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NASA NTRS2013

Swept-Wing Ice Accretion Characterization and Aerodynamics

NASA, FAA, ONERA, the University of Illinois and Boeing have embarked on a significant, collaborative research effort to address the technical challenges associated with icing on large-scale, three-dimensional swept wings. The overall goal is to improve the fidelity of experimental and computational simulation methods for swept-wing ice accretion formation and resulting aerodynamic effect. A seven-phase research effort has been designed that incorporates ice-accretion and aerodynamic experiments and computational simulations. As the baseline, full-scale, swept-wing-reference geometry, this research will utilize the 65% scale Common Research Model configuration. Ice-accretion testing will be conducted in the NASA Icing Research Tunnel for three hybrid swept-wing models representing the 20%, 64% and 83% semispan stations of the baseline-reference wing. Three-dimensional measurement techniques are being developed and validated to document the experimental ice-accretion geometries. Artificial ice shapes of varying geometric fidelity will be developed for aerodynamic testing over a large Reynolds number range in the ONERA F1 pressurized wind tunnel and in a smaller-scale atmospheric wind tunnel. Concurrent research will be conducted to explore and further develop the use of computational simulation tools for ice accretion and aerodynamics on swept wings. The combined results of this research effort will result in an improved understanding of the ice formation and aerodynamic effects on swept wings. The purpose of this paper is to describe this research effort in more detail and report on the current results and status to date. 1

Broeren, Andy P.↗

NASA NTRS2013

Swept-Wing Ice Accretion Characterization and Aerodynamics

NASA, FAA, ONERA, the University of Illinois and Boeing have embarked on a significant, collaborative research effort to address the technical challenges associated with icing on large-scale, three-dimensional swept wings. The overall goal is to improve the fidelity of experimental and computational simulation methods for swept-wing ice accretion formation and resulting aerodynamic effect. A seven-phase research effort has been designed that incorporates ice-accretion and aerodynamic experiments and computational simulations. As the baseline, full-scale, swept-wing-reference geometry, this research will utilize the 65 percent scale Common Research Model configuration. Ice-accretion testing will be conducted in the NASA Icing Research Tunnel for three hybrid swept-wing models representing the 20, 64 and 83 percent semispan stations of the baseline-reference wing. Threedimensional measurement techniques are being developed and validated to document the experimental ice-accretion geometries. Artificial ice shapes of varying geometric fidelity will be developed for aerodynamic testing over a large Reynolds number range in the ONERA F1 pressurized wind tunnel and in a smaller-scale atmospheric wind tunnel. Concurrent research will be conducted to explore and further develop the use of computational simulation tools for ice accretion and aerodynamics on swept wings. The combined results of this research effort will result in an improved understanding of the ice formation and aerodynamic effects on swept wings. The purpose of this paper is to describe this research effort in more detail and report on the current results and status to date.

Broeren, Andy P.↗

NASA NTRS2013

Preliminary MIPCC Enhanced F-4 and F-15 Performance Characteristics for a First Stage Reusable Launch Vehicle

Performance increases in turbojet engines can theoretically be achieved through Mass Injection Pre-Compressor Cooling (MIPCC), a process involving injecting water or oxidizer or both into an afterburning turbojet engine. The injection of water results in pre-compressor cooling, allowing the propulsion system to operate at high altitudes and Mach numbers. In this way, a MIPCC-enhanced turbojet engine could be used to power the first stage of a reusable launch vehicle or be integrated into an existing aircraft that could launch a 100-lbm payload to a reference 100-nm altitude orbit at 28 deg inclination. The two possible candidates for MIPCC flight demonstration that are evaluated in this study are the F-4 Phantom II airplane and the F-15 Eagle airplane (both of McDonnell Douglas, now The Boeing Company, Chicago, Illinois), powered by two General Electric Company (Fairfield, Connecticut) J79 engines and two Pratt & Whitney (East Hartford, Connecticut) F100-PW-100 engines, respectively. This paper presents a conceptual discussion of the theoretical performance of each of these aircraft using MIPCC propulsion techniques. Trajectory studies were completed with the Optimal Trajectories by Implicit Simulation (OTIS) software (NASA Glenn Research Center, Cleveland, Ohio) for a standard F-4 airplane and a standard F-15 airplane. Standard aircraft simulation models were constructed, and the thrust in each was altered in accordance with estimated MIPCC performance characteristics. The MIPCC and production aircraft model results were then reviewed to assess the feasibility of a MIPCC-enhanced propulsion system for use as a first-stage reusable launch vehicle; it was determined that the MIPCC-enhanced F-15 model showed a significant performance advantage over the MIPCC-enhanced F-4 model.

