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NASA NTRS2005

Thermostructural Properties Of Sic/Sic Panels With 2.5d And 3d Fiber Architectures

CMC hot-section components in advanced engines for power and propulsion will typically require high cracking strength, high ultimate strength and strain, high creep- rupture resistance, and high thermal conductivity in all directions. In the past, NASA has demonstrated fabrication of a variety of SiC/SiC flat panels and round tubes with various 2D fiber architectures using the high-modulus high-performance Sylramic-iBN Sic fiber and Sic-based matrices derived by CVI, MI, and/or PIP processes. The thermo- mechanical properties of these CMC have shown state-of-the-art performance, but primarily in the in-plane directions. Currently NASA is extending the thermostructural capability of these SiC/SiC systems in the thru-thickness direction by using various 2.5D and 3D fiber architectures. NASA is also using specially designed fabrication steps to optimize the properties of the BN-based interphase and Sic-based matrices. In this study, Sylramic-iBN/SiC panels with 2D plain weave, 2.5D satin weave, 2.5D ply-to-ply interlock weave, and 3D angle interlock fiber architectures, all woven at AITI, were fabricated using matrix densification routes previously established between NASA and GEPSC for CVI-MI processes and between NASA and Starfire-Systems for PIP processes. Introduction of the 2.5 D fiber architecture along with an improved matrix process was found to increase inter-laminar tensile strength from 1.5 -2 to 3 - 4 ksi and thru-thickness thermal conductivity from 15-20 to 30-35 BTU/ft.hr.F with minimal reduction in in-plane strength and creep-rupture properties. Such improvements should reduce thermal stresses and increase the thermostructural operating envelope for SiC/SiC engine components. These results are analyzed to offer general guidelines for selecting fiber architectures and constituent processes for high-performance SiC/SiC engine components.

Yun, H. M.↗

NASA NTRS2005

System-Level Design of a Shape Memory Alloy Actuator for Active Clearance Control in the High-Pressure Turbine

This paper describes results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 inches. Design results show that an actuator comprised of 10 wires 2 inches in length is adequate for control at critical engine operating points and still exhibits acceptable failsafe operability and cycle life. A proportional-integral-derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

DeCastro, Jonathan A.↗

NASA NTRS2005

Large Liquid Rocket Testing: Strategies and Challenges

Rocket propulsion development is enabled by rigorous ground testing in order to mitigate the propulsion systems risks that are inherent in space flight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth. In particular, large liquid rocket propulsion development and testing over the past five decades of human and robotic space flight has involved a combination of component-level testing and engine-level testing to first demonstrate that the propulsion devices were designed to meet the specified requirements for the Earth to Orbit launchers that they powered. This was followed by a vigorous test campaign to demonstrate the designed propulsion articles over the required operational envelope, and over robust margins, such that a sufficiently reliable propulsion system is delivered prior to first flight. It is possible that hundreds of tests, and on the order of a hundred thousand test seconds, are needed to achieve a high-reliability, flight-ready, liquid rocket engine system. This paper overviews aspects of earlier and recent experience of liquid rocket propulsion testing at NASA Stennis Space Center, where full scale flight engines and flight stages, as well as a significant amount of development testing has taken place in the past decade. The liquid rocket testing experience discussed includes testing of engine components (gas generators, preburners, thrust chambers, pumps, powerheads), as well as engine systems and complete stages. The number of tests, accumulated test seconds, and years of test stand occupancy needed to meet varying test objectives, will be selectively discussed and compared for the wide variety of ground test work that has been conducted at Stennis for subscale and full scale liquid rocket devices. Since rocket propulsion is a crucial long-lead element of any space system acquisition or development, the appropriate plan and strategy must be put in place at the outset of the development effort. A deferment of this test planning, or inattention to strategy, will compromise the ability of the development program to achieve its systems reliability requirements and/or its development milestones. It is important for the government leadership and support team, as well as the vehicle and propulsion development team, to give early consideration to this aspect of space propulsion and space transportation work.

