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NASA NTRSDate not supplied

Flight Deck Design of a Hybrid Turbine/Electric Aircraft

The SUbsonic Single Aft eNgine (SUSAN) program is being developed as a sustainable subsonic regional aircraft. NASA is conducting trade studies for this future hybrid single aisle passenger aircraft. The goal of reducing emission levels by 50% will be enabled through an advanced design. An aft mounted single turbine engine provides thrust and electric power to drive 16 wing mounted electric engines. Using the 16 counter-rotating electric fans will create an efficient, very high bypass ratio, engine. Electric engines allow for distributed thrust, reducing control surfaces and provide a greater dynamic response. Batteries provide boost for takeoff and climb, allowing a smaller, more efficient, turbine engine. As part of the SUSAN effort, two pilot-in-the-loop studies were conducted at NASA Langley Research Center in Virginia to explore flight deck design issues. In particular: how many throttles are required/desired for a 17-engine aircraft, does the hybrid electric design change the answer, what are the requirements for electric engine displays, what system pages are required, and what information is required to monitor the batteries. Objective and subjective data were collected after each scenario and at the end of the day with a guided set of questionnaires from sixteen crews paired by airline. Data along with pilot comments were used to improve the throttle and engine displays between the studies and used to make the final recommendations on flight deck configurations. This paper provides final design recommendations for the SUSAN flight deck and justification for each recommendation.

PAI↗

NASA NTRS1975

Exhaust pollutant emissions from swirl-can combustor module arrays at parametric test conditions

Improved designs of swirl-can combustor modules were tested using seven-module arrays in a combustor. The combustor was operated over a pressure range of 69 to 207 N/sq cm, a fuel-air ratio range of 0.015 to 0.046, at a constant inlet air temperature of 733 K, and at reference velocities of 23.9 and 30.6 m/sec. The three designs tested performed with high combustion efficiency at all conditions tested and exhibited oxides of nitrogen emissions substantially lower than that of conventional gas turbine combustors. A correlating parameter used to extrapolate oxides of nitrogen emissions to full power or takeoff conditions for large commercial turbofan engines predicts oxides of nitrogen emissions somewhat higher than those specified in the 1979 government emissions standards.

Mularz, E. J.↗

NASA NTRS2016

Compatibility Assessment Tool

In support of ground system development for the Space Launch System (SLS), engineers are tasked with building immense engineering models of extreme complexity. The various systems require rigorous analysis of pneumatics, hydraulic, cryogenic, and hypergolic systems. There are certain standards that each of these systems must meet, in the form of pressure vessel system (PVS) certification reports. These reports can be hundreds of pages long, and require many hours to compile. Traditionally, each component is analyzed individually, often utilizing hand calculations in the design process. The objective of this opportunity is to perform these analyses in an integrated fashion with the parametric CADCAE environment. This allows for systems to be analyzed on an assembly level in a semi-automated fashion, which greatly improves accuracy and efficiency. To accomplish this, component specific parameters were stored in the Windchill database to individual Creo Parametric models based on spec control drawings. These parameters were then accessed by using the Prime Analysis within Creo Parametric. MathCAD Prime spreadsheets were created that automatically extracted these parameters, performed calculations, and generated reports. The reports described component compatibility based on local conditions such as pressure, temperature, density, and flow rates. The reports also determined component pairing compatibility, such as properly sizing relief valves with regulators. The reports stored the input conditions that were used to determine compatibility to increase traceability of component selection. The desired workflow for using this tool would begin with a Creo Schematics diagram of a PVS system. This schematic would store local conditions and locations of components. The schematic would then populate an assembly within Creo Parametric, using Windchill database parts. These parts would have their attributes already assigned, and the MathCAD spreadsheets could begin running through database parts to determine which components would be suited for specific locations within the assembly. This eliminates a significant amount of time from the design process, and makes initial analysis assessments more accurate. Each component that would be checked for a location within the assembly would generate a report, showing whether the component was compatible. These reports could be used to generate the PVS report without the need to perform the same analysis multiple times. This process also has the potential to be expanded upon to further automate PVS reports. The integration of software codes or macros could be used to automatically check through hundreds of parts for each location on the schematic. If the software could recognize which type of component would be necessary for each location, it is possible that simply starting the macro could completely choose all the components needed for the schematic, and in turn the system. This would save many hours of work initially selecting components, which could end up saving money. Overall, this process helps to automate initial component selections for PVS systems to fit local design specifications. These selections will automatically generate reports showing how the design criteria are met by the specific component that was chosen. These reports will contribute to easier compilation of the PVS certification reports, which currently take a great amount of time and effort to produce.

