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NASA NTRS1995

Computing Propagation Of Sound In Engine Ducts

Frequency Domain Propagation Model (FREDOM) computer program accounts for acoustic loads applied to components of engines. Models propagation of noise through fluids in ducts between components and through passages within components. Used not only to analyze hardware problems, but also for design purposes. Updated version of FREQPL program easier to use. Devised specifically for use in analyzing acoustic loads in rocket engines. Underlying physical and mathematical concepts implemented also applicable to acoustic propagation in other enclosed spaces; analyzing process plumbing and ducts in industrial buildings with view toward reducing noise in work areas.

Saylor, Silvia↗

NASA NTRS2004

NASA Thermographic Inspection of Advanced Composite Materials

As the use of advanced composite materials continues to increase in the aerospace community, the need for a quantitative, rapid, in situ inspection technology has become a critical concern throughout the industry. In many applications it is necessary to monitor changes in these materials over an extended period of time to determine the effects of various load conditions. Additionally, the detection and characterization of defects such as delaminations, is of great concern. This paper will present the application of infrared thermography to characterize various composite materials and show the advantages of different heat source types. Finally, various analysis methodologies used for quantitative material property characterization will be discussed.

Cramer, K. Elliott↗

NASA NTRS2004

Evaluation of Mobile Phone Interference With Aircraft GPS Navigation Systems

This report compiles and analyzes tests that were conducted to measure cell phone spurious emissions in the Global Positioning System (GPS) radio frequency band that could affect the navigation system of an aircraft. The cell phone in question had, as reported to the FAA (Federal Aviation Administration), caused interference to several GPS receivers on-board a small single engine aircraft despite being compliant with data filed at the time with the FCC by the manufacturer. NASA (National Aeronautics and Space Administration) and industry tests show that while there is an emission in the 1575 MHz GPS band due to a specific combination of amplifier output impedance and load impedance that induces instability in the power amplifier, these spurious emissions (i.e., not the intentional transmit signal) are similar to those measured on non-intentionally transmitting devices such as, for example, laptop computers. Additional testing on a wide sample of different commercial cell phones did not result in any emission in the 1575 MHz GPS Band above the noise floor of the measurement receiver.

Pace, Scott↗

NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗

NASA NTRS2026

Evaluating Energy Absorption Methods for Integrated Composite Seat Designs

Composite materials have become ubiquitous in the aerospace industry due to their exceptionally light weight and high strength characteristics, as well as their unique ability to be engineered and tailored to meet specific loading conditions and performance requirements. These advanced materials offer superior strength-to-weight ratios compared to traditional metallic materials, making them particularly valuable in weight-critical aerospace applications where every pound saved translates to improved efficiency and performance. In currently operating fleets of commercial and military aircraft, composite materials have been successfully applied to critical structural components, including primary load-bearing elements such as the fuselage sections and flooring structures, which must withstand significant in-flight loads and provide passenger safety. Additionally, these materials have been specifically tailored and optimized for aerodynamic components such as wings and tail assemblies, where their ability to be molded into complex shapes while maintaining structural integrity is particularly advantageous. The application of composite materials extends beyond primary structural elements into the realm of internal cabin components, most notably in innovative seat designs where weight reduction and structural integration are paramount concerns. Modern composite seat structures can be designed to integrate multiple functions, including structural support, comfort features, and safety systems, all while maintaining the lightweight characteristics essential for aircraft performance.

Digital image correlation↗

NASA NTRS1985

Space shuttle wheels and brakes

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.

Carsley, R. B.↗

NASA NTRS1986

Advanced photovoltaic solar array program - A preliminary assessment

Two solar array designs developed for the Advanced Photovoltaic Solar Array program are described. The goal of the program is to develop solar arrays with higher mass specific power and power density and good robustness. The specific design requirements are: a beginning-of-life value of 130 W/kg, and end-of-life goals of 105 W/kg and 110 W/sq m. The two array-wing designs consisted of a single blanket. The differences in the blanket material (25 micron-thick Kapton versus 50 micron-thick carbon-loaded Kapton), solar cells (100 micron-thick wrap around versus 50 micron-thick 2 x 4 cm planar contact cells), and performance objectives (proposed industry requirements versus mission objectives) of the two designs are examined.

Scott-Monck, J.↗

NASA NTRS2002

Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance

The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.

