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NASA NTRS2003

Three-Dimensional Magnetic Analysis Technique Developed for Evaluating Stirling Convertor Linear Alternators

The Department of Energy, the Stirling Technology Company (STC), and the NASA Glenn Research Center are developing Stirling convertors for Stirling radioisotope generators to provide electrical power for future NASA deep space missions. STC is developing the 55-We technology demonstration convertor (TDC) under contract to the Department of Energy. The Department of Energy recently named Lockheed Martin as the system integration contractor for the Stirling radioisotope generator development project. Lockheed Martin will develop the Stirling radioisotope generator engineering unit and has contract options to develop the qualification unit and the first flight unit. Glenn s role includes an in-house project to provide convertor, component, and materials testing and evaluation in support of the overall power system development. As a part of this work, Glenn has established an in-house Stirling research laboratory for testing, analyzing, and evaluating Stirling machines. STC has built four 55-We convertors for NASA, and these are being tested at Glenn. A cross-sectional view of the 55-We TDC is shown in the figure. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. In support, Glenn has been developing finite element analysis and finite element method tools for performing various linear alternator thermal and electromagnetic analyses and evaluating design configurations. A three-dimensional magnetostatic finite element model of STC's 55-We TDC linear alternator was developed to evaluate the demagnetization fields affecting the alternator magnets. Since the actual linear alternator hardware is symmetric to the quarter section about the axis of motion, only a quarter section of the alternator was modeled. The components modeled included the mover laminations, the neodymium-iron-boron magnets, the stator laminations, and the copper coils. The three-dimensional magnetostatic model was then coupled with a circuit simulator model of the alternator load and convertor controller. The coupled model was then used to generate alternator terminal voltage and current predictions. The predicted voltage and current waveforms agreed well with the experimental data, which tended to validate the accuracy of the coupled model. The model was then used to generate predictions of the demagnetization fields acting on the alternator magnets for the alternator under load. The preliminary model predictions indicate that the highest potential for demagnetization is along the inside surface of the uncovered magnets. The demagnetization field for the uncovered magnets when the mover is positioned at the end of a stroke is higher than it is when the mover is at the position of maximum induced voltage or maximum alternator current. Assuming normal load conditions, the model predicted that the onset of demagnetization is most likely to occur for magnet temperatures above 101 C.

Geng, Steven M.↗
NASA NTRS2003

Stirling Convertor Technologies Being Developed for a Stirling Radioisotope Generator

The Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and the NASA Glenn Research Center are developing a high-efficiency Stirling Radioisotope Generator (SRG) for NASA space science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. On Mars, rovers with SRGs would be used for missions that might not be able to use photovoltaic power systems, such as exploration at high Martian latitudes and missions of long duration. The projected SRG system efficiency of 23 percent will reduce the required amount of radioisotope by a factor of 4 or more in comparison to currently used Radioisotope Thermoelectric Generators. The Department of Energy recently named Lockheed Martin as the system integration contractor. Lockheed Martin has begun to develop the SRG engineering unit under contract to the Department of Energy, and has contract options to develop the qualification unit and the first flight units. The developers expect the SRG to produce about 114 Wdc at the beginning of mission, using two opposed Stirling convertors and two General Purpose Heat Source modules. STC previously developed the Stirling convertor under contract to the Department of Energy and is now providing further development as a subcontractor to Lockheed Martin. Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. A key milestone was recently reached with the accumulation of 12 000 hr of long-term aging on two types of neodymium-iron boron permanent magnets. These tests are characterizing any possible aging in the strength or demagnetization resistance of the magnets used in the linear alternator. Preparations are underway for a thermal/vacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. In addition, Glenn is developing a charging system for the convertors to ensure clean fills of the helium working fluid and to monitor levels of any possible contaminants at different test intervals. Possible oxidation effects depend on the level of any oxygen contamination-regenerator materials and displacer radiation shields are now being evaluated for possible oxidation effects.

