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Improved Joining of Metal Components to Composite Structures

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Semmes, Edmund↗

Austere Human Missions to Mars

The Design Reference Architecture 5 (DRA 5) is the most recent concept developed by NASA to send humans to Mars in the 2030 time frame using Constellation Program elements. DRA 5 is optimized to meet a specific set of requirements that would provide for a robust exploration program to deliver a new six-person crew at each biennial Mars opportunity and provide for power and infrastructure to maintain a highly capable continuing human presence on Mars. This paper examines an alternate architecture that is scaled back from DRA 5 and might offer lower development cost, lower flight cost, and lower development risk. It is recognized that a mission set using this approach would not meet all the current Constellation Mars mission requirements; however, this 'austere' architecture may represent a minimum mission set that would be acceptable from a science and exploration standpoint. The austere approach is driven by a philosophy of minimizing high risk or high cost technology development and maximizing development and production commonality in order to achieve a program that could be sustained in a flat-funded budget environment. Key features that would enable a lower technology implementation are as follows: using a blunt-body entry vehicle having no deployable decelerators, utilizing aerobraking rather than aerocapture for placing the crewed element into low Mars orbit, avoiding the use of liquid hydrogen with its low temperature and large volume issues, using standard bipropellant propulsion for the landers and ascent vehicle, and using radioisotope surface power systems rather than a nuclear reactor or large area deployable solar arrays. Flat funding within the expected NASA budget for a sustained program could be facilitated by alternating cargo and crew launches for the biennial Mars opportunities. This would result in two assembled vehicles leaving Earth orbit for Mars per Mars opportunity. The first opportunity would send two cargo landers to the Mars surface to preposition a habitat, supplies, and exploration equipment. The next opportunity, two years later, would send to Mars orbit 1) a lander with a Mars Ascent Vehicle (MAV) and 2) a crewed Mars Transit Habitat with an Orion CEV for Earth return. The following opportunity, two years after the first crew, would go back to cargo-only launches. This alternation of cargo and crew opportunities results in a sustainable launch rate of six Ares V launches every two years. It is notable that four of the six launches per Mars opportunity are identical, build-to-print, Tran-Mars Injection stages. This type of production rate could lend itself well to a COTStype service provider, and would make it feasible to have a live spare in place in the event of a single launch failure.

landers↗

Modular antenna design study

The mechanical design of a modular antenna concept was developed sufficiently to allow manufacture of a working demonstration model of a module, to predict mass properties, and to make performance estimates for antenna reflectors composed of these modules. The primary features of this concept are: (1) each module is an autonomous structural element which can be attached to adjacent modules through a three point connection; (2) the upper surface is a folding hexagonal truss plate mechanism which serves as the supporting structure for a reflective surface; and (3) the entire truss and surface can be folded into a cylindrical envelope in which all truss elements are essentially parallel. The kinematic studies and engineering demonstration model fully verified the deployment kinematics, stowing philosophy, and deployment sequencing for large antenna modules. It was established that such modules can be stowed in packages as small as 25 cm in diameter, using 1.27 cm diameter structural tubes. The development activity indicates that this deployable modular approach towards building large structures in space will support erection of 450 m apertures for operation up to 3 GHz with a single space shuttle flight.

Ribble, J. W.↗

Mars Environmental Survey (MESUR): Science objectives and mission description

In-situ observations and measurements of Mars are objectives of a feasibility study beginning at the Ames Research Center for a mission called the Mars Environmental SURvey (MESUR). The purpose of the MESUR mission is to emplace a pole-to-pole global distribution of landers on the Martian surface to make both short- and long-term observations of the atmosphere and surface. The basic concept is to deploy probes which would directly enter the Mars atmosphere, provide measurements of the upper atmospheric structure, image the local terrain before landing, and survive landing to perform meteorology, seismology, surface imaging, and soil chemistry measurements. MESUR is intended to be a relatively low-cost mission to advance both Mars science and human presence objectives. Mission philosophy is to: (1) 'grow' a network over a period of years using a series of launch opportunities, thereby minimizing the peak annual costs; (2) develop a level-of-effort which is flexible and responsive to a broad set of objectives; (3) focus on science while providing a solid basis for human exploration; and (4) minimize project cost and complexity wherever possible. In order to meet the diverse scientific objectives, each MESUR lander will carry the following strawman instrument payload consisting of: (1) Atmospheric structure experiment, (2) Descent and surface imagers, (3) Meteorology package, (4) Elemental composition instrument, (5) 3-axis seismometer, and (6) Thermal analyzer/evolved gas analyzer. The feasibility study is primarily to show a practical way to design an early capability for characterizing Mars' surface and atmospheric environment on a global scale. The goals are to answer some of the most urgent questions to advance significantly our scientific knowledge about Mars, and for planning eventual exploration of the planet by robots and humans.

