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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 253 records · Page 14

Associative Flow Rule Used to Include Hydrostatic Stress Effects in Analysis of Strain-Rate-Dependent Deformation of Polymer Matrix Composites

designing reliable composite engine cases that are lighter than the metal cases in current use. The types of polymer matrix composites that are likely to be used in such an application have a deformation response that is nonlinear and that varies with strain rate. The nonlinearity and the strain-rate dependence of the composite response are due primarily to the matrix constituent. Therefore, in developing material models to be used in the design of impact-resistant composite engine cases, the deformation of the polymer matrix must be correctly analyzed. However, unlike in metals, the nonlinear response of polymers depends on the hydrostatic stresses, which must be accounted for within an analytical model. By applying micromechanics techniques along with given fiber properties, one can also determine the effects of the hydrostatic stresses in the polymer on the overall composite deformation response. First efforts to account for the hydrostatic stress effects in the composite deformation applied purely empirical methods that relied on composite-level data. In later efforts, to allow polymer properties to be characterized solely on the basis of polymer data, researchers at the NASA Glenn Research Center developed equations to model the polymers that were based on a non-associative flow rule, and efforts to use these equations to simulate the deformation of representative polymer materials were reasonably successful. However, these equations were found to have difficulty in correctly analyzing the multiaxial stress states found in the polymer matrix constituent of a composite material. To correct these difficulties, and to allow for the accurate simulation of the nonlinear strain-rate-dependent deformation analysis of polymer matrix composites, in the efforts reported here Glenn researchers reformulated the polymer constitutive equations from basic principles using the concept of an associative flow rule. These revised equations were characterized and validated in an experimental program carried out through a university grant with the Ohio State University, wherein tensile and shear deformation data were obtained for a representative polymer for strain rates ranging from quasi-static to high rates of several hundred per second. Tensile deformation data also were obtained over a variety of strain rates and fiber orientation angles for a representative polymer matrix composite composed using the polymer.

Goldberg, Robert K.↗

A Microfabricated Segmented-Involute-Foil Regenerator for Enhancing Reliability and Performance of Stirling Engines

An actual-size microfabricated regenerator comprised of a stack of 42 disks, 19 mm diameter and 0.25 mm thick, with layers of microscopic, segmented, involute-shaped flow channels was fabricated and tested. The geometry resembles layers of uniformly-spaced segmented-parallel-plates, except the plates are curved. Each disk was made from electro-plated nickel using the LiGA process. This regenerator had feature sizes close to those required for an actual Stirling engine but the overall regenerator dimensions were sized for the NASA/Sunpower oscillating-flow regenerator test rig. Testing in the oscillating-flow test rig showed the regenerator performed extremely well, significantly better than currently used random-fiber material, producing the highest figures of merit ever recorded for any regenerator tested in that rig over its approximately 20 years of use.

Ibrahim, Mounir↗

Sensor Applications and Data Validation

The mechanical configuration of automobiles have changed marginally while improvements in sensors and control have dramatically improved engine efficiency, reliability and useful life. The aviation industry has also taken advantage of sensors and control systems to reduce operational costs. Sensors and high fidelity control systems fly planes at levels of performance beyond human capability. Sophisticated environmental controls allow a greater level of comfort and efficiency in our homes. Sensors have given the medical field a better understanding of the human body and the environment in which we live.

Wiley, John↗

A Microfabricated Segmented-Involute-Foil Regenerator for Enhancing Reliability and Performance of Stirling Engines. Phase III Final Report for the Radioisotope Power Conversion Technology NRA

Under Phase III of NASA Research Announcement contract NAS3-03124, a prototype nickel segmented-involute-foil regenerator was microfabricated and tested in a Sunpower Frequency-Test-Bed (FTB) Stirling convertor. The team for this effort consisted of Cleveland State University, Gedeon Associates, Sunpower Inc. and International Mezzo Technologies. Testing in the FTB convertor produced about the same efficiency as testing with the original random-fiber regenerator. But the high thermal conductivity of the prototype nickel regenerator was responsible for a significant performance degradation. An efficiency improvement (by a 1.04 factor, according to computer predictions) could have been achieved if the regenerator was made from a low-conductivity material. Also, the FTB convertor was not reoptimized to take full advantage of the microfabricated regenerator s low flow resistance; thus, the efficiency would likely have been even higher had the FTB been completely reoptimized. This report discusses the regenerator microfabrication process, testing of the regenerator in the Stirling FTB convertor, and the supporting analysis. Results of the pre-test computational fluid dynamics (CFD) modeling of the effects of the regenerator-test-configuration diffusers (located at each end of the regenerator) are included. The report also includes recommendations for further development of involute-foil regenerators from a higher-temperature material than nickel.

