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NASA NTRS2014

Vibration and Operational Characteristics of a Composite-Steel (Hybrid) Gear

Hybrid gears have been tested consisting of metallic gear teeth and shafting connected by composite web. Both free vibration and dynamic operation tests were completed at the NASA Glenn Spur Gear Fatigue Test Facility, comparing these hybrid gears to their steel counterparts. The free vibration tests indicated that the natural frequency of the hybrid gear was approximately 800 Hz lower than the steel test gear. The dynamic vibration tests were conducted at five different rotational speeds and three levels of torque in a four square test configuration. The hybrid gears were tested both as fabricated (machined, composite layup, then composite cure) and after regrinding the gear teeth to the required aerospace tolerance. The dynamic vibration tests indicated that the level of vibration for either type of gearing was sensitive to the level of load and rotational speed.

Handschuh, Robert F.↗

NASA NTRS2011

A Hybrid Lyot Coronagraph for the Direct Imaging and Spectroscopy of Exoplanet Systems: Recent Results and Prospects

We report our best laboratory contrast demonstrations achieved to date. We review the design, fabrication, performance, and future prospects of a hybrid focal plane occulter for exoplanet coronagraphy. Composed of thickness-profiled metallic and dielectric thin films vacuum deposited on a fused silica substrate, the hybrid occulter uses two superimposed thin films for control over both the real and imaginary parts of the complex attenuation pattern. Together with a deformable mirror for adjustment of wavefront phase, the hybrid Lyot coronagraph potentially exceeds billion-to one contrast over dark fields extending to within angular separations of 3 lambda/D (3 x the cosmological constant / diameter of the telescope) from the central star, over spectral bandwidths of 20 percent or more, and with throughput efficiencies up to 60 percent. We report laboratory contrasts of 3 x 10 (sup -10) degrees over 2 percent bandwidths, 6 x 10 (sup -10) degrees over 10 percent bandwidths, and 2 x 10 (sup -9) over 20 percent bandwidths, achieved across high contrast fields extending from an inner working angle of 3 lambda/D to a radius of 15 lambda/D. Occulter performance is analyzed in light of recent experiments and optical models, and prospects for further improvements are summarized. The science capabilities of the hybrid Lyot coronagraph are compared with requirements of the ACCESS mission, a representative exoplanet space telescope concept study for the direct imaging and spectroscopy of exoplanet systems. This work has been supported by NASA's Technology Demonstration for Exoplanet Missions (TDEM) program.

coronagraph↗

NASA NTRS2015

Mars Hybrid Propulsion System Trajectory Analysis: Crew Missions - Part I

NASAs Human spaceflight Architecture team is developing a reusable hybrid transportation architecture in which both chemical and electric propulsion systems are used to send crew and cargo to Mars destinations such as Phobos, Deimos, the surface of Mars, and other orbits around Mars. By combining chemical and electrical propulsion into a single space- ship and applying each where it is more effective, the hybrid architecture enables a series of Mars trajectories that are more fuel-efficient than an all chemical architecture without significant increases in flight times. This paper provides the analysis of the interplanetary segments of the three Evolvable Mars Campaign crew missions to Mars using the hybrid transportation architecture. The trajectory analysis provides departure and arrival dates and propellant needs for the three crew missions that are used by the campaign analysis team for campaign build-up and logistics aggregation analysis. Sensitivity analyses were performed to investigate the impact of mass growth, departure window, and propulsion system performance on the hybrid transportation architecture. The results and system analysis from this paper contribute to analyses of the other human spaceflight architecture team tasks and feed into the definition of the Evolvable Mars Campaign.

