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Progress in the development of a performance optimized engine system design for an advanced LOX/hydrogen expander cycle engine is reported. Analysis of the components and engine and the resulting drawings is discussed. The status of the orbit transfer vehicle liquid engine transient simulation computer model is given.
A survey of design tools to be used by the aircraft designer is given. Structural reliability, maintainability, cost and predictability, and acoustics expert systems are discussed, as well as scheduling, drawing, engineering systems, sizing functions, and standard parts and materials data bases.
The vulnerability to medical emergencies is greatest in space where there are real limits to the availability or effectiveness of ground based assistance. Moreover, astronaut safety and health maintenance will be of increasing importance as we venture out into space for extended periods of time. It is therefore critical to understand the mechanisms of the regulatory physiology of homeostatic systems (sleep, circadian, neuroendocrine, fluid and nutritional balance) and the key roles played in adaptation. This synergy project has combined aims of the "Human Performance Factors, Sleep and Chronobiology Team"; the "Immunology, Infection and Hematology Team"; and the "Muscle Alterations and Atrophy Team", to broadly address the effects of long term sleep reduction, as is frequently encountered in space exploration, on neuroendocrine, neuroimmune and circulating growth factors. Astronaut sleep is frequently curtailed to averages of between 4- 6.5 hours per night. There is evidence that this amount of sleep is inadequate for maintaining optimal daytime functioning. However, there is a lack of information concerning the effects of chronic sleep restriction, or reduction, on regulatory physiology in general, and there have been no controlled studies of the cumulative effects of chronic sleep reduction on neuroendocrine and neuroimmune parameters. This synergy project represents a pilot study designed to characterize the effects of chronic partial sleep deprivation (PSD) on neuroendocrine, neuroimmune and growth factors. This project draws its subjects from two (of 18) conditions of the larger NSBRI project, "Countermeasures to Neurobehavioral Deficits from Cumulative Partial Sleep Deprivation During Space Flight", one of the projects on the "Human Performance Factors, Sleep and Chronobiology Team ". For the purposes of this study, to investigate the effects of chronic sleep loss on neuroendocrine and neuroimmune function, we have focused on the two extreme sleep conditions from this larger study: a 4.2 hour per night condition, and a 8.2 hour per night condition. During space flight, muscle mass and bone density are reduced, apparently due to loss of GH and IGF-I, associated with microgravity. Since >70% of growth hormone (GH) is secreted at night in normal adults, we hypothesized that the chronic sleep restriction to 4 hours per night would reduce GH levels as measured in the periphery. In this synergy project, in collaboration with the "Muscle Alterations and Atrophy Team ", we are measuring insulin-like growth factor-I (IGF-I) in peripheral circulation to test the prediction that it will be reduced by chronic sleep restriction. In addition to stress modulation of immune function, recent research suggests that sleep is also involved. While we all have the common experience of being sleepy when suffering from infection, and being susceptible to infection when not getting enough sleep, the mechanisms involved in this process are not understood and until recently have gone largely overlooked. We believe that the immune function changes seen in spaceflight may also be related to the cumulative effects of sleep loss. Moreover, in space flight, the possibility of compromised immune function or of the reactivation of latent viruses are serious potential hazards for the success of long term missions. Confined living conditions, reduced sleep, altered diet and stress are all factors that may compromise immune function, thereby increasing the risks of developing and transmitting disease. Medical complications, which would not pose serious problems on earth, may be disastrous if they emerged in space.
