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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 811 records · Page 45
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NASA NTRS2016

Orion EFT-1 Cavity Heating Tile Experiments and Environment Reconstruction

Developing aerothermodynamic environments for deep cavities, such as those produced by micrometeoroids and orbital debris impacts, poses a great challenge for engineers. In order to assess existing cavity heating models, two one-inch diameter cavities were flown on the Orion Multi-Purpose Crew Vehicle during Exploration Flight Test 1 (EFT1). These cavities were manufactured with depths of 1.0 in and 1.4 in, and they were both instrumented. Instrumentation included surface thermocouples upstream, downstream and within the cavities, and additional thermocouples at the TPS-structure interface. This paper will present the data obtained, and comparisons with computational predictions will be shown. Additionally, the development of a 3D material thermal model will be described, which will be used to account for the three-dimensionality of the problem when interpreting the data. Furthermore, using a multi-dimensional inverse heat conduction approach, a reconstruction of a time- and space-dependent flight heating distribution during EFT1 will be presented. Additional discussions will focus on instrumentation challenges and calibration techniques specific to these experiments. The analysis shown will highlight the accuracies and/or deficiencies of current computational techniques to model cavity flows during hypersonic re-entry.

Salazar, Giovanni↗
NASA NTRS2016

Dynamic Mesh CFD Simulations of Orion Parachute Pendulum Motion During Atmospheric Entry

This paper demonstrates the usage of computational fluid dynamics to study the effects of pendulum motion dynamics of the NASAs Orion Multi-Purpose Crew Vehicle parachute system on the stability of the vehicles atmospheric entry and decent. Significant computational fluid dynamics testing has already been performed at NASAs Johnson Space Center, but this study sought to investigate the effect of bulk motion of the parachute, such as pitching, on the induced aerodynamic forces. Simulations were performed with a moving grid geometry oscillating according to the parameters observed in flight tests. As with the previous simulations, OVERFLOW computational fluid dynamics tool is used with the assumption of rigid, non-permeable geometry. Comparison to parachute wind tunnel tests is included for a preliminary validation of the dynamic mesh model. Results show qualitative differences in the flow fields of the static and dynamic simulations and quantitative differences in the induced aerodynamic forces, suggesting that dynamic mesh modeling of the parachute pendulum motion may uncover additional dynamic effects.

Halstrom, Logan D.↗
NASA NTRS2016

Boundary Layer Transition During the Orion Exploration Flight Test 1 (EFT-1)

Boundary layer transition was observed in the thermocouple data on the windside backshell of the Orion reentry capsule. Sensors along the windside centerline, as well as off-centerline, indicated transition late in the flight at approximately Mach 4 conditions. Transition progressed as expected, beginning at the sensors closest to the forward bay cover (FBC) and moving towards the heatshield. Sensors placed in off-centerline locations did not follow streamlines, so the progression of transition observed in these sensors is less intuitive. Future analysis will include comparisons to pre-flight predictions and expected transitional behavior will be investigated. Sensors located within the centerline and off-centerline launch abort system (LAS) attach well cavities on the FBC also showed indications of boundary layer transition. The transition within the centerline cavity was observed in the temperature traces prior to transition onset on the sensors upstream of the cavity. Transition behavior within the off centerline LAS attach well cavity will also be investigated. Heatshield thermocouples were placed within Avcoat plugs to attempt to capture transitional behavior as well as better understand the aerothermal environments. Thermocouples were placed in stacks of two or five vertically within the plugs, but the temperature data obtained at the sensors closest to the surface did not immediately indicate transitional behavior. Efforts to use the in depth thermocouple temperatures to reconstruct the surface heat flux are ongoing and any results showing the onset of boundary layer transition obtained from those reconstructions will also be included in this paper. Transition on additional features of interest, including compression pad ramps, will be included if it becomes available.

Kirk, Lindsay C.↗
NASA NTRS2016

Effects of Material Choice on Biocide Loss in Orion Water Storage Tanks

When preparing for long-duration spaceflight missions, maintaining a safe supply of potable water is of the utmost importance. One major aspect of that is ensuring that microbial growth is minimized. Historically, this challenge has been addressed through the use of biocides. When using biocides, the choice of materials for the storage containers is important, because surface reactions can reduce biocide concentrations below their effective range. In the water storage system baselined for the Orion vehicle, the primary wetted materials are stainless steel (316 L) and a titanium alloy (Ti6Al4V). Previous testing with these materials has shown that the biocide selected for use in the system (ionic silver) will plate out rapidly upon initial wetting of the system. One potential approach for maintaining an adequate biocide concentration is to spike the water supply with high levels of biocide in an attempt to passivate the surface. To evaluate this hypothesis, samples of the wetted materials were tested individually and together to determine the relative loss of biocide under representative surface area-to-volume ratios after 24 hours. Additionally, we have analyzed the efficacy of disinfecting a system containing these materials by measuring reductions in bacterial counts in the same test conditions. Preliminary results indicate that the use of titanium, either individually or in combination with stainless steel, can result in over 95% loss of biocide, while less than 5% is lost when using stainless steel. In bacterial testing, viable organisms were recovered from samples exposed to the titanium coupons after 24 hours. By comparison, no organisms were recovered from the test vessels containing only stainless steel. These results indicate that titanium, while possessing some favorable attributes, may pose additional challenges when used in water storage tanks with ionic silver biocide.

