SEARCH · Engineering Papers

Results for “maintenance engineering”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 811 records · Page 45

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Shoulder Postures in EVA Training in Reduced Gravity Analogues

Shoulder Postures in EVA Training in Reduced Gravity Analogues K. Guhl1, L. Vu2, H. Kim3, S. Rajulu4 1KBR Inc., Houston, TX, 2Aegis Aerospace Inc., Houston, TX, 3Leidos Innovations, Houston, TX, 4NASA Johnson Space Center, Houston, TX. During extravehicular activities (EVAs) and EVA training in both the Neutral Buoyancy Laboratory (NBL) and at the Active Response Gravity Offload System (ARGOS), crewmembers perform a variety of hand-intensive tasks with frequent arm/shoulder repositioning while wearing a pressurized spacesuit. As a result, crewmembers may experience ergonomic stressors such as awkward shoulder postures. The ergonomic shoulder risk is also compounded by limited or restricted shoulder mobility of the spacesuit, extreme work positions such as overhead tasks, and tasks with heavy tools and repetitive motions. Prolonged or frequent shoulder elevation and overhead work, in particular, can lead to excessive stresses and musculoskeletal injuries of the shoulder joints. Future EVA missions, specifically lunar surface EVAs, will also be longer in duration and thus increase the exposure to awkward shoulder postures. In this study, we aimed to assess the ergonomic risk of awkward shoulder postures in simulated lunar surface EVAs by quantifying when and how long the arms are raised above the chest level. We assessed video recordings of pilot lunar EVA simulations (3 lunar trials each in the NBL and at ARGOS and 2 microgravity EVA trials in the NBL). These runs consisted of both training and engineering test objectives. Actual demands for shoulder use varied for different EVA types and analogues, but many EVA runs have common tasks and require similar motion components. A video observation and event logging software was used to document the duration and occurrence of the subject’s arms being raised throughout the video recordings of each EVA run. An arm raised instance was classified as the arm being at 90 degrees or above with relation to gravity for lunar EVA training events and with relation to the body for microgravity EVA training events. Such events included EVA hardware maintenance or heavy geology sampling tool operations. Events where the arm load was partially supported by external objects, like climbing a ladder or leaning against a surface were separately identified and excluded. Statistical analysis was performed to summarize the timing, frequency, and durations of the arm raise events and compared across the different EVA tasks and analogue types. Preliminary observations indicated that the total duration and number of arm raised instances were surprisingly smaller for lunar surface EVA training as compared to microgravity EVA training. The observed difference may be attributed to differing task demands and unique environmental characteristics found in lunar EVAs in comparison to microgravity EVAs. A detailed statistical analysis will be performed between lunar surface EVA training events and microgravity EVA training events in the final submission. Overall, this analysis is expected to provide insight into how ergonomic recommendations can be refined for lunar EVA training with pressurized suits. It may also inform task design and influence suit padding design to better protect crewmembers during future lunar training.

Kaitlyn Lea Guhl↗

NASA NTRS1978

Prop-fan propulsion - Its status and potential

Studies have established that advanced turboprop (prop-fan) equipped aircraft will reduce fuel consumption by 15 to 30 percent compared to aircraft equipped with high-bypass turbofan engines of equivalent technology. A reduction in direct operating costs of approximately 10 percent has been identified for commercial aircraft as well as approximately 20 percent lower gross weight airplane for long endurance military missions. The prop-fan propulsion system is being investigated as part of the NASA Aircraft Energy Efficiency program which includes both analytical studies and experimental tests. The experimental work encompasses performance and acoustic wind tunnel tests on several prop-fan models. The prop-fan technology status is reviewed in the major areas of performance, installed effects, cabin noise, blade structure and maintenance cost. Also, further activities required to complete the technical validation of prop-fans are described.

