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NASA NTRS2004

HSCT Sector Combustor Evaluations for Demonstration Engine

In LET Task 10, critical development issues of the HSCT lean-burn low emissions combustor were addressed with a range of engineering tools. Laser diagnostics and CFD analysis were applied to develop a clearer understanding of the fuel-air premixing process and premixed combustion. Subcomponent tests evaluated the emissions and operability performance of the fuel-air premixers. Sector combustor tests evaluated the performance of the integrated combustor system. A 3-cup sector was designed and procured for laser diagnostics studies at NASA Glenn. The results of these efforts supported the earlier selection of the Cyclone Swirler as the pilot stage premixer and the IMFH (Integrated Mixer Flame Holder) tube as the main stage premixer of the LPP combustor. In the combustor system preliminary design subtask, initial efforts to transform the sector combustor design into a practical subscale engine combustor met with significant challenges. Concerns about the durability of a stepped combustor dome and the need for a removable fuel injection system resulted in the invention and refinement of the MRA (Multistage Radial Axial) combustor system in 1994. The MRA combustor was selected for the HSR Phase II LPP subscale combustor testing in the CPC Program.

Greenfield, Stuart↗

NASA NTRS2004

Johnson Space Center's Role in a Sustainable Future

NASA scientists and many others are contributing to the growing knowledge of our Earth and its ecosystems. Satellites measure sea level rise, and changes in vegetation and air pollutants that travel between countries and continents. The U.S. federal government seeks to be a leader in environmental sustainability efforts through various Executive Orders and policies that save energy, reduce waste, and encourage less reliance on oil as an energy source. NASA, as an agency that is by nature focused on the future, has much to contribute to these efforts. The NASA mission is 'To understand and protect our home planet, to explore the universe and search for life, to inspire the next generation of explorers as only NASA can.' Pollution prevention, affirmative procurement and sustainable design are all programs that are under way at NASA. But more can be done. By sharing ideas and learning from other organizations as well as from the talented workforce we are a part of, JSC can improve its sustainability performance and spread the benefits to our community.

Ewert, Michael K.↗

NASA NTRS2004

An Apparatus for Monitoring the Health of Electrical Cables

As with most elements of infrastructure, electrical wiring is innocuous; usually hidden away and unnoticed until it fails. Failure of infrastructure, however, sometimes leads to serious health and safety hazards. Electrical wiring fails when the polymeric (usually rubber) insulation material that sheathes the conductor gets embrittled with age from exposure to pressure, temperature or radiation cycling or when the insulation gets removed by the chafing of wires against each other. Miles of such wiring can be found in typical aircraft, with significant lengths of the wiring immersed in aviation fuel - a recipe for an explosion if a spark were to occur. Diagnosing the health of wiring is thus an important aspect of monitoring the health of aging aircraft. Stress wave propagation through wiring affords a quick and non-invasive method for health monitoring. The extent to which a stress wave propagating through the cable core gets attenuated depends on the condition of the surrounding insulation. When the insulation is in good condition - supple and pliable, there is more damping or attenuation of the waveform. As the insulation gets embrittled and cracked, the attenuation is likely to reduce and the waveform of the propagating stress wave is likely to change. The monitoring of these changes provides a potential tool to evaluate wiring or cabling in service that is not accessible for visual inspection. This experiment has been designed for use in an introductory mechanical or materials engineering instrumentation lab. Initial setup (after procuring all the materials) should take the lab instructor about 4 hours. A single measurement can be initiated and saved to disk in less than 3 minutes, allowing for all the students in a typical lab section to take their own data rather than share a single set of data for the entire class.

Pai, Devdas M.↗

NASA NTRS2005

Hardware Progress Made in the Early Flight Fission Test Facilities (EFF-TF) To Support Near-Term Space Fission Systems

The EFF-TF provides a facility to experimentally evaluate thermal hydraulic issues through the use of highly effective non-nuclear testing. These techniques provide a rapid, more cost effective method of evaluating designs and support development risk mitigation when concerns are associated with non-nuclear aspects of space nuclear systems. For many systems, electrical resistance thermal simulators can be used to closely mimic the heat deposition of the fission process, providing axial and radial profiles. A number of experimental and design programs were underway in 2004. Initial evaluation of the SAFE-100a (19 module stainless steel/sodium heat pipe reactor with integral gas neat exchanger) was performed with tests up to 17.5 kW of input power at core temperatures of 1000 K. A stainless steel sodium SAFE-100 heat pipe module was placed through repeated freeze/thaw cyclic testing accumulating over 200 restarts to a temperature of 1000 K. Additionally, the design of a 37-fuel pin stainless steel pumped sodium/potassium (NaK) loop was finalized and components procured. Ongoing testing at the EFF-TF is geared towards facilitating both research and development necessary to field a near term space nuclear system. Efforts are coordinated with DOE laboratories, industry, universities, and other NASA centers. This paper describes some of the 2004 efforts.

