Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “MOTOR CASE”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Ares I and Ares V First Stage - Powering Exploration

The National Aeronautics and Space Administration (NASA) Ares Projects Office (APO) is continuing to make progress toward the final design of the first stage propulsion system for the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Ares I and Ares V will provide the space launch capabilities needed to fulfill NASA' s exploration strategy of sending human beings to the Moon, Mars, and beyond. As primary propulsion for the Ares launch vehicles, the Space Shuttle-derived Reusable Solid Rocket Motor (RSRM) is one of the first and most important components to be tested. The first flight of Ares I, called Ares I-X, will occur in April 2009, with booster integration to begin at Kennedy Space Center (KSC) by autumn 2008. The Ares I-X flight will use a combination of flight and simulation hardware to obtain data on controlling the long and narrow crew launch vehicle configuration. The test will use a four-segment RSRM from the Shuttle inventory and a fifth spacer segment to simulate the size and weight of the operational five-segment motor to be used on later flights. The upper stage, Orion crew exploration vehicle, and launch abort system will all be replaced with simulator hardware. Manufacturing work has begun on the spacer segment, as well as the new forward hardware for the booster. Atlas V avionics will be adapted to control Ares I-X' s first stage. That hardware is undergoing hardware-in-the-loop testing in a contractor-provided systems integration laboratory (SIL); a critical design review (CDR) was completed in December 2007. Drogue and main parachute drop tests have also been conducted successfully at Yuma Proving Grounds, allowing the First Stage team to begin fabricating parachutes for Ares I-X. The Ares I-X flight test will be the first flight test for the parachutes. A series of preliminary design technical interchange meetings is being conducted prior to the Ares I-X CDR in January 2007 to ensure readiness for the flight. Much of the First Stage activity in 2007 has focused on a series of preliminary design (PDR) activities associated with each booster subsystem. These events will culminate in a formal preliminary design review in 2008, where subsystems and component specifications will be developed and associated analyses and drawings will be evaluated for technical adequacy. The first stage also has been undergoing a series of trade studies to determine means for upgrading booster performance and reducing operational costs. Performance improvement studies have included changing from polybutadiene acrylonitrile (PBAN) propellant to hydroxyl-terminated polybutadiene (HTPB); replacing aluminum with composite motor casings; and optimizing or upgrading the propellant grain and nozzle structures. Some or all of these changes could result in a block upgrade to the Ares I first stage, after becoming the standard configuration for the Ares V. The cost reduction studies included a change from reusable or recoverable boosters to completely expendable boosters; changing from hydrazine-powered to more environmentally friendly electrohydrostatic actuators (EHAs) on the thrust vector control (TVC) system; and changing the location of the separation plane to reduce the likelihood of recontact upon booster separation. The expendability trade study resulted in a decision to keep the recoverable boosters, as the new hardware costs significantly outweighed the potential operational cost savings due to reduced ground operations. Likewise, due to cost considerations, the team continued using existing hydrazine-powered actuators for the TVC system. The separation plane location for Ares I is still being studied, with results to be announced in 2008. In short, the Ares launch vehicles' first stage is building upon NASA's close familiarity with this Shuttle-derived system, while continuing to seek out improvements for long-term exploration.

Priskos, Alex S.↗
NASA NTRS2009

Fan Performance Testing and Oxygen Compatibility Assessment Results for Future Space Suit Life Support Systems

An advanced portable life support system (PLSS) for the space suit will require a small, robust, and energyefficient system to transport the ventilation gas through the space suit for lunar Extravehicular Activity (EVA) operations. A trade study identified and compared ventilation transport technologies in commercial, military, and space applications to determine which technologies could be adapted for EVA use. Based on the trade study results, five commercially available, 24-volt fans were selected for performance testing at various pressures and flow rates. Measured fan parameters included fan delta-pressures, input voltages, input electrical currents, and in some cases motor windings electrical voltages and currents. In addition, a follow-on trade study was performed to identify oxygen compatibility issues and assess their impact on fan design. This paper outlines the results of the fan performance characterization testing, as well as the results from the oxygen compatibility assessment.

Paul, Heather L.↗
NASA NTRSDate not supplied

A Multi-Disciplinary Analysis Framework for the Design of Small Launch Vehicles

Between the years of 1995 and 2014 the number of small satellites (1-500 kg) went up from 20 to 180. [1] Out of the 180 launched in 2014 66% were Nano satellites (1-10 kg). [1] With this trend of smaller satellites, one would expect a rise in number of small launch vehicles (SLVs are defined by capability to carry 1-100 kg to orbit), but this has not happened: [3] only 8% of all small satellites are launched on SLVs and the others become secondary payloads on regular launch vehicles. [1] This results in small satellites being placed into either suboptimal orbits or waiting for launch schedules to align with bigger launches, resulting in long waiting times. Dedicated SLVs could improve the responsiveness of small satellite launches, but SLV design is complicated by the large architecture space needed to be explored in order to find efficient and affordable designs. The SLV architecture trade space contains many discrete options, e.g. solid vs. liquid fuels, air launch vs. ground launch, number of stages, etc. [2][3] Performing detailed analysis for all the options at once would be prohibitive. Thus, a sizing environment/framework that is capable of providing necessary information for conceptual-level trade studies and can rapidly explore the vast SLV architecture space is necessary. The framework, illustrated in Figure 1, consists of four disciplines central to the sizing and synthesis of launch vehicles: propulsion, aerodynamics, structures, and trajectory. For the aerodynamics and trajectory disciplines, Missile DATCOM and POST2 are used, respectively. The propulsion and structures disciplines are represented in the framework with tools developed at ASDL Georgia Tech. For propulsion, the Solid Motor Analysis Code (SMAC) is a physics-based conceptual design tool for solid rocket motors. SMAC is capable of geometric burn simulation, ballistic analysis, and prediction of thrust performance. [4] For structures, Launch Vehicle Structural Analysis (LVSA) tool is a physics-based tool that focuses on structural dynamic analysis with sizing capability. These tools are integrated into the framework illustrated in Figure 1 with the corresponding connections described in Table 1. The process flow is as follows: first, SMAC sizes insulation and calculates maximum operating pressures for each vehicle stage. The MEOP and insulation thickness values from SMAC are fed to LVSA which then utilizes this information to size the motor casing. This creates a feedback loop between LVSA and SMAC that converges on the radius available for fuel, casing, and insulation thickness. Once the stage sizing is converged on SMAC creates an engine deck that is passed to POST2. Next, the data from SMAC and LVSA goes into Missile DATCOM which generates an aerodynamics database for POST2. Finally, POST2 performs a targeting optimization while maximizing the payload mass to orbit. Within the framework, POST2 is automated in order to be robust to a wide variety of possible designs by performing a Monte Carlo simulation over the initialization vector of the POST2 optimization variables. To demonstrate the capability of this framework, a sample problem of exploring the design space of an SLV capable of placing satellites into a low Earth orbit (inclination=47 deg, 196.5 by 211.3 nm) is used. This sample problem is a ground-launched SLV consisting of four in-line SRM stages. The multidisciplinary design analysis (MDA) environment is utilized to explore a design space consisting of 22 continuous and 12 discrete variables, shown by Table 1 by blocks 1,2,3. Running a full factorial design of experiments (DOE) would have been prohibitively expensive even with this reduced design space, thus a space filling design with 3,502 and then additional expansion of 2,602 cases was used. The first DOE consisted of 3,502 cases, and all of the variables were varied. These input variables are listed in blocks 1, 2, and 3 in Table 1. Most of the variables are propulsion related with stage lengths determining the delta-V split of the SLV. The expansion consisted of 2,602 cases, and the continuous variables were set to be equal to the most promising designs from the sizing of first DOE. For each set of continuous variables, the discrete variables (grain type, star points, and propellant) were to varied. The results of the DOE can be seen in Figure 2; each of the points in this plot represents a closed launch vehicle that reaches the targeted orbit. For each of the cases, there is information on flown trajectory, structural, and propulsion properties of the SLV. For example, Figure 3 shows changes in altitude and velocity with time for a particular case. The right side of Figure 3 clearly shows the coasting (slow decrease) and burning phases (sharp increase) of the SLV mission. LV mass is positively correlated with the optimized payload mass to orbit because heavier LVs carry more fuel and thus have more stored chemical energy. Furthermore, for any given payload mass to orbit, the most efficient design would result in the smallest LV. The results as visualized in Figure 2 shows this tradeoff, and the Pareto frontier of the efficient designs can be seen along the dotted line. Figure 2 can be divided into regions with the lowest mass vehicles corresponding to the minimum bound on radius, and the highest mass vehicles corresponding to the maximum bound on radius. Within a mass region, the discrete variables, such as propellant type and propellant grain arrangement, have the most effect on payload mass. This paper presents an MDA framework that can perform an automated physics-based sizing of SLV designs and a corresponding methodology to utilize the MDA to explore the design space of SLVs. The proposed methodology was applied to a perform a design space exploration for a four stage SLV. The outputs show the expected pareto frontier forming and provide detailed information about the SLV performance and staging. Using the produced data, it will be possible to select a set of pareto optimal designs that can then be further explored in subsequent design cycles. This demonstration shows that automated design space exploration should be used in the early phase design of future SLV concepts.

