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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Test System to Study the Ignition of Metals by Polymers in Oxygen

A new test system that uses Laser energy to ignite a polymer promoter has been developed at the NASA White Sands Test Facility. It will facilitate the study of the spread of fire from a burning polymer material to the metal surrounding it. The system can be used to answer questions regarding the effects of configuration on ignition and combustion. The data obtained from this test could also be used to develop mathematical models for analyzing the effects of configuration on ignition and combustion. The system features a 10,000-psi (69-MPa) test chamber with sight glass windows on either end and a 25-watt carbon dioxide Laser for an ignition source. The test system can be used with gaseous oxygen, nitrogen or any mixture of the two gases. To minimize the effect of preheating the metallic, the polymer is ignited with a minimal amount of Laser energy. Igniting the polymer in this fashion also simplifies the thermodynamic analysis of the ignition and propagation reactions. The system is very robust, versatile and straightforward to use. Depending on the test pressure and configuration, the test system operator can perform as many as 20 tests per day. Test results verify that ignition and combustion of the metallic sample is not only dependent on pressure, material type and temperature, but configuration of both the polymer promoter and metallic sample. Both 6061 aluminum and 316 stainless steel 0.25-inch (6.35-mm) diameter rods with a standard 0-ring groove were tested with Buna-N, Silicone, Teflon and Viton 0-rings. The system ignited all four types of 0-rings in oxygen at pressures ranging from ambient to 10,000 psi (69 MPa). However, neither the stainless steel nor the aluminum rods on which the O-rings were mounted ignited in any test conditions. Future testing may be done on the 0.25-inch (6.35-mm) rod and O-ring configuration to evaluate the lack of ignition in these tests. Future configurations may include a plug of polymer in the base of the sample and replicas of fire-damaged components. Furthermore, the test system may be used in the future to analyze the oxidation rate of Laser-heated metals in gaseous oxygen.

Shoffstall, Michael S.↗
NASA NTRS2001

Wiping Metal Transfer in Friction Stir Welding

Much evidence suggests that as the friction stir pin-tool moves along a weld seam the displacement of metal takes place by a wiping action at the surface of a plug of metal that rotates with the tool. The wiping model is explained and some consequences for the friction stir welding process are drawn.

Nunes, Arthur C., Jr.↗
NASA NTRS2000

Advanced Methods for Aircraft Engine Thrust and Noise Benefits: Nozzle-Inlet Flow Analysis

