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NASA NTRS2011

Space Shuttle Propulsion Finishing Strong

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the SRB's on STS-4 and shutdown of an SSME during ascent on STS- 51F. On STS-112 only half the pyrotechnics fired to release the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early Program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. Human rating of solid rocket motors was truly achieved. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. These major events and lessons for the future are discussed. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The propulsion system elements evolved to high reliability and heavy lift capability. The Shuttle system, though not a operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS) and provided significant logistics and down mass for ISS operations. By the end of the Program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and is a heavy lift earth to orbit propulsion system. The story of this amazing system is discussed in detail in the paper.

Owen, James W.↗

NASA NTRS2011

Designing the Space Shuttle Propulsion System

The major elements of the Space Shuttle Main Propulsion System include two reusable solid rocket motors integrated into recoverable solid rocket boosters, an expendable external fuel and oxidizer tank, and three reusable Space Shuttle Main Engines. Both the solid rocket motors and space shuttle main engines ignite prior to liftoff, with the solid rocket boosters separating about two minutes into flight. The external tank separates after main engine shutdown and is safely expended in the ocean. The SSME's, integrated into the Space Shuttle Orbiter aft structure, are reused after post landing inspections. Both the solid rocket motors and the space shuttle main engine throttle during early ascent flight to limit aerodynamic loads on the structure. The configuration is called a stage and a half as all the propulsion elements are active during the boost phase, and the SSME's continue operation to achieve orbital velocity approximately eight and a half minutes after liftoff. Design and performance challenges were numerous, beginning with development work in the 1970 s. The solid rocket motors were large, and this technology had never been used for human space flight. The SSME s were both reusable and very high performance staged combustion cycle engines, also unique to the Space Shuttle. The multi body side mount configuration was unique and posed numerous integration and interface challenges across the elements. Operation of the system was complex and time consuming. This paper discusses a number of the system level technical challenges including development and operations.

Owen, James↗

NASA NTRS2003

Touchdown Ball-Bearing System for Magnetic Bearings

The torque-limited touchdown bearing system (TLTBS) is a backup mechanical-bearing system for a high-speed rotary machine in which the rotor shaft is supported by magnetic bearings in steady-state normal operation. The TLTBS provides ball-bearing support to augment or supplant the magnetic bearings during startup, shutdown, or failure of the magnetic bearings. The TLTBS also provides support in the presence of conditions (in particular, rotational acceleration) that make it difficult or impossible to control the magnetic bearings or in which the magnetic bearings are not strong enough (e.g., when the side load against the rotor exceeds the available lateral magnetic force).

Kingsbury, Edward P.↗

NASA NTRS2012

Quantitative Global Heat Transfer in a Mach-6 Quiet Tunnel

This project developed quantitative methods for obtaining heat transfer from temperature sensitive paint (TSP) measurements in the Mach-6 quiet tunnel at Purdue, which is a Ludwieg tube with a downstream valve, moderately-short flow duration and low levels of heat transfer. Previous difficulties with inferring heat transfer from TSP in the Mach-6 quiet tunnel were traced to (1) the large transient heat transfer that occurs during the unusually long tunnel startup and shutdown, (2) the non-uniform thickness of the insulating coating, (3) inconsistencies and imperfections in the painting process and (4) the low levels of heat transfer observed on slender models at typical stagnation temperatures near 430K. Repeated measurements were conducted on 7 degree-half-angle sharp circular cones at zero angle of attack in order to evaluate the techniques, isolate the problems and identify solutions. An attempt at developing a two-color TSP method is also summarized.

Sullivan, John P.↗

NASA NTRS2011

Shuttle Propulsion Overview - The Design Challenges

The major elements of the Space Shuttle Main Propulsion System include two reusable solid rocket motors integrated into recoverable solid rocket boosters, an expendable external fuel and oxidizer tank, and three reusable Space Shuttle Main Engines. Both the solid rocket motors and space shuttle main engines ignite prior to liftoff, with the solid rocket boosters separating about two minutes into flight. The external tank separates, about eight and a half minutes into the flight, after main engine shutdown and is safely expended in the ocean. The SSME's, integrated into the Space Shuttle Orbiter aft structure, are reused after post landing inspections. The configuration is called a stage and a half as all the propulsion elements are active during the boost phase, with only the SSME s continuing operation to achieve orbital velocity. Design and performance challenges were numerous, beginning with development work in the 1970's. The solid rocket motors were large, and this technology had never been used for human space flight. The SSME s were both reusable and very high performance staged combustion cycle engines, also unique to the Space Shuttle. The multi body side mount configuration was unique and posed numerous integration and interface challenges across the elements. Operation of the system was complex and time consuming. This paper describes the design challenges and key areas where the design evolved during the program.

