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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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NASA NTRS1990

Balancing low cost with reliable operation in the rotordynamic design of the ALS Liquid Hydrogen Fuel Turbopump

The Air Force/NASA Advanced Launch System (ALS) Liquid Hydrogen Fuel Turbopump (FTP) has primary design goals of low cost and high reliability, with performance and weight having less importance. This approach is atypical compared with other rocket engine turbopump design efforts, such as on the Space Shuttle Main Engine (SSME), which emphasized high performance and low weight. Similar to the SSME turbopumps, the ALS FTP operates supercritically, which implies that stability and bearing loads strongly influence the design. In addition, the use of low cost/high reliability features in the ALS FTP such as hydrostatic bearings, relaxed seal clearances, and unshrouded turbine blades also have a negative influence on rotordynamics. This paper discusses the analysis conducted to achieve a balance between low cost and acceptable rotordynamic behavior, to ensure that the ALS FTP will operate reliably without subsynchronous instabilities or excessive bearing loads.

Greenhill, L. M.↗

NASA NTRS1992

Applications of a damage tolerance analysis methodology in aircraft design and production

Objectives of customer mandated aircraft structural integrity initiatives in design are to guide material selection, to incorporate fracture resistant concepts in the design, to utilize damage tolerance based allowables and planned inspection procedures necessary to enhance the safety and reliability of manned flight vehicles. However, validated fracture analysis tools for composite structures are needed to accomplish these objectives in a timely and economical manner. This paper briefly describes the development, validation, and application of a damage tolerance methodology for composite airframe structures. A closed-form analysis code, entitled SUBLAM was developed to predict the critical biaxial strain state necessary to cause sublaminate buckling-induced delamination extension in an impact damaged composite laminate. An embedded elliptical delamination separating a thin sublaminate from a thick parent laminate is modelled. Predicted failure strains were correlated against a variety of experimental data that included results from compression after impact coupon and element tests. An integrated analysis package was developed to predict damage tolerance based margin-of-safety (MS) using NASTRAN generated loads and element information. Damage tolerance aspects of new concepts are quickly and cost-effectively determined without the need for excessive testing.

Woodward, M. R.↗

NASA NTRS2009

Structural Dynamic Behavior of Wind Turbines

The structural dynamicist s areas of responsibility require interaction with most other members of the wind turbine project team. These responsibilities are to predict structural loads and deflections that will occur over the lifetime of the machine, ensure favorable dynamic responses through appropriate design and operational procedures, evaluate potential design improvements for their impact on dynamic loads and stability, and correlate load and control test data with design predictions. Load prediction has been a major concern in wind turbine designs to date, and it is perhaps the single most important task faced by the structural dynamics engineer. However, even if we were able to predict all loads perfectly, this in itself would not lead to an economic system. Reduction of dynamic loads, not merely a "design to loads" policy, is required to achieve a cost-effective design. The two processes of load prediction and structural design are highly interactive: loads and deflections must be known before designers and stress analysts can perform structural sizing, which in turn influences the loads through changes in stiffness and mass. Structural design identifies "hot spots" (local areas of high stress) that would benefit most from dynamic load alleviation. Convergence of this cycle leads to a turbine structure that is neither under-designed (which may result in structural failure), nor over-designed (which will lead to excessive weight and cost).

Thresher, Robert W.↗

NASA NTRS2011

Grid-Tied Photovoltaic Power System

A grid-tied photovoltaic (PV) power system is connected directly to the utility distribution grid. Facility power can be obtained from the utility system as normal. The PV system is synchronized with the utility system to provide power for the facility, and excess power is provided to the utility. Operating costs of a PV power system are low compared to conventional power technologies. This method can displace the highest-cost electricity during times of peak demand in most climatic regions, and thus reduce grid loading. Net metering is often used, in which independent power producers such as PV power systems are connected to the utility grid via the customers main service panels and meters. When the PV power system is generating more power than required at that location, the excess power is provided to the utility grid. The customer pays the net of the power purchased when the on-site power demand is greater than the onsite power production, and the excess power is returned to the utility grid. Power generated by the PV system reduces utility demand, and the surplus power aids the community. Modern PV panels are readily available, reliable, efficient, and economical, with a life expectancy of at least 25 years. Modern electronics have been the enabling technology behind grid-tied power systems, making them safe, reliable, efficient, and economical with a life expectancy equal to the modern PV panels. The grid-tied PV power system was successfully designed and developed, and this served to validate the basic principles developed, and the theoretical work that was performed. Grid-tied PV power systems are reliable, maintenance- free, long-life power systems, and are of significant value to NASA and the community. Of particular value are the analytical tools and capabilities that have been successfully developed. Performance predictions can be made confidently for grid-tied PV systems of various scales. The work was done under the NASA Hybrid Power Management (HPM) Program, which is the integration of diverse power devices in an optimal configuration for space and terrestrial applications.