The J-2X Upper Stage Engine (USE) will be the first new human-rated upper stage engine since the Apollo program of the 1960s. It is designed to carry the Ares I and Ares V into orbit and send the Ares V to the Moon as part of NASA's Constellation Program. This paper will provide an overview of progress on the design, testing, and manufacturing of this new engine in 2009 and 2010. The J-2X embodies the program goals of basing the design on proven technology and experience and seeking commonality between the Ares vehicles as a way to minimize risk, shorten development times, and live within current budget constraints. It is based on the proven J-2 engine used on the Saturn IB and Saturn V launch vehicles. The prime contractor for the J-2X is Pratt & Whitney Rocketdyne (PWR), which is under a design, development, test, and engineering (DDT&E) contract covering the period from June 2006 through September 2014. For Ares I, the J-2X will provide engine start at approximately 190,000 feet, operate roughly 500 seconds, and shut down. For Ares V, the J-2X will start at roughly 190,000 feet to place the Earth departure stage (EDS) in orbit, shut down and loiter for up to five days, re-start on command and operate for roughly 300 seconds at its secondary power level to perform trans lunar injection (TLI), followed by final engine shutdown. The J-2X development effort focuses on four key areas: early risk mitigation, design risk mitigation, component and subassembly testing, and engine system testing. Following that plan, the J-2X successfully completed its critical design review (CDR) in 2008, and it has made significant progress in 2009 and 2010 in moving from the drawing board to the machine shop and test stand. Post-CDR manufacturing is well under way, including PWR in-house and vendor hardware. In addition, a wide range of component and sub-component tests have been completed, and more component tests are planned. Testing includes heritage powerpack, turbopump inducer water flow, turbine air flow, turbopump seal testing, main injector and gas generator, injector testing, augmented spark igniter testing, nozzle side loads cold flow testing, nozzle extension film cooling flow testing, control system testing with hardware in the loop, and nozzle extension emissivity coating tests. In parallel with hardware manufacturing, work is progressing on the new A-3 test stand to support full duration altitude testing. The Stennis A-2 test stand is scheduled to be turned over to the Constellation Program in September 2010 to be modified for J-2X testing also. As the structural steel was rising on the A-3 stand, work was under way in the nearby E complex on the chemical steam generator and subscale diffuser concepts to be used to evacuate the A-3 test cell and simulate altitude conditions.
The Early Flight Fission-Test Facilities (EFF-TF) team was tasked by Naval Reactors Prime Contract Team (NRPCT) to design, fabricate, and test an actively pumped lithium (Li) flow circuit. This Li circuit takes advantage of work in progress at the EFF TF on a stainless steel sodium/potassium (NaK) circuit. The effort involved modifying the original stainless steel NaK circuit such that it could be operated with Li in place of NaK. This new design considered freeze/thaw issues and required the addition of an expansion tank and expansion/extrusion volumes in the circuit plumbing. Instrumentation has been specified for Li and circuit heaters have been placed throughout the design to ensure adequate operational temperatures and no uncontrolled freezing of the Li. All major components have been designed and fabricated prior to circuit redesign for Li and were not modified. Basic circuit components include: reactor segment, Li to gas heat exchanger, electromagnetic liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and trace heaters. The reactor segment, based on a Los Alamos National Laboratory 100-kW design study with 120 fuel pins, is the only prototypic component in the circuit. However, due to earlier funding constraints, a 37-pin partial-array of the core, including the central three rings of fuel pins (pin and flow path dimensions are the same as those in the full design), was selected for fabrication and test. This Technical Publication summarizes the design and integration of the pumped liquid metal Li flow circuit as of May 1, 2005. This supplement contains drawings, analysis, and calculations
The National Renewable Energy Laboratory (NREL) and Acciona Solar Power (ASP) have developed and are implementing a process that addresses the issue of hydrogen buildup in parabolic trough power plants. Our method selectively removes hydrogen from the expansion tanks of the power plant to control hydrogen levels in the circulating heat-transfer fluid (HTF). During previous work, we developed a sensor that measures hydrogen partial pressure in the expansion-tank headspace gas. We demonstrated that our sensor measures hydrogen levels over a wide range of partial pressure—from 1.33 mbar down to 0.003 mbar. More recently, we conceived and developed an integrated process module that performs both hydrogen sensing and separating functions. The sensor/separator measures hydrogen partial pressure in the headspace gas in the same way as our original sensor design. Additionally, the integrated module separates hydrogen from the headspace gas to reduce hydrogen to the level needed to maintain the performance of receivers in the collector field. We demonstrated the performance of a laboratory-scale version of this module. Testing showed that the module performed as expected: the accuracy of the sensing function was ±7%, and the hydrogen extraction rate for the separating mode was consistent with our modeling predictions. The primary benefit of this module is its simple design, both in terms of function and incorporation into the HTF subsystem of the power plant. Most recently, NREL and ASP planned, specified, and designed a mitigation process that is based on the integrated module. We are currently completing installation of this process at ASP's Nevada Solar One power plant in Boulder City, Nevada, USA. The mitigation process is being installed at ground level below the HTF expansion tanks, where it draws headspace gas from the tanks, removes hydrogen, and returns the treated gas back to the tanks. In this paper, we report progress on the installation and describe some of the many design details and challenges that we addressed during the past year. We will generate initial performance data from the Nevada Solar One mitigation process in early 2020.
