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Calorimeter Heat Flux Trends in NASA’s Subscale Rotating Detonation Rocket Engine
A calorimeter-style rotating detonation rocket engine (RDRE) outer chamber body was designed, additively manufactured in GRCop-42, and hot-fire tested in test cell 105 at NASA Marshall Space Flight Center (MSFC) in Huntsville, AL in August 2024. Steady-state, spatially resolved heat flux and chamber pressure were measured at 13 and 9 locations from the injector face, respectively, for a variety of test conditions and hardware configurations with gaseous methane and oxygen propellants. The 2-in. diameter highly instrumented design, enabled by metal additive manufacturing (AM), allowed for simultaneous measurement of heat flux and chamber pressure through 44 long duration hot-fire tests without failure. Of the 44 tests, only 3 of the tests featured chamber pressures below 100 psia and are discussed in this work. Heat flux trends for this subscale hardware are explored with respect to local propellant mass flux for several different injectors, chamber lengths, and chamber “subsonic” area ratios (contraction ratios). Results show that for increasing chamber pressure, a reduced amount of energy per kilogram of propellant is transferred to the wall. Switching injectors affects the near-face heat flux and chamber pressure profiles. Chamber length does not noticeably affect the heat flux profile but increases bulk heat load. A subsonic area ratio greater than 1 reduces heat losses to the wall compared to a straight annulus case. Equivalence ratio shift did not significantly affect heat flux. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analyses were performed to delineate 3-D heat transfer and coolant mass flow maldistribution effects and create a calorimeter transfer function to transform heat flux data and mitigate the profile distortions. Additional CFD/CHT simulations were performed using experimental data as boundary conditions to assess local nucleate boiling propensity during testing and to assess projected hot wall temperatures for future fatigue assessment. Vapor fractions were observed locally for several cases. It is anticipated that this effort will provide a common framework for coolant system design/analysis in calorimeter systems for rocket-based and air-breathing combustors, ensuring greater repeatability in calorimetry measurements across the research community.
Experimental investigation of the landing dynamics of three-legged spacecraft models
An experimental investigation was conducted to obtain accurate data from two three-legged spacecraft landing systems for purposes of validating current and future computer programs for legged landers. Two landing-gear systems were investigated: an inverted tripod system and a cantilever system. Tests were conducted for eight landing conditions chosen to obtain stability data, maximum loads, and maximum strokes for correlation with analytical results. Data from the two models are not directly comparable because of geometry and mass differences, but both are considered to be typical models of the respective landing-gear systems. Results indicate that maximum accelerations for both models, which occurred during a nearly flat landing on a horizontal surface, were nearly the same (approximately minus 18g). Maximum primary strut forces occurred for landings into a 20 deg slope and were 40 kiloNewtons (9000 lbf) and 47 kiloNewtons (10 500 lbf) for the inverted tripod and cantilever models, respectively; and maximum primary strut strokes for both models were 19 cm (7.4 in.). The inverted tripod model was slightly more stable than the cantilever model because of a larger ratio of footpad radius to center-of-gravity height.
DOE/NASA Mod-0 100KW wind turbine test results
The Wind Turbine demonstrates the capability of automatic unattended operation, including startup, achieving synchronism, and shutdown as dictated by wind conditions. During the course of these operations, a wealth of engineering data was generated. Some of the data which is associated with rotor and machine dynamics problems encountered, and the machine modifications incorporated as a solution are presented. These include high blade loads due to tower shadow, excessive nacelle yawing motion, and power oscillations. The results of efforts to correlate measured wind velocity with power output and wind turbine loads are also discussed.
Analytical and experimental vibration and buckling characteristics of a pretensioned stayed column
Modal vibration tests to determine lateral modes of vibration of a stayed column and static axial compression tests to determine the column's buckling and postbuckling behavior have been performed. Effects of stay tension levels and vibration-load interaction are presented. Two finite element models are used to analyze the column, a three-dimensional frame using NASTRAN and an equivalent two-dimensional frame using an exact dynamic stiffness matrix. Both analyses correlated well with the linear vibration and buckling experimental data. Results indicate premature buckling of the column due to vibration-load interaction and nonlinear oscillations due to stay slackening. Postbuckling behavior of the column is unusual because of stay slackening and results in a postbuckling restoring force of less than the bifurcation buckling load. Guidelines for design of pretensioned structures are presented which consider buckling, postbuckling and vibration behavior.
