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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 127 records · Page 7

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗

A hardware-oriented algorithm for floating-point function generation

An algorithm is presented for performing accurate, high-speed, floating-point function generation for univariate functions defined at arbitrary breakpoints. Rapid identification of the breakpoint interval, which includes the input argument, is shown to be the key operation in the algorithm. A hardware implementation which makes extensive use of read/write memories is used to illustrate the algorithm.

O'Grady, E. Pearse↗

MIDAS, prototype Multivariate Interactive Digital Analysis System for large area earth resources surveys. Volume 1: System description

A third-generation, fast, low cost, multispectral recognition system (MIDAS) able to keep pace with the large quantity and high rates of data acquisition from large regions with present and projected sensots is described. The program can process a complete ERTS frame in forty seconds and provide a color map of sixteen constituent categories in a few minutes. A principle objective of the MIDAS program is to provide a system well interfaced with the human operator and thus to obtain large overall reductions in turn-around time and significant gains in throughput. The hardware and software generated in the overall program is described. The system contains a midi-computer to control the various high speed processing elements in the data path, a preprocessor to condition data, and a classifier which implements an all digital prototype multivariate Gaussian maximum likelihood or a Bayesian decision algorithm. Sufficient software was developed to perform signature extraction, control the preprocessor, compute classifier coefficients, control the classifier operation, operate the color display and printer, and diagnose operation.

Christenson, D.↗

Study of the modifications needed for efficient operation of NASTRAN on the Control Data Corporation STAR-100 computer

NASA structural analysis (NASTRAN) computer program is operational on three series of third generation computers. The problem and difficulties involved in adapting NASTRAN to a fourth generation computer, namely, the Control Data STAR-100, are discussed. The salient features which distinguish Control Data STAR-100 from third generation computers are hardware vector processing capability and virtual memory. A feasible method is presented for transferring NASTRAN to Control Data STAR-100 system while retaining much of the machine-independent code. Basic matrix operations are noted for optimization for vector processing.

Source record↗

Modular biowaste monitoring system

The objective of the Modular Biowaste Monitoring System Program was to generate and evaluate hardware for supporting shuttle life science experimental and diagnostic programs. An initial conceptual design effort established requirements and defined an overall modular system for the collection, measurement, sampling and storage of urine and feces biowastes. This conceptual design effort was followed by the design, fabrication and performance evaluation of a flight prototype model urine collection, volume measurement and sampling capability. No operational or performance deficiencies were uncovered as a result of the performance evaluation tests.

Fogal, G. L.↗

Practical implementation of an accurate method for multilevel design sensitivity analysis

Solution techniques for handling large scale engineering optimization problems are reviewed. Potentials for practical applications as well as their limited capabilities are discussed. A new solution algorithm for design sensitivity is proposed. The algorithm is based upon the multilevel substructuring concept to be coupled with the adjoint method of sensitivity analysis. There are no approximations involved in the present algorithm except the usual approximations introduced due to the discretization of the finite element model. Results from the six- and thirty-bar planar truss problems show that the proposed multilevel scheme for sensitivity analysis is more effective (in terms of computer incore memory and the total CPU time) than a conventional (one level) scheme even on small problems. The new algorithm is expected to perform better for larger problems and its applications on the new generation of computer hardwares with 'parallel processing' capability is very promising.

Nguyen, Duc T.↗

On-orbit coldwelding: Fact or friction?

A study into the potential of on-orbit coldwelding occurring was completed. No instances of cold welding were found during deintegration and subsequent testing and analysis of LDEF hardware. This finding generated wide interest and indicated the need to review previous on-orbit coldwelding experiments and on-orbit spacecraft anomalies to determine whether the absence of coldwelding on LDEF was to be expected. Results show that even though there have been no documented cases of significant on-orbit coldwelding events occurring, precautions should be taken to ensure that neither coldwelding nor galling occurs in the space or prelaunch environment.

Dursch, Harry↗

Interactive boundary delineation of agricultural lands using graphics workstations

A review is presented of the computer-assisted stratification and sampling (CASS) system developed to delineate the boundaries of sample units for survey procedures. CASS stratifies the sampling units by land-cover and land-use type, employing image-processing software and hardware. This procedure generates coverage areas and the boundaries of stratified sampling units that are utilized for subsequent sampling procedures from which agricultural statistics are developed.

