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This collaborative multi-year advanced engine technology project summarized in the report is to develop low mass and high efficiency medium-duty truck engine. The project was proposed as a large-scale engine design and demonstration enabled by an advanced materials and manufacturing development program, with a comprehensive plan spanning a period of four years (two phases).
As NASA moves beyond exploring low earth orbit and into deep space exploration, increased communication delays between astronauts and earth drive a need for crew to become more autonomous (earth-independent). Currently crew on board the International Space Station (ISS) have limited insight into specific vehicle system performance because of the dependency on monitoring and real-time communication with Mission Control. Wearable technology provides a method to bridge the gap between the human (astronaut) and the system (spacecraft) by providing mutual monitoring between the two. For example, vehicle or environmental information can be delivered to astronauts through on-body devices and in return wearables provide data to the spacecraft regarding crew health, location, etc. The Wearable Electronics and Applications Research (WEAR) Lab at the NASA Johnson Space Center utilizes a collaborative approach between engineering and human factors to investigate the use of wearables for spaceflight. Zero and partial gravity environments present unique challenges to wearables that require collaborative, user-centered, and iterative approaches to the problems. Examples of the WEAR Lab's recent wearable projects for spaceflight will be discussed.
As NASA moves beyond exploring low earth orbit and into deep space exploration, increased communication delays between astronauts and earth drive a need for crew to become more autonomous (earth-independent). Currently crew on board the International Space Station (ISS) have limited insight into specific vehicle system performance because of the dependency on monitoring and real-time communication with Mission Control. Wearable technology provides a method to bridge the gap between the human (astronaut) and the system (spacecraft) by providing mutual monitoring between the two. For example, vehicle or environmental information can be delivered to astronauts through on-body devices and in return wearables provide data to the spacecraft regarding crew health, location, etc. The Wearable Electronics and Applications Research (WEAR) Lab at the NASA Johnson Space Center utilizes a collaborative approach between engineering and human factors to investigate the use of wearables for spaceflight. Zero and partial gravity environments present unique challenges to wearables that require collaborative, user-centered, and iterative approaches to the problems. Examples of the WEAR Lab's recent wearable projects for spaceflight will be discussed.
The United States Department of Energy’s Spent Fuel and Waste Disposition (SFWD) program is investigating the design and safety function of generic nuclear geologic repositories in a variety of geologic settings (salt, argillite, and crystalline rock). Different configurations and loadings of spent nuclear fuel and waste within disposal canisters are also being investigated, some of which have the potential to generate repository temperatures higher than previously considered (i.e., temperatures >100ºC) by foreign and domestic concepts. This report expands on engineered barrier material stability in a high temperature crystalline rock repository through high temperature hydrothermal experiments. Experiments were designed to develop engineered barrier system (EBS) concepts in a hightemperature crystalline environment in 1) bentonite-Grimsel Granodiorite interactions, 2) bentonite-cement reactions, and 3) interaction between waste canister materials and bentonite. Experiment results are applied to understanding long-term repository performance in terms of radionuclide isolation. One hydrothermal experiment was completed in the rocking autoclaves at LANL in FY-20: IEBS-6 (Grimsel Granodiorite + Wyoming bentonite + cured ordinary Portland cement + Grimsel Granodiorite synthetic groundwater, 250ºC/150 bar, 8 weeks). Several other experiments were planned but were delayed due to the COVID-19 pause in laboratory work. In addition, some characterization of the reaction products of experiments conducted in FY-20 was prevented by COVID-19. Mineral phase chemistry was not measured via electron microprobe analyses for IEBS-6. Quantitative X-ray diffraction results from IEBS-6 and HBT-1 were not completed. The missing analyses and discussion of the results will be included in next year’s report. New characterization that was completed includes scanning electron microscopy of reaction products from