VanDyke, Melissa↗

NASA NTRS2005

Auxiliary Propulsion Activities in Support of NASA's Exploration Initiative

The Space Launch Initiative (SLI) procurement mechanism NRA8-30 initiated the Auxiliary Propulsion System/Main Propulsion System (APS/MPS) Project in 2001 to address technology gaps and development risks for non-toxic and cryogenic propellants for auxiliary propulsion applications. These applications include reaction control and orbital maneuvering engines, and storage, pressure control, and transfer technologies associated with on-orbit maintenance of cryogens. The project has successfully evolved over several years in response to changing requirements for re-usable launch vehicle technologies, general launch technology improvements, and, most recently, exploration technologies. Lessons learned based on actual hardware performance have also played a part in the project evolution to focus now on those technologies deemed specifically relevant to the Exploration Initiative. Formal relevance reviews held in the spring of 2004 resulted in authority for continuation of the Auxiliary Propulsion Project through Fiscal Year 2005 (FY05), and provided for a direct reporting path to the Exploration Systems Mission Directorate. The tasks determined to be relevant under the project were: continuation of the development, fabrication, and delivery of three 870 lbf thrust prototype LOX/ethanol reaction control engines; the fabrication, assembly, engine integration and testing of the Auxiliary Propulsion Test Bed at White Sands Test Facility; and the completion of FY04 cryogenic fluid management component and subsystem development tasks (mass gauging, pressure control, and liquid acquisition elements). This paper presents an overview of those tasks, their scope, expectations, and results to-date as carried forward into the Exploration Initiative.

Best, Philip J.↗

NASA NTRS2005

Development of the Architectural Simulation Model for Future Launch Systems and its Application to an Existing Launch Fleet

A significant portion of lifecycle costs for launch vehicles are generated during the operations phase. Research indicates that operations costs can account for a large percentage of the total life-cycle costs of reusable space transportation systems. These costs are largely determined by decisions made early during conceptual design. Therefore, operational considerations are an important part of vehicle design and concept analysis process that needs to be modeled and studied early in the design phase. However, this is a difficult and challenging task due to uncertainties of operations definitions, the dynamic and combinatorial nature of the processes, and lack of analytical models and the scarcity of historical data during the conceptual design phase. Ultimately, NASA would like to know the best mix of launch vehicle concepts that would meet the missions launch dates at the minimum cost. To answer this question, we first need to develop a model to estimate the total cost, including the operational cost, to accomplish this set of missions. In this project, we have developed and implemented a discrete-event simulation model using ARENA (a simulation modeling environment) to determine this cost assessment. Discrete-event simulation is widely used in modeling complex systems, including transportation systems, due to its flexibility, and ability to capture the dynamics of the system. The simulation model accepts manifest inputs including the set of missions that need to be accomplished over a period of time, the clients (e.g., NASA or DoD) who wish to transport the payload to space, the payload weights, and their destinations (e.g., International Space Station, LEO, or GEO). A user of the simulation model can define an architecture of reusable or expendable launch vehicles to achieve these missions. Launch vehicles may belong to different families where each family may have it own set of resources, processing times, and cost factors. The goal is to capture the required resource levels of the major launch elements and their required facilities. The model s output can show whether or not a certain architecture of vehicles can meet the launch dates, and if not, how much the delay cost would be. It will also produce aggregate figures of missions cost based on element procurement cost, processing cost, cargo integration cost, delay cost, and mission support cost. One of the most useful features of this model is that it is stochastic where it accepts statistical distributions to represent the processing times mimicking the stochastic nature of real systems.

