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NASA NTRS1999

Three-Dimensional Gear Crack Propagation Studied

Gears used in current helicopters and turboprops are designed for light weight, high margins of safety, and high reliability. However, unexpected gear failures may occur even with adequate tooth design. To design an extremely safe system, the designer must ask and address the question, "What happens when a failure occurs?" With gear-tooth bending fatigue, tooth or rim fractures may occur. A crack that propagates through a rim will be catastrophic, leading to disengagement of the rotor or propeller, loss of an aircraft, and possible fatalities. This failure mode should be avoided. A crack that propagates through a tooth may or may not be catastrophic, depending on the design and operating conditions. Also, early warning of this failure mode may be possible because of advances in modern diagnostic systems. One concept proposed to address bending fatigue fracture from a safety aspect is a splittooth gear design. The prime objective of this design would be to control crack propagation in a desired direction such that at least half of the tooth would remain operational should a bending failure occur. A study at the NASA Lewis Research Center analytically validated the crack-propagation failsafe characteristics of a split-tooth gear. It used a specially developed three-dimensional crack analysis program that was based on boundary element modeling and principles of linear elastic fracture mechanics. Crack shapes as well as the crack-propagation life were predicted on the basis of the calculated stress intensity factors, mixed-mode crack-propagation trajectory theories, and fatigue crack-growth theories. The preceding figures show the effect of the location of initial cracks on crack propagation. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth was simulated in a case study to evaluate crack-propagation paths. Tooth fracture was predicted from the crackgrowth simulation for an initial crack in the tooth fillet region. This was the desired failure mode for an ultrasafe design. Lastly, tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. This effect needs to be considered in the design of a split-tooth configuration. This work was done in-house at Lewis in support of the National Rotorcraft Technology Center project, Ultra-Safe Gear Design, with the Boeing Defense and Space Group. The crack-propagation package was developed by the Cornell Fracture Group at Cornell University. The reported results, which are the initial findings of Lewis gear-crackpropagation research for the Rotorcraft Base Program, will be further investigated to develop generalized gear design guidelines.

Lewicki, David G.↗

NASA NTRS2000

Fiber-Optic Imaging Probe Developed for Space Used to Detect Diabetes Through the Eye

Approximately 16 million Americans have diabetes mellitus, which can severely impair eyesight by causing cataracts, diabetic retinopathy, and glaucoma. Cataracts are 1.6 times more common in people with diabetes than in those without diabetes, and cataract extraction is the only surgical treatment. In many cases, diabetes-related ocular pathologies go undiagnosed until visual function is compromised. This ongoing pilot project seeks to study the progression of diabetes in a unique animal model by monitoring changes in the lens with a safe, sensitive, dynamic light-scattering probe. Dynamic light scattering (DLS), has the potential to diagnose cataracts at the molecular level. Recently, a new DLS fiber-optic probe was developed at the NASA Glenn Research Center at Lewis Field for noncontact, accurate, and extremely sensitive particle-sizing measurements in fluid dispersions and suspensions (ref. 1). This compact, portable, and rugged probe is free of optical alignment, offers point-and-shoot operation for various online field applications and challenging environments, and yet is extremely flexible in regards to sample container sizes, materials, and shapes. No external vibration isolation and no index matching are required. It can measure particles as small as 1 nm and as large as few micrometers in a wide concentration range from very dilute (waterlike) dispersions to very turbid (milklike) suspensions. It is safe and fast to use, since it only requires very low laser power (10 nW to 3 mW) with very short data acquisition times (2 to 10 sec).

