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NASA NTRS2005

Optical Sensing of Combustion Instabilities in Gas Turbines

In a continuing program of research and development, a system has been demonstrated that makes high-speed measurements of thermal infrared radiance from gas-turbine engine exhaust streams. When a gas-turbine engine is operated under conditions that minimize the emission of pollutants, there is a risk of crossing the boundary from stable to unstable combustion. Combustion instability can lead to engine damage and even catastrophic failure. Sensor systems of the type under development could provide valuable data during the development testing of gas-turbine engines or of engine components. A system of the type under development makes high-speed measurements of thermal infrared radiance from the engine exhaust stream. The sensors of this system can be mounted outside the engine, which eliminates the need for engine case penetrations typical with other engine dynamics monitors. This is an important advantage in that turbine-engine manufacturers consider such penetrations to be very undesirable. A prototype infrared sensor system has been built and demonstrated on a turbine engine. This system includes rugged and inexpensive near-infrared sensors and filters that select wavelengths of infrared radiation for high sensitivity. In experiments, low-frequency signatures were consistently observed in the detector outputs. Under some conditions, the signatures also included frequency components having one or two radiance cycles per engine revolution. Although it has yet to be verified, it is thought that the low-frequency signatures may be associated with bulk-mode combustion instabilities or flow instabilities in the compressor section of the engine, while the engine- revolution-related signatures may be indicative of mechanical problems in the engine. The system also demonstrated the ability to detect transient high-radiance events. These events indicate hot spots in the exhaust stream and were found to increase in frequency during engine acceleration.

Markham, James R.↗

NASA NTRS1998

Integrated Advanced Microwave Sounding Unit-A(AMSU-A). Performance Verification Report, METSAT Phase Locked Oscillator Assembly, P/N 1348360-1, S/N's F07 and F08

Two Flight Model AMSU-A Phase Locked Oscillators (PIN 1348360-1, S/N F07 and F08) have been tested per AES Test Procedure AE-26758 Rev. B, which include full functional testing, vibration testing, thermal testing, and AM/FM Noise testing. Both assemblies satisfactorily passed all performance requirements of the AE-26633 Product Specification. During the thermal cycling of both units, spurs developed 1 MHz from the carrier when the units were cold, and TARs were written to document the anomaly. The symptoms observed in both cases were consistent with inadequate tuning. The units were successfully re-tuned. In the case of F08, re-tuning required a design change which allowed a greater range of possible values for tuning resisters. Both units completed thermal cycling without further delay. The results of the required tests are presented in the following section as test data. As indicated on the test data sheets, all measured data passed all requirements.

Pines, D.↗

NASA NTRS1997

Future Aerospace Technology in the Service of the Alliance: Sustained Hypersonic Flight - Volume 3

Sustained Hypersonic Flight capability is envisioned for several future military and civilian applications, such as long range immediate reaction reconnaissance, high speed interception of air targets, long range precision strike against hardened or time critical targets, and access to space. The inherent reduction in time-to-target and low vulnerability will permit new operational tactics. The symposium outlined mission needs and operational scenarios for hypersonic vehicles. Addressed were: Technological issues and challenges in external hypersonic aerodynamics and design, propulsion and engine/airframe integration, military ramjet applications, overall system design including structures and materials development needs, and test facilities. Ground based test facilities cannot provide full simulation at Mach numbers above 5. Therefore, the use of Computational Fluid Dynamics design tools is essential. For routine use of the computational tools in analysis, design and optimization, it is necessary to reduce the time for the entire computational process by two orders of magnitude. Hypersonic boundary layer transition remains a critical design issue because of the important impact on engine drag and on heating, which can affect the choice of materials and thermal protection systems. In addition, reliable prediction of scramjet net thrust is an absolute must in resolving hypersonic air breathing vehicle design issues. Due to current facility and computational shortfalls, the development of future hypersonic flight systems requires research flight tests in the technology areas of boundary layer transition and air-breathing propulsion engine performance. For sustained hypersonic flight beyond Mach 6, the supersonic combustion ramjet (scramjet) engine is the only choice for the near future. Only this air-breathing concept offers a significant promise of large reductions in required propellant fractions, increased payload fractions, and reduced size vehicles, together with a foreseeable technological feasibility. Airframe/engine integration, combustor design and thermal management are the predominant engineering tasks. Fuels, hydrogen or hydrocarbon, must be matched to the operational needs of military or civil use. Experience in existing ramjet propelled missiles capable of speeds up to Mach 4 can support the development effort. The potential mission and cost benefits of sustained hypersonic flight to both military and civil applications are tremendous. From the budget point of view, the possibility of sharing development costs between military and civil programs offers a specific advantage.

