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NASA NTRS2019

Progress in Additively Manufactured Copper-Alloy GRCop-84, GRCop-42, and Bimetallic Combustion Chambers for Liquid Rocket Engines

Additive Manufacturing (AM) has significantly evolved over the last decade for use in the aerospace industry, particularly for liquid rocket engines. AM offers a considerable departure from traditional manufacturing to rapidly fabricate components with complex internal features. High performance liquid rocket engine combustion chambers that operate in a high heat flux environment are fabricated using a copper-alloy liner with a series of integral coolant channels. Copper-alloys provide the necessary conductivity and material strength for adequate design margins offering high performance without the need for film coolant. Copper-alloys present unique challenges to properly melt the powder in laser-based AM processes due to their high reflectivity and conductivity. Starting in 2014, NASA’s Marshall Space Flight Center (MSFC) and Glenn Research Center (GRC) have developed a process for AM of GRCop (Copper- Chrome-Niobium) alloys using Selective Laser Melting (SLM). GRCop, originally developed at GRC, is a high conductivity, high-strength, dispersion strengthened copper-alloy for use in high-temperature, high heat flux applications. NASA has completed significant material characterization and testing, along with hot-fire testing, to demonstrate that GRCop-42 and GRCop-84 alloys are suitable for use in combustion chambers. Additional development and testing has been completed on AM bimetallic chambers using GRCop-84 liners and superalloy jackets, fabricated using two Directed Energy Deposition (DED) processes: Electron Beam Freeform Fabrication (EBF³) and Blown Powder DED. NASA completed hot-fire testing on various AM chambers using GRCop-84, GRCop-42, and bimetallic chambers in Liquid Oxygen (LOX)/Hydrogen, LOX/Methane, and LOX/Kerosene propellants.

Gradl, Paul R.↗

NASA NTRSDate not supplied

Integrated Crewed Mars Mission Analysis, Part II: The Trajectory Strikes Back

Crewed missions to Mars present a challenging problem involving strong interactions between a variety of spacecraft systems. Design and architecture decisions made by one system can have powerful implications for another. Siloed subsystem development and optimization efforts are unlikely to generate optimal results for the integrated system and may lead to counterproductive investments at the mission and system level. Mismatched assumptions between different subsystems can also negatively impact the final result. Integrated systems analysis, trade studies, and sensitivity analysis are a critical element of successful Mars mission design. Previous work examined the linkages between Environmental Control and Life Support System (ECLSS) loop closure, food water content, spares Probability of Sufficiency (POS), and other factors by performing an integrated mass and cost assessment of a variety of Mars habitat and transportation system designs. This paper expands upon that work by evaluating the impact of mission duration, trajectory, and propulsion technology alongside key habitat variables. Transportation system and trajectory design decisions have enormous impacts on overall system mass, and the impacts of those decisions are themselves sensitive to the mass of the habitat that is being transported. This paper examines a variety of mission cases and evaluates total departure mass for each case. An estimate of relative costs for specific cases is also provided. The results are discussed, with an emphasis on the sensitivity of mass, cost, and other figures of merit to key parameters. Interactions and dependencies between various decisions, particularly those that relate to technology investments, are also highlighted. Overall, the various elements, systems, and subsystems required to support human spaceflight should not be optimized and evaluated in isolation, but instead should be analyzed as part of an integrated system. This paper demonstrates how integrated analysis can improve system understanding and lead to more optimal and effective crewed exploration systems.

