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At least 415 records · Page 23

Hot-Gas-Slide and Coolant-Side Heat Transfer in Liquid Rocket Engine Combustors

The objectives of this article are to develop a multidisciplinary, computational methodology to predict the hot-gas-side and coolant-side heat transfer in film cooling assisted, regeneratively cooled liquid rocket engine combustors, and to use it in parametric studies to recommend optimized design of the coolant channels for a developmental combustor. An integrated numerical model which incorporates computational fluid dynamics (CFD) for the hot-gas thermal environment, and thermal analysis for the liner and coolant channels, was developed. This integrated CFD/thermal model was validated by comparing predicted heat fluxes with those of hot-firing test and industrial design methods for a 40-k calorimeter thrust chamber and the Space Shuttle Main Engine main combustion chamber. Parametric studies were performed for the advanced main combustion chamber to find a strategy for a proposed coolant channel design.

Ten-see Wang↗

A CFD Analysis of Hydrogen Leakage During On-Pad Purge in the ORION/ARES I Shared Volume

A common open volume is created by the stacking of the Orion vehicle onto the Ares I Upper Stage. Called the Shared Volume, both vehicles contribute to its gas, fluid, and thermal environment. One of these environments is related to hazardous hydrogen gas. While both vehicles use inert purge gas to mitigate any hazardous gas buildup, there are concerns that hydrogen gas may still accumulate and that the Ares I Hazardous Gas Detection System will not be sufficient for monitoring the integrated volume. This Computational Fluid Dynamics (CFD) analysis has been performed to examine these topics. Results of the analysis conclude that the Ares I Hazardous Gas Detection System will be able to sample the vent effluent containing the highest hydrogen concentrations. A second conclusion is that hydrogen does not accumulate under the Orion Service Module (SM) avionics ring as diffusion and purge flow mixing sufficiently dilute the hydrogen to safe concentrations. Finally the hydrogen concentrations within the Orion SM engine nozzle may slightly exceed the 1 percent volume fraction when the entire worse case maximum full leak is directed vertically into the engine nozzle.

Ajmani, Kumud↗

General MACOS Interface for Modeling and Analysis for Controlled Optical Systems

The General MACOS Interface (GMI) for Modeling and Analysis for Controlled Optical Systems (MACOS) enables the use of MATLAB as a front-end for JPL s critical optical modeling package, MACOS. MACOS is JPL s in-house optical modeling software, which has proven to be a superb tool for advanced systems engineering of optical systems. GMI, coupled with MACOS, allows for seamless interfacing with modeling tools from other disciplines to make possible integration of dynamics, structures, and thermal models with the addition of control systems for deformable optics and other actuated optics. This software package is designed as a tool for analysts to quickly and easily use MACOS without needing to be an expert at programming MACOS. The strength of MACOS is its ability to interface with various modeling/development platforms, allowing evaluation of system performance with thermal, mechanical, and optical modeling parameter variations. GMI provides an improved means for accessing selected key MACOS functionalities. The main objective of GMI is to marry the vast mathematical and graphical capabilities of MATLAB with the powerful optical analysis engine of MACOS, thereby providing a useful tool to anyone who can program in MATLAB. GMI also improves modeling efficiency by eliminating the need to write an interface function for each task/project, reducing error sources, speeding up user/modeling tasks, and making MACOS well suited for fast prototyping.

Sigrist, Norbert↗

From Exploration Flight Test-1 to Artemis II--A NASA Langley's Orion Aerosciences Overview

