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NASA NTRSDate not supplied

Extreme Environment Hot Fire Durability of Post-Processed Additively Manufactured GRCop-Alloy Combustion Chambers in LOX/Hydrogen and LOX/Methane

Extreme environment survivability of metal additive manufactured (AM) GRCop-alloy thrust chambers has been demonstrated in different bi-propellants at near stoichiometric and even oxygen rich combustion. GRCop-alloy chambers tested at NASA Marshall Space Flight Center (MSFC) have accumulated over 26,000 seconds of hot fire duration and over 500 starts. These chambers are produced using an AM process called laser powder bed fusion (L-PBF). A major feature of this process is high wall surface roughness which can be customized in post processing to leverage various performance advantages. Post-processing can include heat treatment, final machining, polishing, and welding and is key to hardware survivability in extreme environments. Surface finish enhancement techniques were applied to the hot wall and coolant channels to reduce the overall total heat load to the chamber walls. Performance optimization of various thrust class TCA’s is a strategic technology goal of NASA MSFC. Three different chamber geometries using cryogenic methane and de-ionized water as coolants were hot fire tested to obtain their life cycle, pressure drop, and heat load performances. Several 1.2K lbf LOX/H2 chambers, 1K lbf LOX/CH4 chambers, and 7K lbf LOX/CH4 chambers were tested. All post-processed configurations performed remarkably well when subjected to extreme hot fire test conditions. Streaking and blanching due to localized oxygen rich conditions were observed on some test articles in their as-built surface finish state. However, this is actually a function of the injector mixing and only serves to further establish the durability of L-PBF GRCop-alloy thrust chambers. Several different polishing techniques were applied to the hot wall and integrated coolant channels prior to hot fire testing and their performances assessed. Overall, AM produced GRCop chambers are extremely reliable, durable, and customizable to the desired performance metrics.

grcop↗

NASA NTRS1971

Computer program optimizes design of nuclear radiation shields

Computer program, OPEX 2, determines minimum weight, volume, or cost for shields. Program incorporates improved coding, simplified data input, spherical geometry, and an expanded output. Method is capable of altering dose-thickness relationship when a shield layer has been removed.

Lahti, G. P.↗

NASA NTRS1993

Optimization of circular orifice jets mixing into a heated crossflow in a cylindrical duct

To examine the mixing characteristics of circular jets in an axisymmetric can geometry, temperature measurements were obtained downstream of a row of cold jet injected into a heated cross stream. The objective was to obtain uniform mixing within one duct radius downstream of the leading edge of the jet orifices. An area weighted standard deviation of the mixture fraction was used to help quantify the degree of mixedness at a given plane. Non-reacting experiments were conducted to determine the influence of the number of jets on the mixedness in a cylindrical configuration. Results show that the number of orifices significantly impacts the mixing characteristics of jets injected from round hole orifices in a can geometry. Optimum mixing occurs when the mean jet trajectory aligns with the radius which divides the cross sectional area of the can into two equal parts at one mixer radius downstream of the leading edge of the orifice. The optimum number of holes at momentum-flux ratios of 25 and 52 is 10 and 15 respectively.

Kroll, J. T.↗

NASA NTRS2007

Efficient Implementation of an Optimal Interpolator for Large Spatial Data Sets

Interpolating scattered data points is a problem of wide ranging interest. A number of approaches for interpolation have been proposed both from theoretical domains such as computational geometry and in applications' fields such as geostatistics. Our motivation arises from geological and mining applications. In many instances data can be costly to compute and are available only at nonuniformly scattered positions. Because of the high cost of collecting measurements, high accuracy is required in the interpolants. One of the most popular interpolation methods in this field is called ordinary kriging. It is popular because it is a best linear unbiased estimator. The price for its statistical optimality is that the estimator is computationally very expensive. This is because the value of each interpolant is given by the solution of a large dense linear system. In practice, kriging problems have been solved approximately by restricting the domain to a small local neighborhood of points that lie near the query point. Determining the proper size for this neighborhood is a solved by ad hoc methods, and it has been shown that this approach leads to undesirable discontinuities in the interpolant. Recently a more principled approach to approximating kriging has been proposed based on a technique called covariance tapering. This process achieves its efficiency by replacing the large dense kriging system with a much sparser linear system. This technique has been applied to a restriction of our problem, called simple kriging, which is not unbiased for general data sets. In this paper we generalize these results by showing how to apply covariance tapering to the more general problem of ordinary kriging. Through experimentation we demonstrate the space and time efficiency and accuracy of approximating ordinary kriging through the use of covariance tapering combined with iterative methods for solving large sparse systems. We demonstrate our approach on large data sizes arising both from synthetic sources and from real applications.