Ansari, Rafat R.↗

NASA NTRS2004

Probabilistic Study Conducted on Sensor-Based Engine Life Calculation

Turbine engine life management is a very complicated process to ensure the safe operation of an engine subjected to complex usage. The challenge of life management is to find a reasonable compromise between the safe operation and the maximum usage of critical parts to reduce maintenance costs. The commonly used "cycle count" approach does not take the engine operation conditions into account, and it oversimplifies the calculation of the life usage. Because of the shortcomings, many engine components are regularly pulled for maintenance before their usable life is over. And, if an engine has been running regularly under more severe conditions, components might not be taken out of service before they exceed their designed risk of failure. The NASA Glenn Research Center and its industrial and academic partners have been using measurable parameters to improve engine life estimation. This study was based on the Monte Carlo simulation of 5000 typical flights under various operating conditions. First a closed-loop engine model was developed to simulate the engine operation across the mission profile and a thermomechanical fatigue (TMF) damage model was used to calculate the actual damage during takeoff, where the maximum TMF accumulates. Next, a Weibull distribution was used to estimate the implied probability of failure for a given accumulated cycle count. Monte Carlo simulations were then employed to find the profiles of the TMF damage under different operating assumptions including parameter uncertainties. Finally, probabilities of failure for different operating conditions were analyzed to demonstrate the importance of a sensor-based damage calculation in order to better manage the risk of failure and on-wing life.

Guo, Ten-Huei↗

NASA NTRS2001

Virtual Reality Used to Serve the Glenn Engineering Community

There are a variety of innovative new visualization tools available to scientists and engineers for the display and analysis of their models. At the NASA Glenn Research Center, we have an ImmersaDesk, a large, single-panel, semi-immersive display device. This versatile unit can interactively display three-dimensional images in visual stereo. Our challenge is to make this virtual reality platform accessible and useful to researchers. An example of a successful application of this computer technology is the display of blade out simulations. NASA Glenn structural dynamicists, Dr. Kelly Carney and Dr. Charles Lawrence, funded by the Ultra Safe Propulsion Project under Base R&T, are researching blade outs, when turbine engines lose a fan blade during operation. Key objectives of this research include minimizing danger to the aircraft via effective blade containment, predicting destructive loads due to the imbalance following a blade loss, and identifying safe, cost-effective designs and materials for future engines.

Carney, Dorothy V.↗

NASA NTRS2002

Dual Microstructure Heat Treatment of a Nickel-Base Disk Alloy Assessed

Gas turbine engines for future subsonic aircraft will require nickel-base disk alloys that can be used at temperatures in excess of 1300 F. Smaller turbine engines, with higher rotational speeds, also require disk alloys with high strength. To address these challenges, NASA funded a series of disk programs in the 1990's. Under these initiatives, Honeywell and Allison focused their attention on Alloy 10, a high-strength, nickel-base disk alloy developed by Honeywell for application in the small turbine engines used in regional jet aircraft. Since tensile, creep, and fatigue properties are strongly influenced by alloy grain size, the effect of heat treatment on grain size and the attendant properties were studied in detail. It was observed that a fine grain microstructure offered the best tensile and fatigue properties, whereas a coarse grain microstructure offered the best creep resistance at high temperatures. Therefore, a disk with a dual microstructure, consisting of a fine-grained bore and a coarse-grained rim, should have a high potential for optimal performance. Under NASA's Ultra-Safe Propulsion Project and Ultra-Efficient Engine Technology (UEET) Program, a disk program was initiated at the NASA Glenn Research Center to assess the feasibility of using Alloy 10 to produce a dual-microstructure disk. The objectives of this program were twofold. First, existing dual-microstructure heat treatment (DMHT) technology would be applied and refined as necessary for Alloy 10 to yield the desired grain structure in full-scale forgings appropriate for use in regional gas turbine engines. Second, key mechanical properties from the bore and rim of a DMHT Alloy 10 disk would be measured and compared with conventional heat treatments to assess the benefits of DMHT technology. At Wyman Gordon and Honeywell, an active-cooling DMHT process was used to convert four full-scale Alloy 10 disks to a dual-grain microstructure. The resulting microstructures are illustrated in the photomicrographs. The fine grain size in the bore can be contrasted with the coarse grain size in the rim. Testing (at NASA Glenn) of coupons machined from these disks showed that the DMHT approach did indeed produce a high-strength, fatigue resistant bore and a creep-resistant rim. This combination of properties was previously unobtainable using conventional heat treatments, which produced disks with a uniform grain size. Future plans are in place to spin test a DMHT disk under the Ultra Safe Propulsion Project to assess the viability of this technology at the component level. This testing will include measurements of disk growth at a high temperature as well as the determination of burst speed at an intermediate temperature.

