Results for “Process Engineering” — Page 94

NASA NTRS2008

Human Rating Requirements for NASA's Constellation Program

NASA s Constellation Program (CxP) will conduct a series of human space expeditions of increasing scope, starting with missions supporting the International Space Station and expanding to encompass the Moon and Mars. Although human-rating is an integral part of all CxP activities throughout their life cycle, NASA Procedural Requirements document NPR 8705.2B, Human-Rating Requirements (HRR) for Space Flight Systems, defines the additional processes, procedures, and requirements necessary to produce human-rated space systems that protect the safety of crew members and passengers on these NASA missions. In order to be in compliance with 8705.2B the CxP must show appropriate implementation or progression toward the HRR, or justification for an exception. Compliance includes an explanation of how the CxP intends to meet the HRR, analyses to be performed to determine implementation; and a matrix to trace the HRR to CxP requirements. The HRR requires the CxP to establish a human system integration team (HSIT), consisting of astronauts, mission operations personnel, training personnel, ground processing personnel, human factors personnel, and human engineering experts, with clearly defined authority, responsibility, and accountability to lead the human-system integration. For example, per the HRR the HSIT is involved in the evaluation of crew workload, human-in-the-loop usability evaluations, determining associated criteria, and in assessment of how these activities influenced system design. In essence, the HSIT is invaluable in CxP s ability to meet the three fundamental tenets of human rating: the process of designing, evaluating, and assuring that the total system can safely conduct the required human missions; the incorporation of design features and capabilities that accommodate human interaction with the system to enhance overall safety and mission success; and the incorporation of design features and capabilities to enable safe recovery of the crew from hazardous situations.

Berdich, Debbie↗

NASA NTRS2018

Composite Bonded Joint: Repair Development

This report documents the details of my work as a NASA KSC intern for the Fall Session from August 27th to December 14th, 2018. My efforts and contributions were with the Materials Science Branch, a staffed organization within the Laboratories, Development, & Testing (NE-L) Division of the Engineering Directorate. The principle responsibilities of the Materials Science group are to support the design, development, and operations activities for materials and processes with the purpose of providing unique solutions for flight hardware, ground support equipment, and customer requests. My role as an intern focused on assisting engineers in developing repair processes to mature bonded joint technology in support of SLS ? scale hardware. My primary goals for this internship were to become more familiar with composite materials and learn more about processes I was unfamiliar with, such as prepregs and out-of-autoclave processing. This project allowed me to learn new skills such as scarfing and curing composites. Additional goals I had were to learn more about NASA's laboratories and projects under development. This internship not only provided me with those experiences, but also allowed me to build relationships with inspiring engineers; a takeaway I will never forget.

Composite Materials↗

NASA NTRS2007

Wireless Acoustic Measurement System

A prototype wireless acoustic measurement system (WAMS) is one of two main subsystems of the Acoustic Prediction/ Measurement Tool, which comprises software, acoustic instrumentation, and electronic hardware combined to afford integrated capabilities for predicting and measuring noise emitted by rocket and jet engines. The other main subsystem is described in the article on page 8. The WAMS includes analog acoustic measurement instrumentation and analog and digital electronic circuitry combined with computer wireless local-area networking to enable (1) measurement of sound-pressure levels at multiple locations in the sound field of an engine under test and (2) recording and processing of the measurement data. At each field location, the measurements are taken by a portable unit, denoted a field station. There are ten field stations, each of which can take two channels of measurements. Each field station is equipped with two instrumentation microphones, a micro- ATX computer, a wireless network adapter, an environmental enclosure, a directional radio antenna, and a battery power supply. The environmental enclosure shields the computer from weather and from extreme acoustically induced vibrations. The power supply is based on a marine-service lead-acid storage battery that has enough capacity to support operation for as long as 10 hours. A desktop computer serves as a control server for the WAMS. The server is connected to a wireless router for communication with the field stations via a wireless local-area network that complies with wireless-network standard 802.11b of the Institute of Electrical and Electronics Engineers. The router and the wireless network adapters are controlled by use of Linux-compatible driver software. The server runs custom Linux software for synchronizing the recording of measurement data in the field stations. The software includes a module that provides an intuitive graphical user interface through which an operator at the control server can control the operations of the field stations for calibration and for recording of measurement data. A test engineer positions and activates the WAMS. The WAMS automatically establishes the wireless network. Next, the engineer performs pretest calibrations. Then the engineer executes the test and measurement procedures. After the test, the raw measurement files are copied and transferred, through the wireless network, to a hard disk in the control server. Subsequently, the data are processed into 1.3-octave spectrograms.

