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NASA NTRS2004

Reliability-Based Life Assessment of Stirling Convertor Heater Head

Onboard radioisotope power systems being developed and planned for NASA's deep-space missions require reliable design lifetimes of up to 14 yr. The structurally critical heater head of the high-efficiency Stirling power convertor has undergone extensive computational analysis of operating temperatures, stresses, and creep resistance of the thin-walled Inconel 718 bill of material. A preliminary assessment of the effect of uncertainties in the material behavior was also performed. Creep failure resistance of the thin-walled heater head could show variation due to small deviations in the manufactured thickness and in uncertainties in operating temperature and pressure. Durability prediction and reliability of the heater head are affected by these deviations from nominal design conditions. Therefore, it is important to include the effects of these uncertainties in predicting the probability of survival of the heater head under mission loads. Furthermore, it may be possible for the heater head to experience rare incidences of small temperature excursions of short duration. These rare incidences would affect the creep strain rate and, therefore, the life. This paper addresses the effects of such rare incidences on the reliability. In addition, the sensitivities of variables affecting the reliability are quantified, and guidelines developed to improve the reliability are outlined. Heater head reliability is being quantified with data from NASA Glenn Research Center's accelerated benchmark testing program.

Shah, Ashwin R.↗
NASA NTRS2004

Coarsening in Solid-Liquid Mixtures-2: A Materials Science Experiment for the ISS

A materials science experiment has been developed and readied for operation aboard the International Space Station (ISS). Components of this experiment are onboard ISS and area awaiting the flight of science samples. The goal of the experiment is to understand the dynamics of Ostwald ripening, also known as coarsening, a process that occurs in nearly any two-phase mixture found in nature. Attempts to obtain experimental data in ground-based laboratories are hindered due to the presence of gravity, which introduces material transport modes other than that of the coarsening phenomenon. This introduces adjustable parameters in the formulation of theory. The original Coarsening in Solid-Liquid Mixtures (CSLM) mission, which flew on the Space Shuttle in 1997, produced data from a coarsened eutectic alloy. Unfortunately, both the science matrix and the hardware, while nominally functional, did not account adequately for operations in microgravity. A significantly redesigned follow-on experiment, CSLM-2 has been developed to redress the inadequacies of the original experiment. This paper reviews the CSLM-2 project: its history, science goals, flight hardware implementation, and planned operations and analysis

Hickman, J. Mark↗
NASA NTRS2004

Effect of Random Thermal Spikes on Stirling Convertor Heater Head Reliability

Onboard radioisotope power systems being developed to support future NASA exploration missions require reliable design lifetimes of up to 14 yr and beyond. The structurally critical heater head of the high-efficiency developmental Stirling power converter has undergone extensive computational analysis of operating temperatures (up to 650 C), stresses, and creep resistance of the thin-walled Inconel 718 bill of material. Additionally assessment of the effect of uncertainties in the creep behavior of the thin-walled heater head, the variation in the manufactured thickness, variation in control temperature, and variation in pressure on the durability and reliability were performed. However, it is possible for the heater head to experience rare incidences of random temperature spikes (excursions) of short duration. These incidences could occur randomly with random magnitude and duration during the desired mission life. These rare incidences could affect the creep strain rate and therefore the life. The paper accounts for these uncertainties and includes the effect of such rare incidences, random in nature, on the reliability. The sensitivities of variables affecting the reliability are quantified and guidelines developed to improve the reliability are outlined. Furthermore, the quantified reliability is being verified with test data from the accelerated benchmark tests being conducted at the NASA Glenn Research Center.

