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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 1,189 records · Page 66

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NASA NTRS2001

Innovative Airbreathing Propulsion Concepts for Access to Space

This paper will present technologies and concepts for novel aeropropulsion systems. These technologies will enhance the safety of operations, reduce life cycle costs, and contribute to reduced costs of air travel and access to space. One of the goals of the NASA program is to reduce the carbon-dioxide emissions of aircraft engines. Engine concepts that use highly efficient fuel cell/electric drive technologies in hydrogen-fueled engines will be presented in the proposed paper. Carbon-dioxide emissions will be eliminated by replacing hydrocarbon fuel with hydrogen, and reduce NOx emissions through better combustion process control. A revolutionary exoskeletal engine concept, in which the engine drum is rotated, will be shown. This concept has the potential to allow a propulsion system that can be used for subsonic through hypersonic flight. Dual fan concepts that have ultra-high bypass ratios, low noise, and low drag will be presented. Flow-controlled turbofans and control-configured turbofans also will be discussed. To increase efficiency, a system of microengines distributed along lifting surfaces and on the fuselage is being investigated. This concept will be presented in the paper. Small propulsion systems for affordable, safe personal transportation vehicles will be discussed. These low-oil/oilless systems use technologies that enable significant cost and weight reductions. Pulse detonation engine-based hybrid-cycle and combined-cycle propulsion systems for aviation and space access will be presented.

Whitlow, Jr., Woodrow↗

NASA NTRS2016

Purpose, Principles, and Challenges of the NASA Engineering and Safety Center

NASA formed the NASA Engineering and Safety Center in 2003 following the Space Shuttle Columbia accident. It is an Agency level, program-independent engineering resource supporting NASA's missions, programs, and projects. It functions to identify, resolve, and communicate engineering issues, risks, and, particularly, alternative technical opinions, to NASA senior management. The goal is to help ensure fully informed, risk-based programmatic and operational decision-making processes. To date, the NASA Engineering and Safety Center (NESC) has conducted or is actively working over 600 technical studies and projects, spread across all NASA Mission Directorates, and for various other U.S. Government and non-governmental agencies and organizations. Since inception, NESC human spaceflight related activities, in particular, have transitioned from Shuttle Return-to-Flight and completion of the International Space Station (ISS) to ISS operations and Orion Multi-purpose Crew Vehicle (MPCV), Space Launch System (SLS), and Commercial Crew Program (CCP) vehicle design, integration, test, and certification. This transition has changed the character of NESC studies. For these development programs, the NESC must operate in a broader, system-level design and certification context as compared to the reactive, time-critical, hardware specific nature of flight operations support.

Gilbert, Michael G.↗

NASA NTRS2003

VPS GRCop-84 Liner Development Efforts

For the past several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc. (PPI) to fabricate combustion chamber liners using the Vacuum Plasma Spray (VPS) process. Multiple liners of a variety of shapes and sizes have been created. Each liner has been fabricated with GRCop-84 (a copper alloy with chromium and niobium) and a functional gradient coating (FGC) on the hot wall. While the VPS process offers versatility and a reduced fabrication schedule, the material system created with VPS allows the liners to operate at higher temperatures, with maximum blanch resistance and improved cycle life. A subscal unit (5K lbf thrust class) is being cycle tested in a LOX/Hydrogen thrust chamber assembly at MSFC. To date, over 75 hot-fire tests have been accumulated on this article. Tests include conditions normally detrimental to conventional materials, yet the VPS GRCop-84 liner has yet to show any signs of degradation. A larger chamber (15K lbf thrust class) has also been fabricated and is being prepared for hot-fire testing at MSFC near the end of 2003. Linear liners have been successfully created to further demonstrate the versatility of the process. Finally, scale up issues for the VPS process are being tackled with efforts to fabricate a full size, engine class liner. Specifically, a liner for the SSME's Main Combustion Chamber (MCC) has recently been attempted. The SSME size was chosen for convenience, since its design was readily available and its size was sufficient to tackle specific issues. Efforts to fabricate these large liners have already provided valuable lessons for using this process for engine programs. The material quality for these large units is being evaluated with destructive analysis and these results will be available by the end of 2003.