Eichenberg, Dennis J.↗

NASA NTRS1972

Problems of Excess Capacity

The problems of excess capacity in the airline industry are discussed with focus on the following topics: load factors; fair rate of return on investment; service-quality rivalry among airlines; pricing (fare) policies; aircraft production; and the impacts of excess capacity on operating costs. Also included is a discussion of the interrelationships among these topics.

Douglas, G.↗

NASA NTRSDate not supplied

Applicability of Loads Estimation Techniques Using Sparse Acceleration Sensor Data to Spacecraft Structural Health Monitoring

The use of structural health monitoring systems on spacecraft structures can play a crucial role in ensuring the safety, reliability, and longevity of the structure by gathering and analyzing onboard sensor data. Of specific importance is monitoring for excessive loading at critical interfaces as any off-nominal structural excitations experienced by spacecraft structures can cause early unpredicted high structural life consumption or damage. The availability and cost of flight-certified sensors along with the size of spacecraft structures and allowable payload mass drives the need for a method to estimate loads using sparsely-located sensors. Numerous approaches such as physics-based, statistical learning, and physics-enhanced statistical learning algorithms have gained popularity among structural prognostics applications. However, developing noise-robust prediction models to assess loads and structural life predictions from a sparse multi-sensor data acquisition system can be a challenging task. This paper discusses the evaluation of physics-based versus machine-learning algorithms for predicting loads and structural life at mission critical locations on the spacecraft structure using a finite element loads analysis with the application of simulated noise and noise reduction techniques. To estimate the loads from accelerations, the physics-based algorithm leverages a loads transformation matrix from a Craig-Bampton reduced finite element model. A System Equivalent Reduction Expansion Process (SEREP) and a pseudo-inverse approach are considered to expand from the onboard sensor degrees of freedom to the Craig-Bampton model degrees of freedom. The machine learning algorithm provides a data driven solution/mapping of the sensor accelerations to the loads at the mission critical locations using a high dimensionality analysis. Although these strategies produce comparable loads prediction without noise, the limitations of these strategies with incorporating simulated noise and noise reduction techniques with low signal to noise ratio signals are evaluated. The study demonstrates the immense potential of statistical learning algorithms for sparse structural prognostic models and enhancing signal denoising techniques. These findings also highlight the need for noise-resilient prognostic models and low-noise data acquisition systems onboard spacecraft structures.

Spacecraft Structural Health Monitoring↗

NASA NTRS1998

Thermal Management Design for the X-33 Lifting Body

The X-33 Advantage Technology Demonstrator offers a rare and exciting opportunity in Thermal Protection System development. The experimental program incorporates the latest design innovation in re-useable, low life cycle cost, and highly dependable Thermal Protection materials and constructions into both ground based and flight test vehicle validations. The unique attributes of the X-33 demonstrator for design application validation for the full scale Reusable Launch Vehicle, (RLV), are represented by both the configuration of the stand-off aeroshell, and the extreme exposures of sub-orbital hypersonic re-entry simulation. There are several challenges of producing a sub-orbital prototype demonstrator of Single Stage to Orbit/Reusable Launch Vehicle (SSTO/RLV) operations. An aggressive schedule with budgetary constraints precludes the opportunity for an extensive verification and qualification program of vehicle flight hardware. However, taking advantage of off the shelf components with proven technologies reduces some of the requirements for additional testing. The effects of scale on thermal heating rates must also be taken into account during trajectory design and analysis. Described in this document are the unique Thermal Protection System (TPS) design opportunities that are available with the lifting body configuration of the X-33. The two principal objectives for the TPS are to shield the primary airframe structure from excessive thermal loads and to provide an aerodynamic mold line surface. With the relatively benign aeroheating capability of the lifting body, an integrated stand-off aeroshell design with minimal weight and reduced procurement and operational costs is allowed. This paper summarizes the design objectives of the X-33 TPS, the flight test requirements driven configuration, and design benefits. Comparisons are made of the X-33 flight profiles and Space Shuttle Orbiter, and lifting body Reusable Launch Vehicle aerothermal environments. The X-33 TPS is based on a design to cost configuration concept. Only RLV critical technologies are verified to conform to cost and schedule restrictions. The one-off prototype vehicle configuration has evolved to minimize the tooling costs by reducing the number of unique components. Low cost approaches such as a composite/blanket leeward aeroshell and the use of Shuttle technology are implemented where applicable. The success of the X-33 will overcome the ballistic re-entry TPS mindset. The X-33 TPS is tailored to an aircraft type mission while maintaining sufficient operational margins. The flight test program for the X-33 will demonstrate that TPS for the RLV is not simply a surface insulation but rather an integrated aeroshell system.