Anderson, Paul D.↗

NASA NTRS2005

Wireless Acoustic Measurement System

A prototype wireless acoustic measurement system (WAMS) is one of two main subsystems of the Acoustic Prediction/Measurement Tool, which comprises software, acoustic instrumentation, and electronic hardware combined to afford integrated capabilities for predicting and measuring noise emitted by rocket and jet engines. The other main subsystem is described in "Predicting Rocket or Jet Noise in Real Time" (SSC-00215-1), which appears elsewhere in this issue of NASA Tech Briefs. The WAMS includes analog acoustic measurement instrumentation and analog and digital electronic circuitry combined with computer wireless local-area networking to enable (1) measurement of sound-pressure levels at multiple locations in the sound field of an engine under test and (2) recording and processing of the measurement data. At each field location, the measurements are taken by a portable unit, denoted a field station. There are ten field stations, each of which can take two channels of measurements. Each field station is equipped with two instrumentation microphones, a micro-ATX computer, a wireless network adapter, an environmental enclosure, a directional radio antenna, and a battery power supply. The environmental enclosure shields the computer from weather and from extreme acoustically induced vibrations. The power supply is based on a marine-service lead-acid storage battery that has enough capacity to support operation for as long as 10 hours. A desktop computer serves as a control server for the WAMS. The server is connected to a wireless router for communication with the field stations via a wireless local-area network that complies with wireless-network standard 802.11b of the Institute of Electrical and Electronics Engineers. The router and the wireless network adapters are controlled by use of Linux-compatible driver software. The server runs custom Linux software for synchronizing the recording of measurement data in the field stations. The software includes a module that provides an intuitive graphical user interface through which an operator at the control server can control the operations of the field stations for calibration and for recording of measurement data. A test engineer positions and activates the WAMS. The WAMS automatically establishes the wireless network. Next, the engineer performs pretest calibrations. Then the engineer executes the test and measurement procedures. After the test, the raw measurement files are copied and transferred, through the wireless network, to a hard disk in the control server. Subsequently, the data are processed into 1/3-octave spectrograms.

Anderson, Paul D.↗

NASA NTRS2006

LM2500+ Brush Seal Case Study

The LM2500+ industrial aeroderivative gas turbine, a 25% enhanced power derivative of the LM2500 gas turbine, recently completed its development test program during the period 5/96 - 10/96. Early in the engine program a Quality Function Deployment (QFD) process was used to determine customer needs for this project.The feedback obtained from the QFD process showed without doubt that gas turbine customers now emphasize product reliability and availability at the top of their needs. One area of development on the LM2500+ was to investigate the use of a brush seal as a means to reduce undesirable turbine cooling leakages within the turbine mid frame in order to enhance part life. This presentation presents a case study on the factors that went into evaluating a brush seal during engine test, test results, and the ultimate decision not to implement the brush seal for cost and other reasons.

Haaser, Fred G.↗

NASA NTRSDate not supplied

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

NASA NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2001

High-Speed Observer: Automated Streak Detection for the Aerospike Engine

A high-frame-rate digital video camera, installed on test stands at Stennis Space Center (SSC), has been used to capture images of the aerospike engine plume during test. These plume images are processed in real time to detect and differentiate anomalous plume events. Results indicate that the High-Speed Observer (HSO) system can detect anomalous plume streaking events that are indicative of aerospike engine malfunction.

Rieckhoff, T. J.↗

NASA NTRS2023

Regulatory response to a hybrid ancestral nitrogenase in Azotobacter vinelandii

Biological nitrogen fixation, the microbial reduction of atmospheric nitrogen to bioavailable ammonia, represents both a major limitation on biological productivity and a highly desirable engineering target for synthetic biology. However, the engineering of nitrogen fixation requires an integrated understanding of how the gene regulatory dynamics of host diazotrophs respond across sequence-function space of its central catalytic metalloenzyme, nitrogenase. Here, we interrogate this relationship by analyzing the transcriptome of Azotobacter vinelandii engineered with a phylogenetically inferred ancestral nitrogenase protein variant. The engineered strain exhibits reduced cellular nitrogenase activity but recovers wild-type growth rates following an extended lag period. We find that expression of genes within the immediate nitrogen fixation network is resilient to the introduced nitrogenase sequence-level perturbations. Rather the sustained physiological compatibility with the ancestral nitrogenase variant is accompanied by reduced expression of genes that support trace metal and electron resource allocation to nitrogenase. Our results spotlight gene expression changes in cellular processes adjacent to nitrogen fixation as productive engineering considerations to improve compatibility between remodeled nitrogenase proteins and engineered host diazotrophs.

nitrogen fixation↗

NASA NTRS1984

Systems engineering - Space Telescope project

At midpoint in the development of the Space Telescope (ST), a review process was conducted which determined that much benefit could be derived from an expanded systems engineering effort. The Systems Engineering Office thus established is responsible for the running of a management information system whose functions encompass design change control and the implementation of a maintenance and refurbishment program. By these means, interface hardware/software incompatibilities between critical ST modules and subsystems have been revealed and corrected.

