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

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NASA NTRS1990

Life prediction technologies for aeronautical propulsion systems

Fatigue and fracture problems continue to occur in aeronautical gas turbine engines. Components whose useful life is limited by these failure modes include turbine hot-section blades, vanes, and disks. Safety considerations dictate that catastrophic failures be avoided, while economic considerations dictate that catastrophic failures be avoided, while economic considerations dictate that noncatastrophic failures occur as infrequently as possible. Therefore, the decision in design is making the tradeoff between engine performance and durability. LeRC has contributed to the aeropropulsion industry in the area of life prediction technology for over 30 years, developing creep and fatigue life prediction methodologies for hot-section materials. At the present time, emphasis is being placed on the development of methods capable of handling both thermal and mechanical fatigue under severe environments. Recent accomplishments include the development of more accurate creep-fatigue life prediction methods such as the total strain version of LeRC's strain-range partitioning (SRP) and the HOST-developed cyclic damage accumulation (CDA) model. Other examples include the development of a more accurate cumulative fatigue damage rule - the double damage curve approach (DDCA), which provides greatly improved accuracy in comparison with usual cumulative fatigue design rules. Other accomplishments in the area of high-temperature fatigue crack growth may also be mentioned. Finally, we are looking to the future and are beginning to do research on the advanced methods which will be required for development of advanced materials and propulsion systems over the next 10-20 years.

Mcgaw, Michael A.↗

NASA NTRS1993

Aerothermoelastic analysis of a NASP demonstrator model

The proposed National AeroSpace Plane (NASP) is designed to travel at speeds up to Mach 25. Because aerodynamic heating during high-speed flight through the atmosphere could destiffen a structure, significant couplings between the elastic and rigid body modes could result in lower flutter speeds and more pronounced aeroelastic response characteristics. These speeds will also generate thermal loads on the structure. The purpose of this research is develop methodologies applicable to the NASP and to apply them to a representative model to determine its aerothermoelastic characteristics when subjected to these thermal loads. This paper describes an aerothermoelastic analysis of the generic hypersonic vehicle configuration. The steps involved in this analysis were: (1) generating vehicle surface temperatures at the appropriate flight conditions; (2) applying these temperatures to the vehicle's structure to predict changes in the stiffness resulting from material property degradation; (3) predicting the vibration characteristics of the heated structure at the various temperature conditions; (4) performing aerodynamic analyses; and (5) conducting flutter analysis of the heated vehicle. Results of these analyses and conclusions representative of a NASP vehicle are provided in this paper.

Heeg, Jennifer↗

NASA NTRS1993

Aerothermoelastic analysis of a NASP demonstrator model

The proposed National Aerospace Plane (NASP) is designed to travel at speeds up to Mach 25. Because aerodynamic heating during high-speed flight through the atmosphere could destiffen a structure, significant couplings between the elastic and rigid body modes could result in lower flutter speeds and more pronounced aeroelastic response characteristics. These speeds will also generate thermal loads on the structure. The purpose of this research is to develop methodologies applicable to the NASP and to apply them to a representative model to determine its aerothermoelastic characteristics when subjected to these thermal loads. This paper describes an aerothermoelastic analysis of the generic hypersonic vehicle configuration. The steps involved in this analysis were: generating vehicle surface temperatures at the appropriate flight conditions; applying these temperatures to the vehicle's structure to predict changes in the stiffness resulting from material property degradation; predicting the vibration characteristics of the heated structure at the various temperature conditions; performing aerodynamic analyses; and conducting flutter analysis of the heated vehicle. Results of these analyses and conclusions representative of a NASP vehicle are provided in this paper.

Heeg, Jennifer↗

NASA NTRS2002

Reliability Analysis of Brittle Material Structures - Including MEMS(?) - With the CARES/Life Program

Brittle materials are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts. thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The CARES/Life code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. For this presentation an interview of the CARES/Life program will be provided. Emphasis will be placed on describing the latest enhancements to the code for reliability analysis with time varying loads and temperatures (fully transient reliability analysis). Also, early efforts in investigating the validity of using Weibull statistics, the basis of the CARES/Life program, to characterize the strength of MEMS structures will be described as as well as the version of CARES/Life for MEMS (CARES/MEMS) being prepared which incorporates single crystal and edge flaw reliability analysis capability. It is hoped this talk will open a dialog for potential collaboration in the area of MEMS testing and life prediction.