Gayda, John↗

NASA NTRS2005

STS-114: Post Launch MMT Briefing

Bill Parsons, Space Shuttle Program Manager, and Wayne Hill, Deputy Manager of the Space Shuttle Program, and Chair of the Mission Management Team talks about the flight day 2 of the Discovery. Bill noted that flight operations are extremely going on well. He also explained an unexpected debris event on a power ramp little ways down where LH2 ramp begins. Before flight and based from technical data, slight modifications were done on the power ramp to ensure safety of return to flight. Bill also noted that STS-114 is a test flight; all data collected and brought back by the crew will be analyzed to ensure that all information needed is sufficient to work on faults and defects and to make appropriate repairs. Wayne discussed on flight safety. He emphasized the need to thoroughly inspect the thermal protection system of the Orbiter to ensure safe entry. Inspection of still photographs from the ISS and the boom sensor system scan are the primary means to understand engineering data in terms of the immediate flight safety. He also reported accomplishments for the day such as survey of the Orbiter boom system, all the wing leading edge, RCC panels and the nose cap, to make sure these are in good shape and working well, and re-emphasized that these are primary methods to clear the thermal protection system of the Orbiter to prove that it is safe to come home on this flight.

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NASA NTRS2005

Managing radiation degradation of CCDs on the Chandra X-ray Observatory II

The CCDs on the Chandra X-ray Observatory are vulnerable to radiation damage from low-energy protons scattered off the telescope's mirrors onto the focal plane. Following unexpected damage incurred early in the mission, the Chandra Team developed, implemented, and maintains a radiation-protection program. This program - involving scheduled radiation safing during radiation-belt passes, intervention based upon real-time space-weather conditions and radiation-environment modeling, and on-board radiation monitoring with autonomous radiation safing - has successfully managed the radiation damage to the CCDs. Since implementing the program, the charge-transfer inefficiency (CTI) has increased at an average annual rate of only 2.9x10^-6 (2.3%) for the front- illuminated CCDs and 0.95x10^-6 (6.5%) for the back-illuminated CCDs. This paper describes the current status of Chandra radiation-management program.

O'Dell, Stephen L.↗

NASA NTRS2004

International Space Station (ISS) Metal Oxide (MetOx) Odor Anomaly

On occasion, seemingly normal operations can have significant effects upon the closed environment of the International Space Station (ISS). An example of such a case occurred on February 20, 2002 when a nominal Metal Oxide (MetOx) canister regeneration operation onboard the ISS resulted in an unexpected, foul odor that affected the crew and station operations. A case study summarizing the root cause for the event and steps taken to ensure that future MetOx regeneration operations proceed safely is presented. Included in the summary are engineering analyses and environmental monitoring results supporting the root cause assessment as well as testing conducted and flight operations changes implemented to ensure safe operations.

Prokhorov, Kimberlee↗

NASA NTRS2004

Proton Exchange Membrane (PEM) Fuel Cells for Space Applications

This presentation will provide a summary of the PEM fuel cell development at the National Aeronautics and Space Administration, Johnson Space Center (NASA, JSC) in support of future space applications. Fuel cells have been used for space power generation due to their high energy storage density for multi-day missions. The Shuttle currently utilizes the alkaline fuel cell technology, which has highly safe and reliable performance. However, the alkaline technology has a limited life due to the corrosion inherent to the alkaline technology. PEM fuel cells are under development by industry for transportation, residential and commercial stationary power applications. NASA is trying to incorporate some of this stack technology development in the PEM fuel cells for space. NASA has some unique design and performance parameters which make developing a PEM fuel cell system more challenging. Space fuel cell applications utilize oxygen, rather than air, which yields better performance but increases the hazard level. To reduce the quantity of reactants that need to be flown in space, NASA also utilizes water separation and reactant recirculation. Due to the hazards of utilizing active components for recirculation and water separation, NASA is trying to develop passive recirculation and water separation methods. However, the ability to develop recirculation components and water separators that are gravity-independent and successfully operate over the full range of power levels is one of the greatest challenges to developing a safe and reliable PEM fuel cell system. PEM stack, accessory component, and system tests that have been performed for space power applications will be discussed.

