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NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗

DOE OSTI2026

Multipoint Aerostructural Optimization of Wind Turbine Rotors Using a Coupled Blade‐Resolved Aerostructural Solver

Physics‐based design optimization workflows thread the needle between computational cost limitations and simulation complexity, often compromising between modeling detail and the range of operating design conditions. Multipoint aerostructural optimization of wind turbine rotors has so far been confined to low‐fidelity analyses or to high‐fidelity studies with simplified structural models, leaving the most complex design trade‐offs unexplored. We close this gap by performing the first tightly coupled gradient‐based multipoint aerostructural rotor optimization using 3D aerodynamic and structural solvers with discrete coupled adjoints. The optimizer simultaneously varies blade planform, airfoil shapes, and structural thickness through more than 270 design variables, minimizing a weighted combination of rotor mass and power across multiple wind speeds. Applied to a modified DTU 10‐MW benchmark under conservative structural and aerodynamic constraints, our multipoint optimization reduces rotor mass by up to 36% and increases power by 12%–15% across the main operating conditions; biasing the objective toward power yields power gains up to 18% and a 17% mass reduction. For a nominal wind distribution, 3‐point rotor designs accounting for low RPM and high thrust conditions capture dominant trade‐offs and outperform single‐point designs. Adding two off‐design points changes individual‐condition power by less than 3% but leaves the weighted average within 0.5%, and the mass‐power bias has a stronger effect on the final design than the operating‐point weighting itself. Our framework extends naturally to richer load cases and site‐specific wind distributions, providing a basis for high‐fidelity multipoint design earlier in industrial workflows.

17 WIND ENERGY↗

NASA NTRS1992

Severe turbulence and maneuvering from airline flight records

Digital flight records from reported clear-air turbulence incidents are used to determine winds, to determine maneuver G loads, and to analyze control problems. Severe turbulence is found downwind of mountains and thunderstorms associated with vortices in atmospheric waves. It is also found in strong updrafts above thunderstorm buildups that are not detected by onboard weather radar. An important finding is that there are large maneuvering loads in over half of the reported clear-air turbulence incidents. Maneuvering loads are determined through an analysis of the short-term variations in elevator deflection and aircraft pitch angle. For altitude control in mountain waves the results indicate that small pitch angle changes with proper timing are sufficient to counter the vertical winds. For airspeed control in strong mountain waves, however, there is neither the available thrust nor the quickness in engine response necessary to counter the large and rapid variations in horizontal wind.

Wingrove, R. C.↗

NASA NTRS2001

Analysis of Measured and Predicted Acoustics From an XV-15 Flight Test

Flight acoustic and vehicle state data from an XV-15 acoustic flight test are examined. Flight predictions using TiltRotor Aeroacoustic Code (TRAC) are performed for a level flight (repeated) and four descent conditions (including a blade vortex interaction (BVI)). The assumptions and procedures used for TRAC flight predictions as well as the variability in flight measurements, which are used for input and comparison to predictions, are investigated in detail. Differences were found in the measured vehicle airspeed, altitude, glideslope, and vehicle orientation (yaw, pitch, and roll angle) between each of the repeat runs. These differences violate some of the prediction assumptions and significantly impacted the resulting acoustic predictions. Multiple acoustic pulses, with a variable time between the pulses, were found in the measured acoustic time histories for the repeat runs. These differences could be attributed in part to the variability in vehicle orientation. Acoustic predictions that used the measured vehicle orientation for the repeat runs captured this multiple pulse variability. Thickness noise was found to be dominant on approach for all the cases, except the BVI condition. After the aircraft passed overhead, broadband noise and low frequency loading noise were dominant. The predicted LowSPL time histories compared well with measurement on approach to the array for the non-BVI conditions and poorly for the BVI condition. Accurate prediction of the lift share between the rotor and fuselage must be known in order to improve predictions. At a minimum, measurements of the rotor thrust and tip-path-plane angle are critical to further develop accurate flight acoustic prediction capabilities.

