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At least 1,477 records · Page 82
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NASA NTRS2006

CLV First Stage Design, Development, Test and Evaluation

The Crew Launch Vehicle (CLV) is an integral part of NASA's Exploration architecture that will provide crew and cargo access to the International Space Station as well as low earth orbit support for lunar missions. Currently in the system definition phase, the CLV is planned to replace the Space Shuttle for crew transport in the post 2010 time frame. It is comprised of a solid rocket booster first stage derived from the current Space Shuttle SRB, a LOX/hydrogen liquid fueled second stage utilizing a derivative of the Space Shuttle Main Engine (SSME) for propulsion, and a Crew Exploration Vehicle (GEV) composed of Command and Service Modules. This paper deals with current DDT&E planning for the CLV first stage solid rocket booster. Described are the current overall point-of-departure design and booster subsystems, systems engineering approach, and milestone schedule requirements.

Burt, Richard K.↗
NASA NTRS2006

RS-25 for the NASA Cargo Launch Vehicle: The Evolution of SSME for Space Exploration

A key element of the National Vision for Space Exploration is the development of a heavy-lift Cargo Launch Vehicle (CaLV). Missions to the Moon, Mars, and beyond are only possible with the logistical capacity of putting large payloads in low-earth orbit. However, beyond simple logistics, there exists the need for this capability to be as cost effective as possible to ensure mission sustainability. An element of the CaLV project is, therefore, the development of the RS-25, which represents the evolution of the proven Space Shuttle Main Engine (SSME) into a high-performance, cost-effective expendable rocket engine. The development of the RS-25 will be built upon the foundation of over one million seconds of accumulated hot-fire time on the SSME. Yet in order to transform the reusable SSME into the more cost-effective, expendable RS-25 changes will have to be made. Thus the project will inevitably strive to maintain a balance between demonstrated heritage products and processes and the utilization of newer technology developments. Towards that end, the Core Stage Engine Office has been established at the NASA Marshall Space Flight Center to initiate the design and development of the RS-25 engine. This paper is being written very early in the formulation phase of the RS-25 project. Therefore the focus of this paper will be to present the scope, challenges, and opportunities for the RS-25 project. Early schedules and development decisions and plans will be explained. For not only must the RS-25 project achieve cost effectiveness through the development of new, evolved components such as a channel-wall nozzle, a new HIP-bonded main combustion chamber, and several others, it must simultaneously develop the means whereby this engine can be manufactured on a scale never envisioned for the SSME. Thus, while the overall project will span the next eight to ten years, there is little doubt that even this schedule is aggressive with a great deal of work to accomplish.

Kynard, Michael H.↗
NASA NTRS2007

Managing External Relations: The Lifeblood of Mission Success

The slide presentation examines the role of customer and stakeholder relations in the success of space missions. Topics include agency transformation; an overview of project and program experience with a discussion of positions, technical accomplishments, and management lessons learned; and approaches to project success with emphasis on communication. Projects and programs discussed include the Space Shuttle Main Engine System, DC-XA Flight Demonstrator, X-33 Flight Demonstrator, Space Launch Initiative/2nd Generation Reusable Launch Vehicle, X-37 Flight Demonstrator, Constellation (pre Dr. Griffin), Safety and Mission Assurance, and Exploration Launch Projects.

