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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23

Reusable launch vehicle: Technology development and test program

The National Aeronautics and Space Administration (NASA) requested that the National Research Council (NRC) assess the Reusable Launch Vehicle (RLV) technology development and test programs in the most critical component technologies. At a time when discretionary government spending is under close scrutiny, the RLV program is designed to reduce the cost of access to space through a combination of robust vehicles and a streamlined infrastructure. Routine access to space has obvious benefits for space science, national security, commercial technologies, and the further exploration of space. Because of technological challenges, knowledgeable people disagree about the feasibility of a single-stage-to-orbit (SSTO) vehicle. The purpose of the RLV program proposed by NASA and industry contractors is to investigate the status of existing technology and to identify and advance key technology areas required for development and validation of an SSTO vehicle. This report does not address the feasibility of an SSTO vehicle, nor does it revisit the roles and responsibilities assigned to NASA by the National Transportation Policy. Instead, the report sets forth the NRC committee's findings and recommendations regarding the RLV technology development and test program in the critical areas of propulsion, a reusable cryogenic tank system (RCTS), primary vehicle structure, and a thermal protection system (TPS).

Source record↗

Materials Testing on the DC-X and DC-XA

Flight testing of thermal protection materials has been carried out over a two year period on the base heat shield of the Delta Clipper (DC-X and DC-XA), as well on a body flap. The purpose was to use the vehicle as a test bed for materials and more efficient repair or maintenance processes which would be potentially useful for application on new entry vehicles (i.e., X-33, RLV, planetary probes), as well as on the existing space shuttle orbiters. Panels containing Thermal Protection Systems (TPS) and/or structural materials were constructed either at NASA Ames Research Center or at McDonnell Douglas Aerospace (MDA) and attached between two of the four thrusters in the base heat shield of the DC-X or DC-XA. Three different panels were flown on DC-X flights 6, 7, and 8. A total of 7 panels were flown on DC-XA flights 1, 2, and 3. The panels constructed at Ames contained a variety of ceramic TPS including flexible blankets, tiles with high emissivity coatings, lightweight ceramic ablators and other ceramic composites. The MDS test panels consisted primarily of a variety of metallic composites. This report focuses on the ceramic TPS test results.

Smith, Dane↗

Design and Analysis of the Aperture Shield Assembly for a Space Solar Receiver

A joint U.S./Russia program has been conducted to design, develop, fabricate, launch, and operate the world's first space solar dynamic power system on the Russian Space Station Mir. The goal of the program was to demonstrate and confirm that solar dynamic power systems are viable for future space applications such as the International Space Station (ISS). The major components of the system include a solar receiver, a closed Brayton cycle power conversion unit, a power conditioning and control unit, a solar concentrator, a radiator, a thermal control system, and a Space Shuttle carrier. Unfortunately, the mission was demanifested from the ISS Phase 1 Space Shuttle Program in 1996. However, NASA Lewis is proposing to use the fabricated flight hardware as part of an all-American flight demonstration on the ISS in 2002. The present paper concerns the design and analysis of the solar receiver aperture shield assembly. The aperture shield assembly comprises the front face of the cylindrical receiver and is located at the focal plane of the solar concentrator. The aperture shield assembly is a critical component that protects the solar receiver structure from highly concentrated solar fluxes during concentrator off-pointing events. A full-size aperture shield assembly was fabricated. This unit was essentially identical to the flight configuration, with the exception of materials substitution. In addition, a thermal shock test aperture shield assembly was fabricated. This test article utilized the flight materials and was used for high-flux testing in the solar simulator test rig at NASA Lewis. This testing is described in a companion paper.