Bouslog, S.↗

NASA NTRS1993

Cockpit control system

The purpose of this project is to provide a detail design for the cockpit control system of the Viper PFT. The statement of work for this project requires provisions for control of the ailerons, elevator, rudder, and elevator trim. The system should provide adjustment for pilot stature, rigging, and maintenance. MIL-STD-1472 is used as a model for human factors criterion. The system is designed to the pilot limit loading outlined in FAR part 23.397. The general philosophy behind this design is to provide a simple, reliable control system which will withstand the daily abuse that is experienced in the training environment without excessive cost or weight penalties.

Lesnewski, David↗

NASA NTRS1980

SPS overview: Requirements, alternatives, and reference system

Basic requirements for the SPS were established. The SPS is considered to be nondepletable with a large positive energy payback over its useful life, capable of base-load operation with no fundamental constraints on capacity. It is compatible with power grids, economically competitive and environmentally acceptable. It should not make excessive use of critical resources, and should be capable of development with reasonable cost, time, and risk. Several of the power generation options and equipment considered are discussed. The reference set of efficiencies defined to represent goals for each step in the power conversion-transmission-reception chain is also described.

Livingston, L. E.↗

NASA NTRS1972

The Economic Effect of Competition in the Air Transportation Industry

The air transportation industry has been described as a highly-competitive, regulated oligopoly or as a price-regulated cartel with blocked entry, resulting in excessive service and low load factors. The current structure of the industry has been strongly influenced by the hypotheses that increased levels of competition are desirable per se, and that more competing carriers can be economically supported in larger markets, in longer haul markets, with lower unit costs, and with higher fare levels. An elementary application of competition/game theory casts doubt on the validity of these hypotheses, but rather emphasizes the critical importance of the short-term non-variable costs in determining economic levels of competition.

Hubbard, H. B.↗

NASA NTRS1993

Micromechanical simulation of damage progression in carbon phenolic composites

Carbon/phenolic composites are used extensively as ablative insulating materials in the nozzle region of solid rocket motors. The current solid rocket motor (RSRM) on the space shuttle is fabricated from woven rayon cloth which is carbonized and then impregnated with the phenolic resin. These plies are layed up in the desired configuration and cured to form the finished part. During firing, the surface of the carbon/phenolic insulation is exposed to 5000 F gases from the rocket exhaust. The resin pyrolizes and the material chars to a depth which progresses with time. The rate of charring and erosion are generally predictable, and the insulation depth is designed to allow adequate safety margins over the firing time of the motor. However, anomalies in the properties and response of the carbon/phenolic materials can lead to severe material damage which may decrease safety margins to unacceptable levels. Three macro damage modes which were observed in fired nozzles are: ply lift, 'wedge out', and pocketing erosion. Ply lift occurs in materials with plies oriented nearly parallel to the surface. The damage occurs in a region below the charred material where material temperatures are relatively low - about 500 F. Wedge out occurs at the intersection of nozzle components whose plies are oriented at about 45 deg. The corner of the block of material breaks off along a ply interface. Pocketing erosion occurs in material with plies oriented normal to the surface. Thermal expansion is restrained in two directions resulting in large tensile strains and material failure normal to the surface. When a large section of material is removed as a result of damage, the insulation thickness is reduced which may lead to failure of the nozzle due to excessive heating of critical components. If these damage events cannot be prevented with certainty, the designer must increase the thickness of the insulator thus adding to both weight and cost. One of the difficulties in developing a full understanding of these macro damage mechanisms is that the loading environment and the material response to that environment are extremely complex. These types of damage are usually only observed in actual motor firings. Therefore, it is difficult and expensive to evaluate the reliability of new materials. Standard material tests which measure mechanical and thermal properties of test specimens can only provide a partial picture of how the material will respond in the service environment. The development of the ANALOG test procedure which can combine high heating rates and mechanical loads on a specimen will improve the understanding of the interactive effects of the various loads on the system. But a mechanistic model of material response which can account for the heterogeneity of the material, the progression of various micromechanical damage mechanisms, and the interaction of mechanical and thermal stresses on the material is required to accurately correlate material tests with response to service environments. A model based on fundamental damage mechanisms which is calibrated and verified under a variety of loading conditions will provide a general tool for predicting the response of rocket nozzles. The development of a micromechanical simulation technique was initiated and demonstrated to be effective for studying across-ply tensile failure of carbon/phenolic composites.

