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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Near Infrared In-situ Measurements for the Detection of Keyhole Porosity in Autogenous Ti-6AL-4V Welds

Certification of additive manufactured metal parts requires nondestructive evaluation (NDE) to ensure build quality. NDE can be performed during the build process or post build. For large parts with complex geometries, post build NDE can be challenging. In-situ NDE potentially provides a way to perform the inspection layer by layer. This work explores the use of a high speed near infrared (NIR) camera that is focused in-line with a laser to obtain high spatial and temporal resolution thermal imagery of the melt pool and associated cooling areas. The thermal data is obtained during a laser melting process using Ti-6AL-4V plate and of particular interest is the detection of keyhole porosity. Keyhole porosity can result from non-optimal build conditions, such as excessive laser power at a given laser scanning speed, that creates an entrapped bubble. The NIR measured melt pool and cooling areas are processed to detect keyhole porosity. The results are compared to X-ray CT results for validation.

additive manufacturing↗
NASA NTRSDate not supplied

Near Infrared In-situ Measurements for the Detection of Keyhole Porosity in Autogenous Ti-6AL-4V Welds

Certification of additive manufactured metal parts requires nondestructive evaluation (NDE) to ensure build quality. NDE can be performed during the build process or post build. For large parts with complex geometries, post build NDE can be challenging. In-situ NDE potentially provides a way to perform the inspection layer by layer. This work explores the use of a high speed near infrared (NIR) camera that is focused in-line with a laser to obtain high spatial and temporal resolution thermal imagery of the melt pool and associated cooling areas. The thermal data is obtained during a laser melting process using a Ti-6Al-4V plate and of particular interest is the detection of keyhole porosity. Keyhole porosity can result from non-optimal build conditions, such as excessive laser power at a given laser scanning speed, that creates an entrapped bubble. The NIR measured melt pool and cooling areas are processed to detect keyhole porosity. The results are compared to X-ray CT results for validation. Small keyhole pores buried deep were not detectable with this technique, however, some larger subsurface elongated pores along with some open surface pores did show some promise for detectability.

additive manufacturing↗
NASA NTRS2016

The Role of Probabilistic Design Analysis Methods in Safety and Affordability

For the last several years, NASA and its contractors have been working together to build space launch systems to commercialize space. Developing commercial affordable and safe launch systems becomes very important and requires a paradigm shift. This paradigm shift enforces the need for an integrated systems engineering environment where cost, safety, reliability, and performance need to be considered to optimize the launch system design. In such an environment, rule based and deterministic engineering design practices alone may not be sufficient to optimize margins and fault tolerance to reduce cost. As a result, introduction of Probabilistic Design Analysis (PDA) methods to support the current deterministic engineering design practices becomes a necessity to reduce cost without compromising reliability and safety. This paper discusses the importance of PDA methods in NASA's new commercial environment, their applications, and the key role they can play in designing reliable, safe, and affordable launch systems. More specifically, this paper discusses: 1) The involvement of NASA in PDA 2) Why PDA is needed 3) A PDA model structure 4) A PDA example application 5) PDA link to safety and affordability.

Safie, Fayssal M.↗
NASA NTRSDate not supplied

Fast Earth-Mars Roundtrip Trajectories to Reduce Health and Safety Risks for Crewed Missions

The extended mission duration of a crewed Mars mission compounds integrated risks to crew health and safety. Shortening mission duration would therefore have a direct impact on reducing many human health and performance risk factors. This paper describes trajectory feasibility analyses performed to examine trajectory options for a fast crewed mission to Mars. Studies were conducted to examine options with short overall mission durations (≤ 400-day roundtrip) and options that focus on minimizing astronaut time in deep space, while allowing for longer Mars surface stays. Trade studies were performed to determine ∆v requirements for a range of launch dates, Mars orbit periods, Mars stay times, and Earth-to-Mars flight time maxima. The implications of a Venus gravity assist are also described. The analyses presented here build on and specifically aim to optimize and address key concerns of assumptions made in previously published studies of fast crewed Mars missions.