Wallace, W. T.↗
NASA NTRS2016

Design and Development of a Sub-Zero Fluid System for Demonstration of Orion's Phase Change Material Heat Exchangers on ISS

NASA's Orion Multipurpose Crew Vehicle's Exploration Mission 2 is expected to loiter in Lunar orbit for a relatively long period of time. In low Lunar orbit (LLO) the thermal environment is cyclic - extremely cold in the eclipse and relatively hot near the subsolar point. Phase change material heat exchangers (PCM HXs) are the best option for long term missions in these environments. A PCM HX allows a vehicle to store excess waste energy by thawing a phase change material such as n-pentadecane wax. During portions of the orbit that are extremely cold, the excess energy is rejected, resolidifying the wax. Due to the inherent risk of compromising the heat exchanger during multiple freeze and thaw cycles, a unique payload was designed for the International Space Station to test and demonstration the functions of a PCM HX. The payload incorporates the use of a pumped fluid system and a thermoelectric heat exchanger to promote the freezing and thawing of the PCM HX. This paper shall review the design and development undertaken to build such a system.

Sheth, Rubik B.↗
NASA NTRS2015

Electrical Pressurization Concept for the Orion MPCV European Service Module Propulsion System

The paper presents the design of the pressurization system of the European Service Module (ESM) of the Orion Multi-Purpose Crew Vehicle (MPCV). Being part of the propulsion subsystem, an electrical pressurization concept is implemented to condition propellants according to the engine needs via a bang-bang regulation system. Separate pressurization for the oxidizer and the fuel tank permits mixture ratio adjustments and prevents vapor mixing of the two hypergolic propellants during nominal operation. In case of loss of pressurization capability of a single side, the system can be converted into a common pressurization system. The regulation concept is based on evaluation of a set of tank pressure sensors and according activation of regulation valves, based on a single-failure tolerant weighting of three pressure signals. While regulation is performed on ESM level, commanding of regulation parameters as well as failure detection, isolation and recovery is performed from within the Crew Module, developed by Lockheed Martin Space System Company. The overall design and development maturity presented is post Preliminary Design Review (PDR) and reflects the current status of the MPCV ESM pressurization system.

Helium↗
NASA NTRS2015

Ames Infusion Stories for NASA Annual Technology Report: Development of an Ablative 3D Quartz / Cyanate Ester Composite Multi-Functional Material for the Orion Spacecraft Compression Pad

Vehicles re-entering Earth's atmosphere require protection from the heat of atmospheric friction. The Orion Multi-Purpose Crew Vehicle (MPCV) has more demanding thermal protection system (TPS) requirements than the Low Earth Orbit (LEO) missions, especially in regions where the structural load passes through. The use of 2-dimensional laminate materials along with a metal insert, used in EFT1 flight test for the compression pad region, are deemed adequate but cannot be extended for Lunar return missions.

Smith, Brandon↗
NASA NTRS2016

Post-Flight Analysis of GPSR Performance During Orion Exploration Flight Test 1

On 5 December 2014, the first test flight of the Orion Multi-Purpose Crew Vehicle executed a unique and challenging flight profile including an elevated re-entry velocity and steeper flight path angle to envelope lunar re-entry conditions. A new navigation system including a single frequency (L1) GPS receiver was evaluated for use as part of the redundant navigation system required for human space flight. The single frequency receiver was challenged by a highly dynamic flight environment including flight above low Earth orbit, as well as single frequency operation with ionospheric delay present. This paper presents a brief description of the GPS navigation system, an independent analysis of flight telemetry data, and evaluation of the GPSR performance, including evaluation of the ionospheric model employed to supplement the single frequency receiver. Lessons learned and potential improvements will be discussed.

Barker, Lee↗
NASA NTRS2016

Orion Exploration Mission Entry Interface Target Line

The Orion Multi-Purpose Crew Vehicle is required to return to the continental United States at any time during the month. In addition, it is required to provide a survivable entry from a wide range of trans-lunar abort trajectories. The Entry Interface (EI) state must be targeted to ensure that all requirements are met for all possible return scenarios, even in the event of no communication with the Mission Control Center to provide an updated EI target. The challenge then is to functionalize an EI state constraint manifold that can be used in the on-board targeting algorithm, as well as the ground-based trajectory optimization programs. This paper presents the techniques used to define the EI constraint manifold and to functionalize it as a set of polynomials in several dimensions.

Rea, Jeremy R.↗
NASA NTRS2016

Absolute Navigation Performance of the Orion Exploration Fight Test 1

Launched in December 2014 atop a Delta IV Heavy from the Kennedy Space Center, the Orion vehicle's Exploration Flight Test-1 (EFT-1) successfully completed the objective to stress the system by placing the un-crewed vehicle on a high-energy parabolic trajectory replicating conditions similar to those that would be experienced when returning from an asteroid or a lunar mission. Unique challenges associated with designing the navigation system for EFT-1 are presented with an emphasis on how redundancy and robustness influenced the architecture. Two Inertial Measurement Units (IMUs), one GPS receiver and three barometric altimeters (BALTs) comprise the navigation sensor suite. The sensor data is multiplexed using conventional integration techniques and the state estimate is refined by the GPS pseudorange and deltarange measurements in an Extended Kalman Filter (EKF) that employs UDU factorization. The performance of the navigation system during flight is presented to substantiate the design.