MIPCC Reusable Launch Vehicle↗

NASA NTRS2014

Computational Aerodynamic Analysis of Three-Dimensional Ice Shapes on a NACA 23012 Airfoil

The present study identifies a process for performing computational fluid dynamic calculations of the flow over full three-dimensional (3D) representations of complex ice shapes deposited on aircraft surfaces. Rime and glaze icing geometries formed on a NACA23012 airfoil were obtained during testing in the NASA Glenn Research Center's Icing Research Tunnel (IRT). The ice shape geometries were scanned as a cloud of data points using a 3D laser scanner. The data point clouds were meshed using Geomagic software to create highly accurate models of the ice surface. The surface data was imported into Pointwise grid generation software to create the CFD surface and volume grids. It was determined that generating grids in Pointwise for complex 3D icing geometries was possible using various techniques that depended on the ice shape. Computations of the flow fields over these ice shapes were performed using the NASA National Combustion Code (NCC). Results for a rime ice shape for angle of attack conditions ranging from 0 to 10 degrees and for freestream Mach numbers of 0.10 and 0.18 are presented. For validation of the computational results, comparisons were made to test results from rapid-prototype models of the selected ice accretion shapes, obtained from a separate study in a subsonic wind tunnel at the University of Illinois at Urbana-Champaign. The computational and experimental results were compared for values of pressure coefficient and lift. Initial results show fairly good agreement for rime ice accretion simulations across the range of conditions examined. The glaze ice results are promising but require some further examination.

Aerodynamics↗

NASA NTRS2014

Computational Aerodynamic Analysis of Three-Dimensional Ice Shapes on a NACA 23012 Airfoil

The present study identifies a process for performing computational fluid dynamic calculations of the flow over full three-dimensional (3D) representations of complex ice shapes deposited on aircraft surfaces. Rime and glaze icing geometries formed on a NACA23012 airfoil were obtained during testing in the NASA Glenn Research Centers Icing Research Tunnel (IRT). The ice shape geometries were scanned as a cloud of data points using a 3D laser scanner. The data point clouds were meshed using Geomagic software to create highly accurate models of the ice surface. The surface data was imported into Pointwise grid generation software to create the CFD surface and volume grids. It was determined that generating grids in Pointwise for complex 3D icing geometries was possible using various techniques that depended on the ice shape. Computations of the flow fields over these ice shapes were performed using the NASA National Combustion Code (NCC). Results for a rime ice shape for angle of attack conditions ranging from 0 to 10 degrees and for freestream Mach numbers of 0.10 and 0.18 are presented. For validation of the computational results, comparisons were made to test results from rapid-prototype models of the selected ice accretion shapes, obtained from a separate study in a subsonic wind tunnel at the University of Illinois at Urbana-Champaign. The computational and experimental results were compared for values of pressure coefficient and lift. Initial results show fairly good agreement for rime ice accretion simulations across the range of conditions examined. The glaze ice results are promising but require some further examination.

Aerodynamics↗

NASA NTRS2014

Validation of 3-D Ice Accretion Measurement Methodology for Experimental Aerodynamic Simulation

Determining the adverse aerodynamic effects due to ice accretion often relies on dry-air wind-tunnel testing of artificial, or simulated, ice shapes. Recent developments in ice accretion documentation methods have yielded a laser-scanning capability that can measure highly three-dimensional features of ice accreted in icing wind tunnels. The objective of this paper was to evaluate the aerodynamic accuracy of ice-accretion simulations generated from laser-scan data. Ice-accretion tests were conducted in the NASA Icing Research Tunnel using an 18-inch chord, 2-D straight wing with NACA 23012 airfoil section. For six ice accretion cases, a 3-D laser scan was performed to document the ice geometry prior to the molding process. Aerodynamic performance testing was conducted at the University of Illinois low-speed wind tunnel at a Reynolds number of 1.8 x 10(exp 6) and a Mach number of 0.18 with an 18-inch chord NACA 23012 airfoil model that was designed to accommodate the artificial ice shapes. The ice-accretion molds were used to fabricate one set of artificial ice shapes from polyurethane castings. The laser-scan data were used to fabricate another set of artificial ice shapes using rapid prototype manufacturing such as stereolithography. The iced-airfoil results with both sets of artificial ice shapes were compared to evaluate the aerodynamic simulation accuracy of the laser-scan data. For four of the six ice-accretion cases, there was excellent agreement in the iced-airfoil aerodynamic performance between the casting and laser-scan based simulations. For example, typical differences in iced-airfoil maximum lift coefficient were less than 3% with corresponding differences in stall angle of approximately one degree or less. The aerodynamic simulation accuracy reported in this paper has demonstrated the combined accuracy of the laser-scan and rapid-prototype manufacturing approach to simulating ice accretion for a NACA 23012 airfoil. For several of the ice-accretion cases tested, the aerodynamics is known to depend upon the small, three dimensional features of the ice. These data show that the laser-scan and rapid-prototype manufacturing approach is capable of replicating these ice features within the reported accuracies of the laser-scan measurement and rapid-prototyping method; thus providing a new capability for high-fidelity ice-accretion documentation and artificial ice-shape fabrication for icing research.