Source record↗

NASA NTRS2013

Space Environmental Testing of the Electrodynamic Dust Shield Technology

NASA's exploration missions to Mars and the moon may be jeopardized by dust that will adhere to surfaces of (a) Optical systems, viewports and solar panels, (b) Thermal radiators, (c) Instrumentation, and (d) Spacesuits. We have developed an active dust mitigation technology, the Electrodynamic Dust Shield, a multilayer coating that can remove dust and also prevents its accumulation Extensive testing in simulated laboratory environments and on a reduced gravity flight shows that high dust removal performance can be achieved Long duration exposure to the space environment as part of the MISSE-X payload will validate the technology for lunar missions.

Calle, Carlos I.↗

NASA NTRS1997

Three d.o.f. Robotic Wrist Actuator Redesign

This paper describes the efforts to redesign, fabricate, assemble and test the wrist actuators on the Automated Tile Processing System (ATPS). The ATPS is a robotic system being developed at Kennedy Space Center to inspect and rewaterproof thermal protection tiles on the space shuttle orbiter prior to launch. The objective of the redesign was to eliminate backlash and provide adequate pitch and yaw actuator force. The wrist actuators have been successfully redesigned, fabricated, tested, and installed. The redesigned wrist actuators meet or exceed all design requirements. The wrist has been reinstalled on the tile processing robot and will be further evaluated during operational testing of the system.

Bonner, Tom↗

NASA NTRS2001

Thermomechanical Response of Shape Memory Alloy Hybrid Composites

This study examines the use of embedded shape memory alloy (SMA) actuators for adaptive control of the thermomechanical response of composite structures. A nonlinear thermomechanical model is presented for analyzing shape memory alloy hybrid composite (SMAHC) structures exposed to steady-state thermal and dynamic mechanical loads. Also presented are (1) fabrication procedures for SMAHC specimens, (2) characterization of the constituent materials for model quantification, (3) development of the test apparatus for conducting static and dynamic experiments on specimens with and without SMA, (4) discussion of the experimental results, and (5) validation of the analytical and numerical tools developed in the study. Excellent agreement is achieved between the predicted and measured SAMHC responses including thermal buckling, thermal post-buckling and dynamic response due to inertial loading. The validated model and thermomechanical analysis tools are used to demonstrate a variety of static and dynamic response behaviors including control of static (thermal buckling and post-buckling) and dynamic responses (vibration, sonic fatigue, and acoustic transmission). and SMAHC design considerations for these applications. SMAHCs are shown to have significant advantages over conventional response abatement approaches for vibration, sonic fatigue, and noise control.

Turner, Travis L.↗

NASA NTRS1985

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints.

Sawyer, J. W.↗

NASA NTRS2012

Thermal Analysis of Small Re-Entry Probe

The Small Probe Reentry Investigation for TPS Engineering (SPRITE) concept was developed at NASA Ames Research Center to facilitate arc-jet testing of a fully instrumented prototype probe at flight scale. Besides demonstrating the feasibility of testing a flight-scale model and the capability of an on-board data acquisition system, another objective for this project was to investigate the capability of simulation tools to predict thermal environments of the probe/test article and its interior. This paper focuses on finite-element thermal analyses of the SPRITE probe during the arcjet tests. Several iterations were performed during the early design phase to provide critical design parameters and guidelines for testing. The thermal effects of ablation and pyrolysis were incorporated into the final higher-fidelity modeling approach by coupling the finite-element analyses with a two-dimensional thermal protection materials response code. Model predictions show good agreement with thermocouple data obtained during the arcjet test.

