Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “building efficiency”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 937 records · Page 52

Predictive Modeling of Carbon Ablators Using Micro and Macro-Scale Modeling

Efforts to build a Predictive Material Modeling (PMM) framework from the micro-scale to the macro-scale are presented in this abstract. To reduce the need for extensive testing, accelerate the design cycle process, and reduce uncertainty margins applied to final designs, NASA is developing simulation and modeling tools that enable characterization of material properties and response to high-enthalpy environments. The Porous Microstructure Analysis (PuMA) code has been developed for computing macroscale (volume averaged) properties of porous materials using microscale images from micro-computed tomography (micro-CT). Microscale modeling requires a realistic representation of a material microstructure; these are obtained either synthetically during the design of the material or through X-ray micro-CT. Volume averaged properties are then used to inform macroscale material response models, such as those implemented in the Porous-material Analysis Toolbox based on OpenFOAM (PATO) software, also actively developed by NASA. The computational model in PATO is a generic heat and mass transfer model for porous reactive materials containing several solid phases and a single gas phase. The detailed chemical interactions occurring between the solid phases and the gas phase are modeled at the pore scale assuming local thermal equilibrium. These tools were developed to efficiently interface with other pre-existing codes such as SPARTA (direct simulation Monte Carlo), DPLR (hypersonic CFD), NEQAIR (radiative transport) and DAKOTA (uncertainty quantification and optimization). Detailed flight data (Mars Science Laboratory [MSL] Entry Descent and Landing Instrument [MEDLI]) is critical for validating these computational tools for NASA applications. Examples of modeling ablative material response using these codes will be presented including 3D simulations of the full-scale heatshield of the MSL capsule. The simulations demonstrate the ability of the modern material response code, PATO, to handle the material response of geometrically complex and large domains, through the use of massively parallel computations.

Thermal Protection Systems↗

Context and future directions for integrating forest carbon into sub-national climate mitigation planning in the RGGI region of the U.S.

International frameworks for climate mitigation that build from national actions have been developed under the United National Framework Convention on Climate Change and advanced most recently through the Paris Climate Agreement. In parallel, sub-national actors have set greenhouse gas (GHG) reduction goals and developed corresponding climate mitigation plans. Within the U.S., multi-state coalitions have formed to facilitate coordination of related science and policy. Here, utilizing the forum of the NASA Carbon Monitoring System’s Multi-State Working Group, we collected and reviewed climate mitigation plans for 11 states in the Regional Greenhouse Gas Initiative region of the Eastern U.S. For each state we reviewed the (a) policy framework for climate mitigation, (b) GHG reduction goals, (c) inclusion of forest activities in the state’s climate action plan, (d) existing science used to quantify forest carbon estimates, and (e) stated needs for forest carbon monitoring science. Across the region, we found important differences across all categories. While all states have GHG reduction goals and framework documents, nearly three-quarters of all states do not account for forest carbon when planning GHG reductions; those that do account for forest carbon use a variety of scientific methods with various levels of planning detail and guidance. We suggest that a common, efficient, standardized forest carbon monitoring system would provide important benefits to states and the geographic region as a whole. In addition, such a system would allow for more effective transparency and progress tracking to support state, national, and international efforts to increase ambition and implementation of climate goals.