Shah, Ashwin R.↗
NASA NTRS2001

Vapor/Mist Used to Lubricate Gears After Loss of Primary Lubrication System

Loss of lubrication in rotorcraft drive systems is a demanding requirement placed on drive system manufacturers. The drive system must operate for at least 30 minutes once the primary lubrication system has failed. This test is a military requirement that must be passed prior to certification of the aircraft. As new aircraft engines, operating at higher speeds, are fielded, the requirements for the drive system become increasingly more difficult. Also, the drive system must be lightweight, which minimizes the opportunity to use the gear bodies to absorb the tremendous amount of heating that takes place. In many cases, the amount of heat generated because of the high speed and load requires an emergency lubrication system that negatively impacts the aircraft's weight, complexity, and cost. A single mesh spur gear test rig is being used at the NASA Glenn Research Center to investigate possible emergency lubrication system improvements that will minimize the impact of having these systems onboard rotorcraft. A technique currently being investigated uses a vapor/mist system to lubricate the contacting surfaces after the primary lubrication system has been shut down. A number of tests were conducted in which the vapor/mist used the same lubricant as the primary system, but at a greatly reduced flow rate. Each test was initiated with the primary lubrication system operational and at steady-state conditions for a given speed and load. Then the primary lubrication system was shut down, and the vapor/mist lubrication system was initiated. An example of the tests conducted is shown in the figures. These preliminary tests have uncovered a mechanism that provides a lubricious, carbonaceous solid on the surface that actually reduces the surface temperature of the meshing gear teeth during operation. Surface analysis of the carbonaceous solid revealed it was graphitic. This mechanism is the synthetic lubricant "coking" on the active profile of the gears, which reduces the friction between the contacting gear surfaces. The level of load affects the onset of this mechanism: the higher the load, the sooner coking takes place. Future work will investigate several other factors that could improve the already promising results that have been attained.

Handschuh, Robert F.↗
NASA NTRS2004

Design and Fabrication of a Stirling Thermal Vacuum Test

A Stirling Radioisotope Generator (SRG110) is being developed for potential use on future NASA space science missions. The development effort is being conducted by Lockheed Martin under contract to the Department of Energy (DOE). The Stirling Technology Company supplies the free-piston Stirling power convertors, and NASA Glenn Research Center (GRC) provides support to the effort in a range of technologies. This generator features higher efficiency and specific power compared to the currently used alternatives. One potential application for the generator would entail significant cruise time in the vacuum of deep space. A test has been conceived at GRC to demonstrate functionality of the Stirling convertors in a thermal vacuum environment. The test article resembles the configuration of the SRG, however the requirement for low mass was not considered. This test will demonstrate the operation of the Stirling convertors in the thermal vacuum environment, simulating deep space, over an extended period of operation. The analysis, design, and fabrication of the test article will be described in this paper.

Oriti, Salvatore M.↗
NASA NTRS2005

Atmospheric Models for Mars Aerocapture

level Mars atmospheric model. Applications include systems design, performance analysis, and operations planning for aerobraking, entry descent and landing, and aerocapture. Typical Mars aerocapture periapsis altitudes (for systems with rigid- aeroshell heat shields) are about 50 km. This altitude is above the 0-40 km height range covered by Mars Global Surveyor Thermal Emission Spectrometer (TES) nadir observations. Recently, TES limb sounding data have been made available, spanning more than two Mars years (more than 200,000 data profiles) with altitude coverage up to about 60 km, well within the height range of interest for aerocapture. Results are presented comparing Mars-GRAM atmospheric density with densities from TES nadir and limb sounding observations. A new Mars-GRAM feature is described which allows individual TES nadir or limb profiles to be extracted from the large TES databases, and to be used as an optional replacement for standard Mars-GRAM background (climatology) conditions. For Monte-Carlo applications such as aerocapture guidance and control studies, Mars-GRAM perturbations are available using these TES profile background conditions.