Preflight transient dynamic analyses of B-52 aircraft carrying Space Shuttle solid rocket booster drop-test vehicle
This paper concerns the transient dynamic analysis of the B-52 aircraft carrying the Space Shuttle solid rocket booster drop test vehicle (SRB/DTV). The NASA structural analysis (NASTRAN) finite element computer program was used in the analysis. The B-52 operating conditions considered for analysis were (1) landing and (2) braking on aborted takeoff runs. The transient loads for the B-52 pylon front and rear hooks were calculated. The results can be used to establish the safe maneuver envelopes for the B-52 carrying the SRB/DTV in landings and brakings.
Prediction of aeroelastic response of a model X-wing rotor
The rotorcraft dynamics analysis was used to predict the aeroelastic responses of a representative X-wing model with a 10 ft diameter rotor. The aeroelastic methodology used and the tests and assumptions involved are reviewed. Results are reported on the findings concerning control power and higher harmonic control in hover, transition flight, vibratory loads at forward speed, and responses in conversion. It is concluded that the analysis can give satisfactory predictions of X-wing behavior.
Prediction of aeroelastic response of a model X-wing rotor
The Rotorcraft Dynamics Analysis was used to predict the aeroelastic responses of a representative X-Wing model with a 10-ft diameter rotor. The aeroelastic methodology used and the tests and assumptions involved are reviewed. Results are reported on the findings concerning control power and higher harmonic control in hover, transition flight, vibratory loads at forward speed, and responses in conversion. It is concluded that the analysis can give satisfactory predictions of X-Wing behavior.
The multiple-function multi-input/multi-output digital controller system for the AFW wind-tunnel model
A real time multiple-function digital controller system was developed for the Active Flexible Wing (AFW) Program. The digital controller system (DCS) allowed simultaneous execution of two control laws: flutter suppression and either roll trim or a rolling maneuver load control. The DCS operated within, but independently of, a slower host operating system environment, at regulated speeds up to 200 Hz. It also coordinated the acquisition, storage, and transfer of data for near real time controller performance evaluation and both open- and closed-loop plant estimation. It synchronized the operation of four different processing units, allowing flexibility in the number, form, functionality, and order of control laws, and variability in the selection of the sensors and actuators employed. Most importantly, the DCS allowed for the successful demonstration of active flutter suppression to conditions approximately 26 percent (in dynamic pressure) above the open-loop boundary in cases when the model was fixed in roll and up to 23 percent when it was free to roll. Aggressive roll maneuvers with load control were achieved above the flutter boundary. The purpose here is to present the development, validation, and wind tunnel testing of this multiple-function digital controller system.
The lightcraft project
Rensselaer Polytechnic Institute has been developing a transatmospheric 'Lightcraft' technology which uses beamed laser energy to propel advanced shuttle craft to orbit. In the past several years, Rensselaer students have analyzed the unique combined-cycle Lightcraft engine, designed a small unmanned Lightcraft Technology Demonstrator, and conceptualized larger manned Lightcraft - to name just a few of the interrelated design projects. The 1990-91 class carried out preliminary and detailed design efforts for a one-person 'Mercury' Lightcraft, using computer-aided design and finite-element structural modeling techniques. In addition, they began construction of a 2.6 m-diameter, full-scale engineering prototype mockup. The mockup will be equipped with three robotic legs that 'kneel' for passenger entry and exit. More importantly, the articulated tripod gear is crucial for accurately pointing at, and tracking the laser relay mirrors, a maneuver that must be performed just prior to liftoff. Also accomplished were further design improvements on a 6-inch-diameter Lightcraft model (for testing in RPI's hypersonic tunnel), and new laser propulsion experiments. The resultant experimental data will be used to calibrate Computational Fluid Dynamic (CFD) codes and analytical laser propulsion models that can simulate vehicle/engine flight conditions along a transatmospheric boost trajectory. These efforts will enable the prediction of distributed aerodynamic and thruster loads over the entire full-scale spacecraft.
Preprocessor that Enables the Use of GridProTM Grids for Unsteady Reynolds-Averaged Navier-Stokes Code TURBO
A preprocessor for the Computational Fluid Dynamics (CFD) code TURBO has been developed and tested. The preprocessor converts grids produced by GridPro (Program Development Company (PDC)) into a format readable by TURBO and generates the necessary input files associated with the grid. The preprocessor also generates information that enables the user to decide how to allocate the computational load in a multiple block per processor scenario.
