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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↗

NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗

NASA NTRSDate not supplied

Additive Manufacturing for Rocket Propulsion Applications

Metal Additive manufacturing (AM) is changing how components are being fabricated for current and next generation spaceflights. AM provides many advantages including cost and schedule reduction, enhanced complexity for light-weighting, consolidation of parts, and improved performance using novel alloys and improved designs. This presentation will highlight some of the use cases of AM in rocket propulsion applications, the various processes and attributes for proper selection, and the integrated lifecycle for proper AM use. As AM evolves, there is a need to better understand these lifecycle design constraints such as geometry, microstructure and resulting properties, and surface texture for proper implementation. Ongoing research is being conducted on integral channel heat exchangers, such as combustion chambers and nozzles, using some of the AM processes. The presentation will conclude with a focus on this AM heat exchanger research and how it may be applied for future spaceflight.

Additive Manufacturing↗

NASA NTRSDate not supplied

Power and Propulsion: Small Core Advanced Thermal Management Project Overview

This presentation is intended to provide an overview of the various efforts under the Advanced Air Transport Technology (AATT) project related to engine thermal management. Sustainable flight is the key motivator for all our efforts, and innovative thermal technologies play a crucial role in achieving this goal. The technologies described in this presentation can be applied to both traditional gas turbines and advanced cycles which utilize alternative fuels. Within our project, we utilize the capabilities of artificial intelligence (AI), machine learning (ML), and additive manufacturing. This ranges from using AI to generate heat exchanger fin topologies, to using ML for a reduction in computational cost which allows for a more thorough design exploration. Many times, the resulting topologies can only be realized through additive manufacturing techniques. Most of what’s presented is currently low TRL, but the intent is to achieve TRL 4 by the end of the project.

Propulsion↗

NASA NTRSDate not supplied

Hybrid-Electric Aero-Propulsion Controls Laboratory: Overview and Capability

A hardware-in-the-loop (HIL) laboratory is developed to investigate control technologies for electrified aircraft propulsion (EAP). The laboratory emulates a propulsion system by reproducing the mechanical shaft interface to the electrical power system in hardware. The experimental electric power system includes supercapacitor energy storage and a dynamically variable electrical load. A novel method of scaling power and inertia is provided in software to accurately reproduce the transient, off-design turbomachinery performance dynamics without including actual turbomachinery. An overview of how the HIL system can accommodate a broad range of EAP architectures, including power extraction and insertion, with capability for transient energy management is described. The real-time system operates in the 100kW power class and is instrumented to emulate turbomachinery – power system interactions. The platform is an agile, flexible laboratory for low-cost, risk-reduction development and testing of propulsion control, operability, and energy management technologies.

Controls↗

NASA NTRSDate not supplied

Hybrid-Electric Aero-Propulsion Controls Laboratory: Overview and Capability

controls↗

NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗

NASA NTRS2024

Development of a Data Fusion Methodology for Lineload Aerodynamic Databases for a Launch Vehicle during Liftoff and Transition

The need for databases for the distributed loading on launch vehicles during the early portion of flight necessitates the use of expensive computational flows in regimes where wake effects dominate. While also being expensive, this is a regime that computational tools tend to historically have problems simulating accurately. To help tackle this problem, a method of data fusion to combine computational results to wind tunnel derived force and moment data is developed. Using this method, significant reduction in computational costs and increases in confidence of the final product is possible and has been used to generate several databases for the Space Launch System (SLS) at NASA. While the full details of database generation are not part of this work, the crucial method at its core is developed here. Two SLS geometries are used throughout the work to demonstrate the techniques. These are two of the larger geometries and represent both planned crewed missions to the Moon as well as potential cargo missions to deep space. The method uses principal component analysis (PCA) to generate a reduced ordered model (ROM) to help fill in the full parameter space. Other similar techniques are explored, but were not found to have a significant result on the predictions of the ROM. Because the full number of components are kept to generate the model, this lack of difference is expected. This method is then extended to ensure that predicted surfaces match trusted force and moment data derived from wind tunnel testing. This extension is done by setting up a constrained optimization problem in order to minimize the deviation from the surface resolved computational data while still integrating to the desired values. When generating the constrained optimization problem, a weighting factor to balance these competing needs is introduced. The work compares previously introduced weighting terms from similar work to the proposed terms and shows that the previously used terms do not have as desirable behavior in this flow regime. This method is then expanded by developing a technique to incorporate uncertainty quantification into the developed data fusion methodology. This expansion takes a two pronged approach. One examines transferring the uncertainties in the force and moment database and characterizes how those adjustments change the predicted lineloads. The second looks at model form error and looks how rebuilding the model using slightly different data changes the predictions. These two terms are then combined in order to create an uncertainty model that takes both effects into account. The limitations of the proposed methods is then discussed as well as possible techniques to address these shortcomings.

