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NASA NTRS2009

Foil Bearing Starting Considerations and Requirements for Rotorcraft Engine Applications

Foil gas bearings under development for rotorcraft-sized, hot core engine applications have been susceptible to damage from the slow acceleration and rates typically encountered during the pre-ignition stage in conventional engines. Recent laboratory failures have been assumed to be directly linked to operating foil bearings below their lift-off speed while following conventional startup procedures for the engines. In each instance, the continuous sliding contact between the foils and shaft was believed to thermally overload the bearing and cause the engines to fail. These failures highlight the need to characterize required acceleration rates and minimum operating speeds for these applications. In this report, startup experiments were conducted with a large, rotorcraft engine sized foil bearing under moderate load and acceleration rates to identify the proper start procedures needed to avoid bearing failure. The results showed that a bearing under a 39.4 kPa static load can withstand a modest acceleration rate of 500 rpm/s and excessive loitering below the bearing lift-off speed provided an adequate solid lubricant is present.

Radil, Kevin C.↗

NASA NTRS2024

Characterization of NUW-LHT-5m, A Lunar Highland Simulant

A new simulant of the lunar highlands regolith, NUW-LHT-5M, was designed by NASA and manufactured by Washington Mills. The simulant was based on Apollo 16 data and is a member of the NU-LHT-series. NASA’s Marshall Space Flight Center and Johnson Space Center have already purchased 3 metric tons of the simulant for advanced engineering work. In support of engineering uses of the simulant, we provided measurements of the simulant including: mineral abundance and composition, liberation, X-ray fluorescence (XRF), ferrous iron, carbon, sulfur, 60 element inductively coupled plasma (ICP), loss on ignition, particle size, both 2D and 3D particle shape, specific surface area, shear, cohesion, internal friction, helium pycnometry, minimum index density, tap density, magnetic susceptibility, cryogenic and high temperature permittivity, visible and near-infrared (VNIR) and middle infra-red spectroscopy (MIR), differential scanning calorimetry (DSC), viscosity, thermal diffusivity, thermal conductivity, thermal gravimetric analysis (TGA), evolved gas analysis (EGA), and spark sintering. For the crystalline components the design of the simulant called for two rocks from the Stillwater Complex, Montana: 17.6 wt% norite, 37.7% anorthosite, and 4.7 wt% olivine from an unspecified commercial source. The other 40% of the simulant was a high calcium (An100), vesicular glass that Washington Mills made specifically for the simulant. Fabrication and quality control processes for both the glass and the simulant are described. Importantly, most of the graphs and tables presented herein provide values for both the new simulant and data for the older NASA mare simulant, JSC-1A. Finally, we discussed the current limitations of NUW-LT-5M and most other lunar regolith simulants to replicate the lunar material.

lunar regolith simulant↗

NASA NTRS1989

Materials compatibility with oxidizer-rich gases at elevated temperatures and pressure

An investigation of oxygen compatibility and resistance to ignition of candidate materials for use in a liquid rocket engine designed to incorporate an oxidizer rich preburner-LOX turbopump configuration was discussed. The program was divided into two basic tasks. The first task was to develop a preliminary design of an oxidizer turbopump preburner section complete with thermal and MS Parameter analyses and to develop a conceptual design of the main injector with a preliminary engine specification as the final product. The second task was directed totally at testing materials in oxygen-rich environments.

Source record↗

NASA NTRS1989

Flight Set 360T004 (STS-30) Insulation Component, Interim Release, Volume 3

The insulation component of the Redesigned Solid Rocket Motor (RSRM) is discussed. The results of all visual evaluations and a thermal safety factor analysis are given. The data contained here supersedes the interim release and the insulation data presented in the Clearfield 10 day report. The objective is to document the postflight condition of the internal and external insulation of nozzle to case joints, the case field joints, the igniter to case joints, and the acreage insulation which made up RSRM-4A and RSRM-4B.

