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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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Selected mechanisms developed for the Spacelab program are discussed. These include: (1) the roller rail used to install/remove the Spacelab floor loaded with racks carrying experiments; (2) the foot restraint; and (3) the lithium hydroxide used for decontamination.
Between 1973 and 1982, the NASA Dryden Flight Research Center conducted "coast-down" tests demonstrating means for reducing the drag of trucks, buses, and motor homes. Numerous configurations were evaluated using a box-shaped test van, a two-axle truck, and a tractor-semitrailer combination. Results from three configurations of the test van are of interest now in view of a trucking industry goal of a 0.25 drag coefficient for tractor-semitrailer combinations. Two test van configurations with blunt-base geometry, similar to present day trucks (one configuration has square front comers and the other has rounded front comers), quantify the base drag increase associated with reduced forebody drag. Hoemer's equations predict this trend; however, test van results, reinforced by large-scale air vehicle data, indicate that Hoemer's formula greatly underestimates this dependence of base drag on forebody efficiency. The demonstrated increase in base drag associated with forebody refinement indicates that the goal of a 0.25 drag coefficient will not be achieved without also reducing afterbody drag. A third configuration of the test van had a truncated boattail to reduce afterbody drag and achieved a drag coefficient of 0.242. These results are included here and references are identified for other means of reducing afterbody drag.
The first Materials Science Research Rack (MSRR-1) will accommodate dual Experiment Modules (EM's) and provide simultaneous on-orbit processing operations capability. The first international Materials Science Experiment Module for the MSRR-1 is an international cooperative research activity between NASA's Marshall Space Flight Center (MSFC) and the European Space Agency's (ESA) European Space Research and Technology Center. (ESTEC). This International Standard Payload Rack (ISPR) will contain the Materials Science Laboratory (MSL) developed by ESA as an Experiment Module. The MSL Experiment Module will accommodate several on-orbit exchangeable experiment-specific Module Inserts. Module Inserts currently planned are a Quench Module Insert, Low Gradient Furnace, Solidification with Quench Furnace, and Diffusion Module Insert. The second Experiment Module for the MSRR-1 configuration is a commercial device supplied by MSFC's Space Products Department (SPD). It includes capabilities for vapor transport processes and liquid metal sintering. This Experiment Module will be replaced on-orbit with other NASA Materials Science EMs.
The first Materials Science Research Rack (MSRR-1) is the primary facility for U.S. sponsored materials science research on the International Space Station. MSRR-1 is contained in an International Standard Payload Rack (ISPR) equipped with the Active Rack Isolation System (ARIS) for the best possible microgravity environment. MSRR-1 will accommodate dual Experiment Modules and provide simultaneous on-orbit processing operations capability. The first Experiment Module for the MSRR-1, the Materials Science Laboratory (MSL), is an international cooperative activity between NASA's Marshall Space Flight Center (MSFC) and the European Space Agency's (ESA) European Space Research and Technology Center (ESTEC). The MSL Experiment Module will accommodate several on-orbit exchangeable experiment-specific Module Inserts which provide distinct thermal processing capabilities. Module Inserts currently planned for the MSL are a Quench Module Insert, Low Gradient Furnace, and a Solidification with Quench Furnace. The second Experiment Module for the MSRR-1 configuration is a commercial device supplied by MSFC's Space Products Development (SPD) Group. Transparent furnace assemblies include capabilities for vapor transport processes and annealing of glass fiber preforms. This Experiment Module is replaceable on-orbit. This paper will describe facility capabilities, schedule to flight and research opportunities.
The Advanced Composite Airframe Program (ACAP) was undertaken to demonstrate the advantages of the application of advanced composite materials and structural design concepts to the airframe structure on helicopters designed to stringent military requirements. The primary goals of the program were the reduction of airframe production costs and airframe weight by 17 and 22 percent respectively. The ACAP effort consisted of a preliminary design phase, detail design, and design support testing, full-scale fabrication, laboratory testing, and a ground/flight test demonstration. Since the completion of the flight test demonstration programs follow-on efforts were initiated to more fully evaluate a variety of military characteristics of the composite airframe structures developed under the original ACAP advanced development contracts. An overview of the ACAP program is provided and some of the design features, design support testing, manufacturing approaches, and the results of the flight test evaluation, as well as, an overview of Militarization Test and Evaluation efforts are described.