Hubbard, G. Scott↗

VMPLOT: A versatile analysis tool for mission operations

VMPLOT is a versatile analysis tool designed by the Magellan Spacecraft Team to graphically display engineering data used to support mission operations. While there is nothing revolutionary or innovative about graphical data analysis tools, VMPLOT has some distinguishing features that set it apart from other custom or commercially available software packages. These features include the ability to utilize time in a Universal Time Coordinated (UTC) or Spacecraft Clock (SCLK) format as an enumerated data type, the ability to automatically scale both axes based on the data to be displayed (including time), the ability to combine data from different files, and the ability to utilize the program either interactively or in batch mode, thereby enhancing automation. Another important feature of VMPLOT not visible to the user is the software engineering philosophies utilized. A layered approach was used to isolate program functionality to different layers. This was done to increase program portability to different platforms and to ease maintenance and enhancements due to changing requirements. The functionality of the unique features of VMPLOT as well as highlighting the algorithms that make these features possible are described. The software engineering philosophies used in the creation of the software tool are also summarized.

Bucher, Allen W.↗

NEML2: A High Performance Library for Constitutive Modeling

NEML2, the New Engineering Material model Library, version 2, is an offshoot of NEML, an earlier material modeling code developed at Argonne National Laboratory. NEML2 extends the key philosophy of its predecessor, i.e., material models are flexible, modular, and can be built from smaller blocks. It also provides modern features that do not exist in the framework of its predecessor such as material model vectorization, automatic differentiation, device-portable just-in-time compilation, operator fusion, lazy tensor evaluation, etc. Moreover, NEML2 can seamlessly integrate with the popular machine learning package PyTorch to take advantage of modern and fast-growing machine learning techniques. In this fiscal year, the development of core library features and capabilities are complete. The purpose of this report is not to serve as a verbatim copy of the software API reference (which is available online at https://reverendbedford.github.io/neml2/). Instead, this report documents the motivation, implementation, design choices, and usage of each core capability as well as their applications in solving practical engineering problems. This report is compiled based on the NEML2 major release 2.0.0.

36 MATERIALS SCIENCE↗

Introduction to NASA Goddard Workshop on Artificial Intelligence

Artificial Intelligence (AI) is a collection of advanced technologies that allows machines to think and act, both humanly and rationally, through sensing, comprehending, acting and learning. AI's foundations lie at the intersection of several traditional fields Philosophy, Mathematics, Economics, Neuroscience, Psychology and Computer Science. Although the inception of AI started in the 1950's, it has recently made a strong comeback in all aspects of society and all over the world; this is mainly due to the timely combination of increased data volumes, advanced and mature algorithms, and improvements in computing power and storage. Current AI applications include big data analytics, robotics, intelligent sensing, assisted decision making, and speech recognition just to name a few.This workshop will be investigating how AI technologies can be adapted or developed to address the following challenges: Discover events of interest and correlations in large amounts of science data; improve the outcomes of science modeling and data assimilation using improved data processing, integration, and analysis. Design advisors for mission planning and operations, including anomaly detection and spacecraft health monitoring. Develop tools for engineering support, including advanced manufacturing, orbit determination, new component design and system engineering. Customize intelligent user interfaces, including visual analytics and natural language processing.