In this project, we continue to develop the previous joint research between the Fluid Mechanics and Acoustics Laboratory (FM&AL) at Hampton University (HU) and the Jet Noise Team (JNT) at the NASA Langley Research Center (NASA LaRC). The FM&AL was established at Hampton University in June of 1996 and has conducted research under two NASA grants: NAG-1-1835 (1996-99), and NAG-1-1936 (1997-00). In addition, the FM&AL has jointly conducted research with the Central AeroHydrodynamics Institute (TsAGI, Moscow) in Russia under a Civilian Research and Development Foundation (CRDF) grant #RE2-136 (1996-99). The goals of the FM&AL programs are twofold: (1) to improve the working efficiency of the FM&AUs team in generating new innovative ideas and in conducting research in the field of fluid dynamics and acoustics, basically for improvement of supersonic and subsonic aircraft engines, and (2) to attract promising minority students to this research and training and, in cooperation with other HU departments, to teach them basic knowledge in Aerodynamics, Gas Dynamics, and Theoretical and Experimental Methods in Aeroacoustics and Computational Fluid Dynamics (CFD). The research at the HU FM&AL supports reduction schemes associated with the emission of engine pollutants for commercial aircraft and concepts for reduction of observables for military aircraft. These research endeavors relate to the goals of the NASA Strategic Enterprise in Aeronautics concerning the development of environmentally acceptable aircraft. It is in this precise area, where the US aircraft industry, academia, and Government are in great need of trained professionals and which is a high priority goal of the Minority University Research and Education (MUREP) Program, that the HU FM&AL can make its most important contribution. The main achievements for the reporting period in the development of concepts for noise reduction and improvement in efficiency for jet exhaust nozzles and inlets for aircraft engines are as follows: (1) Publications- The AIAA Paper #99-1924 has been presented at the 5th AIAA/CEAS Aeroacoustics Conference, May 10-12, 1999, Seattle, WA; the AIAA Paper #00-3315 has been accepted for the 36th AIAA/ASME/ SAE/ASEE Joint Propulsion Conference, 17-19 July, 2000, Huntsville, AL; and another paper has been accepted for the International Environmental Congress, 14-16 June, 2000, St.-Petersburg, Russia. (2) Two patents were granted on July 20, 1999, and January 12, 2000. (3) Three reports/presentations at the NASA LaRC and GRC (06/22199, 09/26/ 99, and 06/25/00). (4) Grants and Proposals: Four proposals were submitted to the NASA and CRDF; a NASA Faculty Award was granted on January, 2000. A CRDF Young Investigator Program Award was granted for a 3 months visit of the Russian scientist to the HU FM&AL (03/99-05/99). (5) Theory and Numerical Simulations- Analytical theory, numerical simulation, comparison of theoretical with experimental results, and modification of theoretical approaches, models, grids etc. have been conducted for several complicated 2D and 3D nozzle and inlet designs using NASA codes based on full Euler and Navier-Stokes solvers: CFL3D, CRAFT, GODUNOV, and others. New approach for environmental monitoring via infrasound. (6) Experimental Tests: Experimental acoustic tests at the TsAGI, Moscow, with nozzles having Screwdriver or Axisymmetric Plug and Permeable Shells. A small scale working model of the NASA Low Speed Wind Tunnel (LSWT) has been installed in the Experimental Hall of the HU FM&AL (June, 1999). Preliminary preparations for experimental tests were made. (7) Students Research Activity: Involvement of the two graduate students as research assistants in the current research project.

Gilinsky, Mikhail↗
NASA NTRS2000

Rapidly Re-Configurable Flight Simulator Tools for Crew Vehicle Integration Research and Design

While simulation is a valuable research and design tool, the time and difficulty required to create new simulations (or re-use existing simulations) often limits their application. This report describes the design of the software architecture for the Reconfigurable Flight Simulator (RFS), which provides a robust simulation framework that allows the simulator to fulfill multiple research and development goals. The core of the architecture provides the interface standards for simulation components, registers and initializes components, and handles the communication between simulation components. The simulation components are each a pre-compiled library 'plug-in' module. This modularity allows independent development and sharing of individual simulation components. Additional interfaces can be provided through the use of Object Data/Method Extensions (OD/ME). RFS provides a programmable run-time environment for real-time access and manipulation, and has networking capabilities using the High Level Architecture (HLA).

Schutte, Paul C.↗
NASA NTRS2000

Gasdynamic Mirror Fusion Propulsion Experiment

A gasdynamic mirror (GDM) fusion propulsion experiment is currently being constructed at the NASA Marshall Space Flight Center (MSFC) to test the feasibility of this particular type of fusion device. Because of the open magnetic field line configuration of mirror fusion devices, they are particularly well suited for propulsion system applications since they allow for the easy ejection of thrust producing plasma. Currently, the MSFC GDM is constructed in three segments. The vacuum chamber mirror segment, the plasma injector mirror segment, and the main plasma chamber segment. Enough magnets are currently available to construct up to three main plasma chamber segments. The mirror segments are also segmented such that they can be expanded to accommodate new end plugging strategies with out requiring the disassembly of the entire mirror segment. The plasma for the experiment is generated in a microwave cavity located between the main magnets and the mirror magnets. Ion heating is accomplished through ambipolar diffusion. The objective of the experiment is to investigate the stability characteristics of the gasdynamic mirror and to map a region of parameter space within which the plasma can be confined in a stable steady state configuration. The mirror ratio, plasma density, and plasma "b" will be varied over a range of values and measurements subsequently taken to determine the degree of plasma stability.

