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NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗

NASA NTRS1997

Structural Verification of the Space Shuttle's External Tank Super LightWeight Design: A Lesson in Innovation

The Super LightWeight Tank (SLWT) team was tasked with a daunting challenge from the outset: boost the payload capability of the Shuttle System by safely removing 7500 lbs. from the existing 65,400 lb. External Tank (ET). Tools they had to work with included a promising new Aluminum Lithium alloy, the concept of a more efficient structural configuration for the Liquid Hydrogen (LH2) tank, and a highly successful, mature Light Weight Tank (LWT) program. The 44 month schedule which the SLWT team was given for the task was ambitious by any measure. During this time the team had to not only design, build, and verify the new tank, but they also had to move a material from the early stages of development to maturity. The aluminum lithium alloy showed great promise, with an approximately 29% increase in yield strength, 15% increase in ultimate strength, 5 deg/O increase in modulus and 5 deg/O decrease in density when compared to the current 2219 alloy. But processes had to be developed and brought under control, manufacturing techniques perfected, properties characterized, and design allowable generated. Because of the schedule constraint, this material development activity had to occur in parallel with design and manufacturing. Initial design was performed using design allowable believed to be achievable with the Aluminum Lithium alloy system, but based on limited test data. Preliminary structural development tests were performed with material still in the process of iteration. This parallel path approach posed obvious challenges and risks, but also allowed a unique opportunity for interaction between the structures and materials disciplines in the formulation of the material.

Otte, Neil↗

NASA NTRS2007

Automatic Conversion of Conceptual Geometry to CFD Geometry for Aircraft Design

Conceptual aircraft design is usually based on simple analysis codes. Its objective is to provide an overall system performance of the developed concept, while preliminary aircraft design uses high-fidelity analysis tools such as computational fluid dynamics (CFD) analysis codes or finite element structural analysis codes. In some applications, such as low-boom supersonic concept development, it is important to be able to explore a variety of drastically different configurations while using CFD analysis to check whether a given configuration can be tailored to have a low-boom ground signature. It poses an extremely challenging problem of integrating CFD analysis in conceptual design. This presentation will discuss a computer code, called iPatch, for automatic conversion of conceptual geometry to CFD geometry. In general, conceptual aircraft geometry is not as well-defined as a CAD geometry model. In particular, a conceptual aircraft geometry model usually does not define the intersection curves for the connecting surfaces. The computer code iPatch eliminates the gap between conceptual geometry and CFD geometry by accomplishing the following three tasks automatically: (1) use bicubic B-splines to extrapolate (if necessary) each surface in a conceptual geometry so that all the independently defined geometry components (such as wing and fuselage) can be intersected to form a watertight CFD geometry, (2) compute the intersection curves of surface patches at any resolution (up to 10-7 accuracy) specified by users, and (3) write the B-spline surface patches and the corresponding boundary points for the watertight CFD geometry in the format that can be directly exported to the meshing tool VGRID in the CFD software TetrUSS. As a result, conceptual designers can get quick feedback on the aerodynamic characteristics of their concepts, which will allow them to understand some subtlety in their concepts and to be able to assess their concepts with a higher degree of confidence. This integration of CFD analysis in conceptual aircraft design will greatly eliminate some uncertainty due to simple analysis codes used to develop the concepts and improve the feasibility/credibility of the final concept. The presentation will highlight the mathematical challenges of accomplishing the aforementioned three tasks and the computational algorithms used by iPatch.

Li, Wu↗

NASA NTRS1989

Flexible missile autopilot design studies with PC-MATLAB/386

Development of a responsive, high-bandwidth missile autopilot for airframes which have structural modes of unusually low frequency presents a challenging design task. Such systems are viable candidates for modern, state-space control design methods. The PC-MATLAB interactive software package provides an environment well-suited to the development of candidate linear control laws for flexible missile autopilots. The strengths of MATLAB include: (1) exceptionally high speed (MATLAB's version for 80386-based PC's offers benchmarks approaching minicomputer and mainframe performance); (2) ability to handle large design models of several hundred degrees of freedom, if necessary; and (3) broad extensibility through user-defined functions. To characterize MATLAB capabilities, a simplified design example is presented. This involves interactive definition of an observer-based state-space compensator for a flexible missile autopilot design task. MATLAB capabilities and limitations, in the context of this design task, are then summarized.