Cheng, Thomas D.↗

The Physics of Hard Spheres Experiment on MSL-1: Required Measurements and Instrument Performance

The Physics of HArd Spheres Experiment (PHaSE), one of NASA Lewis Research Center's first major light scattering experiments for microgravity research on complex fluids, flew on board the Space Shuttle's Microgravity Science Laboratory (MSL-1) in 1997. Using colloidal systems of various concentrations of micron-sized plastic spheres in a refractive index-matching fluid as test samples, illuminated by laser light during and after crystallization, investigations were conducted to measure the nucleation and growth rate of colloidal crystals as well as the structure, rheology, and dynamics of the equilibrium crystal. Together, these measurements support an enhanced understanding of the nature of the liquid-to-solid transition. Achievement of the science objectives required an accurate experimental determination of eight fundamental properties for the hard sphere colloidal samples. The instrument design met almost all of the original measurement requirements, but with compromise on the number of samples on which data were taken. The instrument performs 2-D Bragg and low angle scattering from 0.4 deg. to 60 deg., dynamic and single-channel static scattering from 10 deg. to 170 deg., rheology using fiber optics, and white light imaging of the sample. As a result, PHaSE provided a timely microgravity demonstration of critical light scattering measurement techniques and hardware concepts, while generating data already showing promise of interesting new scientific findings in the field of condensed matter physics.

Doherty, Michael P.↗

Computational Performance of Progressive Damage Analysis of Composite Laminates using Abaqus/Explicit with 16 to 512 CPU Cores

The computational scaling performance of progressive damage analysis using Abaqus/ Explicit is evaluated and quantified using from 16 to 512 CPU cores. Several analyses were conducted on varying numbers of cores to determine the scalability of the code on five NASA high performance computing systems. Two finite element models representative of typical models used for progressive damage analysis of composite laminates were used. The results indicate a 10 to 15 times speed up scaling from 24 to 512 cores. The run times were modestly reduced with newer generations of CPU hardware. If the number of degrees of freedom is held constant with respect to the number of cores, the model size can be increased by a factor of 20, scaling from 16 to 512 cores, with the same run time. An empirical expression was derived relating run time, the number of cores, and the number of degrees of freedom. Analysis cost was examined in terms of software tokens and hardware utilization. Using additional cores reduces token usage since the computational performance increases more rapidly than the token requirement with increasing number of cores. The in- crease in hardware cost with increasing cores was found to be modest. Overall the results show relatively good scalability of the Abaqus/Explicit code on up to 512 cores.

Bergan, A. C.↗

Exploration Extravehicular Mobility Unit (xEMU) Pressure Garment System (PGS) Cycle Testing Overview and Results

With the development of NASA’s next generation spacesuit, the hardware life expectations for the new spacesuit required evaluation. The xPGS team designed and performed a test series to assess the new hardware against the life requirements. The EMU on the International Space Station (ISS) today tests the life of the suit and new components by performing isometric individual joint cycle motions with the requirements based on previously performed Extra-Vehicular Activities (EVAs). The xPGS includes new designs for suit components to provide increased mobility for performance of lunar operations, thus the requirements for the life cycle of the suit had to be developed and tested with these new operations in mind. Cycle requirements shifted to cycles of functional tasks in lieu of isometric cycles to better understand the life of the suit. Manned cycle testing of the xPGS was conducted by performing repetitions of a series of tasks that reflect predicted Lunar EVA operations. The test series utilized a gravity offload system to simulate Lunar gravity environment. Cycle testing concluded after 30 test days in October of 2022 with lessons learned that will be critical for future spacesuit design. Specific lessons learned with regards to suit performance and test methodology will be provided.

spacesuit↗

Generating Real-Time Robotics Control Software from SysML

In this paper, we outline an approach for autogenerating real-time robotics control code from hierarchical state machines and hardware configurations encoded in Systems Modeling Language (SysML). We propose a software architecture that provides an abstract SysML layer with access to device state information and a set of primitive device commands, such as move actuator and release brake, allowing a user to build up a complete functional state machine directly in SysML. The SysML diagram is then exported to a standard SCXML file format and subsequently used to auto-generate hardware control code. Once this architecture is in place, the only explicit code elements that need to be written are the primitive device commands, which can be easily unit tested and reused across different systems. The motivation for this work was the need for a test bed that enables the rapid prototyping of mechanisms and control algorithms for a spacecraft that could ultimately be used for preparing Martian rock samples for their return to Earth. To this end, our software system was also designed to allow for the run-time specification of the hardware layout in SysML, with the hardware-level control functions kept agnostic to the specific parameters or communication bus of any particular device. Further, we outline a system for specifying both the state machine and hardware configuration in the MagicDraw IDE in such a way that the system can be simulated before any code is generated. The resultant software system is easy to debug, understand, and allows users to choose how much information is encoded as a visual or text-based representation.

