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At least 613 records · Page 34

Development of new materials for turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life was experienced. The objective is to identify bearing materials and/or materials processing techniques offering signficant potential for extending HPOTP bearing performance life. Interactive thermomechanical analysis of the HPOTP bearing-shaft system was performed with the SHABERTH computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures and circumferential stress in the inner rings were quantified as functions of radial load, thrust load and ball-race contact friction. Criteria established from the output of this analysis are being used for material candidate selection.

Maurer, R. E.↗

High-efficiency AlGaAs-GaAs Cassegrainian concentrator cells

AlGaAs-GaAs heteroface space concentrator solar cells have been fabricated by metalorganic chemical vapor deposition. AMO efficiencies as high as 21.1% have been observed both for p-n and np structures under concentration (90 to 100X) at 25 C. Both cell structures are characterized by high quantum efficiencies and their performances are close to those predicted by a realistic computer model. In agreement with the computer model, the n-p cell exhibits a higher short-circuit current density.

Werthen, J. G.↗

Bearing optimization for SSME HPOTP application

The space shuttle main engine (SSME) high-pressure oxygen turbopumps (HPOTP) have not experienced the service life required of them. To improve the life of the existing turbopump bearings, modifications to the bearings that could be retrofitted into the present bearing cavity are being investigated. Several bearing parameters were optimized using the computer program SHABERTH, which performs a thermomechanical simulation of a load support system. The computer analysis showed that improved bearing performance is feasible if low friction coefficients can be attained. Bearing geometries were optimized considering heat generation, equilibrium temperatures, and relative life. Two sets of curvatures were selected from the optimization: an inner-raceway curvature of 0.54, an outer-raceway curvature of 0.52, and an inner-raceway curvature of 0.55, an outer-raceway curvature of 0.53. A contact angle of 16 deg was also selected. Thermal gradients through the bearings were found to be lower with liquid lubrication than with solid film lubrication. As the coolant flowrate through the bearing increased, the ball temperature decreased but at a continuously decreasing rate. The optimum flowrate was approximately 4 kg/s. The analytical modeling used to determine these feasible modifications to improve bearing performance is described.

Armstrong, Elizabeth S.↗

Debris/Ice/TPS Assessment and Photographic Analysis for Shuttle Mission STS-40

A debris, ice, Thermal Protection System (TPS) assessment and photographic analysis for Space Shuttle Mission STS-40 was conducted. Debris inspections of the flight elements and launch pad were performed before and after launch. Ice and frost conditions on the External Tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle, followed by on-pad visual inspection. High speed photography was analyzed after launch to identify ice and debris sources and to evaluate potential vehicle damage and/or in-flight anomalies.

Katnik, Gregory N.↗

Transition in a Supersonic Boundary Layer Due to Acoustic Disturbances

The boundary layer receptivity process due to the interaction of three-dimensional slow and fast acoustic disturbances with a blunted flat plate is numerically investigated at a free stream Mach number of 3.5 and at a high Reynolds number of 10(exp 6)/inch. The computations are performed with and without two-dimensional isolated roughness element located near the leading edge. Both the steady and unsteady solutions are obtained by solving the full Navier-Stokes equations using the fifth-order accurate weighted essentially non-oscillatory (WENO) scheme for space discretization and using third-order total-variation-diminishing (TVD) Runge-Kutta scheme for time integration. The simulations showed that the linear instability waves are generated very close to the leading edge. The wavelength of the disturbances inside the boundary layer first increases gradually and becomes longer than the wavelength for the instability waves within a short distance from the leading edge. The wavelength then decreases gradually and merges with the wavelength for the Tollmien-Schlichting wave. The initial amplitudes of the instability waves near the neutral points, the receptivity coefficients, are about 1.20 and 0.07 times the amplitude of the free-stream disturbances for the slow and the fast waves respectively. It was also revealed that small isolated roughness element does not enhance the receptivity process for the given nose bluntness.