Rachel L Lamb↗

Monitoring Airspace Complexity and Determining Contributing Factors

The national airspace has evolved over many years to accommodate increased traffic demand [1] while simultaneously maintaining one of the safest forms of transportation [2], [3]. One of the reasons for this success is the ability of the system and the operators to adapt and accommodate to situations that routinely disrupt optimal operations. These situations may include: adverse weather, delays, early arrivals, equipment outages, and other factors that are outside the operators ability to control. These factors can lead to states where automation is unable to properly handle these issues and therefore air traffic controllers and pilots have to intervene, ultimately increasing communication between operators resulting in higher workload. As controller workload increases to handle sub-optimal operating conditions this can be viewed as an increase in complexity. The reasoning for this is because humans are now required to make tactical decisions in response to external factors, resulting in a departure from the strategic plan where operations would be more efficiently managed. Human operators control airspace complexity under rigid regulations that are constantly changing. The airspace is divided into sectors and the number of aircraft assigned to each controller is limited for safe handling. There has been past work that devised airspace complexity metrics in commercial aviation and related these metrics to controller workload (e.g., [4],[5]). The upper bounds on the system load are pre-determined. Such bounds on complexity make for a safe system, but the system cannot scale and adapt to autonomous, dense, and heterogeneous traffic, including the many types of Unmanned Aerial Vehicles (UAVs) envisioned to be added to the operations. We hypothesize that, as traffic density and heterogeneity grow, and other key metrics change, there will be phase transitions at which the way traffic should be managed changes significantly [6]. We offer a method for in-time detection of contributing factors that lead to phase transitions, characterized by increased complexity. To the best of our knowledge, there is no tool similar to our proposed effort that identifies such contributing factors or precursor patterns. To define the scope we are proposing to measure complexity from the viewpoint of the Terminal Radar Approach Control Facilities (TRACON) controller’s perspective. In particular we are analyzing arrivals into KSFO. With safety as the top concern for airspace operators, it is important to recognize that as density and heterogeneity grow, the focus of the system will change. Times of the day when the airspace has low density and heterogeneity, the flights will follow more efficient paths where the aircraft move on established routes that are more or less directly to the destination. However, when density and heterogeneity increases, the system will begin changing focus to avoiding conflicts and collisions and route the flights in a more flexible way. Higher flexibility requires more communication and coordination between controllers and pilots which the current automation is unable to handle. This paper proposes a novel approach that monitors airspace complexity at multiple scales, uses a Machine Learning-based tool that predicts when operations will transition to a regime of greater complexity, and identifies actions that can reduce the complexity while still maintaining efficient and safe operations. We demonstrate our proposed approach using data from multiple complementary sources. This includes, but is not limited to: historical aircraft surveillance data from NASA’s Sherlock Data Warehouse [7], METAR weather data, and airport configuration data from Aviation System Performance Metrics (ASPM). The surveillance data flight paths are sampled at a variable sample rate — increasing as the aircraft approaches the airport. This is due to how Sherlock manages flight track stitching between different radar facilities which have different sampling rates. The weather and performance data are logged at defined intervals throughout the day at a courser refresh rate. In addition to the logged data and metrics, we leverage pre-defined Standard Terminal Arrival Routes (STARs) procedures to characterize the path of each flight. Each flight files for one of these routes in the flight plan well before entering the terminal airspace, and approximately follows the route until it leaves the STAR, typically on the final fix of a runway transition. However, most flights do not always fly the full STAR procedure to completion [8], but the majority do adhere to the fixes within the common route of the procedure. Our approach leverages fixes in the common route of each of the STARs to build a reference path to the airport. This allows us to characterize the flight paths in what we are defining as the “maneuvering area” (the airspace between the STAR and before the flight is lined up on the runway’s final approach) to determine how off nominal the flights are to calculate its complexity score. Determining airspace complexity is a concept that does not have a concrete answer. In designing this metric, we consider what increases the workload for the air traffic controllers. Consequently more specialized vectoring maneuvers results in higher workload. Accordingly, we start with a theory: each flight has a direct path it takes from the STAR’s common route to the final approach’s outer marker fix for the flight’s landing runway. It is important to note that the direct path is only used as a reference. If the majority of the flights have a large consistent offset as compared to other routes it does not necessarily mean that those flights have higher complexity. We are merely building a distribution based on this direct path for that particular STAR and runway pair to determine the normal mode of operations for that route. Flights that are in the upper tail of these distributions will result in higher complexity scores and flights that fly in the median will represent the normal mode of operations and therefore will have lower complexity scores. Since flights following each STAR route take different paths to the airport, we have a different distribution for each STAR route and therefore can model these distributions to compute a complexity score from their respective normalized distributions. To evaluate the effectiveness of our proposed airspace complexity metric we will compare against an established approach based on trajectory clustering [9]. This unsupervised learning technique consists of the following steps: (1) identify the general maneuvering areas (waypoints) by performing $\kappa$-means or DBSCAN clustering on locations where aircraft frequently turn based on the surveillance radar track data, (2) map flight trajectories onto sequences of waypoints, and (3) cluster the sequences based on their common subsequences. From a high-level perspective, this baseline model learns nominal operations in the airspace through the sequence of waypoints that are representative of where aircraft change direction and defines deviations from the nominal operations as “complex.” Therefore, more deviations from the nominal operations correspond to higher complexity values. For our validation, we re-implemented this technique and tune model hyper-parameters to correctly detect waypoints for the arrival traffic into the San Francisco bay area. We will compute the complexity measure over a one-year period using our proposed technique as well as the baseline. Our validation will be based on each technique’s ability to detect a set of undesirable outcomes (e.g., go-arounds, holding patterns, average time in the airspace, etc.). Since our current complexity metric is derived from the offset from the direct reference path, it’s important to understand what causes these offsets. In many of the flights with high offset distance, flights performing holding patterns and S turns can be observed. These maneuvering tactics are utilized to add distance between the aircraft and the destination runway to prevent multiple flights from having conflicting arrival times. In order to predict a rise in complexity (or the precursor to complexity), it’s necessary to be able to identify these potential conflicts (which in turn, result in higher offsets). To do this, we define a “representative flight” for each STAR route and runway pair. This flight is approximately the path the flight would take if there was a clear path with no other flights in the airspace — including the time remaining to the airport. We first identify the flights for a given STAR runway pair using the offset to the reference path distributions that fall between the 44-55 percentiles. This yields the flights that conform to the most normal mode of operation. Each of these flights is partitioned based on the percent complete from the entry point into the maneuvering areas from 0\% – 100\% complete. Then for each percent “bin”, we take the median value of the flight’s latitude/longitude coordinates, airspeed, and (non causal) time remaining to the airport to construct a lookup table for each percent complete bin on a given route. As a flight enters the maneuvering area, we can find the estimated arrival time of a flight to the airport by finding the closest point to the representative path’s percent complete bin (relative to the flight’s current position at any snapshot in the airspace) and therefore retrieve the corresponding remaining time left on the “representative path”. We assume that the flight will follow the representative path to completion when deriving these estimates. We can then compare these estimated arrival times against other flights for the same snapshot in time to identify potential conflicts. If more flights are estimated to arrive within a tolerance window than there are runways available, then we have a potential conflict. We can use this derived measure along with other factors expected to add disruption to the operation such as weather and runway configuration changes as an input to machine learning tools to detect precursors that increases in our complexity measure. This novel method will assist in uncovering insights into the contributing factors that lead to increased complexity that may allow for in-time responses to avoid reaching a high complexity state in the airspace.