Human Spaceflight↗

NASA NTRSDate not supplied

Integrated Crewed Mars Mission Analysis, Part II: The Trajectory Strikes Back

Human Spaceflight↗

NASA NTRS2007

Propulsion Technology Needs for Exploration

The objectives of currently planned exploration efforts, as well as those further in the future, require significant advancements in propulsion technologies. The current Lunar exploration architecture has set goals and mission objectives that necessitate the use of new systems and the extension of existing technologies beyond present applications. In the near term, the majority of these technologies are the result of a need to apply high performing cryogenic propulsion systems to long duration in-space applications. Advancement of cryogenic propulsion to these applications is crucial to provide higher performing propulsion systems that reduce the vehicle masses; enhance the safety of vehicle systems and ground operations; and provide a path for In-situ Resource Utilization (ISRU).Use of a LOX/LH2 main propulsion system for Lunar Lander Descent is a top priority because more conventional storable propellants are far from meeting the performance needs of the current architecture. While LOX/LH2 pump feed engines have been used in flight applications for many years, these engines have limited throttle capabilities. Engines that are capable of much greater throttling while still meeting high performance goals are a necessity to achieving exploration goals. Applications of LOX/CH4 propulsion to Lander ascent propulsion systems and reaction control systems are also if interest because of desirable performance and operations improvements over conventional storable systems while being more suitable for use of in-situ produced propellants. Within the current lunar architecture, use of cryogenic propulsion for the Earth Departure Stage and Lunar Lander elements also necessitate the need for advanced Cryogenic Fluid Management technologies. These technologies include long duration propellant storage/distribution, low-gravity propellant management, cryogenic couplings and disconnects, light weight composite tanks and support structure, and subsystem integration. In addition to the propulsive and fluid management system technologies described, many component level technologies are also required to enable to the success if the integrated systems. The components include, but are not limited to, variable/throttling valves, variable position actuators, leak detectors, light weight cryogenic fluid pumps, sensor technology and others. NASA, partnering with the Aerospace Industry must endeavor to develop these, and other promising propulsion technologies, to enable the implements of the country's goals in exploration of the Moon, Mars and beyond.

Brown, Thomas↗

NASA NTRS2013

Launch and Assembly Reliability Analysis for Mars Human Space Exploration Missions

NASA s long-range goal is focused upon human exploration of Mars. Missions to Mars will require campaigns of multiple launches to assemble Mars Transfer Vehicles in Earth orbit. Launch campaigns are subject to delays, launch vehicles can fail to place their payloads into the required orbit, and spacecraft may fail during the assembly process or while loitering prior to the Trans-Mars Injection (TMI) burn. Additionally, missions to Mars have constrained departure windows lasting approximately sixty days that repeat approximately every two years. Ensuring high reliability of launching and assembling all required elements in time to support the TMI window will be a key enabler to mission success. This paper describes an integrated methodology for analyzing and improving the reliability of the launch and assembly campaign phase. A discrete event simulation involves several pertinent risk factors including, but not limited to: manufacturing completion; transportation; ground processing; launch countdown; ascent; rendezvous and docking, assembly, and orbital operations leading up to TMI. The model accommodates varying numbers of launches, including the potential for spare launches. Having a spare launch capability provides significant improvement to mission success.

Cates, Grant R.↗

NASA NTRS1992

Modeling of the WSTF frictional heating apparatus in high pressure systems

In order to develop a computer program able to model the frictional heating of metals in high pressure oxygen or nitrogen a number of additions have been made to the frictional heating model originally developed for tests in low pressure helium. These additions include: (1) a physical property package for the gases to account for departures from the ideal gas state; (2) two methods for spatial discretization (finite differences with quadratic interpolation or orthogonal collocation on finite elements) which substantially reduce the computer time required to solve the transient heat balance; (3) more efficient programs for the integration of the ordinary differential equations resulting from the discretization of the partial differential equations; and (4) two methods for determining the best-fit parameters via minimization of the mean square error (either a direct search multivariable simplex method or a modified Levenburg-Marquardt algorithm). The resulting computer program has been shown to be accurate, efficient and robust for determining the heat flux or friction coefficient vs. time at the interface of the stationary and rotating samples.