Design Reference Missions (DRM): Integrated ODM Air-Taxi Mission Features, Hybrid Electric Integrated System Testbed (HEIST) flight control. Structural Health, Energy Storage, Electric Components, Loss of Control, Degraded Systems, System Health, Real-Time IO Operator Geo-Fencing, Regional Noise Abatement and Trusted Autonomy Inter-operability.
The topics covered are presented in viewgraph form and include the following: Eagle-Picher heritage - single pressure vessel (SPV) technology; SPV units in process at Eagle-Pitcher; design features; basic battery design features; cell development considerations; SPV boiler plate cell; cell development activity; SPV cell capacity test - charge and discharge; and current plans.
A conceptual design is presented for fiberglass production systems in both lunar and space environments. The raw material, of lunar origin, will be plagioclase concentrate, high silica content slag, and calcium oxide. Glass will be melted by solar energy. The multifurnace in the lunar plant and the spinning cylinder in the space plant are unique design features. Furnace design appears to be the most critical element in optimizing system performance. A conservative estimate of the total power generated by solar concentrators is 1880 kW; the mass of both plants is 120 tons. The systems will reproduce about 90 times their total mass in fiberglass in 1 year. A new design concept would be necessary if glass rods were produced in space.
Contents include the following: Quench Module Insert (QMI) science requirements. QMI interfaces. QMI design layout. QMI thermal analysis and design methodology. QMI bread board testing and instrumentation approach. QMI thermal probe design parameters. Design features for gradient measurement. Design features for heated zone measurements. Thermal gradient analysis results. Heated zone analysis results. Bread board thermal probe layout. QMI bread board correlation and performance. Summary and conclusions.
Two heat rejection radiator systems for the International Space Station (ISS) have undergone thermal vacuum qualification testing at the NASA Glenn Research Center (GRC), Plum Brook Station, Sandusky, Ohio. The testing was performed in the Space Power Facility (SPF), the largest thermal vacuum chamber in the world. The heat rejection system radiator was tested first; it removes heat from the ISS crew living quarters. The second system tested was the photovoltaic radiator (PVR), which rejects heat from the ISS photovoltaic arrays and the electrical power-conditioning equipment. The testing included thermal cycling, hot- and cold-soaked deployments, thermal gradient deployments, verification of the onboard heater controls, and for the PVR, thermal performance tests with ammonia flow. Both radiator systems are orbital replacement units for ease of replacement on the ISS. One key to the success of these tests was the performance of the infrared heater system. It was used in conjunction with a gaseous-nitrogen-cooled cryoshroud in the SPF vacuum chamber to achieve the required thermal vacuum conditions for the qualification tests. The heater, which was designed specifically for these tests, was highly successful and easily met the test requirements. This report discusses the heating requirements, the heater design features, the design approach, and the mathematical basis of the design.
This final project report covers the design, development, construction, testing and qualification of the NIMBUS D BUV (Backscatter Ultraviolet) instrument. The instrument was designed and constructed in accordance with GSFC specification S-623-P-l and amendments. The design phase consisted of activity in three areas of technology: (1) Optical, (2) Mechanical, and (3) Electrical. Beckman Instruments, Inc. performed the tasks concerned with optical and mechanical design while Analog Technology Corporation was the electronics subcontractor. Initial studies resulted in the development of a breadboard model of the BUV instrument. Following extensive testing, additional mathematical analyses, and required modifications, preliminary and critical design reviews were performed. The results of these activities were the construction of an engineering model, used for extensive testing and demonstration of the final design features. Final design data resulted in the construction of two flight-rated instruments, serial numbers P103 and Fl04. On April 8, 1970, the P103 instrument was successfully launched into orbit on NIMBUS D and is presently fully operational.