Passman, James A.↗

NASA NTRS1993

Laser-initiated ordnance for air-to-air missiles

McDonnell Douglas Missile Systems Company (MDMSC) has developed a laser ignition subsystem (LIS) for air-to-air missile applications. The MDMSC subsystem is designed to activate batteries, unlock fins, and sequence propulsion system events. The subsystem includes Pyro Zirconium Pump (PZP) lasers, mechanical Safe & Arm, fiber-optic distribution system, and optically activated pyrotechnic devices (initiators, detonators, and thermal batteries). The LIS design has incorporated testability features for the laser modules, drive electronics, fiber-optics, and pyrotechnics. Several of the LIS have been fabricated and have supported thermal battery testing, integral rocket ramjet testing, and have been integrated into integral rocket ramjet flight test vehicles as part of the flight control subsystem.

Sumpter, David R.↗

NASA NTRS1999

Interaction of Burning Metal Particles

Physical characteristics of the combustion of metal particle groups have been addressed in this research. The combustion behavior and interaction effects of multiple metal particles has been studied using a microgravity environment, which presents a unique opportunity to create an "aerosol" consisting of relatively large particles, i.e., 50-300 micrometer diameter. Combustion behavior of such an aerosol could be examined using methods adopted from well-developed single particle combustion research. The experiment included fluidizing relatively large (order of 100 micrometer diameter) uniform metal particles under microgravity and igniting such an "aerosol" using a hot wire igniter. The flame propagation and details of individual particle combustion and particle interaction have been studied using a high speed movie and video-imaging with cameras coupled with microscope lenses to resolve individual particles. Interference filters were used to separate characteristic metal and metal oxide radiation bands form the thermal black body radiation. Recorded flame images were digitized and employed to understand the processes occurring in the burning aerosol. The development of individual particle flames, merging or separation, and extinguishing as well as induced particle motion have been analyzed to identify the mechanisms governing these processes. Size distribution, morphology, and elemental compositions of combustion products were characterized and used to link the observed in this project aerosol combustion phenomena with the recently expanded mechanism of single metal particle combustion.

Dreizin, Edward L.↗

NASA NTRS1999

Interaction of Burning Metal Particles

Physical characteristics of the combustion of metal particle groups have been addressed in this research. The combustion behavior and interaction effects of multiple metal particles has been studied using a microgravity environment, which presents a unique opportunity to create an "aerosol" consisting of relatively large particles, i.e., 50-300 m diameter. Combustion behavior of such an aerosol could be examined using methods adopted from well-developed single particle combustion research. The experiment included fluidizing relatively large (order of 100 m diameter) uniform metal particles under microgravity and igniting such an "aerosol" using a hot wire igniter. The flame propagation and details of individual particle combustion and particle interaction have been studied using a high speed movie and video-imaging with cameras coupled with microscope lenses to resolve individual particles. Interference filters were used to separate characteristic metal and metal oxide radiation bands from the thermal black body radiation. Recorded flame images were digitized and various image processing techniques including flame position tracking, color separation, and pixel by pixel image comparison were employed to understand the processes occurring in the burning aerosol. The development of individual particle flames, merging or separation, and extinguishment as well as induced particle motion have been analyzed to identify the mechanisms governing these processes. Size distribution, morphology, and elemental compositions of combustion products were characterized and used to link the observed in this project aerosol combustion phenomena with the recently expanded mechanism of single metal particle combustion.

Dreizin, Edward L.↗

NASA NTRS2013

Quantitative Infrared Image Analysis Of Simultaneous Upstream and Downstream Microgravity Flame Spread over Thermally-Thin Cellulose in Low Speed Forced Flow

The effect of low velocity forced flow on microgravity flame spread is examined using quantitative analysis of infrared video imaging. The objective of the quantitative analysis is to provide insight into the mechanisms of flame spread in microgravity where the flame is able to spread from a central location on the fuel surface, rather than from an edge. Surface view calibrated infrared images of ignition and flame spread over a thin cellulose fuel were obtained along with a color video of the surface view and color images of the edge view using 35 mm color film at 2 Hz. The cellulose fuel samples were mounted in the center of a 12 cm wide by 16 cm tall flow duct and were ignited in microgravity using a straight hot wire across the center of the 7.5 cm wide by 14 cm long samples. Four cases, at 1 atm. 35%O2 in N2, at forced flows from 2 cm/s to 20 cm/s are presented here. This flow range captures flame spread from strictly upstream spread at low flows, to predominantly downstream spread at high flow. Surface temperature profiles are evaluated as a function of time, and temperature gradients for upstream and downstream flame spread are measured. Flame spread rates from IR image data are compared to visible image spread rate data. IR blackbody temperatures are compared to surface thermocouple readings to evaluate the effective emissivity of the pyrolyzing surface. Preheat lengths and pyrolysis lengths are evaluated both upstream and downstream of the central ignition point. A surface energy balance estimates the net heat flux from the flame to the fuel surface along the length of the fuel. Surface radiative loss and gas-phase radiation from soot are measured relative to the net heat feedback from the flame. At high surface heat loss relative to heat feedback, the downstream flame spread does not occur.

