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At least 1,243 records · Page 69

Structures Division

The NASA Lewis Research Center Structures Division is an international leader and pioneer in developing new structural analysis, life prediction, and failure analysis related to rotating machinery and more specifically to hot section components in air-breathing aircraft engines and spacecraft propulsion systems. The research consists of both deterministic and probabilistic methodology. Studies include, but are not limited to, high-cycle and low-cycle fatigue as well as material creep. Studies of structural failure are at both the micro- and macrolevels. Nondestructive evaluation methods related to structural reliability are developed, applied, and evaluated. Materials from which structural components are made, studied, and tested are monolithics and metal-matrix, polymer-matrix, and ceramic-matrix composites. Aeroelastic models are developed and used to determine the cyclic loading and life of fan and turbine blades. Life models are developed and tested for bearings, seals, and other mechanical components, such as magnetic suspensions. Results of these studies are published in NASA technical papers and reference publication as well as in technical society journal articles. The results of the work of the Structures Division and the bibliography of its publications for calendar year 1995 are presented.

Source record↗

Lessons Learned in the Livingstone 2 on Earth Observing One Flight Experiment

The Livingstone 2 (L2) model-based diagnosis software is a reusable diagnostic tool for monitoring complex systems. In 2004, L2 was integrated with the JPL Autonomous Sciencecraft Experiment (ASE) and deployed on-board Goddard's Earth Observing One (EO-1) remote sensing satellite, to monitor and diagnose the EO-1 space science instruments and imaging sequence. This paper reports on lessons learned from this flight experiment. The goals for this experiment, including validation of minimum success criteria and of a series of diagnostic scenarios, have all been successfully net. Long-term operations in space are on-going, as a test of the maturity of the system, with L2 performance remaining flawless. L2 has demonstrated the ability to track the state of the system during nominal operations, detect simulated abnormalities in operations and isolate failures to their root cause fault. Specific advances demonstrated include diagnosis of ambiguity groups rather than a single fault candidate; hypothesis revision given new sensor evidence about the state of the system; and the capability to check for faults in a dynamic system without having to wait until the system is quiescent. The major benefits of this advanced health management technology are to increase mission duration and reliability through intelligent fault protection, and robust autonomous operations with reduced dependency on supervisory operations from Earth. The work-load for operators will be reduced by telemetry of processed state-of-health information rather than raw data. The long-term vision is that of making diagnosis available to the onboard planner or executive, allowing autonomy software to re-plan in order to work around known component failures. For a system that is expected to evolve substantially over its lifetime, as for the International Space Station, the model-based approach has definite advantages over rule-based expert systems and limit-checking fault protection systems, as these do not scale well. The model-based approach facilitates reuse of the L2 diagnostic software; only the model of the system to be diagnosed and telemetry monitoring software has to be rebuilt for a new system or expanded for a growing system. The hierarchical L2 model supports modularity and expendability, and as such is suitable solution for integrated system health management as envisioned for systems-of-systems.

Hayden, Sandra C.↗

Design and Development of Functionally Effective Human-Machine Interfaces for Firing Room Displays

This project involves creating software for support equipment used on the Space l aunch System (SLS). The goal is to create applications and displays that will be used to remotely operate equipment from the firing room and will continue to support the SLS launch vehicle to the extent of its program. These displays include design practices that help to convey information effectively, such as minimizing distractions at normal operating state and displaying intentional distractions during a warning or alarm state. The general practice for creating an operator display is to reduce the detail of unimportant aspects of the display and promote focus on data and dynamic information. These practices include using minimalist design, using muted tones for background colors, using a standard font at a readable text size, displaying alarms visible for Immediate attention, grouping data logically, and displaying data appropriately varying on the type of data. Users of these displays are more likely to stay focused on operating for longer periods by using design practices that reduce eye strain and fatigue. Effective operator displays will improve safety by reducing human errors during operation, which will help prevent catastrophic accidents. This report entails the details of my work on developing remote displays for the Hypergolics ground system. Before developing a prototype display, the design and requirements of the system are outlined and compiled into a document. Then each subsystem has schematic representations drawn tha.t meet the specifications detailed in the document. The schematics are then used as the outline to create display representations of each subsystem. Each display is first tested individually. Then the displays are integrated with a prototype of the master system, and they are tested in a simulated environment then retested in the real environment. Extensive testing is important to ensure the displays function reliably as intended.