IEBS-6, quantitative X-ray diffraction results are presented from IEBS-1 through IBES-5, preliminary scanning electron microscope images and chemical analyses for IEBS-6, X-ray diffraction of the clay fraction from all experiments, measurement/imaging of mineral growth on the surface of steel coupons. Major observations pertaining to bentonite stability in a Grimsel Granodiorite environment include the stability of Na-montmorillonite at 250°C, the formation of trace CSH phases, and the formation of bentonite colloids on experiment cooling. The addition of a cured chip of Portland cement to the bentonite-Grimsel system results in slightly higher pH values and the formation of diverse secondary mineral phases that were not observed in the previous experiments (e.g., analcime, garronite, CSH phases). The new characterization efforts related to the interaction of stainless-steel coupons and bentonite clay focused on thickness and mineralogy of phases that formed at the steel surface. In Wyoming bentonite + Grimsel Granodiorite systems, newly formed minerals at the bentonitesteel coupon interface included alteration of the outermost steel edge to Fe,Cr-oxide phases, followed by Fe-rich phyllosilicates (Fe-saponite, chlorite) and interbedded Fe,Cr,Ni-sulfide phases (pentlandite). Hydrothermal experiments were completed to assess uranium-carbonate complexation at conditions relevant to high-temperature disposal. Autoclave solubility experiments were conducted at 150 to 250ºC with a range of carbonate and uranium concentrations. The experiment results were characterized via situ UV-Visible spectroscopy and synchrotron-based in situ XAS techniques. Results show a significant decrease in the stability of uranyl-carbonate complexes at temperatures above 100ºC along with the precipitation of uranium oxides. Further, at T > 200ºC, results show that uranyl-hydroxyl complexes control solubility of uranium instead of the previously predicted uranyl-carbonate species. These results are significant for understanding the mobility of uranium in the EBS, which will likely contain carbonate-rich fluids. International research efforts focused on three main areas: 1) participation in international conferences, 2) building collaborations with foreign repository programs, and 3) the initiation of an experimental program to complement the full-scale HotBENT test at the Grimsel test site. This experiment included Wyoming bentonite + low carbon steel + Grimsel Granodiorite synthetic groundwater and was run at the planned maximum temperature of the HotBENT test (200°C). Complete characterization of reaction products was hindered by disruptions to laboratory work but will be reported in the next FY. The experimental results obtained in FY-20 continue to document the wide-ranging effects of bulk composition and pressure-temperature conditions in the mineralogical and geochemical evolution of a high-temperature repository environment. Concepts developed will be used to inform models of long-term material stability in a generic crystalline rock-hosted repository.
The JPL Innovation Foundry has established a new approach for exploring, developing, and evaluating early concepts called the A-Team. The A-Team combines innovative collaborative methods with subject matter expertise and analysis tools to help mature mission concepts. Science, implementation, and programmatic elements are all considered during an A-Team study. Methods are grouped by Concept Maturity Level (CML), from 1 through 3, including idea generation and capture (CML 1), initial feasibility assessment (CML 2), and trade space exploration (CML 3). Methods used for each CML are presented, and the key team roles are described from two points of view: innovative methods and technical expertise. A-Team roles for providing innovative methods include the facilitator, study lead, and assistant study lead. A-Team roles for providing technical expertise include the architect, lead systems engineer, and integration engineer. In addition to these key roles, each A-Team study is uniquely staffed to match the study topic and scope including subject matter experts, scientists, technologists, flight and instrument systems engineers, and program managers as needed. Advanced analysis and collaborative engineering tools (e.g. cost, science traceability, mission design, knowledge capture, study and analysis support infrastructure) are also under development for use in A-Team studies and will be discussed briefly. The A-Team facilities provide a constructive environment for innovative ideas from all aspects of mission formulation to eliminate isolated studies and come together early in the development cycle when they can provide the biggest impact. This paper provides an overview of the A-Team, its study processes, roles, methods, tools and facilities.