Owen, James W.↗

NASA NTRS2011

Shuttle Propulsion System Major Events and the Final 22 Flights

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the Solid Rocket Boosters (SRB's) on STS-4 and shutdown of a Space Shuttle Main Engine (SSME) during ascent on STS-51F. On STS-112 only half the pyrotechnics fired during release of the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The Shuttle system, though not as operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS). By the end of the program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and was a heavy lift earth to orbit propulsion system. During the program a number of project management and engineering processes were implemented and improved. Technical performance, schedule accountability, cost control, and risk management were effectively managed and implemented. Award fee contracting was implemented to provide performance incentives. The Certification of Flight Readiness and Mission Management processes became very effective. A key to the success of the propulsion element projects was related to relationships between the MSFC project office and support organizations with their counterpart contractor organizations. The teams worked diligently to understand and satisfy requirements and achieve mission success.

Owen, James W.↗

NASA NTRS2012

Determining Aerosol Plume Height from Two GEO Imagers: Lessons from MISR and GOES

Aerosol plume height is a key parameter to determine impacts of particulate matters generated from biomass burning, wind-blowing dust, and volcano eruption. Retrieving cloud top height from stereo imageries from two GOES (Geostationary Operational Environmental Satellites) have been demonstrated since 1970's and the principle should work for aerosol plumes if they are optically thick. The stereo technique has also been used by MISR (Multiangle Imaging SpectroRadiometer) since 2000 that has nine look angles along track to provide aerosol height measurements. Knowing the height of volcano aerosol layers is as important as tracking the ash plume flow for aviation safety. Lack of knowledge about ash plume height during the 2010 Eyja'rjallajokull eruption resulted in the largest air-traffic shutdown in Europe since World War II. We will discuss potential applications of Asian GEO satellites to make stereo measurements for dust and volcano plumes.

Wu, Dong L.↗

NASA NTRS2012

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

To support the on-going nuclear thermal propulsion effort, a state-of-the-art non nuclear experimental test setup has been constructed to evaluate the performance characteristics of candidate fuel element materials and geometries in representative environments. The facility to perform this testing is referred to as the Nuclear Thermal Rocket Element Environment Simulator (NTREES). This device can simulate the environmental conditions (minus the radiation) to which nuclear rocket fuel components will be subjected during reactor operation. Test articles mounted in the simulator are inductively heated in such a manner so as to accurately reproduce the temperatures and heat fluxes which would normally occur as a result of nuclear fission and would be exposed to flowing hydrogen. Initial testing of a somewhat prototypical fuel element has been successfully performed in NTREES and the facility has now been shutdown to allow for an extensive reconfiguration of the facility which will result in a significant upgrade in its capabilities

Emrich, William J. Jr.↗

NASA NTRS2012

Pressure Dome for High-Pressure Electrolyzer

A high-strength, low-weight pressure vessel dome was designed specifically to house a high-pressure [2,000 psi (approx. = 13.8 MPa)] electrolyzer. In operation, the dome is filled with an inert gas pressurized to roughly 100 psi (approx. = 690 kPa) above the high, balanced pressure product oxygen and hydrogen gas streams. The inert gas acts to reduce the clamping load on electrolyzer stack tie bolts since the dome pressure acting axially inward helps offset the outward axial forces from the stack gas pressure. Likewise, radial and circumferential stresses on electrolyzer frames are minimized. Because the dome is operated at a higher pressure than the electrolyzer product gas, any external electrolyzer leak prevents oxygen or hydrogen from leaking into the dome. Instead the affected stack gas stream pressure rises detectably, thereby enabling a system shutdown. All electrical and fluid connections to the stack are made inside the pressure dome and require special plumbing and electrical dome interfaces for this to be accomplished. Further benefits of the dome are that it can act as a containment shield in the unlikely event of a catastrophic failure. Studies indicate that, for a given active area (and hence, cell ID), frame outside diameter must become ever larger to support stresses at higher operating pressures. This can lead to a large footprint and increased costs associated with thicker and/or larger diameter end-plates, tie-rods, and the frames themselves. One solution is to employ rings that fit snugly around the frame. This complicates stack assembly and is sometimes difficult to achieve in practice, as its success is strongly dependent on frame and ring tolerances, gas pressure, and operating temperature. A pressure dome permits an otherwise low-pressure stack to operate at higher pressures without growing the electrolyzer hardware. The pressure dome consists of two machined segments. An O-ring is placed in an O-ring groove in the flange of the bottom segment and is trapped by the flange on the top dome segment when these components are bolted together with high-strength bolts. The pressure dome has several unique features. It is made (to ASME Pressure Vessel guidelines) in a high-strength aluminum alloy with the strength of stainless steel and the weight benefits of aluminum. The flange of the upper dome portion contains specially machined flats for mounting the dome, and other flats dedicated to the special feedthroughs for electrical connections. A pressure dome can be increased in length to house larger stacks (more cells) of the same diameter with the simple addition of a cylindrical segment. To aid in dome assembly, two stainless steel rings are employed. One is used beneath the heads of the high-strength bolts in lieu of individual hardened washers, and another is used instead of individual nuts. Like electrolyzers could be operated at low or high pressures simply by operating the electrolyzer outside or inside a pressurized dome.