Egbert, James Allen↗

NASA NTRSDate not supplied

The Anatomy of Software Changes and Bugs in Autonomous Operating System

Cyberphysical systems with autonomous functions are complex pieces of software, consisting of many components, some of which implement autonomous functionality and some may use AI or machine learning algorithms. Software bugs in an autonomous system are of particular concern, as they can have catastrophic consequences. However, detailed studies based on empirical data are rare and therefore these bugs are not well understood. This paper aims to contribute towards filling that gap by investigating the software changes and bugs in Autonomy Operating System (AOS) for Unmanned Aircraft Systems (UAS), which consist of 26 components containing about 103,000 lines of code and having a total of 772 bugfixes. Based on the data extracted from the code repository and semi-structured interviews with the developers of AOS, we explore the differences among autonomous software components, components developed using Model-based Software Engineering, and reuse with respect to change proneness, fault proneness, distribution of bugfixes among AOS components and files of these components, and characteristics of bugs of different AOS components. Our results show that the autonomous components were significantly more change prone (measured in number of commits and code churn) and fault prone (measured in bugfixes per KLoC) than non-autonomous components. The distribution of the locations of bugfixes was skewed, both at component and file level (i.e., a small number of components / files contained the majority of bugs). These evidence-based findings provide important insights to researchers and practitioners alike and can be used to efficiently improve the quality and reliability of autonomous systems.

Katerina Goseva-Popstojanova↗

NASA NTRSDate not supplied

Quantification of Design Trade-Offs When Comparing Transonic Truss-Braced Wing to Advanced Tube and Wing Aircraft

Interest in novel aircraft configurations has continued to grow in response to increasing demand for improved fuel efficiency. One such configuration of interest is the Transonic Truss-Braced Wing (TTBW). Because the improvement of the TTBW comes from increased efficiency during cruise, it offers increasing returns as the mission distance increases. As a result, there is often a crossover point which represents the minimum mission range where the TTBW will offer a fuel burn reduction relative to a similar Tube and Wing aircraft with similar component technology levels. Aircraft rarely fly missions at their maximum range, so it is important to investigate not only the maximum benefit, but also the most likely benefit. Design decisions and analysis assumptions that significantly impact this crossover point include whether to put fuel in body tanks, how weight build-up estimation is calibrated, engine technology selection, and flight Mach number. This study, conducted under NASA’s Sustainable Flight Demonstration project and inspired by differing assumptions made by different research teams, details the impacts of changing these design decisions and assumptions.

Carl J Recine↗

NASA NTRSDate not supplied

Quantification of Design Trade-Offs When Comparing Transonic Truss-Braced Wing to Advanced Tube and Wing Aircraft

Carl J Recine↗

NASA NTRS1994

Computational predictive methods for fracture and fatigue

The damage-tolerant design philosophy as used by aircraft industries enables aircraft components and aircraft structures to operate safely with minor damage, small cracks, and flaws. Maintenance and inspection procedures insure that damages developed during service remain below design values. When damage is found, repairs or design modifications are implemented and flight is resumed. Design and redesign guidelines, such as military specifications MIL-A-83444, have successfully reduced the incidence of damage and cracks. However, fatigue cracks continue to appear in aircraft well before the design life has expired. The F16 airplane, for instance, developed small cracks in the engine mount, wing support, bulk heads, the fuselage upper skin, the fuel shelf joints, and along the upper wings. Some cracks were found after 600 hours of the 8000 hour design service life and design modifications were required. Tests on the F16 plane showed that the design loading conditions were close to the predicted loading conditions. Improvements to analytic methods for predicting fatigue crack growth adjacent to holes, when multiple damage sites are present, and in corrosive environments would result in more cost-effective designs, fewer repairs, and fewer redesigns. The overall objective of the research described in this paper is to develop, verify, and extend the computational efficiency of analysis procedures necessary for damage tolerant design. This paper describes an elastic/plastic fracture method and an associated fatigue analysis method for damage tolerant design. Both methods are unique in that material parameters such as fracture toughness, R-curve data, and fatigue constants are not required. The methods are implemented with a general-purpose finite element package. Several proof-of-concept examples are given. With further development, the methods could be extended for analysis of multi-site damage, creep-fatigue, and corrosion fatigue problems.

