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NASA NTRS2000

Manufacturing and NDE of Large Composite Aerospace Structures at MSFC

NASA's vision for transportation to orbit calls for new vehicles built with new materials technology. The goals of this new launch system development are to improve safety, dramatically reduce cost to orbit, and improve vehicle turn around time. Planned Space Shuttle upgrades include new reusable liquid propellant boosters to replace the solid propellant boosters. These boosters are to have wings and return to the launch site for a horizontal landing on an airport runway. New single and two stages to orbit concepts are being investigated. To reduce weight and improve performance composite materials are proposed for fuel and oxidizer tanks, fuel feedlines, valve bodies, aerostructures, turbomachinery components. For large composite structures new methods of fabrication are being proposed and developed. Containment of cryogenic fuel or oxidizer requires emphases on composite material densification and chemical compatibility. Ceramic matrix and fiber composites for hot rotating turbomachinery have been developed with new fabrication processes. The new requirements on the materials for launcher components are requiring development of new manufacturing and inspection methods. This talk will examine new and proposed manufacturing methods to fabricate the revolutionary components. New NDE methods under consideration include alternative X-ray methods, X-ray laminagraphy, advanced CT, Thermography, new ultrasonic methods, and imbedded sensors. The sizes, complexity, use environment, and contamination restrictions will challenge the inspection process. In flight self-diagnosis and rapid depot inspection are also goals of the NDE development.

Whitaker, Ann↗
NASA NTRS2010

Incorporation of alpha-Ketoglutaric Acid as a Fixed Bed Scrubber Media for the Neutralization of Hydrazine Family Hypergolic Fuels

A candidate scrubber media, alpha-ketoglutaric acid (aKGA) adsorbed onto a silica-based substrate was examined as a potential alternative to the hydrazine-family hypergolic fuel neutralization techniques currently utilized at NASA/Kennedy Space Center (KSC). Helvenson et. al. has indicated that aKGA will react with hydrazines to produce non-hazardous, possibly biodegradable products. Furthermore, the authors have previously tested and demonstrated the use of aKGA aqueous solutions as a replacement neutralizing agent for citric acid, which is currently used as a scrubbing agent in liquid scrubbers at KSC. Specific properties examined include reaction efficiency, the loading capacity of aKGA onto various silica substrates, and the comparison of aKGA media performance to that of the citric acid vapor scrubber systems at KSC and a commercial vapor scrubber media. Preliminary investigations showed hydrophobic aerogel particles to be an ideal substrate for the deposition of the aKGA. Current studies have shown that the laboratory produced aKGA-Aerogel absorbent media are more efficient and cost effective than a commercially available fixed bed scrubber media, although much less cost effective than liquid-based citric acid scrubbers (although possibly safer and less labor intensive). A comparison of all three alternative scrubber technologies (liquid aKGA, solid-phase aKGA, and commercially available sorbent materials) is given considering both hypergolic neutralization capabilities and relative costs (as compared to the current citric acid scrubbing technology in use at NASA/KSC).

DeVor, R. W.↗
NASA NTRS2010

In the Beginning...

Having just emerged from the warmest decade on record and watching as the oceans acidify and sea level rises, global resources peak, the world's population continues to climb, and nearly half of all known species face extinction by the end of the century. We stand on the threshold of one of the most important transition in human history-the transition from hunting-and-gathering our energy to cultivating sustainable, carbon-neutral, environmentally-friendly energy supplies. Can we develop an alternative to fossil fuels in time to make a difference for our children and the "children" of all species? NASA puts people into outer space, where all resources (food, water, air, pressure, gravity, energy) are limited and far away and where conditions (temperature, radiation, vacuum) are problematic and dangerous-the life expectancy of an unprotected astronaut (physically exposed to the space environment) is 15 seconds. Therefore, by necessity, NASA has explored and developed "life-support systems" that optimize the use of resources, minimize the use of energy, and recycle, refurbish, re-use everything that on earth would be considered a waste material. Emerging from the legacy of life-support systems, the NASA OMEGA project uses microalgae, municipal wastewater, and the encroaching oceans to address our global needs for a sustainable, carbon-neutral, environmentally friendly energy supply that does not compete with agriculture. The OMEGA project is focused on producing aviation fuel, treating municipal wastewater, and sequestering carbon dioxide. More generally, however, OMEGA is an example of an "ecology of technologies" in which all processes are integrated and inter-dependent and wastes become resources. From a NASA perspective, the OMEGA project is also a reminder that "we are not passengers on Spaceship Earth, we are the crew."

Trent, Jonathan↗
NASA NTRS2011

NASA PEMFC Development Background and History

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. Four vendors have designed and fabricated non-flow-through fuel cell stacks under NASA funding. One of these vendors is considered the "baseline" vendor, and the remaining three vendors are competing for the "alternate" role. Each has undergone testing of their stack hardware integrated with a NASA balance-of-plant. Future Exploration applications for this hardware include primary fuel cells for a Lunar Lander and regenerative fuel cells for Surface Systems.