complexity↗

Fast Track Lunar NTR Systems Assessment for NASA's First Lunar Outpost and Its Evolvability to Mars

Integrated systems and missions studies are presented for an evolutionary lunar-to-Mars space transportation system (STS) based on nuclear thermal rocket (NTR) technology. A 'standardized' set of engine and stage components are identified and used in a 'building block' fashion to configure a variety of piloted and cargo, lunar and Mars vehicles. The reference NTR characteristics include a thrust of 50 thousand pounds force (klbf), specific impulse (I(sub sp)) of 900 seconds, and an engine thrust-to-weight ratio of 4. 3. For the National Aeronautics and Space Administrations (NASA) First Lunar Outpost (FLO) mission, and expendable NTR stage powered by two such engines can deliver approximately 96 metric tonnes (t) to trans-lunar injection (TLI) conditions for an initial mass in low Earth orbit (IMLEO) of approximately 198 t compared to 250 t for a cryogenic chemical system. The stage liquid hydrogen (LH2) tank has a diameter, length, and capacity of 10 m, 14.5 m and 66 t, respectively. By extending the stage length and LH2 capacity to approximately 20 m and 96 t, a single launch Mars cargo vehicle could deliver to an elliptical Mars parking orbit a 63 t Mars excursion vehicle (MEV) with a 45 t surface payload. Three 50 klbf engines and the two standardized LH2 tanks developed for the lunar and Mars cargo vehicles are used to configure the vehicles supporting piloted Mars missions as early as 2010. The 'modular' NTR vehicle approach forms the basis for an efficient STS able to handle the needs of a wide spectrum of lunar and Mars missions.