The Orion Aerosciences program at NASA Langley has played a central role in advancing the aerodynamic and aeroheating prediction capabilities required for the Orion crew vehicle’s return from deep space. This presentation provides a technical overview of aerosciences contributions spanning Exploration Flight Test-1 (EFT-1), Artemis I, and the ongoing post-flight analysis of Artemis II. EFT-1 provided the first high-energy entry dataset for Orion, enabling critical validation of aerodynamic force and moment predictions, static and dynamic stability characteristics, and aeroheating environments at relevant flight Mach and Reynolds numbers. Flight-derived pressure data were used to refine the Flush Air Data System (FADS) methodology for atmospheric density reconstruction and to improve Best Estimated Trajectory (BET) solutions. The EFT-1 data also offered key insights into heat shield performance, including char layer recession, in-depth thermal response, and material retention behavior under flight conditions, informing updates to both thermal response models and uncertainty quantification practices. Building on EFT-1, Artemis I extended the database to true lunar-return conditions. Observations of heat shield performance, including localized char loss, bondline response, and recession variability, provided an unprecedented opportunity to reassess Thermal Protection System (TPS) and aeroheating modeling assumptions. Aerodynamic reconstruction efforts incorporated improved FADS calibration, enhanced atmospheric modeling, and refined force and moment databases to reduce trajectory and load uncertainties. Aeroheating comparisons between pre-flight predictions and flight data enabled targeted model updates, particularly in transitional flow environments and wake heating regions. For Artemis II, these lessons were systematically incorporated into the pre-flight prediction process. Updates included refined aerodynamic databases anchored to flight-validated corrections, improved density estimation and BET methodologies using enhanced database interpolation algorithm and FADS modeling, and revised aeroheating design environments informed by Artemis I material response observations. By the time of the workshop, Artemis II post-flight analysis will be underway, and preliminary findings will be presented where available, including early comparisons of aerodynamic reconstruction, atmospheric density estimation, and thermal protection system performance relative to updated predictions. Collectively, this body of work is a testament to the dedicated and multidisciplinary team whose sustained efforts have contributed to the program’s success and to the progressive maturation of Orion aerosciences modeling through numerical modeling, ground and flight data assimilation. The integrated advancement of aerodynamics, trajectory reconstruction, FADS-based density estimation, and aeroheating analysis has reduced predictive uncertainty and strengthened confidence for future crewed lunar and deep-space missions.

Orion↗

On-Orbit Structural Dynamics Performance of the Roll-Out Solar Array

The Roll-Out Solar Array (ROSA) flight experiment was launched to the International Space Station (ISS) on June 3rd, 2017. ROSA is an innovative, lightweight solar array with a flexible substrate that makes use of the stored strain energy in its composite structural members to provide deployment without the use of motors. This paper will discuss the results of various structural dynamics experiments conducted on the ISS during the weeks following launch. Data gathered from instrumentation on the solar array wing during the experiments are compared with pre-flight predictions from two different finite element modeling efforts. Two distinct methods were used to reconstruct the modal characteristics of ROSA from the data collected on orbit. Of particular interest in this effort are the first few system modes and mode shapes of the array, the amount of structural damping present, and degree of structural thermal interaction seen during eclipse exit. Discrepancies between the behavior predicted by the models and that observed on orbit are identified and discussed. The goal in this effort was to better understand the performance of ROSA and to improve modeling efforts for future designs of similar solar arrays.

Chamberlain, Matthew K.↗

Optimizing a Coupled Solution for the Orion MPCV Using DPLR and NEQAIR

The goal of this project is to study the convective and radiative heat flux predictions using computational fluid dynamics (CFD) on a smooth body representation of the NASA Orion Multi-Purpose Crew Vehicle (MPCV). The Orion MPCV is designed for long duration missions in space and will play a crucial role in transporting astronauts in the upcoming Artemis missions. With Orion's aim for cost-effective reusability comes a need to study its Thermal Protection System (TPS), which allows for safe entry into the atmospheres of the Earth, Moon, and Mars. In order to study the effects of the TPS on test flights and better understand the aerothermal environment, CFD is a necessary tool used to create simulations of entry vehicles and calculate the heat load and heat flux. However, solutions are often performed using an uncoupled approach between the flow and the radiation solver. This leads to an overestimation of the overall heating effects because they do not consider radiative cooling. Furthermore, the effects of radiation on the aft-body is an area of research with significant uncertainty. Through the use of codes developed at NASA Ames, DPLR and NEQAIR, a coupled solution can be attained for the Orion capsule which will more accurately solve for the effects of radiation in both the fore and aft-body regions. This yields more accurate design margins for the TPS, which produces a better estimate of the thickness required. By developing an accurate coupled solution of the TPS on the Orion MPCV, planners will have greater flexibility in carrying out future missions to the Moon and beyond.

Design↗

Dynamic response and acoustic fatigue of stiffened composite structure

The results of acoustic fatigue and dynamic response tests performed on L-1011 graphite-epoxy (GrE) aileron and panel components are reported. The aileron featured glass microballoons between the GrE skins. Tests yielded random fatigue data from double and single cantilever coupons and modal data from impedance hammer and loudspeaker impulses. Numerical and sample test data were obtained on combined acoustic and shear loads, acoustic and thermal loads, random fatigue and damping of the integrally stiffened and secondary bonded panels. The fatigue data indicate a fatigue life beyond 10 million cycles. The acoustic data suggested that noise transmission could be enhanced in the integrally stiffened panels, which were more acoustic-fatigue resistant than were the secondary bonded panels.