Launch Vehicles↗

NASA NTRS1980

Prototype solar power satellite options

The choice of options for the prototype solar power satellite is addressed relative to risk and cost. Emphasis is placed on the reduction of the risk of failure. Risk is the program cost multiplied by the reduction in probability of program success due to the risky action. Four classes of risk are identified. It is suggested that prototyping would reduce the technical risk as well as reduce the effects of the other three types of risk by allowing them to be quantified earlier. Prototype demonstration requirements addressed include electromagnetic power link feasibility demonstration, component integration verification, construction technology verification, and cost performance verification. Specific prototype requirements are listed and prototyping options are given in tabular form.

Sperber, B. R.↗

NASA NTRS1975

Designing for solid rocket booster reusability

The Solid Rocket Booster (SRB) of the Space Shuttle Program has been designed to be recovered, refurbished, and reused up to 19 times on subsequent launches. The design modifications to the SRB to incorporate this capability include the addition of a parachute recovery system and minor structural modifications to the nose cone, forward skirt, aft skirt, and solid rocket motor structures for withstanding the water impact loading. In addition, the detail design of subsystem hardware requires careful attention to corrosion prevention and facility of refurbishment operations. A cost analysis comparing the reusable SRB with an expendable version shows a substantial reduction in Space Shuttle cost per flight is achieved with the reusable design approach.

Nevins, C. D.↗

NASA NTRS2005

In-situ Production of High Density Polyethylene and Other Useful Materials on Mars

This paper describes a revolutionary materials structure and power storage concept based on the in-situ production of abiotic carbon 4 compounds. One of the largest single mass penalties required to support the human exploration of Mars is the surface habitat. This proposal will use physical chemical technologies to produce high density polyethylene (HDPE) inflatable structures and construction materials from Mars atmospheric CO2. The formation of polyethylene from Mars CO2 is based on the use of the Sabatier and modified Fischer Tropsch reactions. The proposed system will fully integrate with existing in-situ propellant production concepts. The technology will also be capable of supplementing human caloric requirements, providing solid and liquid fuels for energy storage, and providing significant reduction in mission risk. The NASA Mars Reference Mission Definition Team estimated that a conventional Mars surface habitat structure would weigh 10 tonnes. It is estimated that this technology could reduce this mass by 80%. This reduction in mass will significantly contribute to the reduction in total mission cost need to make a Mars mission a reality. In addition the potential reduction of risk provided by the ability to produce C4 and potentially higher carbon based materials in-situ on Mars is significant. Food, fuel, and shelter are only three of many requirements that would be impacted by this research.

Flynn, Michael↗

NASA NTRS2010

Fuel Efficient Strategies for Reducing Contrail Formations in United States Air Space

This paper describes a class of strategies for reducing persistent contrail formation in the United States airspace. The primary objective is to minimize potential contrail formation regions by altering the aircraft's cruising altitude in a fuel-efficient way. The results show that the contrail formations can be reduced significantly without extra fuel consumption and without adversely affecting congestion in the airspace. The contrail formations can be further reduced by using extra fuel. For the day tested, the maximal reduction strategy has a 53% contrail reduction rate. The most fuel-efficient strategy has an 8% reduction rate with 2.86% less fuel-burnt compared to the maximal reduction strategy. Using a cost function which penalizes extra fuel consumed while maximizing the amount of contrail reduction provides a flexible way to trade off between contrail reduction and fuel consumption. It can achieve a 35% contrail reduction rate with only 0.23% extra fuel consumption. The proposed fuel-efficient contrail reduction strategy provides a solution to reduce aviation-induced environmental impact on a daily basis.