Justus, C. G.↗
NASA NTRS2005

Intelligent Systems: Terrestrial Observation and Prediction Using Remote Sensing Data

NASA has made science and technology investments to better utilize its large space-borne remote sensing data holdings of the Earth. With the launch of Terra, NASA created a data-rich environment where the challenge is to fully utilize the data collected from EOS however, despite unprecedented amounts of observed data, there is a need for increasing the frequency, resolution, and diversity of observations. Current terrestrial models that use remote sensing data were constructed in a relatively data and compute limited era and do not take full advantage of on-line learning methods and assimilation techniques that can exploit these data. NASA has invested in visualization, data mining and knowledge discovery methods which have facilitated data exploitation, but these methods are insufficient for improving Earth science models that have extensive background knowledge nor do these methods refine understanding of complex processes. Investing in interdisciplinary teams that include computational scientists can lead to new models and systems for online operation and analysis of data that can autonomously improve in prediction skill over time.

Coughlan, Joseph C.↗
NASA NTRS2005

Mars Aerocapture and Validation of Mars-GRAM with TES Data

Mars Global Reference Atmospheric Model (Mars-GRAM) is a widely-used engineering- level Mars atmospheric model. Applications include systems design, performance analysis, and operations planning for aerobraking, entry descent and landing, and aerocapture. Typical Mars aerocapture periapsis altitudes (for systems with rigid-aeroshell heat shields) are about 50 km. This altitude is above the 0-40 km height range covered by Mars Global Surveyor Thermal Emission Spectrometer (TES) nadir observations. Recently, TES limb sounding data have been made available, spanning more than two Mars years (more than 200,000 data profiles) with altitude coverage up to about 60 km, well within the height range of interest for aerocapture. Results are presented comparing Mars-GRAM atmospheric density with densities from TES nadir and limb sounding observations. A new Mars-GRAM feature is described which allows individual TES nadir or limb profiles to be extracted from the large TES databases, and to be used as an optional replacement for standard Mars-GRAM background (climatology) conditions. For Monte-Carlo applications such as aerocapture guidance and control studies, Mars-GRAM perturbations are available using these TES profile background conditions.

Justus, C. G.↗
NASA NTRS2006

Global Reference Atmospheric Models, Including Thermospheres, for Mars, Venus and Earth

This document is the viewgraph slides of the presentation. Marshall Space Flight Center's Natural Environments Branch has developed Global Reference Atmospheric Models (GRAMs) for Mars, Venus, Earth, and other solar system destinations. Mars-GRAM has been widely used for engineering applications including systems design, performance analysis, and operations planning for aerobraking, entry descent and landing, and aerocapture. Preliminary results are presented, comparing Mars-GRAM with measurements from Mars Reconnaissance Orbiter (MRO) during its aerobraking in Mars thermosphere. Venus-GRAM is based on the Committee on Space Research (COSPAR) Venus International Reference Atmosphere (VIRA), and is suitable for similar engineering applications in the thermosphere or other altitude regions of the atmosphere of Venus. Until recently, the thermosphere in Earth-GRAM has been represented by the Marshall Engineering Thermosphere (MET) model. Earth-GRAM has recently been revised. In addition to including an updated version of MET, it now includes an option to use the Naval Research Laboratory Mass Spectrometer Incoherent Scatter Radar Extended Model (NRLMSISE-00) as an alternate thermospheric model. Some characteristics and results from Venus-GRAM and Earth-GRAM thermospheres are also presented.

Justh, Hilary L.↗
NASA NTRS2006

Flood and Landslide Applications of High Time Resolution Satellite Rain Products

Experimental, potentially real-time systems to detect floods and landslides related to heavy rain events are described. A key basis for these applications is high time resolution satellite rainfall analyses. Rainfall is the primary cause for devastating floods across the world. However, in many countries, satellite-based precipitation estimation may be the best source of rainfall data due to insufficient ground networks and absence of data sharing along many trans-boundary river basins. Remotely sensed precipitation from the NASA's TRMM Multi-satellite Precipitation Analysis (TMPA) operational system (near real-time precipitation at a spatial-temporal resolution of 3 hours and 0.25deg x 0.25deg) is used to monitor extreme precipitation events. Then these data are ingested into a macro-scale hydrological model which is parameterized using spatially distributed elevation, soil and land cover datasets available globally from satellite remote sensing. Preliminary flood results appear reasonable in terms of location and frequency of events, with implementation on a quasi-global basis underway. With the availability of satellite rainfall analyses at fine time resolution, it has also become possible to assess landslide risk on a near-global basis. Early results show that landslide occurrence is closely associated with the spatial patterns and temporal distribution of TRMM rainfall characteristics. Particularly, the number of landslides triggered by rainfall is related to rainfall climatology, antecedent rainfall accumulation, and intensity-duration of rainstorms. For the purpose of prediction, an empirical TMPA-based rainfall intensity-duration threshold is developed and shown to have skill in determining potential areas of landslides. These experimental findings, in combination with landslide surface susceptibility information based on satellite-based land surface information, form a starting point towards a potential operational landslide monitoring/warning system around the globe.