Borowski, Stanley K.↗

Quartz/fused silica chip carriers

The primary objective of this research and development effort was to develop monolithic microwave integrated circuit (MMIC) packaging which will operate efficiently at millimeter-wave frequencies. The packages incorporated fused silica as the substrate material which was selected due to its favorable electrical properties and potential performance improvement over more conventional materials for Ka-band operation. The first step towards meeting this objective is to develop a package that meets standard mechanical and thermal requirements using fused silica and to be compatible with semiconductor devices operating up to at least 44 GHz. The second step is to modify the package design and add multilayer and multicavity capacity to allow for application specific integrated circuits (ASIC's) to control multiple phase shifters. The final step is to adapt the package design to a phased array module with integral radiating elements. The first task was a continuation of the SBIR Phase 1 work. Phase 1 identified fused silica as a viable substrate material by demonstrating various plating, machining, and adhesion properties. In Phase 2 Task 1, a package was designed and fabricated to validate these findings. Task 2 was to take the next step in packaging and fabricate a multilayer, multichip module (MCM). This package is the predecessor to the phased array module and demonstrates the ability to via fill, circuit print, laminate, and to form vertical interconnects. The final task was to build a phased array module. The radiating elements were to be incorporated into the package instead of connecting to it with wire or ribbon bonds.

Source record↗

Aerospace Cognitive Engineering Laboratory (ACELAB) Simulator for Electric Vertical Takeoff and Landing (eVOTL) Research and Development

A new generation of aerospace innovators are looking for ways to quickly and efficiently transport people in a safe and environmentally friendly manner. In the not-too-distant future, passengers and goods are expected to routinely fly aboard a new breed of cleaner, smarter air vehicles. This represents a new and significant challenge to the Federal Aviation Agency (FAA) which is responsible for aircraft certification, pilot licensing, operating approval and airspace integration. To help streamline this process, NASA has formulated its Advanced Air Mobility (AAM) project to provide research capabilities for development and evaluation of these new concepts and an environment where industry and regulators can work together to understand the requirements and work toward consensus standards for the new market. This paper will describe the development of the Aerospace Cognitive Engineering Lab Rapid Automation Test (ACELeRATE) simulator. ACELeRATE is an adaptable fixed-base aircraft simulator focused on the investigation of the performance and interaction of pilots and increasingly automated aircraft systems. ACELeRATE can be re-configured to support various simulation environments. The simulator includes a simple reconfigurable cockpit placed within a 10-foot spherical dome with a cluster of real-time image generators, high-resolution displays and highly realistic scenery with the surrounding digital terrain and required cultural area details (e.g., hangars, runways, ramp areas, taxiways, test range apparatus, buildings with designated rooftop landing areas, and other man-made 3D structures). This paper will also describe the various hardware and software tools employed in the ACELeRATE simulator, including engineering tools used by NASA for electric Vertical Takeoff and Landing (eVTOL) vehicle equations of motion, wind-model simulation in an urban environment, as well as the various modeling techniques and tools used to quickly generate highly realistic 3D terrain models for low level flight including urban terrain and obstacle depictions.