Ruth, Michael J.↗

NASA NTRS1994

Conceptual design and analysis of a dynamic scale model of the Space Station Freedom

This report documents the conceptual design study performed to evaluate design options for a subscale dynamic test model which could be used to investigate the expected on-orbit structural dynamic characteristics of the Space Station Freedom early build configurations. The baseline option was a 'near-replica' model of the SSF SC-7 pre-integrated truss configuration. The approach used to develop conceptual design options involved three sets of studies: evaluation of the full-scale design and analysis databases, conducting scale factor trade studies, and performing design sensitivity studies. The scale factor trade study was conducted to develop a fundamental understanding of the key scaling parameters that drive design, performance and cost of a SSF dynamic scale model. Four scale model options were estimated: 1/4, 1/5, 1/7, and 1/10 scale. Prototype hardware was fabricated to assess producibility issues. Based on the results of the study, a 1/4-scale size is recommended based on the increased model fidelity associated with a larger scale factor. A design sensitivity study was performed to identify critical hardware component properties that drive dynamic performance. A total of 118 component properties were identified which require high-fidelity replication. Lower fidelity dynamic similarity scaling can be used for non-critical components.

Davis, D. A.↗

NASA NTRS2017

Mars Organic Molecule Analyzer (MOMA) Laser Desorption/Ionization Source Design and Performance Characterization

The Mars Organic Molecule Analyzer (MOMA), a dual-source, ion trap-based instrument capable of both pyrolysis-gas chromatography mass spectrometry (pyr/GC-MS) and laser desorption/ionization mass spectrometry (LDI-MS), is the core astrobiology investigation on the ExoMars rover. The MOMA instrument will be the first spaceflight mass analyzer to exploit the LDI technique to detect refractory organic compounds and characterize host mineralogy; this mode of analysis will be conducted at Mars ambient conditions. In order to achieve high performance in the Martian environment while keeping the instrument compact and low power, a number of innovative designs and components have been implemented for MOMA. These include a miniaturized linear ion trap (LIT), a fast actuating aperture valve with ion inlet tube, and a Microelectromechanical System (MEMS) Pirani sensor. Advanced analytical capabilities like Stored Waveform Inverse Fourier Transform (SWIFT) for selected ion ejection and tandem mass spectrometry (MS/MS) are realized in LDI-MS mode, and enable the isolation and enhancement of specific mass ranges and structural analysis, respectively. We report here the technical details of these instrument components as well as system-level analytical capabilities, and we review the applications of this technology to Mars and other high-priority targets of planetary exploration.

Xiang Li↗

NASA NTRS1986

KBGIS-2: A knowledge-based geographic information system

The architecture and working of a recently implemented knowledge-based geographic information system (KBGIS-2) that was designed to satisfy several general criteria for the geographic information system are described. The system has four major functions that include query-answering, learning, and editing. The main query finds constrained locations for spatial objects that are describable in a predicate-calculus based spatial objects language. The main search procedures include a family of constraint-satisfaction procedures that use a spatial object knowledge base to search efficiently for complex spatial objects in large, multilayered spatial data bases. These data bases are represented in quadtree form. The search strategy is designed to reduce the computational cost of search in the average case. The learning capabilities of the system include the addition of new locations of complex spatial objects to the knowledge base as queries are answered, and the ability to learn inductively definitions of new spatial objects from examples. The new definitions are added to the knowledge base by the system. The system is currently performing all its designated tasks successfully, although currently implemented on inadequate hardware. Future reports will detail the performance characteristics of the system, and various new extensions are planned in order to enhance the power of KBGIS-2.

Smith, T.↗

NASA NTRS1991

Static performance tests of a flight-type STOVL ejector

The design and development of thrust augmenting STOVL ejectors has typically been based on experimental iteration (i.e., trial and error). Static performance tests of a full scale vertical lift ejector were performed at primary flow temperatures up to 1560 R (1100 F). Flow visualization (smoke generators and yarn tufts) were used to view the inlet air flow, especially around the primary nozzle and end plates. Performance calculations are presented for ambient temperatures close to 480 R (20 F) and 535 R (75 F) which simulate seasonal aircraft operating conditions. Resulting thrust augmentation ratios are presented as functions of nozzle pressure ratio and temperature.

Barankiewicz, Wendy S.↗

NASA NTRS1991

Static performance tests of a flight-type STOVL ejector

Barankiewicz, Wendy S.↗

NASA NTRSDate not supplied

The Spacecraft Mass Balance as a Diagnostic Tool for Cabin Air Quality

The spacecraft-level mass balance is a powerful tool for diagnosing and decoupling factors influencing cabin air quality, especially with respect to trace contaminant propagation. Successful implementation of this approach relies upon accurate and temporally relevant air quality measurements, which are often challenging to attain for emerging trace contaminants. In addition to the proper interpretation of air quality data trends, a thorough understanding of subsystem-level mass transfer is required to characterize process performance. For many Environmental Control and Life Support System processes, subsystem mass transfer may be predicted based on physicochemical properties and classic unit operation design approaches. Gaps in understanding of process performance should be supplemented with thorough ground testing. A high confidence in the fidelity of one of these two aspects, air quality data or process performance, may help offset uncertainties in the other. At minimum, thresholding assumptions and numerical methods can be imposed to constrain unknown parameters within the physical envelope of the situation at hand. Finally, the complexity of cabin-wide integrated mass balances may be reduced by implementing a phenomenological approach towards subsystem discretization.