Balakumar, P.↗

Digital Twin Model for Advanced Manufacture of a Rotating Detonation Engine Injector

A digital twin material model (DTMM) of an additive manufacturing (AM) process was created to advance the state of the art in rotating detonation engine (RDE) injector design. Current RDE injectors are designed with large pressure drops, enabling a stable and repeatable combustion process. However, this comes at the cost of system efficiency. For the technology to transition to commercial fossil-based power generation, it is important to develop injectors with reduced flow losses. Low-loss injectors are difficult to design and manufacture with conventional manufacturing techniques. AM enables new design options, but the AM manufacturing process must be thoroughly understood to result in a robust design. A DTMM provides the necessary insight by defining the cause-effect relationships between process parameters, microstructure features, and properties. Therefore, a DTMM to support the design and manufacturing process was developed and applied to the design of a new additively manufactured low-loss injector. The injector combustion behavior was characterized through hot-fire tests, and mechanical performance was compared to the DTMM predictions. The two project goals were the successful development of the DTMM and the demonstration of an improved RDE injector design. The RDE injector design and DTMM developments occurred on parallel but dependent paths. The injector was designed to reduce pressure drop by increasing the cross-sectional flow area ratio between the injector air passages and the combustor annulus. This resulted in less structural material, raising the concern that thin members would be susceptible to high-cycle fatigue (HCF) under the periodic loading inherent to an RDE. It was most important for the DTMM to predict behavior in these features; therefore, the injector design concept guided the material thicknesses used in fatigue tests. The DTMM development started by manufacturing a series of coupons over the range of possible AM process variations. A design-of-experiment approach was used to select which process variable combinations gave the most efficient coverage relevant to the injector design space. The microstructure in each of these coupons was characterized, and then computational methods were used to create a numerical model of the correlation between process variables and microstructure. Next, a set of HCF samples were tested to calibrate existing models that map microstructure to HCF performance. Together, these two links formed the DTMM that calculates HCF behavior from AM process variables. Two injector prototypes were additively manufactured. The first injector design strategy aggressively pursued low-loss performance by substantially increasing the oxidizer flow area. The combination of manufacturing lead times and the fatigue testing schedule meant that the DTMM was not available when building this first prototype. Therefore, its process parameters were chosen based on a manual review of the available coupon data. This prototype was built successfully and evaluated in 58 combustion tests. Sustained detonation was achieved with remarkably reduced pressure loss, and some tests even displayed pressure loss characteristics similar to conventional gas turbine combustors. This achieved the project goal of improving RDE injector design. The second injector was manufactured according to the optimized parameters predicted by the DTMM. The flow area modifications of this injector were less aggressive than the first injector since demonstrating low pressure loss was not an objective of the second hot-fire test series. Rather, the test objective was to cause high cycle fatigue failure in the part due to periodic loading from the rotating detonation wave. The observed number of cycles to failure was to be compared to the number predicted by the DTMM and thereby assess the utility of the DTMM in component design. However, the required level of vibration was not obtained during combustion. Therefore, high cycle fatigue was not experienced in the hot-fire tests of the second injector. Fatigue data was obtained by further testing the second injector in a conventional HCF test apparatus. The injector demonstrated HCF strength above the DTMM prediction. In fact, it did not fail and testing was only discontinued due to reaching the end of the period of performance. This points to some success in the project’s primary goal of successfully developing and applying the DTMM to a component design. Implementing the DTMM recommendations for optimal processing parameters led to a part with acceptable properties. The DTMM was also shown to be an efficient correlator of data and to provide insight into the relationship between process settings, microstructure, and property performance. However, the failure of the DTMM prediction to match the experimental result of the injector fatigue test also points to the need to include significantly more data in the model development. In this project, coupons made with identical processing parameters exhibited drastically different properties from each other and from the injector part, which clearly influences the accuracy of a model that predicts performance based on parameters. Uncertainties in the build process must be quantified to develop more robust models. A denser and broader matrix of coupon process and geometry variations, several repeated builds of every point, more in-situ build process measurements, and direct observation of tensile and HCF sample microstructure (as opposed to separate microstructure specimens) are recommendations to improve future AM modeling efforts.