Bradley, Karla↗

NASA NTRS2005

A Proposed Role of Aeroelasticity in NASA's New Exploration Vision

On 14 January 2004, NASA received a mandate to return astronauts to the Moon, evolve a sustained presence there, then head out into the solar system to Mars and perhaps beyond. This new space exploration initiative directs NASA to develop human and robotic technologies that can deliver payloads larger than Apollo to the Moon, to Mars, and bring astronauts and samples safely back to Earth at costs much lower than Apollo. These challenges require creative aerospace systems. On proposed technology for safely delivering payloads to the surface of Mars and returning samples to Earth involves deployed flexible and inflatable decelerators for atmospheric entry. Because inflatable decelerators provide the entry vehicle more drag surface area at smaller mass than traditional ablative devices, this class of decelerators can potentially accomodate larger mass payloads. The flexibility of these lightweight aeroshells can pose both vehicle and aeroelastic stability problems if not properly designed for the expected flight regimes. Computational tools need to be developed for modelling the large and nonlinear deformations of these highly flexible structures. Unlike wind tunnel testing, an integrated and efficient aeroelastic analysis tool can explore the entire flight environment. This paper will provide some background on flexible deployable decelerators, survey the current state of technology and outline the proposed development of an aeroelastic analysis and capability.

Bartels, Robert E.↗

NASA NTRS2005

SATS HVO Concept Validation Experiment

A human-in-the-loop simulation experiment was conducted at the NASA Langley Research Center s (LaRC) Air Traffic Operations Lab (ATOL) in an effort to comprehensively validate tools and procedures intended to enable the Small Aircraft Transportation System, Higher Volume Operations (SATS HVO) concept of operations. The SATS HVO procedures were developed to increase the rate of operations at non-towered, non-radar airports in near all-weather conditions. A key element of the design is the establishment of a volume of airspace around designated airports where pilots accept responsibility for self-separation. Flights operating at these airports, are given approach sequencing information computed by a ground based automated system. The SATS HVO validation experiment was conducted in the ATOL during the spring of 2004 in order to determine if a pilot can safely and proficiently fly an airplane while performing SATS HVO procedures. Comparative measures of flight path error, perceived workload and situation awareness were obtained for two types of scenarios. Baseline scenarios were representative of today s system utilizing procedure separation, where air traffic control grants one approach or departure clearance at a time. SATS HVO scenarios represented approaches and departure procedures as described in the SATS HVO concept of operations. Results from the experiment indicate that low time pilots were able to fly SATS HVO procedures and maintain self-separation as safely and proficiently as flying today's procedures.

Consiglio, Maria↗

NASA NTRS2005

Multi-Target Single Cycle Instrument Placement

This presentation is about the robotic exploration of Mars using multiple targets command cycle, safe instrument placements, safe operation, and K9 Rover which has a 6 wheel steer rocket-bogey chassis (FIDO, MER), 70% MER size, 1.2 GHz Pentium M laptop running Linux OS, Odometry and compass/inclinometer, CLARAty architecture, 5 DOF manipulator w/CHAMP microscopic camera, SciCams, NavCams and HazCams.

Pedersen, Liam↗

NASA NTRS2005

Novel Space-based Solar Power Technologies and Architectures for Earth and Beyond