Cabin Air-quality↗

NASA NTRS1995

Centrifugal and Axial Pump Design and Off-Design Performance Prediction

A meanline pump-flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump-flow code PUMPA was written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design-point rotor efficiency and slip factors are obtained from empirical correlations to rotor-specific speed and geometry. The pump code can model axial, inducer, mixed-flow, and centrifugal pumps and can model multistage pumps in series. The rapid input setup and computer run time for this meanline pump flow code make it an effective analysis and conceptual design tool. The map-generation capabilities of the code provide the information needed for interfacing with a rocket engine system modeling code. The off-design and multistage modeling capabilities of PUMPA permit the user to do parametric design space exploration of candidate pump configurations and to provide head-flow maps for engine system evaluation.

Veres, Joseph P.↗

NASA NTRS2002

Design Evolution and Performance Characterization of the GTX Air-Breathing Launch Vehicle Inlet

The design and analysis of a second version of the inlet for the GTX rocket-based combine-cycle launch vehicle is discussed. The previous design did not achieve its predicted performance levels due to excessive turning of low-momentum comer flows and local over-contraction due to asymmetric end-walls. This design attempts to remove these problems by reducing the spike half-angle to 10- from 12-degrees and by implementing true plane of symmetry end-walls. Axisymmetric Reynolds-Averaged Navier-Stokes simulations using both perfect gas and real gas, finite rate chemistry, assumptions were performed to aid in the design process and to create a comprehensive database of inlet performance. The inlet design, which operates over the entire air-breathing Mach number range from 0 to 12, and the performance database are presented. The performance database, for use in cycle analysis, includes predictions of mass capture, pressure recovery, throat Mach number, drag force, and heat load, for the entire Mach range. Results of the computations are compared with experimental data to validate the performance database.

DeBonis, J. R.↗

NASA NTRS2002

Modes 1 and 4 Testing of an Axisymmetric GTX RBCC Engine

Under sponsorship of the NASA Glenn Research Center (NASA GRC), the Johns Hopkins University Applied Physics Laboratory (JHU/APL) designed and built a five-inch diameter, Rocket-Based Combined Cycle (RBCC) engine to investigate mode 1 and mode 4 performance. This engine was designed so that engine area and length ratios were similar to the NASA GRC GTX engine. Unlike the GTX semi-circular engine design, the APL engine is completely axisymmetric. For this design, a traditional rocket thruster was installed inside of the scramjet flowpath, along the engine centerline. A three part test series is currently underway to determine mode 1 and mode 4 engine performance and compare those results to the rocket thruster operating by itself. All tests are to be conducted in APL's Cell 2 Freejet Engine Facility. Testing of the rocket thruster alone has been accomplished and its performance determined (average Isp efficiency = 90%). Mode 1 (air-augmented rocket) testing is to be conducted at various chamber pressure-to-ambient pressure ratios with the engine inlet fully open. Mode 4 (vacuum rocket) testing is to be conducted with chamber pressure-to-ambient pressure ratios greater than 600 with the inlet fully closed to simulate high-altitude flight conditions. The engine is currently installed in Cell 2 and awaiting testing. This paper discusses the engine design and details the results of the rocket-only testing. Comparisons to previous tests and projected mode 1 and mode 4 test conditions are also discussed.

Rice, Tharen↗

NASA NTRS1996

Probabilistic Assessment of National Wind Tunnel

A preliminary probabilistic structural assessment of the critical section of National Wind Tunnel (NWT) is performed using NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) computer code. Thereby, the capabilities of NESSUS code have been demonstrated to address reliability issues of the NWT. Uncertainties in the geometry, material properties, loads and stiffener location on the NWT are considered to perform the reliability assessment. Probabilistic stress, frequency, buckling, fatigue and proof load analyses are performed. These analyses cover the major global and some local design requirements. Based on the assumed uncertainties, the results reveal the assurance of minimum 0.999 reliability for the NWT. Preliminary life prediction analysis results show that the life of the NWT is governed by the fatigue of welds. Also, reliability based proof test assessment is performed.

