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At least 415 records · Page 23

Water impact analysis of space shuttle solid rocket motor by the finite element method

Preliminary analysis showed that the doubly curved triangular shell elements were too stiff for these shell structures. The doubly curved quadrilateral shell elements were found to give much improved results. A total of six load cases were analyzed in this study. The load cases were either those resulting from a static test using reaction straps to simulate the drop conditions or under assumed hydrodynamic conditions resulting from a drop test. The latter hydrodynamic conditions were obtained through an emperical fit of available data. Results obtained from a linear analysis were found to be consistent with results obtained elsewhere with NASTRAN and BOSOR. The nonlinear analysis showed that the originally assumed loads would result in failure of the shell structures. The nonlinear analysis also showed that it was useful to apply internal pressure as a stabilizing influence on collapse. A final analysis with an updated estimate of load conditions resulted in linear behavior up to full load.

Buyukozturk, O.↗

Variable-Speed Induction Motor Drives for Aircraft Environmental Control Compressors

New, more-efficient designs for aircraft jet engines are not capable of supplying the large quantities of bleed air necessary to provide pressurization and air conditioning for the environmental control systems (ECS) of the next generation of large passenger aircraft. System analysis and engineering have determined that electrically-driven ECS can help to maintain the improved fuel efficiencies; and electronic controllers and induction motors are now being developed in a NASA/NPD SBIR Program to drive both types of ECS compressors. Previous variable-speed induction motor/controller system developments and publications have primarily focused on field-oriented control, with large transient reserve power, for maximum acceleration and optimum response in actuator and robotics systems. The application area addressed herein is characterized by slowly-changing inputs and outputs, small reserve power capability for acceleration, and optimization for maximum efficiency. This paper therefore focuses on the differences between this case and the optimum response case, and shows the development of this new motor/controller approach. It starts with the creation of a new set of controller requirements. In response to those requirements, new control algorithms are being developed and implemented in an embedded computer, which is integrated into the motor controller closed loop. Buffered logic outputs are used to drive the power switches in a resonant-technology, power processor/motor-controller, at switching/resonant frequencies high enough to support efficient high-frequency induction motor operation at speeds up to 50,000-RPA

Mildice, J. W.↗

Additive Manufacturing Case Study Test Report

Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally.

15 GEOTHERMAL ENERGY↗

Space Shuttle system solid rocket booster.

Description of the mission and systems requirement of the solid rocket booster as it supports the Shuttle vehicle configuration. The solid booster is equipped with load skirts and linkages that can accommodate full mission loads, a solid propellant motor for delivering required performance, thrust vector control for augmentation of Shuttle vehicle ascent control, staging and separation systems, and electrical subsystems. To recover and reuse the solid booster case a recovery package is provided. The definition of these functional elements of the solid booster are discussed with the requirements placed on each element to satisfy the overall booster objective.

Thomason, H. E.↗

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗

Identification and Study of Validation Level Test Cases for Computational Modeling of Non-Charring Ablators