Emrich, Bill↗
NASA NTRS2000

AST Critical Propulsion and Noise Reduction Technologies for Future Commercial Subsonic Engines: Separate-Flow Exhaust System Noise Reduction Concept Evaluation

This report describes the work performed by General Electric Aircraft Engines (GEAE) and Allison Engine Company (AEC) on NASA Contract NAS3-27720 AoI 14.3. The objective of this contract was to generate quality jet noise acoustic data for separate-flow nozzle models and to design and verify new jet-noise-reduction concepts over a range of simulated engine cycles and flight conditions. Five baseline axisymmetric separate-flow nozzle models having bypass ratios of five and eight with internal and external plugs and 11 different mixing-enhancer model nozzles (including chevrons, vortex-generator doublets, and a tongue mixer) were designed and tested in model scale. Using available core and fan nozzle hardware in various combinations, 28 GEAE/AEC separate-flow nozzle/mixing-enhancer configurations were acoustically evaluated in the NASA Glenn Research Center Aeroacoustic and Propulsion Laboratory. This report describes model nozzle features, facility and data acquisition/reduction procedures, the test matrix, and measured acoustic data analyses. A number of tested core and fan mixing enhancer devices and combinations of devices gave significant jet noise reduction relative to separate-flow baseline nozzles. Inward-flip and alternating-flip core chevrons combined with a straight-chevron fan nozzle exceeded the NASA stretch goal of 3 EPNdB jet noise reduction at typical sideline certification conditions.

Janardan, B. A.↗
NASA NTRS2001

Normal Gravity Testing of a Microchannel Phase Separator for In Situ Resource Utilization

A microchannel separator, with 2.7 millimeters as the smallest dimension, was tested, and a pore throat structure captured and removed liquid from a gas-liquid stream. The microchannel device was tested over a of gas and liquid flow rates ranging from 0.0005 up to 0. 14 volume fraction of liquid. Four liquids were tested with air. The biggest factor affecting the throughput is the capacity of liquid flow through the pore throat, which is dictated by permeability, liquid viscosity, flow area, pore throat thickness, and pressure difference across the pore throat. Typically, complete separation of gas and liquid fractions was lost when the liquid flow rate reached about 40 to 60% of the pore throat capacity. However, this could occur over a range of 10 to 90% utilization of pore throat capacity. Breakthrough occurs in the microchannel phase separator at conditions similar to the annular to plug flow transition of two-phase microgravity pipe flow implying that operating in the proper flow regime is crucial. Analysis indicates that the Bond number did not affect performance, supporting the premise that hydrodynamic, interfacial, and capillary forces are more important than gravity. However, the relative importance of gravity is better discerned through testing under reduced gravity conditions.

TeGrotenhuis, Ward E.↗
NASA NTRS2001

Low-Cost Gas Generator and Ignitor

A gas generator and ignitor assembly for powering a turbine of a turbopump assembly for a rocket engine comprises an injector and a combustion chamber. the injector having a body member including a fuel inlet and an oxidizer inlet spaced one from the other and communicating with respective radially spaced apart annular members in the body member. Three annuli communicate with the fuel inlet and two annuli communicate with the oxidizer inlet. the annuli which communicates with the oxidizer being positioned between pairs of the other annuli, The body member is enclosed by a plate having an array of bores arranged in two series with three radially spaced apart groups of circular rows in each series. The outer series has 28 groups of triplet bores while the inner series has 14 groups of triplet bores. The annuli which communicate with oxidizer feed bores of each series that are between the other bores of a triplet. the latter bores communicating with annuli that communicate with fuel. The inner and outer bores of the triplets of each series are inclined relatively to each other and to the third bore of the triplet so that fuel and oxidizer atomizes as it is sprayed into the inlet of the combustion chamber where the propellants are mixed. and burned. The burning of the propellants is effected by ignition of a plug of solid propellant fuel mounted to communicate with the interior of the combustion chamber.

