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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Managing Programmatic Risk for Complex Space System Developments

Risk management strategies have become a recent important research topic to many aerospace organizations as they prepare to develop the revolutionary complex space systems of the future. Future multi-disciplinary complex space systems will make it absolutely essential for organizations to practice a rigorous, comprehensive risk management process, emphasizing thorough systems engineering principles to succeed. Project managers must possess strong leadership skills to direct high quality, cross-disciplinary teams for successfully developing revolutionary space systems that are ever increasing in complexity. Proactive efforts to reduce or eliminate risk throughout a project's lifecycle ideally must be practiced by all technical members in the organization. This paper discusses some of the risk management perspectives that were collected from senior managers and project managers of aerospace and aeronautical organizations by the use of interviews and surveys. Some of the programmatic risks which drive the success or failure of projects are revealed. Key findings lead to a number of insights for organizations to consider for proactively approaching the risks which face current and future complex space systems projects.

Panetta, Peter V.↗
NASA NTRS2005

Prediction of Fretting Crack Location and Orientation in a Single Crystal Nickel Alloy

Fretting is a structural damage mechanism arising between two nominally clamped surfaces subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high- temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact that could potentially foster crack growth leading to component failure. These contact stresses drive crack nucleation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). Recently, a high-frequency, high-temperature load frame has been designed for experimentally investigating fretting damage of single crystal nickel materials employed in aircraft and spacecraft turbomachinery. A modeling method for characterizing the fretting stresses of the spherical fretting contact stress behavior in this experiment is developed and described. The calculated fretting stresses for a series of experiments are then correlated to the observed fretting damage. Results show that knowledge of the normal stresses and resolved shear stresses on each crystal plane can aid in predicting crack locations and orientations.

Matlik, J. F.↗
NASA NTRS1983

Redundant Gear Train

Tandem harmonic drives are immune to single-point failure. One mechanism continues transmitting power regardless of how other fails. Harmonic drive mechanism, combination of elliptical wave generator and tooth differential between flexible spline and circular spline produces rotational speed reduction in compact volume.

Packard, D. T.↗
NASA NTRS1986

Testing of a variable-stroke Stirling engine

Testing of a variable-stroke Stirling engine at NASA Lewis has been completed. In support of the DOE Stirling Engine Highway Vehicle Systems Program, the engine was tested for about 70 hours total with both He and H2 working fluids over a range of pressures and strokes. A direct comparison was made of part-load efficiencies obtained with variable-stroke (VS) and variable-pressure operation. Two failures with the variable-angle swash-plate drive system limited testing to low power levels. These failures are not thought to be caused by problems inherent with the VS concept but do emphasize the need for careful design in the area of the crossheads.

Thieme, L. G.↗
NASA NTRS1986

Testing of a variable-stroke Stirling engine

Testing of a variable-stroke Stirling engine at NASA Lewis has been completed. In support of the DOE Stirling Engine Highway Vehicle Systems Program, the engine was tested for about 70 hours total with both He and H2 as working fluids over a range of pressures and strokes. A direct comparison was made of part-load efficiencies obtained with variable-stroke (VS) and variable-pressure operation. Two failures with the variable-angle swash-plate drive system limited testing to low power levels. These failures are not thought to be caused by problems inherent with the VS concept but do emphasize the need for careful design in the area of the crossheads.

Thieme, Lanny G.↗
NASA NTRS1974

A self-reorganizing digital flight control system for aircraft

This paper presents a design method for digital self-reorganizing control systems which is optimally tolerant of failures in aircraft sensors. The functions of this system are accomplished with software instead of the popular and costly technique of hardware duplication. The theoretical development, based on M-ary hypothesis testing, results in a bank of M Kalman filters operating in parallel in the failure detection logic. A moving window of the innovations of each Kalman filter drives the detection logic to decide the failure state of the system. The detection logic also selects the optimal state estimate (for control logic) from the bank of Kalman filters. The design process is applied to the design of a self-reorganizing control system for a current configuration of the space shuttle orbiter at Mach 5 and 120,000 feet. The failure detection capabilities of the system are demonstrated using a real-time simulation of the system with noisy sensors.