Dugan, J. F., Jr.↗

NASA NTRS1994

Electronic Engineering Notebook: A software environment for research execution, documentation and dissemination

The electronic engineering notebook (EEN) consists of a free form research notebook, implemented in a commercial package for distributed hypermedia, which includes utilities for graphics capture, formatting and display of LaTex constructs, and interfaces to the host operating system. The latter capability consists of an information computer-aided software engineering (CASE) tool and a means to associate executable scripts with source objects. The EEN runs on Sun and HP workstations. The EEN, in day-to-day use can be used in much the same manner as the sort of research notes most researchers keep during development of projects. Graphics can be pasted in, equations can be entered via LaTex, etc. In addition, the fact that the EEN is hypermedia permits easy management of 'context', e.g., derivations and data can contain easily formed links to other supporting derivations and data. The CASE tool also permits development and maintenance of source code directly in the notebook, with access to its derivations and data.

Moerder, Dan↗

NASA NTRS1986

Programming support environment issues in the Byron programming environment

Issues are discussed which programming support environments need to address in order to successfully support software engineering. These concerns are divided into two categories. The first category, issues of how software development is supported by an environment, includes support of the full life cycle, methodology flexibility, and support of software reusability. The second category contains issues of how environments should operate, such as tool reusability and integration, user friendliness, networking, and use of a central data base. This discussion is followed by an examination of Byron, an Ada based programming support environment developed at Intermetrics, focusing on the solutions Byron offers to these problems, including the support provided for software reusability and the test and maintenance phases of the life cycle. The use of Byron in project development is described briefly, and some suggestions for future Byron tools and user written tools are presented.

Larsen, Matthew J.↗

NASA NTRS2004

The Multistage Compressor Facility

Research and developments of new aerospace technologies is one of Glenn Research Center's specialties. One facility that deals with the research of aerospace technologies is the High-speed Multistage Compressor Facility. This facility will be testing the performance and efficiency of an Ultra Efficient Engine Technology (UEET) two-stage compressor. There is a lot of preparation involved with testing something of this caliber. Before the test article can be installed into the test rig, the facility must be fully operational and ready to run. Meaning all the necessary instrumentation must be calibrated and installed in the facility. The test rig should also be in safe operating condition, and the proper safety permits obtained. In preparation for the test, the Multistage Compressor Facility went through a few changes. For instance the facility will now be utilizing slip rings, the gearbox went through some maintenance, new lubrications systems replaced the old ones, and special instrumentation needs to be fine tuned to achieve the maximum amount of accurate data. Slips rings help gather information off of a rotating device - in this case from a shaft - onto stationary contacts. The contacts (or brushes) need to be cooled to reduce the amount of frictional heat produced between the slip ring and brushes. The coolant being run through the slip ring is AK-225, a material hazardous to the ozone. To abide by the safety regulations the coolant must be run through a closed chiller system. A new chiller system was purchased but the reservoir that holds the coolant was ventilated which doesn t make the system truly closed and sealed. My task was to design and have a new reservoir built for the chiller system that complies with the safety guidelines. The gearbox had some safety issues also. Located in the back of the gearbox an inching drive was set up. When the inching drive is in use the gears and chain are bare and someone can easily get caught up in it. So to prevent anyone from getting hurt in the gears I designed a chain guard. Additional information is included in the original extended abstract.

