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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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The exploration of Mars is covered by the following topics: Mariner spacecraft and launch vehicles, search for Martian life; Voyager spacecraft; creation of Viking; Viking Orbiter and its Mariner inheritance; Viking lander; building a complex spacecraft; selecting landing sites; site certification, and data from Mars.
An attempt has been made to compare the technologies, institutions and procedures of the aerospace and commercial nuclear power industries, in order to characterize similarities and contrasts as well as to identify the most fruitful means by which to transfer information, technology, and procedures between the two industries. The seven working groups involved in this study took as their topics powerplant design formulation and effectiveness, plant safety and operations, powerplant control technology and integration, economic and financial analyses, public relations, and the management of nuclear waste and spent fuel. Consequential differences are noted between the two industries in matters of certification and licencing procedures, assignment of responsibility for both safety and financial performance, and public viewpoint. Areas for beneficial interaction include systems management and control and safety system technology. No individual items are abstracted in this volume
Regulatory changes are proposed for new engine certification for multi-engine helicopters to account for contingency operations when one engine goes out at take-off. The new rules are needed because current regulations define category A and B conditions as one-engine out, land immediately, or continue take-off, respectively. Category A is seldom feasible while Category B requires oversize engines, implying lowered fuel efficiencies. However, NASA studies have shown that engines with large contingency power can operate more efficiently in normal conditions due to decreased coolant flow. Techniques for realizing up to a 50 percent power augmentation with minor modifications of existing engines are described.
This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.
The full scale ground test, ground vibration test, and flight tests conducted to demonstrate a composite structure stabilizer for the Boeing 737 aircraft and obtain FAA certification are described. Detail tools, assembly tools, and overall production are discussed. Cost analyses aspects covered include production costs, composite material usage factors, and cost comparisons.
The horizontal stabilizer of the 737 transport was redesigned. Five shipsets were fabricated using composite materials. Weight reduction greater than the 20% goal was achieved. Parts and assemblies were readily produced on production-type tooling. Quality assurance methods were demonstrated. Repair methods were developed and demonstrated. Strength and stiffness analytical methods were substantiated by comparison with test results. Cost data was accumulated in a semiproduction environment. FAA certification was obtained.
The space shuttle introduced a new dimension in the complexity of the structural dynamics of a space vehicle. The four-body configuration exhibited structural frequencies as low as 2 hertz with a model density on the order of 10 modes per hertz. In the verification process, certain mode shapes and frequencies were identified by the users as more important than others and, as such, the test objectives were oriented toward experimentally extracting those modes and frequencies for analysis and test correlation purposes. To provide the necessary experimental data, a series of ground vibration tests (GVT's) was conducted using test articles ranging from the 1/4-scale structural replica of the space shuttle to the full-scale vehicle. The vibration test and analysis program revealed that the mode shapes and frequency correlations below 10 hertz were good. The quality of correlation of modes between 10 and 20 hertz ranged from good to fair and that of modes above 20 hertz ranged from poor to good. Since the most important modes, based on user preference, were below 10 hertz, it was judged that the shuttle structural dynamic models were adequate for flight certifications.
The space shuttle development program provided the opportunity to challenge many of the established practices and approaches used in prior manned space flight programs. The most significant accomplishments and resulting precedents which emerged during the structural development of the space shuttle and the space shuttle orbiter are reviewed. Innovations in criteria, design solutions, and certification are highlighted, and brief comments on the lessons learned are included. Thermal stress, graphite epoxy moisture, window structure, and structural inspection are discussed under lessons learned.
The Space Shuttle Orbiter wheels were subjected to a combination of tests which are different than any previously conducted in the aerospace industry. The major testing difference is the computer generated dynamic landing profiles used during the certification process which subjected the wheels and tires to simulated landing loading conditions. The orbiter brakes use a unique combination of carbon composite linings and beryllium heat sink to minimize weight. The development of a new lining retention method was necessary in order to withstand the high temperature generated during the braking roll. As with many programs, the volume into which this hardware had to fit was established early in the program, with no provisions made for growth to offset the continuously increasing predicted orbiter landing weight.
The Detailed Test Objectives (DTOs) originated as a test or measurement made to verify the function of a vehicle system for certification of a vehicle system. The Detailed Supplementary Objectives (DSOs) are a demonstration or test which has a lower priority than a DTO. The criteria for inclusion on space shuttle mission is discussed.
This paper presents the technical background for including environmental effects in the design of helicopter composite structures. This effort was supported by test results of components and panels having up to four years of field exposure. The preceeding was part of an eight year program to evaluate in-service environmental factors for comparison with laboratory test results. Full scale static and fatigue tests were conducted on composite components removed from S-76 helicopters used in commercial operations in the Gulf Coast region of Louisiana. Small scale tests were conducted using coupons removed from panels exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. Panel configurations were representative of S-76 components. Moisture analysis and strength tests on components and panels are reported after two, three and four years of exposure. Moisture levels were compared with predicted values. Mechanical test results were compared to initial certification tests for component strength, and to baseline laboratory coupon testing.
