESDIRK4(3)8L[2]SA with γ ≈ 1/10, proves to be the most efficient of the six tested ESDIRK schemes simulating the CNSE.

Diagonally-Implicit Runge-Kutta↗

NASA NTRS1965

The output stage for the ground transmitter at Goonhilly

The power output amplifier of the transmitter for the Goonhilly project uses a travelling tube, type VX527 delivering 4 kW at 6,390 Me/s, with a bandwidth of about 100 Mc/s. This amplifier, together with its power supplies and driver stage is located in a cabin, situated on the turntable underneath the aerial. Input signals for the transmitter are received in the cabin from the main control room at a frequency of 70 Mc/s; they are converted to the to the nominal 6,390 Mc/s before being amplified to about 3 watts by the driver TWT and fed via a waveguide link to the output stage. The output stage, described below, was designed and manufactured by A.E.I. Electronic Apparatus Division, Leicester, England, during the first half of 1962.

TRAVELING WAVE AMPLIFIER↗

NASA NTRS1972

Two-stage magnetometer measures weak magnetic fields

Sensitive magnetometer capable of measuring field strengths of 10 nanogauss is described. High permeability core is aligned parallel to magnetic field in first stage. In second stage, ferromagnetic toroid saturates rapidly. Adjustment of turns and area ratios of each stage provides wide range of sensitivities.

Buntenbach, R. W.↗

NASA NTRS1969

Dynamic characteristics of a variable-mass flexible missile: Dynamics of a two-stage variable-mass flexible rocket

The dynamic characteristics of two-stage slender elastic body were investigated. The first stage, containing a solid-fuel rocket, possesses variable mass while the second stage, envisioned as a flexible case, contains packaged instruments of constant mass. The mathematical formulation was in terms of vector equations of motion transformed by a variational principle into sets of scalar differential equations in terms of generalized coordinates. Solutions to the complete equations were obtained numerically by means of finite difference techniques. The problem has been programmed in the FORTRAN 4 language and solved on an IBM 360/50 computer. Results for limited cases are presented showing the nature of the solutions.

Meirovitch, L.↗

NASA NTRS1972

Single-stage experimental evaluation of compressor blading with slots and vortex generators, part 5

An experimental investigation was conducted to determine the extent that slots and vortex generators can increase the efficiency and stable operating range of highly loaded compressor stages. With slots in the rotor and stator, the stage performance both with and without vortex generators was inferior to that achieved with the unslotted blading. However, with vortex generators, stator slots, and an unslotted rotor, the stable operating range increased 25% and the stage peak efficiency increased 2.1% over the values achieved with the unslotted rotor and stator without vortex generators, at design equivalent rotor speed.

Brent, J. A.↗

NASA NTRS1971

A large granite stage and measuring microscope.

A stage and measuring microscope servocontrolled by a computer have been constructed. The travel of the stage is 0.5 x 0.5 m and the travel of the microscope objective is 7.5 cm. The measuring accuracy is 1 micron in the x-y plane and 5 microns along the z axis. The mechanical and optical construction of the stage and microscope, as well as the way in which the control electronics are organized, permit great flexibility of operation. Possible applications include the scanning and measuring of astronomical plates, the laying out of patterns of semiconductor devices of very large sizes, and the measurement of precision grids.

Alston-Garnjost, M.↗

NASA NTRS1972

High loading, 1800 ft/sec tip speed, transonic compressor fan stage. 2: Final report

Tests were conducted on a 0.5 hub/tip ratio, single-stage fan-compressor designed to produce a pressure ratio of 2.285 an efficiency of 84 percent with a rotor tip speed of 1800 feet per second. A peak efficiency of 82 percent was achieved by the stage at a stall margin of 6.5 percent. Tests showed that stall-limit line was slightly sensitive to tip-radial distortion, but stall-line improvements were noted when the stage was subjected to circumferential and hub-radial flow distortions. Rotor blade passage and trailing edge shock positions were inferred from static pressure contours over the rotor tips.

Morris, A. L.↗

NASA NTRS1971

Expendable Second Stage Reusable Space Shuttle Booster. Volume 10: Technology Requirements

Technology requirements for the expendable second stage of the space shuttle booster system are discussed. The primary objective of the expendable second stage (ESS) program is to define a low-cost system for placing large payloads, such as the space station or reusable nuclear shuttle, into low earth orbit. The proposed concept is to utilize a modified Saturn 5 second stage (S-2) in conjunction with the space shuttle reusable booster. The ESS retains the major S-2 structure, modified for attachment to the space shuttle booster, and incorporates both Saturn and shuttle developed propulsion and avionics hardware. No major technology breakthroughs are required to develop this ESS system. Technology application and implementation efforts in selected areas, however, should be conducted in support of the ESS detail design and development phase. The selected ESS system incorporates recovery of propulsion and avionics hardware by the shuttle orbiter for ESS reuse to minimize cost.

Source record↗

NASA NTRS1973

Design, capability, and cost of a Versatile Upper Stage /VUS/ family of vehicles.

Trade-off studies and a preliminary design were accomplished to investigate the Versatile Upper Stage (VUS) concept. This concept entails the development by one contractor of a family of stages with a great deal of commonality to perform a spectrum of potential unmanned automated missions planned through 1990. The trade studies and analyses revealed areas where the penalty for commonality between stages was excessive in weight and performance loss. This occurred in the selection of the vehicle structural shell. In many of the expensive subsystems, especially astrionics, it was found that establishing the requirements for all family members and the application of commonality in subsystem selection could result in significant savings.

Haltermann, R. L.↗