Chai, Patrick R.↗

NASA NTRS2015

An Investigation on the Use of a Laser Ablation Treatment on Metallic Surfaces and the Influence of Temperature on Fracture Toughness of Hybrid Co-Cured Metal-PMC Interfaces

Hybrid composite laminates that contain alternating layers of titanium alloys and carbon fabric reinforced polyimide matrix composites (PMC) are excellent candidates for light-weight, high-temperature structural materials for high-speed aerospace vehicles. The delamination resistance of the hybrid titanium-PMC interface is of crucial consideration for structural integrity during service. Here, we report the first investigations on the use of laser ablation in combination with sol-gel treatment technique on Ti/NiTi foil surfaces in co-cured hybrid polyimide matrix composite laminates. Mode-I and mode-II fracture toughness of the hybrid Ti/NiTi-PMC interface as a function of temperature were determined via experimental testing and finite element analysis.

Connell, John↗

NASA NTRS2016

Multifunctional Hybrid Carbon Nanotube/Carbon Fiber Polymer Composites

For aircraft primary structures, carbon fiber reinforced polymer (CFRP) composites possess many advantages over conventional aluminum alloys due to their light weight, higher strengthand stiffness-to-weight ratio, and low life-cycle maintenance costs. However, the relatively low electrical and thermal conductivities of CFRP composites fail to provide structural safety in certain operational conditions such as lightning strikes. Despite several attempts to solve these issues with the addition of carbon nanotubes (CNT) into polymer matrices, and/or by interleaving CNT sheets between conventional carbon fiber (CF) composite layers, there are still interfacial problems that exist between CNTs (or CF) and the resin. In this study, hybrid CNT/CF polymer composites were fabricated by interleaving layers of CNT sheets with Hexcel® IM7/8852 prepreg. Resin concentrations from 1 wt% to 50 wt% were used to infuse the CNT sheets prior to composite fabrication. The interlaminar properties of the resulting hybrid composites were characterized by mode I and II fracture toughness testing (double cantilever beam and end-notched flexure test). Fractographical analysis was performed to study the effect of resin concentration. In addition, multi-directional physical properties like thermal conductivity of the orthotropic hybrid polymer composite were evaluated. Interleaving CNT sheets significantly improved the in-plane (axial and perpendicular direction of CF alignment) thermal conductivity of the hybrid composite laminates by 50 - 400%.

Kang, Jin Ho↗

NASA NTRS2016

Thermal Properties of Hybrid Carbon Nanotube/Carbon Fiber Polymer

Carbon fiber reinforced polymer (CFRP) composites possess many advantages for aircraft structures over conventional aluminum alloys: light weight, higher strength- and stiffness-to-weight ratio, and low life-cycle maintenance costs. However, the relatively low thermal and electrical conductivities of CFRP composites are deficient in providing structural safety under certain operational conditions such as lightning strikes. One possible solution to these issues is to interleave carbon nanotube (CNT) sheets between conventional carbon fiber (CF) composite layers. However, the thermal and electrical properties of the orthotropic hybrid CNT/CF composites have not been fully understood. In this study, hybrid CNT/CF polymer composites were fabricated by interleaving layers of CNT sheets with Hexcel (Registered Trademark) IM7/8852 prepreg. The CNT sheets were infused with a 5% solution of a compatible epoxy resin prior to composite fabrication. Orthotropic thermal and electrical conductivities of the hybrid polymer composites were evaluated. The interleaved CNT sheets improved the in-plane thermal conductivity of the hybrid composite laminates by about 400% and the electrical conductivity by about 3 orders of magnitude.

Kang, Jin Ho↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Hybrid propulsion has been investigated as an enhancing technology for a Mars Ascent Vehicle (MAV) concept as part of potential Mars Sample Return (MSR) because of its high specific impulse, restartability, and the ability to operate and survive at extremely low temperatures. A new wax-based hybrid fuel formulation has been developed that could withstand the harsh and variable Mars environment protected solely by a minimal layer of passive insulation. This formulation could provide substantial energy savings for a notional lander and is critical for rover mobility. Preliminary thermal cycle testing has determined that the formulation can survive the expected temperature extremes and lifetime thermal testing is currently underway. A complete preliminary design using this new fuel formulation combined with a low temperature oxidizer such as Mixed Oxides of Nitrogen (MON30) is presented. Several key features associated with a complete hybrid MAV concept are investigated to determine their mission suitability (e.g. Thrust Vector Control and restartable ignition options). Potential challenges along a path towards developing such a system are outlined and future work is suggested as a means of technology maturation. The hybrid design presented here was the lowest Gross Lift Off Mass (GLOM) result of a 2015 Jet Propulsion Laboratory (JPL) led MAV concept study.