Dumbacher, Daniel L.↗
NASA NTRS2007

Flow Separation Side Loads Excitation of Rocket Nozzle FEM

Modern rocket nozzles are designed to operate over a wide range of altitudes, and are also built with large aspect ratios to enable high efficiencies. Nozzles designed to operate over specific regions of a trajectory are being replaced in modern launch vehicles by those that are designed to operate from earth to orbit. This is happening in parallel with modern manufacturing and wall cooling techniques allowing for larger aspect ratio nozzles to be produced. Such nozzles, though operating over a large range of altitudes and ambient pressures, are typically designed for one specific altitude. Above that altitude the nozzle flow is 'underexpanded' and below that altitude, the nozzle flow is 'overexpanded'. In both conditions the nozzle produces less than the maximum possible thrust at that altitude. Usually the nozzle design altitude is well above sea level, leaving the nozzle flow in an overexpanded state for its start up as well as for its ground testing where, if it is a reusable nozzle such as the Space Shuttle Main Engine (SSME), the nozzle will operate for the majority of its life. Overexpansion in a rocket nozzle presents the critical, and sometimes design driving, problem of flow separation induced side loads. To increase their understanding of nozzle side loads, engineers at MSFC began an investigation in 2000 into the phenomenon through a task entitled "Characterization and Accurate Modeling of Rocket Engine Nozzle Side Loads", led by A. Brown. The stated objective of this study was to develop a methodology to accurately predict the character and magnitude of nozzle side loads. The study included further hot-fire testing of the MC-l engine, cold flow testing of subscale nozzles, CFD analyses of both hot-fire and cold flow nozzle testing, and finite element (fe.) analysis of the MC-1 engine and cold flow tested nozzles. A follow on task included an effort to formulate a simplified methodology for modeling a side load during a two nodal diameter fluid/structure interaction for a single moment in time.

Smalley, Kurt B.↗
NASA NTRS2007

Replica-based Crack Inspection

A surface replica-based crack inspection method has recently been developed for use in Space Shuttle main engine (SSME) hydrogen feedline flowliners. These flowliners exist to ensure favorable flow of liquid hydrogen over gimble joint bellows, and consist of two rings each containing 38 elongated slots. In the summer of 2002, multiple cracks ranging from 0.1 inches to 0.6 inches long were discovered; each orbiter contained at least one cracked flowliner. These long cracks were repaired and eddy current inspections ensured that no cracks longer than 0.075 inches were present. However, subsequent fracture-mechanics review of flight rationale required detection of smaller cracks, and was the driving force for development of higher-resolution inspection method. Acetate tape surface replicas have been used for decades to detect and monitor small cracks. However, acetate tape replicas have primarily been limited to laboratory specimens because complexities involved in making these replicas - requiring acetate tape to be dissolved with acetone - are not well suited for a crack inspection tool. More recently developed silicon-based replicas are better suited for use as a crack detection tool. A commercially available silicon-based replica product has been determined to be acceptable for use in SSME hydrogen feedlines. A method has been developed using this product and a scanning electron microscope for analysis, which can find cracks as small as 0.005 inches and other features (e.g., pits, scratches, tool marks, etc.) as small as 0.001 inches. The resolution of this method has been validated with dozens of cracks generated in a laboratory setting and this method has been used to locate 55 cracks (ranging in size from 0.040 inches to 0.004 inches) on space flight hardware. These cracks were removed by polishing away the cracked material and a second round of replicas confirmed the repair.

Newman, John A.↗
NASA NTRS2008

Multi-Scale/Multi-Functional Probabilistic Composite Fatigue

A multi-level (multi-scale/multi-functional) evaluation is demonstrated by applying it to three different sample problems. These problems include the probabilistic evaluation of a space shuttle main engine blade, an engine rotor and an aircraft wing. The results demonstrate that the blade will fail at the highest probability path, the engine two-stage rotor will fail by fracture at the rim and the aircraft wing will fail at 109 fatigue cycles with a probability of 0.9967.