Cordes, J.↗

NASA NTRS1997

Nonlinear Dynamic Analysis of Disordered Bladed-Disk Assemblies

In a effort to address current needs for efficient, air propulsion systems, we have developed some new analytical predictive tools for understanding and alleviating aircraft engine instabilities which have led to accelerated high cycle fatigue and catastrophic failures of these machines during flight. A frequent cause of failure in Jets engines is excessive resonant vibrations and stall flutter instabilities. The likelihood of these phenomena is reduced when designers employ the analytical models we have developed. These prediction models will ultimately increase the nation's competitiveness in producing high performance Jets engines with enhanced operability, energy economy, and safety. The objectives of our current threads of research in the final year are directed along two lines. First, we want to improve the current state of blade stress and aeromechanical reduced-ordered modeling of high bypass engine fans, Specifically, a new reduced-order iterative redesign tool for passively controlling the mechanical authority of shroudless, wide chord, laminated composite transonic bypass engine fans has been developed. Second, we aim to advance current understanding of aeromechanical feedback control of dynamic flow instabilities in axial flow compressors. A systematic theoretical evaluation of several approaches to aeromechanical feedback control of rotating stall in axial compressors has been conducted. Attached are abstracts of two .papers under preparation for the 1998 ASME Turbo Expo in Stockholm, Sweden sponsored under Grant No. NAG3-1571. Our goals during the final year under Grant No. NAG3-1571 is to enhance NASA's capabilities of forced response of turbomachines (such as NASA FREPS). We with continue our development of the reduced-ordered, three-dimensional component synthesis models for aeromechanical evaluation of integrated bladeddisk assemblies (i.e., the disk, non-identical bladeing etc.). We will complete our development of component systems design optimization strategies for specified vibratory stresses and increased fatigue life prediction of assembly components, and for specified frequency margins on the Campbell diagrams of turbomachines. Finally, we will integrate the developed codes with NASA's turbomachinery aeromechanics prediction capability (such as NASA FREPS).

McGee, Oliver G., III↗

NASA NTRS2014

Lessons Learned from the Development and Implementation of the Atmosphere Resource Recovery and Environmental Monitoring Project

The Advanced Exploration Systems (AES) Program's Atmosphere Resource Recovery and Environmental Monitoring (ARREM) Project have been developing atmosphere revitalization and environmental monitoring subsystem architectures suitable for enabling sustained crewed exploration missions beyond low Earth orbit (LEO). Using the International Space Station state-of-the-art (SOA) as the technical basis, the ARREM Project has contributed to technical advances that improve affordability, reliability, and functional efficiency while reducing dependence on a ground-based logistics resupply model. Functional demonstrations have merged new process technologies and concepts with existing ISS developmental hardware and operate them in a controlled environment simulating various crew metabolic loads. The ARREM Project's strengths include access to a full complement of existing developmental hardware that perform all the core atmosphere revitalization functions, unique testing facilities to evaluate subsystem performance, and a coordinated partnering effort among six NASA field centers and industry partners to provide the innovative expertise necessary to succeed. A project overview is provided and the project management strategies that have enabled a multidiscipinary engineering team to work efficiently across project, NASA field center, and industry boundaries to achieve the project's technical goals are discussed. Lessons learned and best practices relating to the project are presented and discussed.