20 FOSSIL-FUELED POWER PLANTS↗

Unsteady Flow in a Supersonic Turbine with Variable Specific Heats

Modern high-work turbines can be compact, transonic, supersonic, counter-rotating, or use a dense drive gas. The vast majority of modern rocket turbine designs fall into these Categories. These turbines usually have large temperature variations across a given stage, and are characterized by large amounts of flow unsteadiness. The flow unsteadiness can have a major impact on the turbine performance and durability. For example, the Space Transportation Main Engine (STME) fuel turbine, a high work, transonic design, was found to have an unsteady inter-row shock which reduced efficiency by 2 points and increased dynamic loading by 24 percent. The Revolutionary Reusable Technology Turbopump (RRTT), which uses full flow oxygen for its drive gas, was found to shed vortices with such energy as to raise serious blade durability concerns. In both cases, the sources of the problems were uncovered (before turbopump testing) with the application of validated, unsteady computational fluid dynamics (CFD) to the designs. In the case of the RRTT and the Alternate Turbopump Development (ATD) turbines, the unsteady CFD codes have been used not just to identify problems, but to guide designs which mitigate problems due to unsteadiness. Using unsteady flow analyses as a part of the design process has led to turbine designs with higher performance (which affects temperature and mass flow rate) and fewer dynamics problems. One of the many assumptions made during the design and analysis of supersonic turbine stages is that the values of the specific heats are constant. In some analyses the value is based on an average of the expected upstream and downstream temperatures. In stages where the temperature can vary by 300 to 500 K, however, the assumption of constant fluid properties may lead to erroneous performance and durability predictions. In this study the suitability of assuming constant specific heats has been investigated by performing three-dimensional unsteady Navier-Stokes simulations for a supersonic turbine stage.

Dorney, Daniel J.↗

High Data Rate Architecture (HiDRA)

One of the greatest challenges in developing new space technology is in navigating the transition from ground based laboratory demonstration at Technology Readiness Level 6 (TRL-6) to conducting a prototype demonstration in space (TRL-7). This challenge is com- pounded by the relatively low availability of new spacecraft missions when compared with aeronautical craft to bridge this gap, leading to the general adoption of a low-risk stance by mission management to accept new, unproven technologies into the system. Also in consideration of risk, the limited selection and availability of proven space-grade components imparts a severe limitation on achieving high performance systems by current terrestrial technology standards. Finally from a space communications point of view the long duration characteristic of most missions imparts a major constraint on the entire space and ground network architecture, since any new technologies introduced into the system would have to be compliant with the duration of the currently deployed operational technologies, and in some cases may be limited by surrounding legacy capabilities. Beyond ensuring that the new technology is verified to function correctly and validated to meet the needs of the end users the formidable challenge then grows to additionally include: carefully timing the maturity path of the new technology to coincide with a feasible and accepting future mission so it flies before its relevancy has passed, utilizing a limited catalog of available components to their maximum potential to create meaningful and unprecedented new capabilities, designing and ensuring interoperability with aging space and ground infrastructures while simultaneously providing a growth path to the future. The International Space Station (ISS) is approaching 20 years of age. To keep the ISS relevant, technology upgrades are continuously taking place. Regarding communications, the state-of-the-art communication system upgrades underway include high-rate laser terminals. These must interface with the existing, aging data infrastructure. The High Data Rate Architecture (HiDRA) project is designed to provide networked store, carry, and forward capability to optimize data flow through both the existing radio frequency (RF) and new laser communications terminal. The networking capability is realized through the Delay Tolerant Networking (DTN) protocol, and is used for scheduling data movement as well as optimizing the performance of existing RF channels. HiDRA is realized as a distributed FPGA memory and interface controller that is itself controlled by a local computer running DTN software. Thus HiDRA is applicable to other arenas seeking to employ next-generation communications technologies, e.g. deep space. In this paper, we describe HiDRA and its far-reaching research implications.