Slattery, Kerry T.↗

NASA NTRSDate not supplied

Endogenous Microbial Survival in Brewed Tea

Loose-leaf bagged tea is a commonly requested beverage item that comprises up to 7% of the microbiological samples from the space food systems. As loose-leaf tea blends often contain herbs and spices that frequently have high microbial loads, they have a high failure rate as defined by the microbiological standards outlined in NASA-STD-3001, which are more stringent than the limits set for industry. Between April 2019 and September 2022, 54.8% of loose-leaf teas submitted for microbiological testing have failed, necessitating the evaluation of a variety of brands and lot numbers of each requested tea type to meet crew preference requests, which are typically specific, resulting in excess labor and material costs to provide a single product for spaceflight consumption. Attempts to identify specific brands or ingredients that are less likely to produce a failure have been unsuccessful, as to date, no trends in those measures have been identified. We have, however, noticed a trend in types of teas (spiced and herbal) which are more likely to fail. Of additional concern, hot water available for brewing tea on ISS is dispensed at a lower temperature than the CDC recommended brewing temperature. In a study we previously reported, we found that that brewing water temperature may not have a significant impact on the number of aerobic bacteria in chamomile tea, as there were no significant differences in the total microbial load between tea brewed with boiling, ISS-like, or room temperature waters. It did appear that ISS temperature water was similarly effective to boiling water against a pathogenic bacterial species. In this study, we aim to assess whether the total number of aerobic bacteria of other high-fail-rate tea types is similarly unaffected when brewing tea in room temperature or boiling water. Data from this study and the previous study, as well as additional analysis of every tea product that has been tested as part of the normal food system since April 2019, will be used to determine the expected typical microbial load for loose-leaf teas, which we will compare to existing industry limits so that we can recommend a new microbiological limit for loose-leaf teas that accurately reflects the true risk of consuming brewed teas in spaceflight.

space flight food↗

NASA NTRS1992

Distribution of human waste samples in relation to sizing waste processing in space

Human waste processing for closed ecological life support systems (CELSS) in space requires that there be an accurate knowledge of the quantity of wastes produced. Because initial CELSS will be handling relatively few individuals, it is important to know the variation that exists in the production of wastes rather than relying upon mean values that could result in undersizing equipment for a specific crew. On the other hand, because of the costs of orbiting equipment, it is important to design the equipment with a minimum of excess capacity because of the weight that extra capacity represents. A considerable quantity of information that had been independently gathered on waste production was examined in order to obtain estimates of equipment sizing requirements for handling waste loads from crews of 2 to 20 individuals. The recommended design for a crew of 8 should hold 34.5 liters per day (4315 ml/person/day) for urine and stool water and a little more than 1.25 kg per day (154 g/person/day) of human waste solids and sanitary supplies.

Parker, Dick↗

NASA NTRS2004

Development and Testing of a Drogue Parachute System for X-37 ALTV/B-52H Separation

Multiple scenarios were identified in which the X-37 approach and landing test vehicle (ALTV) catastrophically recontacts the B-52H carrier aircraft after separation. The most cost-effective recontact risk mitigation is the prelaunch deployment of a drogue parachute that is released after the X-37 ALTV has safely cleared the B-52H. After release, a fully-inflated drogue parachute takes 30 min to reach ground and results in a large footprint that excessively restricts the days available for flight. To reduce the footprint, a passive collapse mechanism consisting of an elastic reefing line attached to the parachute skirt was developed. At flight loads the elastic is stretched, allowing full parachute inflation. After release, drag loads drop dramatically and the elastic line contracts, reducing the frontal drag area. A 50 percent drag reduction results in an approximately 75 percent ground footprint reduction. Eleven individual parachute designs were evaluated at flight load dynamic pressures in the High Velocity Airflow System (HIVAS) at the Naval Air Warfare Center (NAWC), China Lake, California. Various options for the elastic reefing system were also evaluated at HIVAS. Two best parachute designs were selected from HIVAS to be carried forward to flight test. Detailed HIVAS test results are presented in this report.