Soovere, J.↗

Atmospheric moisture measurements - A microwave radiometer-radiosonde comparison

Measurements of the thermal emission of the sky at three frequencies (20.7, 22.2, and 31.4 GHz) with the NASA/Goddard Space Flight Center Crustal Dynamics Project MW Water Vapor Radiometer are reported. These measurements are compared with brightness temperatures inferred from measurements from VAISALA radiosonde packages launched every 3 hr during the experiment period. An error analysis for the radiosonde-inferred brightness temperatures is performed under the assumption of reasonable random uncertainties for the pressure, temperature, and humidity measurements and propagation of these uncertainties through the analysis algorithm. For the assumed uncertainties, the dominant contribution to the total uncertainty comes from the temperature measurement (66-88 percent), whereas the relative humidity measurement contributes only 2-8 percent, except in the vicinity of the water vapor line, where the contribution is 10-20 percent.

England, Martin N.↗

Validation Results for LEWICE 3.0

A research project is underway at NASA Glenn to produce computer software that can accurately predict ice growth under any meteorological conditions for any aircraft surface. This report will present results from version 3.0 of this software, which is called LEWICE. This version differs from previous releases in that it incorporates additional thermal analysis capabilities, a pneumatic boot model, interfaces to computational fluid dynamics (CFD) flow solvers and has an empirical model for the supercooled large droplet (SLD) regime. An extensive comparison of the results in a quantifiable manner against the database of ice shapes and collection efficiency that have been generated in the NASA Glenn Icing Research Tunnel (IRT) has also been performed. The complete set of data used for this comparison will eventually be available in a contractor report. This paper will show the differences in collection efficiency between LEWICE 3.0 and experimental data. Due to the large amount of validation data available, a separate report is planned for ice shape comparison. This report will first describe the LEWICE 3.0 model for water collection. A semi-empirical approach was used to incorporate first order physical effects of large droplet phenomena into icing software. Comparisons are then made to every single element two-dimensional case in the water collection database. Each condition was run using the following five assumptions: 1) potential flow, no splashing; 2) potential flow, no splashing with 21 bin drop size distributions and a lift correction (angle of attack adjustment); 3) potential flow, with splashing; 4) Navier-Stokes, no splashing; and 5) Navier-Stokes, with splashing. Quantitative comparisons are shown for impingement limit, maximum water catch, and total collection efficiency. The results show that the predicted results are within the accuracy limits of the experimental data for the majority of cases.

Wright, William B.↗

Intelligent fault management for the Space Station active thermal control system

The Thermal Advanced Automation Project (TAAP) approach and architecture is described for automating the Space Station Freedom (SSF) Active Thermal Control System (ATCS). The baseline functionally and advanced automation techniques for Fault Detection, Isolation, and Recovery (FDIR) will be compared and contrasted. Advanced automation techniques such as rule-based systems and model-based reasoning should be utilized to efficiently control, monitor, and diagnose this extremely complex physical system. TAAP is developing advanced FDIR software for use on the SSF thermal control system. The goal of TAAP is to join Knowledge-Based System (KBS) technology, using a combination of rules and model-based reasoning, with conventional monitoring and control software in order to maximize autonomy of the ATCS. TAAP's predecessor was NASA's Thermal Expert System (TEXSYS) project which was the first large real-time expert system to use both extensive rules and model-based reasoning to control and perform FDIR on a large, complex physical system. TEXSYS showed that a method is needed for safely and inexpensively testing all possible faults of the ATCS, particularly those potentially damaging to the hardware, in order to develop a fully capable FDIR system. TAAP therefore includes the development of a high-fidelity simulation of the thermal control system. The simulation provides realistic, dynamic ATCS behavior and fault insertion capability for software testing without hardware related risks or expense. In addition, thermal engineers will gain greater confidence in the KBS FDIR software than was possible prior to this kind of simulation testing. The TAAP KBS will initially be a ground-based extension of the baseline ATCS monitoring and control software and could be migrated on-board as additional computation resources are made available.