Wojtalik, F. S.↗

NASA NTRS2010

Product Lifecycle Management and the Quest for Sustainable Space Explorations

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decision-making. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful concept to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting.

Caruso, Pamela W.↗

NASA NTRS2004

Systems engingeering for the Kepler Mission : a search for terrestrial planets

The Kepler mission will launch in 2007 and determine the distribution of earth-size planets (0.5 to 10 earth masses) in the habitable zones (HZs) of solar-like stars. The mission will monitor > 100,000 dwarf stars simultaneously for at least 4 years. Precision differential photometry will be used to detect the periodic signals of transiting planets. Kepler will also support asteroseismology by measuring the pressure-mode (p-mode) oscillations of selected stars. Key mission elements include a spacecraft bus and 0.95 meter, wide-field, CCD-based photometer injected into an earth-trailing heliocentric orbit by a 3-stage Delta II launch vehicle as well as a distributed Ground Segment and Follow-up Observing Program. The project is currently preparing for Preliminary Design Review (October 2004) and is proceeding with detailed design and procurement of long-lead components. In order to meet the unprecedented photometric precision requirement and to ensure a statistically significant result, the Kepler mission involves technical challenges in the areas of photometric noise and systematic error reduction, stability, and false-positive rejection. Programmatic and logistical challenges include the collaborative design, modeling, integration, test, and operation of a geographically and functionally distributed project. A very rigorous systems engineering program has evolved to address these challenges. This paper provides an overview of the Kepler systems engineering program, including some examples of our processes and techniques in areas such as requirements synthesis, validation & verification, system robustness design, and end-to-end performance modeling.

systems engineering↗

NASA NTRS2004

Mission Success for Combustion Science

This presentation describes how mission success for combustion experiments has been obtained in previous spaceflight experiments and how it will be obtained for future International Space Station (ISS) experiments. The fluids and combustion facility is a payload planned for the ISS. It is composed of two racks: the fluids Integrated rack and the Combustion INtegrated Rack (CIR). Requirements for the CIR were obtained from a set of combustion basis experiments that served as surrogates for later experiments. The process for experiments that fly on the ISS includes proposal selection, requirements and success criteria definition, science and engineering reviews, mission operations, and postflight operations. By following this process, the microgravity combustion science program has attained success in 41 out of 42 experiments.

Weiland, Karen J.↗

NASA NTRS2003

Information technology security system engineering methodology

A methodology is described for system engineering security into large information technology systems under development. The methodology is an integration of a risk management process and a generic system development life cycle process. The methodology is to be used by Security System Engineers to effectively engineer and integrate information technology security into a target system as it progresses through the development life cycle. The methodology can also be used to re-engineer security into a legacy system.

Security risk analysis system engineering↗

NASA NTRSDate not supplied

MIKA: Manager for Intelligent Knowledge Access Toolkit for Engineering Knowledge Discovery and Information Retrieval

Repositories of safety reports are often underutilized and only analyzed manually by trained experts, despite safety management systems requiring reports. These collections of documents contain a wealth of information from past projects and operations that could improve system safety and design. Advances in natural language processing techniques have improved information extraction and retrieval in consumer technology, biomedicine, and finance, for instance, but have not been applied to engineering documents on the same scale. To this end, the Manager for Intelligent Knowledge Access (MIKA) open-source toolkit has been developed for rapid knowledge discovery and information retrieval in safety engineering applications. The MIKA toolkit uses state-of-the-art natural language processing algorithms and allows a user to apply these methods to their own dataset. This paper describes the MIKA toolkit and its two primary capabilities, knowledge discovery and information retrieval, and demonstrates the toolkit via a case study on National Transportation Safety Board (NTSB) reports.