Olson, S. L.↗

NASA NTRS1992

Semi-coupled flow and thermal analysis of the field joint during rapid pressurization of the redesigned solid rocket motor

A transient, semi-coupled, multi-dimensional thermal and flow analysis methodology was developed to predict the thermal/gas dynamic conditions in the field joint region of the Redesigned Solid Rocket Motor (RSRM). Transient temperature response, pressure history, and combustion gas flow rate (within the field joint region), were of principle interest, in the course of this study. The thermal environment in the field joint was modeled using SINDA, a finite difference based thermal network analyzer. The combustion gas flow boundary condition was generated using the FLAP code; this code performs a transient, lumped-parameter, control volume analysis to solve the mass, momentum, and energy conservation equations. The FLAP computer code was modified to account for erosion of the NBR insulation material, following ignition. An independent grid sensitivity study was conducted to determine an appropriate grid distribution near the wall. The predicted results, obtained using an optimum grid distribution and computer generated flow boundary condition, were compared with subscale test data.

Ghaffarian, Benny↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Hybrid propulsion has been investigated as an enhancing technology for a Mars Ascent Vehicle (MAV) concept as part of potential Mars Sample Return (MSR) because of its high specific impulse, restartability, and the ability to operate and survive at extremely low temperatures. A new wax-based hybrid fuel formulation has been developed that could withstand the harsh and variable Mars environment protected solely by a minimal layer of passive insulation. This formulation could provide substantial energy savings for a notional lander and is critical for rover mobility. Preliminary thermal cycle testing has determined that the formulation can survive the expected temperature extremes and lifetime thermal testing is currently underway. A complete preliminary design using this new fuel formulation combined with a low temperature oxidizer such as Mixed Oxides of Nitrogen (MON30) is presented. Several key features associated with a complete hybrid MAV concept are investigated to determine their mission suitability (e.g. Thrust Vector Control and restartable ignition options). Potential challenges along a path towards developing such a system are outlined and future work is suggested as a means of technology maturation. The hybrid design presented here was the lowest Gross Lift Off Mass (GLOM) result of a 2015 Jet Propulsion Laboratory (JPL) led MAV concept study.

MSR↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Karp, Ashley C.↗

NASA NTRS1983

An analytical investigation of NO sub x control techniques for methanol fueled spark ignition engines

A thermokinetic SI engine simulation was used to study the effects of simple nitrogen oxide control techniques on performance and emissions of a methanol fueled engine. As part of this simulation, a ring crevice storage model was formulated to predict UBF emissions. The study included spark retard, two methods of compression ratio increase and EGR. The study concludes that use of EGR in high turbulence, high compression engines will both maximize power and thermal efficiency while minimizing harmful exhaust pollutants.

Browning, L. H.↗

NASA NTRS1999

Durability, Performance, and Emission of Diesel Engines Using Carbon Fiber Piston and Liner

This report summarizes the research conducted by NC State University in investigating the durability, performance and emission of a carbon fiber piston and liner in our single cylinder research Diesel engine. Both the piston and liner were supplied to NC State University by NASA LaRC and manufactured by C-CAT under a separate contract to NASA LaRC. The carbon-carbon material used to manufacture the piston and liner has significantly lower thermal conductivity, coefficient of thermal expansion, and superior strength characteristics at elevated temperatures when compared to conventional piston materials such as aluminum. The results of the carbon-carbon fiber piston testing were compared to a baseline configuration, which used a conventional aluminum piston in a steel liner. The parameters measured were the brake specific fuel consumption, ignition delay, frictional horsepower, volumetric efficiency, and durability characteristics of the two pistons. Testing was performed using a naturally aspirated Labeco Direct Injection single cylinder diesel engine. Two test cases were performed over a range of loads and speeds. The fixed test condition between the aluminum and carbon-carbon piston configurations was the brake mean effective pressure. The measured data was the fuel consumption rate, volumetric efficiency, load, speed, cylinder pressure, needle lift, and exhaust gas temperature. The cylinder pressure, and fuel consumption, exhaust gas temperature, and needle lift were recorded using a National Instruments DAQ board and a PC. All test cases used Diesel no. 2 for fuel.