Rabadi, Ghaith↗

NASA NTRS2004

The Office of Inspector General (OIG)

The NASA Office of Inspector General is the Federal Law Enforcement Agency at NASA which conducts criminal and regulatory investigations in which NASA is a victim. The OIG prevents and detects crime, fiaud, waste and abuse and assists NASA management in promoting economy, efficiency, and effectiveness in its programs and operations. Investigations (OI) and the Office of Audits (OA). The investigations side deals with criminal Investigations, administrative investigations, and civil investigations. The Audits side deals with inspections and assessments as well as the Auditing of NASA Programs and Activities. Our mission at the OIG is to conduct and supervise independent and objective audits and investigations relating to agency programs and operations; to promote economy, effectiveness and efficiency within the agency; to prevent and detect crime, fraud, waste and abuse in agency programs and operations; to review and make recommendations regarding existing and proposed legislation and regulations relating to agency programs and operations. We are also responsible for keeping the agency head and the Congress fully and currently informed of problems in agency programs and operations. deal with False Claims, False Statements, Conspiracy, Theft, Computer Crime, Mail Fraud, the Procurement Integrity Act, the Anti-Kickback Act, as well as noncompliance with NASA Management Instructions, the Federal Acquisition Regulations (FAR), and the Code of Federal Regulations (CFR). Most of the casework that is dealt with in our office is generated through gum shoe work or cases that we generate on our own. These cases can come from Law Enforcement Referrals, GIDEP Reports, EPlMS (NASA Quality System), Defense Contract Audit Agency, Newspaper Articles, and Confidential Information. In many cases, confidentiality is the biggest factor to informants coming forward. We are able to maintain confidentiality because the 01 is independent of NASA Management and doesn t report to the Center Directors, therefore the informant s mangers and supervisors are unaware of the informants actions. The only time when an informant s confidentiality may be compromised is when it is needed in a Court of Law and is released through a Judicial Court Order. During my tenure here at the NASA OIG/OI at Glenn Research Center, I have been involved in many different tasks. They have ranged from updating Suspected Unapproved Parts case files to independently interviewing NASA employees to turn up general background information. The 01 has the duty of informing NASA aeronautical safety managers of potential Nonconforming products. My mission is to compile a database of Nonconformance reports for distribution. The background information that I turn up from my interviews is then used to determine NASA s susceptibility to acceptance of unapproved parts. The IG organization is divided up into two separate disciplines, the Office of 01 investigations primarily focus on violations of Federal laws. Some of these violations

Macisco, Christopher A.↗

NASA NTRS1999

Metrology Evaluation of Superfinished Gears Completed

Gears, bearings, and similar mechanical elements transmit loads through the surfaces that are in contact with one another. Thus, the fatigue lives of gears can be improved by providing smoother tooth surfaces. At the NASA Lewis Research Center, we completed a metrology evaluation of one method for making gears with a highly polished, mirrorlike surface. The polished gears were measured carefully. The measurement data showed that the polishing process did, indeed, reduce the surface roughness but did not change the overall tooth shape in any harmful way. This work was done as a partnership of NASA, the U.S. Army, and the University of Wales. NASA provided conventionally ground gear specimens and has begun testing to determine the fatigue lives of the superfinished gears. Under contract, the University of Wales superfinished the gears and inspected them before and after the superfinishing operation. The U.S. Army European Research Office provided the funds and procured the contract with the University of Wales.

Krantz, Timothy L.↗

NASA NTRS2003

Microsystems Fabrication Laboratory-New Class 100 Cleanroom Completed and Certified

A new Microsystems Fabrication Laboratory (MFL), a Class 100 cleanroom fabrication facility, was completed and certified in 2002 at the NASA Glenn Research Center. This facility, to be used by Glenn's Instrumentation and Controls Division, was designed and built as part of the NASA Construction of Facilities Program. The design, construction, and certification phases were managed by personnel from Glenn s Facilities and Test Engineering Division. Because of time constraints and the need for specialized cleanroom expertise, this 1000 ft2 laboratory was completed using a design-build procurement. Facility Planning & Resources (Pittsburgh, PA) was selected as the prime contractor and provided the architectural design and project management. A major subcontractor, AdvanceTEC, LLC (Richmond, VA), provided the mechanical and electrical design and performed the construction services. Throughout this fast-track project, Facilities and Test Engineering Division personnel provided overall project management and worked closely with the contractors to ensure that the customers needs were addressed and that the impact of the project implementation was minimized.