DTN↗

Laminar-Turbulent Transition Behind Discrete Roughness Elements in a High-Speed Boundary Layer

Computations are performed to study the flow past an isolated roughness element in a Mach 3.5, laminar, flat plate boundary layer. To determine the effects of the roughness element on the location of laminar-turbulent transition inside the boundary layer, the instability characteristics of the stationary wake behind the roughness element are investigated over a range of roughness heights. The wake flow adjacent to the spanwise plane of symmetry is characterized by a narrow region of increased boundary layer thickness. Beyond the near wake region, the centerline streak is surrounded by a pair of high-speed streaks with reduced boundary layer thickness and a secondary, outer pair of lower-speed streaks. Similar to the spanwise periodic pattern of streaks behind an array of regularly spaced roughness elements, the above wake structure persists over large distances and can sustain strong enough convective instabilities to cause an earlier onset of transition when the roughness height is sufficiently large. Time accurate computations are performed to clarify additional issues such as the role of the nearfield of the roughness element during the generation of streak instabilities, as well as to reveal selected details of their nonlinear evolution. Effects of roughness element shape on the streak amplitudes and the interactions between multiple roughness elements aligned along the flow direction are also investigated.

Choudhari, Meelan M.↗

A multi-dimensional parametric study of variability in multi-phase flow dynamics during geologic CO 2 sequestration accelerated with machine learning

Successful geologic CO 2 storage projects depend on numerical simulations to predict reservoir performance during site selection, injection verification, and post-injection monitoring phases of the project. These numerical simulations solve non-linear sets of coupled partial differential equations, while accounting for multi-phase fluid dynamics on the basis of constitutive equations that are embedded into the solution scheme. As a consequence, individual simulations often require tens to hundreds of hours to complete on high-performance computing clusters. Moreover, laboratory experiments reveal that parametric functions for capillary pressure and relative permeability exhibit substantial variability, even within the same rock type. This combination of computational expense and wide-ranging parametric variability means that there remains substantial uncertainty in the behavior of multi-phase CO 2 -water systems, particularly in the context of feedbacks between relative permeability and capillary pressure. To bridge this knowledge gap, here we develop a novel workflow that utilizes physics-based numerical simulation to train an artificial neural network (ANN) emulator for interrogating the multivariate parameter space that governs both capillary pressure and relative permeability. With this approach, the ANN is trained to emulate both fluid pressure distribution and CO 2 saturation, which are then interrogated quantitatively to generate parametric response surface mappings with high-fidelity resolution. Results from this study initially show that capillary entry pressure is the dominant control on both CO 2 plume geometry and fluid pressure propagation when considering the combined effects of capillary pressure and relative permeability, particularly when phase interference is low and residual CO 2 saturation is high. Moreover, the ANN emulator provides tremendous computational speed-up by computing 2691 individual simulations in several minutes; whereas, the same simulation ensemble would have required ~3 years of simulation time using only physics-based simulation methods (25,000 times speed up).

58 GEOSCIENCES↗

Automated Generation of Integrated Digital and Spiking Neuromorphic Machine Learning Accelerators

The growing numbers of application areas for artificial intelligence (AI) methods have led to an explosion of domain-specific accelerators that could support every new machine learning (ML) algorithm advancement, clearly highlighting the need for a capability to quickly and automatically transition from algorithm definition to hardware implementation and explore design space along a variety of SWaP (size, weight and Power). The software defined architectures (SODA) synthesizer implements a compiler-based modular infrastructure for the end-to-end generation of machine learning accelerators from high-level frameworks to hardware description language. At the same time, neuromorphic computing, by mimicking how the brain operates, promises to perform artificial intelligence tasks at efficiencies orders of magnitude higher than the current conventional tensor-processing based accelerators, as demonstrated by a variety of specialized designs leveraging Spiking Neural Networks (SNNs). Nevertheless, the mapping of an artificial neural network (ANN) to solutions supporting SNNs is still a non-trivial and very device-specific task, and completely lack the possibility to design hybrid systems that integrate conventional and spiking neural models. In this paper we discuss the support for such an integrated generation leveraging the SODA Synthesizer framework and its modular structure. In particular, we present a new MLIR dialect (part of the SODA frontend) that allows expressing spiking neural network features (e.g., available resources, spiking sequences, analog signal reading, etc.) and illustrate how it enables mapping to Spiking Neurons and deployment to the related specialized hardware (which, in the digital domain, could be generated through the other existing layers of the SODA Synthesizer). We then discuss the opportunities for even deeper integration afforded by the hardware compilation infrastructure, providing a path towards the generation of complex heterogeneous artificial intelligence systems.

