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NASA NTRS2012

Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts

This process is designed to estimate the thickness change of a material through data analysis of a digitized version of an x-ray (or a digital x-ray) containing the material (with the thickness in question) and various tooling. Using this process, it is possible to estimate a material's thickness change in a region of the material or part that is thinner than the rest of the reference thickness. However, that same principle process can be used to determine the thickness change of material using a thinner region to determine thickening, or it can be used to develop contour plots of an entire part. Proper tooling must be used. An x-ray film with an S-shaped characteristic curve or a digital x-ray device with a product resulting in like characteristics is necessary. If a film exists with linear characteristics, this type of film would be ideal; however, at the time of this reporting, no such film has been known. Machined components (with known fractional thicknesses) of a like material (similar density) to that of the material to be measured are necessary. The machined components should have machined through-holes. For ease of use and better accuracy, the throughholes should be a size larger than 0.125 in. (.3 mm). Standard components for this use are known as penetrameters or image quality indicators. Also needed is standard x-ray equipment, if film is used in place of digital equipment, or x-ray digitization equipment with proven conversion properties. Typical x-ray digitization equipment is commonly used in the medical industry, and creates digital images of x-rays in DICOM format. It is recommended to scan the image in a 16-bit format. However, 12-bit and 8-bit resolutions are acceptable. Finally, x-ray analysis software that allows accurate digital image density calculations, such as Image-J freeware, is needed. The actual procedure requires the test article to be placed on the raw x-ray, ensuring the region of interest is aligned for perpendicular x-ray exposure capture. One or multiple machined components of like material/ density with known thicknesses are placed atop the part (preferably in a region of nominal and non-varying thickness) such that exposure of the combined part and machined component lay-up is captured on the x-ray. Depending on the accuracy required, the machined component fs thickness must be carefully chosen. Similarly, depending on the accuracy required, the lay-up must be exposed such that the regions of the x-ray to be analyzed have a density range between 1 and 4.5. After the exposure, the image is digitized, and the digital image can then be analyzed using the image analysis software.

Grau, David↗

NASA NTRS2002

The Maneuver Planning Process for the Microwave Anisotropy Probe (MAP) Mission

The Microwave Anisotropy Probe (MAP) was successfully launched from Kennedy Space Center's Eastern Range on June 30, 2001. MAP will measure the cosmic microwave background as a follow up to NASA's Cosmic Background Explorer (COBE) mission from the early 1990's. MAP will take advantage of its mission orbit about the Sun-Earth/Moon L2 Lagrangian point to produce results with higher resolution, sensitivity, and accuracy than COBE. A strategy comprising highly eccentric phasing loops with a lunar gravity assist was utilized to provide a zero-cost insertion into a lissajous orbit about L2. Maneuvers were executed at the phasing loop perigees to correct for launch vehicle errors and to target the lunar gravity assist so that a suitable orbit at L2 was achieved. This paper will discuss the maneuver planning process for designing, verifying, and executing MAP's maneuvers. A discussion of the tools and how they interacted will also be included. The maneuver planning process was iterative and crossed several disciplines, including trajectory design, attitude control, propulsion, power, thermal, communications, and ground planning. Several commercial, off-the-shelf (COTS) packages were used to design the maneuvers. STK/Astrogator was used as the trajectory design tool. All maneuvers were designed in Astrogator to ensure that the Moon was met at the correct time and orientation to provide the energy needed to achieve an orbit about L2. The Mathworks Matlab product was used to develop a tool for generating command quaternions. The command quaternion table (CQT) was used to drive the attitude during the perigee maneuvers. The MatrixX toolset, originally written by Integrated Systems, Inc., now distributed by Mathworks, was used to create HiFi, a high fidelity simulator of the MAP attitude control system. HiFi was used to test the CQT and to make sure that all attitude requirements were met during the maneuver. In addition, all ACS data plotting and output were generated in MatrixX. A final test used FlatSat, a real-time hardware-in-the-loop simulator, which used identical MAP flight code to simulate operations on the spacecraft. Simulations in FlatSat allowed the MAP team to verify maneuver commands, timing, and spacecraft configuration before the commands were sent up to the spacecraft for execution. The MAP maneuver team successfully pieced together all of these COTS tools for designing MAP's maneuvers and MAP is now collecting data at L2.