Elam, Sandra K.↗

NASA NTRS1984

Optimization applications in aircraft engine design and test

Starting with the NASA-sponsored STAEBL program, optimization methods based primarily upon the versatile program COPES/CONMIN were introduced over the past few years to a broad spectrum of engineering problems in structural optimization, engine design, engine test, and more recently, manufacturing processes. By automating design and testing processes, many repetitive and costly trade-off studies have been replaced by optimization procedures. Rather than taking engineers and designers out of the loop, optimization has, in fact, put them more in control by providing sophisticated search techniques. The ultimate decision whether to accept or reject an optimal feasible design still rests with the analyst. Feedback obtained from this decision process has been invaluable since it can be incorporated into the optimization procedure to make it more intelligent. On several occasions, optimization procedures have produced novel designs, such as the nonsymmetric placement of rotor case stiffener rings, not anticipated by engineering designers. In another case, a particularly difficult resonance contraint could not be satisfied using hand iterations for a compressor blade, when the STAEBL program was applied to the problem, a feasible solution was obtained in just two iterations.

Pratt, T. K.↗

NASA NTRS2002

Virtually Out of This World!

Ames Research Center granted Reality Capture Technologies (RCT), Inc., a license to further develop NASA's Mars Map software platform. The company incorporated NASA#s innovation into software that uses the Virtual Plant Model (VPM)(TM) to structure, modify, and implement the construction sites of industrial facilities, as well as develop, validate, and train operators on procedures. The VPM orchestrates the exchange of information between engineering, production, and business transaction systems. This enables users to simulate, control, and optimize work processes while increasing the reliability of critical business decisions. Engineers can complete the construction process and test various aspects of it in virtual reality before building the actual structure. With virtual access to and simulation of the construction site, project personnel can manage, access control, and respond to changes on complex constructions more effectively. Engineers can also create operating procedures, training, and documentation. Virtual Plant Model(TM) is a trademark of Reality Capture Technologies, Inc.

Source record↗

NASA NTRS1981

Combustion system processes leading to corrosive deposits

Degradation of turbine engine hot gas path components by high temperature corrosion can usually be associated with deposits even though other factors may also play a significant role. The origins of the corrosive deposits are traceable to chemical reactions which take place during the combustion process. In the case of hot corrosion/sulfidation, sodium sulfate was established as the deposited corrosive agent even when none of this salt enters the engine directly. The sodium sulfate is formed during the combustion and deposition processes from compounds of sulfur contained in the fuel as low level impurities and sodium compounds, such as sodium chloride, ingested with intake air. In other turbine and power generation situations, corrosive and/or fouling deposits can result from such metals as potassium, iron, calcium, vanadium, magnesium, and silicon.

Stearns, C. A.↗

NASA NTRS1983

Combustion system processes leading to corrosive deposits

Stearns, C. A.↗

NASA NTRS1988

The PC/AT compatible computer as a mission control center display processor at Ames-Dryden Flight Research Facility

Since 1982, the Western Aeronautical Test Range of the Ames-Dryden Flight Research Facility has been separating the data acquisition and processing function required on all telemetry pulse code modulation (PCM) data and the display processing function required in the flight research mission control centers (MCCs). These two functions historically have been done on the same set of superminicomputers remote from the MCCs. Removing the display processing function from the realm of the superminis or telemetry-radar acquisition and processing system (TRAPS) and out into the MCCs will allow the research engineers the flexibility to configure their own display processing system to optimize performance during a flight research mission. Meanwhile, the TRAPS will have more time to acquire data. One of the processors chosen is an IBM PC/AT compatible rack-mounted personal computer. This class and type machine will not only allow the transfer of the display processing function into the MCCs, but also allow the research engineers a personalized set of analytic and display tools for use on their own unique sets of data.

Hammons, Kevin R.↗

NASA NTRS2013

Twenty Years of Systems Engineering on the Cassini-Huygens Mission

Over the past twenty years, the Cassini-Huygens Mission has successfully utilized systems engineering to develop and execute a challenging prime mission and two mission extensions. Systems engineering was not only essential in designing the mission, but as knowledge of the system was gained during cruise and science operations, it was critical in evolving operational strategies and processes. This paper discusses systems engineering successes, challenges, and lessons learned on the Cassini-Huygens Mission gathered from a thorough study of mission plans and developed scenarios, and interviews with key project leaders across its twenty-year history.