A user's manual is presented for MacPASCO, which is an interactive, graphic, preprocessor for panel design. MacPASCO creates input for PASCO, an existing computer code for structural analysis and sizing of longitudinally stiffened composite panels. MacPASCO provides a graphical user interface which simplifies the specification of panel geometry and reduces user input errors. The user draws the initial structural geometry and reduces user input errors. The user draws the initial structural geometry on the computer screen, then uses a combination of graphic and text inputs to: refine the structural geometry; specify information required for analysis such as panel load and boundary conditions; and define design variables and constraints for minimum mass optimization. Only the use of MacPASCO is described, since the use of PASCO has been documented elsewhere.
A theoretical and preliminary design study of a large flexible tunnel for use at the shuttle/payload interface is discussed. The theoretical study consisted of evaluating various design concepts and determining their adaptability to the tunnel requirements. The theoretical study culminated in the selection of one concept. The selected concept was documented with preliminary drawings of a full-scale ground test model. Supporting preliminary structural, thermal, micrometeoroid, material, and weight analyses were conducted. The specified tunnel requirements could be broadly grouped into two categories; environmental and performance. The environmental requirements were those ambient conditions and loads associated with ground, launch, space and reentry of the shuttle vehicle. Materials are presently available which will meet all these environmental requirements and can be designed into the structure to withstand the specified loads.
NASA selected the J-2X Upper Stage Engine in 2006 to power the upper stages of the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Based on the proven Saturn J-2 engine, this new engine will provide 294,000 pounds of thrust and a specific impulse of 448 seconds, making it the most efficient gas generator cycle engine in history. The engine's guiding philosophy emerged from the Exploration Systems Architecture Study (ESAS) in 2005. Goals established then called for vehicles and components based, where feasible, on proven hardware from the Space Shuttle, commercial, and other programs, to perform the mission and provide an order of magnitude greater safety. Since that time, the team has made unprecedented progress. Ahead of the other elements of the Constellation Program architecture, the team has progressed through System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of February 2010, more than 100,000 development engine parts have been ordered and more than 18,000 delivered. Approximately 1,300 of more than 1,600 engine drawings were released for manufacturing. A major factor in the J-2X development approach to this point is testing operations of heritage J-2 engine hardware and new J-2X components to understand heritage performance, validate computer modeling of development components, mitigate risk early in development, and inform design trades. This testing has been performed both by NASA and its J-2X prime contractor, Pratt & Whitney Rocketdyne (PWR). This body of work increases the likelihood of success as the team prepares for testing the J-2X powerpack and first development engine in calendar 2011. This paper will provide highlights of J-2X testing operations, engine test facilities, development hardware, and plans.
Expert systems are successfully applied to solve recurring NASA Space Shuttle orbiter payload integration problems. Recurrence of these problems is the result of each Space Shuttle mission being unique. The NASA Space Shuttle orbiter was designed to be extremely flexible in its ability to handle many types and combinations of satellites and experiments. This flexibility results in different and unique engineering resource requirements for each of the payload satellites and experiments. The first successful expert system to be applied to these problems was the Orbiter Payload Bay Cabling Expert System (EXCABL), developed at Rockwell International Space Transportation Systems Division. The operational version of EXCABL was delivered in 1986 and successfully solved the payload electrical support services cabling layout problem. As a result of this success, a second expert system, Expert Drawing Matching System (EXMATCH), was developed to generate a list of the reusable installation drawings available for each EXCABL solution. EXMATCH went operational in 1987. As a result of these initial successes, the need for a third expert system was defined and is awaiting development. This new Expert System, called Technical Order Listing Expert System (EXTOL), will generate a list of all the applicable reusable installation drawings available to support the total payload bay mission provisioning and installation effort. This paper describes these expert systems, the individual problems that they were designed to solve, their individual solutions, and the degree of success achieved. These expert systems' instantiate the applicability of this technology to the solution of real-world Space Shuttle payload integration problems.
The rapidly growing demand for cell manufacturing and in vitro tissue fabrication has led to the development of various technologies for biomimetic artificial extracellular matrix (ECM), including three major materials: hydrogels, fibrous scaffolds, and decellularized tissues. The latter two materials are closer to the biomimetic goal of replicating natural ECM. The scalability of the scaffolds made of decellularized tissues is limited. The development of 3D fibrous ECM is at the initial stage owing to the recent advantages of novel nanofiber spinning technologies. These novel technologies brought about simultaneous control over a range of critical characteristics, such as fiber diameter, length, material, draw ratio, spacing, and alignment into well-controlled 3D constructs. There is still a long way to go in designing 3D fibrous scaffolds based on cell response studies. The primary objective of this review is to provide an analysis of the recent progress in novel nano- and microfiber spinning methods and uncover their potential for precise fiber alignment into 3D structures.