Mesarch, Michael A.↗

NASA NTRS2016

Trajectory Design Tools for Libration and Cis-Lunar Environments

Innovative trajectory design tools are required to support challenging multi-body regimes with complex dynamics, uncertain perturbations, and the integration of propulsion influences. Two distinctive tools, Adaptive Trajectory Design and the General Mission Analysis Tool have been developed and certified to provide the astrodynamics community with the ability to design multi-body trajectories. In this paper we discuss the multi-body design process and the capabilities of both tools. Demonstrable applications to confirmed missions, the Lunar IceCube Cubesat lunar mission and the Wide-Field Infrared Survey Telescope (WFIRST) Sun-Earth L2 mission, are presented.

Earth-Moon↗

NASA NTRS2016

Toward Reduced Aircraft Community Noise Impact Via a Perception-Influenced Design Approach

This is an exciting time for aircraft design. New configurations, including small multi-rotor uncrewed aerial systems, fixed- and tilt-wing distributed electric propulsion aircraft, high-speed rotorcraft, hybrid-electric commercial transports, and low-boom supersonic transports, are being made possible through a host of propulsion and airframe technology developments. The resulting noise signatures may be radically different, both spectrally and temporally, than those of the current fleet. Noise certification metrics currently used in aircraft design do not necessarily reflect these characteristics and therefore may not correlate well with human response. Further, as operations and missions become less airport-centric, e.g., those associated with on-demand mobility or package delivery, vehicles may operate in closer proximity to the population than ever before. Fortunately, a new set of tools are available for assessing human perception during the design process in order to affect the final design in a positive manner. The tool chain utilizes system noise prediction methods coupled with auralization and psychoacoustic testing, making possible the inclusion of human response to noise, along with performance criteria and certification requirements, into the aircraft design process. Several case studies are considered to illustrate how this approach could be used to influence the design of future aircraft.

Rizzi, Stephen A.↗

NASA NTRS2003

Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

Adams, Glynn↗

NASA NTRS2004

TEM study of the FSW nugget in AA2195-T81

During fiiction stir welding (FSW) the material being joined is subjected to a thermal- mechanical process in which the temperature, strain and strain rates are not completely understood. To produce a defect fiee weld, process parameters for the weld and tool pin design must be chosen carefully. The ability to select the weld parameters based on the thermal processing requirements of the material, would allow optimization of mechanical properties in the weld region. In this study, an attempt is made to correlate the microstructure with the variation in thermal history the material experiences during the FSW process.

Schneider, J. A.↗

NASA NTRS2009

Efficient Multidisciplinary Analysis Approach for Conceptual Design of Aircraft with Large Shape Change

The conceptual and preliminary design processes for aircraft with large shape changes are generally difficult and time-consuming, and the processes are often customized for a specific shape change concept to streamline the vehicle design effort. Accordingly, several existing reports show excellent results of assessing a particular shape change concept or perturbations of a concept. The goal of the current effort was to develop a multidisciplinary analysis tool and process that would enable an aircraft designer to assess several very different morphing concepts early in the design phase and yet obtain second-order performance results so that design decisions can be made with better confidence. The approach uses an efficient parametric model formulation that allows automatic model generation for systems undergoing radical shape changes as a function of aerodynamic parameters, geometry parameters, and shape change parameters. In contrast to other more self-contained approaches, the approach utilizes off-the-shelf analysis modules to reduce development time and to make it accessible to many users. Because the analysis is loosely coupled, discipline modules like a multibody code can be easily swapped for other modules with similar capabilities. One of the advantages of this loosely coupled system is the ability to use the medium- to high-fidelity tools early in the design stages when the information can significantly influence and improve overall vehicle design. Data transfer among the analysis modules are based on an accurate and automated general purpose data transfer tool. In general, setup time for the integrated system presented in this paper is 2-4 days for simple shape change concepts and 1-2 weeks for more mechanically complicated concepts. Some of the key elements briefly described in the paper include parametric model development, aerodynamic database generation, multibody analysis, and the required software modules as well as examples for a telescoping wing, a folding wing, and a bat-like wing. The paper also includes the verification of a medium-fidelity aerodynamic tool used for the aerodynamic database generation with a steady and unsteady high-fidelity CFD analysis tool for a folding wing example.