Rahman, Shamim A.↗

NASA NTRS2005

Performance (Off-Design) Cycle Analysis for a Turbofan Engine With Interstage Turbine Burner

This report presents the performance of a steady-state, dual-spool, separate-exhaust turbofan engine, with an interstage turbine burner (ITB) serving as a secondary combustor. The ITB, which is located in the transition duct between the high- and the low-pressure turbines, is a relatively new concept for increasing specific thrust and lowering pollutant emissions in modern jet-engine propulsion. A detailed off-design performance analysis of ITB engines is written in Microsoft(Registered Trademark) Excel (Redmond, Washington) macrocode with Visual Basic Application to calculate engine performances over the entire operating envelope. Several design-point engine cases are pre-selected using a parametric cycle-analysis code developed previously in Microsoft(Registered Trademark) Excel, for off-design analysis. The off-design code calculates engine performances (i.e. thrust and thrust-specific-fuel-consumption) at various flight conditions and throttle settings.

Liew, K. H.↗

NASA NTRS2005

Chapter 24 - Propulsion

This chapter provides a basic guide to the flight testing of propulsion system operability and compatibility (O&C). For the purposes of establishing a frame of reference, O&C refers to the ability of the aircrew to establish and maintain the desired level of propulsion system net propulsive force throughout the operating envelope of the aircraft. For the purposes of definition, net propulsive force is used to refer to the vector resultant of all throttle dependant forces acting upon the aircraft. By limiting the discussion in this Section to flight testing of the O&C of the propulsion system, it should not be interpreted to mean that these are the only factors that need to be considered when conducting flight test to evaluate an aircraft propulsion system. Propulsion system structural interfaces, pneumatic interfaces, mechanical interfaces, hydraulic interfaces, thermodynamic interfaces and electrical interfaces must all be evaluated prior to or concurrently with the O&C test program in order to ensure a safe and effective flight test program of the aircraft and propulsion system.

Lawrence A Thomas↗

NASA NTRS2003

High-Flow Jet Exit Rig Designed and Fabricated

The High-Flow Jet Exit Rig at the NASA Glenn Research Center is designed to test single flow jet nozzles and to measure the appropriate thrust and noise levels. The rig has been designed for the maximum hot condition of 16 lbm/sec of combustion air at 1960 R (maximum) and to produce a maximum thrust of 2000 lb. It was designed for cold flow of 29.1 lbm/sec of air at 530 R. In addition, it can test dual-flow nozzles (nozzles with bypass flow in addition to core flow) with independent control of each flow. The High- Flow Jet Exit Rig was successfully fabricated in late 2001 and is being readied for checkout tests. The rig will be installed in Glenn's Aeroacoustic Propulsion Laboratory. The High-Flow Jet Exit Rig consists of the following major components: a single component force balance, the natural-gas-fueled J-79 combustor assembly, the plenum and manifold assembly, an acoustic/instrumentation/seeding (A/I/S) section, a table, and the research nozzles. The rig will be unique in that it is designed to operate uncooled. The structure survives the 1960 R test condition because it uses carefully selected high temperature alloy materials such as Hastelloy-X. The lower plenum assembly was designed to operate at pressures to 450 psig at 1960 R, in accordance with the ASME B31.3 piping code. The natural gas-fueled combustor fires directly into the lower manifold. The hot air is directed through eight 1-1/2-in. supply pipes that supply the upper plenum. The flow is conditioned in the upper plenum prior to flowing to the research nozzle. The 1-1/2-in. supply lines are arranged in a U-shaped design to provide for a flexible piping system. The combustor assembly checkout was successfully conducted in Glenn's Engine Component Research Laboratory in the spring of 2001. The combustor is a low-smoke version of the J79 combustor used to power the F4 Phantom military aircraft. The natural gas-fueled combustor demonstrated high-efficiency combustion over a wide range of operating conditions. This wide operating envelope is required to support the testing of both single- and dual-flow nozzles. Key research goals include providing simultaneous, highly accurate acoustic, flow, and thrust measurements on jet nozzle models in realistic flight conditions, as well as providing scaleable acoustic results. The High-Flow Jet Exit Rig is a second-generation high-flow test rig. Improvements include cleaner flow with reduced levels of particulate, soot, and odor. Choked-flow metering is required with plus or minus 0.25-percent accuracy. Thrust measurements from 0 to 2000 lbf are required with plus or minus 0.25-percent accuracy. Improved acoustics will be achieved by minimizing noise through large pipe bend radii, lower internal flow velocities, and microdrilled choke plates with thousands of 0.040-in.- diameter holes.