Borato, Frances M.↗

NASA NTRS2004

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗

NASA NTRS2005

Dual-Band Deramp Radar Design for Ocean Current Measurements

A mission has been proposed to remotely measure ocean surface currents and surface wind velocities. It will provide the highest resolution and repeat time of these measurements to date for ocean current models with scientific and societal applications. A ground-based experimental radar unit is needed for proof of concept. The proposed experiment set up is to mount the radar on an oil rig to imitate satellite data acquisition. This summer, I completed the radar design. The design employs chirp/deramp topology with simultaneous transmit/receive channels. These two properties allow large system bandwidth, extended sample time, close range imaging, and low sampling rate. The radar operates in the Ku and Ka microwave bands, at 13.5 and 35.5 GHz, respectively, with a system bandwidth of 300 MHz. I completed the radar frequency analysis and research on potential components and antenna configurations. Subsequent work is needed to procure components, as well as to build, test, and deploy the radar.

Haynes, Mark S.↗

NASA NTRS2006

The TPS Advanced Development Project for CEV

The CEV TPS Advanced Development Project (ADP) is a NASA in-house activity for providing two heatshield preliminary designs (a Lunar direct return as well as a LEO only return) for the CEV, including the TPS, the carrier structure, the interfaces and the attachments. The project s primary objective is the development of a single heatshield preliminary design that meets both Lunar direct return and LEO return requirements. The effort to develop the Lunar direct return capable heatshield is considered a high risk item for the NASA CEV development effort due to the low TRL (approx. 4) of the candidate TPS materials. By initiating the TPS ADP early in the development cycle, the intent is to use materials analysis and testing in combination with manufacturing demonstrations to reduce the programmatic risk of using advanced TPS technologies in the critical path for CEV. Due to the technical and schedule risks associated a Lunar return heatshield, the ADP will pursue a parallel path design approach, whereby a back-up TPS/heatshield design that only meets LEO return requirements is also developed. The TPS materials and carrier structure design concept selections will be based on testing, analysis, design and evaluation of scalability and manufacturing performed under the ADP. At the TPS PDR, the preferred programmatic strategy is to transfer the continued (detailed) design, development, testing and evaluation (DDT&E) of both the Lunar direct and LEO return designs to a government/prime contractor coordinated sub-system design team. The CEV prime contractor would have responsibility for the continued heatshield sub-system development. Continued government participation would include analysis, testing and evaluation as well as decision authority at TPS Final System Decision (FSD) (choosing between the primary and back-up heatshields) occurring between TPS PDR and TPS Critical Design Review (CDR). After TPS FSD the prime CEV contractor will complete the detailed design, certification testing, procurement, and integration of the CEV TPS.

Reuther, James↗

NASA NTRS2006

Managing the Implementation of Mission Operations Automation

Reducing the cost of mission operations has necessitated a high level of automation both on spacecraft and ground systems. While automation on spacecraft is implemented during the design phase, ground system automation tends to be implemented during the prime mission operations phase. Experience has shown that this tendency for late automation development can be hindered by several factors: additional hardware and software resources may need to be procured; software must be developed and tested on a non-interference basis with primary operations with limited manpower; and established procedures may not be suited for automation requiring substantial rework. In this paper we will review the experience of successfully automating mission operations for seven on-orbit missions: the Compton Gamma Ray Observatory (CGRO), the Rossi X-Ray Timing Explorer (RXTE), the Advanced Composition Explorer (ACE), the Far Ultraviolet Spectroscopic Explorer (FUSE), Interplanetary Physics Laboratory (WIND), Polar Plasma Laboratory (POLAR), and the Imager for Magnetopause-to-Aurora Global Exploration (IMAGE). We will provide lessons learned in areas such as: spacecraft recorder management, procedure development, lights out commanding from the ground system vs. stored command loads, spacecraft contingency response time, and ground station interfaces. Implementing automation strategies during the mission concept and spacecraft integration and test phase as the most efficient method will be discussed.