Strumpf, Hal J.↗

VentureStar(trademark) Reaping the Benefits of the X-33 Program

Major X-33 flight hardware has been delivered, and assembly of the vehicle is well underway in anticipation of its flight test program commencing in the summer of 1999. Attention has now turned to the operational VentureStar(trademark), the first single-stage-to-orbit (SSTO) reusable launch vehicle. Activities are grouped under two broad categories: (1) vehicle development and (2) market/business planning, each of which is discussed. The mission concept is presented for direct payload delivery to the International Space Station and to low Earth orbit, as well as payload delivery with an upper stage to Geosynchronous Transfer Orbit (GTO) and other high energy orbits. System requirements include flight segment and ground segment. Vehicle system sizing and design status is provided including the application of X-33 traceability and lessons learned. Technology applications to the VentureStar(trademark) are described including the structure, propellant tanks, thermal protection system, aerodynamics, subsystems, payload bay and propulsion. Developing a market driven low cost launch services system for the 21 st Century requires traditional and non-traditional ways of being able to forecast the evolution of the potential market. The challenge is balancing both the technical and financial assumptions of the market. This involves the need to provide a capability to meet market segments that in some cases are very speculative, while at the same time providing the financial community with a credible revenue stream.

Sumrall, J.↗

Guidance and Control Concepts for the X-33 Technology Demonstrator

The X-33 technology demonstrator is a suborbital precursor to the Reusable Launch Vehicle (RLV) with first flight planned for summer of 1999. The flight test program will include about 15 flights originating from Edwards Air Force Base, California, each with widely varying flight profiles in order to test new thermal protection system (TPS) materials, structures, and linear aerospike engines. The first flights will be relatively short range flights with about a 300 nmi range, maximum Mach number of 7, maximum altitude of 190,000 feet, whereas the latter flights will cover about 800 nmi range, with max altitude of about 260,000 feet and max Mach of about 15. The guidance algorithms must be flexible enough to accommodate these various profiles and to adapt to severe off-nominal dispersions, such as early engine failure (partial or total) where possibly more than half the thrust is lost. An onboard real-time performance monitor will be used to assess the viability of the nominal landing site as well as alternate landing sites that would potentially be used in extreme off-nominal conditions. During ascent, a single entry guidance-related parameter, which is easy to calculate, is used to assess the viability of the nominal landing site as well as alternate landing sites. Real-time adjustment of the stored ascent attitude profile will be performed, as required, to maximize the probability of making it to the nominal landing site. Numerical results are given for various engine-out cases to illustrate the adaptability of the performance monitor.

Dukeman, Gregory A.↗

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗

A Two-Stage-to-Orbit Spaceplane Concept With Growth Potential

A two-stage-to-orbit (TSTO) spaceplane concept developed in 1993 is revisited, and new information is provided to assist in the development of the next-generation space transportation vehicles. The design philosophy, TSTO spaceplane concept, and the design method are briefly described. A trade study between cold and hot structures leads to the choice of cold structures with external thermal protection systems. The optimal Mach number for staging the second stage of the TSTO spaceplane (with air-breathing propulsion on the first stage) is 10, based on life-cycle cost analysis. The performance and specification of a prototype/experimental (P/X) TSTO spaceplane with a turbo/ram/scramjet propulsion system and built-in growth potential are presented and discussed. The internal rate of return on investment is the highest for the proposed TSTO spaceplane, vis-A-vis a single-stage-to-orbit (SSTO) rocket vehicle and a TSTO spaceplane without built-in growth. Additional growth potentials for the proposed spaceplane are suggested. This spaceplane can substantially decrease access-to-space cost and risk, and increase safety and reliability in the near term It can be a serious candidate for the next-generation space transportation system.

Mehta, Unmeel B.↗

Optical Spectroscopy of New Materials

Composites are currently used for a rapidly expanding number of applications including aircraft structures, rocket nozzles, thermal protection of spacecraft, high performance ablative surfaces, sports equipment including skis, tennis rackets and bicycles, lightweight automobile components, cutting tools, and optical-grade mirrors. Composites are formed from two or more insoluble materials to produce a material with superior properties to either component. Composites range from dispersion-hardened alloys to advanced fiber-reinforced composites. UV/VIS and FTIR spectroscopy currently is used to evaluate the bonding between the matrix and the fibers, monitor the curing process of a polymer, measure surface contamination, characterize the interphase material, monitor anion transport in polymer phases, characterize the void formation (voids must be minimized because, like cracks in a bulk material, they lead to failure), characterize the surface of the fiber component, and measure the overall optical properties for energy balances.