Littoral Power Systems, Inc. (LPS) is writing a new story when it comes to turning the natural power of water into electricity. h-Modulor™ is a new way of designing and building hydropower plants that addresses the crucial issues of cost, environmental impact and regulatory time frames. For decades hydropower developers, owners and operators have struggled to build new or expanded facilities that didn’t cost so much, were friendlier to the environment and didn’t take so much time to license or build. The problem is particularly acute in smaller installations. The burdensome regulatory pathway for projects under 10MW in capacity have eased the licensing requirements for small hydro projects. But in small projects are still very hard, because capital costs are a much larger percentage of the generation revenues than they are in large facilities. There is an acute need for a cost effective solution. Understanding this need and opportunity, LPS conceived a new type of hydropower equipment – a kit of standard, pre-fabricated modular parts for dam safety, power generation, spill control and other hydropower facility functions to be used to build and operate a hydro plant at substantially lower costs than are currently achievable. This system of prefabricated parts also showed promise to reduce environmental impacts, reduce engineering time involved in the licensing process, and possibly provide a new way for regulators to think about licensing that could lead to reduced regulatory timeframes. Because of this invention’s compelling and intriguing promise the Department of Energy’s (DOE) Water Power Technology Office (WPTO) awarded funding to LPS through the Office of Energy Efficiency and Renewable Energy (EERE) to develop this new type of hydropower equipment to meet a levelized cost of energy (LCOE) goal and analyze it for dam safety. LPS teamed with professional engineers, PhDs, and geotechnical consultants from GZA GeoEnvironental, Inc. (GZA), Alden Research Laboratory (Alden), University of Massachusetts – Dartmouth (UMass-D), the National Renewable Energy Laboratory (NREL) and AECOM. In collaboration with the engineers and managers at the WPTO and EERE they matured the concepts through substantial design shifts. The project exceeded the original goals and delivered designs beyond the proof-of-concept stage backed up by thorough professional engineering analysis of stability, seepage, and structural integrity. A full-scale section with seals successfully retained water in full-head leakage tests. Construction plans and professional engineering cost estimates indicated an LCOE half of the original LCOE goal. A system of these modules is now on track to be used in a 4.5 MW commercial installation.
In this work, an integrated and end-to-end modeling environment was developed to assess the system-level impacts of evolving requirements and design parameters. Researchers at the Georgia Institute of Technology's Aerospace Systems Design Laboratory (ASDL) collaborated with JPL engineers to develop, implement, and test a modeling environment to assess design changes to a notional Europa Mission called the Jupiter Europa Buzzer (JEB). This environment was developed using a Model-Based Systems Engineering (MBSE) approach and consists of three major components: the Systems Model, the Mission Simulator, and the Web Based Interactive Dashboard. In summary, utilizing this environment in a representative notional end-to-end scenario, performance margins were calculated in hours while maintaining consistent analytical, hardware, and operational assumptions.
In this paper, we sketch a framework for interdisciplinary modeling of space systems, by proposing a holistic view. We consider different system dimensions and their interaction. Specifically, we study the interactions between computation, physics, communication, uncertainty and autonomy. The most comprehensive computational paradigm that supports a holistic perspective on autonomous space systems is given by cyber-physical systems. For these, the state of art consists of collaborating multi-engineering efforts that prompt for an adequate formal foundation. To achieve this, we propose a leveraging of the traditional content of formal modeling by a co-engineering process.
As aerospace missions grow larger and more technically complex in the face of ever tighter budgets, it will become increasingly important to use concurrent engineering methods in the development of early conceptual designs because of their ability to facilitate rapid assessments and trades in a cost-efficient manner. To successfully accomplish these complex missions with limited funding, it is also essential to effectively leverage the strengths of individuals and teams across government, industry, academia, and international agencies by increased cooperation between organizations. As a result, the existing concurrent engineering teams will need to increasingly engage in distributed collaborative concurrent design. This paper is an extension of a recent white paper written by the Concurrent Engineering Working Group, which details the unique challenges of distributed collaborative concurrent engineering. This paper includes a short history of aerospace concurrent engineering, and defines the terms 'concurrent', 'collaborative' and 'distributed' in the context of aerospace concurrent engineering. In addition, a model for the levels of complexity of concurrent engineering teams is presented to provide a way to conceptualize information and data flow within these types of teams.