Skowlund, Christopher T.↗

NASA NTRS1982

Computation of incompressible, three-dimensional turbulent boundary layers and comparison with experiment

Incompressible three dimensional, turbulent boundary layer (3DTBL) experiments were simulated numerically by integrating the boundary layer equations together with an algebraic eddy viscosity turbulence model. For the flow treated, the downstream portion, where the crossflow was large, was not predicted with the present computational method; the flow was significantly influenced by elliptic flow field effects. Departures from the boundary layer concept are indicated. Calculations agreed reasonably well with the mean flow development up to separation. In one experiment the normal pressure gradients were found to be neligible in regions with large skewing and allowed testing turbulence models using the boundary layer equations. The simulation of this flow compared favorably with the experimental data throughout the flow field and suggested the applicability of algebraic eddy viscosity models for 3DTBLs.

Mueller, U. R.↗

NASA NTRS2002

A Mechanistic Study of Nucleate Boiling Under Microgravity Conditions

The overall objective of this work is to study nucleate boiling heat transfer under microgravity conditions in such a way that while providing basic knowledge of the phenomena, it also leads to development of simulation models and correlations that can be used as design tools for a wide range of gravity levels. In the study a building block type of approach is used and both pool and low velocity flow boiling are investigated. Starting with experiments using a single bubble, the complexity of the experiments is increased to two or three inline bubbles, to five bubbles placed on a two-dimensional grid. Finally, experiments are conducted where a large number of prescribed cavities nucleate on the heater and when a commercial surface is used. So far experiments have been conducted at earth normal gravity and in the reduced gravity environment of the KC-135 aircraft whereas experiments on the space station are planned. Modeling/complete numerical simulation of the boiling process is an integral part of the total effort. Experiments conducted with single bubbles formed on a nucleation site microfabricated on a polished silicon wafer show that for gravity levels (g) varying from 1.5g(sub e) to 0.01g(sub e), the bubble diameter at departure varies approximately as (g(sub e)/g)(exp 1/2) and the growth period as (g(sub e)/g). When bubbles merge either inline or in a plane, the bubble diameter at departure is found to be smaller than that obtained for a single bubble and shows a weaker dependence on the level of gravity. The possible reason is that as the bubbles merge they create fluid circulation around the bubbles, which in turn induces a lift force that is responsible for the earlier departure of the bubbles. The verification of this proposition is being sought through numerical simulations. There is a merger of two inline, three inline, and several bubbles in a plane in the low gravity environment of the KC-135 aircraft. After merger and before departure, a mushroom type of bubble with several stems attached to the heater surface is clearly evident. Local heat fluxes during growth and departure of a single bubble were also measured. It was found that during most of the growth period of the bubble, generally the wall heat flux decreased with time because of the increased dry area under the bubble. However, the heat flux increased rapidly just prior to departure of the bubble because of the transient conduction into the cold liquid rushing to fill the space vacated by the bubble as the bubble base shrinks. The measured heat fluxes at various radial locations are found to be in qualitative agreement with the numerical predictions. Single bubble studies at earth normal gravity have also been performed on surfaces oriented at different angles to the gravitational acceleration with flow parallel to the surface. It is found that in all cases the bubbles slide along the surface before lift-off from the surface. The lift force generated as a result of the relative motion between the sliding bubbles and the imposed flow is found to play an important role when the normal force due to buoyancy is reduced. An experimental apparatus for the study of the bubble behavior with imposed flow under reduced gravity conditions has been developed and will soon be employed for experiments in the KC-135 aircraft.

Dhir, V. K.↗

NASA NTRS2008

ULTOR(Registered TradeMark) Passive Pose and Position Engine For Spacecraft Relative Navigation

The ULTOR(Registered TradeMark) Passive Pose and Position Engine (P3E) technology, developed by Advanced Optical Systems, Inc (AOS), uses real-time image correlation to provide relative position and pose data for spacecraft guidance, navigation, and control. Potential data sources include a wide variety of sensors, including visible and infrared cameras. ULTOR(Registered TradeMark) P3E has been demonstrated on a number of host processing platforms. NASA is integrating ULTOR(Registerd TradeMark) P3E into its Relative Navigation System (RNS), which is being developed for the upcoming Hubble Space Telescope (HST) Servicing Mission 4 (SM4). During SM4 ULTOR(Registered TradeMark) P3E will perform realtime pose and position measurements during both the approach and departure phases of the mission. This paper describes the RNS implementation of ULTOR(Registered TradeMark) P3E, and presents results from NASA's hardware-in-the-loop simulation testing against the HST mockup.