Chwalowski, Pawel↗

NASA NTRS2007

Integrated Aerodynamic/Structural/Dynamic Analyses of Aircraft with Large Shape Changes

The conceptual and preliminary design processes for aircraft with large shape changes are generally difficult and time-consuming, and the processes are often customized for a specific shape change concept to streamline the vehicle design effort. Accordingly, several existing reports show excellent results of assessing a particular shape change concept or perturbations of a concept. The goal of the current effort was to develop a multidisciplinary analysis tool and process that would enable an aircraft designer to assess several very different morphing concepts early in the design phase and yet obtain second-order performance results so that design decisions can be made with better confidence. The approach uses an efficient parametric model formulation that allows automatic model generation for systems undergoing radical shape changes as a function of aerodynamic parameters, geometry parameters, and shape change parameters. In contrast to other more self-contained approaches, the approach utilizes off-the-shelf analysis modules to reduce development time and to make it accessible to many users. Because the analysis is loosely coupled, discipline modules like a multibody code can be easily swapped for other modules with similar capabilities. One of the advantages of this loosely coupled system is the ability to use the medium-to high-fidelity tools early in the design stages when the information can significantly influence and improve overall vehicle design. Data transfer among the analysis modules are based on an accurate and automated general purpose data transfer tool. In general, setup time for the integrated system presented in this paper is 2-4 days for simple shape change concepts and 1-2 weeks for more mechanically complicated concepts. Some of the key elements briefly described in the paper include parametric model development, aerodynamic database generation, multibody analysis, and the required software modules as well as examples for a telescoping wing, a folding wing, and a bat-like wing.

Samareh, Jamshid A.↗

NASA NTRS1999

Toward a More Flexible Web-Based Framework for Multidisciplinary Design

In today's competitive environment, both industry and government agencies are under pressure to reduce the time and cost of multidisciplinary design projects. New tools have been introduced to assist in this process by facilitating the integration of and communication among diverse disciplinary codes. One such tool, a framework for multidisciplinary design, is defined as a hardware-software architecture that enables integration, execution, and communication among diverse disciplinary processes. An examination of current frameworks reveals weaknesses in various areas, such as sequencing, monitoring, controlling, and displaying the design process. The objective of this research is to explore how Web technology can improve these areas of weakness and lead toward a more flexible framework. This article describes a Web-based system that optimizes and controls the execution sequence of design processes in addition to monitoring the project status and displaying the design results.

Rogers, J. L.↗

NASA NTRS1989

Operations and support cost modeling using Markov chains

Systems for future missions will be selected with life cycle costs (LCC) as a primary evaluation criterion. This reflects the current realization that only systems which are considered affordable will be built in the future due to the national budget constaints. Such an environment calls for innovative cost modeling techniques which address all of the phases a space system goes through during its life cycle, namely: design and development, fabrication, operations and support; and retirement. A significant portion of the LCC for reusable systems are generated during the operations and support phase (OS). Typically, OS costs can account for 60 to 80 percent of the total LCC. Clearly, OS costs are wholly determined or at least strongly influenced by decisions made during the design and development phases of the project. As a result OS costs need to be considered and estimated early in the conceptual phase. To be effective, an OS cost estimating model needs to account for actual instead of ideal processes by associating cost elements with probabilities. One approach that may be suitable for OS cost modeling is the use of the Markov Chain Process. Markov chains are an important method of probabilistic analysis for operations research analysts but they are rarely used for life cycle cost analysis. This research effort evaluates the use of Markov Chains in LCC analysis by developing OS cost model for a hypothetical reusable space transportation vehicle (HSTV) and suggests further uses of the Markov Chain process as a design-aid tool.