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Sand ingestion continues to impact combat ground and air vehicles in military operations in the Middle East. The T-700 engine used in Apache and Blackhawk helicopters has been subjected to increased overhauls due to sand and dust ingestion during desert operations. Engine component wear includes compressor and turbine blades/vanes resulting in decreased engine power and efficiency. Engine labyrinth seals have also been subjected to sand and dust erosion resulting in tooth tip wear, increased clearances, and loss in efficiency. For the current investigation, a brief overview is given of the history of the T-700 engine development with respect to sand and dust ingestion requirements. The operational condition of labyrinth seals taken out of service from 4 different locations of the T-700 engine during engine overhauls are examined. Collaborative efforts between the Army and NASA to improve turbine engine seal leakage and life capability are currently focused on noncontacting, low leakage, compliant designs. These new concepts should be evaluated for their tolerance to sand laden air. Future R&D efforts to improve seal erosion resistance and operation in desert environments are recommended
The NASA Ames Mission Design Center (MDC) has undergone a significant transformation process in recent years, culminating in becoming a true Concurrent Engineering Center. The underlying goal of this transformation is to better serve the Ames PI community in a cost-effective and rapidly-responsive way, providing quality products pivotal to the decision-making proposal strategy of our center. The four pillars of the change focus on four areas: personnel, physical places, tools, and training. Personnel: the MDC switched from using a dedicated pool of engineers—mostly entry-level career—for a matrixed approach with more experienced Subject Matter Experts, usually involved in spaceflight projects. These SMEs get detailed to the MDC for the duration of the study on a part-time or full-time basis. Physical places: The physical aspect pertains mostly to the layout of the new Engineering building and the dedicated concurrent engineering layout to foster collaboration. The current plan includes a dedicated space for concurrent engineering sessions as well as dedicated project rooms for concept studies. Tool: the MDC team is developing a new in-house concurrent engineering tool to facilitate concurrent engineering sessions. The team leveraged the many lessons learned and insight gained from using the current concurrent engineering tool, in use since 2007. SMEs have been involved throughout its design and development, ensuring accuracy and providing validity to the implementation approach. This new tool is database-driven and allows a team to work concurrently on the same model of a mission concept. “Workspaces” are provided for each of the traditional spacecraft mission design disciplines, including cost accounting and systems engineering. There are multiple tiers of fidelity available within each workspace, which can be completed parametrically or independently from the other disciplines as needed or synchronously with the other disciplines. A “commit” step synchronizes a workspace with the mission database and identifies any potential conflicts, along with the user who entered the conflicting data. A Mission Summary workspace enables a Study Lead to run an effective CE session, displaying key graphics, workspace status information, and technical and monetary budget information. This new CE tool will be undergoing Beta Testing with its primary user base and a limited Parts database in the summer of 2020. The team plans to release the first fully operational version in December 2020. Training: working in early concept development and maturation for a space mission requires a unique mindset and being comfortable with uncertainties in an environment where requirements are not yet fully developed, and where changes and trade-offs happen at a high tempo. The MDC started a weekly training program to ensure a common knowledge base on how do develop and mature early concept studies, as well as how to operate in a concurrent engineering environment. In conclusion, the MDC transformation will provide the overall PI community focused on cost-effective small satellite scientific missions with a powerful tool to address and mature early concepts more effectively and efficiently.
The National Aeronautics and Space Administration (NASA) has launched a range of KM activities-from deploying intelligent "know-bots" across millions of electronic sources to ensuring tacit knowledge is transferred across generations. The strategy and implementation focuses on managing NASA's wealth of explicit knowledge, enabling remote collaboration for international teams, and enhancing capture of the key knowledge of the workforce. An in-depth view of the work being done at the Jet Propulsion Laboratory (JPL) shows the integration of academic studies and practical applications to architect, develop, and deploy KM systems in the areas of document management, electronic archives, information lifecycles, authoring environments, enterprise information portals, search engines, experts directories, collaborative tools, and in-process decision capture. These systems, together, comprise JPL's architecture to capture, organize, store, and distribute key learnings for the U.S. exploration of space.
The Upper Stage (US) section of the National Aeronautics and Space Administration's (NASA) Ares I rocket will require internal access platforms for maintenance tasks performed by humans inside the vehicle. Tasks will occur during expensive critical path operations at Kennedy Space Center (KSC) including vehicle stacking and launch preparation activities. Platforms must be translated through a small human access hatch, installed in an enclosed worksite environment, support the weight of ground operators and be removed before flight - and their design must minimize additional vehicle mass at attachment points. This paper describes the application of a user-centered conceptual design process and the unique challenges encountered within NASA's systems engineering culture focused on requirements and "heritage hardware". The NASA design team at Marshall Space Flight Center (MSFC) initiated the user-centered design process by studying heritage internal access kits and proposing new design concepts during brainstorming sessions. Simultaneously, they partnered with the Technology Transfer/Innovative Partnerships Program to research inflatable structures and dynamic scaffolding solutions that could enable ground operator access. While this creative, technology-oriented exploration was encouraged by upper management, some design stakeholders consistently opposed ideas utilizing novel, untested equipment. Subsequent collaboration with an engineering consulting firm improved the technical credibility of several options, however, there was continued resistance from team members focused on meeting system requirements with pre-certified hardware. After a six-month idea-generating phase, an intensive six-week effort produced viable design concepts that justified additional vehicle mass while optimizing the human factors of platform installation and use. Although these selected final concepts closely resemble heritage internal access platforms, challenges from the application of the user-centered process provided valuable lessons for improving future collaborative conceptual design efforts.