Boyd, D. Douglas, Jr.↗

NASA NTRS2001

Analysis of Measured and Predicted Acoustics from an XV-15 Flight Test

Flight acoustic and vehicle state data from an XV-15 acoustic flight test are examined. Flight predictions using TRAC are performed for a level flight (repeated) and four descent conditions (including a BVI). The assumptions and procedures used for TRAC flight predictions as well as the variability in flight measurements, which are used for input and comparison to predictions, are investigated in detail. Differences were found in the measured vehicle airspeed, altitude, glideslope, and vehicle orientation (yaw, pitch and roll angle) between each of the repeat runs. These differences violate some of the prediction assumptions and significantly impacted the resulting acoustic predictions. Multiple acoustic pulses, with a variable time between the pulses, were found in the measured acoustic time histories for the repeat runs. These differences could be attributed in part to the variability in vehicle orientation. Acoustic predictions that used the measured vehicle orientation for the repeat runs captured this multiple pulse variability. Thickness noise was found to be dominant on approach for all the cases, except the BVI condition. After the aircraft passed overhead, broadband noise and low frequency loading noise were dominant. The predicted LowSPL time histories compared well with measurement on approach to the array for the non-BVI conditions and poorly for the BVI condition. Accurate prediction of the lift share between the rotor and fuselage must be known in order to improve predictions. At a minimum, measurements of the rotor thrust and tip-path-plane angle are critical to further develop accurate flight acoustic prediction capabilities.

Boyd, D. Douglas, Jr.↗

NASA NTRS1975

Preliminary analysis of the span-distributed-load concept for cargo aircraft design

A simplified computer analysis of the span-distributed-load airplane (in which payload is placed within the wing structure) has shown that the span-distributed-load concept has high potential for application to future air cargo transport design. Significant increases in payload fraction over current wide-bodied freighters are shown for gross weights in excess of 0.5 Gg (1,000,000 lb). A cruise-matching calculation shows that the trend toward higher aspect ratio improves overall efficiency; that is, less thrust and fuel are required. The optimal aspect ratio probably is not determined by structural limitations. Terminal-area constraints and increasing design-payload density, however, tend to limit aspect ratio.

Whitehead, A. H., Jr.↗

NASA NTRS1994

Severe Turbulence and Maneuvering from Airline Flight Records

Digital flight records from reported clear-air turbulence incidents are used to determine winds and turbulence, to determine maneuver g loads, and to analyze control problems. Many cases of severe turbulence are found downwind of mountains and thunderstorms where sharp, sudden jolts are associated with vortices in atmospheric waves. Other cases of severe turbulence are round in strong updrafts above thunderstorm buildups that may be undetected by onboard weather radar. An important finding is that there are large maneuvering loads in over half of the reported clear-air turbulence incidents. Maneuvering loads are determined through an analysis of the short-term variations in elevator deflection and aircraft pitch angle. For altitude control in mountain waves the results indicate that small pitch angle changes with proper timing are sufficient to counter variations in vertical wind. For airspeed control in strong mountain waves, however, there is neither the available thrust nor the quickness in engine response necessary to counter the large variations in winds.

Wingrove, Rodney C.↗

NASA NTRS1990

Numerical simulation of the actuation system for the ALDF's propulsion control valve

A numerical simulation of the actuation system for the propulsion control valve (PCV) of the NASA Langley Aircraft Landing Dynamics Facility was developed during the preliminary design of the PCV and used throughout the entire project. The simulation is based on a predictive model of the PCV which is used to evaluate and design the actuation system. The PCV controls a 1.7 million-pound thrust water jet used in propelling a 108,000-pound test carriage. The PCV can open and close in 0.300 second and deliver over 9,000 gallons of water per sec at pressures up to 3150 psi. The numerical simulation results are used to predict transient performance and valve opening characteristics, specify the hydraulic control system, define transient loadings on components, and evaluate failure modes. The mathematical model used for numerically simulating the mechanical fluid power system is described, and numerical results are demonstrated for a typical opening and closing cycle of the PCV. A summary is then given on how the model is used in the design process.

Korte, John J.↗

NASA NTRS2014

Real-Time Aircraft Engine-Life Monitoring

This project developed an inservice life-monitoring system capable of predicting the remaining component and system life of aircraft engines. The embedded system provides real-time, inflight monitoring of the engine's thrust, exhaust gas temperature, efficiency, and the speed and time of operation. Based upon this data, the life-estimation algorithm calculates the remaining life of the engine components and uses this data to predict the remaining life of the engine. The calculations are based on the statistical life distribution of the engine components and their relationship to load, speed, temperature, and time.

Klein, Richard↗

NASA NTRS1962

Mission Capabilities of Ion Engines. Phase II

Payloads and mission times were calculated for space vehicles propelled by ion rockets using nuclear power supplies having specific weights from 10 t o 50 lb/kw. Included in the study were five missions: low-altitude lunar satellite, low-altitude Venus satellite, solar probe, Saturn probe, and a Jupiter satellite with a circular orbit at the altitude of Jupiter's fourth moon. The variation of payload with the ration of power supply weight to gross weight was studied and the optimum power levels thereby determined. The ion rocket payload capabilities were compared with those of high-thrust vehicles using hydrogen-oxygen rockets and tungsten-core nuclear rockets; in addition the performance of high- and low-thrust systems staged in combination has been investigated. Launch vehicles considered in this study were the Atlas-Centaur, the Saturn C-1, and the Saturn C-5.