NASA Tech Briefs, July 2011
Topics covered include: 1) Collaborative Clustering for Sensor Networks; 2) Teleoperated Marsupial Mobile Sensor Platform Pair for Telepresence Insertion Into Challenging Structures; 3) Automated Verification of Spatial Resolution in Remotely Sensed Imagery; 4) Electrical Connector Mechanical Seating Sensor; 5) In Situ Aerosol Detector; 6) Multi-Parameter Aerosol Scattering Sensor; 7) MOSFET Switching Circuit Protects Shape Memory Alloy Actuators; 8) Optimized FPGA Implementation of Multi-Rate FIR Filters Through Thread Decomposition; 9) Circuit for Communication Over Power Lines; 10) High-Efficiency Ka-Band Waveguide Two-Way Asymmetric Power Combiner; 11) 10-100 Gbps Offload NIC for WAN, NLR, and Grid Computing; 12) Pulsed Laser System to Simulate Effects of Cosmic Rays in Semiconductor Devices; 13) Flight Planning in the Cloud; 14) MPS Editor; 15) Object-Oriented Multi Disciplinary Design, Analysis, and Optimization Tool; 16) Cryogenic-Compatible Winchester Connector Mount and Retaining System for Composite Tubes; 17) Development of Position-Sensitive Magnetic Calorimeters for X-Ray Astronomy; 18) Planar Rotary Piezoelectric Motor Using Ultrasonic Horns; 19) Self-Rupturing Hermetic Valve; 20) Explosive Bolt Dual-Initiated from One Side; 21) Dampers for Stationary Labyrinth Seals; 22) Two-Arm Flexible Thermal Strap; 23) Carbon Dioxide Removal via Passive Thermal Approaches; 24) Polymer Electrolyte-Based Ambient Temperature Oxygen Microsensors for Environmental Monitoring; 25) Pressure Shell Approach to Integrated Environmental Protection; 26) Image Quality Indicator for Infrared Inspections; 27) Micro-Slit Collimators for X-Ray/Gamma-Ray Imaging; 28) Scatterometer-Calibrated Stability Verification Method; 29) Test Port for Fiber-Optic-Coupled Laser Altimeter; 30) Phase Retrieval System for Assessing Diamond Turning and Optical Surface Defects; 31) Laser Oscillator Incorporating a Wedged Polarization Rotator and a Porro Prism as Cavity Mirror; 32) Generic, Extensible, Configurable Push-Pull Framework for Large-Scale Science Missions; 33) Dynamic Loads Generation for Multi-Point Vibration Excitation Problems; 34) Optimal Control via Self-Generated Stochasticity; 35) Space-Time Localization of Plasma Turbulence Using Multiple Spacecraft Radio Links; 36) Surface Contact Model for Comets and Asteroids; 37) Dust Mitigation Vehicle; 38) Optical Coating Performance for Heat Reflectors of the JWST-ISIM Electronic Component; 39) SpaceCube Demonstration Platform; 40) Aperture Mask for Unambiguous Parity Determination in Long Wavelength Imagers; 41) Spaceflight Ka-Band High-Rate Radiation-Hard Modulator; 42) Enabling Disabled Persons to Gain Access to Digital Media; 43) Cytometer on a Chip; 44) Principles, Techniques, and Applications of Tissue Microfluidics; and 45) Two-Stage Winch for Kites and Tethered Balloons or Blimps.