Nemeth, Noel N.↗

NASA NTRS2003

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (~4 g/cm3) in comparison to superalloys (~8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (~1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

Hebsur, Mohan G.↗

NASA NTRS2002

Instrumentation and Methodology Development for Mars Mission

The Mars environment comprises a dry, cold and low air pressure atmosphere with low gravity (0.38g) and high resistivity soil. The global dust storms that cover a large portion of Mars were observed often from Earth. This environment provides an idea condition for triboelectric charging. The extremely dry conditions on the Martian surface have raised concerns that electrostatic charge buildup will not be dissipated easily. If triboelectrically generated charge cannot be dissipated or avoided, then dust will accumulate on charged surfaces and electrostatic discharge may cause hazards for future exploration missions. The low surface temperature on Mars helps to prolong the charge decay on the dust particles and soil. To better understand the physics of Martian charged dust particles is essential to future Mars missions. We research and design two sensors, velocity/charge sensor and PZT momentum sensors, to detect the velocity distribution, charge distribution and mass distribution of Martian charged dust particles. These sensors are fabricated at NASA Kenney Space Center, Electromagnetic Physics Testbed. The sensors will be tested and calibrated for simulated Mars atmosphere condition with JSC MARS-1 Martian Regolith simulant in this NASA laboratory.

Chen, Yuan-Liang Albert↗

NASA NTRSDate not supplied

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials↗

NASA NTRS2014

A Novel Instrument and Methodology for the In-Situ Measurement of the Stress in Thin Films

We introduce a novel methodology for the in-situ measurement of mechanical stress during thin film growth utilizing a highly sensitive non-contact variation of the classic spherometer. By exploiting the known spherical deformation of the substrate the value of the stress induced curvature is inferred by measurement of only one point on the substrate's surface-the sagittal. From the known curvature the stress can be calculated using the well-known Stoney equation. Based on this methodology, a stress sensor has been designed which is simple, highly sensitive, compact, and low cost. As a result of its compact nature, the sensor can be mounted in any orientation to accommodate a given deposition geometry without the need for extensive modification to an already existing deposition system. The technique employs the use of a double side polished substrate that offers good specular reflectivity and is isotropic in its mechanical properties, such as <111> oriented crystalline silicon or amorphous soda lime glass, for example. The measurement of the displacement of the uncoated side during deposition is performed with a high resolution (i.e. 5nm), commercially available, inexpensive, fiber optic sensor which can be used in both high vacuum and high temperature environments (i.e. 10(exp-7) Torr and 480oC, respectively). A key attribute of this instrument lies in its potential to achieve sensitivity that rivals other measurement techniques such as the micro cantilever method but, due to the comparatively larger substrate area, offers a more robust and practical alternative for subsequent measurement of additional characteristics of the film that can might be correlated to film stress. We present measurement results of nickel films deposited by magnetron sputtering which show good qualitative agreement to the know behavior of polycrystalline films previously reported by Hoffman.

Broadway, David M.↗

NASA NTRS2015

Institutional Schlieren: A Production-Level Wind Tunnel Test Measurement

The following details recent efforts undertaken at the NASA Ames Unitary Plan Wind Tunnel to design and deploy an advanced, institutional, production-level data system for the classical Schlieren-shadowgraph technique. Motivation for the selection of individual system components is discussed along with a software methodology that combines image acquisition and processing into a production-level wind tunnel test measurement. In general terms, a production-level measurement refers to any data system that is seamlessly integrated into the primary wind tunnel data system, and whose data products are available real-time (e.g. force and moment, pressure, temperature data). The advantage of integrating a measurement in such a manner is an immediate increase in data product efficiency, productivity, reliability, and quality. Coupled with these benefits and leveraging recent advancements in high-speed imaging and image processing, automated, synchronized, time-resolved Schlieren-shadowgraph imaging for dynamic flow phenomena is now a reality. This makes possible the synthesis of dynamic off-body imaging with unsteady on-body measurements to produce a uniquely descriptive data product invaluable to the modern researcher.