Le Moigne, Jacqueline↗

General Rotorcraft Aeromechanical Stability Program (GRASP): Theory manual

The general rotorcraft aeromechanical stability program (GRASP) was developed to calculate aeroelastic stability for rotorcraft in hovering flight, vertical flight, and ground contact conditions. GRASP is described in terms of its capabilities and its philosophy of modeling. The equations of motion that govern the physical system are described, as well as the analytical approximations used to derive them. The equations include the kinematical equation, the element equations, and the constraint equations. In addition, the solution procedures used by GRASP are described. GRASP is capable of treating the nonlinear static and linearized dynamic behavior of structures represented by arbitrary collections of rigid-body and beam elements. These elements may be connected in an arbitrary fashion, and are permitted to have large relative motions. The main limitation of this analysis is that periodic coefficient effects are not treated, restricting rotorcraft flight conditions to hover, axial flight, and ground contact. Instead of following the methods employed in other rotorcraft programs. GRASP is designed to be a hybrid of the finite-element method and the multibody methods used in spacecraft analysis. GRASP differs from traditional finite-element programs by allowing multiple levels of substructure in which the substructures can move and/or rotate relative to others with no small-angle approximations. This capability facilitates the modeling of rotorcraft structures, including the rotating/nonrotating interface and the details of the blade/root kinematics for various types. GRASP differs from traditional multibody programs by considering aeroelastic effects, including inflow dynamics (simple unsteady aerodynamics) and nonlinear aerodynamic coefficients.

Hodges, Dewey H.↗

Voltage Optimization

Voltage optimization refers to a volt-var optimization technique which was originally designed to minimize energy consumption and improve end-use efficiency on the distribution system. This reduces source voltage at a substation, which lowers generation demand, reduces system losses, and improves system stability. This has been the conventional implementation of voltage optimization: focusing on regulation of voltages throughout the distribution system via coordinated adjustments of load tap changers, line-voltage regulators, switched shunt compensation, and the targeted placement of new shunt compensation. These methods have received increased focus following a growth in distributed-energy resources (DERs) interconnecting at the distribution level, given their developing capability to participate in voltage regulation. This is paired with the intermittency challenges they pose, load imbalances, and voltage fluctuations. Voltage optimization has long been an area of extensive research within the distribution system, with various strategies and philosophies demonstrating a range of effects. The conventional focus on the distribution system owes to the typical operation of transmission systems, which assumes firm local resources and flows strictly from generation resources to loads. The strategies employed in distribution have also been optimized for this typically radial configuration and operation of the distribution system.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

NASA Research Center Contributions to Space Shuttle Return to Flight (SSRTF)

Contributions provided by the NASA Research Centers to key Space Shuttle return-to-flight milestones, with an emphasis on debris and Thermal Protection System (TPS) damage characterization, are described herein. Several CAIB recommendations and Space Shuttle Program directives deal with the mitigation of external tank foam insulation as a debris source, including material characterization as well as potential design changes, and an understanding of Orbiter TPS material characteristics, damage scenarios, and repair options. Ames, Glenn, and Langley Research Centers have performed analytic studies, conducted experimental testing, and developed new technologies, analysis tools, and hardware to contribute to each of these recommendations. For the External Tank (ET), these include studies of spray-on foam insulation (SOFI), investigations of potential design changes, and applications of advanced non-destructive evaluation (NDE) technologies to understand ET TPS shedding during liftoff and ascent. The end-to-end debris assessment included transport analysis to determine the probabilities of impact for various debris sources. For the Orbiter, methods were developed, and validated through experimental testing, to determine thresholds for potential damage of Orbiter TPS components. Analysis tools were developed and validated for on-orbit TPS damage assessments, especially in the area of aerothermal environments. Advanced NDE technologies were also applied to the Orbiter TPS components, including sensor technologies to detect wing leading edge impacts during liftoff and ascent. Work is continuing to develop certified TPS repair options and to develop improved methodologies for reinforced carbon-carbon (RCC) damage progression to assist in on-orbit repair decision philosophy.