Whitmore, Stephen A.↗

NASA NTRS2004

Development and Testing of a Drogue Parachute System for X-37 ALTV/B-52H Separation

Multiple scenarios were identified in which the X-37 approach and landing test vehicle (ALTV) catastrophically recontacts the B-52H carrier aircraft after separation. The most cost-effective recontact risk mitigation is the prelaunch deployment of a drogue parachute that is released after the X-37 ALTV has safely cleared the B-52H. After release, a fully-inflated drogue parachute takes 30 min to reach ground and results in a large footprint that excessively restricts the days available for flight. To reduce the footprint, a passive collapse mechanism consisting of an elastic reefing line attached to the parachute skirt was developed. At flight loads the elastic is stretched, allowing full parachute inflation. After release, drag loads drop dramatically and the elastic line contracts, reducing the frontal drag area. A 50-percent drag reduction results in an approximately 75-percent ground footprint reduction. Eleven individual parachute designs were evaluated at flight load dynamic pressures in the High Velocity Airflow System (HIVAS) at the Naval Air Warfare Center (NAWC), China Lake, California. Various options for the elastic reefing system were also evaluated at HIVAS. Two best parachute designs were selected from HIVAS to be carried forward to flight test. Detailed HIVAS test results are presented in this report.

Whitmore, Stephen A.↗

NASA NTRS1990

A network flow model for load balancing in circuit-switched multicomputers

In multicomputers that utilize circuit switching or wormhole routing, communication overhead depends largely on link contention - the variation due to distance between nodes is negligible. This has a major impact on the load balancing problem. In this case, there are some nodes with excess load (sources) and others with deficit load (sinks) and it is required to find a matching of sources to sinks that avoids contention. The problem is made complex by the hardwired routing on currently available machines: the user can control only which nodes communicate but not how the messages are routed. Network flow models of message flow in the mesh and the hypercube were developed to solve this problem. The crucial property of these models is the correspondence between minimum cost flows and correctly routed messages. To solve a given load balancing problem, a minimum cost flow algorithm is applied to the network. This permits one to determine efficiently a maximum contention free matching of sources to sinks which, in turn, tells one how much of the given imbalance can be eliminated without contention.

Bokhari, Shahid H.↗

NASA NTRS1993

A network flow model for load balancing in circuit-switched multicomputers

Bokhari, Shahid H.↗

NASA NTRS2007

Neural Net Safety Monitor Design

The National Aeronautics and Space Administration (NASA) at the Dryden Flight Research Center (DFRC) has been conducting flight-test research using an F-15 aircraft (figure 1). This aircraft has been specially modified to interface a neural net (NN) controller as part of a single-string Airborne Research Test System (ARTS) computer with the existing quad-redundant flight control system (FCC) shown in figure 2. The NN commands are passed to FCC channels 2 and 4 and are cross channel data linked (CCDL) to the other computers as shown. Numerous types of fault-detection monitors exist in the FCC when the NN mode is engaged; these monitors would cause an automatic disengagement of the NN in the event of a triggering fault. Unfortunately, these monitors still may not prevent a possible NN hard-over command from coming through to the control laws. Therefore, an additional and unique safety monitor was designed for a single-string source that allows authority at maximum actuator rates but protects the pilot and structural loads against excessive g-limits in the case of a NN hard-over command input. This additional monitor resides in the FCCs and is executed before the control laws are computed. This presentation describes a floating limiter (FL) concept1 that was developed and successfully test-flown for this program (figure 3). The FL computes the rate of change of the NN commands that are input to the FCC from the ARTS. A window is created with upper and lower boundaries, which is constantly floating and trying to stay centered as the NN command rates are changing. The limiter works by only allowing the window to move at a much slower rate than those of the NN commands. Anywhere within the window, however, full rates are allowed. If a rate persists in one direction, it will eventually hit the boundary and be rate-limited to the floating limiter rate. When this happens, a persistent counter begins and after a limit is reached, a NN disengage command is generated. The tunable metrics for the FL are (1) window size, (2) drift rate, and (3) persistence counter. Ultimate range limits are also included in case the NN command should drift slowly to a limit value that would cause the FL to be defeated. The FL has proven to work as intended. Both high-g transients and excessive structural loads are controlled with NN hard-over commands. This presentation discusses the FL design features and presents test cases. Simulation runs are included to illustrate the dramatic improvement made to the control of NN hard-over effects. A mission control room display from a flight playback is presented to illustrate the neural net fault display representation. The FL is very adaptable to various requirements and is independent of flight condition. It should be considered as a cost-effective safety monitor to control single-string inputs in general.

Larson, Richard R.↗