Curzel, Serena↗

Evaluation of PHOENICS as a design analysis tool for SSME

The use of the computational fluid dynamics computer code PHOENICS was proposed as a design analysis tool for improving the Space Shuttle Main Engines (SSME). The PHOENICS is a general purpose computer code for the simulation of fluid-flow, heat-transfer and combustion processes arising in engineering, scientific research and environment. It analyzes one or two-phase flows, in one, two, or three dimensions. The application of PHOENICS to evaluate the performance of high-pressure gaseous-hydrogen filters is examined. The usefulness of the code and the ability of the code to handle successively more complex features of the device are demonstrated.

Ventrice, M. B.↗

Nonlinear heat transfer and structural analyses of SSME turbine blades

Three-dimensional nonlinear finite-element heat transfer and structural analyses were performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine (SSME). Directionally solidified (DS) MAR-M 246 material properties were considered for the analyses. Analytical conditions were based on a typical test stand engine cycle. Blade temperature and stress-strain histories were calculated using MARC finite-element computer code. The study was undertaken to assess the structural response of an SSME turbine blade and to gain greater understanding of blade damage mechanisms, convective cooling effects, and the thermal-mechanical effects.

Abdul-Aziz, A.↗

Shuttle entry aerothermodynamic flight research - The Orbiter Experiments (OEX) Program

Results of the OEX program are summarized with emphasis on the information on entry aerothermodynamic phenomena derived from Space Shuttle operations. The discussion focuses on OEX experiment complement and operational history, freestream environment and vehicle attitude data, aerodynamic force and moment data, aerodynamic surface data, and vehicle configuration data. Attention is also given to orbiter aerodynamic performance, stability and control, high-altitude atmospheric density variability, direct simulation Monte Carlo validation, orbital drag variation, and computational fluid dynamic technique validation.

Throckmorton, David A.↗

SpaceCubeX: A Framework for Evaluating Hybrid Multi-Core CPU FPGA DSP Architectures

The SpaceCubeX project is motivated by the need for high performance, modular, and scalable on-board processing to help scientists answer critical 21st century questions about global climate change, air quality, ocean health, and ecosystem dynamics, while adding new capabilities such as low-latency data products for extreme event warnings. These goals translate into on-board processing throughput requirements that are on the order of 100-1,000 more than those of previous Earth Science missions for standard processing, compression, storage, and downlink operations. To study possible future architectures to achieve these performance requirements, the SpaceCubeX project provides an evolvable testbed and framework that enables a focused design space exploration of candidate hybrid CPU/FPGA/DSP processing architectures. The framework includes ArchGen, an architecture generator tool populated with candidate architecture components, performance models, and IP cores, that allows an end user to specify the type, number, and connectivity of a hybrid architecture. The framework requires minimal extensions to integrate new processors, such as the anticipated High Performance Spaceflight Computer (HPSC), reducing time to initiate benchmarking by months. To evaluate the framework, we leverage a wide suite of high performance embedded computing benchmarks and Earth science scenarios to ensure robust architecture characterization. We report on our projects Year 1 efforts and demonstrate the capabilities across four simulation testbed models, a baseline SpaceCube 2.0 system, a dual ARM A9 processor system, a hybrid quad ARM A53 and FPGA system, and a hybrid quad ARM A53 and DSP system.

