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NASA NTRS2021

NASA Engineering and Safety Center Technical Bulletin No. 21-02: Genesis Flight Mechanics Simulation

Genesis Flight Mechanics Simulation The NASA Engineering and Safety Center (NESC) consolidated and modernized a suite of legacy flight mechanics simulations, including the Flight Analysis and Simulation Tool (FAST), resulting in Genesis, a generic, multi-vehicle, variable-degree-of-freedom flight mechanics simulation for ascent, aerocapture, entry, descent, and landing (A2EDL) trajectory design. Genesis is more flexible, capable, and performant than FAST. It enables trajectory optimization and interactive trajectory generation. Its interoperability with Copernicus, an exo-atmospheric and interplanetary trajectory design tool, facilitates end-to-end trajectory optimization across all mission phases. Genesis is implemented in Julia, a new language for technical computing that combines the ease of use of scripting languages with the run-time performance of compiled languages.

EDL↗

NASA NTRS2022

46th Aerospace Mechanisms Symposium Proceedings

The Aerospace Mechanisms Symposium (AMS) provides a unique forum for those active in the design, production, and use of aerospace mechanisms. A major focus is the reporting of problems and solutions associated with the development, and flight certification of new mechanisms.

mechanisms↗

NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗

NASA NTRS2023

Shock- and Corrosion-Resistant Bearings for Space Mechanisms

Nickel-titanium (NiTi) alloys are an emerging class of materials for rolling element bearing applications that require superior corrosion resistance and/or high load capability. Certain space mechanisms fall into one or both of those categories. Often, due to size and mass considerations, space mechanism systems are limited in torque margin and necessarily require small, precision-instrument bearings with very little frictional drag (i.e., low torque). In addition, space mechanism bearings must survive launch conditions without suffering raceway dents known as brinnelling, which would increase operating torque and reduce overall smoothness. Consequently, a bearing material or design that reduces or eliminates brinnelling under high contact stress conditions would represent a beneficial technology advancement. One specific alloy, nickel-titanium-hafnium (NiTi-Hf), under development for several years at the NASA Glenn Research Center as a bearing material, has the potential to mitigate concerns about brinnelling under extreme load conditions due to its unusually high elastic strain capability. In the present work, a sample of small precision bearings produced with three different ball materials (steel, ceramic, and NiTi-Hf) is subjected to a range of load conditions sufficient to dent the races. The dent depth as a function of load is compared and demonstrates that NiTi-Hf has the potential to increase bearing load capacity from the perspective of brinnelling under severe load conditions; additional testing of full NiTi-Hf bearings demonstrates corrosion resistance superior to that of 440C bearings.

Bearings↗

NASA NTRSDate not supplied

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

NASA NTRSDate not supplied

An Optimization-Based Toolchain for Parametric Mechanism Design

Optimization↗

NASA NTRSDate not supplied

Identifying Human Errors and Error Mechanisms From Accident Reports Using Large Language Models

Emerging operational concepts for aviation hinge on novel paradigms for human machine interaction. Critical to their safe operation is early consideration of human error into the design process. Existing methods for consideration of human error require significant expert input, which is challenging both in early design and in novel systems for which there is little existing safety expertise. In this research, we propose a methodology for identifying human error, error producing factors, and mechanisms in early design from historical incident reports. Additionally, we hypothesize that cross-domain sharing of lessons learned can aid with early design human considerations in circumstances where data is not relevant or incomplete. This is addressed by identifying causes of human error in aviation and railway domains through applying state-of-the art natural language processing techniques to historical incident reports. Using this method, it is possible to extract extensive reports on human error from past incidents. Using the proposed approach, we identify nine human errors from railway reports and fourteen from aviation reports, with three errors common to both domains. There is at least one error producing conditions for each human error while a majority of the errors have more than one error mechanism. We also found that a majority of the human errors, error producing factors, and error mechanisms (even if they are not common between the domains) can be used to inform safe operations across domains as long as the errors are not domain specific and are interpreted and contextualized using engineering judgement.

Human Errors↗

NASA NTRS2024

Short-Term Elevated Temperature Mechanical Performance and Microstructure of A Niobium-Zirconium Alloy Produced via Laser Powder Bed Fusion In-Situ Alloying

Nb-1Zr is a readily fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This low to moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock for powder-based additive manufacturing processes is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a high-purity niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders: ZrO 2 , ZrC, and ZrH 2 . The additively manufactured material was mechanically tested at elevated temperatures within a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested within an identical environment. Examination of the materials’ microstructure and short-term elevated temperature mechanical response determined: in-situ alloying of spherical Nb powder feedstock with Zr-based ceramic nanoparticles can be successfully implemented; the ZrO 2 addition offered the greatest elevated temperature stability and strength but exhibited brittle behavior; the ZrC addition achieved a balance of room temperature ductility and elevated temperature strength; and the ZrH 2 -modified material had the lowest as-built interstitial content and showed high ductility with mechanical performance most similar to wrought Nb-1Zr.