Adler, Robert F.↗
NASA NTRS2005

Operational Aspects of Space Radiation Analysis

Minimizing astronaut's short and long-term medical risks arising from exposure to ionizing radiation during space missions is a major concern for NASA's manned spaceflight program, particularly exploration missions. For ethical and legal reasons, NASA follows the "as low as reasonably achievable" (ALARA) principal in managing astronaut's radiation exposures. One implementation of ALARA is the response to space weather events. Of particular concern are energetic solar particle events, and in low Earth orbit (LEO), electron belt enhancements. To properly respond to these events, NASA's Space Radiation Analysis Group (SRAG), in partnership with the NOAA Space Environment Center (SEC), provides continuous flight support during U.S. manned missions. In this partnership, SEC compiles space weather data from numerous ground and space based assets and makes it available in near real-time to SRAG (along with alerts and forecasts), who in turn uses these data as input to models to calculate estimates of the resulting exposure to astronauts. These calculations and vehicle instrument data form the basis for real-time recommendations to flight management. It is also important to implement ALARA during the design phase. In order to appropriately weigh the risks associated with various shielding and vehicle configuration concepts, the expected environment must be adequately characterized for nominal and worst case scenarios for that portion of the solar cycle and point in space. Even with the best shielding concepts and materials in place (unlikely), there will be numerous occasions where the crew is at greater risk due to being in a lower shielded environment (short term transit or lower shielded vehicles, EVAs), so that accurate space weather forecasts and nowcasts, of particles at the relevant energies, will be crucial to protecting crew health and safety.

Weyland, M. D.↗
NASA NTRS2007

Resilient Propulsion Control Research for the NASA Integrated Resilient Aircraft Control (IRAC) Project

Gas turbine engines are designed to provide sufficient safety margins to guarantee robust operation with an exceptionally long life. However, engine performance requirements may be drastically altered during abnormal flight conditions or emergency maneuvers. In some situations, the conservative design of the engine control system may not be in the best interest of overall aircraft safety; it may be advantageous to "sacrifice" the engine to "save" the aircraft. Motivated by this opportunity, the NASA Aviation Safety Program is conducting resilient propulsion research aimed at developing adaptive engine control methodologies to operate the engine beyond the normal domain for emergency operations to maximize the possibility of safely landing the damaged aircraft. Previous research studies and field incident reports show that the propulsion system can be an effective tool to help control and eventually land a damaged aircraft. Building upon the flight-proven Propulsion Controlled Aircraft (PCA) experience, this area of research will focus on how engine control systems can improve aircraft safe-landing probabilities under adverse conditions. This paper describes the proposed research topics in Engine System Requirements, Engine Modeling and Simulation, Engine Enhancement Research, Operational Risk Analysis and Modeling, and Integrated Flight and Propulsion Controller Designs that support the overall goal.