Memarsadeghi, Nargess↗

NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗

NASA NTRS2006

Large Array Channel Capacity in the Presence of Interference

We develop a model for a large array ground receiver system for use in deep-space communications, and analyze the resulting array channel capacity. The model includes effects of array geometry, time-dependent spacecraft orbital trajectory, point and extended interference sources, and elevation-dependent noise and tropospheric channel variations. Channel capacity is expressed as the ratio of determinants of covariance matrices characterizing source, interference, and additive noise, and then reduced to a simpler quadratic form more amenable to analysis and numerical computation. This formulation facilitates inclusion of array and channel characteristics into the model, as well as comparison of optimal, suboptimal, and equivalent single antenna configurations on achievable throughput. Realistic examples of ground array channel capacity calculations are presented, demonstrating the impact of array geometry, planetary interference sources, and array combining algorithm design upon the achievable data throughput.

Vilnrotter, V.↗

NASA NTRS2008

Static and Dynamic Structural Response of an Aircraft Wing with Damage Using Equivalent Plate Analysis

A process to generate an equivalent plate based on an optimization approach to predict the static and dynamic response of flight vehicle wing structures is proposed. Geometric-scale and frequency-scale factors are defined to construct an equivalent plate with any desired scale to use in simulation and wind tunnel experiments. It is shown that the stiffness and the displacements are scaled linearly with the geometric-scale factor, whereas the load is scaled as the square of the geometric-scale factor. The scaled stiffness of the reference flight vehicle is matched first to construct the equivalent plate. Then the frequency-scale factor is defined to scale the flight vehicle frequencies. The scaled flight vehicle frequencies are matched by placing arbitrary point masses along the equivalent plate geometry. Two simple stiffened-plate examples, one with damage and another without damage, were used to demonstrate the accuracy of the optimization procedure proposed. Geometric-scale factors ranging from 0.2 to 1.0 were used in the analyses. In both examples, the static and dynamic response of the reference stiffened-panel solution is matched accurately. The scaled equivalent plate predicted the first five frequencies of the stiffened panel very accurately. Finally, the proposed equivalent plate procedure was demonstrated in a more realistic typical aircraft wing structure. Two scale equivalent plate models were generated using the geometric-scale factors 1.0 and 0.2. Both equivalent plate models predicted the static response of the wing structure accurately. The equivalent plate models reproduced the first five frequencies of the wing structure accurately.

Krishnamurthy, T.↗

NASA NTRS1993

Calculation of optimum airfoils using direct solutions of the Navier-Stokes equations

A method has been developed which calculates the optimum airfoil shape at a specified operating condition. The Reynolds-averaged Navier-Stokes equations with a turbulence model are used as the governing equations for the fluid flow, and are explicitly introduced into the optimization analysis as constraint equations. The locations of all grid points which define the surface of the airfoil are design variables, eliminating the need for shape functions to describe changes in the airfoil geometry. A generalized reduced-gradient method is used to find the optimum airfoil shape. The use of a direct solution technique (Newton's method) to solve the Navier-Stokes equations allows for the efficient solution of the problem. This paper describes the optimization method and presents sample results.

Felker, Fort F.↗

NASA NTRS1988

Composite panel development at JPL

Parametric computer studies can be use in a cost effective manner to determine optimized composite mirror panel designs. An InterDisciplinary computer Model (IDM) was created to aid in the development of high precision reflector panels for LDR. The materials properties, thermal responses, structural geometries, and radio/optical precision are synergistically analyzed for specific panel designs. Promising panels designs are fabricated and tested so that comparison with panel test results can be used to verify performance prediction models and accommodate design refinement. The iterative approach of computer design and model refinement with performance testing and materials optimization has shown good results for LDR panels.

Mcelroy, Paul↗

NASA NTRS1993

Optimization of circular orifice jets mixing into a heated cross flow in a cylindrical duct