Thieme, Lanny G.↗
NASA NTRS2004

FY 2003 Scientific and Technical Reports, Articles, Papers, and Presentations

This Technical Memorandum (TM) presents formal NASA technical reports, papers published in technical journals, and presentations by Marshall Space Flight Center (MSFC) personnel in FY 2003. It also includes papers of MSFC contractors. After being announced in STAR, all NASA series reports may be obtained from the National Technical Information Service, 5285 Port Royal Road, Spring.eld, VA 22161. The information in this TM may be of value to the scientific and engineering community in determining what information has been published and what is available.

Fowler, B. A.↗
NASA NTRS2005

The Effect of Infrastructure Sharing in Estimating Operations Cost of Future Space Transportation Systems

NASA and the aerospace industry are extremely serious about reducing the cost and improving the performance of launch vehicles both manned or unmanned. In the aerospace industry, sharing infrastructure for manufacturing more than one type spacecraft is becoming a trend to achieve economy of scale. An example is the Boeing Decatur facility where both Delta II and Delta IV launch vehicles are made. The author is not sure how Boeing estimates the costs of each spacecraft made in the same facility. Regardless of how a contractor estimates the cost, NASA in its popular cost estimating tool, NASA Air force Cost Modeling (NAFCOM) has to have a method built in to account for the effect of infrastructure sharing. Since there is no provision in the most recent version of NAFCOM2002 to take care of this, it has been found by the Engineering Cost Community at MSFC that the tool overestimates the manufacturing cost by as much as 30%. Therefore, the objective of this study is to develop a methodology to assess the impact of infrastructure sharing so that better operations cost estimates may be made.

Sundaram, Meenakshi↗
NASA NTRS2005

Proton-Exchange-Membrane Fuel Cell Powerplants Developed and Tested for Exploration Missions

Proton-exchange-membrane fuel cell (PEMFC) technology has received major attention for terrestrial applications, such as the automotive and residential markets, for the past 20 years. This attention has significantly advanced the maturity of the technology, resulting in ever more compact, efficient, reliable, and inexpensive PEMFC designs. In comparison to the terrestrial operating environment, the space operating environment is much more demanding. Microgravity to high-gravity loads and the need to use pure oxygen (rather than air) as the fuel cell oxidizer place more stringent demands on PEMFC technology. NASA and its partners from industry are leveraging terrestrial PEMFC advancements by conducting parallel space technology development for future exploration missions. A team from the NASA Glenn Research Center, NASA Johnson Space Center, and NASA Kennedy Space Center recently completed the first phase of a PEMFC powerplant development effort for exploration missions. The industry partners for this phase of the development effort were ElectroChem, Inc., and Teledyne Energy Systems, Inc. Under contract to Glenn, both of these industry partners successfully designed, fabricated, and tested a breadboard PEMFC powerplant in the 1- to 5-kW power range. These powerplants were based on existing company-proprietary fuel cell stack designs, combined with off-the-shelf components, which formed the balance of the powerplant design. Subsequent to the contractor development efforts, both powerplants were independently tested at Johnson to verify operational and performance characteristics, and to determine suitability for further technology development in the second phase of the NASA-led effort. Following the independent NASA testing, Teledyne Energy Systems, Inc., was selected to develop an engineering model PEMFC powerplant. This effort was initiated by the 2nd Generation Reusable Launch Vehicle (RLV) Program Office in 2001; it transitioned to the Next Generation Launch Technologies (NGLT) Program Office in 2003. The effort is now being funded by the Exploration Program Office. We plan to summarize the results from the ongoing engineering model PEMFC powerplant development in a future Research & Technology article.

Hoberecht, Mark A.↗
NASA NTRS2005

Reliability of the SRG110 Stirling Convertor Quantified

The NASA Glenn Research Center has been involved in the development of Stirling power-conversion technology and is currently providing technical support to the Department of Energy and Lockheed Martin, of Valley Forge, Pennsylvania, their system integration contractor, for the 110-W Stirling Radioisotope Generator (SRG110). Stirling radioisotope power-conversion technology is a potential candidate for future deep-space science and exploration missions. The SRG110 has a multifold increase in efficiency and would reduce the inventory of the radioisotope fuel by a factor of 4 in comparison to systems used to power past missions.