Buehrle, Robert J.↗

NASA NTRS2006

The Effect of the Laboratory Specimen on Fatigue Crack Growth Rate

Over the past thirty years, laboratory experiments have been devised to develop fatigue crack growth rate data that is representative of the material response. The crack growth rate data generated in the laboratory is then used to predict the safe operating envelope of a structure. The ability to interrelate laboratory data and structural response is called similitude. In essence, a nondimensional term, called the stress intensity factor, was developed that includes the applied stresses, crack size and geometric configuration. The stress intensity factor is then directly related to the rate at which cracks propagate in a material, resulting in the material property of fatigue crack growth response. Standardized specimen configurations and experimental procedures have been developed for laboratory testing to generate crack growth rate data that supports similitude of the stress intensity factor solution. In this paper, the authors present laboratory fatigue crack growth rate test data and finite element analyses that show similitude between standard specimen configurations tested using the constant stress ratio test method is unobtainable.

Forth, S. C.↗

NASA NTRS2006

Progress on Shape Memory Alloy Actuator Development for Active Clearance Control

Results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine has been conducted. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 in. Design results show that an actuator comprised of 10 wires 2 in. in length is adequate for control at critical engine operating points and still exhibit acceptable failsafe operability and cycle life. A proportional-integral-derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

DeCastro, Jonathan↗

NASA NTRS2006

Space Shuttle Main Engine Low Pressure Oxidizer Turbo-Pump Inducer Dynamic Environment Characterization through Water Model and Hot-Fire Testing

The Low Pressure Oxidizer Turbopump (LPOTP) inducer on the Block II configuration Space Shuttle Main Engine (SSME) experienced blade leading edge ripples during hot firing. This undesirable condition led to a minor redesign of the inducer blades. This resulted in the need to evaluate the performance and the dynamic environment of the redesign, relative to the current configuration, as part of the design acceptance process. Sub-scale water model tests of the two inducer configurations were performed, with emphasis on the dynamic environment due to cavitation induced vibrations. Water model tests were performed over a wide range of inlet flow coefficient and pressure conditions, representative of the scaled operating envelope of the Block II SSME, both in flight and in ground hot-fire tests, including all power levels. The water test hardware, facility set-up, type and placement of instrumentation, the scope of the test program, specific test objectives, data evaluation process and water test results that characterize and compare the two SSME LPOTP inducers are discussed. In addition, dynamic characteristics of the two water models were compared to hot fire data from specially instrumented ground tests. In general, good agreement between the water model and hot fire data was found, which confirms the value of water model testing for dynamic characterization of rocket engine turbomachinery.

Patrick Arellano↗

NASA NTRS2006

Effects of 'Cooled' Cooling Air on Pre-Swirl Nozzle Design

It is common practice to use Pre-Swirl Nozzles to facilitate getting the turbine blade cooling air onboard the rotating disk with minimum pressure loss and reduced temperature. Higher engine OPR's and expanded aircraft operating envelopes have pushed cooling air temperatures to the limits of current disk materials and are stressing the capability to cool the blade with practical levels of cooling air flow. Providing 'Cooled' Cooling Air is one approach being considered to overcome these limitations. This presentation looks at how the introduction of 'Cooled' Cooling Air impacts the design of the Pre-Swirl Nozzles, specifically in relation to the radial location of the nozzles.

Scricca, J. A.↗

NASA NTRS2008

2006 Icing Cloud Calibration of the NASA Glenn Icing Research Tunnel

In order to improve icing cloud uniformity, changes were made to the tunnel at the NASA Glenn Research Center in the vicinity of the spray bars. These changes necessitated a complete recalibration of the icing clouds. This report describes the methods used in the recalibration, including the procedure used to optimize the uniformity of the icing cloud and the use of a standard icing blade technique for measurement of liquid water content. The instruments and methods used to perform the droplet size calibration are also described. The liquid water content/droplet size operating envelopes of the icing tunnel are shown for a range of airspeeds and compared to the FAA icing certification criteria.

Ide, Robert F.↗

NASA NTRS2008

Simulating Operation of a Large Turbofan Engine

The Commercial Modular Aero- Propulsion System Simulation (C-MAPSS) is a computer program for simulating transient operation of a commercial turbofan engine that can generate as much as 90,000 lb (.0.4 MN) of thrust. It includes a power-management system that enables simulation of open- or closed-loop engine operation over a wide range of thrust levels throughout the full range of flight conditions. C-MAPSS provides the user with a set of tools for performing open- and closed-loop transient simulations and comparison of linear and non-linear models throughout its operating envelope, in an easy-to-use graphical environment.