Hoberecht, Mark↗
NASA NTRS2018

Optimization of a Multifunctional Hot Structure Aeroshell for Mars Entry

Vehicle size and weight are driving cost factors in sending vehicles into space because the cost of launch is directly related to the payload mass being delivered. Vehicle size and weight have a larger impact on deep- space missions compared to sending a payload to low Earth orbit due to the extra fuel and supplies required to complete the longer duration mission. One area of study for possible vehicle volume or weight reduction is the thermal protection system (TPS) of a vehicle. Hot structures have been proposed as a TPS concept which can carry both primary structural loads and thermal loads. The use of hot structures on a Mars entry vehicle may be feasible and have potential volume and weight savings over the current state of the art ablative TPS technology. A preliminary trade study was performed on a mid lift-to-drag aeroshell Mars entry concept vehicle; comparing the weight and skin thickness of a vehicle using ablative TPS with a vehicle using hot structures. Independent thermal and structural analyses were performed to determine the minimum mass designs. The goal of this study was to determine if the use of hot structures was feasible and had potential for significant vehicle volume and weight savings over the current state of the art. This trade study found that use of a hot structures leads to a feasible alternative to ablative TPS technology, with potential 53% weight and 22% thickness (volume) saving benefits that could enable future missions.

Langston, Sarah L.↗
NASA NTRS2024

Additional Aviation Sustainability Strategies

Emissions from the aviation sector are expected to grow significantly in the next few decades due to growing demand for aviation. The U.S. fleet size has increased significantly in the past 20 years, growing from 2,132 aircraft to 5,485 aircraft. Similarly from 1990 to 2019, aviation emissions more than doubled, growing faster than any other transportation mode. These emissions include carbon dioxide (CO2), as well as non-CO2 sources including nitrogen oxides (NOx), sulfur dioxide (SO2), water (H2O), and particulate matter (soot). However, this report focuses specifically on CO2 emissions because the impacts from CO2 are well-understood and long-lived. There are also many climate goals tied to CO2 emissions, including the US Aviation Climate Action Plan which is pushing for net-zero in 2050. CO2 is a greenhouse, or heat-trapping, gas that comes from the extraction and burning of fossil fuels, from wildfires, and natural processes like volcanoes. Greenhouse gases absorb heat radiating from the Earth’s surface and release it in all directions, including back toward Earth’s surface. By adding more CO2 to the atmosphere, humans amplify the natural greenhouse effect, causing global temperature to rise. Since the onset of industrial times in 1750, human activities have raised atmospheric CO2 by 50%. Considering this challenge, the United States has set a climate goal to achieve net-zero CO2 emissions in the U.S. aviation sector by 2050 to reduce the environmental impact of aviation. Net-zero emissions refers to the amount of greenhouse gases (GHGs), such as CO2, methane or SO2, that are removed from the atmosphere being equal to those emitted by human activity. This contrasts with carbon-neutrality, which refers to no net release of carbon dioxide to the atmosphere, especially through offsetting emissions, that could be accomplished through a series of actions. As of 2022, the goal of net-zero has been adopted by much of the aviation industry including multiple airlines and countries. To reach net-zero by 2050, sustainable aviation fuels (SAFs) are identified as the technology that could provide the greatest impact within this timeframe. However, certain challenges may limit the production and/or adoption of SAFs in the marketplace, such as competition for feedstocks, production capacity, and high cost. In this case, SAFs would be insufficient to meet the net-zero CO2 emission goals. Therefore, in addition to SAFs, other strategies will be needed to close the gap on emissions produced as a result of SAF shortfalls or to enhance the impact of SAFs on reducing emissions. NASA’s Aeronautics Research Mission Directorate (ARMD) aims to examine these additional pathways to explore how its research may best contribute to the realization of net-zero emissions by 2050. Specifically, this effort considers strategies that can reduce emissions in the aviation sector in combination with the use of SAFs and carbon offsets while still meeting projected passenger demand. The strategies considered are not only feasible but also could be operationally scalable by 2050. The goal of this report is to investigate additional strategies such as alternative flight and ground operations, providing insight into the CO2 emission reduction potential and feasibility of strategy implementation by 2050.

Carbon Emissions↗
NASA NTRS2002

Evaluation of Impinging Stream Vortex Chamber Concepts for Liquid Rocket Engine Applications

To pursue technology developments for future launch vehicles, NASA/Marshall Space Flight Center (MSFC) is examining vortex chamber concepts for liquid rocket engine applications. Past studies indicated that the vortex chamber schemes potentially have a number of advantages over conventional chamber methods. Due to the nature of the vortex flow, relatively cooler propellant streams tend to flow along the chamber wall. