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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2010

Space Shuttle Main Engine Turbopump Bearing Testing at Marshall Space Flight Center

The Space Shuttle has three main engines that are used for lift off into orbit. These engines are fed propellants by low and high pressure turbopumps on each engine. A main element of the pumps are the bearings supporting the main shaft that spins the turbine and pumps. These bearings must spin at high speeds, support the radial and axial thrust loads, and have high wear resistance without the benefit of lubrication. This paper describes the bearing testing that was done at the Marshall Space Flight Center and the results that were obtained to provide the best bearing design possible for safe and reliable engine performance.

Gibson, Howard↗
NASA NTRS2019

How Certain Physical Considerations Impact Aerostructural Wing Optimization

Wing design optimization has been studied extensively and is of continued interest as optimization tools are developed and become more accessible. In each of these studies, certain assumptions and simplifications are made to make the design problem tractable. However, it is difficult to find systematic studies in which several considerations are added or removed one at a time to study how much impact they have. In this work, we examine how certain physical considerations (viscous drag, wave drag, thrust loads, and inertial relief from structural, fuel, and engine masses), impact the aerostructural optimization results for three distinct aircraft wings. The goal is to help develop a rough idea of how important these physical considerations are. We do this using gradient-based optimization and a multidisciplinary design optimization framework, OpenMDAO. We use the open-source tool OpenAeroStruct that couples a vortex lattice method to a finite element method. We establish a baseline aerostructural design optimization problem then perform a series of optimizations, each with one physical consideration removed from the baseline case. We find that depending on the size of the aircraft and flight conditions, the importance of some of these physical considerations varies considerably whereas the importance of others do not. Specifically, the optimal designs change radically without proper viscous and wave drag considerations and smaller aircraft with more distributed propulsion are more affected by the inclusion of engine loads.

Aeropropulsion↗
NASA NTRS2018

A 6U Hybrid Propulsion Module for CUBESATS

A 6U hybrid propulsion module is presented. It is designed to be used as a stage for a 6U CubeSat with a combined wet mass up to 25 kg. Hybrid rocket propulsion is utilized because it is responsive, high performance, capable of multiple burns and safe/non-toxic. Hybrid rockets employ a solid fuel and liquid or gaseous oxidizer. In this case, the fuel is PolyMethyl MethAcrylate and the oxidizer is gaseous oxygen. This propellant combination produces an Isp of greater than 300 seconds. The gaseous oxidizer simplifies the design and is used in dual mode with cold gas thrusters for attitude control. In general, hybrid propulsion is higher performance and higher thrust than conventional options considered for CubeSats (e.g. monopropellants), making it ideal for larger manuevers such as plane changes. The Attitude Control System has been sized to ensure that the CubeSat can be controlled under the thrust loads of the propulsion system. A hybrid rocket motor of this size is currently being tested at the Jet Propulsion Laboratory. Thirty-four successful tests have been completed at JPL with this propellant combination during the last 2.5 years. Current tests include long duration tests (> 95 seconds) and multiple starts (five). These tests and applicability to potential mission requirements will be discussed. Future test plans to move the motor into a vacuum facility to achieve a Technology Readiness Level of 5 by the end of September 2018 will be discussed, and an overview of the proposed TRL 5 to 6 maturity plan will also be presented.

Nakazono, B.↗
NASA NTRS1976

Thrust and wing loading requirements for short haul aircraft constrained by engine noise and field length

Propulsion system and wing loading requirements are determined for a mechanical flap and an externally blown flap aircraft for various engine noise levels and two engine cycles. Both aircraft are sized to operate from a 914m (3000 ft) runway and perform the same mission. For each aircraft concept, propulsion system sizing is demonstrated for two different engine cycles - one having a fan pressure ratio of 1.5 and a bypass ratio of 9, and the other having a fan pressure ratio of 1.25 and a bypass ratio of 17.8. The results presented include the required thrust-to-weight ratio, wing loading, resulting gross weight, and direct operating costs, as functions of the engine noise level, for each combination of engine cycle and aircraft concept.