The honeybee’s nest has inspired the design of engineering honeycomb core that primarily abstract the hexagonal cell shape and exploit its mass minimizing properties to construct lightweight panels. This work explored three additional design features that are part of the natural honeybee comb but have not been traditionally considered as design features of interest in honeycomb design: the radius at the corner of each cell, the coping at the top of the cell walls, and the interface between cell arrays. These features were first characterized in natural honeycomb using optical and X-ray techniques, and then incorporated into honeycomb core design, and fabricated using an additive manufacturing process. The honeycomb cores were then tested in out-of-plane compression and bending, and since all three design features added mass to the overall structure, all metrics were examined per unit mass to assess performance gains. The study concluded that the addition of an interface increases specific flexural modulus but has little benefit in out-of-plane compression; coping radius positively impacts specific flexural strength; but that the corner radius has no significant effect in bending, and actually is slightly detrimental for out-of-plane compression testing.
All possible overall system configurations, operating modes, and subsystem concepts for a wind turbine configuration for cost effective generation of electrical power were evaluated for both technical feasibility and compatibility with utility networks, as well as for economic attractiveness. A design optimization computer code was developed to determine the cost sensitivity of the various design features, and thus establish the configuration and design conditions that would minimize the generated energy costs. The preliminary designs of both a 500 kW unit and a 1500 kW unit operating in a 12 mph and 18 mph median wind speed respectively, were developed. The various design features and components evaluated are described, and the rationale employed to select the final design configuration is given. All pertinent technical performance data and component cost data is included. The costs of all major subassemblies are estimated and the resultant energy costs for both the 500 kW and 1500 kW units are calculated.
A control valve that can throttle high-pressure cryogenic fluid embodies several design features that distinguish it over conventional valves designed for similar applications. Field and design engineers worked together to create a valve that would simplify installation, trim changes, and maintenance, thus reducing overall cost. The seals and plug stem packing were designed to perform optimally in cryogenic temperature ranges. Unlike conventional high-pressure cryogenic valves, the trim size can be changed independent of the body. The design feature that provides flexibility for changing the trim is a split body. The body is divided into an upper and a lower section with the seat ring sandwiched in between. In order to maintain the plug stem packing at an acceptable sealing temperature during cryogenic service, heat-exchanging fins were added to the upper body section. The body is made of stainless steel. The seat ring is made of a nickel-based alloy having a coefficient of thermal expansion less than that of the body material. Consequently, when the interior of the valve is cooled cryogenically, the body surrounding the seat ring contracts more than the seat ring. This feature prevents external leakage at the body-seat joint. The seat ring has been machined to have small, raised-face sealing surfaces on both sides of the seal groove. These sealing surfaces concentrate the body bolt load over a small area, thereby preventing external leakage. The design of the body bolt circle is different from that of conventional highpressure control valves. Half of the bolts clamp the split body together from the top, and half from the bottom side. This bolt-circle design allows a short, clean flow path, which minimizes frictional flow losses. This bolt-circle design also makes it possible to shorten the face-toface length of the valve, which is 25.5 in. (65 cm). In contrast, a conventional, high-pressure control valve face-to-face dimension may be greater than 40 in. (>1 m) long.
A control valve that can throttle high pressure cryogenic fluid embodies several design features that distinguish it over conventional valves designed for similar applications. Field and design engineers worked together to create a valve that would simplify installation, trim changes, and maintenance, thus reducing overall cost. The seals and plug stem packing were designed to perform optimally in cryogenic temperature ranges. Unlike conventional high-pressure cryogenic valves, the trim size can be changed independent of the body. The design feature that provides flexibility for changing the trim is a split body. The body is divided into an upper and a lower section with the seat ring sandwiched in between. In order to maintain the plug stem packing at an acceptable sealing temperature during cryogenic service, heat-exchanging fins were added to the upper body section (see figure). The body is made of stainless steel.
