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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗
NASA NTRS2010

Smart Sensor Demonstration Payload

Sensors are a critical element to any monitoring, control, and evaluation processes such as those needed to support ground based testing for rocket engine test. Sensor applications involve tens to thousands of sensors; their reliable performance is critical to achieving overall system goals. Many figures of merit are used to describe and evaluate sensor characteristics; for example, sensitivity and linearity. In addition, sensor selection must satisfy many trade-offs among system engineering (SE) requirements to best integrate sensors into complex systems [1]. These SE trades include the familiar constraints of power, signal conditioning, cabling, reliability, and mass, and now include considerations such as spectrum allocation and interference for wireless sensors. Our group at NASA s John C. Stennis Space Center (SSC) works in the broad area of integrated systems health management (ISHM). Core ISHM technologies include smart and intelligent sensors, anomaly detection, root cause analysis, prognosis, and interfaces to operators and other system elements [2]. Sensor technologies are the base fabric that feed data and health information to higher layers. Cost-effective operation of the complement of test stands benefits from technologies and methodologies that contribute to reductions in labor costs, improvements in efficiency, reductions in turn-around times, improved reliability, and other measures. ISHM is an active area of development at SSC because it offers the potential to achieve many of those operational goals [3-5].

Schmalzel, John↗
NASA NTRS1990

Improving stability and strength characteristics of framed structures with nonlinear behavior

In this paper an optimal design procedure is introduced to improve the overall performance of nonlinear framed structures. The design methodology presented here is a multiple-objective optimization procedure whose objective functions involve the buckling eigenvalues and eigenvectors of the structure. A constant volume with bounds on the design variables is used in conjunction with an optimality criterion approach. The method provides a general tool for solving complex design problems and generally leads to structures with better limit strength and stability. Many algorithms have been developed to improve the limit strength of structures. In most applications geometrically linear analysis is employed with the consequence that overall strength of the design is overestimated. Directly optimizing the limit load of the structure would require a full nonlinear analysis at each iteration which would be prohibitively expensive. The objective of this paper is to develop an algorithm that can improve the limit-load of geometrically nonlinear framed structures while avoiding the nonlinear analysis. One of the novelties of the new design methodology is its ability to efficiently model and design structures under multiple loading conditions. These loading conditions can be different factored loads or any kind of loads that can be applied to the structure simultaneously or independently. Attention is focused on optimal design of space framed structures. Three-dimensional design problems are more complicated to carry out, but they yield insight into real behavior of the structure and can help avoiding some of the problems that might appear in planar design procedure such as the need for out-of-plane buckling constraint. Although researchers in the field of structural engineering generally agree that optimum design of three-dimension building frames especially in the seismic regions would be beneficial, methods have been slow to emerge. Most of the research in this area has dealt with the optimization of truss and plane frame structures.

Pezeshk, Shahram↗
NASA NTRS2008

Operability of an Ejector Enhanced Pulse Combustor in a Gas Turbine Environment

A pressure-gain combustor comprised of a mechanically valved, liquid fueled pulsejet, an ejector, and an enclosing shroud, was coupled to a small automotive turbocharger to form a self-aspirating, thrust producing gas turbine engine. The system was constructed in order to investigate issues associated with the interaction of pulsed combustion devices and turbomachinery. Installed instrumentation allowed for sensing of distributed low frequency pressure and temperature, high frequency pressure in the shroud, fuel flow rate, rotational speed, thrust, and laboratory noise. The engine ran successfully and reliably, achieving a sustained thrust of 5 to 6 lbf, and maintaining a rotor speed of approximately 90,000 rpm, with a combustor pressure gain of approximately 4 percent. Numerical simulations of the system without pressure-gain combustion indicated that the turbocharger would not operate. Thus, the new combustor represented a substantial improvement in system performance. Acoustic measurements in the shroud and laboratory indicated turbine stage sound pressure level attenuation of 20 dB. This is consistent with published results from detonative combustion experiments. As expected, the mechanical reed valves suffered considerable damage under the higher pressure and thermal loading characteristics of this system. This result underscores the need for development of more robust valve systems for this application. The efficiency of the turbomachinery components did not appear to be significantly affected by unsteadiness associated with pulsed combustion, though the steady component efficiencies were already low, and thus not expected to be particularly sensitive.