Flegel, Ashlie↗

NASA NTRS2011

A Miniaturized Video System for Monitoring Drosophila Behavior

Long-term spaceflight may induce a variety of harmful effects in astronauts, resulting in altered motor and cognitive behavior. The stresses experienced by humans in space - most significantly weightlessness (microgravity) and cosmic radiation - are difficult to accurately simulate on Earth. In fact, prolonged and concomitant exposure to microgravity and cosmic radiation can only be studied in space. Behavioral studies in space have focused on model organisms, including Drosophila melanogaster. Drosophila is often used due to its short life span and generational cycle, small size, and ease of maintenance. Additionally, the well-characterized genetics of Drosophila behavior on Earth can be applied to the analysis of results from spaceflights, provided that the behavior in space is accurately recorded. In 2001, the BioExplorer project introduced a low-cost option for researchers: the small satellite. While this approach enabled multiple inexpensive launches of biological experiments, it also imposed stringent restrictions on the monitoring systems in terms of size, mass, data bandwidth, and power consumption. Suggested parameters for size are on the order of 100 mm3 and 1 kg mass for the entire payload. For Drosophila behavioral studies, these engineering requirements are not met by commercially available systems. One system that does meet many requirements for behavioral studies in space is the actimeter. Actimeters use infrared light gates to track the number of times a fly crosses a boundary within a small container (3x3x40 mm). Unfortunately, the apparatus needed to monitor several flies at once would be larger than the capacity of the small satellite. A system is presented, which expands on the actimeter approach to achieve a highly compact, low-power, ultra-low bandwidth solution for simultaneous monitoring of the behavior of multiple flies in space. This also provides a simple, inexpensive alternative to the current systems for monitoring Drosophila populations in terrestrial experiments, and could be especially useful in field experiments in remote locations. Two practical limitations of the system should be noted: first, only walking flies can be observed - not flying - and second, although it enables population studies, tracking individual flies within the population is not currently possible. The system used video recording and an analog circuit to extract the average light changes as a function of time. Flies were held in a 5-cm diameter Petri dish and illuminated from below by a uniform light source. A miniature, monochrome CMOS (complementary metal-oxide semiconductor) video camera imaged the flies. This camera had automatic gain control, and this did not affect system performance. The camera was positioned 5-7 cm above the Petri dish such that the imaging area was 2.25 sq cm. With this basic setup, still images and continuous video of 15 flies at one time were obtained. To reduce the required data bandwidth by several orders of magnitude, a band-pass filter (0.3-10 Hz) circuit compressed the video signal and extracted changes in image luminance over time. The raw activity signal output of this circuit was recorded on a computer and digitally processed to extract the fly movement "events" from the waveform. These events corresponded to flies entering and leaving the image and were used for extracting activity parameters such as inter-event duration. The efficacy of the system in quantifying locomotor activity was evaluated by varying environmental temperature, then measuring the activity level of the flies.

Bhattacharya, Sharmila↗

NASA NTRS1983

Systems and operations - Living with complexity and growth

Since the space station concept currently being developed by NASA calls for system updates and additions over a period of at least ten years following launch, attention must be given to the interfaces between station elements. Efforts have begun to develop generic fault detection, isolation, and correction techniques that could simplify on-orbit operations, maintenance and repair. An integrated hydrogen-oxygen system has been identified as the feature promising the greatest reduction in resupply costs. Scavenging excess fuel from the Space Shuttle's internal and external tanks, and using leftover Shuttle payload for fluid tankage, could supply hydrogen and oxygen for consumption in the form of propellants, fuel cell electricity, and life support gases. Advancements in cryogenic fluid management and storage technology are the keys to the design of this integrated system. Attention is given to the Interactive Design and Evaluation of Advanced Spacecraft computer-aided design and analysis system, which allows system engineers to study the integration problems presented by 40 technical modules.

Hook, W. R.↗

NASA NTRS1992

Design study to simulate the development of a commercial freight transportation system

The Notre Dame Aerospace Engineering senior class was divided into six design teams. A request for proposals (RFP) asking for the design of a remotely piloted vehicle (RPV) was given to the class, and each design team was responsible for designing, developing, producing, and presenting an RPV concept. The RFP called for the design of commercial freight transport RPV. The RFP provided a description of a fictitious world called 'Aeroworld'. Aeroworld's characteristics were scaled to provide the same types of challenges for RPV design that the real world market provides for the design of commercial aircraft. Fuel efficiency, range and payload capabilities, production and maintenance costs, and profitability are a few of the challenges that were addressed in this course. Each design team completed their project over the course of a semester by designing and flight testing a prototype, freight-carrying remotely piloted vehicle.

