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All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

[Low-Frequency Flow Oscillation

The results of the research conducted under this grant are presented in detail in three Master theses, by Heinrich, Balow, and Broeren. Additional analysis of the experimental data can be found in two AIAA Journal articles and two conference papers. Citations for all of the studies' publications can be found in the bibliography which is attached. The objective of Heinrich's study was to document the low-frequency flow oscillation on the LRN-1007 airfoil, which had been previously observed at low Reynolds number, to determine its origin, and explore the phenomenon at higher Reynolds number. Heinrich performed detailed flow visualization on the airfoil using surface fluorescent oil and laser-sheet off-body visualization. A large leading-edge separation bubble and trailing-edge separation was identified on the airfoil just prior to the onset of the unsteady stall flow oscillation. From the laser-sheet data, the unsteady flow appeared as a massive boundary-layer separation followed by flow reattachment. Hot-wire data were taken in the wake to identify the presence of the flow oscillation and the dominant frequency. The oscillation was found in the flow from a Reynolds number of 0.3 to 1.3 x 10 exp 6. The Strouhal number based on airfoil projected height was nominally 0.02 and increased slightly with increasing Reynolds number and significantly with increasing airfoil angle of attack. Balow focused his research on the leading-edge separation bubble which was hypothesized to be the origin of the low-frequency oscillation. Initially, experimental measurements in the bubble at the onset of the low-frequency oscillation were attempted to study the characteristics of the bubble and explain possible relationships to the shear-layer-flapping phenomena. Unfortunately, the bubble proved to be extremely sensitive to the probe interference and it drastically reduced the size of the bubble. These detailed measurements were then abandoned by Balow. However, this led to a series of tests where the leading-edge bubble and trailing-edge separation were altered and the affect on the flow-oscillation studied. Balow found that by tripping the airfoil boundary-layer with "zigzag" tape ahead of bubble separation, the bubble was effectively eliminated mid the oscillation suppressed. Wake survey drag measurements showed a drastic reduction in airfoil drag when the bubble and oscillation were eliminated. Using the "zigzag" tape, the trailing-edge separation was moved downstream approximately 5 percent chord. This was found to reduce the amplitude of the oscillation, particularly in the onset stage at low angle of attack (around 14 degrees). Through detailed analysis of the wake behind the airfoil during the unsteady flow oscillation, Balow provided a better understanding of the wake flowfield. Broeren studied the oscillating flowfield in detail at Reynolds number equal 3 x 10 exp 5 and an angle of attack of 15 degrees using laser Doppler velocimetry (LDV). Two-dimensional LDV data were acquired at 687 grid points above the model upper surface while hot-wire data were taken simultaneously in the wake. Using the hot-wire signal, the LDV data were phase averaged into 24 bins to represent a single ensemble average of one oscillation cycle. The velocity data showed a flowfield oscillation that could be divided into three flow regimes. In the first regime, the flow over the airfoil was completely separated initially, the flowfield reattached from the leading edge and the reattachment point moved downstream with increasing time or phase. Broeren referred to this as the reattachment regime. The bubble development regime followed, where a leading-edge separation bubble formed at the leading edge and grew with increasing time. During the initial part of this regime the trailing-edge separation continued to move downstream. However, during the last 30 degrees of phase the trailing-edge separation moved rapidly forward and appeared to merge with the leading-edge bubble. During the third regime, the separation regime, the flow was segmented from the airfoil leading edge and did not reattach to the airfoil surface. The reverse flow was seen to grow in vertical extent up from the model surface as the phase increased. Next reattachment began again at the leading edge signaling the start of the reattachment regime, and so the cycle continued. From Broeren's work, the details of the unsteady flowfield over the airfoil were seen for the first time. From this research a great deal has been learned about the low-frequency flow oscillation which naturally occurs on the LRN-1007 airfoil near stall. The oscillation was seen to persist at higher Reynolds number, the dependence of the Strouhal number on angle of attack and Reynolds number were discovered, the critical role played by the laminar bubble was shown and the entire upper surface flowfield during a flow oscillation cycle was measured and analyzed. What still eludes understanding is the scaling of the flow oscillation and why certain airfoils, such as the LRN, have a very strong low-frequency mode and other airfoils exhibit no organized low-frequency oscillation at all.