Roman, Monsi C.↗

NASA NTRS2018

Aerodynamic Conceptual Design of Boundary Layer Ingestion Propulsor Systems: A Quasi-2D Through Flow Analysis Method and Multi-Fidelity Propulsor Design Framework

A propulsor design framework for maximizing the benefits of boundary layer ingestion is presented. The performance of BLI is strongly affected by all propulsor components, including the boundary layer characteristics (displacement thickness and form factor) of the ingested boundary layer at the inlet, the radical loading characteristics if the fan and exit guide vane (EGV), the area contraction from inlet to nozzle, and flow expansion at the exhaust cone. A strategy and it's associated multi-fidelity design framework are proposed for an efficient conceptual design of the BLI proplusor which inherently differs from the conventional engine. In the frame work, a quasi-2D through flow model served as the underlying fidelity model is introduced to incorporate the radial effect of the boundary layer entering the propulsor. Multi-fidelity design work is conducted to maximize the predefined performance metrics. On top of this efficient quasi-2D model. computational fluid dynamics based 3-D propulsor models are implemented to refine and validate the design. A BLI propulsion system integrated with fuselage is designed to showcase the framework. The performance of the resulting BLI propulsor system is evaluated via body-force model in unstructured Reynolds-Averaged Navier-Stoke (RANS) CFD and improvement is presented.

Lee, B. J.↗

NASA NTRS2016

Achieving Fast Operational Intelligence in NASA's Deep Space Network Through Complex Event Processing

NASA’s Deep Space Network (DSN) is a complex, global project, in which the expertise of human operators remain crucial for its successful operation. To find ways to save costs in operations and to improve its services, a number of modernization efforts are underway in the DSN. One such effort is a research and technology development task at the Jet Propulsion Laboratory that is investigating the use of complex event processing (CEP) for intelligent assessment of situations, trend analysis, and advanced automation. The technology leverages the significant business intelligence (BI) and data science advancements made in the enterprise industries over the last several years. The open source big data processing engine Apache SparkTM and the high-throughput, distributed messaging system Apache Kafka form the core of the DSN Complex Event Processing (DCEP) framework. This paper discusses the system engineering perspective of why achieving efficient, lower-cost operations in the DSN is a challenging problem, how the DCEP system handles the use cases that help realize intelligent operations, and how this solution fits into the overall model of the planned DSN Follow-the- Sun Operations (FtSO).

Choi, Joshua S.↗

NASA NTRSDate not supplied

Bioreactor Development for CO2-Based In Situ Resource Utilization Manufacturing

Sustainable long-duration manned missions on both the Moon and Mars will require in situ resource utilization (ISRU). Carbon dioxide (CO2) has great potential as a harvestable resource, making up 95% of the atmosphere on Mars and being produced as respiratory waste in spacecraft and future planetary habitats. Through ISRU, biomanufacturing has the capability to produce a near limitless array of products from local space resources, which include pharmaceuticals, bioplastics, chemical feedstocks, and industrial enzymes. Here, a CO2-based ISRU recombinant protein bioreactor and associated biomanufacturing organisms were designed to produce a highly stable carbonic anhydrase (CA). Initial work characterized candidate organisms for growth on acetate and formic acid, carbon substrates that can be synthesized via electrochemical conversion of CO2. To improve growth on the CO2 producing substrate formic acid and for direct integration of ISRU CO2, a synthetic Calvin-Benson-Bassam cycle was designed for use in Cyberlindnera jadinii and Escherichia coli. Genetic modifications in E. coli will be facilitated by a tailored CRISPR/Cas9 and λ red recombineering two-vector system. For expression of CA, a blue light regulated T7 promoter was employed for dynamic and small molecule free induction. Efficient bioproduction through a fed-batch exponential feeding strategy was determined via mass balance calculations from ISRU substrates to biomass and CA yield. Flux balance analysis was used to model ISRU substrate metabolism and metabolic pathway engineering in candidate organisms under cultivation strategy conditions for both metabolism reconstruction and pathway design optimization. Finally, a small-scale, disposable bag bioreactor concept for use in the NASA Bioculture System infrastructure was designed to enable CO2-based CA production in reduced-gravity environments.

Biomanufacturing, Pathway Engineering, Flux Balanc↗

NASA NTRS2001

Finite Element Methods for real-time Haptic Feedback of Soft-Tissue Models in Virtual Reality Simulators

We have applied the linear elastic finite element method to compute haptic force feedback and domain deformations of soft tissue models for use in virtual reality simulators. Our results show that, for virtual object models of high-resolution 3D data (>10,000 nodes), haptic real time computations (>500 Hz) are not currently possible using traditional methods. Current research efforts are focused in the following areas: 1) efficient implementation of fully adaptive multi-resolution methods and 2) multi-resolution methods with specialized basis functions to capture the singularity at the haptic interface (point loading). To achieve real time computations, we propose parallel processing of a Jacobi preconditioned conjugate gradient method applied to a reduced system of equations resulting from surface domain decomposition. This can effectively be achieved using reconfigurable computing systems such as field programmable gate arrays (FPGA), thereby providing a flexible solution that allows for new FPGA implementations as improved algorithms become available. The resulting soft tissue simulation system would meet NASA Virtual Glovebox requirements and, at the same time, provide a generalized simulation engine for any immersive environment application, such as biomedical/surgical procedures or interactive scientific applications.