Computational modeling of Thermal Protection System (TPS) materials, used for aerospace applications, provides numerous advantages in preliminary selection and design of a heatshield material and shape for atmospheric entry vehicles. However, to serve as a reliable tool for prediction of material thermal and ablative behavior, the modeling approach needs to be validated against real experimental and flight data, preferably at a range of applied conditions. The validation study is typically very complex as it requires reliable measured data not only for the material thermal response and surface recession, but also well characterized environmental conditions. The validation problem becomes even more complex when the material thermal response is dictated by multi-physics effects such as solid conduction, in-depth thermal decomposition, pyrolysis gas flow and chemical reactions. The multi-physics effects complicate not only the modeling effort, but also the experimental measurement for validation of various aspects of the highly coupled problem. In this study, an attempt is made to identify suitable experimental data that could serve as a source for validation of material thermal response modeling tools. To reduce the computational complexity, this study focuses only on non-charring ablators, where the material thermal response could be modeled with a single governing equation for solid conduction and the ablation is limited only to the surface of the material. With a well characterized and publicly available experimental data being sparse, the study is limited in presenting test cases for only three materials: camphor, graphite and FiberForm® in the sequence of increased modeling complexity. Graphite is a commonly used TPS material for aerospace applications, both for leading edges of high-speed vehicles and internal insulation of solid rocket motors. FiberForm® is a porous carbon pre-form used in preparation of the well known PICA material Tran et al. [1996]. Inclusion of camphor into the list is conditioned with the relative simplicity in modeling the material thermal and chemical response and the low-enthalpy flow environment. In addition, camphor has been used as a simple test material for study of flow transition behavior by Stock and Ginoux [1973] and assessment of a heatshield shape change at flight relevant conditions by Rotondi et al. [2022]. In this work, the identified experimental data was extracted from the public literature and test cases that yet have been published. As it was found from the review, not a single test case contains an exhaustive set of data that would validate every aspect of the material physics. However, in the data collected, various aspects of the material behavior can be still validated, such as surface and in-depth temperature, amount of recession and a shape change. The identified experimental data for each case is accompanied with a characterized flow environment and simulated boundary conditions predicted by a Data-Parallel Line Relaxation (DPLR) code Wright et al. [1998]. In addition, material thermal response numerical simulations in each test case are performed with Kentucky Aerothermodynamics and Thermal Response System (KATS-MR) Zibitsker et al. [2022] providing a comparative study and a sanity check for the proposed validation data. Sample results from the performed numerical study are shown below. Figure 1 shows distribution of surface heat flux and pressure values on a hemi-cylinder model made of FiberForm® and tested in HyMETS arc-jet facility. The results are shown for the high pressure condition among the two tests. Flow simulation was performed with DPLR code on a quarter of original geometry. In the figure, the quarter shape was mirrored across zx and xy planes to show the complete distribution. Figure 2 shows the material response results for the high pressure case (7500 Pa), simulated with KATS-MR and a comparison to the experimental data for the surface temperature and shape shape. The simulation was performed on a 2-D slice, extracted in the xy plane at the middle of the sample. Figure 3 shows the material response simulation for the low pressure case (3500 Pa) and a comparison to the experimental data for surface temperature and shape change.

ablation↗

New principles of self‐organization created through the interplay of DNA condensates, microtubules, and motors