Bragg, Michael B.↗
NASA NTRS1997

The Next Generation Space Telescope: Visiting a Time When Galaxies Were Young

In the spring and summer of 1996, three independent teams studied the feasibility of a large aperture space telescope to follow the Hubble Space Telescope. The scientific goals for the new telescope had been laid out in a report by the HST & Beyond Committee, a group appointed by the Association of Universities for Research in Astronomy to consider the needs of the astronomical community after the nominal end of the HST mission in 2005. The technical capabilities and constraints on the new observatory were daunting: the telescope optics should be at least 4 meters in diameter and passively cooled to achieve optimum sensitivity in the near-infrared portion of the spectrum. Moreover, the costs should be kept within a fraction of those for the HST: approximately $500M for construction and $900M for lifetime costs, not including support for scientific data analysis. In their presentations to NASA on 19-21 August, 1996, the teams led by Lockheed Martin, TRW, and the Goddard Space Flight Center concluded that a Next Generation Space Telescope (NGST) was not only feasible and affordable, but that it could be made more powerful using recent breakthroughs in space technologies. Coming on the heels of breathtaking HST observations of distant galaxies in the process of formation, such an NGST could bridge the gap in our understanding of the earliest origins of stars, galaxies, and the elements that are the foundations of Life. This report presents the findings of the three teams and the technological roadmap which will guide us to the successful development of the NGST over the next decade. We have made liberal use of the written material, tables, and diagrams prepared by the three study teams. We have also taken advantage of the knowledge and ideas of our colleagues in government, industry and academia. In Appendix A, we list the members of the three study groups, the NGST Science Working Group and the NGST Scientific Oversight Committee. We deeply appreciate their assistance, advice, and enthusiasm. The scientific and technological goals of NGST are part of the Origins initiative in the Office of Space Science, NASA Headquarters. We are pleased to acknowledge the support and leadership of Edward Weiler, a steadfast friend of HST, Harley Thronson, a proponent of all things infrared, and Mike Kaplan, a tireless advocate of new technology. John Campbell, Project Manager for HST, initiated the NGST study at GSFC and we deeply appreciate his formative efforts and continued support. We are also grateful for the foresight of Riccardo Giacconi, Director General of the European Southern Observatory (ESO), and the efforts of his staff. We note that European Space Agency (ESA) staff at the Space Telescope Science Institute and ESO played important roles in the NGST scientific and technical studies. We look forward to future collaboration with ESA, ESO, and other international partners.

H.S. Stockman↗
NASA NTRS2014

The CCSDS Next Generation Space Data Link Protocol (NGSLP)