Shah, Ashwin R.↗
NASA NTRS2005

Liquid-Hydrogen-Cooled 450-hp Electric Motor Test Stand Being Developed

With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled aircraft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft s propulsive fans. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are too heavy for aircraft propulsion. We need to develop high-power, lightweight electric motors (highpower- density motors). One approach is to increase the conductivity of the wires by cooling them with liquid hydrogen (LH2). This would allow superconducting rotors with an ironless core. In addition, the motor could use very pure aluminum or copper, substances that have low resistances at cryogenic temperatures. A preliminary design of a 450-hp LH2-cooled electric motor was completed and is being manufactured by a contractor. This motor will be tested at the NASA Glenn Research Center and will be used to test different superconducting materials such as magnesium diboride (MgB2). The motor will be able to operate at speeds of up to 6000 rpm.

Albert F. Kascak↗
NASA NTRS2005

G2 Flywheel Module Operated at 41,000 rpm

NASA Glenn Research Center s Flywheel Development Team designed, built, and successfully operated the new G2 flywheel to 41,000 rpm on September 2, 2004. This work was supported by the Aerospace Flywheel Technology Program--a NASA Office of Aerospace Technology ETC Program funded by the Energetics Project. The work was performed by a team of civil servants, contractors, and grantees managed by Glenn s Electrical Systems Development Branch, Structural Mechanics and Dynamics Branch, and Space Power & Propulsion Test Engineering Branch. The G2 flywheel was designed to be a low-cost modular testbed for flywheel system integration and component demonstrations.

Ralph H Jansen↗
NASA NTRS2005

Damage-Tolerant, Affordable Composite Engine Cases Designed and Fabricated

An integrated team of NASA personnel, Government contractors, industry partners, and university staff have developed an innovative new technology for commercial fan cases that will substantially influence the safety and efficiency of future turbine engines. This effective team, under the direction of the NASA Glenn Research Center and with the support of the Federal Aviation Administration, has matured a new class of carbon/polymer composites and demonstrated a 30- to 50-percent improvement in specific containment capacity (blade fragment kinetic energy/containment system weight). As the heaviest engine component, the engine case/containment system greatly affects both the safety and efficiency of aircraft engines. The ballistic impact research team has developed unique test facilities and methods for screening numerous candidate material systems to replace the traditional heavy, metallic engine cases. This research has culminated in the selection of a polymer matrix composite reinforced with triaxially braided carbon fibers and technology demonstration through the fabrication of prototype engine cases for three major commercial engine manufacturing companies.

Hopkins, Dale A.↗
NASA NTRS2005

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite s White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with landing and turnaround maintenance performed. The Flight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development (R&D). NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of this effort, the X-37 team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff R&D and provides valuable experience to implement the Vision for Space Exploration.

Turner, Susan↗
NASA NTRS2005

Research and Technology 2004

This report selectively summarizes NASA Glenn Research Center's research and technology accomplishments for fiscal year 2004. It comprises 133 short articles submitted by the staff scientists and engineers. The report is organized into three major sections: Programs and Projects, Research and Technology, and Engineering and Technical Services. A table of contents and an author index have been developed to assist readers in finding articles of special interest. This report is not intended to be a comprehensive summary of all the research and technology work done over the past fiscal year. Most of the work is reported in Glenn-published technical reports, journal articles, and presentations prepared by Glenn staff and contractors. In addition, university grants have enabled faculty members and graduate students to engage in sponsored research that is reported at technical meetings or in journal articles. For each article in this report, a Glenn contact person has been identified, and where possible, a reference document is listed so that additional information can be easily obtained. The diversity of topics attests to the breadth of research and technology being pursued and to the skill mix of the staff that makes it possible. For more information, visit Glenn's Web site at http://www.nasa.gov/glenn/. This document is available online (http://www.grc.nasa.gov/WWW/RT/). For publicly available reports, visit the Glenn Technical Report Server (http://gltrs.grc.nasa.gov).

