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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metal Additive Manufacturing for Spaceflight

Metal additive manufacturing (AM) is changing how complex aerospace parts are being designed and manufactured for rocket engines and launch vehicles. NASA has been leading AM efforts since the late 2000’s to mature specialty alloys for AM, advance AM processes, develop standards and infuse AM into rocket engines and the commercial supply chain. There are many types of AM processes and alloys in-use and this presentation will provide an overview of how NASA is applying these for rocket engines and the potential opportunities for AM in the future.

Additive Manufacturing↗
NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗
NASA NTRS1975

Developing the plan

The basic sequence in the planning development process is discussed. Alternative ways of satisfying estimated needs, and the selection of an alternative are described along with the development of a plan to implement the selected alternative.

Source record↗
NASA NTRS1987

Application of Powdered Resin for Foam Insulation

Process developed to apply necessary insulation to valves, fittings, lines, etc. on such space vehicles as Centaur rocket stage. In new process, electrostatic equipment used to apply powdered polyimide resin directly to part to be insulated.

Morris, Glenn R.↗
NASA NTRS2006

Zero to Integration in Eight Months, the Dawn Ground Data System Engineering Challange

The Dawn Project has presented the Ground Data System (GDS) with technical challenges driven by cost and schedule constraints commonly associated with National Aeronautics and Space Administration (NASA) Discovery Projects. The Dawn mission consists of a new and exciting Deep Space partnership among: the Jet Propulsion Laboratory (JPL), responsible for project management and flight operations; Orbital Sciences Corporation (OSC), spacecraft builder and responsible for flight system test and integration; and the University of California, at Los Angeles (UCLA), responsible for science planning and operations. As a cost-capped mission, one of Dawn s implementation strategies is to leverage from both flight and ground heritage. OSC's ground data system is used for flight system test and integration as part of the flight heritage strategy. Mission operations, however, are to be conducted with JPL s ground system. The system engineering challenge of dealing with two heterogeneous ground systems emerged immediately. During the first technical interchange meeting between the JPL s GDS Team and OSC's Flight Software Team, August 2003, the need to integrate the ground system with the flight software was brought to the table. This need was driven by the project s commitment to enable instrument engineering model integration in a spacecraft simulator environment, for both demonstration and risk mitigation purposes, by April 2004. This paper will describe the system engineering approach that was undertaken by JPL's GDS Team in order to meet the technical challenge within a non-negotiable eight-month schedule. Key to the success was adherence to an overall systems engineering process and fundamental systems engineering practices: decomposition of the project request into manageable requirements; definition of a structured yet flexible development process; integration of multiple ground disciplines and experts into a focused team effort; in-process risk management; and aggregation of the intermediate products to an integrated final product. In addition, this paper will highlight the role of lessons learned from the integration experience. The lessons learned from an early GDS deployment have served as the foundation for the design and implementation of the Dawn Ground Data System.

systems engineering↗
NASA NTRSDate not supplied

Development of Buffet Forcing Functions Using Frequency-Dependent Coherence Factors

The current accepted approach to modeling launch vehicle transonic buffet environments is to acquire time-correlated unsteady pressure measurements at discrete locations on a model-scale wind-tunnel model and use these measurements to develop buffet forcing functions (BFFs).Part of the BFF development process is the application of coherence factors to account for the discrete nature of the pressure measurement used in the development of the BFFs. Presently, the Space Launch System (SLS) program divides the launch vehicle into distinct aerodynamic regions, within which, the coherence lengths are assumed to be constant. The coherence factors are computed by averaging the coherence function between sensors within the region over a specified frequency range. The present work validates and examines the impact of two proposed changes to the development of longitudinal coherence factors used in the development of launch vehicle BFFs. One change is to employ frequency-dependent coherence factors instead of coherence factors based on the mean of the coherence function. The second proposed change replaces the aerodynamic regions with a moving-segment approach that varies the calculated coherence lengths as a function of longitudinal location of the transducers. The impact of these approaches is examined using data from two rigid buffet model wind-tunnel tests: (1)a notional launch vehicle geometry through the comparison of discrete measurement-basedBFFs to loads developed by continuous integration of unsteady pressure sensitive paint data and (2) the SLS Block 1 Cargo vehicle configuration for which BFFs have been previously developed using less-mature methods. The trends from this examination of updated coherence factor approaches ultimately result in more intuitive results than currently-accepted coherence methods.