MSR↗

NASA NTRS2017

Control Demonstration of Multiple Doubly-Fed Induction Motors for Hybrid Electric Propulsion

The Convergent Aeronautics Solutions (CAS) High Voltage-Hybrid Electric Propulsion (HVHEP) task was formulated to support the move into future hybrid-electric aircraft. The goal of this project is to develop a new AC power architecture to support the needs of higher efficiency and lower emissions. This proposed architecture will adopt the use of the doubly-fed induction machine (DFIM) for propulsor drive motor application.The Convergent Aeronautics Solutions (CAS) High Voltage-Hybrid Electric Propulsion (HVHEP) task was formulated to support the move into future hybrid-electric aircraft. The goal of this project is to develop a new AC power architecture to support the needs of higher efficiency and lower emissions. This proposed architecture will adopt the use of the doubly-fed induction machine (DFIM) for propulsor drive motor application. DFIMs are attractive for several reasons, including but not limited to the ability to self-start, ability to operate sub- and super-synchronously, and requiring only fractionally rated power converters on a per-unit basis depending on the required range of operation. The focus of this paper is based specifically on the presentation and analysis of a novel strategy which allows for independent operation of each of the aforementioned doubly-fed induction motors. This strategy includes synchronization, soft-start, and closed loop speed control of each motor as a means of controlling output thrust; be it concurrently or differentially. The demonstration of this strategy has recently been proven out on a low power test bed using fractional horsepower machines. Simulation and hardware test results are presented in the paper.

CAS↗

NASA NTRS2015

Hybrid Propulsion In-Situ Resource Utilization Test Facility Results

Hybrid rockets present a promising alternative to conventional chemical propulsion systems for In-Situ Resource Utilization (ISRU) and in-space applications. While they have many benefits for these applications, there are still many small details that require research before they can be adopted into flight systems. A flexible test facility was developed at JPL to test operation of hybrid motors at small scale (5 cm outer diameter fuel grains) over a range of conditions. Specifically, this paper studies two of the major advantages: low temperature performance and throttling. Paraffin-based hybrid rockets are predicted to have good performance at low temperatures. This could significantly decrease the overall system mass by minimizing the thermal conditioning required for Mars or outer planet applications. Therefore, the coefficient of thermal expansion and glass transition of paraffin are discussed. Additionally, deep throttling has been considered for several applications. This was a natural starting point for hotfire testing using the hybrid propulsion ISRU test facility. Additionally, short length to diameter ratio (L/D) fuel grains are tested to determine if these systems can be packaged into geometrically constrained spaces.

Karp, Ashley Chandler↗

NASA NTRS2016

Health Monitoring of a Planetary Rover Using Hybrid Particle Petri Nets

This paper focuses on the application of a Petri Net-based diagnosis method on a planetary rover prototype.The diagnosis is performed by using a model-based method in the context of health management of hybrid systems.In system health management, the diagnosis task aims at determining the current health state of a system and the fault occurrences that lead to this state. The Hybrid Particle Petri Nets (HPPN) formalism is used to model hybrid systems behavior and degradation, and to define the generation of diagnosers to monitor the health states of such systems under uncertainty. At any time, the HPPN-based diagnoser provides the current diagnosis represented by a distribution of beliefs over the health states. The health monitoring methodology is demonstrated on the K11 rover. A hybrid model of the K11 is proposed and experimental results show that the approach is robust to real system data and constraints.