Norman, Timothy↗

NASA NTRS2011

Extended Operation of Stirling Convertors at NASA Glenn Research Center

Glenn Research Center (GRC) is supporting life and reliability database for free-piston Stirilng conversion via extended convertor operation Ongoing convertor operation: 18 convertors (4 TDCs from Infinia, 14 ASCs from Sunpower). 350,000 total convertor hours of operation. 218,000 on Infinia units and 132,000 on Sunpower units. Demonstrating steady convertor performance requires precise maintenance of operating conditions. Sources of disruption : Investigative tests: Varying operating frequency, hot-end temp, cold-end temp. Hot end control method: Constant heat input mode requires more user-adjustment than constant temperature mode. Long-term transients in hot end insulation were observed. Support facility: Open-bath circulator fluid concentration drifting. Nuisance shutdowns (instrumentation failure, EMI, power outages). Ambient temperature fluctuations due to room HVAC.

Oriti, Salvatore↗

NASA NTRS2011

Introduction to: Atlantic Meridional Overturning Circulation(AMOC)

A striking conclusion of the Intergovernmental Panel on Climate Change 2007 report is the crucial role that the Atlantic Meridional Overturning Circulation (AMOC) may play in anthropogenic climate change. However, these IPCC coupled climate simulations show a broad range of uncertainty in the magnitude and timing of AMOC transport change ranging from none to nearly complete collapse within the 21st century. The potential consequences of large changes in the characteristics of AMOC have motivated the creation in the United States of an interagency program and implementation plan to develop monitoring and prediction capabilities for the AMOC This program parallels the development of substantial monitoring efforts by European, South American and African countries -- notably the UK Rapid and Rapid-Watch programs. The papers contained in this volume are derived from presentations at the First U.S. Atlantic Meridional Overturning Circulation (AMOC) Meeting held 4 - 6 May, 2009 to review the US implementation plan and its coordination with other monitoring activities. The Atlantic Meridional Overturning Circulation consists of multiple components illustrated in an attached figure. Water enters the South Atlantic at upper and intermediate depths through both western and eastern routes (where eddy transport is especially important) and is transported northward across the equator, where it recirculates within the northern subtropical and subpolar gyres. The northern end is defined by the sinking regions of the Nordic Seas and the Labrador Sea where the waters that eventually form the upper and lower branches of North Atlantic Deep Water are conditioned. High surface salinities, the result of high net evaporation in the tropics and subtropics (including the Mediterranean Sea), and presence of regions of the Arctic Ocean that remain ice-free even in winter allow for the rapid cooling and thus densification of surface water. This dense surface water becomes the source of deep water formation in the sinking regions. In addition to transporting mass, the AMOC transports roughly half of the total amount of heat carried northward through the northern subtropics (down the temperature-gradient) by the ocean. In contrast in the Southern Hemisphere AMOC transports heat up-gradient from the cool Circumpolar Current to the warm tropics. Paleoevidence suggests that AMOC heat transport in the two hemispheres has varied over time in ways intimately tied to millennial changes in the Earth's climate. In one example, the abrupt Younger Dryas spell of cold weather over the North Atlantic, which began 13,000 years ago, has generally been linked to a millennial shutdown of the AMOC as a result of massive freshwater discharge from the North American continent. The current AMOC monitoring array consists of a series of instrumented transects located across key passages (see Cunningham et al., 2010 for a recent review). In the Arctic and sub-Arctic, transects cross Fram Strait, Denmark Strait and the Faroe Channel (connecting Greenland, Iceland, and the United Kingdom), as well as the entrance to the Labrador Sea. Further south and extending outwards from the east coast of North America there are a series of monitoring arrays including arrays of the Canadian Atlantic Zone Monitoring Program, deployments of the Rapid Western Atlantic Variability Experiment (WAVE), Line W at 39 N, as well as the Rapid-MOC moored array. The latter spans the entire Atlantic basin along 26.5 N. At tropical latitudes we have the Meridional Overturning Variability Experiment (MOVE) array at 16 N, while in the Southern Hemisphere a corresponding basin-spanning transect is being established at the latitude of Cape of Good Hope, complemented by arrays at Drake Passage.