The CCSDS space link protocols i.e., Telemetry (TM), Telecommand (TC), Advanced Orbiting Systems (AOS) were developed in the early growth period of the space program. They were designed to meet the needs of the early missions, be compatible with the available technology and focused on the specific link environments. Digital technology was in its infancy and spacecraft power and mass issues enforced severe constraints on flight implementations. Therefore the Telecommand protocol was designed around a simple Bose, Hocquenghem, Chaudhuri (BCH) code that provided little coding gain and limited error detection but was relatively simple to decode on board. The infusion of the concatenated Convolutional and Reed-Solomon codes5 for telemetry was a major milestone and transformed telemetry applications by providing them the ability to more efficiently utilize the telemetry link and its ability to deliver user data. The ability to significantly lower the error rates on the telemetry links enabled the use of packet telemetry and data compression. The infusion of the high performance codes for telemetry was enabled by the advent of digital processing, but it was limited to earth based systems supporting telemetry. The latest CCSDS space link protocol, Proximity-1 was developed in early 2000 to meet the needs of short-range, bi-directional, fixed or mobile radio links characterized by short time delays, moderate but not weak signals, and short independent sessions. Proximity-1 has been successfully deployed on both NASA and ESA missions at Mars and is planned to be utilized by all Mars missions in development. A new age has arisen, one that now provides the means to perform advanced digital processing in spacecraft systems enabling the use of improved transponders, digital correlators, and high performance forward error correcting codes for all communications links. Flight transponders utilizing digital technology have emerged and can efficiently provide the means to make the next leap in performance for space link communications. Field Programmable Gate Arrays (FPGAs) provide the capability to incorporate high performance forward error correcting codes implemented within software transponders providing improved performance in data transfer, ranging, link security, and time correlation. Given these synergistic technological breakthroughs, the time has come to take advantage of them in applying them to both on going (e.g., command, telemetry) and emerging (e.g., space link security, optical communication) space link applications. However one of the constraining factors within the Data Link Layer in realizing these performance gains is the lack of a generic transfer frame format and common supporting services amongst the existing CCSDS link layer protocols. Currently each of the four CCSDS link layer protocols (TM, TC, AOS, and Proximity-1) have unique formats and services which prohibits their reuse across the totality of all space link applications of CCSDS member space agencies. For example, Mars missions. These missions implement their proximity data link layer using the Proximity-1 frame format and the services it supports but is still required to support the direct from Earth (TC) protocols and the Direct To Earth (AOS/TM) protocols. The prime purpose of this paper, is to describe a new general purpose CCSDS Data Link layer protocol, the NGSLP that will provide the required services along with a common transfer frame format for all the CCSDS space links (ground to/from space and space to space links) targeted for emerging missions after a CCSDS agency-wide coordinated date. This paper will also describe related options that can be included for the Coding and Synchronization sub-layer of the Data Link layer to extend the capacities of the link and additionally provide an independence of the transfer frame sub-layer from the coding sublayer. This feature will provide missions the option of running either the currently performed synchronous coding and transfer frame data link or an asynchronous coding/frame data link, in which the transfer frame length is independent of the block size of the code. The benefits from the elimination of this constraint (frame synchronized to the code block) will simplify the interface between the transponder and the data handling equipment and reduce implementation costs and complexities. The benefits include: inclusion of encoders/decoders into transmitters and receivers without regard to data link protocols, providing the ability to insert latency sensitive messages into the link to support launch, landing/docking, telerobotics. and Variable Coded Modulation (VCM). In addition the ability to transfer different sized frames can provide a backup for delivering stored anomaly engineering data simultaneously with real time data, or relaying of frames from various sources onto a trunk line for delivery to Earth.

Kazz, Greg J.↗
NASA NTRS2022

Analysis of Base Metal Microstructures and Mechanical Properties of a Single-Piece, Spin-Formed Forward Pressure Vessel Bulkhead