Three-Axis Distributed Fiber Optic Strain Measurement in 3D Woven Composite Structures
Recent advancements in composite materials technologies have broken further from traditional designs and require advanced instrumentation and analysis capabilities. Success or failure is highly dependent on design analysis and manufacturing processes. By monitoring smart structures throughout manufacturing and service life, residual and operational stresses can be assessed and structural integrity maintained. Composite smart structures can be manufactured by integrating fiber optic sensors into existing composite materials processes such as ply layup, filament winding and three-dimensional weaving. In this work optical fiber was integrated into 3D woven composite parts at a commercial woven products manufacturing facility. The fiber was then used to monitor the structures during a VARTM manufacturing process, and subsequent static and dynamic testing. Low cost telecommunications-grade optical fiber acts as the sensor using a high resolution commercial Optical Frequency Domain Reflectometer (OFDR) system providing distributed strain measurement at spatial resolutions as low as 2mm. Strain measurements using the optical fiber sensors are correlated to resistive strain gage measurements during static structural loading. Keywords: fiber optic, distributed strain sensing, Rayleigh scatter, optical frequency domain reflectometry
Countermeasures for Mitigation of Sensorimotor Decrements Following Head-Down Tilt Bed Rest
BACKGROUND Astronauts experience postflight disturbances in postural and locomotor control due to sensorimotor adaptations during spaceflight. These alterations may have adverse consequences if a rapid egress is required after landing. Although exercise is partially effective for mitigating cardiovascular and muscular deconditioning, additional countermeasures are needed to further preserve sensorimotor function. Proprioception training and electrical muscle stimulation (EMS) are two promising in-flight countermeasures. Since prolonged head down tilt bed rest (HDTBR) is a spaceflight analog for body unloading and causes postural and locomotor control decrements that parallel those observed after spaceflight, it can be used to facilitate the development of these countermeasures. METHODS This study will determine the effects of proprioception training and EMS on functional task performance and sensorimotor function following 60 days of 6° HDTBR. Subjects will be randomly assigned to one of four groups: 1) an EMS arm, 2) a proprioception training arm, 3) an exercise plus proprioceptive training arm, and 4) a control arm. The EMS countermeasure will include daily bilateral stimulation of selected bilateral lower extremity muscles (30 minutes per session). Proprioception training will be performed three days per week (25 minutes per session) consisting of body-loaded postural tasks in the horizontal position on an air bearing sled. Exercise training will mimic current protocols used on the International Space Station, but treadmill aerobic exercise will be replaced with additional cycling aerobic exercise. Primary outcome measures will include pre- and post- HDTBR functional tests that require high demand for dynamic control of postural stability. Secondary measures will be used to explore key physiological changes that underlie countermeasure benefits. All HDTBR and data collection activities will be completed by the German Aerospace Center (DLR) at the :envihab facility. Given the constrained samples size, a Bayesian modelling approach will be used to quantify the probability that there is an effect of a given magnitude. HARDWARE AND PROTOCOL DEVELOPMENT Final hardware modifications and protocol developments were completed in preparation for Campaign 1, which began in September 2024. These included shipment, setup, and operator training for the transportable gravity bed, horizontal squat device, foam obstacle course, EMS devices, leg dexterity system, foot sole skin sensitivity system, and Radiofrequency Echographic Multi Spectrometry (REMS) ultrasound device. In addition, specialized protocols were developed for data collection using DLR’s equipment, including muscle morphology magnetic resonance imaging (MRI), optical coherence tomography, venous blood flow MRI and ultrasound, muscle ultrasound and impedance, and skin blood flow ultrasound. We will present early data from the first campaign, which concluded in November, 2024. These will be compared with previous data from the recent 30-day HDTBR campaigns (Spaceflight associated neuro-ocular syndrome countermeasures (SANS-CM)) conducted at DLR. RELEVANCE The deliverable from this project will be proof-of-concept sensorimotor countermeasure designs for functional task performance with full assessment of efficacy in a spaceflight analog. If one or more countermeasures are effective, they will be translated for validation with the suite of operationally implemented in-flight countermeasures.
Full Scale Rotor Aeroacoustic Predictions and the Link to Model Scale Rotor Data
The NASA Aeroacoustic Prediction System (NAPS) is used to establish a link between model-scale and full-scale rotor predictions and is partially validated against measured wind tunnel and flight aeroacoustic data. The prediction approach of NAPS couples a comprehensive rotorcraft analysis with acoustic source noise and propagation codes. The comprehensive analysis selected for this study is CAMRAD-II, which provides the performance/trim/wake solution for a given rotor or flight condition. The post-trim capabilities of CAMRAD-II are used to compute high-resolution sectional airloads for the acoustic tone noise analysis, WOPMOD. The tone noise is propagated to observers on the ground with the propagation code, RNM (Rotor Noise Model). Aeroacoustic predictions are made with NAPS for an isolated rotor and compared to results of the second Harmonic Aeroacoustic Rotor Test (HART-II) program, which tested a 40% dynamically and Mach-scaled BO-105 main rotor at the DNW. The NAPS is validated with comparisons for three rotor conditions: a baseline condition and two Higher Harmonic Control (HHC) conditions. To establish a link between model and full-scale rotor predictions, a full-scale BO-105 main rotor input deck for NAPS is created from the 40% scale rotor input deck. The full-scale isolated rotor predictions are then compared to the model predictions. The comparisons include aerodynamic loading, acoustic levels, and acoustic pressure time histories for each of the three conditions. With this link established, full-scale predictions are made for a range of descent flight conditions and compared with measured trends from the recent Rotorcraft Operational Noise Abatement Procedures (RONAP) flight test conducted by DLR and ONERA. Additionally, the effectiveness of two HHC conditions from the HART-II program is demonstrated for the full-scale rotor in flight.