Ibrahim, Mounir B.↗

NASA R&M Efficiency through Findable, Accessible, Interoperable, and Reusable (FAIR) Digital Assets

At the intersection of mission, technology, and place is NASA’s need to modernize for a digital-forward future. Digitalization, the process of moving toward digital business, is occurring everywhere and remains an ongoing process across the federal government.”[1] Whereas, Digital Transformation is “employing digitization/digital technologies (e.g., Artificial Intelligence (AI), mobile, cloud, data) to change a process, product, or capability so dramatically (e.g., real-time, intelligent, personalized, anywhere, anytime) that it is unrecognizable compared to its traditional form.” [2] In order to facilitate a digital transformation it is essential for NASA to understand and identify where data exists today and which data are value-needed in the future, understand where there are unfulfilled data needs that limit the advancement of NASA work, and ensure NASA efficiency through Findable, Accessible, Interoperable, and Reusable (FAIR) digital assets in the future. Therefore, NASA’s Reliability & Maintainability (R&M) Enterprise Data Sharing team is working to leverage both Digitization and Digital Transformation to achieve their vision of developing an R&M data discovery framework that enables our community, our partners, and our stakeholders with the ability to efficiently, robustly, and seamlessly access information that enables real-time knowledge and model-based, analytics driven, decision-making impacting R&M. As a result the R&M Enterprise Data Sharing team has conducted a survey of its Reliability, Maintainability, and Availability (RMA) community members to identify data existence (created or used) and where there are corresponding barriers to data acquisition and/or R&M or other issues as shown within this presentation.

Digital Transformation↗

Trilateral Task Force – Reliability Analysis Supporting Mission Extension/Post Mission Disposal

At the intersection of mission, technology, and place is NASA’s need to modernize for a digital-forward future. Digitalization, the process of moving toward digital business, is occurring everywhere and remains an ongoing process across the federal government.”[1] Whereas, Digital Transformation is “employing digitization/digital technologies (e.g., Artificial Intelligence (AI), mobile, cloud, data) to change a process, product, or capability so dramatically (e.g., real-time, intelligent, personalized, anywhere, anytime) that it is unrecognizable compared to its traditional form.” [2] In order to facilitate a digital transformation it is essential for NASA to understand and identify where data exists today and which data are value-needed in the future, understand where there are unfulfilled data needs that limit the advancement of NASA work, and ensure NASA efficiency through Findable, Accessible, Interoperable, and Reusable (FAIR) digital assets in the future. Therefore, NASA’s Reliability & Maintainability (R&M) Enterprise Data Sharing team is working to leverage both Digitization and Digital Transformation to achieve their vision of developing an R&M data discovery framework that enables our community, our partners, and our stakeholders with the ability to efficiently, robustly, and seamlessly access information that enables real-time knowledge and model-based, analytics driven, decision-making impacting R&M. As a result the R&M Enterprise Data Sharing team has conducted a survey of its Reliability, Maintainability, and Availability (RMA) community members to identify data existence (created or used) and where there are corresponding barriers to data acquisition and/or R&M or other issues as shown within this presentation.