In 2012, a pathfinder forward pressure vessel bulkhead (FPVBH) for the Orion Multi-Purpose Crew Vehicle (MPCV) was fabricated using aluminum (Al) alloy 2219. The demonstration article was offered as a replacement for the baseline configuration, which at that time was a multi-piece welded construction using aluminum-lithium (Al-Li) alloy 2195. In 2014, the NASA Engineering and Safety Center (NESC) funded a Phase I effort to explore spin-forming as a manufacturing method to produce a complex-shaped, single-piece FPVBH for the crew module (CM) [1]. The primary focus of the NESC effort was to expand spin-forming technology to the fabrication of an Al-Li 2195 FPVBH. As a result, limited testing and analysis was performed on the original Al 2219 article. In this study, a sufficiently large plate of Al 2219 was not available for the fabrication of a FPVBH. Therefore, the forming blank comprised two plates (from different lots) butt welded together using a single friction stir weld. The welded forming blank was then spin formed into the FPVBH configuration and heat treated to the T62 temper. Mechanical property testing of the spin-formed 2219-T62 FPVBH revealed that the tensile properties were comparable to the Metallic Material Properties Development and Standardization (MMPDS) A-basis allowable for Al 2219-T6 wrought products. However, post-spin forming application of the standard heat treatment produced large, recrystallized grains in the material. The response varied within the two plates; one plate lot exhibited nearly complete recrystallization, while the other lot contained bands of recrystallization. Although no reduction in tensile properties was observed due to these microstructural variations, a more detailed investigation was recommended to better understand the effect of spin forming on the recrystallization mechanism and the impact on other material properties. The current study examined the microstructure and mechanical properties of the fully processed Al 2219-T62 FPVBH with emphasis on comparing differences between the two plates. Testing was limited to the cone region of the FPVBH. The two specific tasks in this study were: a) Characterization of the microstructure and mechanical properties in the two plates used in the FPVBH. b) Isolation of the impact of each step in the thermo-mechanical processing (TMP) sequence of the FPVBH on recrystallization and grain growth. Mechanical property testing sampled regions containing both large, recrystallized and small, unrecrystallized grains. Tensile strengths and elongations were equivalent in both regions and exceeded MMPDS A-basis allowables. Fracture toughness was equivalent in both regions and fracture morphology was typical of aluminum alloys. The fatigue precrack region of the fracture toughness specimens appeared more faceted in the recrystallized plate. This suggests that property testing that is more sensitive to grain size, such as fatigue crack growth rate and stress corrosion cracking, may be warranted. Alcoa reviewed the production records for the two plate lots and confirmed that composition of both plates was within the allowable range for Al 2219 and that plate processing steps were all performed within production limits. However, the Fe content was notably higher in the fully recrystallized plate, resulting in a greater volume fraction of large Fe-bearing inclusions and Al-Cu constituent particles. Alcoa did not provide details regarding plate processing variables for the two plate lots. It was surmised that deformation by hot rolling was the most accurate TMP simulation of commercial spin forming within a laboratory setting. Both hot rolling and spin forming comprise combinations of shear and compressive deformation. The through-thickness strain caused by hot rolling is symmetrical about the mid-plane, as the rollers contact both sides of the material. Shear strains are maximum at the inner and outer surfaces and trend toward zero at the mid-thickness. In contrast, spin forming utilizes a single roller on the outer surface, producing a gradient in shear stress through the thickness. Shear strains in spin-formed material are highest at the outer surface due to direct contact with the roller, and trend toward zero at the inner surface. Consequently, there will undoubtedly be some discrepancies in the mechanical response of hot-rolled and spin-formed products in the through-thickness direction. Interrupted TMP simulations were performed on remnant plate from the FPVBH forming blank in order to isolate the effects of a post-weld anneal, spin-forming deformation/thermal cycling, and solution heat treatment (SHT) on development of the recrystallized microstructures. Analysis confirmed that large, recrystallized grains formed exclusively during SHT and only after a certain deformation level was exceeded. Remnant plate from both lots that received thermal processing only did not exhibit recrystallization but exhibited fully recrystallized microstructures when processed by hot rolling. This indicates that (1) the level of deformation exceeded the critical level for recrystallization in both plates and (2) that the level of deformation during hot rolling was greater than that which accumulated during spin forming of the FPVBH. Comparison of the hot-rolled plate with the spin-formed material showed that the recrystallized grain size was larger in the FPVBH, providing further evidence that deformation levels were lower in the FPVBH. The most plausible explanation for the differing degrees of recrystallization in the two plates is particle stimulated nucleation (PSN) at the Fe-bearing inclusions and large Al-Cu constituent particles. In the plate with higher solute content, the greater volume fraction of these particles reduces the deformation level required to promote recrystallization. During spin forming the critical deformation level was likely exceeded for the higher Fe content plate resulting in a fully recrystallized microstructure. The lower Fe content plate developed a microstructure that exhibited bands of recrystallization due to the combination of a non-uniform distribution of particles and deformation. The critical deformation required for recrystallization was likely only exceeded during spin forming in regions of higher particle content. While there were differences in Fe content between these lots of Al 2219 plate, the composition of both was within defined alloy limits and Alcoa reported no anomalies during plate production. The observed differences in recrystallization after spin forming may reflect the inherent variability between these two lots of plate. The spin-forming vendor, Spincraft, reported that similar variations in recrystallized microstructures have been observed during examination of multiple spin-forming trials of a different 2xxx series aluminum alloy. Hence, tighter chemical specification limits on impurity levels in Al 2219 plate may help ensure uniform, predictable microstructures. Finally, the tensile and fracture toughness properties were not affected by the microstructural variations noted.