Chamis, Christos C.↗
NASA NTRS2008

Combustion Devices CFD Team Analyses Review

A variety of CFD simulations performed by the Combustion Devices CFD Team at Marshall Space Flight Center will be presented. These analyses were performed to support Space Shuttle operations and Ares-1 Crew Launch Vehicle design. Results from the analyses will be shown along with pertinent information on the CFD codes and computational resources used to obtain the results. Six analyses will be presented - two related to the Space Shuttle and four related to the Ares I-1 launch vehicle now under development at NASA. First, a CFD analysis of the flow fields around the Space Shuttle during the first six seconds of flight and potential debris trajectories within those flow fields will be discussed. Second, the combusting flows within the Space Shuttle Main Engine's main combustion chamber will be shown. For the Ares I-1, an analysis of the performance of the roll control thrusters during flight will be described. Several studies are discussed related to the J2-X engine to be used on the upper stage of the Ares I-1 vehicle. A parametric study of the propellant flow sequences and mixture ratios within the GOX/GH2 spark igniters on the J2-X is discussed. Transient simulations will be described that predict the asymmetric pressure loads that occur on the rocket nozzle during the engine start as the nozzle fills with combusting gases. Simulations of issues that affect temperature uniformity within the gas generator used to drive the J-2X turbines will described as well, both upstream of the chamber in the injector manifolds and within the combustion chamber itself.

Rocker, Marvin↗
NASA NTRS2008

Replica-Based Crack Inspection

Surface replication has been proposed as a method for crack detection in space shuttle main engine flowliner slots. The results of a feasibility study show that examination of surface replicas with a scanning electron microscope can result in the detection of cracks as small as 0.005 inch, and surface flaws as small as 0.001 inch, for the flowliner material.

Newman, John A.↗
NASA NTRS2008

Calibrating the Helium Pressurization System for the Space Shuttle Liquid-Hydrogen Tank

Analysis of the results from the STS-114 tanking tests and subsequent launch called into question existing thermal and mass models of helium pressurization of the liquid hydrogen tank. This hydrogen tank, which makes up the bottom two-thirds of the External Tank, is pressurized prior to launch to avoid cavitation in the Shuttle Main Engine pumps. At about 2 minutes prior to launch, the main vent valve is closed, and pressurized helium flows into the tank ullage space to achieve set point pressure. As the helium gas cools, its pressure drops, calling for additional helium. Subsequent helium flows are provided in short, timed pulses. The number of pulses is taken as a rough leak indicator. An analysis of thermal models by Marshall Space Flight Center showed considerable uncertainty in the pressure-versus-time behavior of the helium ullage space and the ability to predict the number of pulses normally expected. Kennedy Space Center proposed to calibrate the dime-sized orifice, which together with valves, controls the helium flow quantity (Figure 1). Pressure and temperature sensors were installed to provide upstream and downstream measurements necessary to compute flow rate based on the orifice discharge coefficient. An assessment of flow testing with helium indicated an extremely costly use of this critical resource. In order to reduce costs, we proposed removing the orifices from each Mobile Launcher Platform (MLP) and asking Colorado Engineering Experiment Station Inc. (CEESI) to calibrate the flow. CEESI has a high-pressure air flow system with traceable flow meters capable of handling the large flow rates. However, literature research indicated that square-edged orifices of small diameters often exhibit significant hysteresis and nonrepeatability in the vicinity of choked or sonic flow. Fortunately, the MLP orifices behaved relatively well in testing (Figure 2). Using curve fitting of the air-flow data, in conjunction with ASME orifice modeling equations, a method of relating the helium mass flow to measured air flow data was obtained. This analysis showed that the highest uncertainty in flow occurred in the vicinity of the choking pressure ratio, as would be expected. In addition, analysis of typical flow pulses showed that most of the helium flow occurred either well below or well above this uncertain area. The final result is the ability to provide postlaunch estimates of helium mass flows that are within 1.5 percent of the actual value.

Source record↗
NASA NTRS2008

An Investigation of State-Space Model Fidelity for SSME Data

In previous studies, a variety of unsupervised anomaly detection techniques for anomaly detection were applied to SSME (Space Shuttle Main Engine) data. The observed results indicated that the identification of certain anomalies were specific to the algorithmic method under consideration. This is the reason why one of the follow-on goals of these previous investigations was to build an architecture to support the best capabilities of all algorithms. We appeal to that goal here by investigating a cascade, serial architecture for the best performing and most suitable candidates from previous studies. As a precursor to a formal ROC (Receiver Operating Characteristic) curve analysis for validation of resulting anomaly detection algorithms, our primary focus here is to investigate the model fidelity as measured by variants of the AIC (Akaike Information Criterion) for state-space based models. We show that placing constraints on a state-space model during or after the training of the model introduces a modest level of suboptimality. Furthermore, we compare the fidelity of all candidate models including those embodying the cascade, serial architecture. We make recommendations on the most suitable candidates for application to subsequent anomaly detection studies as measured by AIC-based criteria.