Research, development and studies of novel space-based solar power systems, technologies and architectures for Earth and beyond are needed to reduce the cost of clean electrical power for terrestrial use and to provide a stepping stone for providing an abundance of power in space, i.e., manufacturing facilities, tourist facilities, delivery of power between objects in space, and between space and surface sites. The architectures, technologies and systems needed for space to Earth applications may also be used for in-space applications. Advances in key technologies, i.e., power generation, power management and distribution, power beaming and conversion of beamed power are needed to achieve the objectives of both terrestrial and extraterrestrial applications. Power beaming or wireless power transmission (WPT) can involve lasers or microwaves along with the associated power interfaces. Microwave and laser transmission techniques have been studied with several promising approaches to safe and efficient WPT identified. These investigations have included microwave phased array transmitters, as well as laser transmission and associated optics. There is a need to produce "proof-of-concept" validation of critical WPT technologies for both the near-term, as well as far-term applications. Investments may be harvested in near-term beam safe demonstrations of commercial WPT applications. Receiving sites (users) include ground-based stations for terrestrial electrical power, orbital sites to provide power for satellites and other platforms, future space elevator systems, space vehicle propulsion, and space to surface sites. This paper briefly discusses achieving a promising approach to the solar power generation and beamed power conversion. The approach is based on a unique high-power solar concentrator array called Stretched Lens Array (SLA) for both solar power generation and beamed power conversion. Since both versions (solar and laser) of SLA use many identical components (only the photovoltaic cells need to be different), economies of manufacturing and scale may be realized by using SLA on both ends of the laser power beaming system in a space solar power application. Near-term uses of this SLA-laser-SLA system may include terrestrial and space exploration in near Earth space. Later uses may include beamed power for bases or vehicles on Mars.

Howell, Joe T.↗

NASA NTRS2006

Structural Requirements for the Space Propulsion Engine Systems

In January 2004, the National Aeronautics and Space Administration (NASA) was given a vision for Space Exploration by President Bush, setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. As NASA gets ready to meet the vision set by President Bush, failures are not an option. Reliability of the propulsion engine systems will play an important role in establishing an overall safe and reliable operation of these new space systems. A new standard, NASA-STD-5012, Strength and Life Assessment for Space Propulsion System Engines, has been developed to provide structural requirements for assessment of the propulsion systems engine. This standard is a complement to the current NASA-wide standard NASA-STD-5001, Structural Design and Test Factors of Safety for Spaceflight Hardware, which excluded the requirement for the engine systems (rotatory structures) along with pressure vessels. As developed, this document builds on the heritage of the multiple industrial standards related to strength and life assessment of the structures. For assuring a safe and reliable operation of a product and/or mission, establishing a set of structural assessment requirements is a key ingredient. Hence, a concentrated effort was made to improve the requirements where there are known lessons learned during the design, test, and operation phases of the Space Shuttle Main Engine (SSME) and other engine development programs. Requirements delineated in this standard are also applicable for the reusable and/or human missions. It shall be noted that "reliability of a system cannot be tested and inspected but can only be achieved if it is first designed into a system." Hence, these strength and life assessment requirements for the space propulsion system engines shall be used along with other good engineering practices, requirements, and policies.

Aggarwal, Pravin K.↗

NASA NTRS2006

Ka-Band Wide-Bandgap Solid-State Power Amplifier: Prototype Combiner Spurious Mode Suppression and Power Constraints

Results of prototype hardware activities related to a 120-W, 32-GHz (Ka-band) solid-state power amplifier (SSPA) architecture study are presented. Spurious mode suppression and the power-handling capability of a prototype 24-way radial combiner and a prototype 2-way septum binary combiner were investigated. Experimental data indicate that a commercial absorptive filter, designed to pass the circular TE01 mode, effectively suppressed the higher-order modes generated by a narrowband, flower-petal-type mode transducer. However, the same filter was not effective in suppressing higher-order modes generated by the broadband Marie mode transducer that is used in the prototype waveguide radial combiner. Should greater filtering be required by a particular SSPA application, a broadband mode filter that can suppress specifically those higher-order modes that are generated by the Marie transducer will need to be developed. A back-to-back configuration of the prototype radial combiner was tested with drive power up to approximately 50 W. No anomalous behavior was observed. Power measurements of the septum combiner indicate that up to 10-W radio frequency (RF) can be dissipated in the integrated resistive element before a permanent performance shift is observed. Thus, a given adder (a single-stage, 2-way combiner) can safely combine two 20-W sources, and the adder will not be damaged in the event of a source failure. This result is used to calculate the maximum source power that can be safely combined as a function of the number of sources combined and the number of source failures allowed in a multi-stage combiner. The analysis shows that SSPA power >140 W can be generated by power combining 16 sources producing 10 W each. In this configuration, up to three sources could fail with the guarantee that the combiner would not be damaged. Finally, a modified prototype septum combiner design was verified. The improved design reduced the assembly time from over 2 hours to about 15 minutes per adder.