single-piece↗
NASA NTRS2007

Investigation of MMOD Impact on STS-115 Shuttle Payload Bay Door Radiator

The Orbiter radiator system consists of eight individual 4.6 m x 3.2 m panels located with four on each payload bay door. Forward panels #1 and #2 are 2.3 cm thick while the aft panels #3 and #4 have a smaller overall thickness of 1.3 cm. The honeycomb radiator panels consist of 0.028 cm thick Aluminum 2024-T81 facesheets and Al5056-H39 cores. The face-sheets are topped with 0.005 in. (0.127 mm) silver-Teflon tape. The radiators are located on the inside of the shuttle payload bay doors, which are closed during ascent and reentry, limiting damage to the on-orbit portion of the mission. Post-flight inspections at the Kennedy Space Center (KSC) following the STS-115 mission revealed a large micrometeoroid/orbital debris (MMOD) impact near the hinge line on the #4 starboard payload bay door radiator panel. The features of this impact make it the largest ever recorded on an orbiter payload bay door radiator. The general location of the damage site and the adjacent radiator panels can be seen in Figure 2. Initial measurements of the defect indicated that the hole in the facesheet was 0.108 in. (2.74 mm) in diameter. Figure 3 shows an image of the front side damage. Subsequent observations revealed exit damage on the rear facesheet. Impact damage features on the rear facesheet included a 0.03 in. diameter hole (0.76 mm), a approx.0.05 in. tall bulge (approx.1.3 mm), and a larger approx.0.2 in. tall bulge (approx.5.1 mm) that exhibited a crack over 0.27 in. (6.8 mm) long. A large approx.1 in. (25 mm) diameter region of the honeycomb core was also damaged. Refer to Figure 4 for an image of the backside damage to the panel. No damage was found on thermal blankets or payload bay door structure under the radiator panel. Figure 5 shows the front facesheet with the thermal tape removed. Ultrasound examination indicated a maximum facesheet debond extent of approximately 1 in. (25 mm) from the entry hole. X-ray examinations revealed damage to an estimated 31 honeycomb cells with an extent of 0.85 in. x 1.1 in. (21.6 x 27.9 mm). Pieces of the radiator at and surrounding the impact site were recovered during the repair procedures at KSC. They included the thermal tape, front facesheet, honeycomb core, and rear facesheet. These articles were examined at JSC using a scanning electron microscope (SEM) with an energy dispersive x-ray spectrometer (EDS). Figure 6 shows SEM images of the entry hole in the facesheet. The asymmetric height of the lip may be attributed to projectile shape and impact angle. Numerous instances of a glass-fiber organic matrix composite were observed in the facesheet tape sample. The fibers were approximately 10 micrometers in diameter and variable lengths. EDS analysis indicated a composition of Mg, Ca, Al, Si, and O. Figures 7 and 8 present images of the fiber bundles, which were believed to be circuit board material based on similarity in fiber diameter, orientation, consistency, and composition. A test program was initiated in an attempt to simulate the observed damage to the radiator facesheet and honeycomb. Twelve test shots were performed using projectiles cut from a 1.6 mm thick fiberglass circuit board substrate panel. Results from test HITF07017, shown in figures 9 and 10, correlates with the observed impact features reasonably well. The test was performed at 4.14 km/sec with an impact angle of 45 degrees using a cylindrical projectile with a diameter and length of 1.25 mm. The fiberglass circuit board material had a density of 1.65 g/cu cm, giving a projectile mass of 2.53 mg. An analysis was performed using the Bumper code to estimate the probability of impact to the shuttle from a 1.25 mm diameter particle. Table 1 shows a 1.6% chance (impact odds = 1 in 62) of a 1.25 mm or larger MMOD impact on the radiators of the vehicle during a typical ISS mission. There is a 0.4% chance (impact odds = 1 in 260) that a 1.25 mm or larger MMOD particle would impact the RCC wing leading edge and nose cap during a typical miion. Figure 11 illustrates the vulnerable areas of the wing leading edge reinforced carbon-carbon (RCC), an area of the vehicle that is very sensitive to impact damage. The highlighted red, orange, yellow, and light green areas would be expected to experience critical damage if impacted by an OD particle such as the one that hit the RH4 radiator panel on STS-115.

Hyde, J.↗