Frank, Andreas O.↗

NASA NTRS2003

High-Flow Jet Exit Rig Designed and Fabricated

The High-Flow Jet Exit Rig at the NASA Glenn Research Center is designed to test single flow jet nozzles and to measure the appropriate thrust and noise levels. The rig has been designed for the maximum hot condition of 16 lbm/sec of combustion air at 1960 R (maximum) and to produce a maximum thrust of 2000 lb. It was designed for cold flow of 29.1 lbm/sec of air at 530 R. In addition, it can test dual-flow nozzles (nozzles with bypass flow in addition to core flow) with independent control of each flow. The High- Flow Jet Exit Rig was successfully fabricated in late 2001 and is being readied for checkout tests. The rig will be installed in Glenn's Aeroacoustic Propulsion Laboratory. The High-Flow Jet Exit Rig consists of the following major components: a single component force balance, the natural-gas-fueled J-79 combustor assembly, the plenum and manifold assembly, an acoustic/instrumentation/seeding (A/I/S) section, a table, and the research nozzles. The rig will be unique in that it is designed to operate uncooled. The structure survives the 1960 R test condition because it uses carefully selected high temperature alloy materials such as Hastelloy-X. The lower plenum assembly was designed to operate at pressures to 450 psig at 1960 R, in accordance with the ASME B31.3 piping code. The natural gas-fueled combustor fires directly into the lower manifold. The hot air is directed through eight 1-1/2-in. supply pipes that supply the upper plenum. The flow is conditioned in the upper plenum prior to flowing to the research nozzle. The 1-1/2-in. supply lines are arranged in a U-shaped design to provide for a flexible piping system. The combustor assembly checkout was successfully conducted in Glenn's Engine Component Research Laboratory in the spring of 2001. The combustor is a low-smoke version of the J79 combustor used to power the F4 Phantom military aircraft. The natural gas-fueled combustor demonstrated high-efficiency combustion over a wide range of operating conditions. This wide operating envelope is required to support the testing of both single- and dual-flow nozzles. Key research goals include providing simultaneous, highly accurate acoustic, flow, and thrust measurements on jet nozzle models in realistic flight conditions, as well as providing scaleable acoustic results. The High-Flow Jet Exit Rig is a second-generation high-flow test rig. Improvements include cleaner flow with reduced levels of particulate, soot, and odor. Choked-flow metering is required with plus or minus 0.25-percent accuracy. Thrust measurements from 0 to 2000 lbf are required with plus or minus 0.25-percent accuracy. Improved acoustics will be achieved by minimizing noise through large pipe bend radii, lower internal flow velocities, and microdrilled choke plates with thousands of 0.040-in.- diameter holes.

Buehrle, Robert J.↗

NASA NTRS1981

Prolonging thermal barrier coated specimen life by thermal cycle management

Thermal barrier coatings applied to the heated side of engine components such as seals, combustor, and blades of a gas turbine offer a potential increase in efficiency through the use of higher gas temperatures or less cooling air or benefits arising from extended component life by reducing component metal temperatures. The considered investigation has the objective to show that while a thermal barrier coated (TBC) specimen can be brought to a fixed temperature using various fuel-air ratio (F/A) values, lower calculated stresses are associated with lower (F/A) values. This implies that control of (F/A) values (i.e., rates of heat input) during the starting transient and to a lesser extent during shutdown and operation, offers a potential method of improving TBC lifetime through thermal cycle management.