DellaCorte, Christopher↗

NASA NTRS2008

Extreme Environment Technologies for Space and Terrestrial Applications

Over the next decades, NASA's planned solar system exploration missions are targeting planets, moons and small bodies, where spacecraft would be expected to encounter diverse extreme environmental (EE) conditions throughout their mission phases. These EE conditions are often coupled. For instance, near the surface of Venus and in the deep atmospheres of giant planets, probes would experience high temperatures and pressures. In the Jovian system low temperatures are coupled with high radiation. Other environments include thermal cycling, and corrosion. Mission operations could also introduce extreme conditions, due to atmospheric entry heat flux and deceleration. Some of these EE conditions are not unique to space missions; they can be encountered by terrestrial assets from the fields of defense,oil and gas, aerospace, and automotive industries. In this paper we outline the findings of NASA's Extreme Environments Study Team, including discussions on state of the art and emerging capabilities related to environmental protection, tolerance and operations in EEs. We will also highlight cross cutting EE mitigation technologies, for example, between high g-load tolerant impactors for Europa and instrumented projectiles on Earth; high temperature electronics sensors on Jupiter deep probes and sensors inside jet engines; and pressure vessel technologies for Venus probes and sea bottom monitors. We will argue that synergistic development programs between these fields could be highly beneficial and cost effective for the various agencies and industries. Some of these environments, however, are specific to space and thus the related technology developments should be spear headed by NASA with collaboration from industry and academia.

extreme environments↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS1978

Mapping of chlorophyll a distributions in coastal zones

It is pointed out that chlorophyll a is an important environmental parameter for monitoring water quality, nutrient loads, and pollution effects in coastal zones. High chlorophyll a concentrations occur in areas which have high nutrient inflows from sources such as sewage treatment plants and industrial wastes. Low chlorophyll a concentrations may be due to the addition of toxic substances from industrial wastes or other sources. Remote sensing provides an opportunity to assess distributions of water quality parameters, such as chlorophyll a. A description is presented of the chlorophyll a analysis and a quantitative mapping of the James River, Virginia. An approach considered by Johnson (1977) was used in the analysis. An application of the multiple regression analysis technique to a data set collected over the New York Bight, an environmentally different area of the coastal zone, is also discussed.

Johnson, R. W.↗

NASA NTRS1990

Manufacture and evaluation of Li/BCX DD cells

This project is divided into four main tasks: cell manufacture, acceptance, and lot certification of cells, performance testing of cells, and abuse testing of cells. Lithium/bromine chloride in thionyl chloride (Li/BCX) 149 DD cells (PN 3B2085-XA) were built according to the provisions of Electrochem Industries Quality Plan 17096. Acceptance and lot certification testing was performed according to NASA JSC Document EP5-83-025, Revision B. Acceptance testing included open circuit and load voltage check, visual examination, size and weight measurements, and high temperature exposure. Lot certification tests were performed for capacity performance and for performance under conditions of thermal and electrical abuse. These tests included 149 C exposure, capacity discharge, fuse check, high temperature exposure, high rate discharge, short circuit, vibration, and overdischarge testing. A quantity of 200 cells was delivered to Johnson Space Center for life test evaluation. A parametric evaluation of the capacity discharge of Li/BCX DD cells was performed over a variety of temperatures and discharge rates. This testing served to map the performance capability of the cell. Tests were also performed over a variety of electrical and thermal abuse conditions. Abuse tests included short circuit, charging, overdischarge, high temperature exposure, shock, and vibration.

Meyer, S.↗

NASA NTRS1998

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗

NASA NTRS2005

Flight Test of the F/A-18 Active Aeroelastic Wing Airplane

Successful flight-testing of the Active Aeroelastic Wing airplane was completed in March 2005. This program, which started in 1996, was a joint activity sponsored by NASA, Air Force Research Laboratory, and industry contractors. The test program contained two flight test phases conducted in early 2003 and early 2005. During the first phase of flight test, aerodynamic models and load models of the wing control surfaces and wing structure were developed. Design teams built new research control laws for the Active Aeroelastic Wing airplane using these flight-validated models; and throughout the final phase of flight test, these new control laws were demonstrated. The control laws were designed to optimize strategies for moving the wing control surfaces to maximize roll rates in the transonic and supersonic flight regimes. Control surface hinge moments and wing loads were constrained to remain within hydraulic and load limits. This paper describes briefly the flight control system architecture as well as the design approach used by Active Aeroelastic Wing project engineers to develop flight control system gains. Additionally, this paper presents flight test techniques and comparison between flight test results and predictions.

Clarke, Robert↗

NASA NTRS2005

Flight Test of the F/A-18 Active Aeroelastic Wing Airplane

Clarke, Robert↗

NASA NTRS2010

Three-Body Abrasion Testing Using Lunar Dust Simulants to Evaluate Surface System Materials