Scale Models↗

NASA NTRS2012

Core-Noise Research

This presentation is a technical summary of and outlook for NASA-internal and NASA-sponsored external research on core noise funded by the Fundamental Aeronautics Program Subsonic Fixed Wing (SFW) Project. Sections of the presentation cover: the SFW system-level noise metrics for the 2015 (N+1), 2020 (N+2), and 2025 (N+3) timeframes; SFW strategic thrusts and technical challenges; SFW advanced subsystems that are broadly applicable to N+3 vehicle concepts, with an indication where further noise research is needed; the components of core noise (compressor, combustor and turbine noise) and a rationale for NASAʼs current emphasis on the combustor-noise component; the increase in the relative importance of core noise due to turbofan design trends; the need to understand and mitigate core-noise sources for high-efficiency small gas generators; and the current research activities in the core-noise area, with additional details given about forthcoming updates to NASAʼs Aircraft Noise Prediction Program (ANOPP) core-noise prediction capabilities, two NRA efforts (Honeywell International, Phoenix, AZ and University of Illinois at Urbana-Champaign, respectively) to improve the understanding of core-noise sources and noise propagation through the engine core, and an effort to develop oxide/oxide ceramic-matrix-composite (CMC) liners for broadband noise attenuation suitable for turbofan-core application. Core noise must be addressed to ensure that the N+3 noise goals are met. Focused, but long-term, core-noise research is carried out to enable the advanced high-efficiency small gas-generator subsystem, common to several N+3 conceptual designs, needed to meet NASAʼs technical challenges. Intermediate updates to prediction tools are implemented as the understanding of the source structure and engine-internal propagation effects is improved. The NASA Fundamental Aeronautics Program has the principal objective of overcoming today's national challenges in air transportation. The SFW Quiet-Aircraft Subproject aims to develop concepts and technologies to reduce perceived community noise attributable to aircraft with minimal impact on weight and performance. This reduction of aircraft noise is critical to enabling the anticipated large increase in future air traffic.

Hultgren, Lennart S.↗

NASA NTRS2015

Validation of 3-D Ice Accretion Measurement Methodology for Experimental Aerodynamic Simulation

Determining the adverse aerodynamic effects due to ice accretion often relies on dry-air wind-tunnel testing of artificial, or simulated, ice shapes. Recent developments in ice-accretion documentation methods have yielded a laser-scanning capability that can measure highly three-dimensional (3-D) features of ice accreted in icing wind tunnels. The objective of this paper was to evaluate the aerodynamic accuracy of ice-accretion simulations generated from laser-scan data. Ice-accretion tests were conducted in the NASA Icing Research Tunnel using an 18-in. chord, two-dimensional (2-D) straight wing with NACA 23012 airfoil section. For six ice-accretion cases, a 3-D laser scan was performed to document the ice geometry prior to the molding process. Aerodynamic performance testing was conducted at the University of Illinois low-speed wind tunnel at a Reynolds number of 1.8 × 10(exp 6) and a Mach number of 0.18 with an 18-in. chord NACA 23012 airfoil model that was designed to accommodate the artificial ice shapes. The ice-accretion molds were used to fabricate one set of artificial ice shapes from polyurethane castings. The laser-scan data were used to fabricate another set of artificial ice shapes using rapid prototype manufacturing such as stereolithography. The iced-airfoil results with both sets of artificial ice shapes were compared to evaluate the aerodynamic simulation accuracy of the laser-scan data. For five of the six ice-accretion cases, there was excellent agreement in the iced-airfoil aerodynamic performance between the casting and laser-scan based simulations. For example, typical differences in iced-airfoil maximum lift coefficient were less than 3 percent with corresponding differences in stall angle of approximately 1 deg or less. The aerodynamic simulation accuracy reported in this paper has demonstrated the combined accuracy of the laser-scan and rapid-prototype manufacturing approach to simulating ice accretion for a NACA 23012 airfoil. For several of the ice-accretion cases tested, the aerodynamics is known to depend upon the small, three-dimensional features of the ice. These data show that the laser-scan and rapid-prototype manufacturing approach is capable of replicating these ice features within the reported accuracies of the laser-scan measurement and rapid-prototyping method; thus providing a new capability for high-fidelity ice-accretion documentation and artificial ice-shape fabrication for icing research.

