Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Engineering Design”

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 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗
NASA NTRS1954

An Experimental Investigation of Hollow Turbine Blades for Expandable Jet Engines

An experimental investigation was made to determine the feasibility of using hollow turbine blades in engines designed for short service life. Airfoils were fabricated from sheet material and techniques of welding and brazing attachment were investigated. The airfoils were not intended to be cooled. A principal objective was the reduction of strategic material requirements primarily as a function of direct weight reduction. The materials considered were in the density range of 0.28 to 0.31 pound per cubic inch. Three materials were used for airfoils: N-155, Inconel-X and L-605. These were attached to J47 turbine blade bases and operated to destruction at maximum service conditions of turbine speed and temperature. It was found that L-605 airfoils brazed to suitable bases satisfied the requirements for expendable engines. Service life varied from 11 to 40 hours.

Morgan, W C↗
NASA NTRS2004

Terrestrial Environment (Climatic) Criteria Handbook For Use in Aerospace Vehicle Development

An update of the NASA 'Terrestrial Environment (Climatic) Criteria Handbook for Use in Aerospace Vehicle Development' (NASA-HDBK-1001) is currently in the final process of completion for release in late-2004 or early 2005. The current version of the Handbook was approved by the NASA Chief Engineer in 2000 as a NASA Preferred Technical Standard. However, it was based on natural environment criteria developed mostly in the early 1990's. Therefore, a task was approved to completely update the Handbook in order to reflect the current state-of-the-art in the various terrestrial environmental climatic criteria areas. The technical areas include: Winds, atmospheric constituents, thermodynamic parameters/models/extremes, humidity, electricity, precipitation/fog/icing, cloud phenomena/cover, diffusion/toxic release, severe weather/tornado/hurricane, solar/thermal radiation, geologic hazards, and sea state. A summary of this extensive update will be presented along with some key examples of the new contents. Earlier versions of this publication have been extensively used by the aerospace community, especially program managers and design engineers for required natural terrestrial environment inputs to use in mission planning, development studies and trades, plus by those concerned with terrestrial environment descriptions for the major test ranges within the United States.

Johnson, Dale↗
NASA NTRS2011

Achieving the Proper Balance Between Crew and Public Safety

A paramount objective of all human-rated launch and reentry vehicle developers is to ensure that the risks to both the crew onboard and the public are minimized within reasonable cost, schedule, and technical constraints. Past experience has shown that proper attention to range safety requirements necessary to ensure public safety must be given early in the design phase to avoid additional operational complexities or threats to the safety of people onboard, and the design engineers must give these requirements the same consideration as crew safety requirements. For human spaceflight, the primary purpose and operational concept for any flight safety system is to protect the public while maximizing the likelihood of crew survival. This paper will outline the policy considerations, technical issues, and operational impacts regarding launch and reentry vehicle failure scenarios where crew and public safety are intertwined and thus addressed optimally in an integrated manner. An overview of existing range and crew safety policy requirements will be presented. Application of these requirements and lessons learned from both the Space Shuttle and Constellation Programs will also be discussed. Using these past programs as examples, the paper will detail operational, design, and analysis approaches to mitigate and balance the risks to people onboard and in the public. Manned vehicle perspectives from the Federal Aviation Administration (FAA) and Air Force organizations that oversee public safety will be summarized as well. Finally, the paper will emphasize the need to factor policy, operational, and analysis considerations into the early design trades of new vehicles to help ensure that both crew and public safety are maximized to the greatest extent possible.

Gowan, John↗
DOE OSTI2024

Liquid metal walls

Here, the plasma performance of fusion devices depends strongly on the chosen wall materials. Solid plasma-facing components (PFCs) are predominantly used in present devices, and are the most investigated candidates for fusion designs. High-Z materials such as tungsten (W) are the leading solid PFC material candidates. To date, a material choice that scales to steady-state reactor conditions has not been identified. Moreover, if plasma transient events such as edge-localized modes and disruptions cannot be altogether avoided or sufficiently mitigated, the projected peak heat and particle loads far exceed the power exhaust capabilities of solids. Liquid metal (LM) PFCs represent an intrinsic self-healing boundary that are both resilient to surface damage from transients, and that could handle high steady-state heat and particle fluxes. Flowing LM PFCs can be designed to remove “slag,” the buildup of material erosion due to plasma-material interactions, including charge exchange sputtering in the main chamber. Further, LM offer the prospect to manage hydrogenic species otherwise retained in the PFCs, which is important from a safety and inventory standpoint. The two most promising LMs are lithium (Li) and tin (Sn), although Sn–Li eutectics may be considered. While Sn offers a higher temperature window with low vapor pressure and low hydrogen retention, Li offers the prospect of enhanced energy confinement and higher acceptable core contamination limits, and this section focuses on Li PFCs. An LM PFC development research program developed LM PFC concepts for a nuclear fusion device via engineering design calculations, single-effect experiments, and staged prototypical experiments. A self-consistent design window was identified with liquid Li flow speeds ~5–10 m/s; plasma contamination was negligible for predicted Li evolution rates. While these preconceptual designs hold promise, there is substantial R&D needed to advance the technical readiness levels of LM PFCs for application to fusion power plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1998