Hendricks, R. C.↗

NASA NTRS2013

Updated Assessment of an Open Rotor Airplane Using an Advanced Blade Design

Application of open rotor propulsion systems (historically referred to as "advanced turboprops" or "propfans") to subsonic transport aircraft received significant attention and research in the 1970s and 1980s when fuel efficiency was the driving focus of aeronautical research. Recent volatility in fuel prices and concern for aviation's environmental impact have renewed interest in open rotor propulsion, and revived research by NASA and a number of engine manufacturers. Over the last few years, NASA has revived and developed analysis capabilities to assess aircraft designs with open rotor propulsion systems. These efforts have been described in several previous papers along with initial results from applying these capabilities. The initial results indicated that open rotor engines have the potential to provide large reductions in fuel consumption and emissions. Initial noise analysis indicated that current noise regulations can be met with modern baseline blade designs. Improved blades incorporating low-noise features are expected to result in even lower noise levels. This paper describes improvements to the initial assessment, plus a follow-on study using a more advanced open rotor blade design to power the advanced singleaisle transport. The predicted performance and environmental results of these two advanced open rotor concepts are presented and compared.

Hendricks, Eric S.↗

NASA NTRS2015

Cryogenic Insulation Standard Data and Methodologies Project

Extending some recent developments in the area of technical consensus standards for cryogenic thermal insulation systems, a preliminary Inter-Laboratory Study of foam insulation materials was performed by NASA Kennedy Space Center and LeTourneau University. The initial focus was ambient pressure cryogenic boil off testing using the Cryostat-400 flat-plate instrument. Completion of a test facility at LETU has enabled direct, comparative testing, using identical cryostat instruments and methods, and the production of standard thermal data sets for a number of materials under sub-ambient conditions. The two sets of measurements were analyzed and indicate there is reasonable agreement between the two laboratories. Based on cryogenic boiloff calorimetry, new equipment and methods for testing thermal insulation systems have been successfully developed. These boiloff instruments (or cryostats) include both flat plate and cylindrical models and are applicable to a wide range of different materials under a wide range of test conditions. Test measurements are generally made at large temperature difference (boundary temperatures of 293 K and 78 K are typical) and include the full vacuum pressure range. Results are generally reported in effective thermal conductivity (ke) and mean heat flux (q) through the insulation system. The new cryostat instruments provide an effective and reliable way to characterize the thermal performance of materials under subambient conditions. Proven in through thousands of tests of hundreds of material systems, they have supported a wide range of aerospace, industry, and research projects. Boiloff testing technology is not just for cryogenic testing but is a cost effective, field-representative methodology to test any material or system for applications at sub-ambient temperatures. This technology, when adequately coupled with a technical standards basis, can provide a cost-effective, field-representative methodology to test any material or system for applications at sub-ambient to cryogenic temperatures. A growing need for energy efficiency and cryogenic applications is creating a worldwide demand for improved thermal insulation systems for low temperatures. The need for thermal characterization of these systems and materials raises a corresponding need for insulation test standards and thermal data targeted for cryogenic-vacuum applications. Such standards have a strong correlation to energy, transportation, and environment and the advancement of new materials technologies in these areas. In conjunction with this project, two new standards on cryogenic insulation were recently published by ASTM International: C1774 and C740. Following the requirements of NPR 7120.10, Technical Standards for NASA Programs and Projects, the appropriate information in this report can be provided to the NASA Chief Engineer as input for NASA's annual report to NIST, as required by OMB Circular No. A-119, describing NASA's use of voluntary consensus standards and participation in the development of voluntary consensus standards and bodies.

Technology Portfolio System↗

NASA NTRS1987

Numerical grid generation and flow simulation in SSME thrust chamber

The development of liquid and solid rocket engines for future space projects demands a detailed optimization process for highly efficient performance and cost reasons. Also, testing of full size engines may not be feasible when the large size requires test facilities which are cost prohibitive or if vacuum operation cannot be acquired. For such situations only scaling from small test scale measurements or accurate analytical predictions will provide the performance prior to actually flying the mission. A rigorous approach for simulating the combustion processes in liquid rocket engines by employing a direct solution of Navier-Stokes equations within the entire volume of the thrust chambers is presented. This method is illustrated in the solution of reactive flow in the Space Shuttle Main Engine (SSME) thrust chamber. The objective is to review recent improvements in the mathematical model and to present the grid generation methodology suitable for rocket thrust chamber geometries.

Gross, K. W.↗