The current design of the Space Shuttle Main Engine has passed 11 certification cycles, amassed approximately a quarter million seconds of engine test time in 1200 tests and successfully launched the Space Shuttle 17 times of 51 engine launches through May 1985. Building on this extensive background, two development programs are underway at Rocketdyne to improve the flow of hot gas through the powerhead and evaluate the changes to increase the performance margins in the engine. These two programs, called Phase II+ and Technology Test Bed Precursor program are described. Phase II+ develops a two-tube hot-gas manifold that improves the component environment. The Precursor program will evaluate a larger throat main combustion chamber, conduct combustion stability testing of a baffleless main injector, fabricate an experimental weld-free heat exchanger tube, fabricate and test a high pressure oxidizer turbopump with an improved inlet, and develop and test methods for reducing temperature transients at start and shutdown.
The continuing development of PMR-15 composite materials and their associated design properties is pacing the implementation of this technology on commercial aircraft. The guidelines that the FAA has issued regarding the certification of advanced composite structures are very significant with respect to future PMR-15 research and development activities. The FAA has issued an advisory circular dated 1-5-83 concerning guidelines for composite aircraft structures. Of particular significance to PMR-15 technology development is the reliance on combined environmental exposure and component testing, coupled with the stipulation that reliance on previous experience be limited to where common structures and materials have been used for a similar function. Critical environmental exposures for commercial propulsion structures include 50,000 cycle service life, exposure to skydrol, moisture and other fluids, and nacelle fire conditions.
Sounding rockets have served as a relatively inexpensive and easy method of carrying experiments into the upper atmosphere. Limited observation time and pointing capabilities suggested the development of a new sounding rocket type carrier compatible with NASA's Space Transportation System. This concept evolved into the Spartan program, now credited with a successful Spartan 101 mission launched in June 1985. The next series of Spartans will use a service module primary structure. This newly designed reusable and universal component in the Spartan carrier system required thorough analysis and evaluation for flight certification. Using advanced finite element modeling techniques, the structure was analyzed and determined acceptable by meeting strict design goals and will be tested for verification of the analytical results.
Improvement of the productivity of astronaut crew instructors in the Space Shuttle program and beyond is proposed. It is suggested that instructor certification plans should be established to shorten the time required for trainers to develop their skills and improve their ability to convey those skills. Members of the training cadre should be thoroughly cross trained in their task. This provides better understanding of the overall task and greater flexibility in instructor utilization. Improved facility access will give instructors the benefit of practical application experience. Former crews should be integrated into the training of upcoming crews to bridge some of the gap between simulated conditions and the real world. The information contained in lengthy and complex training manuals can be presented more clearly and efficiently as computer lessons. The illustration, animation and interactive capabilities of the computer combine an effective means of explanation.
The tracking and communication division computer aided design/computer aided engineering system is now operational. The system is utilized in an effort to automate certain tasks that were previously performed manually. These tasks include detailed test configuration diagrams of systems under certification test in the ESTL, floorplan layouts of future planned laboratory reconfigurations, and other graphical documentation of division activities. The significant time savings achieved with this CAD/CAE system are examined: (1) input of drawings and diagrams; (2) editing of initial drawings; (3) accessibility of the data; and (4) added versatility. It is shown that the Applicon CAD/CAE system, with its ease of input and editing, the accessibility of data, and its added versatility, has made more efficient many of the necessary but often time-consuming tasks associated with engineering design and testing.
Generally, it has been documented that the wearing of engine parts forms a failure distribution which can be approximated by a function developed by Weibull. The purpose here is to examine to what extent the Weibull distribution approximates failure data for designated engine parts of the Space Shuttle Main Engine (SSME). The current testing certification requirements will be examined in order to establish confidence levels. An examination of the failure history of SSME parts/assemblies (turbine blades, main combustion chamber, or high pressure fuel pump first stage impellers) which are limited in usage by time or starts will be done by using updated Weibull techniques. Efforts will be made by the investigator to predict failure trends by using Weibull techniques for SSME parts (turbine temperature sensors, chamber pressure transducers, actuators, and controllers) which are not severely limited by time or starts.
Efforts to automate electromagnetic compatibility (EMC) test facilities at Marshall Space Flight Center are discussed. The present facility is used to accomplish a battery of nine standard tests (with limited variations) deigned to certify EMC of Shuttle payload equipment. Prior to this project, some EMC tests were partially automated, but others were performed manually. Software was developed to integrate all testing by means of a desk-top computer-controller. Near real-time data reduction and onboard graphics capabilities permit immediate assessment of test results. Provisions for disk storage of test data permit computer production of the test engineer's certification report. Software flexibility permits variation in the tests procedure, the ability to examine more closely those frequency bands which indicate compatibility problems, and the capability to incorporate additional test procedures.