SiC-SiC ceramic matrix composites (CMCs) manufactured by the slurry -cast melt-infiltration (MI) process are leading candidates for many hot-section turbine engine components. A collaborative program between Goodrich Corporation and NASA-Glenn Research Center is aimed at determining and optimizing woven SiC/SiC CMC performance and reliability. A variety of composites with different fiber types, interphases and matrix compositions have been fabricated and evaluated. Particular focus of this program is on the development of interphase systems that will result in improved intermediate temperature stressed-oxidation properties of this composite system. The effect of the different composite variations on composite properties is discussed and, where appropriate, comparisons made to properties that have been generated under NASA's Ultra Efficient Engine Technology (UEET) Program.
Pacific Northwest National Laboratory (PNNL) and the Pacific Northwest Site Office (PNSO) have recently completed an effort to identify the current state of the campus and gaps that exist with regards to space needs, facilities and infrastructure. This effort has been used to establish a campus strategy to ensure PNNL is ready to further the United States (U.S.) Department of Energy (DOE) mission. Ten-year business projections and the impacts on space needs were assessed and incorporated into the long-term facility plans. In identifying/quantifying the space needs for PNNL, the following categories were addressed: Multi-purpose Programmatic (wet chemistry and imaging laboratory space), Strategic (Systems Engineering and Computation Analytics, and Collaboration space), Remediation (space to offset the loss of the Research Technology Laboratory [RTL] Complex due to decontamination and demolition), and Optimization (the exit of older and less cost-effective facilities). The findings of the space assessment indicate a need for wet chemistry space, imaging space, and strategic space needs associated with systems engineering and collaboration space.
The Advanced Subsonic Combustion Rig (ASCR), a unique, state-of-the-art facility for conducting combustion research, is located at the NASA Lewis Research Center in Cleveland, Ohio. The ASCR, which was nearing completion at the close of 1995, will be capable of simulating the very high pressure and high temperature conditions that are expected to exist in future, advanced subsonic gas turbine (jet) engines. Future environmental regulations will require much cleaner burning (more environmentally friendly) aircraft engines. The ASCR is critical to the development of these cleaner engines. It will allow NASA and U.S. aircraft engine industry researchers to identify and test promising clean-burning gas turbine engine combustion concepts under the pressure and temperature conditions that are expected for those future engines. Combustion processes will be investigated for a variety of next-generation aircraft engine sizes, including engines for large, long-range aircraft (with typical trip lengths of about 3000 mi) and for regional aircraft (with typical trip lengths of about 400 mi). The ASCR design was conceived and initiated in 1993, and fabrication and construction of the rig, including the buildup of an advanced control room, took place throughout 1994 and 1995. In early 1996, the ASCR will be operational for obtaining research data. The ASCR is an intricate part of the NASA Advanced Subsonic Technology Propulsion Program, which is aimed at developing technologies critical to the next generation of gas turbine engines. This effort is in collaboration with the U.S. aircraft gas turbine engine industry. A goal of the Advanced Subsonic Technology Propulsion Program is to develop combustion concepts and technologies that will result in gas turbine engines that produce 50 percent less nitrous oxide (NO_x) pollutants than current engines do. This facility is unique in its capability to simulate advanced subsonic engine pressure, temperature, and air flow rate conditions. Specifically, it will provide operating temperatures up to 3000 F and pressures up to 60 atm. Under these conditions, researchers will obtain detailed combustion temperatures, pressures, and flow velocities as well as the chemical compositions of the combustion exhaust. Researchers also will be able to obtain data by using nonintrusive laser diagnostic techniques. The ASCR facility will be used to test fundamental combustion configurations (flametubes) for detailed study of combustion processes, to test sectors of gas turbine combustors to study the process in configurations more like those of aircraft engines, and in some cases to test full annular combustors.