Paxson, Daniel E.↗
NASA NTRS2011

Advanced Development of a Compact 5-15 lbf Lox/Methane Thruster for an Integrated Reaction Control and Main Engine Propulsion System

This paper describes the advanced development and testing of a compact 5 to 15 lbf LOX/LCH4 thruster for a pressure-fed integrated main engine and RCS propulsion system to be used on a spacecraft "vertical" test bed (VTB). The ability of the RCS thruster and the main engine to operate off the same propellant supply in zero-g reduces mass and improves mission flexibility. This compact RCS engine incorporates several features to dramatically reduce mass and parts count, to ease manufacturing, and to maintain acceptable performance given that specific impulse (Isp) is not the driver. For example, radial injection holes placed on the chamber body for easier drilling, and high temperature Haynes 230 were selected for the chamber over other more expensive options. The valve inlets are rotatable before welding allowing different orientations for vehicle integration. In addition, the engine design effort selected a coil-on-plug ignition system which integrates a relay and coil with the plug electrode, and moves some exciter electronics to avionics driver board. The engine injector design has small dribble volumes to target minimum pulse widths of 20 msec. and an efficient minimum impulse bit of less than 0.05 lbf-sec. The propellants, oxygen and methane, were chosen because together they are a non-toxic, Mars-forward, high density, space storable, and high performance propellant combination that is capable of pressure-fed and pump-fed configurations and integration with life support and power subsystems. This paper will present the results of the advanced development testing to date of the RCS thruster and the integration with a vehicle propulsion system.

Hurlbert, Eric A.↗
NASA NTRS2015

Advancing the State-of-the-Practice for Liquid Rocket Engine Injector Design

Current shortcomings in both the overall injector design process and its underlying combustion stability assessment methodology are rooted in the use of empirically based or low fidelity representations of complex physical phenomena and geometry details that have first order effects on performance, thermal environments and combustion stability. The result is a design and analysis capability that is often inadequate to reliably arrive at a suitable injector design in an efficient manner. Specifically, combustion instability has been particularly difficult to predict and mitigate. Large hydrocarbon-fueled booster engines have been especially problematic in this regard. Where combustion instability has been a problem, costly and time-consuming redesign efforts have often been an unfortunate consequence. This paper presents an overview of a recently completed effort at NASA Marshall Space Flight Center to advance the state-of-the-practice for liquid rocket engine injector design. Multiple perturbations of a gas-centered swirl coaxial (GCSC) element that burned gaseous oxygen and RP-1 were designed, assessed for combustion stability, and tested. Three designs, one stable, one marginally unstable and one unstable, were used to demonstrate both an enhanced overall injector design process and an improved combustion stability assessment process. High-fidelity results from state-of-the-art computational fluid dynamics CFD simulations were used to substantially augment and improve the injector design methodology. The CFD results were used to inform and guide the overall injector design process. They were also used to upgrade selected empirical or low-dimensional quantities in the ROCket Combustor Interactive Design (ROCCID) stability assessment tool. Hot fire single element injector testing was used to verify both the overall injector designs and the stability assessments. Testing was conducted at the Air Force Research Laboratory and at Purdue University. Companion papers provide details of the overall injector design process, full- and sub-scale testing, ROCCID-based stability assessments and the CFD simulations.

Tucker, P. K.↗
NASA NTRS1981

Aerodynamic design data for a cruise-matched high performance single-engine airplane

Design data are presented for a class of high-performance single-engine business airplanes. The design objectives include a cruise speed of 300 knots, a cruise altitude of 10,700 m (35,000 ft), a cruise payload of six passengers (including crew and baggage), and a no-reserves cruise range of 1300 n.mi. Two unconventional aerodynamic technologies were evaluated: the individual and combined effects of cruise-matched wing loading and of a natural laminar flow airfoil were analyzed. The trade-off data presented illustrate the ranges of wing geometries, propulsion requirements, airplane weights, and aerodynamic characteristics which are necessary to meet the design objectives. Very large design and performance improvements resulted from use of the aerodynamic technologies evaluated. It is shown that the potential exists for achieving more than 200-percent greater fuel efficiency than is achieved by current airplanes capable of similar cruise speeds, payloads, and ranges.