Hakkinen, Sirpa↗

NASA NTRS2012

Restoration and Reexamination of Data from the Apollo 11, 12, 14, and 15 Dust, Thermal and Radiation Engineering Measurements Experiments

As part of an effort by the Lunar Data Node (LDN) we are restoring data returned by the Apollo Dust, Thermal, and Radiation Engineering Measurements (DTREM) packages emplaced on the lunar surface by the crews of Apollo 11, 12, 14, and 15. Also commonly known as the Dust Detector experiments, the DTREM packages measured the outputs of exposed solar cells and thermistors over time. They operated on the surface for up to nearly 8 years, returning data every 54 seconds. The Apollo 11 DTREM was part of the Early Apollo Surface Experiments Package (EASEP), and operated for a few months as planned following emplacement in July 1969. The Apollo 12, 14, and 15 DTREMs were mounted on the central station as part of the Apollo Lunar Surface Experiments Package (ALSEP) and operated from deployment until ALSEP shutdown in September 1977. The objective of the DTREM experiments was to determine the effects of lunar and meteoric dust, thermal stresses, and radiation exposure on solar cells. The LDN, part of the Geosciences Node of the Planetary Data System (PDS), operates out of the National Space Science Data Center (NSSDC) at Goddard Space Flight Center. The goal of the LDN is to extract lunar data stored on older media and/or in obsolete formats, restore the data into a usable digital format, and archive the data with PDS and NSSDC. For the DTREM data we plan to recover the raw telemetry, translate the raw counts into appropriate output units, and then apply calibrations. The final archived data will include the raw, translated, and calibrated data and the associated conversion tables produced from the microfilm, as well as ancillary supporting data (metadata) packaged in PDS format.

McBride, Marie J.↗

NASA NTRS2012

International Space Station Payload Operations Integration Center (POIC) Overview

Objectives and Goals: Maintain and operate the POIC and support integrated Space Station command and control functions. Provide software and hardware systems to support ISS payloads and Shuttle for the POIF cadre, Payload Developers and International Partners. Provide design, development, independent verification &validation, configuration, operational product/system deliveries and maintenance of those systems for telemetry, commanding, database and planning. Provide Backup Control Center for MCC-H in case of shutdown. Provide certified personnel and systems to support 24x7 facility operations per ISS Program. Payloads CoFR Implementation Plan (SSP 52054) and MSFC Payload Operations CoFR Implementation Plan (POIF-1006).

Ijames, Gayleen N.↗

NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Phase II Upgrade Activities

Emrich, William J.↗

NASA NTRS2013

Self Diagnostic Accelerometer Ground Testing on a C-17 Aircraft Engine

The self diagnostic accelerometer (SDA) developed by the NASA Glenn Research Center was tested for the first time in an aircraft engine environment as part of the Vehicle Integrated Propulsion Research (VIPR) program. The VIPR program includes testing multiple critical flight sensor technologies. One such sensor, the accelerometer, measures vibrations to detect faults in the engine. In order to rely upon the accelerometer, the health of the accelerometer must be ensured. Sensor system malfunction is a significant contributor to propulsion in flight shutdowns (IFSD) which can lead to aircraft accidents when the issue is compounded with an inappropriate crew response. The development of the SDA is important for both reducing the IFSD rate, and hence reducing the rate at which this component failure type can put an aircraft in jeopardy, and also as a critical enabling technology for future automated malfunction diagnostic systems. The SDA is a sensor system designed to actively determine the accelerometer structural health and attachment condition, in addition to making vibration measurements. The SDA uses a signal conditioning unit that sends an electrical chirp to the accelerometer and recognizes changes in the response due to changes in the accelerometer health and attachment condition. In an effort toward demonstrating the SDAs flight worthiness and robustness, multiple SDAs were mounted and tested on a C-17 aircraft engine. The engine test conditions varied from engine off, to idle, to maximum power. The two SDA attachment conditions used were fully tight and loose. The newly developed SDA health algorithm described herein uses cross correlation pattern recognition to discriminate a healthy from a faulty SDA. The VIPR test results demonstrate for the first time the robustness of the SDA in an engine environment characterized by high vibration levels.