Cho, Henry↗

Design and Development of Functionally Effective Human-Machine Interfaces for Firing Room Displays

This project involves creating software for support equipment used on the Space Launch System (SLS). The goal is to create applications and displays that will be used to remotely operate equipment from the firing room and will continue to support the SLS launch vehicle to the extent of its program. These displays include design practices that help to convey information effectively, such as minimizing distractions at normal operating state and displaying intentional distractions during a warning or alarm state. The general practice for creating an operator display is to reduce the detail of unimportant aspects of the display and promote focus on data and dynamic information. These practices include using minimalist design, using muted tones for background colors, using a standard font at a readable text size, displaying alarms visible for immediate attention, grouping data logically, and displaying data appropriately varying on the type of data. Users of these displays are more likely to stay focused on operating for longer periods by using design practices that reduce eye strain and fatigue. Effective operator displays will improve safety by reducing human errors during operation, which will help prevent catastrophic accidents. This report entails the details of my work on developing remote displays for the Hypergolic fuel servicing system. Before developing a prototype display, the design and requirements of the system are outlined and compiled into a document. Then each subsystem has schematic representations drawn that meet the specifications detailed in the document. The schematics are then used as the outline to create display representations of each subsystem. Each display is first tested individually. Then the displays are integrated with a prototype of the master system, and they are tested in a simulated environment then retested in the real environment. Extensive testing is important to ensure the displays function reliably as intended.

displays↗

Utilizing Gaps and Key Performance Parameters to Inform NASA Environmental Control and Life Support Capability Technology Decisions

Human spaceflight is a complex endeavor requiring multiple capabilities for transportation, crew health, scientific goals, and safe return to Earth. The difference between spaceflight proven capabilities and those needed for future exploration architectures is defined as a capability gap. Capability gaps are not technology specific. Each capability gap may be closed with a wide array of technologies that have unique benefits and challenges. Determining what a capability’s relevant and distinguishing key performance parameters (KPPs) are for a mission is critical. Mass, power, and volume are always constrained and important, but defining these in a way normalized by performance is very important. KPP definition for reliability, dormancy, and integration needs are hard to define but critical. Outside of technical considerations, the programmatic factors of the estimated time to develop the technology vs when a mission element is also a strong consideration in which technologies should be pursued. The Environmental Control and Life Support (ECLSS) capability areas include: life support, environmental monitoring, fire safety, and logistics. These capability areas are decomposed to high level gaps. While KPPs should be technology agnostic, they can be used to both compare technologies and measure progress of technology development over time. KPPs help define when the gap is closed, and the core mission objectives can be accomplished. Proposed technology improvements to enhance a capability should balance improved KPPs and against investments in other capabilities that are not yet closed. A selection of ECLSS gaps and KPPs and their formulation, current state, and how they inform capability roadmap planning are discussed.

Life Support↗

Utilizing Gaps and Performance Measures to Inform NASA Environmental Control and Life Support Systems and Human Health and Performance Capability Technology Decisions

Human spaceflight is a complex endeavor requiring multiple capabilities for transportation, crew health, scientific goals, and safe return to Earth. The difference between spaceflight proven capabilities and those needed for future exploration architectures is defined as a capability gap. Capability gaps are not technology specific. Each capability gap may be closed with a wide array of technologies that have unique benefits and challenges. Determining what a capability’s relevant and distinguishing key performance parameters (KPPs) are for a mission is critical. Mass, power, and volume are always constrained and important, but defining these in a way normalized by performance is very important. KPP definition for reliability, dormancy, and integration needs are hard to define but critical. Outside of technical considerations, the programmatic factors of the estimated time to develop the technology and how the technology validation objectives are matured are strong considerations in which technologies should be pursued and how they should leverage earlier mission elements. The Environmental Control and Life Support (ECLSS) and Crew Health and Performance (CHP) capability areas are decomposed to high level gaps. While KPPs should be technology agnostic, they can be used to both compare technologies and measure progress of technology development over time. KPPs help define when the gap is closed, and the core mission objectives can be accomplished. Proposed technology improvements to enhance a capability should balance improved KPPs and against investments in other capabilities that are not yet closed. A selection of gaps, KPPs, and validation objectives and their formulation, current state, and how they inform capability roadmap planning are discussed.