Aircraft Icing↗

NASA NTRS1961

A General Computer Program for Ionospheric Ray-Tracing

The study of the ionosphere using the Faraday rotation effect has been undertaken recently by means of rocket, satellite, and moon echo experiments. Different approximations have been used by different authors, resulting in methods with different degrees of complexity, and it is possible to say that the more accurate a method is, the more difficult its application becomes. However, the use of modern high-speed digital computers offers the possibility of using more complex methods in the solution of this problem, The program described in this report was written for the ILLIAC, the digital computer of the University of Illinois. Only the general features common to most digital computers will be mentioned. This program was prepared having in mind the analysis of the Faraday rotation effect, as recorded from artificial satellites. It is intended to be as general as possible in the conditions imposed on the assumed propagating medium: specifically there are no restrictions on the models of the electron density distribution and the earth's magnetic fields. long as the ray theory Ls valid. The program will trace separately the ordinary and the extraordinary mode, and it will find the virtual phase path length of a ray of each mode between the transmitter (satellite) and a receiver (station). The difference between respective phase path-lengths is related to the Faraday rotation through a constant which depends on the frequency.

Gonzales, Victor H.↗

NASA NTRS2015

Airborne Simulation of Launch Vehicle Dynamics

In this paper we present a technique for approximating the short-period dynamics of an exploration-class launch vehicle during flight test with a high-performance surrogate aircraft in relatively benign endoatmospheric flight conditions. The surrogate vehicle relies upon a nonlinear dynamic inversion scheme with proportional-integral feedback to drive a subset of the aircraft states into coincidence with the states of a time-varying reference model that simulates the unstable rigid body dynamics, servodynamics, and parasitic elastic and sloshing dynamics of the launch vehicle. The surrogate aircraft flies a constant pitch rate trajectory to approximate the boost phase gravity turn ascent, and the aircraft's closed-loop bandwidth is sufficient to simulate the launch vehicle's fundamental lateral bending and sloshing modes by exciting the rigid body dynamics of the aircraft. A novel control allocation scheme is employed to utilize the aircraft's relatively fast control effectors in inducing various failure modes for the purposes of evaluating control system performance. Sufficient dynamic similarity is achieved such that the control system under evaluation is configured for the full-scale vehicle with no changes to its parameters, and pilot-control system interaction studies can be performed to characterize the effects of guidance takeover during boost. High-fidelity simulation and flight-test results are presented that demonstrate the efficacy of the design in simulating the Space Launch System (SLS) launch vehicle dynamics using the National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center Fullscale Advanced Systems Testbed (FAST), a modified F/A-18 airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois), over a range of scenarios designed to stress the SLS's Adaptive Augmenting Control (AAC) algorithm.

airborne simulation↗

NASA NTRS2015

Flight Tests of a Supersonic Natural Laminar Flow Airfoil

A flight-test campaign of a supersonic natural laminar flow airfoil has been recently completed. The test surface was an 80-inch (203 cm) chord and 40-inch (102 cm) span article mounted on the centerline store location of an F-15B airplane (McDonnell Douglas Corporation, now The Boeing Company, Chicago, Illinois). The test article was designed with a leading edge sweep of effectively 0 deg to minimize boundary layer crossflow. The test article surface was coated with an insulating material to avoid significant heat transfer to and from the test article structure to maintain a quasi-adiabatic wall. An aircraft-mounted infrared camera system was used to determine boundary layer transition and the extent of laminar flow. The tests were flown up to Mach 2.0 and chord Reynolds numbers in excess of 30 million. The objectives of the tests were to determine the extent of laminar flow at high Reynolds numbers and to determine the sensitivity of the flow to disturbances. Both discrete (trip dots) and 2-D disturbances (forward-facing steps) were tested. A series of oblique shocks, of yet unknown origin, appeared on the surface, which generated sufficient crossflow to affect transition. Despite the unwanted crossflow, the airfoil performed well. The results indicate the sensitivity of the flow to the disturbances, which can translate into manufacturing tolerances, were similar to that of subsonic natural laminar flow wings.