Unal, Resit↗

NASA NTRS1978

Computer Programs (Turbomachinery)

NASA computer programs are extensively used in design of industrial equipment. Available from the Computer Software Management and Information Center (COSMIC) at the University of Georgia, these programs are employed as analysis tools in design, test and development processes, providing savings in time and money. For example, two NASA computer programs are used daily in the design of turbomachinery by Delaval Turbine Division, Trenton, New Jersey. The company uses the NASA splint interpolation routine for analysis of turbine blade vibration and the performance of compressors and condensers. A second program, the NASA print plot routine, analyzes turbine rotor response and produces graphs for project reports. The photos show examples of Delaval test operations in which the computer programs play a part. In the large photo below, a 24-inch turbine blade is undergoing test; in the smaller photo, a steam turbine rotor is being prepared for stress measurements under actual operating conditions; the "spaghetti" is wiring for test instrumentation

Source record↗

NASA NTRS2011

Mathematical Design Optimization of Wide-Field X-ray Telescopes: Mirror Nodal Positions and Detector Tilts

We describe a mathematical formalism for determining the mirror shell nodal positions and detector tilts that optimize the spatial resolution averaged over a field-of-view for a nested x-ray telescope, assuming known mirror segment surface prescriptions and known detector focal surface. The results are expressed in terms of ensemble averages over variable combinations of the ray positions and wave vectors in the flat focal plane intersecting the optical axis at the nominal on-axis focus, which can be determined by Monte-Carlo ray traces of the individual mirror shells. This work is part of our continuing efforts to provide analytical tools to aid in the design process for wide-field survey x-ray astronomy missions.

Elsner, R. F.↗

NASA NTRS2011

Mathematical Design Optimization of Wide-Field X-ray Telescopes: Mirror Nodal Positions and Detector Tilts

We describe a mathematical formalism for determining the mirror shell nodal positions and detector tilts that optimize the spatial resolution averaged over a field-of-view for a nested x-ray telescope, assuming known mirror segment surface prescriptions and known detector focal surface. The results are expressed in terms of ensemble averages over variable combinations of the ray positions and wavevectors in the flat focal plane intersecting the optical axis at the nominal on-axis focus, which can be determined by Monte-Carlo ray traces of the individual mirror shells. This work is part of our continuing efforts to provide analytical tools to aid in the design process for wide-field survey x-ray astronomy missions.

Elsner, Ronald↗

NASA NTRS2013

Small Launch Vehicle Trade Space Definition: Development of a Zero Level Mass Estimation Tool with Trajectory Validation

Recent high level interest in the capability of small launch vehicles has placed significant demand on determining the trade space these vehicles occupy. This has led to the development of a zero level analysis tool that can quickly determine the minimum expected vehicle gross liftoff weight (GLOW) in terms of vehicle stage specific impulse (Isp) and propellant mass fraction (pmf) for any given payload value. Utilizing an extensive background in Earth to orbit trajectory experience a total necessary delta v the vehicle must achieve can be estimated including relevant loss terms. This foresight into expected losses allows for more specific assumptions relating to the initial estimates of thrust to weight values for each stage. This tool was further validated against a trajectory model, in this case the Program to Optimize Simulated Trajectories (POST), to determine if the initial sizing delta v was adequate to meet payload expectations. Presented here is a description of how the tool is setup and the approach the analyst must take when using the tool. Also, expected outputs which are dependent on the type of small launch vehicle being sized will be displayed. The method of validation will be discussed as well as where the sizing tool fits into the vehicle design process.