AAM Simulation Cockpit↗

Traveling-Wave Maser for 32 GHz

The figure depicts a traveling-wave ruby maser that has been designed (though not yet implemented in hardware) to serve as a low-noise amplifier for reception of weak radio signals in the frequency band of 31.8 to 32.3 GHz. The design offers significant improvements over previous designs of 32-GHz traveling-wave masers. In addition, relative to prior designs of 32-GHz amplifiers based on high-electron-mobility transistors, this design affords higher immunity to radio-frequency interference and lower equivalent input noise temperature. In addition to the basic frequency-band and low-noise requirements, the initial design problem included a requirement for capability of operation in a closed-cycle helium refrigerator at a temperature .4 K and a requirement that the design be mechanically simplified, relative to prior designs, in order to minimize the cost of fabrication and assembly. Previous attempts to build 32- GHz traveling-wave masers involved the use of metallic slow-wave structures comprising coupled transverse electromagnetic (TEM)-mode resonators that were subject to very tight tolerances and, hence, were expensive to fabricate and assemble. Impedance matching for coupling signals into and out of these earlier masers was very difficult. A key feature of the design is a slow-wave structure, the metallic portions of which would be mechanically relatively simple in that, unlike in prior slow-wave structures, there would be no internal metal steps, irises, or posts. The metallic portions of the slow-wave structure would consist only of two rectangular metal waveguide arms. The arms would contain sections filled with the active material (ruby) alternating with evanescent-wave sections. This structure would be transparent in both the signal-frequency band (the aforementioned range of 31.8 to 32.3 GHz) and the pump-frequency band (65.75 to 66.75 GHz), and would impose large slowing factors in both frequency bands. Resonant ferrite isolators would be placed in the evanescent-wave sections to provide reverse loss needed to suppress reverse propagation of power at the signal frequency. This design is expected to afford a large gain-bandwidth product at the signal frequency and efficient coupling of the pump power into the paramagnetic spin resonances of the ruby sections. The more efficiently the pump power could be thus coupled, the more efficiently it could be utilized and the heat load on the refrigerator correspondingly reduced.

Shell, James↗

Additive Manufacturing Design Considerations for Liquid Engine Components

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Whitten, Dave↗

Enabling Airspace Integration for High-Density On-Demand Mobility Operations

Aviation technologies and concepts have reached a level of maturity that may soon enable an era of on-demand mobility (ODM) fueled by quiet, efficient, and largely automated air taxis. However, successfully bringing such a system to fruition will require introducing orders of magnitude more aircraft to a given airspace volume than can be accommodated by the traditional air traffic control system, among other important technical challenges. The airspace integration problem is further compounded by requirements to set aside appropriate ground infrastructure for take-off and landing areas and ensuring these new aircraft types and their operations do not burden traditional airspace users and air traffic control. This airspace integration challenge may be significantly reduced by extending the concepts and technologies developed to manage small unmanned aircraft systems (UAS) at low altitudethe UAS traffic management (UTM) systemto higher altitudes and new aircraft types, or by equipping ODM aircraft with advanced sensors, algorithms, and interfaces. The precedent of operational freedom inherent in visual flight rules and the technologies developed for large UAS and commercial aircraft automation will contribute to the evolution of an ODM system enabled by UTM. This paper describes the set of air traffic services, normally provided by the traditional air traffic system, that an ODM system would implement to achieve the high densities needed for ODMs economic viability. Finally, the paper proposes a framework for integrating, evaluating, and deploying low-, medium-, and high-density ODM concepts that build on each other to ensure operational and economic feasibility at every step.