Shah, A. R.↗

NASA NTRS1986

Helicopter rotor and engine sizing for preliminary performance estimation

Methods are presented for estimating some of the more fundamental design variables of single-rotor helicopters (tip speed, blade area, disk loading, and installed power) based on design requirements (speed, weight, fuselage drag, and design hover ceiling). The well-known constraints of advancing-blade compressibility and retreating-blade stall are incorporated into the estimation process, based on an empirical interpretation of rotor performance data from large-scale wind-tunnel tests. Engine performance data are presented and correlated with a simple model usable for preliminary design. When approximate results are required quickly, these methods may be more convenient to use and provide more insight than large digital computer programs.

Talbot, P. D.↗

NASA NTRS1994

Orbital management and design considerations for NiCd satellite power systems

Several recently manufactured 50 and 60 ampere hour aerospace NiCd battery cell lots, produced by Gates Aerospace Batteries, are prone to premature on orbit performance degradation. The failure mechanism is cadmium migration, and the consequent development of soft shorts. A Martin Marietta Astronautics satellite program instituted an orbital management strategy for a set of these batteries that reduced the rate of degradation and brought the system to stable operation. This strategy involves: (1) minimizing the accumulated battery overcharge; (2) regular discharge exercises; and (3) periodic battery reconditioning. Because of changes in the NiCd cell manufacturing process, the actual performance of subsequent lots of NiCd cells is open to question. Future NiCd based power system designs should therefore allow for fine control of charge parameters, and an on orbit battery reconditioning capability. To minimize risk, it is much better to perform a full life test to qualify the cells before launch, rather than in parallel with orbital operations. If there are any changes in the manufacturing process of cells, it is extremely important to maintain very strong cognizance of secondary subcontractors, recognizing that the cell and battery manufacturing discipline is easily atrophied.

Tausch, Benjamin J., II↗

NASA NTRSDate not supplied

Conceptual Design of a Tiltduct Reference Vehicle for Urban Air Mobility

NASA is establishing a fleet of conceptual air vehicle designs to support research and development for Urban Air Mobility (UAM). This fleet of vehicles will enable examination of the sensitivity of UAM vehicle designs to technology assumptions, identify key research and development needs for UAM aircraft, and provide the UAM community with reference vehicles that are publicly available and based upon known assumptions. To date, five six-passenger reference vehicles have been published: a quadrotor, a side-by-side, a lift-plus-cruise, a single-main-rotor helicopter, and a tiltwing. To increase the breadth of vehicle technologies encapsulated in the fleet of NASA UAM reference vehicles, this paper establishes a tiltduct vehicle as an addition to the fleet. The fleet will continue to evolve as future analyses and trade studies are performed. The tiltduct reference vehicle has six tilting ducted proprotors. This paper describes the initial configuration downselection; discusses ducted proprotor design rules of thumb as they applied to the conceptual design of the reference vehicle; describes the vehicle sizing, trade studies, and tuning of models performed; and finally, compares the resulting tiltduct vehicle against the other six-passenger NASA UAM reference vehicles. The high-level analyses performed for this study did not indicate significant differences in performance between the tiltduct and tiltwing reference vehicles, and so vehicle performance alone may not be a key driver in the selection of a tiltduct vehicle over a tiltwing vehicle. However, if ducts are found to have significant acoustical benefits, then acoustical priorities may provide a compelling reason to incorporate ducted proprotors. One significant limitation of the design presented in this paper is that the ducted proprotor performance was tuned based upon performance characteristics observed during historical tests with disk loadings (defined as thrust divided by proprotor disk area) of 125-250 lb/ft^2. The tiltduct vehicle designed in this study has a disk loading of 30 lb/ft^2, to be more representative of UAM vehicles; further studies to understand performance of ducted proprotors at representative disk loadings are warranted.

Tiltduct↗

NASA NTRS1984

Mathematical synthesization of complex structures

A mathematical synthesization approach for rapidly modeling and analyzing complex structures comprised of hundreds or thousands of repeating individual structural members, interconnecting hardware, and other components was described. The techniques are applicable to any structure with repeating structural members. The capabilities are embodied within the Interactive Design and Evaluation of Advanced Spacecraft (IDEAS) computer-aided design system. IDEAS has a full range of integrated spacecraft modeling, design, analysis, performance, and cost estimating capabilities which include about 40 technical program and executive, data base, and file management systems. With IDEAS, a single user at an interactive terminal can create, design, analyze, and conduct parametric studies of Earth orbiting spacecraft in a timely, cost-efficient manner. The system is particularly useful in the conceptual design phases of advanced space missions when a multiplicity of concepts must be evaluated. The IDEAS interactive finite-element modeling capabilities are discussed. The mathematical synthesization programs were structured not only to provide a detailed finite-element model of the structure but also to automatically perform the many auxiliary computations needed to analyze the spacecraft in its orbital operational environment.

Garrett, L. B.↗