Litt, Jonathan S.↗

NASA NTRS2008

Tool Support for Parametric Analysis of Large Software Simulation Systems

The analysis of large and complex parameterized software systems, e.g., systems simulation in aerospace, is very complicated and time-consuming due to the large parameter space, and the complex, highly coupled nonlinear nature of the different system components. Thus, such systems are generally validated only in regions local to anticipated operating points rather than through characterization of the entire feasible operational envelope of the system. We have addressed the factors deterring such an analysis with a tool to support envelope assessment: we utilize a combination of advanced Monte Carlo generation with n-factor combinatorial parameter variations to limit the number of cases, but still explore important interactions in the parameter space in a systematic fashion. Additional test-cases, automatically generated from models (e.g., UML, Simulink, Stateflow) improve the coverage. The distributed test runs of the software system produce vast amounts of data, making manual analysis impossible. Our tool automatically analyzes the generated data through a combination of unsupervised Bayesian clustering techniques (AutoBayes) and supervised learning of critical parameter ranges using the treatment learner TAR3. The tool has been developed around the Trick simulation environment, which is widely used within NASA. We will present this tool with a GN&C (Guidance, Navigation and Control) simulation of a small satellite system.

Schumann, Johann↗

NASA NTRS2009

Adaptive Behavior for Mobile Robots

The term "System for Mobility and Access to Rough Terrain" (SMART) denotes a theoretical framework, a control architecture, and an algorithm that implements the framework and architecture, for enabling a land-mobile robot to adapt to changing conditions. SMART is intended to enable the robot to recognize adverse terrain conditions beyond its optimal operational envelope, and, in response, to intelligently reconfigure itself (e.g., adjust suspension heights or baseline distances between suspension points) or adapt its driving techniques (e.g., engage in a crabbing motion as a switchback technique for ascending steep terrain). Conceived for original application aboard Mars rovers and similar autonomous or semi-autonomous mobile robots used in exploration of remote planets, SMART could also be applied to autonomous terrestrial vehicles to be used for search, rescue, and/or exploration on rough terrain.

Huntsberger, Terrance↗

NASA NTRS2009

Real-Time Simulation of Ares I Launch Vehicle

The Ares Real-Time Environment for Modeling, Integration, and Simulation (ARTEMIS) has been developed for use by the Ares I launch vehicle System Integration Laboratory (SIL) at the Marshall Space Flight Center (MSFC). The primary purpose of the Ares SIL is to test the vehicle avionics hardware and software in a hardware-in-the-loop (HWIL) environment to certify that the integrated system is prepared for flight. ARTEMIS has been designed to be the real-time software backbone to stimulate all required Ares components through high-fidelity simulation. ARTEMIS has been designed to take full advantage of the advances in underlying computational power now available to support HWIL testing. A modular real-time design relying on a fully distributed computing architecture has been achieved. Two fundamental requirements drove ARTEMIS to pursue the use of high-fidelity simulation models in a real-time environment. First, ARTEMIS must be used to test a man-rated integrated avionics hardware and software system, thus requiring a wide variety of nominal and off-nominal simulation capabilities to certify system robustness. The second driving requirement - derived from a nationwide review of current state-of-the-art HWIL facilities - was that preserving digital model fidelity significantly reduced overall vehicle lifecycle cost by reducing testing time for certification runs and increasing flight tempo through an expanded operational envelope. These two driving requirements necessitated the use of high-fidelity models throughout the ARTEMIS simulation. The nature of the Ares mission profile imposed a variety of additional requirements on the ARTEMIS simulation. The Ares I vehicle is composed of multiple elements, including the First Stage Solid Rocket Booster (SRB), the Upper Stage powered by the J- 2X engine, the Orion Crew Exploration Vehicle (CEV) which houses the crew, the Launch Abort System (LAS), and various secondary elements that separate from the vehicle. At launch, the integrated vehicle stack is composed of these stages, and throughout the mission, various elements separate from the integrated stack and tumble back towards the earth. ARTEMIS must be capable of simulating the integrated stack through the flight as well as propagating each individual element after separation. In addition, abort sequences can lead to other unique configurations of the integrated stack as the timing and sequence of the stage separations are altered.