Cockrell, Charles E., Jr.↗

RFID and Memory Devices Fabricated Integrally on Substrates

Electronic identification devices containing radio-frequency identification (RFID) circuits and antennas would be fabricated integrally with the objects to be identified, according to a proposal. That is to say, the objects to be identified would serve as substrates for the deposition and patterning of the materials of the devices used to identify them, and each identification device would be bonded to the identified object at the molecular level. Vacuum arc vapor deposition (VAVD) is the NASA derived process for depositing layers of material on the substrate. This proposal stands in contrast to the current practice of fabricating RFID and/or memory devices as wafer-based, self-contained integrated-circuit chips that are subsequently embedded in or attached to plastic cards to make smart account-information cards and identification badges. If one relies on such a chip to store data on the history of an object to be tracked and the chip falls off or out of the object, then one loses both the historical data and the means to track the object and verify its identity electronically. Also, in contrast is the manufacturing philosophy in use today to make many memory devices. Today s methods involve many subtractive processes such as etching. This proposal only uses additive methods, building RFID and memory devices from the substrate up in thin layers. VAVD is capable of spraying silicon, copper, and other materials commonly used in electronic devices. The VAVD process sprays most metals and some ceramics. The material being sprayed has a very strong bond with the substrate, whether that substrate is metal, ceramic, or even wood, rock, glass, PVC, or paper. An object to be tagged with an identification device according to the proposal must be compatible with a vacuum deposition process. Temperature is seldom an issue as the substrate rarely reaches 150 F (66 C) during the deposition process. A portion of the surface of the object would be designated as a substrate for the deposition of the device. By use of a vacuum arc vapor deposition apparatus, a thin electrically insulating film would first be deposited on the substrate. Subsequent layers of materials would then be deposited and patterned by use of known integrated-circuit fabrication techniques. The total thickness of the deposited layers could be much less than the 100- m thickness of the thinnest state-of-the-art self-contained microchips. Such a thin deposit could be readily concealed by simply painting over it. Both large vacuum chambers for production runs and portable hand-held devices for in situ applications are available.

Schramm, Harry F.↗

The crucial role of diagnostics in achieving ignition on the National Ignition Facility (NIF)

Well over 100 diagnostics can operate on the National Ignition Facility (NIF) as a result of several decades of development on NIF, and before that on Nova, OMEGA, and earlier LLNL lasers. A subset of these have guided the approach to achieving ignition on the NIF in 2022 [H. Abu-Shawareb et al. (Indirect Drive ICF Collaboration), Phys. Rev. Lett. 129(7), 075001 (2022)]. Achieving ignition on NIF has required many types of experiments with this core set of diagnostics, some constraining known unknowns and some revealing surprises—arguably unknown unknowns. Early design work realized that the extreme precision required for ignition on NIF would require fine-tuning by experiment, that is, measuring and adjusting known unknowns. Many examples are given where the use of the core set of ignition diagnostics in experimental arrangements called platforms demonstrated control of the key theoretical parameters defined as shape, adiabat, velocity, and mix. The direction of the adjustments to input conditions is found either by trend analysis or, in many cases, by observing from the diagnostic data the direction to make an adjustment. In addition, diagnostics have revealed some unexpected or neglected known issues, which degrade performance, or unexpected issues, unknown unknowns. Some of these factors had been previously considered, but underestimated or difficult to calculate at the time. The overall methodology can be described as a variant of Popper's falsifiability philosophy [K. Popper, The Logic of Scientific Discovery (Hutchinson, 1974)]. This paper summarizes the role of ignition diagnostics in terms of falsification or validation of theory or experimental setup as well as uncovering unexpected issues. The journey to ignition started in the seventies with a 1-µm wavelength laser producing disastrous results. Diagnostics have guided us to the recent multi-decadal goal of demonstrating ignition and burn in the laboratory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Assured crew return capability Crew Emergency Return Vehicle (CERV) avionics

The Crew Emergency Return Vehicle (CERV) is being defined to provide Assured Crew Return Capability (ACRC) for Space Station Freedom. The CERV, in providing the standby lifeboat capability, would remain in a dormat mode over long periods of time as would a lifeboat on a ship at sea. The vehicle must be simple, reliable, and constantly available to assure the crew's safety. The CERV must also provide this capability in a cost effective and affordable manner. The CERV Project philosophy of a simple vehicle is to maximize its useability by a physically deconditioned crew. The vehicle reliability goes unquestioned since, when needed, it is the vehicle of last resort. Therefore, its systems and subsystems must be simple, proven, state-of-the-art technology with sufficient redundancy to make it available for use as required for the life of the program. The CERV Project Phase 1'/2 Request for Proposal (RFP) is currently scheduled for release on October 2, 1989. The Phase 1'/2 effort will affirm the existing project requirements or amend and modify them based on a thorough evaluation of the contractor(s) recommendations. The system definition phase, Phase 2, will serve to define CERV systems and subsystems. The current CERV Project schedule has Phase 2 scheduled to begin October 1990. Since a firm CERV avionics design is not in place at this time, the treatment of the CERV avionics complement for the reference configuration is not intended to express a preference with regard to a system or subsystem.

