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At least 775 records · Page 43

Ultra-efficient Engine Diameter Study

Engine fan diameter and Bypass Ratio (BPR) optimization studies have been conducted since the beginning of the turbofan age with the recognition that reducing the engine core jet velocity and increasing fan mass flow rate generally increases propulsive efficiency. However, performance tradeoffs limit the amount of fan flow achievable without reducing airplane efficiency. This study identifies the optimum engine fan diameter and BPR, given the advanced Ultra-Efficient Engine Technology (UEET) powerplant efficiencies, for use on an advanced subsonic airframe. Engine diameter studies have historically focused on specific engine size options, and were limited by existing technology and transportation infrastructure (e.g., ability to fit bare engines through aircraft doors and into cargo holds). This study is unique in defining the optimum fan diameter and drivers for future 2015 (UEET) powerplants while not limiting engine fan diameter by external constraints. This report follows on to a study identifying the system integration issues of UEET engines. This Engine Diameter study was managed by Boeing Phantom Works, Seattle, Washington through the NASA Glenn Revolutionary Aero Space Engine Research (RASER) contract under task order 10. Boeing Phantom Works, Huntington Beach, completed the engine/airplane sizing optimization, while the Boeing Commercial Airplane group (BCA) provided design oversight. A separate subcontract to support the overall project was issued to Tuskegee University.

Daggett, David L.↗

Enhancing the Design Process for Complex Space Systems through Early Integration of Risk and Variable-Fidelity Modeling

An important enabler of the new national Vision for Space Exploration is the ability to rapidly and efficiently develop optimized concepts for the manifold future space missions that this effort calls for. The design of such complex systems requires a tight integration of all the engineering disciplines involved, in an environment that fosters interaction and collaboration. The research performed under this grant explored areas where the space systems design process can be enhanced: by integrating risk models into the early stages of the design process, and by including rapid-turnaround variable-fidelity tools for key disciplines. Enabling early assessment of mission risk will allow designers to perform trades between risk and design performance during the initial design space exploration. Entry into planetary atmospheres will require an increased emphasis of the critical disciplines of aero- and thermodynamics. This necessitates the pulling forward of EDL disciplinary expertise into the early stage of the design process. Radiation can have a large potential impact on overall mission designs, in particular for the planned nuclear-powered robotic missions under Project Prometheus and for long-duration manned missions to the Moon, Mars and beyond under Project Constellation. This requires that radiation and associated risk and hazards be assessed and mitigated at the earliest stages of the design process. Hence, RPS is another discipline needed to enhance the engineering competencies of conceptual design teams. Researchers collaborated closely with NASA experts in those disciplines, and in overall space systems design, at Langley Research Center and at the Jet Propulsion Laboratory. This report documents the results of this initial effort.

Mavris, Dimitri↗

2012 Alabama Lunabotics Systems Engineering Paper

Excavation will hold a key role for future lunar missions. NASA has stated that "advances in lunar regolith mining have the potential to significantly contribute to our nation's space vision and NASA space exploration operations." [1]. The Lunabotics Mining Competition is an event hosted by NASA that is meant to encourage "the development of innovative lunar excavation concepts from universities which may result in clever ideas and solutions which could be applied to an actual lunar excavation device or payload." [2]. Teams entering the competition must "design and build a remote controlled or autonomous excavator, called a lunabot, that can collect and deposit a minimum of 10 kilograms of lunar simulant within 10 minutes." [2]. While excavation will play an important part in lunar missions, there will still be many other tasks that would benefit from robotic assistance. An excavator might not be as well suited for these tasks as other types of robots might be. For example a lightweight rover would do well with reconnaissance, and a mobile gripper arm would be fit for manipulation, while an excavator would be comparatively clumsy and slow in both cases. Even within the realm of excavation it would be beneficial to have different types of excavators for different tasks, as there are on Earth. The Alabama Lunabotics Team at the University of Alabama has made it their goal to not only design and build a robot that could compete in the Lunabotics Mining Competition, but would also be a multipurpose tool for future NASA missions. The 2010-2011 resulting robot was named the Modular Omnidirectional Lunar Excavator (MOLE). Using the Systems Engineering process and building off of two years of Lunabotics experience, the 20ll-2012 Alabama Lunabotics team (Team NASACAR) has improved the MOLE 1.0 design and optimized it for the 2012 Lunabotics Competition rules [I]. A CAD model of MOLE 2.0 can be seen below in Fig. 1.