Bioinspired design—which holds great promise for a new generation of materials that are robust to defects, scalable under green manufacture, environmentally responsive, and programmably reconfigurable—requires mastery over molecular self-organization. Yet, from its specific mechanisms to most general architectures, the principles governing self-organization remain poorly understood and not even fully enumerated. For living systems, one obvious architectural principle is the modular reuse of a few simple molecular components in myriad combinations to achieve more complex phenomena. For example, the mechanical tasks of a cell are driven by the nonequilibrium dynamics of cytoskeletal filaments and molecular motors—the same filaments and motors, reprogrammed by a variety of modulators, perform tasks ranging from cell movement to division. Similarly, many compartmentalization tasks are performed by liquid-like condensates of simple components, which act as membraneless organelles to localize particular molecules in space and time (e.g. for gene regulation or RNA processing). In a few cases, condensates combine and interact with the cytoskeleton to create still more complex phenomena, e.g. the nucleation of microtubule asters from the centrosome (a protein condensate) to form the mitotic spindle during cell division. Very little is known about the fundamental mechanisms of such filament-plus-condensate phenomena. Despite few examples, the landscape of behaviors that can be achieved through the combination of condensates, filaments, and motors appears vast. However, exploration has been hindered by a lack of systems that have sufficiently programmable and dynamically tunable interactions between component condensates, filaments, and motors. We proposed to combine programmable DNA condensates, filamentous microtubules, and light-controlled motors into self-organizing systems whose principles go beyond those that have been observed in nature. In one limit, our systems will use microtubules and motors to create the molecular analog of a network of roads, which will organize droplets of DNA condensates capable of carrying molecular cargo. DNA condensates coupled to motors will flow from one microtubule aster hub to another, with their direction and timing controlled by DNA circuits. In another limit, microtubules will swim through bulk DNA condensates and exhibit strong interactions with boundaries between different types of condensates. Microtubule swimmers will reflect, get trapped, or refract at boundaries, under a mechanical analog of the classical optical index of refraction. DNA condensates having different mechanical indexes of refraction will be used to construct the analog of optical lenses, so that microtubule swimmers can be manipulated like light—collimated, diffracted, focused, and sorted based on properties analogous to wavelength. These two limits define two new architectures, within which multiple new mechanistic principles for self-organization will be discovered and explored. To explore these architectures, the motor-based coupling between DNA condensates and filaments will be controlled in time and space through the use of opto-proteins that create reversible links between DNA condensates and motors upon illumination. For each principle of interest, patterns of light will create virtual experiments by defining patterns of activity where DNA condensates walk along filaments, or filaments swim through condensates, and patterns of inactivity which will serve either as controls, or as boundary conditions vital to create the desired phenomena. This research serves the goals of Basic Energy Sciences Biomolecular Material Program by elucidating the principles by which the emergent, nonequilibrium behavior of collections of DNA condensates, motors, and microtubules can be programmed by environmental light patterns to create complex motion and materials transport. Because DNA condensates can be readily coupled to virtually any high performance nanomaterial, from carbon nanotubes, to metal nanoparticles, to light harvesting systems, this work provides a path to the construction, self-maintenance and reconfiguration of materials relevant to the Department of Energy.

60 APPLIED LIFE SCIENCES↗

The Business Case for Spiral Development in Heavy Lift Launch Vehicle Systems

Performance capabilities of a specific combination of the Space Shuttle external tank and various liquid engines in an in-line configuration, two-stage core vehicle with multiple redesigned solid rocket motor strap-ons are reexamined. This concept proposes using existing assets, hardware, and capabilities that are already crew-rated, flight certified, being manufactured under existing contracts, have a long history of component and system ground testing, and have been flown for over 20 yr. This paper goes beyond describing potential performance capabilities of specific components to discuss the overall system feasibility-from end to end, start to finish-describing the inherent cost advantages of the Spiral Development concept, which builds on existing capabilities and assets, as opposed to starting up a "fresh sheet" heavy-lift launch vehicle program from scratch.

Farr, Rebecca A.↗

Acceleration effects in solid propellant rocket motors

The performance variations due to acceleration loads imposed on spinning solid propellant rocket motors are investigated. The four potentially most significant modes of acceleration-induced phenomena are identified from a study of the literature and modeled. The four modes are a mechanical mode which deals with deformations of the propellant and case: a thermodynamic mode which covers acceleration-induced combustion phenomena; a stress mode which covers the stressed propellant's effect on burn rate; and a gas dynamic mode which deals with changes in gas flow in the chamber and through the nozzle. Simplified models of each mode are developed or taken from the literature and are added to an internal ballistics evaluation computer program. The resulting analysis is the first to include all of the modes. In order to do this an original analysis of the mechanical and stress modes was necessary. However, the analysis shows that the stress mode is not important for the circular perforated grains studied. The other effects are shown to have a significant influence on solid rocket motor performance. The magnitude of the different mode effects are such that one may not be ignored over the others as has been done in the past. The results of the analysis are compared to published rocket motor data. The comparisons indicate an erosive burning effect that is a function of spin rate. A qualitative explanation of the erosive effect is presented.