Henry J Dennis, Jr↗
NASA NTRS2001

Development of a Gas-Fed Pulse Detonation Research Engine

In response to the growing need for empirical data on pulse detonation engine performance and operation, NASA Marshall Space Flight Center has developed and placed into operation a low-cost gas-fed pulse detonation research engine. The guiding design strategy was to achieve a simple and flexible research apparatus, which was inexpensive to build and operate. As such, the engine was designed to operate as a heat sink device, and testing was limited to burst-mode operation with run durations of a few seconds. Wherever possible, maximum use was made of standard off-the-shelf industrial or automotive components. The 5-cm diameter primary tube is about 90-cm long and has been outfitted with a multitude of sensor and optical ports. The primary tube is fed by a coaxial injector through an initiator tube, which is inserted directly into the injector head face. Four auxiliary coaxial injectors are also integrated into the injector head assembly. All propellant flow is controlled with industrial solenoid valves. An automotive electronic ignition system was adapted for use, and spark plugs are mounted in both tubes so that a variety of ignition schemes can be examined. A microprocessor-based fiber-optic engine control system was developed to provide precise control over valve and ignition timing. Initial shakedown testing with hydrogen/oxygen mixtures verified the need for Schelkin spirals in both the initiator and primary tubes to ensure rapid development of the detonation wave. Measured pressure wave time-of-flight indicated detonation velocities of 2.4 km/sec and 2.2 km/sec in the initiator and primary tubes, respectively. These values implied a fuel-lean mixture corresponding to an H2 volume fraction near 0.5. The axial distribution for the detonation velocity was found to be essentially constant along the primary tube. Time-resolved thrust profiles were also acquired for both underfilled and overfilled tube conditions. These profiles are consistent with previous time-resolved measurements on single-cycle tubes where the thrust is found to peak as the detonation wave exits the tube, and decay as the tube blows down.

Litchford, Ron J.↗
NASA NTRS2001

An Algorithm for Interactive Modeling of Space-Transportation Engine Simulations: A Constraint Satisfaction Approach

In this research we have developed an algorithm for the purpose of constraint processing by utilizing relational algebraic operators. Van Beek and others have investigated in the past this type of constraint processing from within a relational algebraic framework, producing some unique results. Apart from providing new theoretical angles, this approach also gives the opportunity to use the existing efficient implementations of relational database management systems as the underlying data structures for any relevant algorithm. Our algorithm here enhances that framework. The algorithm is quite general in its current form. Weak heuristics (like forward checking) developed within the Constraint-satisfaction problem (CSP) area could be also plugged easily within this algorithm for further enhancements of efficiency. The algorithm as developed here is targeted toward a component-oriented modeling problem that we are currently working on, namely, the problem of interactive modeling for batch-simulation of engineering systems (IMBSES). However, it could be adopted for many other CSP problems as well. The research addresses the algorithm and many aspects of the problem IMBSES that we are currently handling.

Mitra, Debasis↗
NASA NTRS2001

Telescience Support Center (TSC) at MSFC

Marshall Space Flight Center (MSFC) is assigned authority and responsibility to manage and execute the microgravity flight and ground projects within the materials sciences, biotechnology sciences, and glovebox program for the Microgravity Research Program. The objective of this project is to provide the three MSFC science disciplines a dedicated area for their individual science flight payloads and operations and to explore the Plug-n-Play philosophy.