Godart, Peter↗

2nd & 3rd Generation Vehicle Subsystems

This paper contains viewgraph presentation on the "2nd & 3rd Generation Vehicle Subsystems" project. The objective behind this project is to design, develop and test advanced avionics, power systems, power control and distribution components and subsystems for insertion into a highly reliable and low-cost system for a Reusable Launch Vehicles (RLV). The project is divided into two sections: 3rd Generation Vehicle Subsystems and 2nd Generation Vehicle Subsystems. The following topics are discussed under the first section, 3rd Generation Vehicle Subsystems: supporting the NASA RLV program; high-performance guidance & control adaptation for future RLVs; Evolvable Hardware (EHW) for 3rd generation avionics description; Scaleable, Fault-tolerant Intelligent Network or X(trans)ducers (SFINIX); advance electric actuation devices and subsystem technology; hybrid power sources and regeneration technology for electric actuators; and intelligent internal thermal control. Topics discussed in the 2nd Generation Vehicle Subsystems program include: design, development and test of a robust, low-maintenance avionics with no active cooling requirements and autonomous rendezvous and docking systems; design and development of a low maintenance, high reliability, intelligent power systems (fuel cells and battery); and design of a low cost, low maintenance high horsepower actuation systems (actuators).

Source record↗

Advanced architectures and the required technologies for next-generation communications satellite systems

The hardware requirements for multibeam operation and onboard data processing and switching on future communication satellites are reviewed. Topics addressed include multiple-beam antennas, frequency-addressable beams, baseband vs IF switching, FDM/TDMA systems, and bulk demodulators. The proposed use of these technologies in the NASA ACTS, Italsat, and the Japanese ETS-VI is discussed in detail and illustrated with extensive diagrams, maps, drawings, and tables of projected performance data.

Arnold, Ray↗

PLOTTER: An independent computer program for the generation of graphical displays

A computer program is described for generating graphical information from input data or auxiliary analysis programs on a variety of graphical devices. Options are presented for tabulating the data in columnar format and for plotting auxiliary text in the vicinity of the plotted information. Display device selection is accomplished by interfacing the basic computer code through routines which convert the internally generated plot vectors to hardware commands for the display device. The plotting techniques employed in the computer program are discussed. User's instructions are presented with examples which illustrate the use of the program in generating plotted information from various sources and presenting the information in alternate plot formats. Technical discussion of the computer code is presented giving the physical characteristics, computer loading instructions and descriptions of the subroutines.

Glatt, C. R.↗

Environmental Control and Life Support Integration Strategy for 6-Crew Operations Stephanie Duchesne

The International Space Station (ISS) crew compliment has increased in size from 3 to 6 crew members . In order to support this increase in crew on ISS, the United States on-orbit Segment (USOS) has been outfitted with a suite of regenerative Environmental Control and Life Support (ECLS) hardware including an Oxygen Generation System(OGS), Waste and Hygiene Compartment (WHC), and a Water Recovery System (WRS). The WRS includes the Urine Processor Assembly (UPA) and the Water Processor Assembly (WPA). With this additional life support hardware, the ISS has achieved full redundancy in its on-orbit life support system between the USOS and Russian Segment (RS). The additional redundancy created by the Regenerative ECLS hardware creates the opportunity for independent support capabilities between segments, and for the first time since the start of ISS, the necessity to revise Life Support strategy agreements. Independent operating strategies coupled with the loss of the Space Shuttle supply and return capabilities in 2010 offer new and unique challenges. This paper will discuss the evolution of the ISS Life Support hardware strategy in support of 6-Crew on ISS, as well as the continued work that is necessary to ensure the support of crew and ISS Program objectives through the life of station.

Duchesne, Stephanie M.↗

Environmental Control and Life Support Integration Strategy for 6-Crew Operations

The International Space Station (ISS) crew complement has increased in size from 3 to 6 crew members. In order to support this increase in crew on ISS, the United States on-orbit Segment (USOS) has been outfitted with a suite of regenerative Environmental Control and Life Support (ECLS) hardware including an Oxygen Generation System (OGS), Waste and Hygiene Compartment (WHC), and a Water Recovery System (WRS). The WRS includes the Urine Processor Assembly (UPA) and the Water Processor Assembly (WPA). With this additional life support hardware, the ISS has achieved full redundancy in its on-orbit life support system between the t OS and Russian Segment (RS). The additional redundancy created by the Regenerative ECLS hardware creates the opportunity for independent support capabilities between segments, and for the first time since the start of ISS, the necessity to revise Life Support strategy agreements. Independent operating strategies coupled with the loss of the Space Shuttle supply and return capabilities in 2010 offer new and unique challenges. This paper will discuss the evolution of the ISS Life Support hardware strategy in support of 6-Crew on ISS, as well as the continued work that is necessary to ensure the support of crew and ISS Program objectives through the life of station

Duchesne, Stephanie M.↗