Afify, E. M.↗

NASA NTRS2000

Analysis of the NASA White Sands Test Facility (WSTF) Test System for Friction-Ignition of Metallic Materials

Friction is a known ignition source for metals in oxygen-enriched atmospheres. The test system developed by the NASA White Sands Test Facility in response to ASTM G-94 has been used successfully to determine the relative ignition from friction of numerous metallic materials and metallic materials pairs. These results have been ranked in terms of a pressure-velocity product (PV) as measured under the prescribed test conditions. A high value of 4.1(exp 8) watts per square meter for Inconel MA 754 is used to imply resistance to friction ignition, whereas a low value of 1.04(exp 8) watts per square meter for stainless steel 304 is taken as indicating material susceptible to friction ignition. No attempt has been made to relate PV values to other material properties. This work reports the analysis of the WSTF friction-ignition test system for producing fundamental properties of metallic materials relating to ignition through friction. Three materials, aluminum, titanium, and nickel were tested in the WSTF frictional ignition instrument system under atmospheres of oxygen or nitrogen. Test conditions were modified to reach a steady state of operation, that is applied, the force was reduced and the rotational speed was reduced. Additional temperature measurements were made on the stator sample. The aluminum immediately galled on contact (reproducible) and the test was stopped. Titanium immediately ignited as a result of non-uniform contact of the stator and rotor. This was reproducible. A portion of the stator sampled burned, but the test continued. Temperature measurements on the stator were used to validate the mathematical model used for estimating the interface (stator/rotor) temperature. These interface temperature measurements and the associate thermal flux into the stator were used to distinguish material-phase transitions, chemical reaction, and mechanical work. The mechanical work was used to analyze surface asperities in the materials and to estimate a coefficient of fiction. The coefficient of fiction was analyzed in terms of material properties that is, hardness, Young's modulus and elasticity/plasticity of the material.

Shoffstall, Michael S.↗

NASA NTRS2017

X-Ray Reflection and an Exceptionally Long Thermonuclear Helium Burst from IGR J17062-6143

Thermonuclear X-ray bursts from accreting neutron stars power brief but strong irradiation of their surroundings, providing a unique way to study accretion physics. We analyze MAXI/Gas Slit Camera and Swift/XRT spectra of a day-long flash observed from IGR J17062-6143 in 2015. It is a rare case of recurring bursts at a low accretion luminosity of 0.15% Eddington. Spectra from MAXI, Chandra, and NuSTAR observations taken between the 2015 burst and the previous one in 2012 are used to determine the accretion column. We find it to be consistent with the burst ignition column of 5x10(exp 10) g cm (exp −2), which indicates that it is likely powered by burning in a deep helium layer. The burst flux is observed for over a day, and decays as a straight power law: F gamma t (exp −1.15). The burst and persistent spectra are well described by thermal emission from the neutron star, Comptonization of this emission in a hot optically thin medium surrounding the star, and reflection off the photoionized accretion disk. At the burst peak, the Comptonized component disappears, when the burst may dissipate the Comptonizing gas, and it returns in the burst tail. The reflection signal suggests that the inner disk is truncated at approximately 102 gravitational radii before the burst, but may move closer to the star during the burst. At the end of the burst, the flux drops below the burst cooling trend for 2 days, before returning to the pre-burst level.