Shadowgraph↗

NASA NTRS2011

Development of Jet Noise Power Spectral Laws

High-quality jet noise spectral data measured at the Aero-Acoustic Propulsion Laboratory (AAPL) at NASA Glenn is used to develop jet noise scaling laws. A FORTRAN algorithm was written that provides detailed spectral prediction of component jet noise at user-specified conditions. The model generates quick estimates of the jet mixing noise and the broadband shock-associated noise (BBSN) in single-stream, axis-symmetric jets within a wide range of nozzle operating conditions. Shock noise is emitted when supersonic jets exit a nozzle at imperfectly expanded conditions. A successful scaling of the BBSN allows for this noise component to be predicted in both convergent and convergent-divergent nozzles. Configurations considered in this study consisted of convergent and convergent- divergent nozzles. Velocity exponents for the jet mixing noise were evaluated as a function of observer angle and jet temperature. Similar intensity laws were developed for the broadband shock-associated noise in supersonic jets. A computer program called sJet was developed that provides a quick estimate of component noise in single-stream jets at a wide range of operating conditions. A number of features have been incorporated into the data bank and subsequent scaling in order to improve jet noise predictions. Measurements have been converted to a lossless format. Set points have been carefully selected to minimize the instability-related noise at small aft angles. Regression parameters have been scrutinized for error bounds at each angle. Screech-related amplification noise has been kept to a minimum to ensure that the velocity exponents for the jet mixing noise remain free of amplifications. A shock-noise-intensity scaling has been developed independent of the nozzle design point. The computer program provides detailed narrow-band spectral predictions for component noise (mixing noise and shock associated noise), as well as the total noise. Although the methodology is confined to single streams, efforts are underway to generate a data bank and algorithm applicable to dual-stream jets. Shock-associated noise in high-powered jets such as military aircraft can benefit from these predictions.

Khavaran, Abbas↗

NASA NTRS1996

Integrated Design Software Predicts the Creep Life of Monolithic Ceramic Components

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated-temperature applications. As design protocols emerge for these material systems, designers must be aware of several innate features, including the degrading ability of ceramics to carry sustained load. Usually, time-dependent failure in ceramics occurs because of two different, delayedfailure mechanisms: slow crack growth and creep rupture. Slow crack growth initiates at a preexisting flaw and continues until a critical crack length is reached, causing catastrophic failure. Creep rupture, on the other hand, occurs because of bulk damage in the material: void nucleation and coalescence that eventually leads to macrocracks which then propagate to failure. Successful application of advanced ceramics depends on proper characterization of material behavior and the use of an appropriate design methodology. The life of a ceramic component can be predicted with the NASA Lewis Research Center's Ceramics Analysis and Reliability Evaluation of Structures (CARES) integrated design programs. CARES/CREEP determines the expected life of a component under creep conditions, and CARES/LIFE predicts the component life due to fast fracture and subcritical crack growth. The previously developed CARES/LIFE program has been used in numerous industrial and Government applications.

Source record↗

NASA NTRS2016

Approximation of Engine Casing Temperature Constraints for Casing Mounted Electronics

The performance of propulsion engine systems is sensitive to weight and volume considerations. This can severely constrain the configuration and complexity of the control system hardware. Distributed Engine Control technology is a response to these concerns by providing more flexibility in designing the control system, and by extension, more functionality leading to higher performing engine systems. Consequently, there can be a weight benefit to mounting modular electronic hardware on the engine core casing in a high temperature environment. This paper attempts to quantify the in-flight temperature constraints for engine casing mounted electronics. In addition, an attempt is made at studying heat soak back effects. The Commercial Modular Aero Propulsion System Simulation 40k (C-MAPSS40k) software is leveraged with real flight data as the inputs to the simulation. A two-dimensional (2-D) heat transfer model is integrated with the engine simulation to approximate the temperature along the length of the engine casing. This modification to the existing C-MAPSS40k software will provide tools and methodologies to develop a better understanding of the requirements for the embedded electronics hardware in future engine systems. Results of the simulations are presented and their implications on temperature constraints for engine casing mounted electronics is discussed.