Batill, Stephen M.↗

NASA NTRS1977

Industrial Productivity

NASTRAN is an offshoot of the computer-design technique used in construction of airplanes and spacecraft. [n this technique engineers create a mathematical model of the aeronautical or space vehicle and "fly" it on the ground by means of computer simulation. The technique enables them to study performance and structural behavior of a number of different designs before settling on the final configuration and proceeding with construction. From this base of aerospace experience, NASA-Goddard developed the NASTRAN general purpose computer program, which offers an exceptionally wide range of analytic capability with regard to structures. NASTRAN has been applied to autos, trucks, railroad cars, ships, nuclear power reactors, steam turbines, bridges, and office buildings. NASA-Langley provides program maintenance services regarded as vital by many NASTRAN users. NASTRAN is essentially a predictive tool. It takes an electronic look at a computerire$.dedgn and reports how the structure will react under a great many different conditions. It can, for example, note areas where high stress levels will occur-potential failure points that need strengthening. Conversely, it can identify over-designed areas where weight and material might be saved safely. NASTRAN can tell how pipes stand up under strong fluid flow, how metals are affected by high temperatures, how a building will fare in an earthquake or how powerful winds will cause a bridge to oscillate. NASTRAN analysis is quick and inexpensive. It minimizes trial-and-error in the design process and makes possible better, safe, lighter structures affording large-scale savings in development time and materials. Some examples of the broad utility NASTRAN is finding among industrial firms are shown on these pages.

Source record↗

NASA NTRS1976

Energy consumption characteristics of transports using the prop-fan concept

The fuel saving and economic potentials of the prop-fan high-speed propeller concept were evaluated for twin-engine commercial transport airplanes designed for 3333.6 km range, 180 passengers, and Mach 0.8 cruise. A fuel saving of 9.7% at the design range was estimated for a prop-fan airplane having wing-mounted engines, while a 5.8% saving was estimated for a design having the engines mounted on the aft body. The fuel savings and cost were found to be sensitive to the propeller noise level and to aerodynamic drag effects due to wing-slipstream interaction. Uncertainties in these effects could change the fuel savings as much as + or - 50%. A modest improvement in direct operating cost (DOC) was estimated for the wing-mounted prop-fan at current fuel prices. This improvement could become substantial in the event of further relative increases in the price of oil. The improvement in DOC requires the achievement of the nominal fuel saving and reductions in propeller and gearbox maintenance costs relative to current experience.

Source record↗

NASA NTRS2013

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗

NASA NTRS1992

Conceptual analysis of a lunar base transportation system

Important to the planning for a lunar base is the development of transportation requirements for the establishment and maintenance of that base. This was accomplished as part of a lunar base systems assessment study conducted by the NASA Langley Research Center in conjunction with the NASA Johnson Space Center. Lunar base parameters are presented using a baseline lunar facility concept and timeline of developmental phases. Masses for habitation and scientific modules, power systems, life support systems, and thermal control systems were generated, assuming space station technology as a starting point. The masses were manifested by grouping various systems into cargo missions and interspersing manned flights consistent with construction and base maintenance timelines. A computer program that sizes the orbital transfer vehicles (OTV's), lunar landers, lunar ascenders, and the manned capsules was developed. This program consists of an interative technique to solve the rocket equation successively for each velocity correction (delta V) in a mission. The delta V values reflect integrated trajectory values and include gravity losses. As the program computed fuel masses, it matched structural masses from General Dynamics' modular space-based OTV design. Variables in the study included the operation mode (i.e., expendable vs. reusable and single-stage vs. two-stage OTV's), cryogenic specific impulse, reflecting different levels of engine technology, and aerobraking vs. all-propulsive return to Earth orbit. The use of lunar-derived oxygen was also examined for its general impact. For each combination of factors, the low-Earth orbit (LEO) stack masses and Earth-to-orbit (ETO) lift requirements are summarized by individual mission and totaled for the developmental phase. In addition to these discrete data, trends in the variation of study parameters are presented.