Agrawal, Parul↗

NASA NTRS1987

A 2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

The technological readiness of a long-life multipropellant resistojet for space station auxiliary propulsion is demonstrated. A laboratory model resistojet made from grain-stabilized platinum served as a test bed to evaluate the design characteristics, fabrication methods, and operating strategies for an engineering model multipropellant resistojet developed under contract by the Rocketdyne Division of Rockwell International and Technion Incorporated. The laboratory model thruster was subjected to a 2000-hr, 2400-thermal-cycle endurance test using carbon dioxide propellant. Maximum thruster temperatures were approximately 1400 C. The post-test analyses of the laboratory model thruster included an investigation of component microstructures. Significant observations from the laboratory model thruster are discussed as they relate to the design of the engineering model thruster.

Morren, W. Earl↗

NASA NTRS1987

2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

Morren, W. Earl↗

NASA NTRSDate not supplied

Extending the Applicability of Thermal Protection System Ballistic Limit Equations Beyond the Testable Regime

All spacecraft use some sort of thermal insulation in their design, which is usually placed on the spacecraft’s exterior. As such, it is highly susceptible to high-speed impacts by meteoroids and orbital debris. These high-speed impacts can damage the insulation to a point where the protection it offers is below acceptable limits. It is, therefore, important to be able to characterize expected TPS damage levels stemming from such high-speed impacts. In a recent paper, we presented the results of a study that sought to characterize the high-speed impact damage that would be sustained by two thermal protection materials that have recently gained attention for possible use in interplanetary missions. As part of the analyses performed, ballistic limit equations for these materials were developed using recent high-speed impact test data, and then assessed by comparing their predictions against test data. In this paper, we extend the applicability of the ballistic limit equation for one of those thermal materials beyond the testable regime using the results of series of Smooth Particle Hydrodynamics Code (SPHC) impact simulations at velocities in excess of 10 km/s. When the predictions of the updated and expanded BLE were compared against the results of the SPHC runs, the predictions were seen to be consistent with the data: non-perforation data points were typically below the BLE curves, while perforation data points were typically above them.

Thermal Protection System↗

NASA NTRS2001

Long-Term Durability of a Matrix for High-Temperature Composites Predicted

Polymer matrix composites (PMC's) are being increasingly used in applications where they are exposed for long durations to harsh environments such as elevated temperatures, moisture, oils and solvents, and thermal cycling. The exposure to these environments leads to the degradation of structures made from these materials. This also affects the useful lifetimes of these structures. Some of the more prominent aerospace applications of polymer matrix composites include engine supports and cowlings, reusable launch vehicle parts, radomes, thrust-vectoring flaps, and the thermal insulation of rocket motors. This demand has led to efforts to develop lightweight, high-strength, high-modulus materials that have upper-use temperatures over 316 C. A cooperative program involving two grants to the Massachusetts Institute of Technology and in-house work at the NASA Glenn Research Center was conducted to identify the mechanisms and the measurement of mechanical and physical properties that are necessary to formulate a mechanism-based model for predicting the lifetime of high-temperature polymer matrix composites. The polymer that was studied was PMR-15 polyimide, a leading matrix resin for use in high-temperature-resistant aerospace composite structures such as propulsion systems. The temperature range that was studied was from 125 to 316 C. The diffusion behavior of PMR-15 neat resin was characterized and modeled. Thermogravimetric analysis (TGA) was also conducted in nitrogen, oxygen, and air to provide quantitative information on thermal and oxidative degradation reactions. A new low-cost technique was developed to collect chemical degradation data for isothermal tests lasting up to 4000 hr in duration. In the temperature range studied, results indicate complex behavior that was not observed by previous TGA tests, including the presence of weight-gain reactions. These were found to be significant in the initial periods of aging from 125 to 225 C. Two types of weight loss reactions dominated at aging temperatures above 225 C. One was concentrated at the surface of the polymer and was very active at temperatures above 225 C. The second was observed to dominate in the latter stages of aging at temperatures below 260 C. This three-reaction model satisfactorily explains past findings that the degradation mechanism of PMR-15 appears to change around 316 C. It also indicates that the second weight gain mechanism is a significant factor at temperatures below 204 C. On the basis of these results, a predictive model was developed for the thermal degradation of PMR-15 at 316 C. A comparison of data generated by this model with actual experimental data is shown in the following figure.