Manor-Chapman, Emily↗

NASA NTRS2023

Requirements Engineering Scorecard and the Next-Generation Space Suit

The objective for a NASA contractor, the performing organization in this case study, is to provide engineering services to develop and deliver the next generation space suit to NASA, the customer in this case study. A case study with qualitative and quantitative analyses regarding a new process and approach to requirements engineering is described, with the intent that if utilized, these tools may have contributed to improvements across the project in terms of meeting cost, scope, budget and quality while appropriately accounting for risk management. The procedure entails a research method in which the current state of the project, current state of the art, and the identified systems engineering challenges are evaluated. Iterative models are tempered through development by continual improvements by engineering evaluation of engineers on the project. The current results have produced a prototype of a requirements engineering scorecard with implementations of FMEA and quantitative analysis to (i) identify root cause of underdeveloped requirements and (ii) project management impacts with regards to project risk. Forward work includes customer, performing organization, acceptance against applicable INCOSE community accepted practices.

INCOSE↗

NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2011

Using Innovative Technologies for Manufacturing and Evaluating Rocket Engine Hardware

Many of the manufacturing and evaluation techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing and evaluating hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) and white light scanning are being adopted and evaluated for their use on J-2X, with hopes of employing both technologies on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powdered metal manufacturing process in order to produce complex part geometries. The white light technique is a non-invasive method that can be used to inspect for geometric feature alignment. Both the DMLS manufacturing method and the white light scanning technique have proven to be viable options for manufacturing and evaluating rocket engine hardware, and further development and use of these techniques is recommended.

Betts, Erin M.↗

NASA NTRSDate not supplied

From BERTopic to SysML: Informing Model-Based Failure Analysis With Natural Language Processing for Complex Aerospace Systems

The development of emerging complex aerospace systems will require new approaches for capturing safety incident scenarios as early as possible in the design phase. However, for novel systems, relevant data available is limited. In this work, we propose a framework informing model-based mission assurance activities with historical incident reports, lessons learned, or other relevant engineering documents using natural language processing. In doing so, we investigate whether there is useful information in data sets that are relevant, if not identical, to the system under design and whether, through rigorous systems engineering practice, this information can be effectively leveraged through model-based failure analysis. In a worked case study, we apply state-of-the-art topic modeling techniques to two data sets, a mission relevant data set and a system relevant data set. The sets of topics are merged and interpreted to form a preliminary list of failure topics that can be used to inform the identification of off-nominal modes in the model-based failure modes and effects analysis development. Once data from the system in operation is available, it can be used to update the topics identified. By extracting information about likely failures from relevant historical data sets and utilizing model-based mission assurance to ensure relevance and rigor, unanticipated failures can be reduced, and projects can more effectively learn from past missions.

Failure Analysis↗

NASA NTRSDate not supplied

From BERTopic to SysML: Informing Model-Based Failure Analysis With Natural Language Processing for Complex Aerospace Systems

Failure Analysis↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS1951

Analysis of thrust augmentation of turbojet engines by water injection at compressor inlet including charts for calculating compression processes with water injection

A psychrometric chart having total pressure (sum of partial pressures of air and water vapor) as a variable, a Mollier diagram for air saturated with water vapor, and charts showing the thermodynamic properties of various air-water vapor and exhaust gas-water vapor mixtures are presented as aids in calculating the thrust augmentation of a turbojet engine resulting from the injection of water at the compressor inlet. Curves are presented that show the theoretical performance of the augmentation method for various amounts of water injected and the effects of varying flight Mach number, altitude, ambient-air temperature, ambient relative humidity, compressor pressure ratio, and inlet-diffuser efficiency. Numerical examples, illustrating the use of the psychrometric chart and the Mollier diagram in calculating both compressor-inlet and compressor-outlet conditions when water is injected at the compressor inlet, are presented.

Wilcox, E Clinton↗

NASA NTRS1992

Intelligent systems for KSC ground processing

The ground processing and launch of Shuttle vehicles and their payloads is the primary task of Kennedy Space Center. It is a process which is largely manual and contains little inherent automation. Business is conducted today much as it was during previous NASA programs such as Apollo. In light of new programs and decreasing budgets, NASA must find more cost effective ways in which to do business while retaining the quality and safety of activities. Advanced technologies including artificial intelligence could cut manpower and processing time. This paper is an overview of the research and development in Al technology at KSC with descriptions of the systems which have been implemented, as well as a few under development which are promising additions to ground processing software. Projects discussed cover many facets of ground processing activities, including computer sustaining engineering, subsystem monitor and diagnosis tools and launch team assistants. The deployed Al applications have proven an effectiveness which has helped to demonstrate the benefits of utilizing intelligent software in the ground processing task.

Heard, Astrid E.↗