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Electronic test identifies flawed units passing hardness tests. Eddy-current test detects weakness in head-to-shank junctions of 1/4-28 cup-washer lock bolts. Developed for alloy A286 steel bolts in Space Shuttle main engine fuel turbo-pump. Test examines full volume of head, including head-to-shank transition and nondestructively screens out potentially defective units. Test adapts to any other alloys.
Test chamber improvised from large bag. Cumulative sizes of leaks in large, complicated machinery measure with relatively simple variation of helium leak-checking technique. When used to check Space Shuttle main engine, new technique gave repeatable and correct results within 0.5 stdin.3/min (1.4 x 10 negative to the seventh power stdm3/s).
Simulation circuit operates under remote, automatic, or manual control to produce electrical outputs similar to pressure transducer. Specific circuit designed for simulations of Space Shuttle main engine. General circuit concept adaptable to other simulation and control systems involving several operating modes. Switches and amplifiers respond to external control signals and panel control settings to vary differential excitation of resistive bridge. Output voltage or passive terminal resistance made to equal pressure transducer in any of four operating modes.
A multiyear program is performed with the objective to develop generic load models with multiple levels of progressive sophistication to simulate the composite (combined) load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen (LOX) posts. Progress of the first year's effort includes completion of a sufficient portion of each task -- probabilistic models, code development, validation, and an initial operational code. This code has from its inception an expert system philosophy that could be added to throughout the program and in the future. The initial operational code is only applicable to turbine blade type loadings. The probabilistic model included in the operational code has fitting routines for loads that utilize a modified Discrete Probabilistic Distribution termed RASCAL, a barrier crossing method and a Monte Carlo method. An initial load model was developed by Battelle that is currently used for the slowly varying duty cycle type loading. The intent is to use the model and related codes essentially in the current form for all loads that are based on measured or calculated data that have followed a slowly varying profile.
Three analytic consequences of the nonlinear Jeffcott equations are examined. The primary application of these analyses is directed toward understanding the excessive vibrations recorded in the Liquid Oxygen (LOX) pump of the Space Shuttle Main Engine (SSME) during hot firing ground testing. The first task is to provide bounds on the coefficients of the equations which delimit the two cases of numerical solution as a circle or an annulus. The second task examines the mathematical generalization to multiple forcing functions, which includes the special problems of mass imbalance, side force, rubbing, and combination of these forces. Finally, stability and boundedness of the steady-state solutions is discussed and related to the corresponding linear problem.
Several Space Shuttle Main Engines (SSME) have experienced very high acceleration responses measured in the main injector of the powerhead during static firings. Data from previous hot fire SSME tests relating to the 4000 hertz phenomenon were reviewed to provide a better understanding of the nature of this structural response. The objective was to technically understand the way this phenomenon works, recommend a fix and test the fix.
A study was completed of mathematically proper boundary conditions for unique numerical solution of internal, viscous, subsonic flows in the space shuttle main engine. The study has concentrated on well posed considerations, with emphasis on computational efficiency and numerically stable boundary condition statements. The method of implementing the established boundary conditions is applicable to a wide variety of finite difference and finite element codes, as demonstrated.
The development of a three-dimensional inelastic analysis methodology for the Space Shuttle main engine (SSME) structural components is described. The methodology is composed of: (1) composite load spectra, (2) probabilistic structural analysis methods, (3) the probabilistic finite element theory, and (4) probabilistic structural analysis. The methodology has led to significant technical progress in several important aspects of probabilistic structural analysis. The program and accomplishments to date are summarized.
The laminar, steady juncture flow around single or multiple posts mounted between two flat plates is simulated using the three dimensional incompressible Navier-Stokes code, INS3D. The three dimensional separation of the boundary layer and subsequent formation and development of the horseshoe vortex is computed. The computed flow compares favorably with the experimental observation. The recent numerical study to understand and quantify the juncture flow relevant to the Space Shuttle main engine power head is summarized.
An approach to computing flow and dynamic characteristics for seals or bearings is discussed. The local average velocity was strongly influenced by inlet and exit effects and fluid injection, which in turn drove zones of secondary flow. For the restricted three-dimensional model considered, the integral averaged results were in reasonable agreement with selected data. Unidirectional pressure measurements alone were insufficient to define such flow variations. However, for seal and bearing leakage correlations the principles of corresponding states were found to be useful. Also discussed are three phenomena encountered during testing of three eccentric nonrotating seal configurations for the Space Shuttle Main Engine (SSME) Program. Fluid injection, choking within a seal, and pressure profile crossover are related to postulated zones of secondary flow or separation and to direct stiffness.
The fluid flow inside the space shuttle main engine (SSME) traverses through a complex geometrical configuration. The flow is compressible, viscous, and turbulent with pockets of separated regions. Several computer codes are being developed to solve three dimensional Navier-Stokes equations with different turbulence models for analyzing the SSME internal flow. The locally implicit scheme is a computationally efficient scheme which converges rapidly in multi-grid modes for elliptic problems. It has the promise of providing a rapidly converging algorithm for steady-state viscous flow problems.