Baker, Justin↗

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

BioNutrients-2: Improvements to the BioNutrients-1 Nutrient Production System

The BioNutrients (BN) project aims to develop an on-demand nutrient production system capable of rapid and safe delivery of multiple nutrients in a single-use production pack for long-duration missions. The general concept of this system will be to develop an edible engineered microorganism capable of surviving during long-term storage, revival and growth of that microorganism for product production, and delivery of precise quantities of nutrients for human consumption. BN-1 is a five-year flight project currently on the International Space Station (ISS). It is testing the long-term storage of various microorganisms for the biomanufacturing of space relevant compounds and to validate the performance of the first generation (Gen-1) of production packs. The BN-2 project is a continuation of the BN-1 flight project and intends to expand the projects overall scope by introducing novel products, broadening the range of microbial food sources, and improving previously designed hardware from the BN-1 project. We are in the process of optimizing our platform biomanufacturing technology for in situ production of yogurt and kefir on the ISS. BN-2 will test the efficacy of this technology for future delivery of probiotic organisms which can be engineered to produce additional nutritional supplements (consumption by the crew is not planned in this project). Furthermore, to improve the feasibility of this technology for mission use we have transitioned from a hard-shell pack to a Gen-2, fluorinated ethylene propylene (FEP) bag. The single-use FEP bioreactor will facilitate growth of known organisms and ensure a contaminant free environment, while reducing mass and volume. These bioreactors will be employed for production of additional space relevant products in the BN-2 project. On-orbit testing of Gen-2 production packs will be necessary for future iterations, in order to optimize bag design and product production for eventual flight use by the crew.

BioNutrients↗

Plasma-assisted physical vapor deposition surface treatments for tribological control

In any mechanical or engineering system where contacting surfaces are in relative motion, adhesion, wear, and friction affect reliability and performance. With the advancement of space age transportation systems, the tribological requirements have dramatically increased. This is due to the optimized design, precision tolerance requirements, and high reliability expected for solid lubricating films in order to withstand hostile operating conditions (vacuum, high-low temperatures, high loads, and space radiation). For these problem areas the ion-assisted deposition/modification processes (plasma-based and ion beam techniques) offer the greatest potential for the synthesis of thin films and the tailoring of adherence and chemical and structural properties for optimized tribological performance. The present practices and new approaches of applying soft solid lubricant and hard wear resistant films to engineering substrates are reviewed. The ion bombardment treatments have increased film adherence, lowered friction coefficients, and enhanced wear life of the solid lubricating films such as the dichalcogenides (MoS2) and the soft metals (Au, Ag, Pb). Currently, sputtering is the preferred method of applying MoS2 films; and ion plating, the soft metallic films. Ultralow friction coefficients (less than 0.01) were achieved with sputtered MoS2. Further, new diamond-like carbon and BN lubricating films are being developed by using the ion assisted deposition techniques.

Spalvins, Talivaldis↗

Application Table: A Bridge Connecting the Designing “With-The-Material” and “The-Material” Paradigms

Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.

Materials↗

Application Table: A Bridge Connecting the Designing “With-the-Material” and “the-Material”