Zanetti, Renato↗
NASA NTRS2016

Encke-Beta Predictor for Orion Burn Targeting and Guidance

The state vector prediction algorithm selected for Orion on-board targeting and guidance is known as the Encke-Beta method. Encke-Beta uses a universal anomaly (beta) as the independent variable, valid for circular, elliptical, parabolic, and hyperbolic orbits. The variable, related to the change in eccentric anomaly, results in integration steps that cover smaller arcs of the trajectory at or near perigee, when velocity is higher. Some burns in the EM-1 and EM-2 mission plans are much longer than burns executed with the Apollo and Space Shuttle vehicles. Burn length, as well as hyperbolic trajectories, has driven the use of the Encke-Beta numerical predictor by the predictor/corrector guidance algorithm in place of legacy analytic thrust and gravity integrals.

Robinson, Shane↗
NASA NTRS2016

The Orion Exploration Flight Test Post Flight Solid Particle Flight Environment Inspection and Analysis

Orbital debris in the millimeter size range can pose a hazard to current and planned spacecraft due to the high relative impact speeds in Earth orbit. Fortunately, orbital debris has a relatively short life at lower altitudes due to atmospheric effects; however, at higher altitudes orbital debris can survive much longer and has resulted in a band of high flux around 700 to 1,500 km above the surface of the Earth. While large orbital debris objects are tracked via ground based observation, little information can be gathered about small particles except by returned surfaces, which until the Orion Exploration Flight Test number one (EFT-1), has only been possible for lower altitudes (400 to 500 km). The EFT-1 crew module backshell, which used a porous, ceramic tile system with surface coatings, has been inspected post-flight for potential micrometeoroid and orbital debris (MMOD) damage. This paper describes the pre- and post-flight activities of inspection, identification and analysis of six candidate MMOD impact craters from the EFT-1 mission.

Miller, Joshua E.↗
NASA NTRS2015

Spin Forming of an Aluminum 2219-T6 Aft Bulkhead for the Orion Multi-Purpose Crew Vehicle: Phase II Supplemental Report

The principal focus of this project was to assist the Orion Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the aft bulkhead of the pressure vessel. The spin forming process will enable a single piece aluminum (Al) 2219 aft bulkhead which will eliminate the current multiple piece welded construction, simplify fabrication, and lead to an enhanced design that will reduce vehicle weight by eliminating welds. Phase I of this assessment explored spin forming the single-piece forward pressure vessel bulkhead from aluminum-lithium 2195.

Piascik, Robert S.↗
NASA NTRS2016

Assessment of Fencing on the Orion Heatshield

This paper presents recession measurements of arc-jet test articles that simulate an ablator with gap filler and were exposed to various heating profiles. Results were used to derive empirically-based differential recession models used for the baseline sizing of the Orion block heatshield architecture. The profile test conditions represent different local flight environments associated with different regions of the heatshield. Recession measurements were collected during and after arc-jet tests, and the results were used to observe the heating profiles’ effect on differential recession. Arc-jet tests were conducted at the Aerodynamic Heating Facility at NASA Ames Research Center.

Arc-jet testing↗
NASA NTRS2017

A First Look at the Navigation Design and Analysis for the Orion Exploration Mission 2

This paper will detail the navigation and dispersion design and analysis of the first Orion crewed mission. The optical navigation measurement model will be described. The vehicle noise includes the residual acceleration from attitude deadbanding, attitude maneuvers, CO2 venting, wastewater venting, ammonia sublimator venting and solar radiation pressure. The maneuver execution errors account for the contribution of accelerometer scale-factor on the accuracy of the maneuver execution. Linear covariance techniques are used to obtain the navigation errors and the trajectory dispersions as well as the DV performance. Particular attention will be paid to the accuracy of the delivery at Earth Entry Interface and at the Lunar Flyby.

D'Souza, Chris D.↗
NASA NTRS2017

Fixed Base Modal Survey of the MPCV Orion European Service Module Structural Test Article

Recently, the MPCV Orion European Service Module Structural Test Article (E-STA) underwent sine vibration testing using the multi-axis shaker system at NASA GRC Plum Brook Station Mechanical Vibration Facility (MVF). An innovative approach using measured constraint shapes at the interface of E-STA to the MVF allowed high-quality fixed base modal parameters of the E-STA to be extracted, which have been used to update the E-STA finite element model (FEM), without the need for a traditional fixed base modal survey. This innovative approach provided considerable program cost and test schedule savings. This paper documents this modal survey, which includes the modal pretest analysis sensor selection, the fixed base methodology using measured constraint shapes as virtual references and measured frequency response functions, and post-survey comparison between measured and analysis fixed base modal parameters.

modal testing↗