Tobbe, Patrick↗

NASA NTRS2009

Parametric Analysis of a Hover Test Vehicle using Advanced Test Generation and Data Analysis

Large complex aerospace systems are generally validated in regions local to anticipated operating points rather than through characterization of the entire feasible operational envelope of the system. This is due to the large parameter space, and complex, highly coupled nonlinear nature of the different systems that contribute to the performance of the aerospace system. We have addressed the factors deterring such an analysis by applying a combination of technologies to the area of flight envelop assessment. We utilize n-factor (2,3) combinatorial parameter variations to limit the number of cases, but still explore important interactions in the parameter space in a systematic fashion. The data generated is automatically analyzed through a combination of unsupervised learning using a Bayesian multivariate clustering technique (AutoBayes) and supervised learning of critical parameter ranges using the machine-learning tool TAR3, a treatment learner. Covariance analysis with scatter plots and likelihood contours are used to visualize correlations between simulation parameters and simulation results, a task that requires tool support, especially for large and complex models. We present results of simulation experiments for a cold-gas-powered hover test vehicle.

Gundy-Burlet, Karen↗

NASA NTRS2007

Loss-of-Control-Inhibitor Systems for Aircraft

Systems to provide improved tactile feedback to aircraft pilots are being developed to help the pilots maintain harmony between their control actions and the positions of aircraft control surfaces, thereby helping to prevent loss of control. A system of this type, denoted a loss-of-control-inhibitor system (LOCIS) can be implemented as a relatively simple addition to almost any pre-existing flight-control system. The LOCIS concept offers at least a partial solution to the problem of (1) keeping a pilot aware of the state of the control system and the aircraft and (2) maintaining sufficient control under conditions that, as described below, have been known to lead to loss of control. Current commercial aircraft exhibit uneven responses of primary flight-control surfaces to aggressive pilot control commands, leading to deterioration of pilots ability to control their aircraft. In severe cases, this phenomenon can result in loss of control and consequent loss of aircraft. For an older aircraft equipped with a purely mechanical control system, the loss of harmony between a pilot s command action and the control- surface response can be attributed to compliance in the control system (caused, for example, by stretching of control cables, flexing of push rods, or servo-valve distortion). In a newer aircraft equipped with a fly-by-wire control system, the major contributions to loss of harmony between the pilot and the control surfaces are delays attributable to computer cycle time, control shaping, filtering, aliasing, servo-valve distortion, and actuator rate limiting. In addition, a fly-by-wire control system provides no tactile feedback that would enable the pilot to sense such features of the control state as surface flutter, surface jam, position limiting, actuator rate limiting, and control limiting imposed by the aircraft operational envelope. Hence, for example, when a pilot is involved in aggressive closed-loop maneuvering, as when encountering a wake-vortex upset on final landing approach, the control-surface delay can lead to loss of control. Aggressive piloting can be triggered and exacerbated by control-system anomalies, which the pilot cannot diagnose because of the lack of symptoms caused by the absence of feedback through the controls. The purpose served by a LOCIS is to counteract these adverse effects by providing real-time feedback that notifies the pilot that the aircraft is tending to lag the pilot s commands. A LOCIS (see figure) includes cockpit control input-position sensors, control-surface output-position sensors, variable dampers (for example, shock absorbers containing magneto-rheological fluids such that the damping forces can be varied within times of the order of milliseconds by varying applied magnetic fields) attached to the cockpit control levers, electromagnet coils to apply the magnetic fields, and feedback control circuits to drive the electromagnet coils. The feedback control gains are chosen so that the current applied to each electromagnet coil results in a damping force that increases in a suitable nonlinear manner (e.g., exponentially) with the difference between the actual and commanded positions of the affected control surface. The increasing damping force both alerts the pilot to the onset of a potentially dangerous situation and resists the pilot s effort to command a control surface to change position at an excessive rate

AHarrah, Ralph C.↗

NASA NTRS2009

NASA DFRC Practices for Prototype Qualification

This slide presentation reviews the practices that Dryden uses for qualification of the prototypes of aircraft. There are many views of aircraft that Dryden has worked with. Included is a discussion of basic considerations for strength, a listing of standards and references, a discussion of typical safety of flight approaches, a discussion of the prototype design, using the X-29A as an example, and requirements for new shapes (i.e., the DAST-ARW1 , F-8 Super Critical Wing, AFTI/F-111 MAW), new control laws (i.e., AAW F-18), new operating envelope (i.e., F-18 HARV), limited sope add-on or substitute structure (i.e., SR-71 LASRE, ECLIPSE, F-16XL SLFC), and extensively modified or replaced structure (i.e., SOFIA, B747SP). There is a listing of causes for the failure of the prototype.

Lokos, William A.↗