supersonic boundary layer↗

NASA NTRS2016

Ice Accretions and Full-Scale Iced Aerodynamic Performance Data for a Two-Dimensional NACA 23012 Airfoil

This report documents the data collected during the large wind tunnel campaigns conducted as part of the SUNSET project (StUdies oN Scaling EffecTs due to ice) also known as the Ice-Accretion Aerodynamics Simulation study: a joint effort by NASA, the Office National d'Etudes et Recherches Aérospatiales (ONERA), and the University of Illinois. These data form a benchmark database of full-scale ice accretions and corresponding ice-contaminated aerodynamic performance data for a two-dimensional (2D) NACA 23012 airfoil. The wider research effort also included an analysis of ice-contaminated aerodynamics that categorized ice accretions by aerodynamic effects and an investigation of subscale, low- Reynolds-number ice-contaminated aerodynamics for the NACA 23012 airfoil. The low-Reynolds-number investigation included an analysis of the geometric fidelity needed to reliably assess aerodynamic effects of airfoil icing using artificial ice shapes. Included herein are records of the ice accreted during campaigns in NASA Glenn Research Center's Icing Research Tunnel (IRT). Two different 2D NACA 23012 airfoil models were used during these campaigns; an 18-in. (45.7-cm) chord (subscale) model and a 72-in. (182.9-cm) chord (full-scale) model. The aircraft icing conditions used during these campaigns were selected from the Federal Aviation Administration's (FAA's) Code of Federal Regulations (CFR) Part 25 Appendix C icing envelopes. The records include the test conditions, photographs of the ice accreted, tracings of the ice, and ice depth measurements. Model coordinates and pressure tap locations are also presented. Also included herein are the data recorded during a wind tunnel campaign conducted in the F1 Subsonic Pressurized Wind Tunnel of ONERA. The F1 tunnel is a pressured, high- Reynolds-number facility that could accommodate the full-scale (72-in. (182.9-cm) chord) 2D NACA 23012 model. Molds were made of the ice accreted during selected test runs of the full-scale model in the IRT. From these molds, castings were made that closely replicated the features of the accreted ice. The castings were then mounted on the full-scale model in the F1 tunnel, and aerodynamic performance measurements were made using model surface pressure taps, the facility force balance system, and a large wake rake designed specifically for these tests. Tests were run over a range of Reynolds and Mach numbers. For each run, the model was rotated over a range of angles-of-attack that included airfoil stall. The benchmark data collected during these campaigns were, and continue to be, used for various purposes. The full-scale data form a unique, ice-accretion and associated aerodynamic performance dataset that can be used as a reference when addressing concerns regarding the use of subscale ice-accretion data to assess full-scale icing effects. Further, the data may be used in the development or enhancement of both ice-accretion prediction codes and computational fluid dynamic codes when applied to study the effects of icing. Finally, as was done in the wider study, the data may be used to help determine the level of geometric fidelity needed for artificial ice used to assess aerodynamic degradation due to aircraft icing. The structured, multifaceted approach used in this research effort provides a unique perspective on the aerodynamic effects of aircraft icing. The data presented in this report are available in electronic form upon formal approval by proper NASA and ONERA authorities.

Addy, Harold E., Jr.↗

NASA NTRS2017

Investigation of the High-Energy Oxidation of FiberForm from DSMC Analysis of Molecular Beam Experiments

A collaborative effort between the University of Illinois at Urbana-Champaign (UIUC), NASA Ames Research Center (ARC) and Montana State University (MSU) succeeded at developing a new finite-rate carbon oxidation model from molecular beam scattering experiments on vitreous carbon (VC). We now aim to use the direct simulation Monte Carlo (DSMC) code SPARTA to apply the model to each fiber of the porous fibrous Thermal Protection Systems (TPS) material FiberForm (FF). The detailed micro-structure of FF was obtained from X-ray micro-tomography and then used in DSMC. Both experiments and simulations show that the CO/O products ratio increased at all temperatures from VC to FF. We postulate this is due to the larger number of collisions an O atom encounters inside the porous FF material compared to the flat surface of VC. For the simulations, we particularly focused on the lowest and highest temperatures studied experimentally, 1023 K and 1823 K, and found good agreement between the finite-rate DSMC simulations and experiments.