Mueller, Eric↗

Autonomous In-Situ Resources Prospector

This presentation will describe the concept of an autonomous, intelligent, rover-based rapid surveying system to identify and map several key lunar resources to optimize their ISRU (In Situ Resource Utilization) extraction potential. Prior to an extraction phase for any target resource, ground-based surveys are needed to provide confirmation of remote observation, to quantify and map their 3-D distribution, and to locate optimal extraction sites (e.g. ore bodies) with precision to maximize their economic benefit. The system will search for and quantify optimal minerals for oxygen production feedstock, water ice, and high glass-content regolith that can be used for building materials. These are targeted because of their utility and because they are, or are likely to be, variable in quantity over spatial scales accessible to a rover (i.e., few km). Oxygen has benefits for life support systems and as an oxidizer for propellants. Water is a key resource for sustainable exploration, with utility for life support, propellants, and other industrial processes. High glass-content regolith has utility as a feedstock for building materials as it readily sinters upon heating into a cohesive matrix more readily than other regolith materials or crystalline basalts. Lunar glasses are also a potential feedstock for oxygen production, as many are rich in iron and titanium oxides that are optimal for oxygen extraction. To accomplish this task, a system of sensors and decision-making algorithms for an autonomous prospecting rover is described. One set of sensors will be located in the wheel tread of the robotic search vehicle providing contact sensor data on regolith composition. Another set of instruments will be housed on the platform of the rover, including VIS-NIR imagers and spectrometers, both for far-field context and near-field characterization of the regolith in the immediate vicinity of the rover. Also included in the sensor suite are a neutron spectrometer, ground-penetrating radar, and an instrumented cone penetrometer for subsurface assessment. Output from these sensors will be evaluated autonomously in real-time by decision-making software to evaluate if any of the targeted resources has been detected, and if so, to quantify their abundance. Algorithms for optimizing the mapping strategy based on target resource abundance and distribution are also included in the autonomous software. This approach emphasizes on-the-fly survey measurements to enable efficient and rapid prospecting of large areas, which will improve the economics of ISRU system approaches. The mature technology will enable autonomous rovers to create in-situ resource maps of lunar or other planetary surfaces, which will facilitate human and robotic exploration.

Dissly, R. W.↗

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100hrs to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne (AR) is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗

Initial Development of A Digital Twin Model for an Electrified Aircraft Propulsion Emulation Rig

In support of aviation fuel burn and emission reduction goals, NASA is pursing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP), which relies on the generation, storage, transmission, and use of electrical power for producing thrust and optimizing propulsion system efficiency. Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes advances in propulsion controls, which will be vital for ensuring coordinated efficient operation of the complex integrated subsystems that comprise EAP architectures. To support EAP controls research, the NASA Glenn Research Center has developed the Hybrid Propulsion Emulation Rig (HyPER). The HyPER laboratory hardware includes shaft-mounted electric machines, power converters, power supplies, power distribution cables, and an energy storage device that can be reconfigured to represent a variety of EAP architectures. It also includes an integrated real-time computer system that hosts developed EAP control software and turbomachinery simulations. This enables the electrical system and rotating shafts of EAP designs to be implemented in actual hardware and integrated with turbomachinery simulations and system-level EAP control logic implemented in software. In this form, the HyPER laboratory provides a partially simulated, partially hardware-in-the-loop test environment enabling the initial development and evaluation of EAP control technology. A prerequisite for the development of EAP control designs is the availability of a system model that accurately reflects the operation of the electrical system hardware. To support this need, a digital twin model of the HyPER electrical system hardware is under development. This model is being coded in the MATLAB Simulink environment and uses the NASA-developed Electrical Modeling and Thermal Analysis Toolbox (EMTAT) to construct a digital twin framework. EMTAT contains generic electrical component building blocks that are simulated at turbomachinery timescales. Associated inputs and outputs allow the blocks to be combined to model complete electrical systems. The EMTAT blocks also contain adjustable internal maps and parameters that can be set to reflect the operation of a specific electrical component. For the HyPER digital twin, the settings of these EMTAT block internal maps and parameters is determined through machine learning approaches applied to characterization run data collected from the laboratory. During characterization runs the laboratory electrical system hardware is subjected to a full range of torque, speed, and power settings. Acquired data is then used to estimate EMTAT block parameters using a variety of machine learning techniques. The resulting digital twin model is found to match the operation of actual HyPER hardware with an accuracy suitable for control development purposes. It also holds promise for other applications including modeling the performance of HyPER laboratory reconfigurations and model-based anomaly detection. Planned follow-on work to automate post-processing of acquired laboratory data to update the HyPER digital twin model will also be presented and discussed.