Three-Dimensional Vibration Isolator for Suppressing High-Frequency Responses for Sage III Contamination Monitoring Package (CMP)
The Stratospheric Aerosol and Gas Experiment (SAGE) III - International Space Station (ISS) instrument will be used to study ozone, providing global, long-term measurements of key components of the Earth's atmosphere for the continued health of Earth and its inhabitants. SAGE III is launched into orbit in an inverted configuration on SpaceX;s Falcon 9 launch vehicle. As one of its four supporting elements, a Contamination Monitoring Package (CMP) mounted to the top panel of the Interface Adapter Module (IAM) box experiences high-frequency response due to structural coupling between the two structures during the SpaceX launch. These vibrations, which were initially observed in the IAM Engineering Development Unit (EDU) test and later verified through finite element analysis (FEA) for the SpaceX launch loads, may damage the internal electronic cards and the Thermoelectric Quartz Crystal Microbalance (TQCM) sensors mounted on the CMP. Three-dimensional (3D) vibration isolators were required to be inserted between the CMP and IAM interface in order to attenuate the high frequency vibrations without resulting in any major changes to the existing system. Wire rope isolators were proposed as the isolation system between the CMP and IAM due to the low impact to design. Most 3D isolation systems are designed for compression and roll, therefore little dynamic data was available for using wire rope isolators in an inverted or tension configuration. From the isolator FEA and test results, it is shown that by using the 3D wire rope isolators, the CMP high-frequency responses have been suppressed by several orders of magnitude over a wide excitation frequency range. Consequently, the TQCM sensor responses are well below their qualification environments. It is indicated that these high-frequency responses due to the typical instrument structural coupling can be significantly suppressed by a vibration passive control using the 3D vibration isolator. Thermal and contamination issues were also examined during the isolator selection period for meeting the SAGE III-ISS instrument requirements.
Investigation of instability, dynamic forces, and effect of dynamic loading on strength of cages for the bearings in the high pressure oxygen turbopumps for the space shuttle main engine
Experiments were performed to determine the effect of cyclic loading on bearing cage strength. A long term working tensile load of approximately 1300 N (300 lbs) was found to be the likely maximum. Higher loads caused a decrease in cage tensile strength after the 125,000 cycle testing period. Poisson's ratio in compression was found to be highly dependent upon the direction of the fiberglass plies. At room temperature the value was 0.15 with the plies and 0.68 across the plies. At -196 C (-321 F), the value with the plies was 0.20. The results of the analyses conducted have again demonstrated the critical need for improved lubrication in the high pressure oxygen turbopump bearings. Lubricant films with low shear strength and low friction coefficients promote cage stability and decrease ball/cage forces during marginal operating conditions. The analysis of the effect of combined bearing loads on ball/cage loads has identified a radial load of 3600 N (800 lbs) as the maximum for the current clearance of the balls and cage pockets. Liquid oxygen impinging on the cage in the direction of rotation was found to enhance cage stability.
Access flight hardware design and development
Several items were found to be of immense value in the design and development of the Assembly Concept for Construction of Erectable Space Structures (ACCESS) hardware. The early availability of mock-up and engineering test hardware helped to develop the concept and prove the feasibility of the experiment. The extensive neutral buoyancy testing was invaluable in developing the procedures and timelines, proving that the hardware functioned as intended, and effectively trained the astronauts. The early involvement of the crew systems/astronaut personnel was extremely beneficial in shaping the design to meet the EVA compatibility requirements. Also, the early definition of coupled loads and on-orbit dynamic responses can not be overemphasized due to the relative uncertainty in the magnitude of these loads and their impact on the design.