Langhenry, M. T.↗

Improvements in rocket engine nozzle and high altitude plume computations

The characteristics of rocket exhaust flow fields are very complex, and many phenomena are involved. Previously, it was necessary to use a multitude of codes to treat a nozzle/plume flow in detail. In connection with both computational and economic standpoints, however, it is desirable to have a single code which can treat all the dominant phenomena in a rocket nozzle/plume flow field. The present investigation has the objective to describe a nozzle plume flowfield code which has capabilities that do not presently exist in a single computer code. The RAMP code considered by Penny et al. (1976) was used as a basis in the development of the new code. The basic RAMP employs modular construction and provides a two-phase, reacting gas, supersonic inviscid nozzle/plume solution. Other capabilities needed, which in most cases already exist in other computer codes, were incorporated into the RAMP code to enhance its usefulness. Attention is given to results of plume calculations for bipropellant and solid propellant motors.

Smith, S. D.↗

A Fully Coupled Multi-Rigid-Body Fuel Slosh Dynamics Model Applied to the Triana Stack

A somewhat general multibody model is presented that accounts for energy dissipation associated with fuel slosh and which unifies some of the existing more specialized representations. This model is used to predict the mutation growth time constant for the Triana Spacecraft, or Stack, consisting of the Triana Observatory mated with the Gyroscopic Upper Stage of GUS (includes the solid rocket motor, SRM, booster). At the nominal spin rate of 60 rpm and with 145 kg of hydrazine propellant on board, a time constant of 116 s is predicted for worst case sloshing of a spherical slug model compared to 1,681 s (nominal), 1,043 s (worst case) for sloshing of a three degree of freedom pendulum model.

London, K. W.↗

Flight set 360H005 (STS-28) seals, volume 4

The performance is assessed of the 360H005, Fifth flight, Redesigned Solid Rocket Motors (RSMR) in respect to joint sealing issues as seen from post flight inspection of the seals and sealing surfaces. The factory joint disassembly inspections have resumed for 360H005. The new factory joint grease application is in effect and now can be assessed during the disassembly process. The RSRM is illustrated consisting of capture feature field joints as is the J-joint insulation configuration. The nozzle-to-case joint design is also illustrated, which includes 100, 7/8 inch radial bolts in conjunction with a wiper O-ring and modified insulation design. The ignition system seals and a cross section of the igniter are illustrated. The configuration of all the internal nozzle joints are also shown. The postflight inspection of both motors showed the seal components to be in excellent condition except for the indentation found on the inner primary seal of the right hand inner igniter gasket, aft face. Detailed inspection results, and inspections performed by the O-ring Inspection Team are presented.

Curry, Jeffrey T.↗

Evaluation of the efficiency and reliability of software generated by code generators

There are numerous studies which show that CASE Tools greatly facilitate software development. As a result of these advantages, an increasing amount of software development is done with CASE Tools. As more software engineers become proficient with these tools, their experience and feedback lead to further development with the tools themselves. What has not been widely studied, however, is the reliability and efficiency of the actual code produced by the CASE Tools. This investigation considered these matters. Three segments of code generated by MATRIXx, one of many commercially available CASE Tools, were chosen for analysis: ETOFLIGHT, a portion of the Earth to Orbit Flight software, and ECLSS and PFMC, modules for Environmental Control and Life Support System and Pump Fan Motor Control, respectively.

Schreur, Barbara↗

Minimum energy trap states of dual-spin spacecraft

The general solution to the bearing axis motor torque required to escape a minimum energy trap state is presented for oblate dual-spin spacecraft. A simplified, reduced order analysis of the bearing torque is then obtained for the case of small static imbalances, dynamic imbalances, and asymmetries on the rotor and the stator. This analysis is extended to include large asymmetry on one of the bodies. The results are applied to the design of the Galileo spacecraft.