Factors Affecting Fiber Design and Selection for Advanced Ceramic Composites

Structural Ceramic Matrix Composites (CMC) have the potential for application in the hot sections of a variety of advanced propulsion and power systems. It is therefore necessary to have a general understanding of the key properties of CMC and Reinforcing Fibers. This need is complicated by the wide variety of application conditions and structural requirements for which CMC's will be used, and the proprietary concerns of the design engineers. CMC's, to be successful, must display properties which are competitive with the currently used high temperature structural materials: (i.e., Iron and Nickel based superalloys, tough monolithic ceramics, and carbon/carbon composites.) Structural CMC offers several areas of competition: (1) performance, (i.e., strength and strength retention, creep resistance, and thermal conductivity), (2) reliability (i.e., environmental durability, and damage tolerance) and (3) processing (i.e., capability for varying sizes and shapes, and cost effective fabrication). The presentation further discusses, and illustrates with fiber and CMC data the key fiber properties and processes which strongly affect each CMC area of competition. The presentation further discusses the current knowledge of the important factors which control the key fiber properties. A design guidelines for the optimum fiber characteristics is developed, and the currently available fibers are compared against those guidelines.

DiCarlo, James A.↗
NASA NTRS2006

Methodology for Life Testing of Refractory Metal/Sodium Heat Pipes

The focus of this work was to establish an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. To accomplish this goal acceleration is required to compress 10 years of operational life into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Specific test series have been identi3ed, based on American Society for Testing and Materials (ASTM) specifications, to investigate long term corrosion rates. The refractory metal selected for demonstration purposes is a Molybdenum-44.5%Rhenium alloy formed by powder metallurgy. The heat pipe makes use of an annular crescent wick design formed by hot isostatic pressing of Molybdenum-Rhenium wire mesh. The heat pipes are filled using vacuum distillation and purity sampling is considered. Testing of these units is round-the-clock with 6-month destructive and non-destructive inspection intervals to identify the onset and level of corrosion. Non-contact techniques are employed for providing power to the evaporator (radio frequency induction heating at I to 5 kW per unit) and calorimetry at the condenser (static gas gap coupled water cooled calorimeter). The planned operating temperature range would extend from 1123 to 1323 K. Accomplishments prior to project cancellation included successful demonstration of the heat pipe wick fabrication technique, establishment of all engineering designs, baselined operational test requirements and procurement/assembly of supporting test hardware systems.

Martin, James J.↗
NASA NTRS1982

A discrete gust model for use in the design of wind energy conversion systems

A discrete gust model has been designed which includes an expression for the number of times per unit time thy wind exceeds a specific value. This expression, based on Rice's (1944, 1945) number-of-crossings model, assumes that the yearly mean wind speed is averaged over a period of 10 minutes to 1 (one) hour. Vertical and lateral coherence functions are the basis for a mathematical filter which isolates atmospheric disturbances of a characteristic size (e. g., those which would completely engulf a rotor). Predictions are calculated usising the given definition of cut-off frequency, then they are compared with actual data, showing that the model is reliable. The expression is provided in a format such that it may be used for engineering design calculations.