Over the last few decades, advances in high-performance computing, new material characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. In 2016 NASA sponsored a 2040 Vision study (which appeared in 2018) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. The study envisions a cyber-physical-social ecosystem comprised of experimentally verified and validated (V & V) computational models, tools, and techniques, along with the associated digital tapestry, that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of “fit-for-purpose” materials, components, and systems. Consequently, the development of a robust information management system that incorporates (across the full life cycle) both experimental (real data) and virtual data resulting from the application of various simulation tools (at single or multiple length scales), therefore enabling the virtual design and optimization of materials throughout their processing – internal structure – property – performance envelope, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality, and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. This is particularly true when attempting to merge ICME practices with recent additive manufacturing technology which will enable production of the resulting 2040 Vision material and structural designs. At NASA Glenn Research Center we are exploring the future of material science through the use of novel characterization methodologies, high performance computing, and recently an emphasis on integrated computational materials engineering (ICME). Herein, recent efforts to incorporate an Application Table within NASA Glenn Research Center’s ICME Granta MI database is presented. The goal is to provide a place where material and structural application information/requirements can be linked so as to marry the “design the-material” and the “design-with-material” paradigms and thereby enable application-driven design and optimization of materials and structures by providing a central location that links material processing at various length scales to the application’s performance requirements. This paper discusses the specifics of this Application Table as well as best practices and key principles for the development of a robust materials information management system to enable the 2040 Vision integrated materials and structures ecosystem. Furthermore, it presents the intended role of the Application Table in the future of ICME design of “fit-for-purpose” materials, showing the need for a well-established framework that can successfully bridge the gap between the design “the material” and design “with-the-material” paradigms.

Materials↗

Multidisciplinary Optimization Branch Experience Using iSIGHT Software

The Multidisciplinary Optimization (MDO) Branch at NASA Langley Research Center is investigating frameworks for supporting multidisciplinary analysis and optimization research. An optimization framework call improve the design process while reducing time and costs. A framework provides software and system services to integrate computational tasks and allows the researcher to concentrate more on the application and less on the programming details. A framework also provides a common working environment and a full range of optimization tools, and so increases the productivity of multidisciplinary research teams. Finally, a framework enables staff members to develop applications for use by disciplinary experts in other organizations. Since the release of version 4.0, the MDO Branch has gained experience with the iSIGHT framework developed by Engineous Software, Inc. This paper describes experiences with four aerospace applications: (1) reusable launch vehicle sizing, (2) aerospike nozzle design, (3) low-noise rotorcraft trajectories, and (4) acoustic liner design. All applications have been successfully tested using the iSIGHT framework, except for the aerospike nozzle problem, which is in progress. Brief overviews of each problem are provided. The problem descriptions include the number and type of disciplinary codes, as well as all estimate of the multidisciplinary analysis execution time. In addition, the optimization methods, objective functions, design variables, and design constraints are described for each problem. Discussions on the experience gained and lessons learned are provided for each problem. These discussions include the advantages and disadvantages of using the iSIGHT framework for each case as well as the ease of use of various advanced features. Potential areas of improvement are identified.

Padula, S. L.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade-offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗

Influence of noise requirements on STOL propulsion system designs

The severity of proposed noise goals for STOL systems has resulted in a new design approach for aircraft propulsion systems. It has become necessary to consider the influence of the noise goal on the design of engine components, engine systems, and the integrated nacelle, separately and collectively, from the onset of the design effort. This integrated system design approach is required in order to effect an optimization of the propulsion and aircraft system. Results from extensive design studies and pertinent test programs are presented which show the effect of noise specifications on component and system design, and the trade-offs possible of noise versus configuration and performance. The design optimization process of propulsion systems for powered lift systems is presented beginning with the component level and proceeding through to the final integrated propulsion system. Designs are presented which are capable of meeting future STOL noise regulations and the performance, installation and economic penalties are assessed as a function of noise level.

Rulis, R. J.↗

Structural tailoring of high-speed turbine blades (SSME/STAEBL)

Space shuttle main engine (SSME) blades are subject to severe thermal, pressure, and forced vibration environments. Structural optimization provides an automated alternative to time consuming iterations. Any number of analyses, design variables, and constraints can be incorporated in a structural optimization computer code. This idea was applied to develop the code SSME/STAEBL, which is a stand alone code suitable for automated design of SSME turbopump blades. Additions and modifications of STAEBL included in SSME/STAEBL include the following: (1) thermal stress analysis, (2) gas dynamic (pressure) loads, (3) temperature-dependent material and thermal properties, (4) forced vibrations, (5) tip displacement constraints, (6) single crystal material analysis, (7) blade cross-section stacking offsets, and (8) direct time integration algorithm for transient dynamic response.