ccretion↗

NASA NTRS2000

Flammability: A Review and Analysis

With its founding in 1975, Committee G-4 of the American Society for Testing and Materials (ASTM) embarked on the process of defining the flammability of metallic materials in oxygen-enriched atmospheres. In this process, they are joined by the National Aeronautics and Space Administration (NASA), the National Fire Protection Association (NFPA), and the Compressed Gas Association (CGA). Although none of these organizations has explicitly defined flammability, the following definitions and statements provide a composite understanding of the concept: 1. "This Standard Guide (ASTM G94-92) is concerned primarily with the properties of a material associated with its relative susceptibility to ignition and propagation of combustion." 2. "A material is considered flammable at the maximum use pressure if at least one sample burns more than 6 in. (15.2 cm). At least, five samples must be tested." NASA 3. "Flammable: Capable, when ignited of maintaining combustion under the specified environmental conditions." NFPA 53. 4. "Combustion: A complex sequence of chemical reactions between a fuel and an oxidant accompanied by the evolution of heat, and usually, the emission of light." NFPA 53. and 5. "A safe oxygen-piping transmission or distribution system is one that is designed and installed in accordance with all applicable codes and regulations for the service conditions and locations involved and further meets the special requirements for oxygen services." CGA-G4 Flammability thus equates, after ignition, to propagation of combustion, synonymous with steady state burning, under specified environmental conditions. Properties for which quantitative values are given in ASTM G94-92 and which are used to describe metals flammability consistent with the concept of steady state burning are either system independent properties, such as, enthalpies of reaction, burn ratios, flame temperatures, thermal conductivity, and heat release; or system dependent properties, such as, oxygen index, promoted combustion, threshold pressure and burn rates. Each property is reviewed and analyzed as to whether it provides an absolute or relative measure for flammability. It is shown that burn ratio, as applied to the actual steady state combustion condition, approaches the desired absolute measure of flammability.

Wilson, D. Bruce↗

NASA NTRS1932

Considerations of Air Flow in Combustion Chambers of High-Speed Compression-Ignition Engines

The air flow in combustion chambers is divided into three fundamental classes - induced, forced, and residual. A generalized resume is given of the present status of air flow investigations and of the work done at this and other laboratories to determine the direction and velocity of air movement in auxiliary and integral combustion chambers. The effects of air flow on engine performance are mentioned to show that although air flow improves the combustion efficiency, considerable induction, friction, and thermal losses must be guarded against.

Spanogle, J A↗

NASA NTRS2013

Orion GNC Mitigation Efforts for Van Allen Radiation

The Orion Crew Module (CM) is NASA's next generation manned space vehicle, scheduled to return humans to lunar orbit in the coming decade. The Orion avionics and GN&C architectures have progressed through a number of project phases and are nearing completion of a major milestone. The first unmanned test mission, dubbed "Exploration Flight Test One" (EFT-1) is scheduled to launch from NASA Kennedy Space Center late next year and provides the first integrated test of all the vehicle systems, avionics and software. The EFT-1 mission will be an unmanned test flight that includes a high speed re-entry from an elliptical orbit, which will be launched on an expendable launch vehicle (ELV). The ELV will place CM and the ELV upper stage into a low Earth orbit (LEO) for one revolution. After the first LEO, the ELV upper stage will re-ignite and place the combined upper stage/CM into an elliptical orbit whose perigee results in a high energy entry to test CM response in a relatively high velocity, high heating environment. While not producing entry velocities as high as those experienced in returning from a lunar orbit, the trajectory was chosen to provide higher stresses on the thermal protection and guided entry systems, as compared against a lower energy LEO entry. However the required entry geometry with constraints on inclination and landing site result in a trajectory that lingers for many hours in the Van Allen radiation belts. This exposes the vehicle and avionics to much higher levels of high energy proton radiation than a typical LEO or lunar trajectory would encounter. As a result, Van Allen radiation poses a significant risk to the Orion avionics system, and particularly the Flight Control Module (FCM) computers that house the GN&C flight software. The measures taken by the Orion GN&C, Flight Software and Avionics teams to mitigate the risks associated with the Van Allen radiation on EFT-1 are covered in the paper. Background on the Orion avionics subsystem is provided, as well as an overview of the GN&C software architecture. The measures taken to handle radiation induced failure of the one or both of the FCM's are presented, and finally simulation and actual hardware-in-the-loop (HWIL) results are shown confirming the validity of the implementation. The paper presents an overview of the Orion avionics architecture describing the GNC sensors, onboard data network as well as the flight control computers and their planned restart capabilities. GN&C sensors include two Orion Inertial Measurement Units (OIMU's), a Vision Processing Unit (VPU) to process camera images, three barometric altimeters and a single GPS receiver. All of the sensors communicate to one of two Power and Data Units (PDU's). The PDU's multiplex analog and serial data from the sensors and write the data to the Orion Data Network (ODN). The OIMU s write measurement messages directly as onto the ODN, but they are routed through PDU network switches.

King, Ellis T.↗