Mars↗
NASA NTRS2013

Circularly Polarized Microwave Antenna Element with Very Low Off-Axis Cross-Polarization

The goal of this work was to improve off-axis cross-polarization performance and ease of assembly of a circularly polarized microwave antenna element. To ease assembly, the initial design requirement of Hexweb support for the internal circuit part, as well as the radiating disks, was eliminated. There is a need for different plating techniques to improve soldering. It was also desirable to change the design to eliminate soldering as well as the need to use the Hexweb support. Thus, a technique was developed to build the feed without using solder, solving the lathing and soldering issue. Internal parts were strengthened by adding curvature to eliminate Hexweb support, and in the process, the new geometries of the internal parts opened the way for improving the off-axis cross-polarization performance as well. The radiating disks curvatures were increased for increased strength, but it was found that this also improved crosspolarization. Optimization of the curvatures leads to very low off-axis cross-polarization. The feed circuit was curved into a cylinder for improved strength, eliminating Hexweb support. An aperture coupling feed mechanism eliminated the need for feed pins to the disks, which would have required soldering. The aperture coupling technique also improves cross-polarization performance by effectively exciting the radiating disks very close to the antenna s central axis of symmetry. Because of the shape of the parts, it allowed for an all-aluminum design bolted together and assembled with no solder needed. The advantage of a solderless design is that the reliability is higher, with no single-point failure (solder), and no need for special plating techniques in order to solder the unit together. The shapes (curved or round) make for a more robust build without extra support materials, as well as improved offaxis cross-polarization.

Greem. David↗
NASA NTRS1995

Low Temperature Performance of High-Speed Neural Network Circuits

Artificial neural networks, derived from their biological counterparts, offer a new and enabling computing paradigm specially suitable for such tasks as image and signal processing with feature classification/object recognition, global optimization, and adaptive control. When implemented in fully parallel electronic hardware, it offers orders of magnitude speed advantage. Basic building blocks of the new architecture are the processing elements called neurons implemented as nonlinear operational amplifiers with sigmoidal transfer function, interconnected through weighted connections called synapses implemented using circuitry for weight storage and multiply functions either in an analog, digital, or hybrid scheme.

artificial neural networks image processing signal↗
NASA NTRS1996

A Model-based Approach to Reactive Self-Configuring Systems

This paper describes Livingstone, an implemented kernel for a self-reconfiguring autonomous system, that is reactive and uses component-based declarative models. The paper presents a formal characterization of the representation formalism used in Livingstone, and reports on our experience with the implementation in a variety of domains. Livingstone's representation formalism achieves broad coverage of hybrid software/hardware systems by coupling the concurrent transition system models underlying concurrent reactive languages with the discrete qualitative representations developed in model-based reasoning. We achieve a reactive system that performs significant deductions in the sense/response loop by drawing on our past experience at building fast prepositional conflict-based algorithms for model-based diagnosis, and by framing a model-based configuration manager as a prepositional, conflict-based feedback controller that generates focused, optimal responses. Livingstone automates all these tasks using a single model and a single core deductive engine, thus making significant progress towards achieving a central goal of model-based reasoning. Livingstone, together with the HSTS planning and scheduling engine and the RAPS executive, has been selected as the core autonomy architecture for Deep Space One, the first spacecraft for NASA's New Millennium program.

Williams, Brian C.↗
NASA NTRS2019

Numerical Investigation and Optimization of a Flushwall Injector for Scramjet Applications at Hypervelocity Flow Conditions

An investigation utilizing Reynolds-averaged simulations (RAS) was performed in order to demonstrate the use of design and analysis of computer experiments (DACE) methods in Sandia’s DAKOTA software package for surrogate modeling and optimization. These methods were applied to a flow- path fueled with an interdigitated flushwall injector suitable for scramjet applications at hyper- velocity conditions and ascending along a constant dynamic pressure flight trajectory. The flight Mach number, duct height, spanwise width, and injection angle were the design variables selected to maximize two objective functions: the thrust potential and combustion efficiency. Because the RAS of this case are computationally expensive, surrogate models are used for optimization. To build a surrogate model a RAS database is created. The sequence of the design variables comprising the database were generated using a Latin hypercube sampling (LHS) method. A methodology was also developed to automatically build geometries and generate structured grids for each design point. The ensuing RAS analysis generated the simulation database from which the two objective functions were computed using a one-dimensionalization (1D) of the three-dimensional simulation data. The data were fitted using four surrogate models: an artificial neural network (ANN), a cubic polynomial, a quadratic polynomial, and a Kriging model. Variance-based decomposition showed that both objective functions were primarily driven by changes in the duct height. Multiobjective design optimization was performed for all four surrogate models via a genetic algorithm method. Optimal solutions were obtained at the upper and lower bounds of the flight Mach number range. The Kriging model predicted an optimal solution set that exhibited high values for both objective functions. Additionally, three challenge points were selected to assess the designs on the Pareto fronts. Further sampling among the designs of the Pareto fronts may be required to lower the surrogate model errors and perform more accurate surrogate-model-based optimization.