Frost, W.↗
NASA NTRSDate not supplied

Flight Performance and Stability of Space Launch System Core Stage Thrust Vector Control

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The Core Stage TVC shares vehicle control authority with the SLS 5-segment Solid Rocket Boosters (SRBs) during boost phase flight, and is the sole means of vehicle flight control during in exoatmospheric flight following SRB separation. TVC responses during Green Run Hot Fire (GRHF) testing revealed that the TVC did not meet its performance specifications. Step and frequency responses exhibited unexpected departures from prior laboratory data and modeled behavior. Post-test analysis determined that the characteristics of the structure and gimbal friction are significantly influenced by the thrust-loaded conditions, and the command avionics exhibited a small but important gain nonlinearity. Using the available test data, the design team augmented the flight control TVC models to bound the observed results and include the additional fidelity needed for vehicle flight control analysis so as to build sufficient rationale for flight certification. Prior to the Green Run tests, “simplex” linear models typically used for flight control analysis did not include gimbal friction and other nonlinearities owing to long-standing assumptions that these effects were negligible in the Shuttle Orbiter TVC system. Following the Green Run findings, simulation analysis of the flight dynamics in the time and frequency domain revealed the propensity for a flight control limit cycle oscillation (LCO) if friction and structural compliances fell near the edges of test-predicted bounds. While the “most probable” models did not predict an in-flight LCO, the SLS Program conservatively proceeded with a system-wide evaluation and ultimate acceptance of the possibility for a small amplitude, low-frequency TVC LCO in flight. A final validation of the extensive test and modeling effort occurred when the first flight of SLS successfully demonstrated the fully integrated performance of the vehicle’s TVC system This paper is the final installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the development of flight rationale in light of the TVC responses observed in Green Run is discussed, along with a review of the flight telemetry illustrating the correlation of the preflight predictions with the observed performance.

John H. Wall↗
NASA NTRS1966

Special tooling for joining tubing in place

The Saturn S-II stage and the Apollo spacecraft will include in their design and construction various pressurized tubing systems that will encounter service temperatures of 280° F to -423° F. Design engineering and reliability requirements and weight restrict ions have dictated new concepts to assure leak-tight joints for rocket engine fuel lines, pressurization systems, utility systems, and hydraulic systems. An investigation was initiated at North American Aviation, Inc., Space and Information Systems Division, utilizing the in-place automatically controlled miniaturized fusion-welding equipment originally developed by the Los Angeles Division of NAA and modified to meet the needs of Apollo and Saturn welded tubular systems. The objective was to make circumferential flanged weld joints in any position in 304L stainless for Saturn S-II and sleeve-type joints in 304L for Apollo. Inconel X, commercially pure titanium, 5052-0 aluminum, and 6061 T6 aluminum were also tested experimentally. Extensive environmental, static, and dynamic testing programs were conducted to determine the as-welded mechanical properties, design allowables, and reliability for the tube joints. This paper discusses both the experimental and production phases. Subsequently, the new tube welding process was approved and incorporated into manufacturing fabrication methods for tube joining.

Saturn S-II stage↗
NASA NTRS1992

Space Transportation Main Engine

The topics are presented in viewgraph form and include the following: Space Transportation Main Engine (STME) definition, design philosophy, robust design, maximum design condition, casting vs. machined and welded forgings, operability considerations, high reliability design philosophy, engine reliability enhancement, low cost design philosophy, engine systems requirements, STME schematic, fuel turbopump, liquid oxygen turbopump, main injector, and gas generator. The major engine components of the STME and the Space Shuttle Main Engine are compared.

Jan C. Monk↗
NASA NTRS2007

Shear History Extensional Rheology Experiment: A Proposed ISS Experiment

The Shear History Extensional Rheology Experiment (SHERE) is a proposed International Space Station (ISS) glovebox experiment designed to study the effect of preshear on the transient evolution of the microstructure and viscoelastic tensile stresses for monodisperse dilute polymer solutions. Collectively referred to as Boger fluids, these polymer solutions have become a popular choice for rheological studies of non-Newtonian fluids and are the non-Newtonian fluid used in this experiment. The SHERE hardware consists of the Rheometer, Camera Arm, Interface Box, Cabling, Keyboard, Tool Box, Fluid Modules, and Stowage Tray. Each component will be described in detail in this paper. In the area of space exploration, the development of in-situ fabrication and repair technology represents a critical element in evolution of autonomous exploration capability. SHERE has the capability to provide data for engineering design tools needed for polymer parts manufacturing systems to ensure their rheological properties have not been impacted in the variable gravity environment and this will be briefly addressed.