Holmes, B. J.↗
NASA NTRS2014

Logistics Reduction Technologies for Exploration Missions

Human exploration missions under study are limited by the launch mass capacity of existing and planned launch vehicles. The logistical mass of crew items is typically considered separate from the vehicle structure, habitat outfitting, and life support systems. Although mass is typically the focus of exploration missions, due to its strong impact on launch vehicle and habitable volume for the crew, logistics volume also needs to be considered. NASA's Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) Project is developing six logistics technologies guided by a systems engineering cradle-to-grave approach to enable after-use crew items to augment vehicle systems. Specifically, AES LRR is investigating the direct reduction of clothing mass, the repurposing of logistical packaging, the use of autonomous logistics management technologies, the processing of spent crew items to benefit radiation shielding and water recovery, and the conversion of trash to propulsion gases. Reduction of mass has a corresponding and significant impact to logistical volume. The reduction of logistical volume can reduce the overall pressurized vehicle mass directly, or indirectly benefit the mission by allowing for an increase in habitable volume during the mission. The systematic implementation of these types of technologies will increase launch mass efficiency by enabling items to be used for secondary purposes and improve the habitability of the vehicle as mission durations increase. Early studies have shown that the use of advanced logistics technologies can save approximately 20 m(sup 3) of volume during transit alone for a six-person Mars conjunction class mission.

Broyan, James L., Jr.↗
NASA NTRS1994

Combustor technology for future small gas turbine aircraft

To enhance fuel efficiency, future advanced small gas turbine engines will utilize engine cycles calling for overall engine pressure ratios, leading to higher combustor inlet pressures and temperatures. Further, the temperature rise through the combustor and the corresponding exit temperature are also expected to increase. This report describes future combustor technology needs for small gas turbine engines. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is anticipated in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors. Due to combustor size considerations, staged combustion is more easily accommodated in large engines. The inclusion of staged combustion in small engines will pose greater combustor design challenges.

Lyons, Valerie J.↗
NASA NTRS1989

DSN 70-meter antenna microwave optics design and performance improvements. Part 1: Design optimization

The design optimizations associated with the microwave and structural upgrade of the DSN 64-m antennas are discussed. Expected area efficiency/gain performances at S- and X-band are given for both the original 64-m systems and the upgraded 70-m systems, and error estimates are developed. The DSN 70-m Upgrade Project specifications, based on predesign estimates, were 1.4-dB gain at S-band and 1.9-dB at X-band, with no degradation to critical receiving system noise temperatures. The measurements show an S-band gain increase of 1.9 dB and an average increase of 2.1 dB at X-band. The Project also delivered small receiving system noise decreases at both frequency bands. The three DSN 70-m antennas, in the initial state of mechanical adjustment as of the end of calendar year 1988, are performing with very high peak microwave area efficiencies at very nearly the engineering design expectations of 76 percent at S-band and 71 percent at X-band.

Bathker, D. A.↗
NASA NTRS2006

Building Operations Efficiencies into NASA's Ares I Crew Launch Vehicle Design

The U.S. Vision for Space Exploration guides the National Aeronautics and Space Administration s (NASA's) challenging missions that expand humanity s boundaries and open new routes to the space frontier. With the Agency's commitment to complete the International Space Station (ISS) and to retire the venerable Space Shuttle by 2010, the NASA Administrator commissioned the Exploration Systems Architecture Study (ESAS) in mid 2005 to analyze options for safe, simple, cost-efficient launch solutions that could deliver human-rated space transportation capabilities in a timely manner within fixed budget guidelines. The Exploration Launch Projects Office, chartered in October 2005, has been conducting systems engineering studies and business planning over the past few months to successively refine the design configurations and better align vehicle concepts with customer and stakeholder requirements, such as significantly reduced life-cycle costs. As the Agency begins the process of replacing the Shuttle with a new generation of spacecraft destined for missions beyond low-Earth orbit to the Moon and Mars, NASA is designing the follow-on crew and cargo launch systems for maximum operational efficiencies. To sustain the long-term exploration of space, it is imperative to reduce the $4.5 billion NASA typically spends on space transportation each year. This paper gives top-level information about how the follow-on Ares I Crew Launch Vehicle (CLV) is being designed for improved safety and reliability, coupled with reduced operations costs.