Tokars, Roger P.↗

NASA NTRS2013

Status on the Verification of Combustion Stability for the J-2X Engine Thrust Chamber Assembly

Development is underway of the J -2X engine, a liquid oxygen/liquid hydrogen rocket engine for use on the Space Launch System. The Engine E10001 began hot fire testing in June 2011 and testing will continue with subsequent engines. The J -2X engine main combustion chamber contains both acoustic cavities and baffles. These stability aids are intended to dampen the acoustics in the main combustion chamber. Verification of the engine thrust chamber stability is determined primarily by examining experimental data using a dynamic stability rating technique; however, additional requirements were included to guard against any spontaneous instability or rough combustion. Startup and shutdown chug oscillations are also characterized for this engine. This paper details the stability requirements and verification including low and high frequency dynamics, a discussion on sensor selection and sensor port dynamics, and the process developed to assess combustion stability. A status on the stability results is also provided and discussed.

Casiano, Matthew↗

NASA NTRS2014

On-Demand Cell Internal Short Circuit Device

A device implantable in Li-ion cells that can generate a hard internal short circuit on-demand by exposing the cell to 60C has been demonstrated to be valuable for expanding our understanding of cell responses. The device provides a negligible impact to cell performance and enables the instigation of the 4 general categories of cell internal shorts to determine relative severity and cell design susceptibility. Tests with a 18650 cell design indicates that the anode active material short to the aluminum cathode current collector tends to be more catastrophic than the 3 other types of internal shorts. Advanced safety features (such as shutdown separators) to prevent or mitigate the severity of cell internal shorts can be verified with this device. The hard short success rate achieved to date in 18650 cells is about 80%, which is sufficient for using these cells in battery assemblies for field-failure-relevant, cell-cell thermal runaway propagation verification tests

Darcy, Eric↗

NASA NTRS2014

Spring 2014 Internship Diffuser Data Analysis

J-2X engine testing on the A-2 test stand at the NASA John C. Stennis Space Center (SSC) has recently concluded. As part of that test campaign, the engine was operated at lower power levels in support of expanding the use of J-2X to other missions. However, the A-2 diffuser was not designed for engine testing at the proposed low power levels. To evaluate the risk of damage to the diffuser, computer simulations were created of the rocket engine exhaust plume inside the 50ft long, water-cooled, altitude-simulating diffuser. The simulations predicted that low power level testing would cause the plume to oscillate in the lower sections of the diffuser. This can possibly cause excessive vibrations, stress, and heat transfer from the plume to the diffuser walls. To understand and assess the performance of the diffuser during low power level engine testing, nine accelerometers and four strain gages were installed around the outer surface of the diffuser. The added instrumentation also allowed for the verification of the rocket exhaust plume computational model. Prior to engine hot-fire testing, a diffuser water-flow test was conducted to verify the proper operation of the newly installed instrumentation. Subsequently, two J-2X engine hot-fire tests were completed. Hot-Fire Test 1 was 11.5 seconds in duration, and accelerometer and strain data verified that the rocket engine plume oscillated in the lower sections of the diffuser. The accelerometers showed very different results dependent upon location. The diffuser consists of four sections, with Section 1 being closest to the engine nozzle and Section 4 being farthest from the engine nozzle. Section 1 accelerometers showed increased amplitudes at startup and shutdown, but low amplitudes while the diffuser was started. Section 3 accelerometers showed the opposite results with near zero G amplitudes prior to and after diffuser start and peak amplitudes to +/- 100G while the diffuser was started. Hot-Fire Test 1 strain gages showed different data dependent on section. Section 1 strains were small, and were in the range of 50 to 150 microstrain, which would result in stresses from 1.45 to 4.35 ksi. The yield stress of the material, A-285 Grade C Steel, is 29.7 ksi. Section 4 strain gages showed much higher values with strains peaking at 1600 microstrain. This strain corresponds to a stress of 46.41 ksi, which is in excess of the yield stress, but below the ultimate stress of 55 to 75 ksi. The decreased accelerations and strain in Section 1, and the increased accelerations and strain in Sections 3 and 4 verified the computer simulation prediction of increased plume oscillations in the lower sections of the diffuser. Hot-Fire Test 2 ran for a duration of 125 seconds. The engine operated at a slightly higher power level than Hot-Fire Test 1 for the initial 35 seconds of the test. After 35 seconds the power level was lowered to Hot-Fire Test 1 levels. The acceleration and strain data for Hot-Fire Test 2 was similar during the initial part of the test. However, just prior to the engine being lowered to the Hot-Fire Test 1 power level, the strain gage data in Section 4 showed a large decrease to strains near zero microstrain from their peak at 1500 microstrain. Future work includes further strain and acceleration data analysis and evaluation.

Laigaie, Robert T.↗