White, Susan M.↗

Space and Atmospheric Environments

This viewgraph presentation provides information on space environments and the protection of materials and structures from their harsh conditions. Space environments are complex, and the complexity of spacecraft systems is increasing. Design accommodation must be realistic. Environmental problems can be limited at low cost relative to spacecraft cost.

Barth, Janet L.↗

X-37 and Our Future in Space: Breaking Barriers to Achieve New Milestones in Space Settlement

The X-37 flight demonstrator will serve as a testbed and technology demonstrator for a variety of aerospace technologies needed to produce a successor to the Space Shuttle. Lithium-ion (Li-ion) batteries, thermal protection systems, and hot structures such as flaperons and ruddervators are systems onboard the X-37 which will be of particular use to this effort. This viewgraph presentation identifies stakeholders and participants in the X-37 flight demonstrator program and includes a section of notes which correspond to each of its slides.

Sexton, Jeff↗

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite's White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with and turnaround maintenance performed. The fight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development. NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This recent partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of the X-37 effort, the team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff research and development and provides valuable experience to implement the exploration vision.

Turner, Susan↗

Materials Challenges in Space Exploration

The new vision of space exploration encompasses a broad range of human and robotic missions to the Moon, Mars and beyond. Extended human space travel requires high reliability and high performance systems for propulsion, vehicle structures, thermal and radiation protection, crew habitats and health monitoring. Advanced materials and processing technologies are necessary to meet the exploration mission requirements. Materials and processing technologies must be sufficiently mature before they can be inserted into a development program leading to an exploration mission. Exploration will be more affordable by in-situ utilization of materials on the Moon and Mars.

Vickers, John↗

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite s White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with landing and turnaround maintenance performed. The Flight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development (R&D). NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of this effort, the X-37 team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff R&D and provides valuable experience to implement the Vision for Space Exploration.

Turner, Susan↗

Thin Film Ceramic Strain Sensor Development for Harsh Environments: Interim Report on Identification of Candidate Thin Film Ceramics to Test for Viability for Static Strain Sensor Development

The need to consider ceramic sensing elements is brought about by the temperature limits of metal thin film sensors in propulsion system applications. In order to have a more passive method of negating changes of resistance due to temperature, an effort is underway at NASA Glenn to develop high temperature thin film ceramic static strain gauges for application in turbine engines, specifically in the fan and compressor modules on blades. Other applications can be on aircraft hot section structures and on thermal protection systems. The near-term interim goal of the research effort was to identify candidate thin film ceramic sensor materials to test for viability and provide a list of possible thin film ceramic sensor materials and corresponding properties to test for viability. This goal was achieved by a thorough literature search for ceramics that have the potential for application as high temperature thin film strain gauges, reviewing potential candidate materials for chemical and physical compatibility with our microfabrication procedures and substrates.

Wrbanek, John D.↗

Thin Film Ceramic Strain Sensor Development for Harsh Environments: Identification of Candidate Thin Film Ceramics to Test for Viability for Static Strain Sensor Development

The need to consider ceramic sensing elements is brought about by the temperature limits of metal thin film sensors in propulsion system applications. In order to have a more passive method of negating changes of resistance due to temperature, an effort is underway at NASA GRC to develop high temperature thin film ceramic static strain gauges for application in turbine engines, specifically in the fan and compressor modules on blades. Other applications include on aircraft hot section structures and on thermal protection systems. The near-term interim goal of this research effort was to identify candidate thin film ceramic sensor materials to test for viability and provide a list of possible thin film ceramic sensor materials and corresponding properties to test for viability. This goal was achieved by a thorough literature search for ceramics that have the potential for application as high temperature thin film strain gauges, reviewing potential candidate materials for chemical & physical compatibility with NASA GRC's microfabrication procedures and substrates.