On the composite cryotank technology development (CCTD) project, the Boeing Company built two cryotanks as a means of advancing technology and manufacturing readiness levels (TRL and MRL) and lowering the risk of fabricating full-scale fuel containment vessels.1 CCTD focused on upper stage extended duration applications where long term storage of propellants is required. The project involved the design, analysis, fabrication, and test of manufacturing demonstration units (MDU), a 2.4 m (precursor) and a 5.5 m composite cryotank. Key design features included one-piece wall construction to minimize overall weight (eliminating the need for a bellyband joint), 3-dimensionally (3D) reinforced y-joint material to alleviate stress concentrations at the tank to skirt interface and a purge-able fluted core skirt to carry high axial launch loads. The tanks were made with OoA curing pre-impregnated (prepreg) carbon/epoxy (C/E) slit-tape tow (STT) that contained thin micro-crack resistant plies in the tank wall center to impede permeation. The tanks were fabricated at Boeing's Seattle-based Advanced Development Center (ADC) using RAFP and multipiece break-down tooling. The tooling was designed and built by Janicki Industries (JI) at Sedro Woolley, Washington. Tank assemblage consisted of co-bonded dome covers, one-piece fluted core skirts and mechanical fastened cover/sump. Ultrasonic inspection was performed after every cure or bond and a structural health monitoring system (SHMS) was installed to identify potential impact damage events (in-process and/or during transportation). The tanks were low temperature tested at NASA's George C. Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The testing, which consisted of a sequence of fill/drain pressure and thermal cycles using LH2, was successfully concluded in 2012 on the 2.4 m tank and in 2014 on the 5.5 m tank. Structural, thermal, and permeation performance data was obtained. 2 Critical design features and manufacturing advancements, which helped to validate 25% weight and 30% cost reduction projections, were matured. These advancements will help to guide future composite tank integration activities on next generation long duration aircraft and space launch vehicles. Because CCTD addressed innovative design features, heavy lift size scale-up, multipiece captured tooling, new generation automated material placement (AMP) equipment and OoA materials, this chapter should be of interest to educators, students and manufacturers of composite hardware and flight vehicles.
Concepts of Propellant Management Devices (PMDs) were designed for lunar descent stage reaction control system (RCS) and lunar ascent stage (main and RCS propulsion) missions using liquid oxygen (LO2) and liquid methane (LCH4). Study ground rules set a maximum of 19 days from launch to lunar touchdown, and an additional 210 days on the lunar surface before liftoff. Two PMDs were conceptually designed for each of the descent stage RCS propellant tanks, and two designs for each of the ascent stage main propellant tanks. One of the two PMD types is a traditional partial four-screen channel device. The other type is a novel, expanding volume device which uses a stretched, flexing screen. It was found that several unique design features simplified the PMD designs. These features are (1) high propellant tank operating pressures, (2) aluminum tanks for propellant storage, and (3) stringent insulation requirements. Consequently, it was possible to treat LO2 and LCH4 as if they were equivalent to Earth-storable propellants because they would remain substantially subcooled during the lunar mission. In fact, prelaunch procedures are simplified with cryogens, because any trapped vapor will condense once the propellant tanks are pressurized in space.
The design features and operational performance from the test flight of the fourth generation of spherical geometry cosmic ray detectors developed at Bristol University (Bristol University Gas Scintillator 4 - BUGS-4) are presented. The flight from Ft. Sumner (NM) in Sept. 1993 was the premier flight of a large (1m radius) spherical drift chamber which also gave gas scintillation and Cerenkov signals. The combinations of this chamber with one gas and two solid Cerenkov radiators lead to a large aperture factor (4.5 m2sr), but low (approximately 3.5 g/sq cm) instrument mass over the energy sensitive range 1 to several hundred GeV/a. Moreover, one simple timing measurement determined the impact parameter which provided a trajectory (path length) correction for all detector elements. This innovative and efficient design will be of interest to experimental groups engaged in studies of energetic charged particles. Although there were technical problems on the flight, which were compounded by the total destruction of BUGS-4 by fire while landing in Oklahoma, there was a period of stable operation during which the instrument was exposed at float altitude (approximately 125,000 ft.) to high energy cosmic rays. We present the performance of the instrument as determined from the analysis of these data and an appraisal of its novel design features. Suggestions for design improvements in a future instrument are made.