Hall, Nancy R.↗
DOE OSTI2026

FY25 Ion Exchange Processing for the West Area Risk Management (WARM) Project

The West Area Risk Management (WARM) Project was established to enable near-term retrieval and pretreatment of tank waste from Hanford’s 200 West Area and to support deployment of an ion exchange (IX) system capable of producing cesium-depleted supernate suitable for offsite treatment and disposal. The WARM experimental campaign was designed to provide key data for design and operational planning of the 200 W IX system, which plans to utilize crystalline silicotitanate (CST) as the active media for cesium removal. This report documents a comprehensive FY25 experimental campaign designed to produce key technical data required for design and operational planning of the WARM IX system. Testing includes assessing Cs and Sr breakthrough performance in a 4-column system, Cs capacity batch contact testing, phosphate precipitation assessments, reduced-hydroxide feed displacement evaluation, and Sr speciation impacts on Sr removal. The experimental results provide detailed trends in Cs and Sr loading behavior, breakthrough performance across a 4-column staged IX system, distribution profiles within CST beds, and projections of operational flowrates relative to Waste Acceptance Criteria (WAC) limits. Batch contact testing established equilibrium partitioning behavior for the S1–S5 simulants and characterized how matrix chemistry influenced Cs sorption onto CST. Additionally, further evaluations on waste matrix as it pertains to precipitation potential were also determined. Collectively, these datasets support engineering design choices for WARM system throughput and pretreatment planning.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2001

Disk Alloy Development

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA HSR/EPM disk program to have extended durability at 1150 to 1250 "Fin large disks. Scaled-up disks of this alloy were produced at the conclusion of this program to demonstrate these properties in realistic disk shapes. The objective of the UEET disk program was to assess the mechanical properties of these ME3 disks as functions of temperature, in order to estimate the maximum temperature capabilities of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor / Turbine Disk program were sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. Additional sub-scale disks and blanks were processed and tested to explore the effects of several processing variations on mechanical properties. Scaled-up disks of an advanced regional disk alloy, Alloy 10, were used to evaluate dual microstructure heat treatments. This allowed demonstration of an improved balance of properties in disks with higher strength and fatigue resistance in the bores and higher creep and dwell fatigue crack growth resistance in the rims. Results indicate the baseline ME3 alloy and process has 1300 to 1350 O F temperature capabilities, dependent on detailed disk and engine design property requirements. Chemistry and process enhancements show promise for further increasing temperature capabilities.

Gabb, Tim↗
NASA NTRS1980

Should we attempt global (inlet engine airframe) control design?

The feasibility of multivariable design of the entire airplane control system is briefly addressed. An intermediate step in that direction is to design a control for an inlet engine augmentor system by using multivariable techniques. The supersonic cruise large scale inlet research program is described which will provide an opportunity to develop, integrate, and wind tunnel test a control for a mixed compression inlet and variable cycle engine. The integrated propulsion airframe control program is also discussed which will introduce the problem of implementing MVC within a distributed processing avionics architecture, requiring real time decomposition of the global design into independent modules in response to hardware communication failures.

Carlin, C. M.↗
DOE OSTI2024

DASSH-F: Subchannel Based Thermal Analysis

The DASSH thermal analysis code is designed to rapidly allow a reactor design engineer to obtain flow rates requirements that satisfy peak temperature constraints in the domain. The advantage of using DASSH over a hand calculation is that it has a more rigorous treatment of the pin power distribution and coolant heat transfer within an assembly and between assemblies. The advantage of using DASSH over a conventional 3D subchannel code or a computational fluid dynamics code (CFD) is that it can obtain the desired solution in a matter of minutes in serial with minor computer memory needs. The DASSH methodology is virtually identical to SUPERENERGY-2 with additional functionalities taken from follow on work to SUPERENERGY-2 done at ANL in the 1980s. DASSH today is an integral component of the Argonne Fast Reactor analysis suite for reactor design work. DASSH obtains the power distribution from a coupled neutron-gamma heating calculation in GAMSOR (including DIF3D) at each time point of a companion fuel cycle analysis calculation with REBUS. The domain in DASSH assumes a hexagonal grid typical for fast reactors with much of the geometry information taken from the DIF3D model. DASSH assumes the assemblies that are loaded into each grid position are ducted to control the coolant flow. Considerable detail is given on the subchannel formulation of DASSH in this document. Much of the formulation and design of the code builds upon research done by previous authors with little new investigation. Thus the decisions made in developing the subchannel model used in DASSH have their origins over 50 years ago. Much of the heat transfer methodology in DASSH is built upon correlations for both the coolant mixing and heat transfer coefficients for pins and ducts. DASSH is thus not a rigorous treatment of a given problem, but a rapid assessment of the temperature field that has known limitations with respect to an experimental measurement or CFD calculation. The DASSH input and output are detailed along with usage of the software. The DASSH output provides tables of evaluated material properties and key coolant and pin temperature results. DASSH can create Python scripts that generate domain summary pictures. DASSH can also generate assembly temperature maps and VTK output files which allow the DASSH solution to be visualized. As the primary purpose of the DASSH software is to compute the coolant and fuel pin temperature distribution for a given model of a reactor, much of the output focus is giving the user quick summary tables needed to assess the performance of a given orifice flow specification. The present version of DASSH has a crude orifice search capability and an efficient orifice flow search capability. The flow search tries to meet user specified constraints for 1) peak 2-sigma clad midwall temperature, 2) peak coolant temperature, and 3) desired bulk outlet temperature. There are many development shortcomings in DASSH detailed in this document, but this version is functional for modern analysis needs. This document serves as the manual for the Fortran based DASSH software that was developed to replace the Python version of DASSH developed as part of the VTR program.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2006