Hill, Tim↗

Evaluation of an Active Clearance Control System Concept

Reducing blade tip clearances through active tip clearance control in the high pressure turbine can lead to significant reductions in emissions and specific fuel consumption as well as dramatic improvements in operating efficiency and increased service life. Current engines employ scheduled cooling of the outer case flanges to reduce high pressure turbine tip clearances during cruise conditions. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, reburst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). In an effort to improve upon current thermal methods, a first generation mechanically-actuated active clearance control (ACC) system has been designed and fabricated. The system utilizes independent actuators, a segmented shroud structure, and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. Ambient temperature performance tests of this first generation ACC system assessed individual seal component leakage rates and both static and dynamic overall system leakage rates. The ability of the nine electric stepper motors to control the position of the seal carriers in both open- and closed-loop control modes for single and multiple cycles was investigated. The ability of the system to follow simulated engine clearance transients in closed-loop mode showed the system was able to track clearances to within a tight tolerance (0.001 in. error).

Steinetz, Bruce M.↗

Evaluation of an Active Clearance Control System Concept

Reducing blade tip clearances through active tip clearance control in the high pressure turbine can lead to significant reductions in emissions and specific fuel consumption as well as dramatic improvements in operating efficiency and increased service life. Current engines employ scheduled cooling of the outer case flanges to reduce high pressure turbine tip clearances during cruise conditions. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, reburst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). In an effort to improve upon current thermal methods, a first generation mechanically-actuated active clearance control (ACC) system has been designed and fabricated. The system utilizes independent actuators, a segmented shroud structure, and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. Ambient temperature performance tests of this first generation ACC system assessed individual seal component leakage rates and both static and dynamic overall system leakage rates. The ability of the nine electric stepper motors to control the position of the seal carriers in both open- and closed-loop control modes for single and multiple cycles was investigated. The ability of the system to follow simulated engine clearance transients in closed-loop mode showed the system was able to track clearances to within a tight tolerance ( 0.001 in. error).

Steinetz, Bruce M.↗

Molecular Dynamics of ULTEM 9085 for 3D Manufacturing: Spectra, Thermodynamic Properties, and Shear Viscosity.

We present results of a molecular dynamic analysis of welding at the polymer-polymer interface. The analysis is performed for polyetherimide/ polycarbonate polymer blends. The work is motivated by the applications to 3D manufacturing in space. In the first part of the report, we discuss bulk and spectral characteristics of the amorphous polymer blends. The vibrational and infra-red spectra obtained using auto-correlation functions calculations in molecular dynamics are compared with the experimental spectra. The mechanical and thermal properties of the samples including heat capacity, bulk modulus, and thermal expansion coefficients are estimated and compared with experimental values. In the second part of the report, we discuss the result of molecular dynamical modeling of shear viscosity in a fully atomistic model of amorphous polymer blends with flat interface. The key result of the research is the demonstration of shear thinning behavior of the shear viscosity as a function of shear rate which is in good agreement with experimental data.

Luchinsky, Dmitry G.↗

Development of response models for the Earth Radiation Budget Experiment (ERBE) sensors. Part 1: Dynamic models and computer simulations for the ERBE nonscanner, scanner and solar monitor sensors

Dynamic models and computer simulations were developed for the radiometric sensors utilized in the Earth Radiation Budget Experiment (ERBE). The models were developed to understand performance, improve measurement accuracy by updating model parameters and provide the constants needed for the count conversion algorithms. Model simulations were compared with the sensor's actual responses demonstrated in the ground and inflight calibrations. The models consider thermal and radiative exchange effects, surface specularity, spectral dependence of a filter, radiative interactions among an enclosure's nodes, partial specular and diffuse enclosure surface characteristics and steady-state and transient sensor responses. Relatively few sensor nodes were chosen for the models since there is an accuracy tradeoff between increasing the number of nodes and approximating parameters such as the sensor's size, material properties, geometry, and enclosure surface characteristics. Given that the temperature gradients within a node and between nodes are small enough, approximating with only a few nodes does not jeopardize the accuracy required to perform the parameter estimates and error analyses.

Halyo, Nesim↗

Design of a Shape Memory Alloy deployment hinge for reflector facets

A design concept for a Shape Memory Alloy (SMA) actuated hinge mechanism for deploying segmented facet-type reflector surfaces on antenna truss structures is presented. The mechanism uses nitinol, a nickel-titanium shape memory alloy, as a displacement-force micro-actuator. An electrical current is used to resistively heat a 'plastically' elongated SMA actuator wire, causing it to contract in response to a thermally-induced phase transformation. The resulting tension creates a moment, imparting rotary motion between two adjacent panels. Mechanical stops are designed into the device to limit its range of motion and to establish positioning accuracy at the termination of deployment. The concept and its operation are discussed in detail, and an analytical dynamic simulation model is presented. The model has been used to perform nondimensionalized parametric design studies.