Owen, Clark T.↗
NASA NTRS1995

Performance Evaluation Tools for Next Generation Scalable Computing Platforms

The Federal High Performance and Communications (HPCC) Program continue to focus on R&D in a wide range of high performance computing and communications technologies. Using its accomplishments in the past four years as building blocks towards a Global Information Infrastructure (GII), an Implementation Plan that identifies six Strategic Focus Areas for R&D has been proposed. This white paper argues that a new generation of system software and programming tools must be developed to support these focus areas, so that the R&D we invest today can lead to technology pay-off a decade from now. The Global Computing Infrastructure (GCI) in the Year 2000 and Beyond would consists of thousands of powerful computing nodes connected via high-speed networks across the globe. Users will be able to obtain computing in formation services the GCI with the ease of using a plugging a toaster into the electrical outlet on the wall anywhere in the country. Developing and managing the GO requires performance prediction and monitoring capabilities that do not exist. Various accomplishments in this field today must be integrated and expanded to support this vision.

Yan, Jerry C.↗
NASA NTRS2001

X-33 Tank Failure During Autoclave Fabrication

During a repair cure cycle on tank #1 of the X-33 liquid hydrogen tanks, a skin to core disbond occurred. Both the inner skin and outer skin of the lobe #1 sandwich panel was noted to have been disbonded and cracked- An investigation was undertaken to determine the cause of this failure. The investigation consisted of reviewing all of the processing data and performing testing on the failed lobe #1, as well as the other lobes, which did not fail during the cure cycle. The tests consisted of residual stress measurements in one of the intact lobes and "plug-pulls" to assess skin to core strength on all of the remaining lobes. Results showed an extremely low bondline strength due to lack of proper filleting of the adhesive, in addition, tests showed a very rapid decrease in strength with increasing temperature, as well as a further decrease in strength with a larger number of cycles. Also, the honeycomb used was not vented so pressure could build up within the cells. All of these factors appeared to be contributors to the failure.

Nettles, Alan T.↗
NASA NTRS1999

X-33 Ascent Flight Controller Design by Trajectory Linearization: A Singular Perturbational Approach

The flight control of X-33 poses a challenge to conventional gain-scheduled flight controllers due to its large attitude maneuvers from liftoff to orbit and reentry. In addition, a wide range of uncertainties in vehicle handling qualities and disturbances must be accommodated by the attitude control system. Nonlinear tracking and decoupling control by trajectory linearization can be viewed as the ideal gain-scheduling controller designed at every point on the flight trajectory. Therefore it provides robust stability and performance at all stages of flight without interpolation of controller gains, and eliminates costly controller redesigns due to minor airframe alteration or mission reconfiguration. A prototype trajectory linearization design for X-33 ascent flight controller was designed and tested with 3-DOF and 6-DOF simulations during the 10 weeks SFFP. It is noted that the 6-DOF results were obtained from the 3-DOF design with only a few hours of tuning, which demonstrates the inherent robustness of the design technique. It is this "plug-and-play" feature that is much needed by NASA for the development, test and routine operations of the RLVs. Plans for further research are also presented.

Zhu, J. Jim↗
NASA NTRS1999

Flow Trajectories in Friction Stir Welding

In the Friction Stir Welding (FSW) process, a rotating, shouldered tool with a threaded pin is inserted under pressure along the seam of two pieces of metal which are tightly clamped together, and secured against a rigid anvil underneath. The rotating pin travels along the seam and through a combination of pressure and friction heating produces a zone of plastic deformation around the pin within the workpiece on either side of the seam. As the pin is moved in the direction of welding, the plasticised material moves around the tool and bonds together behind it. The elements of the material flow behavior are a combination of three elements. There is a rotational transport of material being carried around the tool, extrusion of material being forced around the pin on both sides into the cavity created behind it, and a lifting and dropping of material as it is stirred and mixed by the rotating action of the pin. It was assumed that rotational motion of the plastic zone is the primary mechanism for transport of material around the welding tool. A kinematic mathematical model was used to compute trajectories of material movement for various distributions of rotational slip within the plastic zone. These trajectories were then compared with the results of an experiment that produced radiographs of markers embedded in a workpiece that was welded with the FSW process. It was assumed that the copper wire markers retained their original length as the aluminum material flowed around them. The kinematic model included a constraint so that the displacements were such that the total length of the wire markers did not increase after deformation. There was good agreement between the calculated trajectories for the case of localized slip at the outer surface of the plastic deformation zone and the radiographs of the copper wire markers. The trajectories differed markedly from the radiograph traces when a distributed slip zone was assumed. It was concluded that the flow field could be described generally by a rotating plug model with slip occurring on the surface at the outer boundary of the plastic zone.