Kroll, J. T.↗

NASA NTRS2007

Efficient Implementation of an Optimal Interpolator for Large Spatial Data Sets

Scattered data interpolation is a problem of interest in numerous areas such as electronic imaging, smooth surface modeling, and computational geometry. Our motivation arises from applications in geology and mining, which often involve large scattered data sets and a demand for high accuracy. The method of choice is ordinary kriging. This is because it is a best unbiased estimator. Unfortunately, this interpolant is computationally very expensive to compute exactly. For n scattered data points, computing the value of a single interpolant involves solving a dense linear system of size roughly n x n. This is infeasible for large n. In practice, kriging is solved approximately by local approaches that are based on considering only a relatively small'number of points that lie close to the query point. There are many problems with this local approach, however. The first is that determining the proper neighborhood size is tricky, and is usually solved by ad hoc methods such as selecting a fixed number of nearest neighbors or all the points lying within a fixed radius. Such fixed neighborhood sizes may not work well for all query points, depending on local density of the point distribution. Local methods also suffer from the problem that the resulting interpolant is not continuous. Meyer showed that while kriging produces smooth continues surfaces, it has zero order continuity along its borders. Thus, at interface boundaries where the neighborhood changes, the interpolant behaves discontinuously. Therefore, it is important to consider and solve the global system for each interpolant. However, solving such large dense systems for each query point is impractical. Recently a more principled approach to approximating kriging has been proposed based on a technique called covariance tapering. The problems arise from the fact that the covariance functions that are used in kriging have global support. Our implementations combine, utilize, and enhance a number of different approaches that have been introduced in literature for solving large linear systems for interpolation of scattered data points. For very large systems, exact methods such as Gaussian elimination are impractical since they require 0(n(exp 3)) time and 0(n(exp 2)) storage. As Billings et al. suggested, we use an iterative approach. In particular, we use the SYMMLQ method, for solving the large but sparse ordinary kriging systems that result from tapering. The main technical issue that need to be overcome in our algorithmic solution is that the points' covariance matrix for kriging should be symmetric positive definite. The goal of tapering is to obtain a sparse approximate representation of the covariance matrix while maintaining its positive definiteness. Furrer et al. used tapering to obtain a sparse linear system of the form Ax = b, where A is the tapered symmetric positive definite covariance matrix. Thus, Cholesky factorization could be used to solve their linear systems. They implemented an efficient sparse Cholesky decomposition method. They also showed if these tapers are used for a limited class of covariance models, the solution of the system converges to the solution of the original system. Matrix A in the ordinary kriging system, while symmetric, is not positive definite. Thus, their approach is not applicable to the ordinary kriging system. Therefore, we use tapering only to obtain a sparse linear system. Then, we use SYMMLQ to solve the ordinary kriging system. We show that solving large kriging systems becomes practical via tapering and iterative methods, and results in lower estimation errors compared to traditional local approaches, and significant memory savings compared to the original global system. We also developed a more efficient variant of the sparse SYMMLQ method for large ordinary kriging systems. This approach adaptively finds the correct local neighborhood for each query point in the interpolation process.

Memarsadeghi, Nargess↗

NASA NTRSDate not supplied

Roughness Parameter Optimization of the McClain Model in GlennICE

Aircraft icing remains a significant threat to aviation safety. Software that predicts the impingement and ice accretion on full aircraft geometries and aircraft components are in demand and NASA Glenn is committed to produce software that meets this need. One of the key parameters affecting an accurate prediction of iced geometry is the effect of ice roughness on the heat transfer coefficient. While many efforts have been made to implement the roughness in the flow solver, this report takes a correlation for roughness height distribution that is based on experimental measurements and demonstrates how to relate those measurements to an augmentation to the heat transfer coefficient provided by the flow solution. The outcome of this effort was the calibration of defaults for user supplied parameters to this correlation through comparison with 95 large glaze conditions from experiment by adjusting user-supplied parameters in the roughness augmentation equation.

Aircraft Icing↗

NASA NTRS1995

Grid Sensitivity and Aerodynamic Optimization of Generic Airfoils

An algorithm is developed to obtain the grid sensitivity with respect to design parameters for aerodynamic optimization. The procedure is advocating a novel (geometrical) parameterization using spline functions such as NURBS (Non-Uniform Rational B- Splines) for defining the airfoil geometry. An interactive algebraic grid generation technique is employed to generate C-type grids around airfoils. The grid sensitivity of the domain with respect to geometric design parameters has been obtained by direct differentiation of the grid equations. A hybrid approach is proposed for more geometrically complex configurations such as a wing or fuselage. The aerodynamic sensitivity coefficients are obtained by direct differentiation of the compressible two-dimensional thin-layer Navier-Stokes equations. An optimization package has been introduced into the algorithm in order to optimize the airfoil surface. Results demonstrate a substantially improved design due to maximized lift/drag ratio of the airfoil.