Sridhar, Banavar↗

NASA NTRS2001

Report by the International Space Station (ISS) Management and Cost Evaluation (IMCE) Task Force

The International Space Station (ISS) Management and Cost Evaluation Task Force (IMCE) was chartered to conduct an independent external review and assessment of the ISS cost, budget, and management. In addition, the Task Force was asked to provide recommendations that could provide maximum benefit to the U.S. taxpayers and the International Partners within the President's budget request. The Task Force has made the following principal findings: (1) The ISS Program's technical achievements to date, as represented by on-orbit capability, are extraordinary; (2) The Existing ISS Program Plan for executing the FY 02-06 budget is not credible; (3) The existing deficiencies in management structure, institutional culture, cost estimating, and program control must be acknowledged and corrected for the Program to move forward in a credible fashion; (4) Additional budget flexibility, from within the Office of Space Flight (OSF) must be provided for a credible core complete program; (5) The research support program is proceeding assuming the budget that was in place before the FY02 budget runout reduction of $1B; (6) There are opportunities to maximize research on the core station program with modest cost impact; (7) The U.S. Core Complete configuration (three person crew) as an end-state will not achieve the unique research potential of the ISS; (8) The cost estimates for the U.S.-funded enhancement options (e.g., permanent seven person crew) are not sufficiently developed to assess credibility. After these findings, the Task Force has formulated several primary recommendations which are published here and include: (1) Major changes must be made in how the ISS program is managed; (2) Additional cost reductions are required within the baseline program; (3) Additional funds must be identified and applied from the Human Space Flight budget; (4) A clearly defined program with a credible end-state, agreed to by all stakeholders, must be developed and implemented.

Young, A. Thomas↗

NASA NTRS2014

Evaluating Tradeoffs Between Environmental Impact and Operational Costs for Enroute Air Traffic

The rapid growth of air traffic has drawn attention to aircraft-induced environmental impact. Aviation operations affect the environment mainly through the release of emissions and by the formation of contrails. Recent research has shown that altering aircraft cruise altitudes can reduce aviation environmental impact by reducing Absolute Global Temperature Change Potential, a climate assessment metric that adapts a linear system for modeling the global temperature response to aviation emissions and contrails. However, these methods will increase fuel consumption that leads to higher operational costs imposed on airlines resulting in reluctance to adopt a new routing strategy. This paper evaluates the tradeoff between environmental impact reduction and the corresponding added operational costs for enroute air traffic. The concept of social cost of carbon and the carbon auction price from California's recent cap-and-trade system were used to provide estimates and a methodology to evaluate environmental costs for carbon dioxide emissions and contrail formations. Depending on the specific environmental policy, the strategy is considered favorable when the reduction in environmental costs exceeds the increase in operational costs. The results show how the net environmental bene t varies with different decision-making time horizons, different carbon and fuel costs, and different days. The study provides guidance towards the development of the environmental reduction strategies.

environmental impact↗

NASA NTRS2011

A Concept for Flexible Operations and Optimized Traffic into Metroplex Regions

A "Flexible Flight Operations" concept for airport metroplexes was studied. A flexible flight is one whose destination airport is not assigned until a threshold is reached near the arrival area at which time the runway which reduces overall delay is assigned. The concept seeks to increase throughput by exploiting flexibility. The quantification of best-case benefits from the concept was pursued to establish whether concept research is warranted. Findings indicate that indeed the concept has potential for significant reductions in delay (and cost due to delay) in the N90 (NY/NJ) and SCT (Southern California) metroplexes. Delay reductions of nearly 26% are possible in N90 when 30% of the commercial airline flights are flexible (smartly selected by their low probability of connecting passengers); nearly 40% delay reduction is found when 50% of the flights are flexible. In the SCT metroplex, delay reductions estimates are greater. Greater reductions result at SCT since it is less constrained currently than N90, providing "more room" to take advantage of flexibility. Using the flexible operations concept for on-demand/air taxi and General Aviation flights were found to be beneficial at NY/NJ, indicating the flexible operations concepts may be useful to wide variety of users..