Hannah, S. Joel↗

NASA NTRS2011

Use of Smoothed Measured Winds to Predict and Assess Launch Environments

Since many of the larger launch vehicles are operated near their design limits during the ascent phase of flight to optimize payload to orbit, it often becomes necessary to verify that the vehicle will remain within certification limits during the ascent phase as part of the go/no-go review made prior to launch. This paper describes the approach used to predict Ares I-X launch vehicle structural air loads and controllability prior to launch which represents a distinct departure from the methodology of the Space Shuttle and Evolved Expendable Launch Vehicle (EELV) programs. Protection for uncertainty of key environment and trajectory parameters is added to the nominal assessment of launch capability to ensure that critical launch trajectory variables would be within the integrated vehicle certification envelopes. This process was applied by the launch team as a key element of the launch day go/no-go recommendation. Pre-launch assessments of vehicle launch capability for NASA's Space Shuttle and the EELV heavy lift versions require the use of a high-resolution wind profile measurements, which have relatively small sample size compared with low-resolution profile databases (which include low-resolution balloons and radar wind profilers). The approach described in this paper has the potential to allow the pre-launch assessment team to use larger samples of wind measurements from low-resolution wind profile databases that will improve the accuracy of pre-launch assessments of launch availability with no degradation of mission assurance or launch safety.

Cordova, Henry S.↗

NASA NTRS2005

Considerations in the Integration of Small Aircraft Transportation System Higher Volume Operations (SATSHVO) in the National Airspace System (NAS)

The Small Aircraft Transportation System Higher Volume Operations (SATS HVO) concept holds the promise for increased efficiency and throughput at many of the nations under-used airports. This concept allows for concurrent operations at uncontrolled airports that under today s procedures are restricted to one arrival or one departure operation at a time, when current-day IFR separation standards are applied. To allow for concurrent operations, SATS HVO proposes several fundamental changes to today's system. These changes include: creation of dedicated airspace, development of new procedures and communications (phraseologies), and assignment of roles and responsibilities for pilots and controllers, among others. These changes would affect operations on the airborne side (pilot) as well as the groundside (controller and air traffic flow process). The focus of this paper is to discuss some of the issues and potential problems that have been considered in the development of the SATS HVO concept, in particular from the ground side perspective. Reasonable solutions to the issues raised here have been proposed by the SATS HVO team, and are discussed in this paper.