Martin, Rodney Alexander↗
NASA NTRS2007

Roller Bearing Health Monitoring Using CPLE Frequency Analysis Method

This paper describes a unique vibration signature analysis technique Coherence Phase Line Enhancer (CPLE) Frequency Analysis - for roller bearing health monitoring. Defects of roller bearing (e.g. wear, foreign debris, crack in bearing supporting structure, etc.) can cause small bearing characteristic frequency shifts due to minor changes in bearing geometry. Such frequency shifts are often too small to detect by the conventional Power Spectral Density (PSD) due to its frequency bandwidth limitation. This Coherent Phase Line Enhancer technology has been evolving over the last few years and has culminated in the introduction of a new and novel frequency spectrum which is fully described in this paper. This CPLE technology uses a "key phasor" or speed probe as a preprocessor for this analysis. With the aid of this key phasor, this CPLE technology can develop a two dimensional frequency spectrum that preserves both amplitude and phase that is not normally obtained using conventional frequency analysis. This two-dimensional frequency transformation results in several newly defined spectral functions; i. e. CPLE-PSD, CPLE-Coherence and the CPLE-Frequency. This paper uses this CPLE frequency analysis to detect subtle, low level bearing related signals in the High Pressure Fuel Pump (HPFP) of the Space Shuttle Main Engine (SSME). For many rotating machinery applications, a key phasor is an essential measurement that is used in the detection of bearing related signatures. There are times however, when a key phasor is not available; i. e. during flight of any of the SSME turbopumps or on the SSME High Pressure Oxygen Turbopump (HPOTP) where no speed probe is present. In this case, the CPLE analysis approach can still be achieved using a novel Pseudo Key Phasor (PKP) technique to reconstruct a 1/Rev PKP signal directly from external vibration measurements. This paper develops this Pseudo Key Phasor technique and applies it to the SSME vibration data.

Jong, Jen-Yi↗
NASA NTRS2009

Application of Digital Radiography to Weld Inspection for the Space Shuttle External Fuel Tank

This slide presentation reviews NASA's use of digital radiography to inspect the welds of the external tanks used to hold the cryogenic fuels for the Space Shuttle Main Engines. NASA has had a goal of replacing a significant portion of film used to inspect the welds, with digital radiography. The presentation reviews the objectives for converting to a digital system from film, the characteristics of the digital system, the Probability of detection study, the qualification and implementation of the system.

Ussery, Warren↗
NASA NTRS2010

Investigating Dynamics of Eccentricity in Turbomachines

A methodology (and hardware and software to implement the methodology) has been developed as a means of investigating coupling between certain rotordynamic and hydrodynamic phenomena in turbomachines. Originally, the methodology was intended for application in an investigation of coupled rotordynamic and hydrodynamic effects postulated to have caused high synchronous vibration in the space shuttle s high-pressure oxygen turbopump (HPOTP). The methodology can also be applied in investigating (for the purpose of developing means of suppressing) undesired hydrodynamic rotor/stator interactions in turbomachines in general. The methodology and the types of phenomena that can be investigated by use of the methodology are best summarized by citing the original application as an example. In that application, in consideration of the high synchronous vibration in the space-shuttle main engine (SSME) HPOTP, it was determined to be necessary to perform tests to investigate the influence of inducer eccentricity and/or synchronous whirl motion on inducer hydrodynamic forces under prescribed flow and cavitation conditions. It was believed that manufacturing tolerances of the turbopump resulted in some induced runout of the pump rotor. Such runout, if oriented with an inducer blade, would cause that blade to run with tip clearance smaller than the tip clearances of the other inducer blades. It was hypothesized that the resulting hydraulic asymmetry, coupled with alternating blade cavitation, could give rise to the observed high synchronous vibration. In tests performed to investigate this hypothesis, prescribed rotor whirl motions have been imposed on a 1/3-scale water-rig version of the SSME LPOTP inducer (which is also a 4-biased inducer having similar cavitation dynamics as the HPOTP) in a magnetic-bearing test facility. The particular magnetic-bearing test facility, through active vibration control, affords a capability to impose, on the rotor, whirl orbits having shapes and whirl rates prescribed by the user, and to simultaneously measure the resulting hydrodynamic forces generated by the impeller. Active control also made it possible to modulate the inducer-blade running tip clearance and consequently effect alternating blade cavitation. The measured hydraulic forces have been compared and correlated with shroud dynamic-pressure measurements.