Bowles, J. V.↗
NASA NTRS1976

Dual-action gas thrust bearing for improving load capacity

The principle of utilizing hydrodynamic effects in diverging films to improve the load carrying capacity in gas thrust bearings is discussed. A new concept of a dual action bearing based on that principle is described and analyzed. The potential of the new bearing is demonstrated both analytically for an infinitely long slider and by numerical solution for a flat sector shaped thrust bearing. It is shown that the dual action bearing can extend substantially the range of load carrying capacity in gas lubricated thrust bearings and can improve their efficiency.

Etsion, I.↗
NASA NTRSDate not supplied

Methodology and Development of SLS Ascent Loads

The methodology and development of the Space Launch System (SLS) Block 1 Boost and Core phase Ascent loads will be presented in this paper. As is common practice, a series of fixed time/mass Finite Element Models of the vehicle were developed for the purpose of evaluating the structural loads and accelerations for particular Mach or time ranges associated with the Boost and Core phases of flight. Load contributors, which vary between bins, include the flight mechanic induced portion of the loads (e.g., Static-Elastic (STEL) or Vehicle Load Indicator (VLI) tool results), gust loads, buffet loads, Solid Rocket Booster thrust oscillations, Core Stage Engine thrust oscillations, maneuvering loads, thrust vector-related dispersions, and Programmed Test Input induced loads. Each of these load contributors will be examined in this paper, as well as the Loads Combination Equations used to generate the final loads. In addition to the typical coupled loads analysis, an Ascent loads evaluation is included in the SLS Artemis 1 Day of Launch process; a summary of this evaluation will also be presented in this paper.

SLS↗
NASA NTRS1976

The dual action gas thrust bearing - A new high load bearing concept

The principle of utilizing hydrodynamic effects in diverging films for improving load capacity in gas thrust bearings is discussed. A new concept of dual action bearing based on that principle is described and analyzed. The potential of the new bearing is demonstrated both analytically for an infinitely long slider and by numerical solution for a flat sector shaped thrust bearing. It is shown that the dual action bearing can extend substantially the range of load carrying capacity in gas lubricated thrust bearings and improve their efficiency.

Etsion, I.↗
NASA NTRS1993

A piloted simulation investigation of the normal load factor and longitudinal thrust required for air-to-air acquisition and tracking

A piloted simulation study was performed by the U.S. Army Aeroflighydynamics Directorate to develop insight into the maneuverability requirements for aggressive helicopter maneuvering tasks such as air-to-air combat. Both a conventional helicopter and a helicopter with auxiliary thrust were examined. The aircraft parameters of interest were the normal and longitudinal load factor envelopes. Of particular interest were the mission performance and handling qualities tradeoffs with the parameters of interest. Two air-to-air acquisition and tracking tasks and a return-to-cover task were performed to assess mission performance. Results indicate that without auxiliary thrust, the ownship normal load factor capability needs to match that of the adversary in order to provide satisfactory handling qualities. Auxiliary thrust provides significant handling qualities advantages and can be substituted to some extent for normal load factor capability. Auxiliary thrust levels as low as 0.2 thrust/weight can provide significant handling qualities advantages.

Whalley, Matthew S.↗
NASA NTRS2003

Oil-Free Turbomachinery Research Enhanced by Thrust Bearing Test Capability

NASA Glenn Research Center s Oil-Free Turbomachinery research team is developing aircraft turbine engines that will not require an oil lubrication system. Oil systems are required today to lubricate rolling-element bearings used by the turbine and fan shafts. For the Oil-Free Turbomachinery concept, researchers combined the most advanced foil (air) bearings from industry with NASA-developed high-temperature solid lubricant technology. In 1999, the world s first Oil-Free turbocharger was demonstrated using these technologies. Now we are working with industry to demonstrate Oil-Free turbomachinery technology in a small business jet engine, the EJ-22 produced by Williams International and developed during Glenn s recently concluded General Aviation Propulsion (GAP) program. Eliminating the oil system in this engine will make it simpler, lighter (approximately 15 percent), more reliable, and less costly to purchase and maintain. Propulsion gas turbines will place high demands on foil air bearings, especially the thrust bearings. Up until now, the Oil-Free Turbomachinery research team only had the capability to test radial, journal bearings. This research has resulted in major improvements in the bearings performance, but journal bearings are cylindrical, and can only support radial shaft loads. To counteract axial thrust loads, thrust foil bearings, which are disk shaped, are required. Since relatively little research has been conducted on thrust foil air bearings, their performance lags behind that of journal bearings.