Hoy, Trevor D.↗

NASA NTRS1998

X-33/RLV System Health Management/Vehicle Health Management

To reduce operations costs, Reusable Launch Vehicles (RLVS) must include highly reliable robust subsystems which are designed for simple repair access with a simplified servicing infrastructure, and which incorporate expedited decision-making about faults and anomalies. A key component for the Single Stage To Orbit (SSTO) RLV system used to meet these objectives is System Health Management (SHM). SHM incorporates Vehicle Health Management (VHM), ground processing associated with the vehicle fleet (GVHM), and Ground Infrastructure Health Management (GIHM). The primary objective of SHM is to provide an automated and paperless health decision, maintenance, and logistics system. Sanders, a Lockheed Martin Company, is leading the design, development, and integration of the SHM system for RLV and for X-33 (a sub-scale, sub-orbit Advanced Technology Demonstrator). Many critical technologies are necessary to make SHM (and more specifically VHM) practical, reliable, and cost effective. This paper will present the X-33 SHM design which forms the baseline for the RLV SHM, and it will discuss applications of advanced technologies to future RLVs. In addition, this paper will describe a Virtual Design Environment (VDE) which is being developed for RLV. This VDE will allow for system design engineering, as well as program management teams, to accurately and efficiently evaluate system designs, analyze the behavior of current systems, and predict the feasibility of making smooth and cost-efficient transitions from older technologies to newer ones. The RLV SHM design methodology will reduce program costs, decrease total program life-cycle time, and ultimately increase mission success.

Mouyos, William↗

NASA NTRS2006

Integrated Vehicle Health Management (IVHM) for Aerospace Systems

To achieve NASA's ambitious Integrated Space Transportation Program objectives, aerospace systems will implement a variety of new concept in health management. System level integration of IVHM technologies for real-time control and system maintenance will have significant impact on system safety and lifecycle costs. IVHM technologies will enhance the safety and success of complex missions despite component failures, degraded performance, operator errors, and environment uncertainty. IVHM also has the potential to reduce, or even eliminate many of the costly inspections and operations activities required by current and future aerospace systems. This presentation will describe the array of NASA programs participating in the development of IVHM technologies for NASA missions. Future vehicle systems will use models of the system, its environment, and other intelligent agents with which they may interact. IVHM will be incorporated into future mission planners, reasoning engines, and adaptive control systems that can recommend or execute commands enabling the system to respond intelligently in real time. In the past, software errors and/or faulty sensors have been identified as significant contributors to mission failures. This presentation will also address the development and utilization of highly dependable sohare and sensor technologies, which are key components to ensure the reliability of IVHM systems.