Montgomery, R. C.↗
NASA NTRS2018

Coupled Thermo-Mechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and nonuniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading.

thermally grown oxide↗
NASA NTRS2018

Coupled Thermomechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting critical components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) from extreme thermal/chemical environments. However, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination. Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermo-mechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and non-uniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites (Aboudi et al., 1999, Composites B). For example, HOTFGM was previously used (Arnold et al, 1995, NASA CP 10178, paper 34), to assess interlaminar stresses (including free edge effects) in a substrate with a thermal barrier coating (TBC). In this study, HOTFGM micromechanics analyses will be used to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer between a silicon carbide substrate and a ytterbium disilicate EBC. In order to realistically simulate TGO growth, an evolution law will be incorporated into HOTFGM. In addition, the effect of TGO roughness will be explored consistent with previous TBC work (Pindera et al., 2000. Material Science and Engineering, A284, pp. 158-175). This model represents a first step in developing a robust analysis tool that can ultimately be used to design durable EBC systems. Additional failure modes will be considered as part of a future work.

environmental barrier coating↗
NASA NTRS1979

IC Ku-band Impatt Amplifier

High efficiency GaAs low-high-low IMPATTs were investigated. Theoretical analyses were employed to establish a design window for the material parameters to maximize microwave performance. Single mesa devices yielded typically 2 to 3 W with 16 to 23% efficiency in waveguide oscillator test circuits. IMPATTs with high reliability Pt/TiW/Pt/Au metallizations were subjected to temperature stress, non-rf bias-temperature stress, and rf bias-temperature stress. Assuming that temperature is the driving force behind the dominant failure mechanism, a mean-time-to-failure considerably greater than 500,000 hours is indicated by the stress tests. A 15 GHz, 4W, 56 dB gain microstrip amplifier was realized using GaAs FETs and IMPATTs. Power combining using a 3 db Lange coupler is employed in the power output stage having an intrinsic power-added efficiency of 15.7%. Overall dc-to-rf efficiency of the amplifier is 10.8%. The amplifier has greater than a 250 MHz, 1 db bandwidth; operates over the 0 deg to 50 C (base plate) temperature range with less than 0.5 db change in the power output; weighs 444 grams; and has a volume of 220 cu cm.

Sokolov, V.↗
NASA NTRS1986

A Sensor Failure Simulator for Control System Reliability Studies

A real-time Sensor Failure Simulator (SFS) was designed and assembled for the Advanced Detection, Isolation, and Accommodation (ADIA) program. Various designs were considered. The design chosen features an IBM-PC/XT. The PC is used to drive analog circuitry for simulating sensor failures in real-time. A user defined scenario describes the failure simulation for each of the five incoming sensor signals. Capabilities exist for editing, saving, and retrieving the failure scenarios. The SFS has been tested closed-loop with the Controls Interface and Monitoring (CIM) unit, the ADIA control, and a real-time F100 hybrid simulation. From a productivity viewpoint, the menu driven user interface has proven to be efficient and easy to use. From a real-time viewpoint, the software controlling the simulation loop executes at greater than 100 cycles/sec.

Melcher, K. J.↗
NASA NTRS2014

Test Facility Simulation Results for Aerospace Loss-of-Lubrication of Spur Gears

Prior to receiving airworthiness certification, extensive testing is required during the development of rotary wing aircraft drive systems. Many of these tests are conducted to demonstrate the drive system's ability to operate at extreme conditions, beyond that called for in the normal to maximum power operating range. One of the most extreme tests is referred to as the loss-of-lubrication or run dry test. During this test, the drive system is expected to last at least 30 min without failure while the primary lubrication system is disabled for predetermined, scripted flight conditions. Failure of this test can lead to a partial redesign of the drive system or the addition of an emergency lubrication system. Either of these solutions can greatly increase the aircraft drive system cost and weight and extend the schedule for obtaining airworthiness certification. Recent work at NASA Glenn Research Center focused on performing tests, in a relevant aerospace environment, to simulate the behavior of spur gears under loss-of-lubrication conditions. Tests were conducted using a test facility that was used in the past for spur gear contact fatigue testing. A loss-oflubrication test is initiated by shutting off the single into mesh lubricating jet. The test proceeds until the gears fail and can no longer deliver the applied torque. The observed failures are typically plastically deformed gear teeth, due to the high tooth temperatures, that are no longer in mesh. The effect of several different variables to gear tooth condition during loss-of-lubrication have been tested such as gear pitch, materials, shrouding, lubrication condition, and emergency supplied mist lubrication in earlier testing at NASA. Recent testing has focused on newer aerospace gear steels and imbedding thermocouples in the shrouding to measure the air-oil temperatures flung off the gear teeth. Along with the instrumented shrouding, an instrumented spur gear was also tested. The instrumented spur gear had five thermocouples installed at different locations on the gear tooth and web. The data from these two types of measurements provided important information as to the thermal environment during the loss-of-lubrication event. This data is necessary to validate on-going modeling efforts.