The implementation of a software system for managing Space Shuttle Main Engine (SSME) test/flight historical data is presented. The software system uses the database management system RIM7 for primary data storage and routine data management, but includes several FORTRAN programs, described here, which provide customized access to the RIM7 database. The consolidation, modification, and transfer of data from the database THIST, to the RIM7 database THISRM is discussed. The RIM7 utility modules for generating some standard reports from THISRM and performing some routine updating and maintenance are briefly described. The FORTRAN accessing programs described include programs for initial loading of large data sets into the database, capturing data from files for database inclusion, and producing specialized statistical reports which cannot be provided by the RIM7 report generator utility. An expert system tutorial, constructed using the expert system shell product INSIGHT2, is described. Finally, a potential expert system, which would analyze data in the database, is outlined. This system could use INSIGHT2 as well and would take advantage of RIM7's compatibility with the microcomputer database system RBase 5000.
Due to the various parts found in a Space Shuttle Main Engine (SSME), analyzation of every part is not feasible or needed. Based on previous mathematical modeling experience of high velocity cryogenic equipment, the environmental traits of location of the part, temperature range, fluid velocity, pressure range, and elevation variation of fluid flow as being significant factors were determined. Six parts categories were developed. The part categories are: (1) fuel turbomachinery, (2) oxidizer, (3) combustion devices, (4) valves, (5) ducts, and (6) lines. Due to a suspicion that superficial failure modes exist, six status codes were developed. The codes are: (1) part is in service presently, (2) part is out-of-service due to its own failure, (3) part is out-of-service due to engine (or some other part failure), (4) part is out-of-service because it's retired/obsolete (time related), (5) never fired-scrapped due to own problem or part is store, and (6) part is out-of-service for repair. It was suggested that to properly model failure behavior of SSME parts that: (1) significant factors contributing to failure must be examined, (2) relatively precision based on real life data must be examined, and (3) alternative definitions of failure must be initialized by the engineers.
The expressions for the maximum likelihood functions are given when the failure data are censored at a given point or at multiple points, or when the data come in groups. Different models applicable to failure data are presented with their characteristics. A graphical method of distinguishing different models by using cumulative hazard fucnction is discussed. For the failure data on controllers the model is determined by cumulative hazard function and chi-square goodness of fit. Using the Weibull Model the maximum likelihood estimators of the shape parameter and the failure rate parameter are obtained. The confidence intervals, meantime between failures, and B1 are determined. Similarly, for the data on Space Shuttle Main Engine (SSME) blade failures the maximum likelihood estimators are obtained for the Weibull parameters. The variances, confidence intervals, meantime between failures, and reliability are determined. The analysis is performed under assumption of grouped data as well as randomly placed data.
Statistical and probabilistic reliability methodologies were developed for the determination of hardware life limits for the Space Shuttle Main Engine (SSME). Both methodologies require that a mathematical reliability model of the engine (system) performance be developed as a function of the reliabilities of the components and parts. The system reliability model should be developed from the Failute Modes and Effects Analysis/Critical Items List. The statistical reliability methodology establishes hardware life limits directly from the failure distributions of the components and parts obtained from statistically-designed testing. The probabilistic reliability methodology establishes hardware life limits from a decision analysis methodology which incorporates the component/part reliabilities obtained from a probabilistic structural analysis, a calibrated maintenance program, inspection techniques, and fabrication procedures. Probilistic structural analysis is recommended as a tool to prioritize upgrading of the components and parts. The Weibull probability distribution is presently being investigated by NASA/MSFC to characterize the failure distribution of the SSME hardware from a limited data base of failures.
Current Space Shuttle Main Engine (SSME) high pressure fuel turbopump problems have generated a desire to analyze the flow field of rotating machinery. The status of Computational Fluid Dynamics (CFD) has reached the point that soon the capability to solve unsteady three-dimensional viscous flow fields will be at hand. The work presented involves upgrading the computational efficiency of an operational three-dimensional algorithm. The modifications include algorithm development, algorithm approximation and acceleration, and special coding optimizations. The overall result of these modifications has reduced processing time by nearly 80%.
The numerical results of statistical analysis of the test data of Space Shuttle Main Engine high pressure fuel turbopump second-stage turbine blades, including some with cracks are presented. Several statistical methods use the test data to determine the application of differences in frequency variations between the uncracked and cracked blades.
The combustion chamber liner of the space shuttle main engine is made of NARloy-Z, a copper-silver-zirconium alloy. This alloy was produced by vacuum melting and vacuum centrifugal casting; a production method that is currently now available. Using conventional melting, casting, and forging methods, NASA has produced an alloy of the same composition called NASA-Z. This report compares the composition, microstructure, tensile properties, low-cycle fatigue life, and hot-firing life of these two materials. The results show that the materials have similar characteristics.