buffet, unsteady aerodynamics, launch vehicle, win↗
NASA NTRSDate not supplied

Development of Buffet Forcing Functions Using Frequency-Dependent Coherence Factors

The current accepted approach to modeling launch vehicle transonic buffet environments is to acquire time-correlated unsteady pressure measurements at discrete locations on a model-scale wind-tunnel model and use these measurements to develop buffet forcing functions (BFFs). Part of the BFF development process is the application of coherence factors to account for the discrete nature of the pressure measurement used in the development of the BFFs. Presently, the Space Launch System (SLS) program divides the launch vehicle into distinct aerodynamic regions, within which, the coherence lengths are assumed to be constant. The coherence factors are computed by averaging the coherence function between sensors within the region over a specified frequency range. The present work validates and examines the impact of two proposed changes to the development of longitudinal coherence factors used in the development of launch vehicle BFFs. One change is to employ frequency-dependent coherence factors instead of coherence factors based on the mean of the coherence function. The second proposed change replaces the aerodynamic regions with a moving-segment approach that varies the calculated coherence lengths as a function of longitudinal location of the transducers. The impact of these approaches is examined using data from two rigid buffet model wind-tunnel tests: (1) a notional launch vehicle geometry through the comparison of discrete measurement-based BFFs to loads developed by continuous integration of unsteady pressure sensitive paint data and (2) the SLS Block 1 Cargo vehicle configuration for which BFFs have been previously developed using less-mature methods. The trends from this examination of updated coherence factor approaches ultimately result in more intuitive results than currently-accepted coherence methods.

buffet↗
NASA NTRS1977

The multiple nesting of mesoscale, submesoscale, and nonhydrostatic microscale numerical models for a case of mesocyclogenesis and severe storm development

A fundamental approach involving the integration of two different numerical models over several different spatial mesh lengths is considered. Model I is a hydrostatic, incompressible, and adiabatic primitive (Newtonian) equation set with no boundary layer forcing, i.e., surface heat or moisture flux or external frictional stresses. Typically this model is initialized from conventional radiosonde data and run for a 12-15 hour forecast period over a 40 km horizontal mesh. If phase I of the tornado developmental processes develops, the data is 'frozen' in space and time, interpolated to a 20 km mesh, and integrated for a shorter time period (3 hours) with a shorter time step. Model II is a nonhydrostatic compressible 18-level complement of model I. If model II indicates the development of the intensification of phase V dynamical processes, the data is frozen and interpolated to finer mesh lengths until the tornadic circulation system is approximated

Kaplan, M. L.↗
NASA NTRS1994

Automated inspection of turbine blades: Challenges and opportunities

Current inspection methods for complex shapes and contours exemplified by aircraft engine turbine blades are expensive, time-consuming and labor intensive. The logistics support of new manufacturing paradigms such as integrated product-process development (IPPD) for current and future engine technology development necessitates high speed, automated inspection of forged and cast jet engine blades, combined with a capability of retaining and retrieving metrology data for process improvements upstream (designer-level) and downstream (end-user facilities) at commercial and military installations. The paper presents the opportunities emerging from a feasibility study conducted using 3-D holographic laser radar in blade inspection. Requisite developments in computing technologies for systems integration of blade inspection in production are also discussed.

Mehta, Manish↗
NASA NTRS1973

An investigation of the Sutcliffe development theory

Two case studies were used to test the Sutcliffe-Peterssen development theory for both cyclonic and anticyclonic development over the eastern United States. Each term was examined to determine when and where it made a significant contribution to the development process. Results indicate the advection of vorticity at the level of non-divergence exerts the dominant influence for initial cyclone development, and that the thermal terms (advection of thickness, stability, and diabatic influence) become important after development has begun. Anticyclonic development, however, depends primarily on the stability term throughout the life cycle of the anticyclone. Simple procedures for forecasting the development and movement of cyclones and anticyclones are listed. These rules indicate that routine National Meteorological Center analyses may be used to locate areas where the positive advection of 500-mb vorticity, indicative of cyclonic development, coincides with regions of severe weather activity. The development of anticyclones also is predicted easily. Regions of increasing stability, indicating anticyclonic development, may be located by use of National Meteorological Center radar summaries and analyses for 1000-500-mb thickness. A test of these techniques found them to be satisfactory for the case examined.