Numerous unexpected operational issues relating to the abrasive nature of lunar dust, such as scratched visors and spacesuit pressure seal leaks, were encountered during the Apollo missions. To avoid reoccurrence of these unexpected detrimental equipment problems on future missions to the Moon, a series of two- and three-body abrasion tests were developed and conducted in order to begin rigorously characterizing the effect of lunar dust abrasiveness on candidate surface system materials. Two-body scratch tests were initially performed to examine fundamental interactions of a single particle on a flat surface. These simple and robust tests were used to establish standardized measurement techniques for quantifying controlled volumetric wear. Subsequent efforts described in the paper involved three-body abrasion testing designed to be more representative of actual lunar interactions. For these tests, a new tribotester was developed to expose samples to a variety of industrial abrasives and lunar simulants. The work discussed in this paper describes the three-body hardware setup consisting of a rotating rubber wheel that applies a load on a specimen as a loose abrasive is fed into the system. The test methodology is based on ASTM International (ASTM) B611, except it does not mix water with the abrasive. All tests were run under identical conditions. Abraded material specimens included poly(methyl methacrylate) (PMMA), hardened 1045 steel, 6061-T6 aluminum (Al) and 1018 steel. Abrasives included lunar mare simulant JSC- 1A-F (nominal size distribution), sieved JSC-1A-F (<25 m particle diameter), lunar highland simulant NU-LHT-2M, alumina (average diameter of 50 m used per ASTM G76), and silica (50/70 mesh used per ASTM G65). The measured mass loss from each specimen was converted using standard densities to determine total wear volume in cm3. Abrasion was dominated by the alumina and the simulants were only similar to the silica (i.e., sand) on the softer materials of aluminum and PMMA. The nominal JSC- 1A-F consistently showed more abrasion wear than the sieved version of the simulant. The lunar dust displayed abrasivity to all of the test materials, which are likely to be used in lunar landing equipment. Based on this test experience and pilot results obtained, recommendations are made for systematic abrasion testing of candidate materials intended for use in lunar exploration systems and in other environments with similar dust challenges.

Kobrick, Ryan L.↗

NASA NTRS2012

Sizing and Lifecycle Cost Analysis of an Ares V Composite Interstage

The Interstage Element of the Ares V launch vehicle was sized using a commercially available structural sizing software tool. Two different concepts were considered, a metallic design and a composite design. Both concepts were sized using similar levels of analysis fidelity and included the influence of design details on each concept. Additionally, the impact of the different manufacturing techniques and failure mechanisms for composite and metallic construction were considered. Significant details were included in analysis models of each concept, including penetrations for human access, joint connections, as well as secondary loading effects. The designs and results of the analysis were used to determine lifecycle cost estimates for the two Interstage designs. Lifecycle cost estimates were based on industry provided cost data for similar launch vehicle components. The results indicated that significant mass as well as cost savings are attainable for the chosen composite concept as compared with a metallic option.

Mann, Troy↗

NASA NTRS2002

The NASA Low-Pressure Turbine Flow Physics Program: A Review

An overview of the NASA Glenn Low-Pressure Turbine (LPT) Flow Physics Program will be presented. The flow in the LPT is unique for the gas turbine. It is characterized by low Reynolds number and high freestream turbulence intensity and is dominated by interplay of three basic mechanisms: transition, separation and wake interaction. The flow of most interest is on the suction surface, where large losses are generated due to separation. The LPT is a large, multistage, heavy, jet engine component that suffers efficiency degradation between takeoff and cruise conditions due to decrease in Reynolds number with altitude. The performance penalty is around 2 points for large commercial bypass engines and as much as 7 points for small, high cruise altitude, military engines. The gas-turbine industry is very interested in improving the performance of the LPT and in reducing its weight, part count and cost. Many improvements can be accomplished by improved airfoil design, mainly by increasing the airfoil loading that can yield reduction of airfoils and improved performance. In addition, there is a strong interest in reducing the design cycle time and cost. Key enablers of the needed improvements are computational tools that can accurately predict LPT flows. Current CFD tools in use cannot yet satisfactorily predict the unsteady, transitional and separated flow in the LPT. The main reasons are inadequate transition & turbulence models and incomplete understanding of the LPT flow physics. NASA Glenn has established its LPT program to answer these needs. The main goal of the program is to develop and assess models for unsteady CFD of LPT flows. An approach that consists of complementing and augmenting experimental and computational work elements has been adopted. The work is performed in-house and by several academic institutions, in cooperation and interaction with industry. The program was reviewed at the Minnowbrook II meeting in 1997. This review will summarize the progress that was made since and will introduce newly started projects. The LPT program is focused on three areas: acquisition of experimental and numerical databases and on modeling and computation. Priority was initially given to experiments. There are three classes of experiments: simulated LPT passages, linear cascade, both with and without wakes, and low-speed rotating rig. They are being conducted as follows: At NASA GRC on a flat surface with blade pressure distribution, at the US Naval Academy on a curved surface. The addition of wakes is studied at the University of Minnesota in a curved passage with a retractable wake generator, and at Texas A&M University in a linear cascade with continuously running wake generator. The pressure distribution of the Pratt & Whitney blade 'Pak B' is used in all these experiments. Experiments have been performed also in the GEAE Low-Speed Rotating Turbine (LSRT) rig with GE-designed airfoils. Work on numerically generated database is in progress at the University of Kentucky, using the DNS/LES code LESTool developed there. Turbulence/transition model assessment and development is performed also at the University of Kentucky, where a new intermittency transport model was developed and many experimental test cases have been numerically computed. Assessments of models using simulations of multistage LPT experiments were performed at Virginia Commonwealth University using the Corsair code. Work on suction surface separation delay, using passive and active flow-control, has also been initiated. Following the overview, Principal Investigators attending the workshop will present in detail several of the projects supported by NASA.

Ashpis, David E.↗