Bernstein, Edward L.↗
NASA NTRS1998

Model Based Autonomy for Robust Mars Operations

Space missions have historically relied upon a large ground staff, numbering in the hundreds for complex missions, to maintain routine operations. When an anomaly occurs, this small army of engineers attempts to identify and work around the problem. A piloted Mars mission, with its multiyear duration, cost pressures, half-hour communication delays and two-week blackouts cannot be closely controlled by a battalion of engineers on Earth. Flight crew involvement in routine system operations must also be minimized to maximize science return. It also may be unrealistic to require the crew have the expertise in each mission subsystem needed to diagnose a system failure and effect a timely repair, as engineers did for Apollo 13. Enter model-based autonomy, which allows complex systems to autonomously maintain operation despite failures or anomalous conditions, contributing to safe, robust, and minimally supervised operation of spacecraft, life support, In Situ Resource Utilization (ISRU) and power systems. Autonomous reasoning is central to the approach. A reasoning algorithm uses a logical or mathematical model of a system to infer how to operate the system, diagnose failures and generate appropriate behavior to repair or reconfigure the system in response. The 'plug and play' nature of the models enables low cost development of autonomy for multiple platforms. Declarative, reusable models capture relevant aspects of the behavior of simple devices (e.g. valves or thrusters). Reasoning algorithms combine device models to create a model of the system-wide interactions and behavior of a complex, unique artifact such as a spacecraft. Rather than requiring engineers to all possible interactions and failures at design time or perform analysis during the mission, the reasoning engine generates the appropriate response to the current situation, taking into account its system-wide knowledge, the current state, and even sensor failures or unexpected behavior.

Kurien, James A.↗
NASA NTRS2002

RF Manipulation of Ions in the High Performance Antiproton Trap (HiPAT)

The annihilation of antimatter provides the highest mass specific energy of any other known reaction. Proper harnessing of this energy holds great promise for future space propulsion systems. Many different propulsion concepts have been proposed that take advantage of antimatter, either using matter-antimatter as the primary fuel, or as a 'spark plug' for fusion and fission systems. In order to begin to address these concepts experimentally, a method of storing and transporting antimatter must be developed. The High Performance Antiproton Trap (HiPAT) is a first-generation storage and transportation device designed to store and transport 10(exp 12) antiprotons with a storage half-life of 18 days. It uses a Penning-Malmberg ion trap with a 4T magnetic field and 20 kV potential. This will enable researchers much more flexibility in the design of antimatter experiments related to propulsion. Ions cannot be stored indefinitely in a real trap, as ion cloud instabilities develop from imperfections in manufacturing and misalignments in assembly. Previous work has been done at both the National Institute of Standards and University of California in San Diego in using RF (radio frequency) signals to both diagnose and confine the ion cloud. Two electrodes in the trap have been segmented to allow both reception and transmission of RF waves in the ion cloud. Experiments are underway to determine the number of ions and density in the cloud by "listening" to protons contained in the HiPAT. Currently we believe the density of ions stored in the trap is roughly 10(exp 15) m(exp -3). Development of non-destructive techniques is vital to the project goals, enabling continuous monitoring of the quantities stored in the system. Experimental work is also being done in identifying RF transmission frequencies that can manipulate the density of the cloud, by exchanging energy and momentum between the RF wave and the ions. Preliminary experiments have demonstrated this interaction.

Pearson, J. Boise↗