Myers, Harvey Dean↗

Closing the Loops on Solar Photovoltaics Modules: An Agent-Based Modeling Approach for the Study of Circular Economy Strategies

Solar photovoltaics (PV) installed capacity have grown exponentially since the early 2000s (average annual growth rate of 50%). With 4,700 GW projected installed capacity by 2050, the volume of PV panels waste is also expected to become substantial. Though renewables are a sine qua non to the establishment of a truly circular economy (CE), the issue arising from their end-of-life management needs to be resolved. The management of PV end-of-life also represent a singular opportunity to create value, from recovered valuable, rare or critical materials (e.g. silver, tellurium, indium). Moreover, the PV case illustrates some of the current barriers to CE; for instance, the need for a common definition of waste (PV are defined as e-waste in the European Union but as general waste in the United States) and potential loss of innovations' advantages (PV average efficiency has continuously grown the past 10 years). In this study, an agent-based modeling (ABM) approach is proposed to simulate PV end-of-life management in the United States. The model explores how the decisions of the various actors involved in handling PV waste affect the quantities of PV that are reused, recycled, or land-filled. In the model, manufacturers, residential, and nonresidential PV owners, installers, and recyclers are represented by agents while governmental policies and regulations are treated as exogenous variables. PV-market data are used to define agents' characteristics (e.g., installed PV capacities or producing costs). Agents' decision rules draw on the literature related to industrial symbiosis (IS) and peoples' waste behaviors as they appear as the most widely used model to implement CE principles at a meso level. Specifically, the concepts of mutual trust between IS actors and knowledge about the IS philosophy are yielded to define the agents' decision process. The primary outputs of the ABM are the costs and volume of waste associated with each end-of-life pathway. Preliminaries results indicate recycling of residential PV is affected by the cost, perceived difficulty of recycling behaviors, and social norms. Moreover, the type of network connecting agents and the initial recycling rate strongly influence results. The model also highlights the crucial role of recycling behavior adoption: in case of early failure of PV, recycled volumes increase by about 40%. This represents an additional 5.7 billion USD from potential recovered silver. Finally, although results for the PV case are presented here, the developed ABM aims at being a general tool for the study of CE strategies and the CE transition. Furthermore, steps of this research include extending the model to encompass circular economy strategies (e.g., design for recycling or lifetime extension) and validating its general architecture from various case studies.

14 SOLAR ENERGY↗

Validation of the Mars 2020 Fault Protection Design: Navigating the Infinity of the Off-Nominal

On July 30th 2020, the Mars 2020 mission successfully launched out of Cape Canaveral, Florida, passed through the Earth’s shadow, and began its short cruise to Mars. Less than seven months later, the Perseverance rover touched down safely in Jezero Crater to begin its ambitious mission that includes looking for signs of ancient life and collecting samples for future return to Earth. Getting to the successful landing, or “Tango Delta Nominal,” could not have been achieved without also considering the off-nominal. One of the teams supporting this ambitious mission is the fault protection (FP) team. This team is tasked with assessing the various failures, or faults, that could prevent mission success and with ensuring that the autonomous behaviors built into the software and hardware can detect faults and recover the vehicle to a safe state. As part of its charter, the FP team designed a test campaign to provide confidence in the system’s robustness to off-nominal scenarios across all of Mars 2020’s mission phases. The greatest challenge associated with designing such a validation campaign was reducing the infinite number of anomalous scenarios into a finite test suite. In addition, the tests needed to be executed efficiently in order to utilize the team’s limited test venue access, but still needed to maintain a level of rigor that guaranteed confidence in the test outcomes. Given that each test scenario generated massive amounts of data, the team also developed methods for quickly ascertaining whether the autonomous fault protection behaviors maintained vehicle safety in the presence of an anomaly. This paper summarizes the processes that the Mars 2020 fault protection team employed to execute its off-nominal validation campaign. It captures both the methods of generating a suite of off-nominal tests, as well as reducing it to a subset that can be realistically executed within schedule and resource constraints. It also describes the various processes and philosophies that the team utilized to execute the tests efficiently, including creating a standardized procedure template, keeping the test cases modular so that they could be easily interchanged, and capturing common fault injections in a change-controlled database. Finally, it will describe the tools and processes for assessing the test data, focusing in particular on a tool that evaluated vehicle state using “secondary” sources of data to validate that the software had truly configured the spacecraft to the expected safe state.