Digital Transformation, Reliability Engineering↗

NASA Physics of Failure (PoF) for Reliability

An item’s reliability or longevity is dependent not only on its design but also on how it is used, manufactured, tested, and the stresses it has or will experience. Stresses include operational and environmental exposures to thermal, voltage, current, age/exposure, mechanical, and radiation mechanisms. Therefore, in reliability analysis, it is important to consider the contributions of all of these factors when predicting the failure rates of components. Historically, there has been a reliance on handbook data (e.g., MIL-HDBK-217), but experience has shown that these values and distributions are not representative of actual performance (1,2). Therefore, to make more credible reliability and risk assessments for its missions, NASA must transition to estimating likelihoods of failure based on an item’s reliability/longevity factors (or the physical susceptibilities and strengths impacting the design’s performance) has or will experience, whenever possible. To facilitate this transition a “Handbook on Methodology for Physics of Failure Based Reliability Assessments” has been developed by NASA to assist in applying physics experiences or experiment physics for empirical analysis and conceptualized physics exposures or theoretical physics for deterministic analysis, to develop and aggregate realistic likelihoods of failure leading to more credible forecasts of item performance and longevity. In addition, since it is NASA’s intention that this document continues to evolve based on community lessons learned and the introduction of new assessment methodologies, NASA is encouraging and appreciates the contributions of current and future authors to maintain and enhance this handbook and its supporting case studies.

Physics of Failure↗

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

Transient Reliability of Ceramic Structures For Heat Engine Applications

The objectives of this report was to develop a methodology to predict the time-dependent reliability (probability of failure) of brittle material components subjected to transient thermomechanical loading, taking into account the change in material response with time. This methodology for computing the transient reliability in ceramic components subjected to fluctuation thermomechanical loading was developed, assuming SCG (Slow Crack Growth) as the delayed mode of failure. It takes into account the effect of varying Weibull modulus and materials with time. It was also coded into a beta version of NASA's CARES/Life code, and an example demonstrating its viability was presented.

Nemeth, Noel N.↗

Care 3 model overview and user's guide, first revision

A manual was written to introduce the CARE III (Computer-Aided Reliability Estimation) capability to reliability and design engineers who are interested in predicting the reliability of highly reliable fault-tolerant systems. It was also structured to serve as a quick-look reference manual for more experienced users. The guide covers CARE III modeling and reliability predictions for execution in the CDC CYber 170 series computers, DEC VAX-11/700 series computer, and most machines that compile ANSI Standard FORTRAN 77.

Bavuso, S. J.↗

Understanding the Space Shuttle Main Engine Hydraulic Actuation System and Reviewing Its Evolution

The complex engine start and thrust control requirements of the Space Shuttle Main Engine (SSME) require unique valve, actuator and control system hardware. The Hydraulic Actuation System (HAS) was designed, developed, and now operates to meet tight engine control requirement limits to assure safe, reliable and correct engine thrust at all times. The actuator is designed to be fail safe and fail operate in the areas where redundancy is important. The HAS has an additional pneumatic operating capability that insures a safe sequential closure of all actuators and propellant valves in the event of the loss of hydraulic system pressure or loss of electrical closed loop control of the actuator. The objective of this paper is to provide a complete description of the actuator s internal operating system, along with its interaction with all SSME system interfaces. Additionally the paper addresses the challenges, problems identified, and corrected, and lessons learned, during the course of the almost 35 years of engine operation.

McWade, Robert J.↗

Torsional vibration of aircraft engines

Exhaustive torsional-vibration investigations are required to determine the reliability of aircraft engines. A general outline of the methods used for such investigations and of the theoretical and mechanical means now available for this purpose is given, illustrated by example. True vibration diagrams are usually obtained from vibration measurements on the completed engine. Two devices for this purpose and supplementing each other, the D.V.L. torsiograph and the D.V.L. torsion recorder, are described in this report.

Lurenbaum, Karl↗

Non-Toxic Reaction Control System for the Reusable First Stage Vehicle

This paper presents the Boeing Reusable Space Systems vision of a Reaction Control System (RCS) for the Reusable First Stage (RFS) being considered as a replacement for the Solid Rocket Booster for the Space Shuttle. The requirement is to,achieve reliable vehicle control during the upper atmospheric portion of the RFS trajectory while enabling more efficient ground operations, unhindered by constraints caused by operating with highly toxic RCS propellants. Boeing's objective for this effort is to develop a safer, more efficient and environmentally friendly RCS design approach that is suitable for the RFS concept of operations, including a low cost, efficient turnaround cycle. The Boeing RCS concept utilizes ethanol and liquid oxygen in place of the highly toxic, suspected carcinogen, ozone- depleting mono-methyl-hydrazine and highly toxic nitrogen tetroxide. The Space Shuttle Upgrade program, under the leadership of the NASA Johnson Space Flight Center, is currently developing liquid oxygen and ethanol (ethyl alcohol) technology for use as non-toxic orbital maneuvering system (OMS) and RCS. The development of this liquid oxygen and ethanol technology for the Space Shuffle offers a significant leverage to select much of the same technology for the RFS program. There are significant design and development issues involved with bringing this liquid oxygen and ethanol technology to a state of maturity suitable for an operational RCS, The risks associated with a new LOX and Ethanol RCS are mitigated by maintaining kerosene and hydrogen peroxide RCS technology as an alternative. These issues, presented within this paper, include managing the oxygen supply and achieving reliable ignition in the short pulse mode of engine operation. Performance, reliability and operations requirements are presented along with a specific RCS design concept to satisfying these requirements. The work reported in this paper was performed under NASA Marshall Space Flight Center Contract to define Reusable First Stage design concepts for the Space Shuttle.