Visual Risk Assessment of Space Radiation Exposure for Future Space Exploration Missions

Protecting astronauts from space radiation exposure during an interplanetary mission is an important challenge for mission design and operations. If sufficient protection is not provided near solar maximum, the risk can be significant due to exposure to sporadic solar particle events (SPEs) as well as to the continuous galactic cosmic radiation (GCR). Polyethylene shielded "storm shelters" inside spacecraft have been shown to limit total exposure from a large SPE to a permissible level, preventing acute risks and providing a potential approach to fulfill the ALARA (as low as reasonably achievable) requirement. For accurate predictions of radiation dose to astronauts involved in future space exploration missions, detailed variations of radiation shielding properties are required. Radiation fluences and doses vary considerably across both the spacecraft geometry and the body-shielding distribution. A model using a modern CAD tool ProE(TradeMark), which is the leading engineering design platform at NASA, has been developed to account for these local variations in the radiation distribution. Visual assessment of radiation distribution at different points inside a spacecraft module and in the human body for a given radiation environment are described. Results will ultimately guide in developing requirements for maximal protection for astronauts from space radiation.

Hussein, Hesham F.↗
NASA NTRS2024

Reliable and Efficient Electrochemical Recovery of O 2 from Metabolic CO 2 at the International Space Station (ISS)

Maximum O 2 recovery from metabolic carbon dioxide (CO 2 ) is desired for future long-duration missions beyond Low Earth Orbit (LEO). The O 2 recovery for the Environmental Control and Life Support System (ECLSS) at the International Space Station (ISS), presently limited to 50% (Sabatier), must be highly reliable and efficient and recover a minimum of 75% oxygen (O 2 ) from metabolic CO 2 . An alternative technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) via a Microfluidic Electrochemical Reactor (MFECR) approach has the potential to increase O 2 recovery significantly and reduce the complexity of the ECLSS O 2 recovery at the ISS as it would replace three pieces, the CO 2 Reduction Assembly (CRA) (Sabatier reactor), the Oxygen Generation Assembly (OGA), and the Plasma Pyrolysis Assembly (PPA). The MFECR's electrochemical process generates ethylene (C 2 H 4 ) and carbon moxide (CO) instead of methane (CH 4 ) (Sabatier) as a byproduct, eliminating the need for further dehydrogenation through the PPA. As in the OGA, the MFECR's electrochemical process generates O 2 and hydrogen (H 2 ) from the water electrolysis process. MSFC and the University of Texas in Arlington (UTA) have jointly designed and fabricated an MFECR's single cell that operates at ambient conditions and utilizes a proprietary catalysis highly selective on reducing CO 2 to C 2 H 4 and CO at the cathode. This MFECR's single cell consists of gas diffusion layers at the cathode and anode for respective intake of CO 2 and output of O 2 from the catalytic layer. This approach is expected to substantially improve the ISS ECLSS sustainability and reduce power and weight requirements as the MFECR would replace three units currently installed in the ISS. In this paper, the authors discuss the outcome of preliminary tests, the current development, and the evaluation efforts on different alternatives for the cathode and the anode configurations, the setup of the MFECR at an engineering development unit (EDU) scale, and the O 2 recovery performance, and evaluation efforts on different alternatives on not only the configuration and setup of the MFECR at an Engineering Design Unit (EDU) scale but also the selection of component materials.

Jesus A Dominguez↗