Life Support↗

Utilizing Gaps and Performance Measures to Inform NASA Environmental Control and Life Support Systems and Crew Health and Performance Technology Decisions

Human spaceflight is a complex endeavor requiring multiple capabilities for transportation, crew health, scientific goals, and safe return to Earth. The difference between spaceflight proven capabilities and those needed for future exploration architectures is defined as a capability gap. Capability gaps are not technology specific. Each capability gap may be closed with a wide array of technologies that have unique benefits and challenges. Determining what a capability’s relevant and distinguishing key performance parameters (KPPs) are for a mission is critical. Mass, power, and volume are always constrained and important, but defining these in a way normalized by performance is very important. KPP definition for reliability, dormancy, and integration needs are hard to define but critical. Outside of technical considerations, the programmatic factors of the estimated time to develop the technology and how the technology validation objectives are matured are strong considerations in which technologies should be pursued and how they should leverage earlier mission elements. The Environmental Control and Life Support (ECLSS) and Crew Health and Performance (CHP) capability areas are decomposed to high level gaps. While KPPs should be technology agnostic, they can be used to both compare technologies and measure progress of technology development over time. KPPs help define when the gap is closed, and the core mission objectives can be accomplished. Proposed technology improvements to enhance a capability should balance improved KPPs and against investments in other capabilities that are not yet closed. A selection of gaps, KPPs, and validation objectives and their formulation, current state, and how they inform capability roadmap planning are discussed.

Life Support↗

Extended performance solar electric propulsion thrust system study. Volume 2: Baseline thrust system

Several thrust system design concepts were evaluated and compared using the specifications of the most advanced 30- cm engineering model thruster as the technology base. Emphasis was placed on relatively high-power missions (60 to 100 kW) such as a Halley's comet rendezvous. The extensions in thruster performance required for the Halley's comet mission were defined and alternative thrust system concepts were designed in sufficient detail for comparing mass, efficiency, reliability, structure, and thermal characteristics. Confirmation testing and analysis of thruster and power-processing components were performed, and the feasibility of satisfying extended performance requirements was verified. A baseline design was selected from the alternatives considered, and the design analysis and documentation were refined. The baseline thrust system design features modular construction, conventional power processing, and a concentractor solar array concept and is designed to interface with the space shuttle.

Poeschel, R. L.↗

Development of software fault-tolerance techniques

As computers become more widely used, and in particular as they become used in more safety critical applications, the reliability of the computer system and its software becomes more important. There is also an increasing need for high levels of reliability in applications involving very large numbers of inexpensive units where recall of the units would be disproportionately expensive. The nature of faults and the assumptions made by different approaches to correct operation are considered. The recovery block approach is described and a probabilistic analysis of its effectiveness, with and without correlated design errors is provided. Mechanisms for generating acceptance tests from specifications, and for providing recovery in the presence of asynchrony, are described. An analysis of, and design for, the provision of recovery blocks in the microprogram of the Bendix BDX930 processor is provided. An example of the use of recovery blocks in a simple operating system is also provided.

Melliar-Smith, P. M.↗

Regional climate change predictions from the Goddard Institute for Space Studies high resolution GCM

Model simulations of global climate change are seen as an essential component of any program aimed at understanding human impact on the global environment. A major weakness of current general circulation models (GCMs), however, is their inability to predict reliably the regional consequences of a global scale change, and it is these regional scale predictions that are necessary for studies of human/environmental response. This research is directed toward the development of a methodology for the validation of the synoptic scale climatology of GCMs. This is developed with regard to the Goddard Institute for Space Studies (GISS) GCM Model 2, with the specific objective of using the synoptic circulation form a doubles CO2 simulation to estimate regional climate change over North America, south of Hudson Bay. This progress report is specifically concerned with validating the synoptic climatology of the GISS GCM, and developing the transfer function to derive grid-point temperatures from the synoptic circulation. Principal Components Analysis is used to characterize the primary modes of the spatial and temporal variability in the observed and simulated climate, and the model validation is based on correlations between component loadings, and power spectral analysis of the component scores. The results show that the high resolution GISS model does an excellent job of simulating the synoptic circulation over the U.S., and that grid-point temperatures can be predicted with reasonable accuracy from the circulation patterns.

Crane, Robert G.↗

Operations Analysis of the 2nd Generation Reusable Launch Vehicle

The Space Launch Initiative (SLI) program is developing a second-generation reusable launch vehicle. The program goals include lowering the risk of loss of crew to 1 in 10,000 and reducing annual operations cost to one third of the cost of the Space Shuttle. The SLI missions include NASA, military and commercial satellite launches and crew and cargo launches to the space station. The SLI operations analyses provide an assessment of the operational support and infrastructure needed to operate candidate system architectures. Measures of the operability are estimated (i.e. system dependability, responsiveness, and efficiency). Operations analysis is used to determine the impact of specific technologies on operations. A conceptual path to reducing annual operations costs by two thirds is based on key design characteristics, such as reusability, and improved processes lowering labor costs. New operations risks can be expected to emerge. They can be mitigated with effective risk management with careful identification, assignment, tracking, and closure. SLI design characteristics such as nearly full reusability, high reliability, advanced automation, and lowered maintenance and servicing coupled with improved processes are contributors to operability and large operating cost reductions.