Dumbacher, Daniel↗
NASA NTRS2017

Manned Versus Unmanned Risk and Complexity Considerations for Future Midsized X-Planes

The objective of this work was to identify and estimate complexity and risks associated with the development and testing of new low-cost medium-scale X-plane aircraft primarily focused on air transport operations. Piloting modes that were evaluated for this task were manned, remotely piloted, and unmanned flight research programs. This analysis was conducted early in the data collection period for X-plane concept vehicles before preliminary designs were complete. Over 50 different aircraft and system topics were used to evaluate the three piloting control modes. Expert group evaluations from a diverse set of pilots, engineers, and other experts at Aeronautics Research Mission Directorate centers within the National Aeronautics and Space Administration provided qualitative reasoning on the many issues surrounding the decisions regarding piloting modes. The group evaluations were numerically rated to evaluate each topic quantitatively and were used to provide independent criteria for vehicle complexity and risk. An Edwards Air Force Base instruction document was identified that emerged as a source of the effects found in our qualitative and quantitative data. The study showed that a manned aircraft was the best choice to align with test activities for transport aircraft flight research from a low-complexity and low-risk perspective. The study concluded that a manned aircraft option would minimize the risk and complexity to improve flight-test efficiency and bound the cost of the flight-test portion of the program. Several key findings and discriminators between the three modes are discussed in detail.

x-planes↗
NASA NTRS2017

Manned Versus Unmanned Risk and Complexity Considerations for Future Midsized X-Planes

The objective of this work was to identify and estimate complexity and risks associated with the development and testing of new low-cost medium-scale X-plane aircraft primarily focused on air transport operations. Piloting modes that were evaluated for this task were manned, remotely piloted, and unmanned flight research programs. This analysis was conducted early in the data collection period for X-plane concept vehicles before preliminary designs were complete. Over 50 different aircraft and system topics were used to evaluate the three piloting control modes. Expert group evaluations from a diverse set of pilots, engineers, and other experts at Aeronautics Research Mission Directorate centers within the National Aeronautics and Space Administration provided qualitative reasoning on the many issues surrounding the decisions regarding piloting modes. The group evaluations were numerically rated to evaluate each topic quantitatively and were used to provide independent criteria for vehicle complexity and risk. An Edwards Air Force Base instruction document was identified that emerged as a source of the effects found in our qualitative and quantitative data. The study showed that a manned aircraft was the best choice to align with test activities for transport aircraft flight research from a low-complexity and low-risk perspective. The study concluded that a manned aircraft option would minimize the risk and complexity to improve flight-test efficiency and bound the cost of the flight-test portion of the program. Several key findings and discriminators between the three modes are discussed in detail.

quanitive analysis↗
NASA NTRS1982

Experimental study of an integral catalytic combustor: Heat exchanger for Stirling engines

The feasibility of using catalytic combustion with heat removal for the Stirling engine to reduce exhaust emissions and also improve heat transfer to the working fluid was studied using spaced parallel plates. An internally air-cooled heat exchanger was placed between two noble metal catalytic plates. A preheated fuel-air mixture passed between the plates and reacted on the surface of the catalyzed plates. Heat was removed from the catalytic surface by radiation and convection to the aircooled heat exchangers to control temperature and minimize thermal nitrogen oxide emissions. Test conditions were inlet combustion air temperatures from 850 to 900 K, inlet velocities of about 10 m/s, equivalence ratios from 0.5 to 0.9, and pressures from 1.3x10 to the 5th power to 2.0x10 to the 5th power Pa. Propane fuel was used for all testing. Combustion efficiencies greater than 99.5 percent were measured. Nitrogen oxide emissions ranged from 1.7 to 3.3 g NO2/kg fuel. The results demonstrate the feasibility of the concept and indicate that further investigation of the concept is warranted.