Bauman, Steven W.↗
NASA NTRS1980

Performance of computer-optimized tapered-roller bearings to 2.4 million DN

The performance of 120.65 mm bore high speed design tapered roller bearings was investigated at shaft speeds to 20,000 rpm under combined thrust and radial load. The test bearing design was computer optimized for high speed operation. Temperature distribution and bearing heat generation were determined as a function of shaft speed, radial and thrust loads, lubricant flow rates, and lubricant inlet temperature. The roller bearing operated successfully at shaft speeds up to 20,000 rpm under heavy thrust and radial loads. Cup cooling was effective in decreasing the high cup temperatures to levels equal to the cone temperature.

Parker, R. J.↗
NASA NTRS1980

Lubrication of optimized-design tapered-roller bearings to 2.4 million DN

The performance of 120.65 mm (4.75 in.) bore high speed design, tapered roller bearings was investigated at shaft speeds to 20,000 rpm (2.4 million DN) under combined thrust and radial load. The test bearing design was computer optimized for high speed operation. Temperature distribution bearing heat generation were determined as a function of shaft speed, radial and thrust loads, lubricant flow rates, and lubricant inlet temperature. The high speed design, tapered roller bearing operated successfully at shaft speeds up to 20,000 rpm under heavy thrust and radial loads. Bearing temperatures and heat generation with the high speed design bearing were significantly less than those of a modified standard bearing tested previously. Cup cooling was effective in decreasing the high cup temperatures to levels equal to the cone temperature.

Parker, R. J.↗
NASA NTRS1976

Preliminary Sizing and Performance Evaluation of Supersonic Cruise Aircraft

The basic processes of a method that performs sizing operations on a baseline aircraft and determines their subsequent effects on aerodynamics, propulsion, weights, and mission performance are described. The input requirements of the associated computer program are defined and its output listings explained. Results obtained by applying the method to an advanced supersonic technology concept are discussed. These results include the effects of wing loading, thrust-to-weight ratio, and technology improvements on range performance, and possible gains in both range and payload capability that become available through growth versions of the baseline aircraft. The results from an in depth contractual study that confirm the range gain predicted for a particular wing loading, thrust-to-weight ratio combination are also included.

Fetterman, D. E., Jr.↗
NASA NTRS1975

Improvement of propeller static thrust estimation

The problem of improving the performance estimation of propellers operating in the heavily loaded static thrust condition was studied. The Goldstein theory was assessed as it applies to propellers operating in the static thrust. A review of theoretical considerations is presented along with a summary of the attempts made to obtain a numerical solution. The chordwise pressure distribution was determined during operation at a tip speed of 500 ft/sec. Chordwise integration of the pressures leads to the spanwise load distribution and further integration would give the axial thrust.

Brusse, J.↗
NASA NTRS1976

Technical challenges of integrating the Space Shuttle

A review is presented of the technology involved in integrating the Space Shuttle system. A powered flight analysis of the Shuttle is presented, touching upon the following areas: ascent profile and abort mode integration, sizing and design, control of load factor by a stage thrust shaping, structural load constraints, flight performance reserve and trajectory design for the orbital flight test. A discussion is presented of aerothermodynamics including aerodynamic and plume heating. Flight control and separation is considered with attention paid to liftoff, ascent to booster staging, elevon load relief, booster tailoff thrust mismatch and gimbal limitations and booster separation. Structural analysis and dynamics is examined, considering: vehicle loads and modes and the pogo effect. Propulsion aspects (hydraulics, the LH2 recirculation system, the antigeyser system, the pressurization system, etc.), ground vibration tests, separation system verification and flight readiness firing are all described.

Martin, A. C.↗
NASA NTRS1986

Analyzing Static Loading of Complex Structures

Critical loading conditions determined from analysis of each structural element. Automated Thrust Structures Loads and Stresses (ATLAS) system is series of programs developed to analyze elements of complex structure under static-loading conditions. ATLAS calculates internal loads, beam-bending loads, column- and web-buckling loads, beam and panel stresses, and beam-corner stresses. Programs written in FORTRAN IV and Assembler for batch execution.

Gallear, D. C.↗