Nikita S Birbasov↗
NASA NTRS2022

A Damage Resistance Comparison of Wet-Wound IM7 and T1100 Carbon Fiber/Epoxy Cylinders

This technical report presents the results of a damage tolerance comparison of two wet-wound cylinders; one made with IM7 carbon fiber and the other with T1100 carbon fiber. Damage was inflicted on the cylinders in the form of impact and the resulting damage was assessed mainly by cross-sectional examination of the damage zone after impact. Due to financial restraints, no residual strength testing was performed in this study. The amount of fiber breakage was the response variable of interest since fiber breakage, rather than delaminations or other matrix damage, governs the burst strength of rocket motor cases. The results showed that the T1100 fiber may be slightly more damage resistant than the IM7 fiber.

A T Nettles↗
NASA NTRS2020

Simulation-Based Analysis and Prediction of Thrust Vector Servoelastic Coupling

A method of analysis and prediction of servoelastic coupling in launch vehicles is presented, surveying the discovery and subsequent resolution of a predicted servoelastic resonance phenomenon affecting the NASA Space Launch System launch vehicle at specific flight conditions. A physics-based linearized multibody mechanization of the governing equations is combined with first principles analysis to demonstrate that antisymmetric bending of the solid rocket motors leads to a reduction of equivalent viscous modal damping through coupling with the thrust vector control actuators. The sensitivity to parameters and the effects of the resonance phenomenon on flight control performance and stability are confirmed through extensive simulation verification in the time and frequency domain. A novel enhancement in model fidelity that accounts for Coriolis effects of fluid flow on bending within the solid rocket motor case and nozzle is shown to add sufficient damping to reduce the risk of adverse control-structure interaction.

Jeb S Orr↗
NASA NTRS1989

Conjugate (solid/fluid) computational fluid dynamics analysis of the space shuttle solid rocket motor nozzle/case and case field joints

Three-dimensional, conjugate (solid/fluid) heat transfer analyses of new designs of the Solid Rocket Motor (SRM) nozzle/case and case field joints are described. The main focus was to predict the consequences of multiple rips (or debonds) in the ambient cure adhesive packed between the nozzle/case joint surfaces and the bond line between the mating field joint surfaces. The models calculate the transient temperature responses of the various materials neighboring postulated flow/leakpaths into, past, and out from the nozzle/case primary O-ring cavity and case field capture O-ring cavity. These results were used to assess if the design was failsafe (i.e., no potential O-ring erosion) and reusable (i.e., no excessive steel temperatures). The models are adaptions and extensions of the general purpose PHOENICS fluid dynamics code. A non-orthogonal coordinate system was employed and 11,592 control cells for the nozzle/case and 20,088 for the case field joints are used with non-uniform distribution. Physical properties of both fluid and solids are temperature dependent. A number of parametric studies were run for both joints with results showing temperature limits for reuse for the steel case on the nozzle joint being exceeded while the steel case temperatures for the field joint were not. O-ring temperatures for the nozzle joint predicted erosion while for the field joint they did not.

Doran, D.↗
NASA NTRS1993

Lightning tests and analyses of tunnel bond straps and shielded cables on the Space Shuttle solid rocket booster

The purposes of the tests and analyses described in this report are as follows: (1) determine the lightning current survivability of five alternative changed designs of the bond straps which electrically bond the solid rocket booster (SRB) systems tunnel to the solid rocket motor (SRM) case; (2) determine the amount of reduction in induced voltages on operational flight (OF) tunnel cables obtained by a modified design of tunnel bond straps (both tunnel cover-to-cover and cover-to-motor case); (3) determine the contribution of coupling to the OF tunnel cables by ground electrical and instrumentation (GEI) cables which enter the systems tunnel from unshielded areas on the surfaces of the motor case; and (4) develop a model (based on test data) and calculate the voltage levels at electronic 'black boxes' connected to the OF cables that run in the systems tunnel.