Wrbanek, John D.↗

Thin Film Ceramic Strain Sensor Development for Harsh Environments

The need to consider ceramic sensing elements is brought about by the temperature limits of metal thin film sensors in propulsion system applications. In order to have a more passive method of negating changes of resistance due to temperature, an effort is underway at NASA GRC to develop high temperature thin film ceramic static strain gauges for application in turbine engines, specifically in the fan and compressor modules on blades. Other applications include on aircraft hot section structures and on thermal protection systems. The near-term interim goal of this research effort was to identify candidate thin film ceramic sensor materials to test for viability and provide a list of possible thin film ceramic sensor materials and corresponding properties to test for viability. This goal was achieved by conducting a thorough literature search for ceramics that have the potential for application as high temperature thin film strain gauges chemically and physically compatible and selecting potential candidate materials for with NASA GRC's microfabrication procedures and substrates.

Wrbanek, John D.↗

Neural Net Safety Monitor Design

The National Aeronautics and Space Administration (NASA) at the Dryden Flight Research Center (DFRC) has been conducting flight-test research using an F-15 aircraft (figure 1). This aircraft has been specially modified to interface a neural net (NN) controller as part of a single-string Airborne Research Test System (ARTS) computer with the existing quad-redundant flight control system (FCC) shown in figure 2. The NN commands are passed to FCC channels 2 and 4 and are cross channel data linked (CCDL) to the other computers as shown. Numerous types of fault-detection monitors exist in the FCC when the NN mode is engaged; these monitors would cause an automatic disengagement of the NN in the event of a triggering fault. Unfortunately, these monitors still may not prevent a possible NN hard-over command from coming through to the control laws. Therefore, an additional and unique safety monitor was designed for a single-string source that allows authority at maximum actuator rates but protects the pilot and structural loads against excessive g-limits in the case of a NN hard-over command input. This additional monitor resides in the FCCs and is executed before the control laws are computed. This presentation describes a floating limiter (FL) concept1 that was developed and successfully test-flown for this program (figure 3). The FL computes the rate of change of the NN commands that are input to the FCC from the ARTS. A window is created with upper and lower boundaries, which is constantly floating and trying to stay centered as the NN command rates are changing. The limiter works by only allowing the window to move at a much slower rate than those of the NN commands. Anywhere within the window, however, full rates are allowed. If a rate persists in one direction, it will eventually hit the boundary and be rate-limited to the floating limiter rate. When this happens, a persistent counter begins and after a limit is reached, a NN disengage command is generated. The tunable metrics for the FL are (1) window size, (2) drift rate, and (3) persistence counter. Ultimate range limits are also included in case the NN command should drift slowly to a limit value that would cause the FL to be defeated. The FL has proven to work as intended. Both high-g transients and excessive structural loads are controlled with NN hard-over commands. This presentation discusses the FL design features and presents test cases. Simulation runs are included to illustrate the dramatic improvement made to the control of NN hard-over effects. A mission control room display from a flight playback is presented to illustrate the neural net fault display representation. The FL is very adaptable to various requirements and is independent of flight condition. It should be considered as a cost-effective safety monitor to control single-string inputs in general.

Larson, Richard R.↗

Thin Film Ceramic Strain Sensor Development for Harsh Environments

The need to consider ceramic sensing elements is brought about by the temperature limits of metal thin film sensors in propulsion system applications. In order to have a more passive method of negating changes of resistance due to temperature, an effort is underway at NASA GRC to develop high temperature thin film ceramic static strain gauges for application in turbine engines, specifically in the fan and compressor modules on blades. Other applications include on aircraft hot section structures and on thermal protection systems. The near-term interim goal of this research effort was to identify candidate thin film ceramic sensor materials to test for viability and provide a list of possible thin film ceramic sensor materials and corresponding properties to test for viability. This goal was achieved by conducting a thorough literature search for ceramics that have the potential for application as high temperature thin film strain gauges chemically and physically compatible and selecting potential candidate materials for with NASA GRC's microfabrication procedures and substrates.

Fralick, Gustave C.↗