Keith, E. L.↗

Non-Toxic Reaction Control System for the Reusable First Stage Vehicle

This paper presents the Boeing Reusable Space Systems vision of a Reaction Control System (RCS) for the Reusable First Stage (RFS) being considered as a replacement for the Solid Rocket Booster for the Space Shuttle. The requirement is to achieve reliable vehicle control during the upper atmospheric portion of the RFS trajectory while enabling more efficient ground operations, unhindered by constraints caused by operating with highly toxic RCS propellants. Boeing's objective for this effort is to develop a safer, more efficient and environmentally friendly RCS design approach that is suitable for the RFS concept of operations, including a low cost, efficient turnaround cycle. The Boeing RCS concept utilizes ethanol and liquid oxygen in place of the highly toxic, suspected carcinogen, ozone-depleting mono-methyl-hydrazine and highly toxic nitrogen tetroxide. The Space Shuttle Upgrade program, under the leadership of the NASA Johnson Space Flight Center, is currently developing liquid oxygen and ethanol (ethyl alcohol) technology for use as non-toxic orbital maneuvering system (OMS) and RCS. The development of this liquid oxygen and ethanol technology for the Space Shuttle offers a significant leverage to select much of the same technology for the RFS program. There are significant design and development issues involved with bringing this liquid oxygen and ethanol technology to a state of maturity suitable for an operational RCS. The risks associated with a new LOX and Ethanol RCS are mitigated by maintaining kerosene and hydrogen peroxide RCS technology as an alternative. These issues, presented within this paper, include managing the oxygen supply and achieving reliable ignition in the short pulse mode of engine operation. Performance, reliability and operations requirements are presented along with a specific RCS design concept to satisfying these requirements. The work reported in this paper was performed under NASA Marshall Space Flight Center Contract Number NAS8-97272 to define Reusable First Stage design concepts for the Space Shuttle.

Keith, E. L.↗

Test Planning Approach and Lessons

As NASA began technology risk reduction activities and planning for the next generation launch vehicle under the Space Launch Initiative (SLI), now the Next Generation Launch Technology (NGLT) Program, a review of past large liquid rocket engine development programs was performed. The intent of the review was to identify any significant lessons from the development testing programs that could be applied to current and future engine development programs. Because the primary prototype engine in design at the time of this study was the Boeing-Rocketdyne RS-84, the study was slightly biased towards LOX/RP-1 liquid propellant engines. However, the significant lessons identified are universal. It is anticipated that these lessons will serve as a reference for test planning in the Engine Systems Group at Marshall Space Flight Center (MSFC). Towards the end of F-1 and J-2 engine development testing, NASA/MSFC asked Rocketdyne to review those test programs. The result was a document titled, Study to Accelerate Development by Test of a Rocket Engine (R-8099). The "intent (of this study) is to apply this thinking and learning to more efficiently develop rocket engines to high reliability with improved cost effectivenes" Additionally, several other engine programs were reviewed - such as SSME, NSTS, STME, MC-1, and RS-83- to support or refute the R-8099. R-8099 revealed two primary lessons for test planning, which were supported by the other engine development programs. First, engine development programs can benefit from arranging the test program for engine system testing as early as feasible. The best test for determining environments is at the system level, the closest to the operational flight environment. Secondly, the component testing, which tends to be elaborate, should instead be geared towards reducing risk to enable system test. Technical risk can be reduced at the component level, but the design can only be truly verified and validated after engine system testing.

Parkinson, Douglas A.↗