Secondary organic aerosol (SOA), atmospheric particulate matter formed from low-volatility products of volatile organic compound (VOC) oxidation, affects both air quality and climate. Current 3D models, however, cannot reproduce the observed variability in atmospheric organic aerosol. Because many SOA model descriptions are derived from environmental chamber experiments, our ability to represent atmospheric conditions in chambers directly affects our ability to assess the air quality and climate impacts of SOA. Here, we develop an approach that leverages global modeling and detailed mechanisms to design chamber experiments that mimic the atmospheric chemistry of organic peroxy radicals (RO 2 ), a key intermediate in VOC oxidation. Drawing on decades of laboratory experiments, we develop a framework for quantitatively describing RO 2 chemistry and show that no previous experimental approaches to studying SOA formation have accessed the relevant atmospheric RO 2 fate distribution. We show proof-of-concept experiments that demonstrate how SOA experiments can access a range of atmospheric chemical environments and propose several directions for future studies.
Activities in packaging components into integral module arrangements compatible with engine design requirements for the 1137400E flight engine baseline are summarized along with the applied mechanics and thermal analysis. Revisions to drawings, configurations, and support structures are discussed.
A cylindrical shell skirt structure was subjected to a design and analysis study using a wide variety of structural materials and concepts. The design loading, axial compression, and torsion is representative of that expected on a typical space tug skirt section. Structural concepts evaluated included honeycomb sandwich, truss, isogrid, and skin/stringer/frame. The materials considered included a wide variety of structural metals as well as glass, graphite, and boron-reinforced composites. Honeycomb sandwich with aluminum faceskins, honeycomb sandwich with graphite/epoxy faceskins, and aluminum truss with fiberglass meteoroid protection layers were the designs selected for further evaluation. Procurement of materials required for fabrication is reported and the structural test plan and fabrication drawings are included. Construction of the graphite/epoxy faceskins, chem mill of the aluminum faceskins, chem mill of aluminum truss components, and fabrication of the graphite/epoxy honeycomb sandwich development panel is also reported.
The use of unmanned space probes for investigating the conditions existing on and around the outer planets of the solar system is discussed. The subjects included in the report are: (1) the design of a common entry probe for outer planet missions, (2) the significant trades related to the development of a common probe design, (3) the impact of bus selection on probe design, (4) the impact of probe requirements on bus modifications, and (5) the key technology elements recommended for advanced development. Drawings and illustrations of typical probes are included to show the components and systems used in the space probes.
A monitoring system developed to test the capability of a water recovery system to reject the passage of viruses into the recovered water is described. A nonpathogenic marker virus, bacteriophage F2, is fed into the process stream before the recovery unit and the reclaimed water is assayed for its presence. Detection of the marker virus consists of two major components, concentration and isolation of the marker virus, and detection of the marker virus. The concentration system involves adsorption of virus to cellulose acetate filters in the presence of trivalent cations and low pH with subsequent desorption of the virus using volumes of high pH buffer. The detection of the virus is performed by a passive immune agglutination test utilizing specially prepared polystyrene particles. An engineering preliminary design was performed as a parallel effort to the laboratory development of the marker virus test system. Engineering schematics and drawings of a fully functional laboratory prototype capable of zero-G operation are presented. The instrument consists of reagent pump/metering system, reagent storage containers, a filter concentrator, an incubation/detector system, and an electronic readout and control system.
Analysis of hardness of local water, average insolation for site, and daily hot water requirements insures suitability of solar-energy system design. Report describes two units which are designed to supply 81 percent of motel's annual hot water demand based on hypothetical 85 percent occupancy. Report includes drawings, operating and maintenance instructions, and test results for 1 day of operation.
The development of a mathematical software tools in workbench environment to model related objects more straightforward is outlined. A computer model from informal drawings and a plastic model of a helicopter is discussed. Lofting was the predominant, characteristic modelling technique. Ships and airplane designs use lofting as a technique because they have defined surfaces, (hulls and fuselages) from vertical station cuts perpendicular to the vertical center plane defining the major axis of reflective symmetry. A turbine blade from a jet engine was modelled in this way. The aerodynamic portion and the root comes from different paradigms. The union of these two parts into a coherent model is shown.