health monitoring↗

NASA NTRS2018

Evaluation of a Variable Thickness Hybrid Composite Bull Gear

For several years, NASA Glenn Research Center and the U.S. Army Research Laboratory have been investigating hybrid (compositesteel) gear technology for use in vertical lift drive systems. The hybrid gear concept replaces the structural portion of a gear between the shaft and the gear rim with a lightweight carbon fiber composite, in an effort to reduce the overall weight of a gear and increase the drive system power density. An overview of the concept of the hybrid gear design is described in Ref. 1, 2, and 3. The research presented in these references includes both small-scale and large-scale hybrid gear concepts all of which have a constant composite thickness throughout. The design described in this paper is of a variable thickness, such that the composite is thickest at the inner diameter and this thickness is gradually reduced toward the outer diameter. The resulting stair stepped design stems from dropping plies of the braided carbon fiber composite fabric gradually with increased radius. Additionally, the interlock pattern at the inner metallic adapter was adjusted slightly from previous designs to obtain a better stress distribution on the inner metallic adapter. The manufactured variable thickness web was tested both in static torsion tests and operationally in a relevant gearbox environment. The results of these experiments will be presented and compared to a baseline steel configuration.

Rotorcraft Propulsion↗

NASA NTRS2018

Low Temperature Hybrid Mars Ascent Vehicle Concept Development at MSFC

A hybrid propulsion system is being developed as an option for the Mars Ascent Vehicle. There are several potential advantages to this system including low temperature survivability and higher performance. Both attributes could allow a hybrid system to be a single stage to orbit vehicle, with two firings of the motor. There are some processing and manufacturing issues with the fuel and the motor that must be understood in order for the advantages of a hybrid propulsion system to be realized. This paper discusses recent progress in the manufacturing of the hybrid fuel grains and subscale test firings conducted to characterize design features at MSFC.

Story, George T.↗

NASA NTRS2019

Qualification of a Hybrid Propulsion System for the Mars Ascent Vehicle

Technology for a hybrid based propulsion system is being developed to support a potential Mars Sample Return campaign. A Mars Ascent Vehicle (MAV) concept for launching samples off of Mars, and delivering them to orbit for further transport to Earth may utilize hybrid propulsion due to the predicted favorable low temperature characteristics and high performance of this option. However, the hybrid option is still undergoing technology development to demonstrate these capabilities. Once development of a capable hybrid propulsion system is proven, further work will be required. This will include environmental testing relative to the mission, and integration with the vehicle reaction control systems and payload. Qualification of such a system will be a significant effort. It will require specialized procurements for the propellants and environments involved, and further testing of the more specialized designs. This paper details an estimate of the tasks required to complete development efforts from Technical Readiness Level 5 (TRL5) through qualification. A success based program was formulated to reach the required performance metrics sufficient for a standard Preliminary Design Review (PDR). Using task level inputs from team members cost and schedule were conceived for continued progress to Critical Design Review (CDR), then through Qualification.

Prince, Andrew↗

NASA NTRS2016

A Hybrid Mars Ascent Vehicle Design and FY 2016 Technology Development

Hybrid propulsion is currently favored for a Mars Ascent Vehicle (MAV) concept from a thermal performance and Gross Lift Off Mass standpoint. However, it is at a relatively low level of maturity compared to conventional propulsion options. Technology development efforts are currently underway to bring hybrid propulsion to a technology readiness level that would enable its infusion into potential Mars Sample Return. A new propellant combination is being considered for this design that has excellent low temperature behavior. Preliminary results of two ground test campaigns are currently underway to characterize this propellant combination. Hotfire testing is being carried out in parallel at Parabilis Space Technologies and Space Propulsion Group. In addition to the new propellant combination, several other technologies are being pursued for a potential hybrid MAV: hypergolic ignition and Liquid Injection Thrust Vector Control. Both of these technologies have been applied in other rocket applications, e.g. liquid propulsion commonly uses hypergolic propellants and missiles, such as the Minuteman II, have used LITVC in the past. Hypergolic ignition, when oxidizer and fuel combust upon contact, is highly desirable for multiple starts required by the MAV concept. Therefore, testing at Penn State and Purdue is being completed in this area. An updated hybrid propulsion system design for a Mars Ascent Vehicle concept based on JPL’s current understanding of potential Mars Sample Return requirements will be presented, leveraging the advances in technology development as well as updated understanding of how requirements may evolve.