Bowles, Kenneth J.↗

NASA NTRS1991

Space Shuttle Redesigned Solid Rocket Motor nozzle natural frequency variations with burn time

The effects of erosion and thermal degradation on the Space Shuttle Redesigned Solid Rocket Motor (RSRM) nozzle's structural dynamic characteristics were analytically evaluated. Also considered was stiffening of the structure due to internal pressurization. A detailed NASTRAN finite element model of the nozzle was developed and used to evaluate the influence of these effects at several discrete times during motor burn. Methods were developed for treating erosion and thermal degradation, and a procedure was developed to account for internal pressure stiffening using differential stiffness matrix techniques. Results were verified using static firing test accelerometer data. Fast Fourier Transform and Maximum Entropy Method techniques were applied to the data to generate waterfall plots which track modal frequencies with burn time. Results indicate that the lower frequency nozzle 'vectoring' modes are only slightly affected by erosion, thermal effects and internal pressurization. The higher frequency shell modes of the nozzle are, however, significantly reduced.

Lui, C. Y.↗

NASA NTRS1978

A method for determining structural properties of RCC thermal protection material

A method was developed for evaluation and prediction of effects of oxidation of the graphitic substrate on structural properties of Reinforced Carbon-Carbon (RCC) thermal protection material. Test specimens of RCC material were exposed to successive periods of convective heating in a plasma-jet facility to simulate the chemical reactions of Shuttle atmospheric entry. After each period of testing, the test specimen mass loss and performance in a nondestructive flexure test were determined. A computational model of the RCC specimen was developed for the NASA Structural Analysis (NASTRAN) program and validated by comparison of calculated and experimental results of flexure tests. The elastic moduli and ultimate loads in tension and compression were then computed for various levels of substrate oxidation.

Wakefield, R. M.↗

NASA NTRS2006

Modular, Reconfigurable, High-Energy Technology Development

The Modular, Reconfigurable High-Energy (MRHE) Technology Demonstrator project was to have been a series of ground-based demonstrations to mature critical technologies needed for in-space assembly of a highpower high-voltage modular spacecraft in low Earth orbit, enabling the development of future modular solar-powered exploration cargo-transport vehicles and infrastructure. MRHE was a project in the High Energy Space Systems (HESS) Program, within NASA's Exploration Systems Research and Technology (ESR&T) Program. NASA participants included Marshall Space Flight Center (MSFC), the Jet Propulsion Laboratory (JPL), and Glenn Research Center (GRC). Contractor participants were the Boeing Phantom Works in Huntsville, AL, Lockheed Martin Advanced Technology Center in Palo Alto, CA, ENTECH, Inc. in Keller, TX, and the University of AL Huntsville (UAH). MRHE's technical objectives were to mature: (a) lightweight, efficient, high-voltage, radiation-resistant solar power generation (SPG) technologies; (b) innovative, lightweight, efficient thermal management systems; (c) efficient, 100kW-class, high-voltage power delivery systems from an SPG to an electric thruster system; (d) autonomous rendezvous and docking technology for in-space assembly of modular, reconfigurable spacecraft; (e) robotic assembly of modular space systems; and (f) modular, reconfigurable distributed avionics technologies. Maturation of these technologies was to be implemented through a series of increasingly-inclusive laboratory demonstrations that would have integrated and demonstrated two systems-of-systems: (a) the autonomous rendezvous and docking of modular spacecraft with deployable structures, robotic assembly, reconfiguration both during assembly and (b) the development and integration of an advanced thermal heat pipe and a high-voltage power delivery system with a representative lightweight high-voltage SPG array. In addition, an integrated simulation testbed would have been developed containing software models representing the technologies being matured in the laboratory demos. The testbed would have also included models for non-MRHE developed subsystems such as electric propulsion, so that end-to-end performance could have been assessed. This paper presents an overview of the MRHE Phase I activities at MSFC and its contractor partners. One of the major Phase I accomplishments is the assembly demonstration in the Lockheed Martin Advanced Technology Center (LMATC) Robot-Satellite facility, in which three robot-satellites successfully demonstrated rendezvous & docking, self-assembly, reconfiguration, adaptable GN&C, deployment, and interfaces between modules. Phase I technology maturation results from ENTECH include material recommendations for radiation hardened Stretched Lens Array (SLA) concentrator lenses, and a design concept and test results for a hi-voltage PV receiver. UAH's accomplishments include Supertube heatpipe test results, which support estimates of thermal conductivities at 30,000 times that of an equivalent silver rod. MSFC performed systems trades and developed a preliminary concept design for a 100kW-class modular reconfigurable solar electric propulsion transport vehicle, and Boeing Phantom Works in Huntsville performed assembly and rendezvous and docking trades. A concept animation video was produced by SAIC, wllich showed rendezvous and docking and SLA-square-rigger deployment in LEO.