Sadrehaghighi, Ideen↗

NASA NTRS1973

Counter tube window and X-ray fluorescence analyzer study

A study was performed to determine the best design tube window and X-ray fluorescence analyzer for quantitative analysis of Venusian dust and condensates. The principal objective of the project was to develop the best counter tube window geometry for the sensing element of the instrument. This included formulation of a mathematical model of the window and optimization of its parameters. The proposed detector and instrument has several important features. The instrument will perform a near real-time analysis of dust in the Venusian atmosphere, and is capable of measuring dust layers less than 1 micron thick. In addition, wide dynamic measurement range will be provided to compensate for extreme variations in count rates. An integral pulse-height analyzer and memory accumulate data and read out spectra for detail computer analysis on the ground.

Hertel, R.↗

NASA NTRS1990

Toward decimeter Topex orbit determination using GPS

Several practical aspects of precision GPS-based Topex orbit determination are investigated. Multipath signals contaminating Topex pseudorange data are greatly reduced by placing the GPS antenna on a conducting backplate consisting of concentric choke rings to attenuate signals coming in from the Topex horizon and below, and by elevating it on a boom to keep it well above all reflecting surfaces. A proper GPS antenna cutoff view angle is chosen so that a sufficient number of GPS satellites with good geometry are in view while reception of reflected signals is minimized. The geometrical strength of the tracking data is optimized by properly selecting GPS satellites to be observed so as to provide data with moderate continuity, low PDOP, and common visibility with ground tracking sites. The tracking performance is greatly enhanced when three complementary sites are added to the minimum ground tracking network consisting of the three NASA DSN sites.

Wu, Sien-Chong↗

NASA NTRS1990

Work/control stations in Space Station weightlessness

An ergonomic integration of controls, displays, and associated interfaces with an operator, whose body geometry and dynamics may be altered by the state of weightlessness, is noted to rank in importance with the optimal positioning of controls relative to the layout and architecture of 'body-ported' work/control stations applicable to the NASA Space Station Freedom. A long-term solution to this complex design problem is envisioned to encompass the following features: multiple imaging, virtual optics, screen displays controlled by a keyboard ergonomically designed for weightlessness, cursor control, a CCTV camera, and a hand-controller featuring 'no-grip' vernier/tactile positioning. This controller frees all fingers for multiple-switch actuations, while retaining index/register determination with the hand controller. A single architectural point attachment/restraint may be used which requires no residual muscle tension in either brief or prolonged operation.

Willits, Charles↗

NASA NTRS2003

Optimization of Elastically Tailored Tow-Placed Plates with Holes

Elastic stiffness tailoring of laminated composite panels by allowing the fibers to curve within the plane of the laminate is a design concept that has been demonstrated to be both beneficial and practical. The objective of the present paper is to demonstrate the effectiveness of stiffness tailoring through the use of curvilinear fibers to reduce stress concentrations around the hole and improve the load carrying capability of panels. Preliminary panel designs that are to be manufactured and tested were determined through design studies for flat plates without holes under axial compression using an optimization program. These candidate designs were then analyzed with finite element models that accurately reflect the test conditions and geometries in order to decide upon the final designs for manufacture and testing. An advanced tow-placement machine is used to manufacture the test panels with varying fiber orientation angles. A total of six large panels measuring three feet by six feet, each of which is used to produce four specimens with or without holes, are fabricated. The panels were machined into specimens with holes and tested at NASA Langley Research Center. Buckling response and failure of panels without holes and with two different hole dimensions are presented. Buckling and failure loads of tow-steered specimens are significantly greater than the buckling and failure loads of traditional straight-fiber specimens.

Jegley, Dawn C.↗

NASA NTRS2017

Variable-Depth Liner Evaluation Using Two NASA Flow Ducts

Four liners are investigated experimentally via tests in the NASA Langley Grazing Flow Impedance Tube. These include an axially-segmented liner and three liners that use reordering of the chambers. Chamber reordering is shown to have a strong effect on the axial sound pressure level profiles, but a limited effect on the overall attenuation. It is also shown that bent chambers can be used to reduce the liner depth with minimal effects on the attenuation. A numerical study is also conducted to explore the effects of a planar and three higher-order mode sources based on the NASA Langley Curved Duct Test Rig geometry. A four-segment liner is designed using the NASA Langley CDL code with a Python-based optimizer. Five additional liner designs, four with rearrangements of the first liner segments and one with a redistribution of the individual chambers, are evaluated for each of the four sources. The liner configuration affects the sound pressure level profile much more than the attenuation spectra for the planar and first two higher-order mode sources, but has a much larger effect on the SPL profiles and attenuation spectra for the last higher-order mode source. Overall, axially variable-depth liners offer the potential to provide improved fan noise reduction, regardless of whether the axially variable depths are achieved via a distributed array of chambers (depths vary from chamber to chamber) or a group of zones (groups of chambers for which the depth is constant).

Jones, M. G.↗