Machine Learning↗

NASA NTRS2000

A Future Vision of a Data Acquisition: Distributed Sensing, Processing, and Health Monitoring

This paper presents a vision fo a highly enhanced data acquisition and health monitoring system at NASA Stennis Space Center (SSC) rocket engine test facility. This vision includes the use of advanced processing capabilities in conjunction with highly autonomous distributed sensing and intelligence, to monitor and evaluate the health of data in the context of it's associated process. This method is expected to significantly reduce data acquisitions costs and improve system reliability. A Universal Signal Conditioning Amplifier (USCA) based system, under development at Kennedy Space Center, is being evaluated for adaptation to the SSC testing infrastructure. Kennedy's USCA architecture offers many advantages including flexible and auto-configuring data acquisition with improved calibration and verifiability. Possible enhancements at SSC may include multiplexing the distributed USCAs to reduce per channel cost, and the use of IEEE-485 to Allen-Bradley Control Net Gateways for interfacing with the resident control systems.

Figueroa, Fernando↗

NASA NTRS2013

Preliminary MIPCC Enhanced F-4 and F-15 Preformance Characteristics for a First Stage Reusable Launch Vehicle

Performance increases in turbojet engines can theoretically be achieved through Mass Injection Pre-Compressor Cooling (MIPCC), a process involving injecting water or oxidizer or both into an afterburning turbojet engine. The injection of water results in pre-compressor cooling, allowing the propulsion system to operate at high altitudes and Mach numbers. In this way, a MIPCC-enhanced turbojet engine could be used to power the first stage of a reusable launch vehicle or be integrated into an existing aircraft that could launch a 100-lbm payload to a reference 100-nm altitude orbit at 28 deg inclination. The two possible candidates for MIPCC flight demonstration that are evaluated in this study are the F-4 Phantom II airplane and the F-15 Eagle airplane (both of McDonnell Douglas, now The Boeing Company, Chicago, Illinois), powered by two General Electric Company (Fairfield, Connecticut) J79 engines and two Pratt & Whitney (East Hartford, Connecticut) F100-PW-100 engines, respectively. This paper presents a conceptual discussion of the theoretical performance of each of these aircraft using MIPCC propulsion techniques. Trajectory studies were completed with the Optimal Trajectories by Implicit Simulation (OTIS) software (NASA Glenn Research Center, Cleveland, Ohio) for a standard F-4 airplane and a standard F-15 airplane. Standard aircraft simulation models were constructed, and the thrust in each was altered in accordance with estimated MIPCC performance characteristics. The MIPCC and production aircraft model results were then reviewed to assess the feasibility of a MIPCC-enhanced propulsion system for use as a first-stage reusable launch vehicle; it was determined that the MIPCC-enhanced F-15 model showed a significant performance advantage over the MIPCC-enhanced F-4 model.

Air Breathing Launch Systems↗

NASA NTRS2013

Preliminary MIPCC Enhanced F-4 and F-15 Performance Characteristics for a First Stage Reusable Launch Vehicle

Performance increases in turbojet engines can theoretically be achieved through Mass Injection Pre-Compressor Cooling (MIPCC), a process involving injecting water or oxidizer or both into an afterburning turbojet engine. The injection of water results in pre-compressor cooling, allowing the propulsion system to operate at high altitudes and Mach numbers. In this way, a MIPCC-enhanced turbojet engine could be used to power the first stage of a reusable launch vehicle or be integrated into an existing aircraft that could launch a 100-lbm payload to a reference 100-nm altitude orbit at 28 deg inclination. The two possible candidates for MIPCC flight demonstration that are evaluated in this study are the F-4 Phantom II airplane and the F-15 Eagle airplane (both of McDonnell Douglas, now The Boeing Company, Chicago, Illinois), powered by two General Electric Company (Fairfield, Connecticut) J79 engines and two Pratt & Whitney (East Hartford, Connecticut) F100-PW-100 engines, respectively. This paper presents a conceptual discussion of the theoretical performance of each of these aircraft using MIPCC propulsion techniques. Trajectory studies were completed with the Optimal Trajectories by Implicit Simulation (OTIS) software (NASA Glenn Research Center, Cleveland, Ohio) for a standard F-4 airplane and a standard F-15 airplane. Standard aircraft simulation models were constructed, and the thrust in each was altered in accordance with estimated MIPCC performance characteristics. The MIPCC and production aircraft model results were then reviewed to assess the feasibility of a MIPCC-enhanced propulsion system for use as a first-stage reusable launch vehicle; it was determined that the MIPCC-enhanced F-15 model showed a significant performance advantage over the MIPCC-enhanced F-4 model.

MIPCC Reusable Launch Vehicle↗