Electrified Aircraft Propulsion↗

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100 kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5 kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100 hours to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗

Enabling Airspace Integration for High-Density On-Demand Mobility Operations

Aviation technologies and concepts have reached a level of maturity that may soon enable an era of on-demand mobility (ODM) fueled by quiet, efficient, and largely automated air taxis. However, successfully bringing such a system to fruition will require introducing orders of magnitude more aircraft to a given airspace volume than can be accommodated by the traditional air traffic control system, among other important technical challenges. The airspace integration problem is further compounded by requirements to set aside appropriate ground infrastructure for take-off and landing areas and ensuring these new aircraft types and their operations do not burden traditional airspace users and air traffic control. This airspace integration challenge may be significantly reduced by extending the concepts and technologies developed to manage small unmanned aircraft systems (UAS) at low altitude - the UAS traffic management (UTM) system - to higher altitudes and new aircraft types, or by equipping ODM aircraft with advanced sensors, algorithms, and interfaces. The precedent of operational freedom inherent in visual flight rules and the technologies developed for large UAS and commercial aircraft automation will contribute to the evolution of an ODM system enabled by UTM. This paper describes the set of air traffic services, normally provided by the traditional air traffic system, that an ODM system would implement to achieve the high densities needed for ODM's economic viability. Finally, the paper proposes a framework for integrating, evaluating, and deploying low-, medium-, and high-density ODM concepts that build on each other to ensure operational and economic feasibility at every step.

Mueller, Eric↗

CAPRI: Using a Geometric Foundation for Computational Analysis and Design

CAPRI (Computational Analysis Programming Interface) is a software development tool intended to make computerized design, simulation and analysis faster and more efficient. The computational steps traditionally taken for most engineering analysis (Computational Fluid Dynamics (CFD), structural analysis, etc.) are: Surface Generation, usually by employing a Computer Aided Design (CAD) system; Grid Generation, preparing the volume for the simulation; Flow Solver, producing the results at the specified operational point; Post-processing Visualization, interactively attempting to understand the results. It should be noted that the structures problem is more tractable than CFD; there are fewer mesh topologies used and the grids are not as fine (this problem space does not have the length scaling issues of fluids). For CFD, these steps have worked well in the past for simple steady-state simulations at the expense of much user interaction. The data was transmitted between phases via files. In most cases, the output from a CAD system could go IGES files. The output from Grid Generators and Solvers do not really have standards though there are a couple of file formats that can be used for a subset of the gridding (i.e. PLOT3D) data formats and the upcoming CGNS). The user would have to patch up the data or translate from one format to another to move to the next step. Sometimes this could take days. Instead of the serial approach to analysis, CAPRI takes a geometry centric approach. CAPRI is a software building tool-kit that refers to two ideas: (1) A simplified, object-oriented, hierarchical view of a solid part integrating both geometry and topology definitions, and (2) programming access to this part or assembly and any attached data. The connection to the geometry is made through an Application Programming Interface (API) and not a file system.

Haimes, Robert↗

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗

Enabling Airspace Integration for High Density Urban Air Mobility

Aviation technologies and concepts have reached a level of maturity that may soon enable an era of on-demand mobility (ODM) fueled by quiet, efficient, and largely automated air taxis. However, successfully bringing such a system to fruition will require introducing orders of magnitude more aircraft to a given airspace volume than can be accommodated by the traditional air traffic control system, among other important technical challenges. The airspace integration problem is further compounded by requirements to set aside appropriate ground infrastructure for take-off and landing areas and ensuring these new aircraft types and their operations do not burden traditional airspace users and air traffic control. These challenge for ODM may be significantly reduced by extending the concepts and technologies developed to manage small unmanned aircraft systems (UAS) at low altitude the UAS traffic management (UTM) system to higher altitudes and aircraft with humans onboard in controlled airspace, or by equipping ODM aircraft with advanced sensors, algorithms, and interfaces. The precedent of operational freedom inherent in visual flight rules and the technologies developed for large UAS and commercial aircraft automation will contribute to the evolution of an ODM system enabled by UTM. This paper describes the set of air traffic services, normally provided by the traditional air traffic system, that an ODM system would implement to achieve the high densities needed for ODMs economic viability. Finally, the paper proposes a framework for integrating, evaluating, and deploying low-, medium-, and high-density ODM concepts that build on each other to ensure operational and economic feasibility at every step.

Mueller, Eric Richard↗

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↗