Hollars, M. G.↗

Gesture Based Control and EMG Decomposition

This paper presents two probabilistic developments for use with Electromyograms (EMG). First described is a new-electric interface for virtual device control based on gesture recognition. The second development is a Bayesian method for decomposing EMG into individual motor unit action potentials. This more complex technique will then allow for higher resolution in separating muscle groups for gesture recognition. All examples presented rely upon sampling EMG data from a subject's forearm. The gesture based recognition uses pattern recognition software that has been trained to identify gestures from among a given set of gestures. The pattern recognition software consists of hidden Markov models which are used to recognize the gestures as they are being performed in real-time from moving averages of EMG. Two experiments were conducted to examine the feasibility of this interface technology. The first replicated a virtual joystick interface, and the second replicated a keyboard. Moving averages of EMG do not provide easy distinction between fine muscle groups. To better distinguish between different fine motor skill muscle groups we present a Bayesian algorithm to separate surface EMG into representative motor unit action potentials. The algorithm is based upon differential Variable Component Analysis (dVCA) [l], [2] which was originally developed for Electroencephalograms. The algorithm uses a simple forward model representing a mixture of motor unit action potentials as seen across multiple channels. The parameters of this model are iteratively optimized for each component. Results are presented on both synthetic and experimental EMG data. The synthetic case has additive white noise and is compared with known components. The experimental EMG data was obtained using a custom linear electrode array designed for this study.

Wheeler, Kevin R.↗

Techniques for Embedding Instrumentation in Pressure Vessel Test Articles

Many interesting structural and thermal events occur in materials that are housed within a surrounding pressure vessel. In order to measure the environment during these events and explore their causes instrumentation must be installed on or in the material. Transducers can be selected that are small enough to be embedded within the test material but these instruments must interface with an external system in order to apply excitation voltages and output the desired data. The methods for installing the instrumentation and creating an interface are complicated when the material is located in a case or housing containing high pressures and hot gases. Installation techniques for overcoming some of these difficulties were developed while testing a series of small-scale solid propellant and hybrid rocket motors at Marshall Space Flight Center. These techniques have potential applications in other test articles where data are acquired from materials that require containment due to the severe environment encountered during the test process. This severe environment could include high pressure, hot gases, or ionized atmospheres. The development of these techniques, problems encountered, and the lessons learned from the ongoing testing process are summarized.

Cornelius, Michael↗

Investigation of the acoustic properties of composite materials

An effort to provide inspection of the bondlines in the Space Shuttle Solid Rocket Motor (SRM) is discussed. Investigation of the bondlines in the membrane region of the SRM has centered on representative samples provided by Morton Thiokol. These samples have pull-tabs, or in one case grafoil inserts, to simulate delaminations at various points in the multilayer structure of steel case, liner, insulation, liner, and propellant. Discussed here is the continuing approach to examining these defects which is predicated on a model of an ultrasonic wave propagating in a lossy multilayer resonant structure, the experimental arrangements used, and the results of these experiments.

Smith, B. T.↗

Flight motor set 360L001 (STS-26R). Volume 1: System overview, revision A

The NASA space shuttle flight STS-26R, launched at 11:37.00.009 am, EDT on 29 Sep. 1988, used the redesigned solid rocket motors (RSRM) 360L001A and 360L001B. Evaluation of the ground environment instrumentation (GEI) data recorded prior to flight showed no launch commit criteria violations; that the field joint heater and aft skirt thermal conditioning systems performed adequately; and that the GEI data showed good agreement with thermal model predictions. Evaluation of the developmental flight instrumentation (DFI) revealed excellent agreement with both the predicted and required ballistic specifications. All parameters were well within the GEI specification requirements including propellant burn rates, specific impulse values, and thrust imbalance. Recorded strain values also indicated satisfactory radial growth and stress levels, as well as verification of adequate safety factors. Postflight inspection of the insulation, seals, case, and nozzles showed overall excellent performance. Some thermal DFI protective cork was missing, and inoperative field joint vent valves on the thermal protection cork allowed water entry into the field joints upon splashdown. Evaluation of these anomalies, as well as complete evaluation of all Redesigned Solid Rocket Motor components, is contained.

Garecht, Diane M.↗