Dushan, J. D.↗
NASA NTRS1980

Anti-reflection coatings applied by acid leaching process

The Magicote C process developed by S.M. Thompsen was evaluated for use in applying an antireflective coating to the cover plates of solar panels. The process uses a fluosilicic acid solution supersaturated with silica at elevated temperature to selectively attack the surface of soda-lime glass cover plates and alter the physical and chemical composition of a thin layer of glass. The altered glass layer constitutes an antireflective coating. The process produces coatings of excellent optical quality which possess outstanding resistance to soiling and staining. The coatings produced are not resistant to mechanical abrasion and are attacked to some extent by glass cleansers. Control of the filming process was found to be difficult.

Pastirik, E.↗
NASA NTRS1984

NASA guidelines for assuring the adequacy and appropriateness of security safeguards in sensitive applications

The Office of Management and Budget (OMB) Circular A-71, transmittal Memorandum No. 1, requires that each agency establish a management control process to assure that appropriate administrative, physical and technical safeguards are incorporated into all new computer applications. In addition to security specifications, the management control process should assure that the safeguards are adequate for the application. The security activities that should be integral to the system development process are examined. The software quality assurance process to assure that adequate and appropriate controls are incorporated into sensitive applications is also examined. Security for software packages is also discussed.

Tompkins, F. G.↗
NASA NTRS1987

Fluidized-Bed Cleaning of Silicon Particles

Fluidized-bed chemical cleaning process developed to remove metallic impurities from small silicon particles. Particles (250 micrometer in size) utilized as seed material in silane pyrolysis process for production of 1-mm-size silicon. Product silicon (1 mm in size) used as raw material for fabrication of solar cells and other semiconductor devices. Principal cleaning step is wash in mixture of hydrochloric and nitric acids, leaching out metals and carrying them away as soluble chlorides. Particles fluidized by cleaning solution to assure good mixing and uniform wetting.

Rohatgi, Naresh K.↗
NASA NTRS1994

Developing and flight testing the HL-10 lifting body: A precursor to the Space Shuttle

The origins of the lifting-body idea are traced back to the mid-1950's, when the concept of a manned satellite reentering the Earth's atmosphere in the form of a wingless lifting body was first proposed. The advantages of low reentry deceleration loads, range capability, and horizontal landing of a lifting reentry vehicle (as compared with the high deceleration loads and parachute landing of a capsule) are presented. The evolution of the hypersonic HL-10 lifting body is reviewed from the theoretical design and development process to its selection as one of two low-speed flight vehicles for fabrication and piloted flight testing. The design, development, and flight testing of the low-speed, air-launched, rocket-powered HL-10 was part of an unprecedented NASA and contractor effort. NASA Langley Research Center conceived and developed the vehicle shape and conducted numerous theoretical, experimental, and wind-tunnel studies. NASA Flight Research Center (now NASA Dryden Flight Research Center) was responsible for final low-speed (Mach numbers less than 2.0) aerodynamic analysis, piloted simulation, control law development, and flight tests. The prime contractor, Northrop Corp., was responsible for hardware design, fabrication, and integration. Interesting and unusual events in the flight testing are presented with a review of significant problems encountered in the first flight and how they were solved. Impressions by the pilots who flew the HL-10 are included. The HL-10 completed a successful 37-flight program, achieved the highest Mach number and altitude of this class vehicle, and contributed to the technology base used to develop the space shuttle and future generations of lifting bodies.