Anders, W. S.↗

Enhanced Boiling on Micro-Configured Composite Surfaces Under Microgravity Conditions

In order to accommodate the growing thermal management needs of future space platforms, several two-phase active thermal control systems (ATCSs) have evolved and were included in the designs of space stations. Compared to the pumped single-phase liquid loops used in the conventional Space Transportation System and Spacelab, ATCSs offer significant benefits that may be realized by adopting a two-phase fluid-loop system. Alternately, dynamic power systems (DPSs), based on the Rankine cycle, seem inevitably to be required to supply the electrical power requirements of expanding space activities. Boiling heat transfer is one of the key technologies for both ATCSs and DPSs. Nucleate boiling near critical heat flux (CHF) can transport very large thermal loads with much smaller device size and much lower pumping power. However, boiling performance deteriorates in a reduced gravity environment and operation in the CHF regime is precarious because any slight overload will cause the heat transfer to suddenly move to the film boiling regime, which in turn, will result in burnout of the heat transfer surfaces. New materials, such as micro-configured metal-graphite composites, can provide a solution for boiling enhancement. It has been shown experimentally that this type of material manifests outstanding boiling heat transfer performance and their CHF is also extended to higher values. Due to the high thermal conductivity of graphite fiber (up to 1,200 W/m-K in the fiber direction), the composite surfaces are non-isothermal during the boiling process. The composite surfaces are believed to have a much wider safe operating region (a more uniform boiling curve in the CHF regime) because non-isothermal surfaces have been found to be less sensitive to variations of wall superheat in the CHF regime. The thermocapillary forces formed by the temperature difference between the fiber tips and the metal matrix play a more important role than the buoyancy in the bubble detachment, for the bubble detachment manifests itself by a necking process which should not be weakened by reduced gravity. In addition, the composite surfaces introduce no extra pressure drop, no fouling and do not impose significant primary or maintenance costs. All of these suggest that this type of composite is an ideal material for the challenge of accounting for both reliability and economy of the relevant components applied in the ATCSs, the DPSs and other devices in future space missions. The aim of the proposed work is to experimentally investigate high nucleate pool boiling performance on a micro-configured metal-graphite composite surface and to determine the mechanisms of the nucleate boiling heat transfer both experimentally and theoretically. Freon-113 and water will be used as the test liquids to investigate wettability effects on boiling characteristics. The Cu-Gr and Al-Gr composites with various volume fractions of graphite fibers will be tested to obtain the heat transfer characteristic data in the nucleate boiling region and in the CHF regime. In the experiments, the bubble emission and coalescence processes will be recorded by a video camera with a magnifying borescope probe immersed in the working fluid. The temperature profile in the thermal boundary layer on the composite surfaces will be measured by a group of micro thermocouples consisting of four ultra fine micro thermocouples. This instrument was developed and successfully used to measure the temperature profile of evaporating liquid thin layers by the proposers in a study performed at the NASA/Lewis Research Center. A two tier model to explain the nucleate boiling process and the performance enhancement on the composite surfaces has been suggested by the authors. According to the model, the thicknesses of the microlayer and the macrolayer underneath the bubbles and mushrooms, can be estimated by the geometry of the composite surface. The experimental results will be compared to the predictions from the model, and in turn, to revise and improve it.

Zhang, Nengli↗

Experimental Results From a 2kW Brayton Power Conversion Unit

This paper presents experimental test results from operation of a 2 kWe Brayton power conversion unit. The Brayton converter was developed for a solar dynamic power system flight experiment planned for the Mir Space Station in 1997. The flight experiment was cancelled, but the converter was tested at Glenn Research Center as part of the Solar Dynamic Ground Test Demonstration system which included a solar concentrator, heat receiver, and space radiator. In preparation for the current testing, the heat receiver was removed and replaced with an electrical resistance heater, simulating the thermal input of a steady-state nuclear source. The converter was operated over a full range of thermal input power levels and rotor speeds to generate an overall performance map. The converter unit will serve as the centerpiece of a Nuclear Electric Propulsion Testbed at Glenn. Future potential uses for the Testbed include high voltage electrical controller development, integrated electric thruster testing and advanced radiator demonstration testing to help guide high power Brayton technology development for Nuclear Electric Propulsion (NEP).

Hervol, David↗

Modeling and Analysis of Stirling Power Convertors

NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors for Dynamic Radioisotope Power Systems (DRPS). American Superconductor (AMSC) and Sunpower Inc. are the two of the firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively, to meet DRPS requirements. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics.

Stirling↗