Baun, Daniel↗
NASA NTRS2007

Programs for Testing an SSME-Monitoring System

A suite of computer programs has been developed for special test equipment (STE) that is used in verification testing of the Health Management Computer Integrated Rack Assembly (HMCIRA), a ground-based system of analog and digital electronic hardware and software for "flight-like" testing for development of components of an advanced health-management system for the space shuttle main engine (SSME). The STE software enables the STE to simulate the analog input and the data flow of an SSME test firing from start to finish.

Lang, Andre↗
NASA NTRS2010

Multiscale/Multifunctional Probabilistic Composite Fatigue

A multilevel (multiscale/multifunctional) evaluation is demonstrated by applying it to three different sample problems. These problems include the probabilistic evaluation of a space shuttle main engine blade, an engine rotor and an aircraft wing. The results demonstrate that the blade will fail at the highest probability path, the engine two-stage rotor will fail by fracture at the rim and the aircraft wing will fail at 109 fatigue cycles with a probability of 0.9967.

Chamis, Christos C.↗
NASA NTRS2010

SSME Electrical Harness and Cable Development and Evolution

The Space Shuttle Main Engine (SSME) electrical harness and cable system consists of the various interconnecting devices necessary for operation of complex rocket engine functions. Thirty seven harnesses incorporate unique connectors, backshell adapters, conductors, insulation, shielding, and physical barriers for a long maintenance-free life while providing the means to satisfy performance requirements and to mitigate adverse environmental influences. The objective of this paper is to provide a description of the SSME electrical harness and cable designs as well as the development history and lessons learned.

Abrams, Russ↗
NASA NTRS2010

From Research to Flight: Thinking About Implementation While Performing Fundamental Research

This slide presentation calls for a strategy to implement new technologies. Such a strategy would allow advanced space transportation technologies to mature for exploration beyond Earth orbit. It discusses the difference between technology push versus technology pull. It also reviews the three basic technology readiness levels (TRL). The presentation traces examples of technology development to flight application: the Space Shuttle Main Engine Advanced Health Management System, the Friction Stir Welding technology the (auto-adjustable pin tool). A couple of technologies currently not in flight, but are being reviewed for potential use are: cryogenic fluid management (CFM), and solar sail propulsion. There is also an attempt to explain why new technologies are so difficult to field.

Johnson, Les↗
NASA NTRS2011

NASA TEERM Hexavalent Chrome Alternatives Projects

This slide presentation reviews the NASA project to select an alternative to hexavalent chrome in the aerospace industry. Included is a recent historic testing and research that the Agency has performed on (1) the external tank, (2) the shuttle orbiter, (3) the Shuttle Rocket Booster, and (4) the Space Shuttle Main Engine. Other related Technology Evaluation for Environmental Risk Mitigation (TEERM) projects are reviewed. The Phase I process of the project performed testing of alternatives the results are shown in a chart for different coating systems. International collaboration was also reviewed. Phase II involves further testing of pretreatment and primers for 6 and 12 months of exposure to conditions at Launch Pad and the beach. Further test were performed to characterize the life cycle corrosion of the space vehicles. A new task is described as a joint project with the Department of Defense to identify a Hex Chrome Free Coatings for Electronics.

Kessel, Kurt↗