Gears↗
NASA NTRS1990

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier

In this paper, surface cracking and interface reactions of a ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions that were largely enhanced by the coating surface cracking in the water vapor environment were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions. The coating design issues will also be discussed based on the observed failure mechanisms under the high-heat-flux test conditions.

Zhu, Dongming↗
NASA NTRS1981

A Solution in Search of Problems

Ferrofluids offered vast-problem solving potential. Under license for the NASA technology, Dr. Ronald Moskowitz and Dr. Ronald Rosensweig formed Ferrofluids Corporation. First problem they found a solution for was related to the manufacture of semiconductor "chips" for use in electronic systems. They developed a magnetic seal composed of ferrofluid and a magnetic circuit. Magnetic field confines the ferrofluid in the regions between the stationary elements and the rotary shaft of the seal. Result is a series of liquid barriers that totally bar passage of contaminants. Seal is virtually wear-proof and has a lifetime measured in billions of shaft revolutions. It has reduced maintenance, minimizes "downtime" of production equipment, and reduces the cost of expensive materials that had previously been lost through seal failures. Products based on ferrofluid are exclusion seals for computer disc drives and inertia dampers for stepper motors. Uses are performance-improving, failure-reducing coolants for hi-fi loudspeakers. Other applications include analytical instrumentation, medical equipment, industrial processes, silicon crystal growing furnaces, plasma processes, fusion research, visual displays, and automated machine tools.

Source record↗
NASA NTRS1972

Installation effects on performance of multiple model V/STOL lift fans

An experimental program was performed in which the individual performance of multiple VTOL model lift fans was measured. The model tested consisted of three 5.5 in. diameter tip-turbine driven model VTOL lift fans mounted chordwise in a two-dimensional wing to simulate a pod-type array. The performance data provided significant insight into possible thrust variations and losses caused by the presence of cover doors, adjacent fuselage panels, and adjacent fans. The effect of a partial loss of drive air supply (simulated gas generator failure) on fan performance was also investigated. The results of the tests demonstrated that lift fan installation variables and hardware can have a significant effect on the thrust of the individual fans.

Diedrich, J. H.↗
NASA NTRS1985

On-orbit attitude control of the Cosmic Background Explorer (COBE)

The way in which COBE (launched by the SS in late 1982) performs its attitude control is described, along with the design of its on-orbit system. COBE, to be situated in a 900 km high, sun-synchronous orbit, contains two unique control features: (1) the orientation of the spinning satellite is controlled to a sun-normal attitude in the sun/local vertical plane; and (2) pitch and roll control is maintained by a unique triaxial arrangement of reaction wheels, magnetic torque bars and sensors, located in the body's tranverse plane. Inherent in this triaxial configuration concept is a built-in redundancy that will maintain attitude control in the event of any single-point sensor/actuator component failure. Each of the three control drive electronics operates independently and directly of a system of dedicated sensors. This system functions independently of a computer or an ephemeris communication link, leading to greater reliability.

Bramberg, B.↗
NASA NTRS1989

A dynamic model of stress and sustained attention

Arguments are presented that an integrated view of stress and performance must consider the task demanding a sustained attention as a primary source of cognitive stress. A dynamic model is developed on the basis of the concept of adaptability in both physiological and psychological terms, that addresses the effects of stress on vigilance and, potentially, a wide variety of attention-demanding performance tasks. The model provides an insight into the failure of an operator under the driving influences of stress and opens a number of potential avenues through which solutions to the complex challenge of stress and performance might be posed.

Hancock, P. A.↗
NASA NTRS1998

Life Testing of the Vapor Compression Distillation/Urine Processing Assembly (VCD/UPA) at the Marshall Space Flight Center (1993 to 1997)

Wastewater and urine generated on the International Space Station will be processed to recover pure water using vapor compression distillation (VCD). To verify the long-term reliability and performance of the VCD Urine Processor Assembly (UPA), life testing was performed at the Marshall Space Flight Center (MSFC) from January 1993 to April 1996. Two UPA'S, the VCD-5 and VCD-5A, were tested for 204 days and 665 days, respectively. The compressor gears and the distillation centrifuge drive belt were found to have operating lives of approximately 4,800 hours, equivalent to 3.9 years of operation on ISS for a crew of three at an average processing rate of 1.76 kg/h (3.97 lb/h). Precise alignment of the flex-splines of the fluids and purge pump motor drives is essential to avoid premature failure after about 400 hours of operation. Results indicate that, with some design and procedural modifications and suitable quality control, the required performance and operational life can be met with the VCD/UPA.

Wieland, P.↗