Engine↗

NASA NTRS2017

Approximation of Engine Casing Temperature Constraints for Casing Mounted Electronics

Engine↗

NASA NTRS2006

Development of a Numerical Model for High-Temperature Shape Memory Alloys

A thermomechanical hysteresis model for a high-temperature shape memory alloy (HTSMA) actuator material is presented. The model is capable of predicting strain output of a tensile-loaded HTSMA when excited by arbitrary temperature-stress inputs for the purpose of actuator and controls design. Common quasi-static generalized Preisach hysteresis models available in the literature require large sets of experimental data for model identification at a particular operating point, and substantially more data for multiple operating points. The novel algorithm introduced here proposes an alternate approach to Preisach methods that is better suited for research-stage alloys, such as recently-developed HTSMAs, for which a complete database is not yet available. A detailed description of the minor loop hysteresis model is presented in this paper, as well as a methodology for determination of model parameters. The model is then qualitatively evaluated with respect to well-established Preisach properties and against a set of low-temperature cycled loading data using a modified form of the one-dimensional Brinson constitutive equation. The computationally efficient algorithm demonstrates adherence to Preisach properties and excellent agreement to the validation data set.

DeCastro, Jonathan A.↗

NASA NTRS2009

Turboelectric Distributed Propulsion Engine Cycle Analysis for Hybrid-Wing-Body Aircraft

Meeting NASA's N+3 goals requires a fundamental shift in approach to aircraft and engine design. Material and design improvements allow higher pressure and higher temperature core engines which improve the thermal efficiency. Propulsive efficiency, the other half of the overall efficiency equation, however, is largely determined by the fan pressure ratio (FPR). Lower FPR increases propulsive efficiency, but also dramatically reduces fan shaft speed through the combination of larger diameter fans and reduced fan tip speed limits. The result is that below an FPR of 1.5 the maximum fan shaft speed makes direct drive turbines problematic. However, it is the low pressure ratio fans that allow the improvement in propulsive efficiency which, along with improvements in thermal efficiency in the core, contributes strongly to meeting the N+3 goals for fuel burn reduction. The lower fan exhaust velocities resulting from lower FPRs are also key to meeting the aircraft noise goals. Adding a gear box to the standard turbofan engine allows acceptable turbine speeds to be maintained. However, development of a 50,000+ hp gearbox required by fans in a large twin engine transport aircraft presents an extreme technical challenge, therefore another approach is needed. This paper presents a propulsion system which transmits power from the turbine to the fan electrically rather than mechanically. Recent and anticipated advances in high temperature superconducting generators, motors, and power lines offer the possibility that such devices can be used to transmit turbine power in aircraft without an excessive weight penalty. Moving to such a power transmission system does more than provide better matching between fan and turbine shaft speeds. The relative ease with which electrical power can be distributed throughout the aircraft opens up numerous other possibilities for new aircraft and propulsion configurations and modes of operation. This paper discusses a number of these new possibilities. The Boeing N2 hybrid-wing-body (HWB) is used as a baseline aircraft for this study. The two pylon mounted conventional turbofans are replaced by two wing-tip mounted turboshaft engines, each driving a superconducting generator. Both generators feed a common electrical bus which distributes power to an array of superconducting motor-driven fans in a continuous nacelle centered along the trailing edge of the upper surface of the wing-body. A key finding was that traditional inlet performance methodology has to be modified when most of the air entering the inlet is boundary layer air. A very thorough and detailed propulsion/airframe integration (PAI) analysis is required at the very beginning of the design process since embedded engine inlet performance must be based on conditions at the inlet lip rather than freestream conditions. Examination of a range of fan pressure ratios yielded a minimum Thrust-specific-fuel-consumption (TSFC) at the aerodynamic design point of the vehicle (31,000 ft /Mach 0.8) between 1.3 and 1.35 FPR. We deduced that this was due to the higher pressure losses prior to the fan inlet as well as higher losses in the 2-D inlets and nozzles. This FPR is likely to be higher than the FPR that yields a minimum TSFC in a pylon mounted engine. 1