Guo, Ten-Huei↗
NASA NTRS2008

"Built-In" Action/Issues Tracking and Post-Ops Analysis Tool for Realtime Console Operations

Marshall Space Flight Center's (MSFC) Payload Operations Integration Center (POIC) for the International Space Station (ISS) uses a number of formal databases to manage and track flight plan changes, onboard and ground equipment anomalies, and other events. However, individual console positions encounter many action items and/or occurrences that don't fit neatly into the databases, and while console logs are comprehensive, manual or automated searches do not always yield consistent results. The Payload Communications Manager (PAYCOM) team, whose members speak directly with the ISS onboard crew with respect to NASA payload operations, has found a creative way to reformat a mandatory Daily Report to organize action items, standing reminders, significant events, and other comments. While the report keeps others appraised of PAYCOMs activities and issues of the moment, the format makes it easy to capture very brief summaries of the items in a "Roll Off Matrix", including start and stop dates, resolution, and possible applicability to future ops. The matrix provides accountability for all action items, gives direct insight into the issues surrounding various payloads and methods of dealing with them, yields indirect information on PAYCOM priorities and processes, and provides a roadmap that makes it easier to get back to extensive details if needed. This paper describes how the ISS PAYCOM Daily Report and Roll Off Matrix are organized, used, and inter-related to each other and the PAYCOM operations log. While the application is for a manned vehicle, the concepts could apply in a wide spectrum of operational settings.

Scott, David W.↗
NASA NTRS2009

Converting CSV Files to RKSML Files

A computer program converts, into a format suitable for processing on Earth, files of downlinked telemetric data pertaining to the operation of the Instrument Deployment Device (IDD), which is a robot arm on either of the Mars Explorer Rovers (MERs). The raw downlinked data files are in comma-separated- value (CSV) format. The present program converts the files into Rover Kinematics State Markup Language (RKSML), which is an Extensible Markup Language (XML) format that facilitates representation of operations of the IDD and enables analysis of the operations by means of the Rover Sequencing Validation Program (RSVP), which is used to build sequences of commanded operations for the MERs. After conversion by means of the present program, the downlinked data can be processed by RSVP, enabling the MER downlink operations team to play back the actual IDD activity represented by the telemetric data against the planned IDD activity. Thus, the present program enhances the diagnosis of anomalies that manifest themselves as differences between actual and planned IDD activities.

Trebi-Ollennu, Ashitey↗
NASA NTRS2008

Effect of Surface Traffic Count on Taxi Time at Dallas-Fort Worth (DFW) International Airport

As the amount of air traffic increases over the years, most airports simply do not have the means of expanding to handle the intensified traffic on the surface that will ensue. Precise surveillance equipment and automation concepts, as well as advanced surface traffic algorithms are being developed to improve airport efficiency. These surface algorithms require inputs unique to each airport to ensure maximum efficiency, and minimal taxi delay. This study analyzes surface traffic at Dallas-Fort Worth International Airport (DFW) to determine the effect of the number of aircraft on the surface and the amount of stop and go situations they experience to the amount of additional taxi time encountered. If the surface capacity of an airport is known, minimal delay can be accomplished by limiting the number of taxiing aircraft to that capacity. This concept is related to highways, where traffic flow drastically decreases as more cars occupy the road. An attempt to minimize this effect on highways is seen with the use of metering lights at freeway on-ramps. Since the surface traffic at airports is highly regulated, and aircraft are less mobile on the ground, limiting the surface count to a certain number can greatly reduce the amount of additional taxi time encountered, as well as reduce hazardous emissions. This study will also find the regions of an airport that encounter the most additional taxi time when the number of aircraft in that area is increased. This could help surface traffic algorithms avoid congesting that area, or re-route aircraft to different runways when that area reaches its capacity. The relationship between the amount of stop and go situations an aircraft encounters and their effect on the taxi time of that aircraft will also be investigated. This will help to determine the effect of holding an aircraft on the taxiway as opposed to re-routing it. The lesser of the two should be used when developing surface traffic algorithms to further minimize the delay encountered. The fields investigated in this study include taxi time, the number of aircraft on the surface, the number of stop and go situations, and the time stopped for each aircraft. Taxi time is defined as spot to runway for departures, and runway to spot for arrivals. It does not include ramp area taxi time because the ramp area is controlled differently, and surface traffic schedulers do not currently incorporate them. Taxi time is found by finding the difference between take-off time (OFF) and spot crossing time for departures, and spot crossing time and landing time (ON) for arrivals. All surface data was either found directly using the Surface Operations Data Analysis and Adaptation (SODAA), a tool to analyze the Surface Management System (SMS) generated log files, or indirectly from SODAA using Matlab to derive values from SODAA data. The number of aircraft on the surface is found by looping through the ON times, OFF times, and spot times for each aircraft during a particular day. For each departure aircraft, surface counts are taken at its spot crossing and OFF time. The average of these two is used as the surface count for that aircraft. For arrivals, surface counts are taken at its ON time and its spot crossing time. The average of these two is used.