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NASA NTRS1998

An Inflatable L-Band Microstrip SAR Array

Inflatable structures have been identified as one of the enabling technologies to achieve low mass, high packaging efficiency, and reliable deployment for future NASA spaceborne synthetic aperture radar (SAR) array antennas. A current L-band SAR antenna development, with aperture size of 10 m x 3 m, is required to have the capabilities of dual-linear polarization, 80-MHz bandwidth, electronic beam scanning, and less than 100 kg of mass. An inflatable concept, which employs the inflatable tubular frame structure to support a multilayer, thin membrane, microstrip array radiating aperture, has been identified. It uses a "roll-up" concept, for deploying the thin membranes to form a planar array aperture. To demonstrate this concept, two contracts were independently given to ILC Dover, Inc. and L'Garde Corp. for each to construct a 1/3 size (3.3 m x 1.0 m) functional model with an inflatable structure at L-band frequency. JPL provided both contractors with the antenna RF design and the etched thin membranes. The ILC Dover model has been delivered to JPL and gone through a series of deployment and RF tests. This is believed to be the first inflatable array antenna ever developed. This paper presents the mechanical and electrical constructions of this inflatable array and its test results.

Huang, J.↗
NASA NTRS1994

Wind Prelaunch Mission Operations Report (MOR)

The National Aeronautics and Space Administration (NASA) Wind mission is the first mission of the Global Geospace Science (GGS) initiative. The Wind laboratory will study the properties of particles and waves in the region between the Earth and the Sun. Using the Moon s gravity to save fuel, dual lunar swing-by orbits enable the spacecraft to sample regions close to and far from the Earth. During the three year mission, Wind will pass through the bow shock of Earth's magnetosphere to begin a thorough investigation of the solar wind. Mission objectives require spacecraft measurements in two orbits: lunar swing- by ellipses out to distances of 250 Earth radii (RE) and a small orbit around the Lagrangian point L-l that remains between the Earth and the Sun. Wind will be placed into an initial orbit for approximately 2 years. It will then be maneuvered into a transition orbit and ultimately into a halo orbit at the Earth-Sun L-l point where it will operate for the remainder of its lifetime. The Wind satellite development was managed by NASA's Goddard Space Flight Center with the Martin Marietta Corporation, Astro-Space Division serving as the prime contractor. Overall programmatic direction was provided by NASA Headquarters, Office of Space Science. The spacecraft will be launched under a launch service contract with the McDonnell Douglas Corporation on a Delta II Expendable Launch Vehicle (ELV) within a November l-l4, 1994 launch window. The Wind spacecraft carries six U.S. instruments, one French instrument, and the first Russian instrument ever to fly on an American satellite. The Wind and Polar missions are the two components of the GGS Program. Wind is also the second mission of the International Solar Terrestrial Physics (ISTP) Program. The first ISTP mission, Geotail, is a joint project of the Institute of Space and Astronautical Science of Japan and NASA which launched in 1992. The Wind mission is planned to overlap Geotail by six months and Polar by one year. The Wind and Polar missions, together with the Geotail mission (launched on July 24, 1992) and supporting equatorial measurements, will provide simultaneous data to enable the study of solar wind input to the magnetosphere and key elements of the magnetospheric response: ring current energy storage, geomagnetic tail energy storage, and ionospheric energy input.

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NASA NTRS2005

Searching for 'Unknown Unknowns'

The NASA Engineering and Safety Center (NESC) was established to improve safety through engineering excellence within NASA programs and projects. As part of this goal, methods are being investigated to enable the NESC to become proactive in identifying areas that may be precursors to future problems. The goal is to find unknown indicators of future problems, not to duplicate the program-specific trending efforts. The data that is critical for detecting these indicators exist in a plethora of dissimilar non-conformance and other databases (without a common format or taxonomy). In fact, much of the data is unstructured text. However, one common database is not required if the right standards and electronic tools are employed. Electronic data mining is a particularly promising tool for this effort into unsupervised learning of common factors. This work in progress began with a systematic evaluation of available data mining software packages, based on documented decision techniques using weighted criteria. The four packages, which were perceived to have the most promise for NASA applications, are being benchmarked and evaluated by independent contractors. Preliminary recommendations for "best practices" in data mining and trending are provided. Final results and recommendations should be available in the Fall 2005. This critical first step in identifying "unknown unknowns" before they become problems is applicable to any set of engineering or programmatic data.