Hybrid Flight Architectures↗

Impact of NASA’s Entry Systems Modeling Project on Planetary Mission Design

Planetary missions continue to grow larger and more complex. Furthermore, the current focus on human exploration of the Moon and Mars, as well as Mars Sample Return(MSR), place increas-ingly stringent requirements on the reliability of the entry, descent, and landing (EDL) system that ensures the safe delivery of payload or crew to their destination. Planetary EDL is an area in which mission designers are critically reliant on modeling and simulation to demonstrate the reliability of the system, as there are no ground facilities that are able to fully test these systems in a flight-relevant environment. NASA’s state-of-the-art modeling and simulation capability must continually evolve to meet the needs of the next generation of planetary EDL. To accomplish this aim, NASA’s Entry Systems Modeling (ESM) Project was formed in 2013and is funded bythe Space Technology Mission Directorate(STMD) and Science Mission Directorate (SMD). ESM is the Agency’s only cross-cutting effort for advancing entry systems modeling and simulation capabilities across a range of technical disciplines and Solar System destinations. ESM is a portfolio project covering a variety of mid-TRL research efforts within four core EDL-related areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Aerosciences, and (4) Guidance, navigation, and con-trol. The material modeling group creates detailed material response modelsof thermal protection systems (TPS)from the micro to macro scale, and at the fun-damental and engineering levels. Shock layer kinetics and radiation focuses on radiative heating of space-craft, quantum chemistry and benchmark experiments for validation.Aerosciences is a broad research area that impacts many aspects of entry systems, including parachutes, aerodynamics, and turbulent heating augmentation due to TPS roughness.The guidance, navigation,and control effort under ESM is expanding the capabilities of NASA’s main flight mechanics tool, POST2, for use on high-performance computing architectures and to generalize interoperability with external applications for more detailed end-to-end simula-tion.In addition, several focusedresearch topics have been approvedto augment ESM’s core portfolio. These include efforts for deep post-flight analysis of Mars 2020/MEDLI2 flight data; development ofTPS failure models; improvement of hypersonic wakeflow models; and a recently concluded effort to provide material response models for NuSil-coated PICA heat-shield material. This presentation will discuss each of these investment areas and demonstrate via real mission examples how advances to the state-of-the-art enabled by ESM are directly impacting the missions of today and tomorrow, including InSight, Mars 2020, Mars Sample Return, Orion, and Dragonfly.

Entry Systems Modeling↗

Portable Flow Device Using Fourier Ptychography Microscopy and Deep Learning for Detection of Biosignatures

A proof-of-concept, compact, portable Fourier Ptychographic Microscope (FPM) to perform wide field-of-view, high spatial resolution imaging (<1 μm) for biosignature motility in liquid samples, is presented. The FPM has the potential to be developed as a space-based payload for future landers destined to the Ocean Worlds. A portable FPM using an existing Fourier ptychography (FP) algorithm adapted for reconstruction is demonstrated. A NVIDIA Jetson Nano board and camera combined with FP, is used to computationally reconstruct sub-micron resolution images. Additionally, deep learning was employed to perform inferencing prediction which enables the on-edge FPM device.

Fourier↗

Advanced Technologies for Future Spacecraft Cockpits and Space-based Control Centers

The National Aeronautics and Space Administration (NASA) is embarking on a new era of Space Exploration, aimed at sending crewed spacecraft beyond Low Earth Orbit (LEO), in medium and long duration missions to the Lunar surface, Mars and beyond. The challenges of such missions are significant and will require new technologies and paradigms in vehicle design and mission operations. Current roles and responsibilities of spacecraft systems, crew and the flight control team, for example, may not be sustainable when real-time support is not assured due to distance-induced communication lags, radio blackouts, equipment failures, or other unexpected factors. Therefore, technologies and applications that enable greater Systems and Mission Management capabilities on-board the space-based system will be necessary to reduce the dependency on real-time critical Earth-based support. The focus of this paper is in such technologies that will be required to bring advance Systems and Mission Management capabilities to space-based environments where the crew will be required to manage both the systems performance and mission execution without dependence on the ground. We refer to this concept as autonomy. Environments that require high levels of autonomy include the cockpits of future spacecraft such as the Mars Exploration Vehicle, and space-based control centers such as a Lunar Base Command and Control Center. Furthermore, this paper will evaluate the requirements, available technology, and roadmap to enable full operational implementation of onboard System Health Management, Mission Planning/re-planning, Autonomous Task/Command Execution, and Human Computer Interface applications. The technology topics covered by the paper include enabling technology to perform Intelligent Caution and Warning, where the systems provides directly actionable data for human understanding and response to failures, task automation applications that automate nominal and Off-nominal task execution based on human input or integrated health state-derived conditions. Shifting from Systems to Mission Management functions, we discuss the role of automated planning applications (tactical planning) on-board, which receive data from the other cockpit automation systems and evaluate the mission plan against the dynamic systems and mission states and events, to provide the crew with capabilities that enable them to understand, change, and manage the timeline of their mission. Lastly, we discuss the role of advanced human interface technologies that organize and provide the system md mission information to the crew in ways that maximize their situational awareness and ability to provide oversight and control of aLl the automated data and functions.

Garcia-Galan, Carlos↗