Waters, Eric D.↗

NASA NTRS2011

Control System Modeling for the Thirty Meter Telescope Primary Mirror

The Thirty Meter Telescope primary mirror is composed of 492 segments that are controlled to high precision in the presence of wind and vibration disturbances, despite the interaction with structural dynamics. The higher bandwidth and larger number of segments compared with the Keck telescopes requires greater attention to modeling to ensure success. We focus here on the development and validation of a suite of quasi-static and dynamic modeling tools required to support the design process, including robustness verification, performance estimation, and requirements flowdown. Models are used to predict the dynamic response due to wind and vibration disturbances, estimate achievable bandwidth in the presence of control-structure-interaction (CSI) and uncertainty in the interaction matrix, and simulate and analyze control algorithms and strategies, e.g. for control of focus-mode, and sensor calibration. Representative results illustrate TMT performance scaling with parameters, but the emphasis is on the modeling framework itself.

uncetainty↗

NASA NTRS2018

Coupled Thermo-Mechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and nonuniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading.

thermally grown oxide↗

NASA NTRS2019

Thermal design and validation of Mars 202 gas Dust Removal Tool (gDRT)

As part of the science goals for the planned Mars 2020 mission, two instruments, PIXL and SHERLOC, intend to study the Mars surface at a close scale. These two instruments are planned to be used on smooth rock surfaces that are free of dust and other particles. Such surfaces are prepared by using a drill with an abrading drill bit; residual dust and particles are then blown away using a compressed gas system—the Gas Dust Removal Tool (gDRT). Early in the design process a risk of valve leakage below the vendor’s -20C rating was identified. To mitigate this risk a parallel path was implemented: 1) qualify the valves to operate at -135C, and 2) develop thermal control capability to elevated temperatures in case qualification efforts are unsuccessful. While qualification efforts are ongoing, it is expected that the valves will be qualified to an operating temperature of -135C. In the event that qualification is not successful, thermal control has been realized via a thermally isolated valve configuration and thermostatically controlled heaters. Thermal testing of gDRT has validated this design and enabled thermal model correlation in order to provide more accurate survival energy predictions. The resulting energy consumption for heating the valves at the Jezero landing site represents a minimal impact to the Rover energy budget.

Novak, Keith↗

NASA NTRS2022

Balancing Predictive and Reactive Science Planning for Mars 2020 Perseverance

The design of the science planning process for a space science mission needs to find a balance between operational and resource constraints and scientific decision-making. Science planning has previously been characterized as either predictive or reactive. Predictive science planning is needed when constraints drive science activities to be planned far in advance. For example, a combination of long one-way light time plus high-stakes science decisions drove the Cassini-Huygens mission to Saturn to have an extremely predictive planning process. On the other extreme, reactive science planning is needed when constraints drive science activities to be planned based on the results of the previous plan. For example, the Mars Exploration Rover mission interacted with the surface of Mars, and so the planning team needed to know the state of the rover at the end of each planning cycle before starting the next cycle. Operational and resource constraints that require management on intermediate timescales has led to the development of a science planning process between these two extremes. For example, the Mars Science Laboratory is a technically complex rover and has a parallel predictive process that allows the operations team to manage engineering constraints several days in advance while maintaining the reactive tactical planning process similar to that of MER. The Mars 2020 Perseverance rover is a technically complex rover in the MSL style, but has an added layer of science complexity: it is tasked with collecting a returnable cache of scientifically valuable samples of Mars within prime mission. Thus, the science planning process also needs to accommodate high-stakes longer-term science decisions in the style of Cassini. In order to balance the push-pull of these constraints, we have developed a science campaign-focused operational paradigm for Mars 2020 Perseverance that allows for both predictive planning to accommodate technological complexity and high-stakes science decisions as well as reactive planning to accommodate the realities of interacting with the martian surface. This paradigm influenced the design of operational processes and operational tools.

Spanovich, Nicole↗