Niobium Alloy↗

NASA NTRSDate not supplied

Updates to PATO’s Thermo-Mechanical Model

The solid mechanics module within the Porous material Analysis Toolbox (PATO) material response code was updated to model the stress contribution from both internal pressure and pyrolysis shrinkage as function of material’s decomposition. Incorporating these physical phenomena, alongside the previously included temperature dependent mechanical properties, thermal expansion, and aerodynamic loads, allows for a more accurate thermo-mechanical behavior modeling of Thermal Protection System (TPS) materials, which is critical to assess spallation risks during atmospheric entry. This poster outlines the workflow for obtaining the necessary PATO inputs, derived from dilatometry experiments, which are used to model the stress field in TPS materials due to thermal expansion and pyrolysis shrinkage. Furthermore, to analyze the relevance of the stress contribution from the internal pressure, a study was conducted using TACOT with different permeability values.

TPS↗

NASA NTRSDate not supplied

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗

NASA NTRS2022

Design and Development Requirements for Mechanisms

This NASA Technical Standard is published by the National Aeronautics and Space Administration (NASA) to provide uniform engineering and technical requirements for processes, procedures, practices, and methods endorsed as standard for NASA programs and projects, including requirements for selection, application, and design criteria of an item. This Standard is approved for use by NASA Headquarters and NASA Centers, including Component Facilities and Technical and Service Support Centers; applicable technical requirements may be cited in contract, program, and other Agency documents. This language applies to the Jet Propulsion Laboratory (a Federally Funded Research and Development Center), other contractors, recipients of grants, cooperative agreements, or other agreements only to the extent specified or referenced in the applicable contracts, grants, or agreements. This Standard establishes uniform design, development, and verification requirements for mechanisms and mechanism components whose correct operation is required for safety or mission success.

Mechanism↗

NASA NTRS1963

The mechanical design of the horn-reflector antenna and radome

This paper describes the mechanical design of the horn-reflector antenna and the associated radome. The mechanical considerations dictating the final configuration of the antenna structure are discussed, along with the engineering aspects of the design, fabrication, and erection of the structure. The mechanical features of the data take-off and antenna drive systems are given in detail. The final section presents an account of the requirements, manufacture, and installation of the radome and its accessory equipment.

HORN ANTENNA↗

NASA NTRS1967

Mechanical properties of wire insulation automatically determined

Three separate mechanisms test the insulation on electrical wire specimens for mechanical resistance to flexure, abrasion or wear, and vibration. The test mechanisms perform the evaluation tests on insulated wire specimens in a chamber which can be controlled to simulate space or spacecraft cabin environments.

Dawn, F. S.↗

NASA NTRS1967

Review of biological mechanisms for application to instrument design

Biological sensors are the mechanisms which enable a living organism to monitor its environment. Ways in which the functional mechanism of biosensors can be applied to develop new concepts of instrumentation, enhance and extend the human senses, and improve the sensitivity of existing instrumentation are described in a review of these mechanisms.

Healer, J.↗

NASA NTRS1962

Mechanical Design of Spacecraft

In the spring of 1962, engineers from the Engineering Mechanics Division of the Jet Propulsion Laboratory gave a series of lectures on spacecraft design at the Engineering Design seminars conducted at the California Institute of Technology. Several of these lectures were subsequently given at Stanford University as part of the Space Technology seminar series sponsored by the Department of Aeronautics and Astronautics. Presented here are notes taken from these lectures. The lectures were conceived with the intent of providing the audience with a glimpse of the activities of a few mechanical engineers who are involved in designing, building, and testing spacecraft. Engineering courses generally consist of heavily idealized problems in order to allow the more efficient teaching of mathematical technique. Students, therefore, receive a somewhat limited exposure to actual engineering problems, which are typified by more unknowns than equations. For this reason it was considered valuable to demonstrate some of the problems faced by spacecraft designers, the processes used to arrive at solutions, and the interactions between the engineer and the remainder of the organization in which he is constrained to operate. These lecture notes are not so much a compilation of sophisticated techniques of analysis as they are a collection of examples of spacecraft hardware and associated problems. They will be of interest not so much to the experienced spacecraft designer as to those who wonder what part the mechanical engineer plays in an effort such as the exploration of space.

STRUCTURAL MATERIAL↗

NASA NTRS1970

Lunar Orbiter photo-subsystem mechanisms

Lunar Orbiter photo subsystem mechanisms, discussing film transport, vacuum and mechanical clamps, focal plane shutter, processor-dryer and optical mechanical scan

Bradley, G.↗

NASA NTRS1971

High-reliability release mechanism

Release mechanism employing simple clevis fitting in combination with two pin-pullers achieves high reliability degree through active mechanical redundancy. Mechanism releases solar arrays. It is simple and inexpensive and performs effectively. It adapts to other release-system applications with variety of pin-puller devices.

Paradise, J. J.↗

NASA NTRS1972

Drive mechanism for production of simulated human breath

Simulated breath drive mechanism was developed as subsystem to breathing metabolic simulator. Mechanism reproduces complete range of human breath rate, breath depth, and breath waveform, as well as independently controlled functional residual capacity. Mechanism was found capable of simulating various individual human breathing characteristics without any changes of parts.

Bartlett, R. G.↗