Druen, William M.↗
NASA NTRS1990

Qualification of the RSRM case membrane case-to-insulation bondline inspection using the Thiokol Corporation ultrasonic RSRM bondline inspection system

Qualification testing of Combustion Engineering's AMDATA Intraspect/98 Data Acquisition and Imaging System that applies to the redesigned solid rocket motor (RSRM) case membrane case-to-insulation bondline inspection was performed. Testing was performed at M-67, the Thiokol Corp. RSRM Assembly Facility. The purpose of the inspection was to verify the integrity of the case membrane case-to-insulation bondline. The case membrane scanner was calibrated on the redesigned solid rocket motor case segment calibration standard, which had an intentional 1.0 by 1.0 in. case-to-insulation unbond. The case membrane scanner was then used to scan a 20 by 20 in. membrane area of the case segment. Calibration of the scanner was then rechecked on the calibration standard to ensure that the calibration settings did not change during the case membrane scan. This procedure was successfully performed five times to qualify the unbond detection capability of the case membrane scanner.

Cook, M.↗
NASA NTRS1988

Lightweight structural design of a bolted case joint for the Space Shuttle Solid Rocket Motor

This paper presents the structural design of a bolted joint with a static face seal which can be used to join Space Shuttle Solid Rocket Motor (SRM) case segments. Results from numerous finite element parametric studies indicate that the bolted joint meets the design requirement of preventing joint opening at the O-ring locations during SRM pressurization. A final design recommended for further development has the following parameters: 180 1-inch-diameter studs, stud center line offset of .5 inches radially inward from the shell wall center line, flange thickness of 0.75 inches, bearing plate thickness of 0.25 inches, studs prestressed to 70 percent of ultimate load, and the intermediate alcove. The design has a mass penalty of 1096 lbm, which is 164 lbm greater than the currently proposed capture tang redesign.

Dorsey, John T.↗
NASA NTRS1988

Lightweight structural design of a bolted case joint for the space shuttle solid rocket motor

The structural design of a bolted joint with a static face seal which can be used to join Space Shuttle Solid Rocket Motor (SRM) case segments is given. Results from numerous finite element parametric studies indicate that the bolted joint meets the design requirement of preventing joint opening at the O-ring locations during SRM pressurization. A final design recommended for further development has the following parameters: 180 one-in.-diam. studs, stud centerline offset of 0.5 in radially inward from the shell wall center line, flange thickness of 0.75 in, bearing plate thickness of 0.25 in, studs prestressed to 70 percent of ultimate load, and the intermediate alcove. The design has a mass penalty of 1096 lbm, which is 164 lbm greater than the currently proposed capture tang redesign.

Dorsey, John T.↗
NASA NTRS1989

Small Displacement, Long Life On-Orbit Compressor Design and Fabrication

The focus is the generation of technology and fabrication of prototype hardware applicable to seven Space Station compressor system applications. The compressors are of the single acting reciprocating piston type and, in general, may be termed miniature in size compared with normal commercially available equipment. The initial technology development is focused on improved valve designs, and the control of pulsations and heating effects in order to increase compressor efficiency and reduce cycle temperatures, thus permitting significantly increased stage pressure ratios. The initial test compressor was successfully operated at pressure ratios of up to 50:1, and this significant extension of allowable pressure ratio will result in a reduction of the number of required stages and, hence, total hardware thereby reducing system weight and volume. These experiments have also identified the need to employ low shaft speeds, on the order of 250 to 500 rpm, to enhance heat transfer and increase life. The prototype compressor currently being designed, is to be driven by a low-speed brushless dc motor sealed in a case common to the compressor drive mechanism case. The compressor and motor case will communicate with stage suction pressure so that any minor gas leakage past the piston rings will be returned to the suction. Emphasis in this prototype design is being placed on simplicity, durability, commonality of components, and high efficiency.

Gerlach, C. R.↗
NASA NTRS2017

Elastomeric Thermal Insulation Design Considerations in Long, Aluminized Solid Rocket Motors