Karp, Ashley C.↗

NASA NTRS2017

Hybrid CMOS System-on-Chip / InP MMIC Systems for Deep-Space Planetary Exploration at mm-Wave and THz

This paper discusses the applicability of hybrid CMOS/InP-MMIC mm-Wave systems to remote sensing instrumentation for space exploration in Earth and Planetary science. We review the need for lower power and lighter weight instruments to accommodate the limited payload resources of exploration spacecraft, and then demonstrate how hybrid systems can address these challenges. An example hybrid CMOS-InP radiometer operating at 100 GHz is discoursed in detail including circuit & system design, interfacing and packaging techniques. Measurements are presented showing that the hybrid approach does not compromise instrument sensitivity.

Tang, Adrian↗

NASA NTRS2019

Mars Ascent Vehicle Hybrid Propulsion Development

Hybrid propulsion is being investigated as a propulsion method for a possible Mars Ascent Vehicle (MAV) application. MAV is part of a proposed larger Mars Sample Return (MSR) campaign plan to bring samples from Mars to earth for examination. The Mars Ascent Vehicle would launch Mars surface samples found and packaged by the Mars 2020 mission to orbit around Mars. This version of hybrid propulsion is based on a wax based solid fuel, called SP7A, and a Mixed Oxides of Nitrogen oxidizer, MON-25. SP7 is a new fuel formulation developed by Space Propulsion Group and was modified for this application to be resistant to Mars temperature extremes and modified again to lower the regression rate to become SP7A. MON-25 was chosen for its low freezing temperature. Due to cost constraints, MON-3 was the oxidizer used during testing through 2018. In 2019, full scale hybrid testing with MON-25 commenced in Mojave, CA by Whittinghill Aerospace. One flight motor will be subjected to thermal cycling in a vacuum and later fired in a vacuum to demonstrate the proposed Liquid Injection Thrust Vector Control system performance at White Sands Test Facility (WSTF). In addition, there will be MON-25 characterization work done at Purdue University and WSTF. Additional testing of subscale and full scale motors will be conducted with MON-3 with fuel grain stress, fuel grain support and case design test objectives by Space Propulsion Group Inc. of Butte, MT. This paper documents some of the testing, issues and accomplishments with the MAV hybrid propulsion option that is being considered (along with a two-stage solid propulsion option).

Story, G. T.↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Karp, Ashley C.↗

NASA NTRS2020

Feasibility of a Solid Oxide Fuel Cell System Applied to Hybrid-Electric Regional Aircraft

NASA’s vision for the future of flight includes highly energy efficient aircraft that are environmentally friendly and have positive national economic impact. Although battery-powered electric aircraft are a viable alternative to reduce environmental impact, purely electric aircraft have drawbacks such as the low specific energy of batteries, which translates to an unfavorable weight scaling. Solid oxide fuel cell (SOFC) systems also have promise in providing environmentally friendly electrical power for new aircraft configurations at a higher efficiency than current methods, such as electrical generators. This study explores the use of the Fostering Ultra-Efficient, Low Emitting Aviation Power (FUELEAP) power system architecture for hybrid-electric regional aircraft. The FUELEAP power system utilizes a SOFC as part of a hybrid-electric power system architecture, enabling higher efficiency and specific power with a reduction in carbon and NOx emissions compared to state-of-the-art hybrid-electric SOFC architectures. The study includes comparisons of hybrid-electric power architectures and integration of the FUELEAP power system for two regional-sized passenger aircraft concepts. Results suggest that use of the FUELEAP power system as a replacement for onboard batteries may provide up to a 50% reduction in the weight of the electric d energy system for a typical regional aircraft mission.

Geuther, Steven↗