Lohr, Gary W.↗

NASA NTRS2008

Integrated Network Architecture for NASA's Orion Missions

NASA is planning a series of short and long duration human and robotic missions to explore the Moon and then Mars. The series of missions will begin with a new crew exploration vehicle (called Orion) that will initially provide crew exchange and cargo supply support to the International Space Station (ISS) and then become a human conveyance for travel to the Moon. The Orion vehicle will be mounted atop the Ares I launch vehicle for a series of pre-launch tests and then launched and inserted into low Earth orbit (LEO) for crew exchange missions to the ISS. The Orion and Ares I comprise the initial vehicles in the Constellation system of systems that later includes Ares V, Earth departure stage, lunar lander, and other lunar surface systems for the lunar exploration missions. These key systems will enable the lunar surface exploration missions to be initiated in 2018. The complexity of the Constellation system of systems and missions will require a communication and navigation infrastructure to provide low and high rate forward and return communication services, tracking services, and ground network services. The infrastructure must provide robust, reliable, safe, sustainable, and autonomous operations at minimum cost while maximizing the exploration capabilities and science return. The infrastructure will be based on a network of networks architecture that will integrate NASA legacy communication, modified elements, and navigation systems. New networks will be added to extend communication, navigation, and timing services for the Moon missions. Internet protocol (IP) and network management systems within the networks will enable interoperability throughout the Constellation system of systems. An integrated network architecture has developed based on the emerging Constellation requirements for Orion missions. The architecture, as presented in this paper, addresses the early Orion missions to the ISS with communication, navigation, and network services over five phases of a mission: pre-launch, launch from T0 to T+6.5 min, launch from T+6.5 min to 12 min, in LEO for rendezvous and docking with ISS, and return to Earth. The network of networks that supports the mission during each of these phases and the concepts of operations during those phases are developed as a high level operational concepts graphic called OV-1, an architecture diagram type described in the Department of Defense Architecture Framework (DoDAF). Additional operational views on organizational relationships (OV-4), operational activities (OV-5), and operational node connectivity (OV-2) are also discussed. The system interfaces view (SV-1) that provides the communication and navigation services to Orion is also included and described. The challenges of architecting integrated network architecture for the NASA Orion missions are highlighted.

Bhasin, Kul B.↗

NASA NTRS2012

Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum

This software processes the flyby spectra of the Chirp Transform Spectrometer (CTS) of the Microwave Instrument for Rosetta Orbiter (MIRO). The tool corrects the effect of Doppler shift and local-oscillator (LO) frequency shift during the flyby mode of MIRO operations. The frequency correction for CTS flyby spectra is performed and is integrated with multiple spectra into a high signal-to-noise averaged spectrum at the rest-frame RF frequency. This innovation also generates the 8 molecular line spectra by dividing continuous 4,096-channel CTS spectra. The 8 line spectra can then be readily used for scientific investigations. A spectral line that is at its rest frequency in the frame of the Earth or an asteroid will be observed with a time-varying Doppler shift as seen by MIRO. The frequency shift is toward the higher RF frequencies on approach, and toward lower RF frequencies on departure. The magnitude of the shift depends on the flyby velocity. The result of time-varying Doppler shift is that of an observed spectral line will be seen to move from channel to channel in the CTS spectrometer. The direction (higher or lower frequency) in the spectrometer depends on the spectral line frequency under consideration. In order to analyze the flyby spectra, two steps are required. First, individual spectra must be corrected for the Doppler shift so that individual spectra can be superimposed at the same rest frequency for integration purposes. Second, a correction needs to be applied to the CTS spectra to account for the LO frequency shifts that are applied to asteroid mode.

Lee, Seungwon↗

NASA NTRS1973

Auroral ion velocity distributions using a relaxation model.

Calculation of ion velocity distributions for a weakly-ionized plasma subjected to crossed electric and magnetic fields for application to the auroral ionosphere. By replacing the Boltzmann collision integral with a simple relaxation model, an exact solution to Boltzmann's equation could be obtained. This solution has the advantage over a series expansion in that all the higher-order velocity moments are inherent in it. The exact solution is particularly advantageous when studying large departures of the distribution from its Maxwellian form, because these departures are caused by the higher velocity moments. In general, however, a simple relaxation model can only be used to obtain qualitative information on the distribution function. Consequently, it is possible to determine when the higher-order velocity moments affect the ion velocity distribution and the nature of their effect, but it is not possible to obtain accurate quantitative results.

St-Maurice, J.-P.↗

NASA NTRS2011

Flight Test of L1 Adaptive Control Law: Offset Landings and Large Flight Envelope Modeling Work

This paper presents new results of a flight test of the L1 adaptive control architecture designed to directly compensate for significant uncertain cross-coupling in nonlinear systems. The flight test was conducted on the subscale turbine powered Generic Transport Model that is an integral part of the Airborne Subscale Transport Aircraft Research system at the NASA Langley Research Center. The results presented include control law evaluation for piloted offset landing tasks as well as results in support of nonlinear aerodynamic modeling and real-time dynamic modeling of the departure-prone edges of the flight envelope.