Morantz, Chaz↗

Adaptations of guidance, navigation, and control verification and validation philosophies for small spacecraft

Decades of experience developing increasingly capable and more complex space-craft have resulted in a set of accepted practices and philosophies to verify and validate (V&V) guidance, navigation, and control (GN&C) subsystems. Until recently, small, low-cost spacecraft have had very simple or non-existent GN&C subsystems requiring minimal or no subsystem testing. As the next generation of small spacecraft take on more challenging GN&C requirements, the GN&C community is struggling with how to scale the subsystem V&V effort to produce spacecraft approaching the reliability of flagship-class missions while staying within the reduced resources of a small satellite project.For this paper, we will examine five aspects of GN&C V&V (requirements definition, software testing and analysis, hardware component testing, integrated vehicle testing, and in-flight V&V) and compare the V&V campaign of a flagship-class mission (Mars 2020) to that of two recent, successful CubeSat missions: ASTERIA and MarCO. Experiences from the development of these CubeSats yield valuable lessons learned and guidelines for future small spacecraft designers.

Chen, George T.↗

Adaptations of Guidance, Navigation and Control Verification and Validation Philosophies for Small Spacecraft

Decades of experience developing increasingly capable and more complex space-craft have resulted in a set of accepted practices and philosophies to verify and validate (V&V) guidance, navigation, and control (GN&C) subsystems. Until recently, small, low-cost spacecraft have had very simple or non-existent GN&C subsystems requiring minimal or no subsystem testing. As the next generation of small spacecraft take on more challenging GN&C requirements, the GN&C community is struggling with how to scale the subsystem V&V effort to produce spacecraft approaching the reliability of flagship-class missions while staying within the reduced resources of a small satellite project. For this paper, we will examine five aspects of GN&C V&V (requirements definition, software testing and analysis, hardware component testing, integrated vehicle testing, and in-flight V&V) and compare the V&V campaign of a flagship-class mission (Mars 2020) to that of two recent, successful CubeSat missions: ASTERIA and MarCO. Experiences from the development of these CubeSats yield valuable lessons learned and guidelines for future small spacecraft designers.

Pong, Christopher M.↗

Inlet-Compressor Analysis using Coupled CFD Codes

Propulsion performance and operability are key factors in the development of a successful aircraft. For high-speed supersonic aircraft, mixed-compression inlets offer high performance but are susceptible to an instability referred to as unstart. An unstart occurs when a disturbance originating in the atmosphere or the engine causes the shock system to be expelled from the inlet. This event can have adverse effects on control of the aircraft, which is unacceptable for a passenger plane such as the high speed civil transport (HSCT). The ability to predict the transient response of such inlets to flow perturbations is, therefore, important to the proper design of the inlet and the control measures used to prevent unstart. Computational fluid dynamics (CFD) is having an increasing role in the analysis of individual propulsion components. Isolated inlet studies are relatively easy to perform, but a major uncertainty is the boundary condition used at the inlet exit to represent the engine - the so-called compressor face boundary condition. A one-dimensional (1-D) Euler inlet simulation showed that the predicted inlet unstart tolerance to free-stream pressure perturbations can vary by as much as a factor of about six, depending on the boundary condition used. Obviously a thorough understanding of dynamic interactions between inlets and compressors/fans is required to provide the proper boundary condition. To aid in this understanding and to help evaluate possible boundary conditions, an inlet-engine experiment was conducted at the University of Cincinnati. The interaction of acoustic pulses, generated in the inlet, with the engine were investigated. Because of the availability of experimental data for validation, it was decided to simulate the experiment using CFD. The philosophy here is that the inlet-engine system is best simulated by coupling (existing) specialized CFD component-codes. The objectives of this work were to aid in a better understanding of inlet-compressor interaction physics and the formulation of a more realistic compressor-face boundary condition for time-accurate CFD simulations of inlets. Previous simulations have used 1-D Euler engine simulations in conjunction with 1-D Euler and axisymmetric Euler inlet simulations. This effort is a first step toward CFD simulation of an entire engine by coupling multidimensional component codes.

Cole, Gary↗