IONIC PROPULSION↗

DOE OSTI2022

Large-Eddy Simulation of a wind turbine using a Filtered Actuator Line Model

When dealing with multirotor devices such as quadcopters or wind farms, the cost of blade-resolved large-eddy simulation (LES) becomes prohibitive. Combining LES with a family of lower-fidelity models, called actuator line models (ALMs), has grown in popularity in the past decade. ALM replaces full blade resolution with an array of actuator points or lines parameterized by aerodynamic lift/drag polar plots along the blades. Body forces computed based on these actuator points are then projected onto the LES flow mesh, mimicking the effect of rotating blades on the flow. However, the optimal projection radius and the associated LES grid size is often too restrictive for multirotor simulations. Recently, a new tip-correction-based filtered ALM (F-ALM) was proposed by Martinez-Tossas and Meneveau (2019), which allows coarser-than-optimal grids by avoiding the associated overprediction of thrust. In this work, F-ALM is implemented into a high-order, in-house LES code to simulate National Renewable Energy Laboratory Phase VI wind turbine. It is then followed by a comparison between the baseline ALM and the newly implemented F-ALM in terms of instantaneous and time-averaged flow fields and blade loads, revealing the advantages of F-ALM in preventing the overprediction of power on coarse grids. Finally, this encourages accurate and affordable simulations of multirotor devices in the future.

17 WIND ENERGY↗

NASA NTRS1988

Real-time flight test analysis and display techniques for the X-29A aircraft

The X-29A advanced technology demonstrator flight envelope expansion program and the subsequent flight research phase gave impetus to the development of several innovative real-time analysis and display techniques. These new techniques produced significant improvements in flight test productivity, flight research capabilities, and flight safety. These techniques include real-time measurement and display of in-flight structural loads, dynamic structural mode frequency and damping, flight control system dynamic stability and control response, aeroperformance drag polars, and aircraft specific excess power. Several of these analysis techniques also provided for direct comparisons of flight-measured results with analytical predictions. The aeroperformance technique was made possible by the concurrent development of a new simplified in-flight net thrust computation method. To achieve these levels of on-line flight test analysis, integration of ground and airborne systems was required. The capability of NASA Ames Research Center, Dryden Flight Research Facility's Western Aeronautical Test Range was a key factor in enabling implementation of these methods.

Hicks, John W.↗

NASA NTRS1989

Real-time flight test analysis and display techniques for the X-29A aircraft

Hicks, John W.↗

NASA NTRS1993

Ram acceleration from a two phase detonative system

A concept for ram acceleration is presented here, which uses a combination of a gas core and a layer of solid explosive or propellant to generate high thrust densities. The concept can be either self-synchronized or externally synchronized, and may be reusable. It has the potential to achieve very high acceleration rates, higher exit velocities and to lower the tube length requirements. Preliminary numerical simulations are presented and discussed, which show the characteristics of the flow fields. Stable conditions can be achieved for low mass loadings of solid explosive, and relatively slow combustion. Accurate knowledge of the thermo-chemical properties and the equations of state of the gas and solid components is essential for further tuning of the concept.

Cambier, Jean-Luc↗

NASA NTRS1948

Calculated Condenser Performance for a Mercury-Turbine Power Plant for Aircraft

As part of an investigation af the application of nuclear energy to various types of power plants for aircraft, calculations have been made to determine the effect of several operating conditions on the performance of condensers for mercury-turbine power plants. The analysis covered 8 range of turbine-outlet pressures from 1 to 200 pounds per square inch absolute, turbine-inlet pressures from 300 to 700 pounds per square inch absolute,and a range of condenser cooling-air pressure drops, airplane flight speeds, and altitudes. The maximum load-carrying capacity (available for the nuclear reactor, working fluid, and cargo) of a mercury-turbine powered aircraft would be about half the gross weight of the airplane at a flight speed of 509 miles per hour and an altitude of 30,000 feet. This maximum is obtained with specific condenser frontal areas of 0.0063 square foot per net thrust horsepower with the condenser in a nacelle and 0.0060 square foot per net thrust horsepower with the condenser submerged in the wings (no external condenser drag) for a turbine-inlet pressure of 500 pounds per square inch absolute, a turbine-outlet pressure of 10 pounds per square inch absolute, and 8 turbine-inlet temperature of 1600 F.