Felder, James L.↗

NASA NTRS1992

NASA F-16XL supersonic laminar flow control program overview

The viewgraphs and discussion of the NASA supersonic laminar flow control program are provided. Successful application of laminar flow control to a High Speed Civil Transport (HSCT) offers significant benefits in reductions of take-off gross weight, mission fuel burn, cruise drag, structural temperatures, engine size, emissions, and sonic boom. The ultimate economic success of the proposed HSCT may depend on the successful adaption of laminar flow control, which offers the single most significant potential improvements in lift drag ratio (L/D) of all the aerodynamic technologies under consideration. The F-16XL Supersonic Laminar Flow Control (SLFC) Experiment was conceived based on the encouraging results of in-house and NASA supported industry studies to determine if laminar flow control is feasible for the HSCT. The primary objective is to achieve extensive laminar flow (50-60 percent chord) on a highly swept supersonic wing. Data obtained from the flight test will be used to validate existing Euler and Navier Stokes aerodynamic codes and transition prediction boundary layer stability codes. These validated codes and developed design methodology will be delivered to industry for their use in designing supersonic laminar flow control wings. Results from this experiment will establish preliminary suction system design criteria enabling industry to better size the suction system and develop improved estimates of system weight, fuel volume loss due to wing ducting, turbocompressor power requirements, etc. so that benefits and penalties can be more accurately assessed.

Fischer, Michael C.↗

NASA NTRS2013

Design of Test Support Hardware for Advanced Space Suits

As a member of the Space Suit Assembly Development Engineering Team, I designed and built test equipment systems to support the development of the next generation of advanced space suits. During space suit testing it is critical to supply the subject with two functions: (1) cooling to remove metabolic heat, and (2) breathing air to pressurize the space suit. The objective of my first project was to design, build, and certify an improved Space Suit Cooling System for manned testing in a 1‐G environment. This design had to be portable and supply a minimum cooling rate of 2500 BTU/hr. The Space Suit Cooling System is a robust, portable system that supports very high metabolic rates. It has a highly adjustable cool rate and is equipped with digital instrumentation to monitor the flowrate and critical temperatures. It can supply a variable water temperature down to 34 deg., and it can generate a maximum water flowrate of 2.5 LPM. My next project was to design and build a Breathing Air System that was capable of supply facility air to subjects wearing the Z‐2 space suit. The system intakes 150 PSIG breathing air and regulates it to two operating pressures: 4.3 and 8.3 PSIG. It can also provide structural capabilities at 1.5x operating pressure: 6.6 and 13.2 PSIG, respectively. It has instrumentation to monitor flowrate, as well as inlet and outlet pressures. The system has a series of relief valves to fully protect itself in case of regulator failure. Both projects followed a similar design methodology. The first task was to perform research on existing concepts to develop a sufficient background knowledge. Then mathematical models were developed to size components and simulate system performance. Next, mechanical and electrical schematics were generated and presented at Design Reviews. After the systems were approved by the suit team, all the hardware components were specified and procured. The systems were then packaged, fabricated, and thoroughly tested. The next step was to certify the equipment for manned used, which included generating a Hazard Analysis and giving a presentation to the Test Readiness Review Board. Both of these test support systems will perform critical roles in the development of next‐generation space suits. They will used on a regular basis to test the NASA's new Z‐2 Space Suit. The Space Suit Cooling System is now the primary cooling system for all advanced suit tests.

Watters, Jeffrey A.↗

NASA NTRSDate not supplied

Designed Experiment Results for Constituent Effects on NBR Based Solid Rocket Motor Insulation Performance

Solid rocket motor internal insulations are facing serious issues with obsolescence of constituents and the need for improved performance. The design community is at a unique point with a large number of rocket motors requiring reformulation of insulation or design upgrades at the same time. Unfortunately, performance data related to component choice is not generally available to aid development. A study of insulation component materials, conducted at Marshall Space Flight Center over the last four years, used designed experiments to understand the contribution of each material to the performance of a formulation. This report covers work with Nitrile Butadiene Rubber (NBR) based formulations. In-house compounding provided modified formulations allowing for isolation of both individual and synergistic effects. All formulas were tested for mechanical, thermal and producibility properties to evaluate performance. This presentation will describe the methodology for, and results from, identifying the individual and combined effects of components used in our formulations. Specific properties investigated include, rheology, cure characteristics, density, tensile strength, along with erosion/ablation under various heat loads and flame chemistries. Scale up of several formulas from lab to production size batches was accomplished. We will discuss troubleshooting problems of scale and the new set of designed experiments with Ethylene Propylene Diene Monomer (EPDM) based formulations.

Insulation↗