An all-new sounding rocket was designed at NASA's Marshall Space Flight Center that featured an aft finocyl, aluminized solid propellant grain and silica-filled ethylene-propylene-diene monomer (SFEPDM) internal insulation. Upon the initial static firing of the first of this new design, the solid rocket motor (SRM) case failed thermally just upstream of the aft closure early in the burn time. Subsequent fluid modeling indicated that the high-velocity combustion-product jets emanating from the fin-slots in the propellant grain were likely inducing a strongly swirling flow, thus substantially increasing the severity of the convective environment on the exposed portion of the SFEPDM insulation in this region. The aft portion of the fin-slots in another of the motors were filled with propellant to eliminate the possibility of both direct jet impingement on the exposed SFEPDM and the appearance of strongly swirling flow in the aft region of the motor. When static-fired, this motor's case still failed in the same axial location, and, though somewhat later than for the first static firing, still in less than 1/3rd of the desired burn duration. These results indicate that the extreme material decomposition rates of the SFEPDM in this application are not due to gas-phase convection or shear but rather to interactions with burning aluminum or alumina slag. Further comparisons with between SFEPDM performance in this design and that in other hot-fire tests provide insight into the mechanisms of SFEPDM decomposition in SRM aft domes that can guide the upcoming redesign effort, as well as other future SRM designs. These data also highlight the current limitations of modeling elastomeric insulators solely with diffusion-controlled, gas-phase thermochemistry in SRM regions with significant viscous shear and/or condense-phase impingement or flow.

Martin, Heath T.↗
NASA NTRS1988

Simulated impact damage in a thick graphite/epoxy laminate using spherical indenters

A study was made to determine the extent of fiber damage caused by low-velocity impact of spherical impactors to a very thick graphite/epoxy laminate. The laminate was cut from a filament wound case being developed for the Space Shuttle solid rocket motors. The case was wound using a wet process with AS4W graphite fiber and HBRF-55A epoxy. Impacts were simulated under quasi-static conditions by pressing hemispherically shaped indenters against the laminate at different locations. The contact force and indenter diameter were varied from location to location. The forces were chosen for each indenter diameter to produce contact pressures below and above that required to initiate damage. After the forces were applied, the laminate was cut into smaller pieces so that each piece contained a test site. The pieces were then deplied and the individual plies examined to determine the extent of fiber damage. Broken fibers were found in the outer layers directly beneath the contact site. The locus of broken fibers in each layer resembled a crack normal to the direction of the fibers. The maximum length and depth of the cracks increased with increasing contact pressure and indenter diameter. The internal stresses in the laminate were calculated using Hertz's law and Love's solution for pressure applied on part of the boundary of a semi-infinite body. The maximum length and depth of the cracks were predicted using a maximum shear stress criterion. Predictions and measurements were in good agreement.

Poe, C. C., Jr.↗
NASA NTRS1989

Generic system components of the Thiokol ultrasonic RSRM case-to-insulation bondline inspection system

Qualification testing of the Ultrasonic Redesigned Solid Rocket Motor Bondline Inspection Systems (URBIS) was conducted at the Thiokol Nondestructive Evaluation Test Facility M337A and at the Rotation Process Storage Facility at Kennedy Space Center. The test was performed on portions of the URBIS that are generic to redesigned solid rocket motor case-to-insulation bondline inspections. Testing began on Feb. 13, 1989 and was completed on May 26, 1989. The main purpose of the test was to verify that each URBIS performed to the manufacturer's specifications in the same manner and to make any procedural changes necessary for specific redesigned solid rocket motor inspections. All five URBISs passed every stage of the qualification test. Each URBIS is now qualified for use on redesigned solid rocket motors. Verifying the fact that each URBIS obtains and analyzes data in a similar fashion has eliminated concerns about variations in data between the five systems. The following recommendations were made as a result of this test: (1) each URBIS should be located within a stable environment; (2) an electronic preventative maintenance program should be established for each URBIS; (3) when the URBIS is being utilized to perform transducer analysis, the URBIS equipment setting should match the equipment setting noted on the manufacturer-supplied transducer certification sheet; and (4) optimum scan velocities for each inspection technique (clevis, capture feature, pinhole and membrane) should be determined through further testing.

Cook, M.↗
NASA NTRS1992

ASRM case insulation design and development

This paper describes the achievements made on the Advanced Solid Rocket Motor (ASRM) case insulation design and development program. The ASRM case insulation system described herein protects the metal case and joints from direct radiation and hot gas impingement. Critical failure of solid rocket systems is often traceable to failure of the insulation design. The wide ranging accomplishments included the development of a nonasbestos insulation material for ASRM that replaced the existing Redesigned Solid Rocket Motor (RSRM) asbestos-filled nitrile butadiene rubber (NBR) along with a performance gain of 300 pounds, and improved reliability of all the insulation joint designs, i.e., segmented case joint, case-to-nozzle and case-to-igniter joint. The insulation process development program included the internal stripwinding process. This process advancement allowed Aerojet to match to exceed the capability of other propulsion companies.

Bell, Matthew S.↗