Bulzan, D. L.↗
NASA NTRS1983

Development of strain tolerant thermal barrier coating systems, tasks 1 - 3

Insulating ceramic thermal barrier coatings can reduce gas turbine airfoil metal temperatures as much as 170 C (about 300 F), providing fuel efficiency improvements greater than one percent and durability improvements of 2 to 3X. The objective was to increase the spalling resistance of zirconia based ceramic turbine coatings. To accomplish this, two baseline and 30 candidate duplex (layered MCrAlY/zirconia based ceramic) coatings were iteratively evaluated microstructurally and in four series of laboratory burner rig tests. This led to the selection of two candidate optimized 0.25 mm (0.010 inch) thick plasma sprayed partially stabilized zirconia ceramics containing six weight percent yttria and applied with two different sets of process parameters over a 0.13 mm (0.005 inch) thick low pressure chamber sprayed MCrAlY bond coat. Both of these coatings demonstrated at least 3X laboratory cyclic spalling life improvement over the baseline systems, as well as cyclic oxidation life equivalent to 15,000 commercial engine flight hours.

Anderson, N. P.↗
NASA NTRS1985

Aeronautical technology 2000: A projection of advanced vehicle concepts

The Aeronautics and Space Engineering Board (ASEB) of the National Research Council conducted a Workshop on Aeronautical Technology: a Projection to the Year 2000 (Aerotech 2000 Workshop). The panels were asked to project advances in aeronautical technologies that could be available by the year 2000. As the workshop was drawing to a close, it became evident that a more comprehensive investigation of advanced air vehicle concepts than was possible in the limited time available at the workshop would be valuable. Thus, a special panel on vehicle applications was organized. In the course of two meetings, the panel identified and described representative types of aircraft judged possible with the workshop's technology projections. These representative aircraft types include: military aircraft; transport aircraft; rotorcraft; extremely high altitude aircraft; and transatmospheric aircraft. Improvements in performance, efficiency, and operational characteristics possible through the application of the workshop's year 2000 technology projections were discussed. The subgroups also identified the technologies considered essential and enhancing or supporting to achieve the projected aircraft improvements.

Source record↗
NASA NTRS1995

High Pressure Earth Storable Rocket Technology Program: Basic Program

The HIPES Program was conducted for NASA-LeRC by TRW. The Basic Program consisted of system studies, design of testbed engine, fabrication and testing of engine. Studies of both pressure-fed and pump-fed systems were investigated for N2O4 and both MMH and N2H4 fuels with the result that N2H4 provides the maximum payload for all satellites over MMH. The higher pressure engine offers improved performance with smaller envelope and associated weight savings. Pump-fed systems offer maximum payload for large and medium weight satellites while pressure-fed systems offer maximum payload for small light weight satellites. The major benefits of HIPES are high performance within a confined length maximizing payload for lightsats which are length (volume) constrained. Three types of thrust chambers were evaluated -- Copper heatsink at 400, 500 and 600 psia chamber pressures for performance/thermal; water cooled to determine heat absorbed to predict rhenium engine operation; and rhenium to validate the concept. The HIPES engine demonstrated very high performance at 50 lbf thrust (epsilon = 150) and Pc = 500 psia with both fuels: Isp = 337 sec using N2O4-N2H4 and ISP = 327.5 sec using N2O4-MMH indicating combustion efficiencies greater than 98%. A powder metallurgy rhenium engine demonstrated operation with high performance at Pc = 500 psia which indicated the viability of the concept.

Chazen, M. L.↗
NASA NTRS2007

Simulating Operations at a Spaceport

SPACESIM is a computer program for detailed simulation of operations at a spaceport. SPACESIM is being developed to greatly improve existing spaceports and to aid in designing, building, and operating future spaceports, given that there is a worldwide trend in spaceport operations from very expensive, research- oriented launches to more frequent commercial launches. From an operational perspective, future spaceports are expected to resemble current airports and seaports, for which it is necessary to resolve issues of safety, security, efficient movement of machinery and people, cost effectiveness, timeliness, and maximizing effectiveness in utilization of resources. Simulations can be performed, for example, to (1) simultaneously analyze launches of reusable and expendable rockets and identify bottlenecks arising from competition for limited resources or (2) perform what-if scenario analyses to identify optimal scenarios prior to making large capital investments. SPACESIM includes an object-oriented discrete-event-simulation engine. (Discrete- event simulation has been used to assess processes at modern seaports.) The simulation engine is built upon the Java programming language for maximum portability. Extensible Markup Language (XML) is used for storage of data to enable industry-standard interchange of data with other software. A graphical user interface facilitates creation of scenarios and analysis of data.

Nevins, Michael R.↗