Kempel, Robert W.↗
NASA NTRS1993

The maturing of the quality improvement paradigm in the SEL

The Software Engineering Laboratory uses a paradigm for improving the software process and product, called the quality improvement paradigm. This paradigm has evolved over the past 18 years, along with our software development processes and product. Since 1976, when we first began the SEL, we have learned a great deal about improving the software process and product, making a great many mistakes along the way. Quality improvement paradigm, as it is currently defined, can be broken up into six steps: characterize the current project and its environment with respect to the appropriate models and metrics; set the quantifiable goals for successful project performance and improvement; choose the appropriate process model and supporting methods and tools for this project; execute the processes, construct the products, and collect, validate, and analyze the data to provide real-time feedback for corrective action; analyze the data to evaluate the current practices, determine problems, record findings, and make recommendations for future project improvements; and package the experience gained in the form of updated and refined models and other forms of structured knowledge gained from this and prior projects and save it in an experience base to be reused on future projects.

Basili, Victor R.↗
NASA NTRS2003

Liner-less Tanks for Space Application - Design and Manufacturing Considerations

Composite pressure vessels, used extensively for gas and fuel containment in space vehicles, are generally constructed with a metallic liner, while the fiber reinforcement carries the major portion of the pressure-induced load. The design is dominated by the liner s low strain at yield since the reinforcing fibers cannot operate at their potential load-bearing capability without resorting to pre-stressing (or autofrettaging). An ultra high-efficiency pressure vessel, which operates at the optimum strain capability of the fibers, can be potentially achieved with a liner-less construction. This paper discusses the design and manufacturing challenges to be overcome in the development of such a pressure vessel. These include: (1) gas/liquid containment and permeation, (2) design and structural analysis, and (3) manufacturing process development. The paper also presents the development and validation tests on a liner-less pressure vessel developed by Kaiser Compositek Inc. (KCI). It should be noted that KCI s liner-less tank exhibits a highly controlled leak-before-burst mode. This feature results in a structure having the highest level of safety.

Jones, Brian H.↗
NASA NTRS2005

Reliability Improvements in Liquid Rocket Engine Instrumentation

Instrumentation hardware is often the weak link in advanced liquid fueled propulsion systems. The development of the Space Shuttle Main Engine (SSME) was no exception. By sheer necessity, a reusable, high energy, low weight engine system often relegates the instrumentation hardware to the backseat in the critical hardware development process. This produces less than optimum hardware constraints; including size, location, mounting, redundancy, and signal conditioning. This can negatively affect the development effort and ultimately the system reliability. The challenge was clear, however, the outcome was less certain. Unfortunately, the SSME hardware development culminated in series of measurement failures, most significant of which was the premature engine shutdown during the launch of STS-51F on July 29, 1985. The Return to Flight activities following the Challenger disaster redoubled our efforts to eliminate, once and for all, sensor malfunctions as the determining factor in overall engine reliability. This paper describes each phase of this effort in detail and includes discussion of the tasks related to improving measurement reliability.

Hill, A.↗
NASA NTRS2010

Materials Development: Pitfalls, Successes, and Lessons

The incorporation of new or improved materials in aerospace systems, or indeed any systems, can yield tremendous payoffs in the system performance or cost, and in many cases can be enabling for a mission or concept. However, the availability of new materials requires advance development, and too often this is neglected or postponed, leaving a project or mission with little choice. In too many cases, the immediate reaction is to use what was used before; this usually turns out not to be possible and results in large sums of money, and amounts of time, being expended on reinvention rather than development of a material with extended capabilities. Material innovation and development is time consuming, with some common wisdom claiming that the timeline is at least 20 years. This time expands considerably when development is stopped and restarted, or knowledge is lost. Down selection of materials is necessary, especially as the Technical Readiness Level (TRL) increases. However, the costs must be considered and approaches should be taken to retain knowledge and allow for restarting the development process. Regardless of the exact time required, it is clear that it is necessary to have materials, at all stages of development, in a research and development pipeline and available for maturation as required. This talk will discuss some of theses issues, including some of the elements for a development path for materials. Some history of materials developments will be included. The usefulness of computational materials science, as a route to decreasing material development time, will be an important element of this discussion. Collaboration with outside institutions and nations is also critical for innovation, but raises the issues of intellectual property and protections, and national security (ITAR rules, for example).

Johnson, Sylvia M.↗