Gregory, Irene M.↗

DOE OSTI2022

Thermal hydraulic analysis of the AFIP-7 irradiation test in the Advanced test Reactor – Model correlation and performance evaluation

We report as a system level code, RELAP5 is widely used in the nuclear field for the reactor hydraulic analysis. In the component/experimental level, it is frequently employed as well. This paper demonstrates that the RELAP5 flow simulation of the AFIP-7 irradiation experiment which has a complicated 3D geometry/flow path deviates by ~28% from the flow evaluation through a computational fluid dynamics (CFD) simulation, which has been validated against a flow test performed at Oregon State University. Thermal safety compliance analysis of an experiment planned to be irradiated in the Advanced Test Reactor is usually performed using the finite element analysis code, Abaqus. This research reveals the disadvantages of the Abaqus simulation in the flow instability and departure from nucleate boiling evaluations via a conjugate heat transfer analysis of the AFIP-7 irradiation experiment. As a result, a detailed CFD simulation is suggested for irradiation experiments with complicated flow paths, rather than a simplified RELAP5 simulation or hand calculations. The validated simulation approach will be integrated with the Boehmite correlations to investigate the oxide growth prediction on the fuel cladding in Part II of this research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2018

Performance Evaluation of Conflict-Free Trajectory Taxiing in Airport Ramp Area Using Fast-Time Simulations

The German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA) have been collaborating to conduct joint research addressing future surface traffic management challenges. The surface management tool from DLR, called Taxi Routing for Aircraft: Creation and Controlling (TRACC), was adapted to be integrated in NASA's fast-time simulation environment called Surface Operations Simulator and Scheduler (SOSS). The research described in this paper 1) applied TRACC to trajectory-based ramp traffic management, where TRACC generates conflict-free aircraft trajectories in a congested ramp area, 2) investigated the feasibility of the concept through the integrated TRACC-SOSS fast-time simulation, and 3) evaluated the performance of the integrated system. For this activity, TRACC was adapted for ramp operations at Charlotte Douglas International Airport, called TRACC_PB (TRACC for pushback optimization). TRACC_PB provides four-dimensional taxi trajectories with a command speed profile for each aircraft following standard taxi routes within the ramp area. In this study, departures are given the Target Movement Area entry Times (TMATs) provided by the baseline surface metering scheduler based on NASA's Spot and Runway Departure Advisor (SARDA). TRACC_PB also calculates optimal pushback times for departures, as well as the times when arrivals shall enter the ramp, the Target Movement area Exit Times (TMETs). The initial results showed that the TRACC_PB successfully generated conflict-free trajectories for the ramp area taxi operations and improved taxiing efficiency compared to the baseline results. TRACC_PB aimed to provide conflict-free taxi routes avoiding any stops while taxiing. This resulted in longer gate hold times for departures and postponed throughput values compared to the baseline simulation without trajectory optimization. Having conflict-free routes without stoppage also created shorter taxi times but required renegotiation of the given TMATs. TRACC_PB also achieved reductions in both fuel consumption and engine emissions (17% for departures and 10% for arrivals), which correlate with the ramp taxi time reduction.

trajectory-based taxi operations↗

NASA NTRS2020

Air Traffic Simulation Technology for High-Population Metroplexes

IAI's MetroSim optimizes air traffic by simulating departures, arrivals, and activity in air and onthe ground in busy metroplexes, where flights impact each other at a single airport and among traffic at nearby airports. MetroSim evolved out of several NASA SBIR/STTR Awards and has since been used by NASA for flight simulation analysis. MetroSim has also been integrated with FAA and DOT technology, has produced studies for the Port Authority of New York and New Jersey, and is under development to support the Navy

Cannon, Kimberly A.↗