Noneman, Steven R.↗

Vibration Monitoring Techniques Applied to Detect Damage in Rotating Disks

Rotor health monitoring and online damage detection are increasingly gaining the interest of the manufacturers of aircraft engines. This is primarily due to the need for improved safety during operation as well as the need for lower maintenance costs. Applied techniques for detecting damage in and monitoring the health of rotors are essential for engine safety, reliability, and life prediction. The goals of engine safety are addressed within the NASA-sponsored Aviation Safety Program (AvSP). AvSP provides research and technology products needed to help the Federal Aviation Administration and the aerospace industry improve aviation safety. The Nondestructive Evaluation Group at the NASA Glenn Research Center is addressing propulsion health management and the development of propulsion-system-specific technologies intended to detect potential failures prior to catastrophe.

Gyekenyesi, Andrew L.↗

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Legume Crop Testing for Space

Long-duration missions beyond low-Earth orbit will encounter challenges in maintaining adequate nutrition and crew acceptability in the food system. In situ production of fresh produce can supplement nutrient deficiencies in the prepackaged diet. Currently, there are a relatively small number of crops that can be reliably grown for space crop production efforts. Recent challenges with Veggie plant growth technical demonstrations, such as interveinal chlorosis and necrosis of Tokyo Bekana Chinese cabbage when grown under elevated CO 2 (~3000 ppm) and narrow-band LED lighting, have highlighted the necessity to conduct rigorous ISS-relevant crop screening on the ground. Additionally, crops should be selected to address specific nutritional deficits, as identified by NASA’s Human Research Program, with an emphasis on having a diversity of crops to meet nutritional requirements and crew acceptability. To achieve this, the concept of Crop Readiness Level (CRL) has been developed to gauge readiness of crops for spaceflight applications. CRL determination includes assessing environmental compatibility, food safety considerations, relevant nutritional analysis, and sensory analysis. Recent testing at Kennedy Space Center has focused on advancing the CRL of a variety of legumes. Twenty-four varieties of peas ( Pisum sativum ) and beans ( Phaseolus vulgaris ) were grown under 300 μmol m -2 s -1 PPFD from LED lights, 3000 ppm CO2, and 23 °C to simulate an ISS environment. Crops were harvested and size and yield were assessed. Then, baseline nutritional analysis (Vitamins B1, C, K; elemental analysis; proximate analysis) and sensory evaluation were performed on eight down-selected varieties. These baseline tests will help in selecting candidate crops for future missions and assessing crop production hardware and changes in environmental conditions on future crop performance and nutritional quality.

LaShelle E Spencer↗

Fracture mechanics technology for optimum pressure vessel design.

A technique has been developed to design a maximum efficiency reliable pressure vessel of given geometry and service life. The technique for ensuring reliability of the minimum weight vessel relies on the application of linear elastic fracture mechanics and fracture mechanics concepts. The resultant design incorporates potential fatigue and stress corrosion crack extension during service of a worst case initial flaw. Maximum stress for safe life is specified by the design technique, thereby minimizing weight. Ratios of pressure and toughness parameters are employed to avoid arbitrary specification of design stress level which would lead to a suboptimum design.

Bjeletich, J. G.↗

A hierarchical approach to reliability modeling of fault-tolerant systems

A methodology for performing fault tolerant system reliability analysis is presented. The method decomposes a system into its subsystems, evaluates vent rates derived from the subsystem's conditional state probability vector and incorporates those results into a hierarchical Markov model of the system. This is done in a manner that addresses failure sequence dependence associated with the system's redundancy management strategy. The method is derived for application to a specific system definition. Results are presented that compare the hierarchical model's unreliability prediction to that of a more complicated tandard Markov model of the system. The results for the example given indicate that the hierarchical method predicts system unreliability to a desirable level of accuracy while achieving significant computational savings relative to component level Markov model of the system.

Gossman, W. E.↗

Specification and testing for power by wire aircraft

A power by wire aircraft is one in which all active functions other than propulsion are implemented electrically. Other nomenclature are 'all electric airplane,' or 'more electric airplane.' What is involved is the task of developing and certifying electrical equipment to replace existing hydraulics and pneumatics. When such functions, however, are primary flight controls which are implemented electrically, new requirements are imposed that were not anticipated by existing power system designs. Standards of particular impact are the requirements of ultra-high reliability, high peak transient bi-directional power flow, and immunity to electromagnetic interference and lightning. Not only must the electromagnetic immunity of the total system be verifiable, but box level tests and meaningful system models must be established to allow system evaluation. This paper discusses some of the problems, the system modifications involved, and early results in establishing wiring harness and interface susceptibility requirements.

Hansen, Irving G.↗