Sodano, R.↗

NASA NTRS1997

Design of the Cassini Gimbal Actuator: Some Lessons Learned Along the Way

The evolution of a linear servoactuator design is presented. The linear actuator was needed to position Cassini's redundant rocket motors. A device design inherited from JPL's Mariner and Viking Mars missions served as a starting point. The various improvements made and the efforts involved in developing new component sources are discussed. Because the brush type DC motor from the old design was retained, special attention was placed on the reliability testing of the motor and mechanism at all stages of procurement and assembly.

actuators DC motors reliability lifetime↗

NASA NTRS2004

Systems engingeering for the Kepler Mission : a search for terrestrial planets

The Kepler mission will launch in 2007 and determine the distribution of earth-size planets (0.5 to 10 earth masses) in the habitable zones (HZs) of solar-like stars. The mission will monitor > 100,000 dwarf stars simultaneously for at least 4 years. Precision differential photometry will be used to detect the periodic signals of transiting planets. Kepler will also support asteroseismology by measuring the pressure-mode (p-mode) oscillations of selected stars. Key mission elements include a spacecraft bus and 0.95 meter, wide-field, CCD-based photometer injected into an earth-trailing heliocentric orbit by a 3-stage Delta II launch vehicle as well as a distributed Ground Segment and Follow-up Observing Program. The project is currently preparing for Preliminary Design Review (October 2004) and is proceeding with detailed design and procurement of long-lead components. In order to meet the unprecedented photometric precision requirement and to ensure a statistically significant result, the Kepler mission involves technical challenges in the areas of photometric noise and systematic error reduction, stability, and false-positive rejection. Programmatic and logistical challenges include the collaborative design, modeling, integration, test, and operation of a geographically and functionally distributed project. A very rigorous systems engineering program has evolved to address these challenges. This paper provides an overview of the Kepler systems engineering program, including some examples of our processes and techniques in areas such as requirements synthesis, validation & verification, system robustness design, and end-to-end performance modeling.

systems engineering↗

NASA NTRS2006

Mission Benefits of Gridded Ion and Hall Thruster Hybrid Propulsion Systems

The NASA In-Space Propulsion Technology (ISPT) Project Office has been developing the NEXT gridded ion thruster system and is planning to procure a low power Hall system. The new ion propulsion systems will join NSTAR as NASA's primary electric propulsion system options. Studies have been performed to show mission benefits of each of the stand alone systems. A hybrid ion propulsion system (IPS) can have the advantage of reduced cost, decreased flight time and greater science payload delivery over comparable homogeneous systems. This paper explores possible advantages of combining various thruster options for a single mission.

Dankanich, John W.↗

NASA NTRS2006

Acoustic Characteristics of Various Treatment Panel Designs for HSCT Ejector Liner Acoustic Technology Development Program

The objectives of the initial effort (Phase I) of HSR Liner Technology Program, the selection of promising liner concepts, design and fabrication of these concepts for laboratory tests, testing these liners in the laboratory by using impedance tube and flow ducts, and developing empirical impedance/suppression correlation, are successfully completed. Acoustic and aerodynamic criteria for the liner design are established. Based on these criteria several liners are designed. The liner concepts designed and fabricated include Single-Degree-of-Freedom (SDOF), Two-Degree-of-Freedom (2DOF), and Bulk Absorber. Two types of SDOF treatment are fabricated, one with a perforated type face plate and the other with a wiremesh (woven) type faceplate. In addition, special configurations of these concepts are also included in the design. Several treatment panels are designed for parametric study. In these panels the facesheets of different porosity, hole diameter, and sheet thickness are utilized. Several deep panels (i.e., 1 in. deep) are designed and instrumented to measure DC flow resistance and insitu impedance in the presence of grazing flow. Basic components of these panels (i.e., facesheets, bulk materials, etc.) are also procured and tested. The results include DC flow resistance, normal impedance, and insertion loss.

Salikuddin, M.↗

NASA NTRS2006

Characterization Tests of WFC3 Filters

The WFC3 instrument to be installed on HST during the next servicing mission consists of a UVIS and an IR channel. Each channel is allocated its own complement of filters: 48 elements for the UVIS (42 filters, 5 quads, and 1 UV grism) and 17 slots for the IR (15 filters and 2 grisms). While a majority of the UVIS filters exhibit excellent performance consistent with or exceeding expectations, a subset show significant filter ghosts. Procurement of improved replacement filters is in progress and a summary of the characterization tests being performed on the new filters is presented. In the IR channel, while no filter ghosting was detected in any of the filters during thermal vacuum testing, the grisms were found to be installed incorrectly; they have been removed and will be reinstalled. In addition, due to the significantly improved response blueward of 800nm expected in the new substrate-removed IR detector (see Invited talk by R.A.Kimble, this volume), two IR filters originally constructed on a fused silica substrate are being remade using an IR transmitting color glass to block any visible light transmission. Tests of the new IR filters and preparations for the grism reinstallation are summarized

Baggett, S.↗