Shenoy, Rajiv R.↗
NASA NTRS2023

Development Unit for In-Space Pneumatic Helium Transfer Compressor

High-pressure gaseous helium (GHe) plays a critical role in spacecraft propulsion due to its near exclusive use for pressurization of propellant tanks. Several different designs for helium compressor technologies have been developed for use on Earth; however, significant design changes are required to meet the power, thermal/heat dissipation, vacuum, vibration/shock, size, mass, and efficiency requirements needed for space and launch environments. Currently, no capability exists for mass efficient on-orbit GHe (or xenon) transfer, nor has it ever been attempted. This effort proposed several challenging requirements for the vendor to develop a one-of-a-kind pneumatic compressor prototype. In order to develop a compressor prototype at a TRL 4, a partnership with Air Squared, Inc. was established. This CIF project concluded with the receipt of a prototype along with a proposed design for a flight unit; however, it will not be built due to funding limitations. The vendor had moderate success with initial testing of the prototype at lower pressures (with shimming configured for low pressure). There were delays with testing since the unit was built for higher pressures and the low pressure shimming was challenging to implement. It was found that operation of the compressor at lower pressures caused increased friction on the motor shaft which resulted in the unit drawing more power (current). This was initially thought to be a motor or controller defect. Subsequent high pressure testing at KSC showed that the friction was reduced for the optimal design point (with a high pressure shimming configuration) and the motor (and controller) performed nominally. Following the vendor testing, the unit was tuned/shimmed for a nominal inlet pressure and shipped to KSC for high pressure testing using the custom-designed setup in the Vehicle Assembly Building. The unit performed well, showing the capability to achieve over higher pressure of compression. The pressure differential could likely increase, however, the maximum output of the power supply used for testing was reached, limiting the compressor motor’s capability. Following the GN2 testing, the test setup was converted to GHe with at high pressure. It was shown that although the unit was unable to achieve similar high pressure differentials due to reverse leakage of the GHe through the scroll tip seals, it did achieve the desired GHe compression. This may still be useful for some applications, however, for the purpose of on-orbit GHe transfer, the single stage design would need to be changed to include multiple stages to achieve the compression goals initially proposed by the project.

Brian Nufer↗
NASA NTRS1994

Minimal time change detection algorithm for reconfigurable control system and application to aerospace

System parameters should be tracked on-line to build a reconfigurable control system even though there exists an abrupt change. For this purpose, a new performance index that we are studying is the speed of adaptation- how quickly does the system determine that a change has occurred? In this paper, a new, robust algorithm that is optimized to minimize the time delay in detecting a change for fixed false alarm probability is proposed. Simulation results for the aircraft lateral motion with a known or unknown change in control gain matrices, in the presence of doublet input, indicate that the algorithm works fairly well. One of its distinguishing properties is that detection delay of this algorithm is superior to that of Whiteness Test.

Kim, Sungwan↗
NASA NTRS2024

Automation of the ICME Workflow Incorporating Material Digital Twins at Different Length Scales Within a Robust Information Management System

Recent successes in Integrated Computational Materials Engineering (ICME) have demonstrated the potential in designing ‘fit-for-purpose’ materials for a given application in a cost and time efficient manner. However, the material design process must contain a level of judicious automation in the material decision process; that is implementing some optimization algorithms to truly enable the benefits of ICME, particularly when considering materials at multiple length and time scales. Furthermore, the ability to effectively store developed material models, experimental data used for validation, and link models at multiple length and time scales must be implemented to ensure traceability across the material design process, such that the data gathered can be leveraged towards efficient material design. To enable such an optimization scheme a robust framework must exist: (1) that can capture changes made at a given length scale, (2) automatically propagate changes upstream to the highest scale, and (3) evaluate the material’s performance at the structural level. In this work, a developed framework for tracking material changes, automatically running the necessary simulations to determine the properties at the next highest scale, and saving each iteration of the design process to maintain the application’s digital thread is presented for polymer matrix composites (PMCs). The Automated Information Management Across Organizations and Scales (AIMAOS) program offers users an interactive graphical user interface (GUI) for defining constituent materials, building lamina and laminates, and applying effective laminate properties to finite element and composite optimization third party software. At each length scale, the necessary input files are automatically written, and subsequent analysis tools are called to solve for effective properties at the next scale, which are then read by the AIMAOS tool and displayed to the user. As changes are made to the material at lower length scales, information is automatically propagated upstream to higher length scales, and changes made are automatically tracked and versioned to maintain traceability during the design process. The AIMAOS tools serves as the first step in enabling optimized design of composites from the nano to the macroscale for a given application.