Kistler, Matthew Stephen↗
NASA NTRS2010

Project Interface Requirements Process Including Shuttle Lessons Learned

Most failures occur at interfaces between organizations and hardware. Processing interface requirements at the start of a project life cycle will reduce the likelihood of costly interface changes/failures later. This can be done by adding Interface Control Documents (ICDs) to the Project top level drawing tree, providing technical direction to the Projects for interface requirements, and by funding the interface requirements function directly from the Project Manager's office. The interface requirements function within the Project Systems Engineering and Integration (SE&I) Office would work in-line with the project element design engineers early in the life cycle to enhance communications and negotiate technical issues between the elements. This function would work as the technical arm of the Project Manager to help ensure that the Project cost, schedule, and risk objectives can be met during the Life Cycle. Some ICD Lessons Learned during the Space Shuttle Program (SSP) Life Cycle will include the use of hardware interface photos in the ICD, progressive life cycle design certification by analysis, test, & operations experience, assigning interface design engineers to Element Interface (EI) and Project technical panels, and linking interface design drawings with project build drawings

Bauch, Garland T.↗
NASA NTRS2010

ISS and Shuttle Payload Research Development and Processing

NASA's ISS and Spacecraft Processing Directorate (UB) is charged with the performance of payload development for research originating through NASA, ISS international partners, and the National Laboratory. The Payload Development sector of the Directorate takes biological research approved for on orbit experimentation from its infancy stage and finds a way to integrate and implement that research into a payload on either a Shuttle sortie or Space Station increment. From solicitation and selection, to definition, to verification, to integration and finally to operations and analysis, Payload Development is there every step of the way. My specific work as an intern this summer has consisted of investigating data received by separate flight and ground control Advanced Biological Research Systems (ABRS) units for Advanced Plant Experiments (APEX) and Cambium research. By correlation and analysis of this data and specific logbook information I have been working to explain changes in environmental conditions on both the flight and ground control unit. I have then, compiled all of that information into a form that can be presentable to the Principal Investigator (PI). This compilation allows that PI scientist to support their findings and add merit to their research. It also allows us, as the Payload Developers, to further inspect the ABRS unit and its performance

Calhoun, Kyle A.↗
NASA NTRS2010

Extraction of Modal Parameters from Spacecraft Flight Data

The modeled response of spacecraft systems must be validated using flight data as ground tests cannot adequately represent the flight. Tools from the field of operational modal analysis would typically be brought to bear on such structures. However, spacecraft systems have several complicated issues: 1. High amplitudes of loads; 2. Compressive loads on the vehicle in flight; 3. Lack of generous time-synchronized flight data; 4. Changing properties during the flight; and 5. Major vehicle changes due to staging. A particularly vexing parameter to extract is modal damping. Damping estimation has become a more critical issue as new mass-driven vehicle designs seek to use the highest damping value possible. The paper will focus on recent efforts to utilize spacecraft flight data to extract system parameters, with a special interest on modal damping. This work utilizes the analysis of correlation functions derived from a sliding window technique applied to the time record. Four different case studies are reported in the sequence that drove the authors understanding. The insights derived from these four exercises are preliminary conclusions for the general state-of-the-art, but may be of specific utility to similar problems approached with similar tools.

James, George H.↗