Rubinstein, Robert↗

Ordering design tasks based on coupling strengths

The design process associated with large engineering systems requires an initial decomposition of the complex system into modules of design tasks which are coupled through the transference of output data. In analyzing or optimizing such a coupled system, it is essential to be able to determine which interactions figure prominently enough to significantly affect the accuracy of the system solution. Many decomposition approaches assume the capability is available to determine what design tasks and interactions exist and what order of execution will be imposed during the analysis process. Unfortunately, this is often a complex problem and beyond the capabilities of a human design manager. A new feature for DeMAID (Design Manager's Aid for Intelligent Decomposition) will allow the design manager to use coupling strength information to find a proper sequence for ordering the design tasks. In addition, these coupling strengths aid in deciding if certain tasks or couplings could be removed (or temporarily suspended) from consideration to achieve computational savings without a significant loss of system accuracy. New rules are presented and two small test cases are used to show the effects of using coupling strengths in this manner.

Rogers, James L., Jr.↗

Alternate Propulsion Subsystem Concepts Tripropellant Comparison Study

A study was conducted under MSFC contract NAS8-39210 to compare tripropellant and bipropellant engine configurations for the SSTO mission. The objective was to produce an 'apples-to-apples' comparison to isolate the effects of design implementation, designing company, year of design, or technologies included from the basic tripropellant/bipropellant comparison. Consequently, identical technologies were included (e.g., jet pumps) and the same design groundrules and practices were used. Engine power cycles were examined as were turbomachinery/preburner arrangements for each cycle. The bipropellant approach and two tripropellant approaches were separately optimized in terms of operating parameters: exit pressures, mixture ratios, thrust splits, etc. This briefing presents the results of the study including engine weights for both tripropellant and bipropellant engines; dry vehicle weight performance for a range of engine chamber pressures; discusses the basis for the results; examines vehicle performance due to engine cycles and the margin characteristics of various cycles; and identifies technologies with significant payoffs for this application.

Levack, Daniel↗

Ordering Design Tasks Based on Coupling Strengths

The design process associated with large engineering systems requires an initial decomposition of the complex system into modules of design tasks which are coupled through the transference of output data. In analyzing or optimizing such a coupled system, it is essential to be able to determine which interactions figure prominently enough to significantly affect the accuracy of the system solution. Many decomposition approaches assume the capability is available to determine what design tasks and interactions exist and what order of execution will be imposed during the analysis process. Unfortunately, this is often a complex problem and beyond the capabilities of a human design manager. A new feature for DeMAID (Design Manager's Aid for Intelligent Decomposition) will allow the design manager to use coupling strength information to find a proper sequence for ordering the design tasks. In addition, these coupling strengths aid in deciding if certain tasks or couplings could be removed (or temporarily suspended) from consideration to achieve computational savings without a significant loss of system accuracy. New rules are presented and two small test cases are used to show the effects of using coupling strengths in this manner.

Rogers, J. L.↗

Modified Universal Design Survey: Enhancing Operability of Launch Vehicle Ground Crew Worksites

Operability is a driving requirement for next generation space launch vehicles. Launch site ground operations include numerous operator tasks to prepare the vehicle for launch or to perform preflight maintenance. Ensuring that components requiring operator interaction at the launch site are designed for optimal human use is a high priority for operability. To promote operability, a Design Quality Evaluation Survey based on Universal Design framework was developed to support Human Factors Engineering (HFE) evaluation for NASA s launch vehicles. Universal Design per se is not a priority for launch vehicle processing however; applying principles of Universal Design will increase the probability of an error free and efficient design which promotes operability. The Design Quality Evaluation Survey incorporates and tailors the seven Universal Design Principles and adds new measures for Safety and Efficiency. Adapting an approach proven to measure Universal Design Performance in Product, each principle is associated with multiple performance measures which are rated with the degree to which the statement is true. The Design Quality Evaluation Survey was employed for several launch vehicle ground processing worksite analyses. The tool was found to be most useful for comparative judgments as opposed to an assessment of a single design option. It provided a useful piece of additional data when assessing possible operator interfaces or worksites for operability.

Blume, Jennifer L.↗