Brandon L Hearley↗
NASA NTRS1974

The Energy Systems Optimization Computer Program /ESOP/ developed for Modular Integrated Utility Systems /MIUS/ analysis

A significant energy and cost savings can be obtained by integrating various utility services (space heating and cooling, electrical power generation, solid waste disposal, potable water, and waste water treatment) into a single unit which provides buildings or groups of buildings with these services. This paper presents a description of a computer program, called the Energy Systems Optimization Program (ESOP). This program predicts the loads, energy requirements, equipment sizes, and life-cycle costs of alternative methods of meeting these utility requirements. The program has been used extensively for performing energy analyses of Modular Integrated Utility Systems (MIUS).

Ferden, S. L.↗
NASA NTRS2017

Educational Projects in Unmanned Aerial Systems at the NASA Ames Research Center

Unmanned aerial systems (UAS), autonomy and robotics technology have been fertile ground for developing a wide variety of interdisciplinary student learning opportunities. In this talk, several projects will be described that leverage small fixed-wing UAS that have been modified to carry science payloads. These aircraft provide a unique hands-on experience for a wide range of students from college juniors to graduate students pursuing degrees in electrical engineering, aeronautical engineering, mechanical engineering, applied mathematics, physics, structural engineering and other majors. By combining rapid prototyping, design reuse and open-source philosophies, a sustainable educational program has been organized structured as full-time internships during the summer, part-time internships during the school year, short details for military cadets, and paid positions. As part of this program, every summer one or more UAS is developed from concept through design, build and test phases using the tools and facilities at the NASA Ames Research Center, ultimately obtaining statements of airworthiness and flight release from the Agency before test flights are performed. In 2016 and 2017 student projects focused on the theme of 3D printed modular airframes that may be optimized for a given mission and payload. Now in its fifth year this program has served over 35 students, and has provided a rich learning experience as they learn to rapidly develop new aircraft concepts in a highly regulated environment, on systems that will support principal investigators at university, NASA, and other US federal agencies.

UA↗
NASA NTRS2022

Environmental Testing of the OVEN System for Lunar Water Extraction and Prospecting

Introduction: The presence of water ice in permanently shadowed regions on the lunar surface [1] may enable a sustained human presence on the Moon with minimal need for consumables. However, in order to develop a long term utilization plan that includes the usage of in-situ water we must first understand the abundance, stratigraphy and distribution of this re-source. Multiple space agencies currently have plans for lunar water prospecting missions. The Optimized Volatile Extraction Node (OVEN) was designed for water prospecting missions that require samples to be weighed, sealed, and heated as the means of determining water concentration. This method of water quantification necessitates a fair amount of automation, so a rigorous environmental test program was performed in order to build confidence in the performance of the OVEN design. The work presented here describes the OVEN environmental test program as well as ongoing efforts to improve on the design. Vibration: The OVEN participated in two rounds of random vibration tests. The first test was a stand-alone test performed at the Energy Systems Test Area of the Johnson Space Center. The second test was an integrated test with the mobile platform developed for the Resource Prospector project. The OVEN survived both tests without damage, but the tests did provide valuable lessons learned with regards to specific operations. Thermal Vacuum: The OVEN was successfully demonstrated at a temperature range of -50 to 75 C in a thermal vacuum chamber. The need to heat motor gearboxes at lower temperatures was predetermined so this test program was completed by implementing a method of gearbox heating that used the existing circuitry within the motors. Dust: A custom dynamometer was built in order to determine the torque required to move the various mechanisms within the OVEN at a range of temperatures. The OVEN system was coated with lunar dust simulant in order to determine mechanism torques under a worst-case operating condition. Sublimation: Sublimation losses within the OVEN were quantified through a series of test configurations, including an integrated test in a thermal vacuum chamber at Glenn Research Center [2]. Current Work: The OVEN subsystem is currently not a component of any existing prospecting missions, but work continues that will take the lessons learned from previous environmental tests and improve on the design in order to be considered for future prospecting opportunities. References: [1] Colaprete, A., Schultz, P., Heldmann, J., Wooden, D., Shirley, M., Ennico, K., ... & Sollitt, L. (2010). Detection of water in the LCROSS ejecta plume. science, 330(6003), 463-468. [2] Kleinhenz, J., Smith, J., Roush, T., Colaprete, A., Zacny, K., Paulsen, G., ... & Paz, A. (2018). Volatiles Loss from water bearing regolith simulant at Lunar Environments. In Earth and Space 2018: Engineering for Extreme Environments (pp. 454-466). Reston, VA: American Society of Civil Engineers.