Carrington, Connie↗

NASA NTRS2014

Low-Cost Radiator for Fission Power Thermal Control

NASA Glenn Research Center (GRC) is developing fission power system technology for future Lunar surface power applications. The systems are envisioned in the 10 to 100kW(sub e) range and have an anticipated design life of 8 to 15 years with no maintenance. NASA GRC is currently setting up a 55 kW(sub e) non-nuclear system ground test in thermal-vacuum to validate technologies required to transfer reactor heat, convert the heat into electricity, reject waste heat, process the electrical output, and demonstrate overall system performance. Reducing the radiator mass, size, and cost is essential to the success of the program. To meet these goals, Advanced Cooling Technologies, Inc. (ACT) and Vanguard Space Technologies, Inc. (VST) are developing a single facesheet radiator with heat pipes directly bonded to the facesheet. The facesheet material is a graphite fiber reinforced composite (GFRC) and the heat pipes are titanium/water. By directly bonding a single facesheet to the heat pipes, several heavy and expensive components can be eliminated from the traditional radiator design such as, POC(TradeMark) foam saddles, aluminum honeycomb, and a second facesheet. A two-heat pipe radiator prototype, based on the single facesheet direct-bond concept, was fabricated and tested to verify the ability of the direct-bond joint to withstand coefficient of thermal expansion (CTE) induced stresses during thermal cycling. The thermal gradients along the bonds were measured before and after thermal cycle tests to determine if the performance degraded. Overall, the results indicated that the initial uniformity of the adhesive was poor along one of the heat pipes. However, both direct bond joints showed no measureable amount of degradation after being thermally cycled at both moderate and aggressive conditions.

Bonding↗

NASA NTRS2015

Conformal Ablative Thermal Protection Systems (CA-TPS) for Venus and Saturn Backshells

The new conformal ablator C-PICA, which was developed under STMD GCD, is an optimal candidate for use on the backshells for high velocity entry vehicles at both Venus and Saturn. The material has been tested at heat fluxes up to 400 Wcm2 in shear and over 1800 Wcm2 and 1.5 atm in stagnation with good results. C-PICA has similar density to PICA, but shows half the thermal penetration and similar recession at the same conditions, allowing for a lighter weight TPS to be flown. This poster for VEXAG will show the progress made in the development of the material and why it should be considered for use.

Conformal Ablative↗

NASA NTRS2015

Numerical Modeling of Self-Pressurization and Pressure Control by Thermodynamic Vent System in a Cryogenic Tank

This paper presents a numerical model of a system-level test bed - the multipurpose hydrogen test bed (MHTB) using Generalized Fluid System Simulation Program (GFSSP). MHTB is representative in size and shape of a fully integrated space transportation vehicle liquid hydrogen (LH2) propellant tank and was tested at Marshall Space Flight Center (MSFC) to generate data for cryogenic storage. GFSSP is a finite volume based network flow analysis software developed at MSFC and used for thermo-fluid analysis of propulsion systems. GFSSP has been used to model the self-pressurization and ullage pressure control by Thermodynamic Vent System (TVS). A TVS typically includes a Joule-Thompson (J-T) expansion device, a two-phase heat exchanger, and a mixing pump and spray to extract thermal energy from the tank without significant loss of liquid propellant. Two GFSSP models (Self-Pressurization & TVS) were separately developed and tested and then integrated to simulate the entire system. Self-Pressurization model consists of multiple ullage nodes, propellant node and solid nodes; it computes the heat transfer through Multi-Layer Insulation blankets and calculates heat and mass transfer between ullage and liquid propellant and ullage and tank wall. TVS model calculates the flow through J-T valve, heat exchanger and spray and vent systems. Two models are integrated by exchanging data through User Subroutines of both models. The integrated models results have been compared with MHTB test data of 50% fill level. Satisfactory comparison was observed between test and numerical predictions.

Majumdar, Alok↗