Oxidation↗

NASA NTRS2014

Observational Results of a Multi-Telescope Campaign in Search of Interstellar Urea [(NH2)2CO]

In this paper, we present the results of an observational search for gas phase urea [(NH2)2CO] observed toward the Sgr B2(N-LMH) region. We show data covering urea transitions from ∼100 GHz to 250 GHz from five different observational facilities: the Berkeley-Illinois-Maryland-Association (BIMA) Array, the Combined Array for Research in Millimeter-wave Astronomy (CARMA), the NRAO 12 m telescope, the IRAM 30 m telescope, and the Swedish-ESO Submillimeter Telescope (SEST). The results show that the features ascribed to urea can be reproduced across the entire observed bandwidth and all facilities by best-fit column density, temperature, and source size parameters which vary by less than a factor of two between observations merely by adjusting for telescope-specific parameters. Interferometric observations show that the emission arising from these transitions is cospatial and compact, consistent with the derived source sizes and emission from a single species. Despite this evidence, the spectral complexity of both (NH2)2CO and of Sgr B2(N) makes the definitive identification of this molecule challenging. We present observational spectra, laboratory data, and models, and discuss our results in the context of a possible molecular detection of urea.

clouds - ISM↗

NASA NTRS2018

NASA's Centennial Challenge for 3D-Printed Habitat: Phase II Outcomes and Phase III Competition Overview

The 3D-Printed Habitat Challenge is part of NASA's Centennial Challenges Program. NASA's Centennial Challenges seek to accelerate innovation in aerospace technology development through public competitions. The 3D-Printed Habitat Challenge, launched in 2015, is part of the Centennial Challenges portfolio and focuses on habitat design and development of large-scale additive construction systems capable of fabricating structures from in situ materials and/or mission recyclables. The challenge is a partnership between NASA, Caterpillar (primary sponsor), Bechtel, Brick and Mortar Ventures, and Bradley University. Phase I of the challenge was an architectural concept competition in which participants generated conceptual renderings of habitats on Mars which could be constructed using locally available resources. Phase II asked teams to develop the printing systems and material formulations needed to translate these designs into reality. Work under the phase II competition, which concluded in August 2017 with a head to head competition at Caterpillar's Edward Demonstration Facility in Peoria, Illinois, is discussed, including the key technology development outcomes resulting from this portion of the competition. The phase III competition consists of both virtual and construction subcompetitions. Virtual construction asks teams to render high fidelity architectural models of a habitat and all the accompanying information required for construction of the pressure retaining and load bearing portions of the structure. In construction phase III, teams are asked to scale up their printing systems to produce a 1/3 scale habitat on-site at Caterpillar. The levels of the phase III construction competition (which include printing of a foundation and printing and hydrostatic testing of a habitat element) are discussed. Phase III construction also has an increased focus on autonomy, as these systems are envisioned for robotic precursor missions which would buildup infrastructure prior to the arrival of crew. Results of the phase III competition through July 2017 (which includes virtual construction level 1) are discussed. This Centennial Challenge enables an assessment of the scaleability and efficacy of various processes, material systems, and designs for planetary construction. There are also near-term terrestrial applications, from disaster response to affordable housing and infrastructure refurbishment, for these technologies.

Prater, T. J.↗

NASA NTRS2019

NASA Centennial Challenge: 3D Printed Habitat, Phase 3 Final Results

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Construction↗

NASA NTRS2019

Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

Centennial challenge↗

NASA NTRS1993

Surfactant Studies for Bench Scale Operation

A study has been carried out to examine the effect of a surfactant, sodium lignosulfonate, on the coal liquefaction process to increase coal conversions. A series of coal liquefaction experiments with surfactant addition were conducted in a stirred batch autoclave with 1:2 coal-solvent mixtures with Illinois #6 coal at temperatures from 300 to 400 degrees C and hydrogen pressures from 1500 to 1800 psig. The treated products were analyzed for overall conversion and the distribution of the converted products into lighter and heavy oil fractions, respectively. The batch autoclave results indicate an increase in coal conversions due to surfactant addition at all processing conditions. The analysis also indicates an upgrading of the product slate for temperatures not exceeding 350 degrees C...

Sharma, Pramod K.↗