A Paz↗
NASA NTRS2012

Thermodynamic Vent System for an On-Orbit Cryogenic Reaction Control Engine

A report discusses a cryogenic reaction control system (RCS) that integrates a Joule-Thompson (JT) device (expansion valve) and thermodynamic vent system (TVS) with a cryogenic distribution system to allow fine control of the propellant quality (subcooled liquid) during operation of the device. It enables zero-venting when coupled with an RCS engine. The proper attachment locations and sizing of the orifice are required with the propellant distribution line to facilitate line conditioning. During operations, system instrumentation was strategically installed along the distribution/TVS line assembly, and temperature control bands were identified. A sub-scale run tank, full-scale distribution line, open-loop TVS, and a combination of procured and custom-fabricated cryogenic components were used in the cryogenic RCS build-up. Simulated on-orbit activation and thruster firing profiles were performed to quantify system heat gain and evaluate the TVS s capability to maintain the required propellant conditions at the inlet to the engine valves. Test data determined that a small control valve, such as a piezoelectric, is optimal to provide continuously the required thermal control. The data obtained from testing has also assisted with the development of fluid and thermal models of an RCS to refine integrated cryogenic propulsion system designs. This system allows a liquid oxygenbased main propulsion and reaction control system for a spacecraft, which improves performance, safety, and cost over conventional hypergolic systems due to higher performance, use of nontoxic propellants, potential for integration with life support and power subsystems, and compatibility with in-situ produced propellants.

Hurlbert, Eric A.↗
NASA NTRS1994

Structural Health Monitoring of Large Structures

This paper describes a damage detection and health monitoring method that was developed for large space structures using on-orbit modal identification. After evaluating several existing model refinement and model reduction/expansion techniques, a new approach was developed to identify the location and extent of structural damage with a limited number of measurements. A general area of structural damage is first identified and, subsequently, a specific damaged structural component is located. This approach takes advantage of two different model refinement methods (optimal-update and design sensitivity) and two different model size matching methods (model reduction and eigenvector expansion). Performance of the proposed damage detection approach was demonstrated with test data from two different laboratory truss structures. This space technology can also be applied to structural inspection of aircraft, offshore platforms, oil tankers, ridges, and buildings. In addition, its applications to model refinement will improve the design of structural systems such as automobiles and electronic packaging.

Kim, Hyoung M.↗
NASA NTRS2013

Mission Data System Java Edition Version 7

The Mission Data System framework defines closed-loop control system abstractions from State Analysis including interfaces for state variables, goals, estimators, and controllers that can be adapted to implement a goal-oriented control system. The framework further provides an execution environment that includes a goal scheduler, execution engine, and fault monitor that support the expression of goal network activity plans. Using these frameworks, adapters can build a goal-oriented control system where activity coordination is verified before execution begins (plan time), and continually during execution. Plan failures including violations of safety constraints expressed in the plan can be handled through automatic re-planning. This version optimizes a number of key interfaces and features to minimize dependencies, performance overhead, and improve reliability. Fault diagnosis and real-time projection capabilities are incorporated. This version enhances earlier versions primarily through optimizations and quality improvements that raise the technology readiness level. Goals explicitly constrain system states over explicit time intervals to eliminate ambiguity about intent, as compared to command-oriented control that only implies persistent intent until another command is sent. A goal network scheduling and verification process ensures that all goals in the plan are achievable before starting execution. Goal failures at runtime can be detected (including predicted failures) and handled by adapted response logic. Responses can include plan repairs (try an alternate tactic to achieve the same goal), goal shedding, ignoring the fault, cancelling the plan, or safing the system.

Reinholtz, William K.↗
NASA NTRS2005

Multidisciplinary Multiobjective Optimal Design for Turbomachinery Using Evolutionary Algorithm

This report summarizes Dr. Lian s efforts toward developing a robust and efficient tool for multidisciplinary and multi-objective optimal design for turbomachinery using evolutionary algorithms. This work consisted of two stages. The first stage (from July 2003 to June 2004) Dr. Lian focused on building essential capabilities required for the project. More specifically, Dr. Lian worked on two subjects: an enhanced genetic algorithm (GA) and an integrated optimization system with a GA and a surrogate model. The second stage (from July 2004 to February 2005) Dr. Lian formulated aerodynamic optimization and structural optimization into a multi-objective optimization problem and performed multidisciplinary and multi-objective optimizations on a transonic compressor blade based on the proposed model. Dr. Lian s numerical results showed that the proposed approach can effectively reduce the blade weight and increase the stage pressure ratio in an efficient manner. In addition, the new design was structurally safer than the original design. Five conference papers and three journal papers were published on this topic by Dr. Lian.

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