Doyle, Ronald B.↗

NASA NTRS2004

A Probabilistic Assessment of NASA Ultra-Efficient Engine Technologies for a Large Subsonic Transport

NASA's Ultra Efficient Engine Technology (UEET) program features advanced aeropropulsion technologies that include highly loaded turbomachinery, an advanced low-NOx combustor, high-temperature materials, intelligent propulsion controls, aspirated seal technology, and an advanced computational fluid dynamics (CFD) design tool to help reduce airplane drag. A probabilistic system assessment is performed to evaluate the impact of these technologies on aircraft fuel burn and NOx reductions. A 300-passenger aircraft, with two 396-kN thrust (85,000-pound) engines is chosen for the study. The results show that a large subsonic aircraft equipped with the UEET technologies has a very high probability of meeting the UEET Program goals for fuel-burn (or equivalent CO2) reduction (15% from the baseline) and LTO (landing and takeoff) NOx reductions (70% relative to the 1996 International Civil Aviation Organization rule). These results are used to provide guidance for developing a robust UEET technology portfolio, and to prioritize the most promising technologies required to achieve UEET program goals for the fuel-burn and NOx reductions.

Tong, Michael T.↗

NASA NTRS2006

Microthruster Propulsion for the Space Technology 7 (ST7) Technology Demonstration Mission

For future applications to precision formation flying missions, NASA's New Millennium Program is scheduled to test colloid micro-Newton thrusters (CMNTs) on the ST7 technology demonstration mission. These CMNTs are part of a disturbance reduction system (DRS) on the ESA SMART-2 Spacecraft or LISA Pathfinder. The goal of the ST7 DRS is to demonstrate technologies necessary to meet the nanometer precision positioning control requirements of the LISA mission. In order to achieve these goals, the CMNTs are required to demonstrate a thrust resolution of less than 0.1 micro-N and a thrust noise of less than 0.1 micro-N/[square root]Hz for thrust levels between 5 and 30 micro-N. Developed by Busek Co. with support from JPL in testing an design, the CMNT has been developed over the last four years into a flight-ready microthrust system. The development, validation testing, and flight unit production of the CMNTs are described. Development tests and analysis include preliminary wear tests, propellant loading process verification, flow testing, and performance verification. Validation and flight unit verification includes thermal and structural analysis, life testing, thermal and dynamic load testing, and performance verification. Final delivery of the units is planned in 2007 with and planned launch and flight demonstration 2009.

microthruster↗

NASA NTRS2011

Space Shuttle Main Engine - The Relentless Pursuit of Improvement

The Space Shuttle Main Engine (SSME) is the only reusable large liquid rocket engine ever developed. The specific impulse delivered by the staged combustion cycle, substantially higher than previous rocket engines, minimized volume and weight for the integrated vehicle. The dual pre-burner configuration permitted precise mixture ratio and thrust control while the fully redundant controller and avionics provided a very high degree of system reliability and health diagnosis. The main engine controller design was the first rocket engine application to incorporate digital processing. The engine was required to operate at a high chamber pressure to minimize engine volume and weight. Power level throttling was required to minimize structural loads on the vehicle early in flight and acceleration levels on the crew late in ascent. Fatigue capability, strength, ease of assembly and disassembly, inspectability, and materials compatibility were all major considerations in achieving a fully reusable design. During the multi-decade program the design evolved substantially using a series of block upgrades. A number of materials and manufacturing challenges were encountered throughout SSME s history. Significant development was required for the final configuration of the high pressure turbopumps. Fracture control was implemented to assess life limits of critical materials and components. Survival in the hydrogen environment required assessment of hydrogen embrittlement. Instrumentation systems were a challenge due to the harsh thermal and dynamic environments within the engine. Extensive inspection procedures were developed to assess the engine components between flights. The Space Shuttle Main Engine achieved a remarkable flight performance record. All flights were successful with only one mission requiring an ascent abort condition, which still resulted in an acceptable orbit and mission. This was achieved in large part via extensive ground testing to fully characterize performance and to establish acceptable life limits. During the program over a million seconds of accumulated test and flight time was achieved. Post flight inspection and assessment was a key part of assuring proper performance of the flight hardware. By the end of the program the predicted reliability had improved by a factor of four. These unique challenges, evolution of the design, and the resulting reliability will be discussed in this paper.

VanHooser, Katherine P.↗