Parsons, Vickie S.↗
NASA NTRS1996

Foundation and Development of Local Trimble User Groups: Perspectives from the Beginning

Trimble Navigation was one of the original contractors building military grade GPS receivers and has been a dominant manufacturer in the civilian market. Two Trimble user groups have been formed. By participating in GPS user groups, members become more aware of GPS capabilities and opportunities, meet people with similar interests and needs, expand business opportunities, and provide Trimble with valuable information needed to engineer better GPS equipment.

Duncan, Brean W.↗
NASA NTRS2005

An Overview of the James Webb Space Telescope (JWST) Project

The JWST project at the GSFC is responsible for the development, launch, operations and science data processing for the James Webb Space Telescope. The JWST project is currently in phase B with its launch scheduled for August 2011. The project is a partnership between NASA, ESA and CSA. The U.S. JWST team is now fully in place with the selection of Northrop Grumman Space Technology (NGST) as the prime contractor for the telescope and the Space Telescope Science Institute (STScI) as the mission operations and science data processing lead. This paper will provide an overview of the current JWST architecture and mission status including technology developments and risks.

Sabelhaus, Phillip A.↗
NASA NTRS2005

2004 NASA Seal/Secondary Air System Workshop, Volume 1

The 2004 NASA Seal/Secondary Air System workshop covered the following topics: (1) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (2) Overview of the NASA-sponsored Ultra-Efficient Engine Technology (UEET) program; (3) Overview of NASA Glenn s seal program aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (4) Reviews of NASA prime contractor and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (5) Reviews of material development programs relevant to advanced seals development. The NASA UEET overview illustrated for the reader the importance of advanced technologies, including seals, in meeting future turbine engine system efficiency and emission goals. For example, the NASA UEET program goals include an 8- to 15-percent reduction in fuel burn, a 15-percent reduction in CO2, a 70-percent reduction in NOx, CO, and unburned hydrocarbons, and a 30-dB noise reduction relative to program baselines. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle, as part of NASA s new Exploration Initiative. Plans to develop the necessary mechanism and androgynous seal technologies were reviewed. Seal challenges posed by reusable re-entry space vehicles include high-temperature operation, resiliency at temperature to accommodate gap changes during operation, and durability to meet mission requirements.

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NASA NTRS2005

Water Injection Feasibility for Boeing 747 Aircraft

Can water injection be offered at a reasonable cost to large airplane operators to reduce takeoff NO( sub x) emissions? This study suggests it may be possible. This report is a contract deliverable to NASA Glenn Research Center from the prime contractor, The Boeing Commercial Airplane Company of Seattle, WA. This study was supported by a separate contract to the Pratt & Whitney Engine Company of Hartford, CT (contract number NNC04QB58P). Aviation continues to grow and with it, environmental pressures are increasing for airports that service commercial airplanes. The feasibility and performance of an emissions-reducing technology, water injection, was studied for a large commercial airplane (e.g., Boeing 747 with PW4062 engine). The primary use of the water-injection system would be to lower NOx emissions while an important secondary benefit might be to improve engine turbine life. A tradeoff exists between engine fuel efficiency and NOx emissions. As engines improve fuel efficiency, by increasing the overall pressure ratio of the engine s compressor, the resulting increased gas temperature usually results in higher NOx emissions. Low-NO(sub x) combustors have been developed for new airplanes to control the increases in NO(sub x) emissions associated with higher efficiency, higher pressure ratio engines. However, achieving a significant reduction of NO(sub x) emissions at airports has been challenging. Using water injection during takeoff has the potential to cut engine NO(sub x) emissions some 80 percent. This may eliminate operating limitations for airplanes flying into airports with emission constraints. This study suggests an important finding of being able to offer large commercial airplane owners an emission-reduction technology that may also save on operating costs.

Daggett, David L.↗