Baroth, Edmund C.↗

NASA NTRS2012

NASA Advanced Explorations Systems: Concepts for Logistics to Living

The NASA Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) project strives to enable a largely mission-independent cradle-to-grave-to-cradle approach to minimize logistics contributions to total mission architecture mass. The goals are to engineer logistics materials, common crew consumables, and container configurations to meet the following five basic goals: 1. Minimize intrinsic logistics mass and improve ground logistics flexibility. 2. Allow logistics components to be directly repurposed for on-orbit non-logistics functions (e.g., crew cabin outfitting) thereby indirectly reducing mass/volume. 3. Compact and process logistics that have not been directly repurposed to generate useful on-orbit components and/or compounds (e.g., radiation shielding, propellant, other usable chemical constituents). 4. Enable long-term stable storage and disposal of logistics end products that cannot be reused or repurposed (e.g., compaction for volume reduction, odor control, and maintenance of crew cabin hygienic conditions). 5. Allow vehicles in different mission phases to share logistics resources. This paper addresses the work being done to meet the second goal, the direct repurposing of logistics components to meet other on-orbit needs, through a strategy termed Logistics to Living (L2L). L2L has several areas but can be defined as repurposing or converting logistical items (bags, containers, foam, components, etc.) into useful crew items or life support augmentation on-orbit after they have provided their primary logistics function. The intent is that by repurposing items, dedicated crew items do not have to be launched and overall launch mass is decreased. For non-LEO missions, the vehicle interior volume will be relatively fixed so L2L will enable this volume to be used more effectively through reuse and rearrangement of logistical components. Past work in the area of L2L has already conceptually developed several potential technologies [Howe, Howard 2010]. Several of the L2L concepts that have shown the most potential in the past are based on NASA cargo transfer bags (CTBs) or their equivalents which are currently used to transfer cargo to and from the ISS. A high percentage of all logistics supplies are packaging mass and for a 6-month mission a crew of four might need over 100 CTBs. These CTBs are used for on-orbit transfer and storage but eventually becomes waste after use since down mass is very limited. The work being done in L2L also considering innovative interior habitat construction that integrate the CTBs into the walls of future habitats. The direct integration could provide multiple functions: launch packaging, stowage, radiation protection, water processing, life support augmentation, as well as structure. Reuse of these CTBs would reduce the amount of waste generated and also significantly reduce future up mass requirements for exploration missions. Also discussed here is the L2L water wall , an innovative reuse of an unfolded CTB as a passive water treatment system utilizing forward osmosis. The bags have been modified to have an inner membrane liner that allows them to purify wastewater. They may also provide a structural water-wall element that can be used to provide radiation protection and as a structural divider. Integration of the components into vehicle/habitat architecture and consideration of operations concepts and human factors will be discussed. In the future these bags could be designed to treat wastewater, concentrated brines, and solid wastes, and to dewater solid wastes and produce a bio-stabilized construction element. This paper will describe the follow-on work done in design, fabrication and demonstrations of various L2L concepts, including advanced CTBs for reuse/repurposing, internal outfitting studies and the CTB-based forward osmosis water wall.

Shull, Sarah A.↗

NASA NTRS1972

Speed in Information Processing with a Computer Driven Visual Display in a Real-time Digital Simulation

Information transfer between the operator and computer-generated display systems is an area where the human factors engineer discovers little useful design data relating human performance to system effectiveness. This study utilized a computer-driven, cathode-ray-tube graphic display to quantify human response speed in a sequential information processing task. The performance criteria was response time to sixteen cell elements of a square matrix display. A stimulus signal instruction specified selected cell locations by both row and column identification. An equal probable number code, from one to four, was assigned at random to the sixteen cells of the matrix and correspondingly required one of four, matched keyed-response alternatives. The display format corresponded to a sequence of diagnostic system maintenance events, that enable the operator to verify prime system status, engage backup redundancy for failed subsystem components, and exercise alternate decision-making judgements. The experimental task bypassed the skilled decision-making element and computer processing time, in order to determine a lower bound on the basic response speed for given stimulus/response hardware arrangement.

Kyle, R. G.↗

NASA NTRS1991

Application of enhanced modern structured analysis techniques to Space Station Freedom electric power system requirements

A team of Space Station Freedom (SSF) system engineers are in the process of extensive analysis of the SSF requirements, particularly those pertaining to the electrical power system (EPS). The objective of this analysis is the development of a comprehensive, computer-based requirements model, using an enhanced modern structured analysis methodology (EMSA). Such a model provides a detailed and consistent representation of the system's requirements. The process outlined in the EMSA methodology is unique in that it allows the graphical modeling of real-time system state transitions, as well as functional requirements and data relationships, to be implemented using modern computer-based tools. These tools permit flexible updating and continuous maintenance of the models. Initial findings resulting from the application of EMSA to the EPS have benefited the space station program by linking requirements to design, providing traceability of requirements, identifying discrepancies, and fostering an understanding of the EPS.

Biernacki, John↗

NASA NTRS2004

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