DeLaurentis, Daniel↗

NASA NTRS1978

Characteristics of future air cargo demand and impact on aircraft development - A report on the Cargo/Logistic Airlift Systems Study /CLASS/ project

The considered study has been conducted to evaluate the future potential for an advanced air cargo transport. A current operations analysis is discussed, taking into account the traffic structure, modal cost comparisons, terminal operations, containerization, and institutional factors. Attention is also given to case studies, a demand forecast, and an advanced air cargo systems analysis. The effects of potential improvements on reducing costs are shown. Improvement to the current infrastructure can occur from 1978 to 1985 with off-the-shelf technology, which when combined with higher load factors for aircraft and containers, can provide up to a 16 percent reduction in total operating costs and a 15 percent rate reduction. The results of the analysis indicate that the proposed changes in the infrastructure and improved cargo loading efficiencies are as important to improving the airlines' financial posture as is the anticipated large dedicated cargo aircraft.

Whitehead, A. H., Jr.↗

NASA NTRS2015

Neutron Spectrometer Prospecting During the Mojave Volatiles Project Analog Field Test

We know there are volatiles sequestered at the poles of the Moon. While we have evidence of water ice and a number of other compounds based on remote sensing, the detailed distribution, and physical and chemical form are largely unknown. Additional orbital studies of lunar polar volatiles may yield further insights, but the most important next step is to use landed assets to fully characterize the volatile composition and distribution at scales of tens to hundreds of meters. To achieve this range of scales, mobility is needed. Because of the proximity of the Moon, near real-time operation of the surface assets is possible, with an associated reduction in risk and cost. This concept of operations is very different from that of rovers on Mars, and new operational approaches are required to carry out such real-time robotic exploration. The Mojave Volatiles Project (MVP) is a Moon- Mars Analog Mission Activities (MMAMA) program effort aimed at (1) determining effective approaches to operating a real-time but short-duration lunar surface robotic mission, and (2) performing prospecting science in a natural setting, as a test of these approaches. We know there are volatiles sequestered at the poles of the Moon. While we have evidence of water ice and a number of other compounds based on remote sensing, the detailed distribution, and physical and chemical form are largely unknown. Additional orbital studies of lunar polar volatiles may yield further insights, but the most important next step is to use landed assets to fully characterize the volatile composition and distribution at scales of tens to hundreds of meters. To achieve this range of scales, mobility is needed. Because of the proximity of the Moon, near real-time operation of the surface assets is possible, with an associated reduction in risk and cost. This concept of operations is very different from that of rovers on Mars, and new operational approaches are required to carry out such robotic exploration. The Mojave Volatiles Project (MVP) is a Moon- Mars Analog Mission Activities (MMAMA) program effort aimed at (1) determining effective approaches to operating a real-time but short-duration lunar surface robotic mission, and (2) performing prospecting science in a natural setting, as a test of these approaches. Here we describe some results from the first such test, carried out in the Mojave Desert between 16 and 24 October, 2014. The test site was an alluvial fan just E of the Soda Mountains, SW of Baker, California. This site contains desert pavements, ranging from the late Pleistocene to early-Holocene in age. These pavements are undergoing dissection by the ongoing development of washes. A principal objective was to determine the hydration state of different types of desert pavement and bare ground features. The mobility element of the test was provided by the KREX-2 rover, designed and operated by the Intelligent Robotics Group at NASA Ames Research Center.

Moon- Mars Analog Mission Activities (MMAMA)↗

NASA NTRS1973

Investigation of low-cost fabrication of ablative heat shields

The fabrication, testing, and evaluation of materials and techniques employed in the fabrication of ablative heat shield panels are described. Results of this effort show projected reductions in labor man-hours for dielectric curing of panels when compared to panels molded in a steam-heated press. In addition, panels were fabricated with more than one density within the cross-section. These dual-density panels show significant weight and cost reduction potentials.

Massions, V. P.↗