Khan, P.↗

NASA NTRS2006

Towards Robust Designs Via Multiple-Objective Optimization Methods

Fabricating and operating complex systems involves dealing with uncertainty in the relevant variables. In the case of aircraft, flow conditions are subject to change during operation. Efficiency and engine noise may be different from the expected values because of manufacturing tolerances and normal wear and tear. Engine components may have a shorter life than expected because of manufacturing tolerances. In spite of the important effect of operating- and manufacturing-uncertainty on the performance and expected life of the component or system, traditional aerodynamic shape optimization has focused on obtaining the best design given a set of deterministic flow conditions. Clearly it is important to both maintain near-optimal performance levels at off-design operating conditions, and, ensure that performance does not degrade appreciably when the component shape differs from the optimal shape due to manufacturing tolerances and normal wear and tear. These requirements naturally lead to the idea of robust optimal design wherein the concept of robustness to various perturbations is built into the design optimization procedure. The basic ideas involved in robust optimal design will be included in this lecture. The imposition of the additional requirement of robustness results in a multiple-objective optimization problem requiring appropriate solution procedures. Typically the costs associated with multiple-objective optimization are substantial. Therefore efficient multiple-objective optimization procedures are crucial to the rapid deployment of the principles of robust design in industry. Hence the companion set of lecture notes (Single- and Multiple-Objective Optimization with Differential Evolution and Neural Networks ) deals with methodology for solving multiple-objective Optimization problems efficiently, reliably and with little user intervention. Applications of the methodologies presented in the companion lecture to robust design will be included here. The evolutionary method (DE) is first used to solve a relatively difficult problem in extended surface heat transfer wherein optimal fin geometries are obtained for different safe operating base temperatures. The objective of maximizing the safe operating base temperature range is in direct conflict with the objective of maximizing fin heat transfer. This problem is a good example of achieving robustness in the context of changing operating conditions. The evolutionary method is then used to design a turbine airfoil; the two objectives being reduced sensitivity of the pressure distribution to small changes in the airfoil shape and the maximization of the trailing edge wedge angle with the consequent increase in airfoil thickness and strength. This is a relevant example of achieving robustness to manufacturing tolerances and wear and tear in the presence of other objectives.

Man Mohan, Rai↗

NASA NTRS2006

Vortex-Free Flight Corridors for Aircraft Executing Compressed Landing Operations

A factor that limits airport arrival and departure rates is the need to wait between operations for the wake vortices of preceding aircraft to decay to a safe level. As airport traffic demand increases, creative methods will be needed to overcome the limitations caused by the hazard posed by vortex wakes so that airport capacities can be increased. The problem addressed here is the design of vortex-free trajectories for aircraft as they fly from their cruise altitudes down to their final approach paths and to a landing. The guidelines presented recommend that the flight path of each aircraft in a group executing nearly-simultaneous landings be spaced far enough apart laterally along organized flight paths so that the vortex wakes of preceding aircraft will not intrude into the airspace to be used by following aircraft. An example is presented as to how a combination of straight lines and circular arcs is able to provide each aircraft in a group with a vortex-free trajectory so that all are able to safely form the pattern needed for nearly simultaneous landings on a set of closely-spaced parallel runways. Although the guidelines me described for aircraft on approach, they are also applicable to departure, and to en route operations.

Rossow, Vernon J.↗

NASA NTRS2005

Monitoring Wake Vortices for More Efficient Airports

Wake vortices are generated by all aircraft during flight. The larger the aircraft, the stronger the wake, so the Federal Aviation Administration (FAA) separates aircraft to ensure wake turbulence has no effect on approaching aircraft. Currently, though, the time between planes is often larger than it needs to be for the wake to dissipate. This unnecessary gap translates into arrival and departure delays, but since the wakes are invisible, the delays are nearly inevitable. If, however, the separation between aircraft can be reduced safely, then airport capacity can be increased without the high cost of additional runways. Scientists are currently studying these patterns to identify and introduce new procedures and technologies that safely increase airport capacity. NASA, always on the cutting edge of aerospace research, has been contributing knowledge and testing to these endeavors.

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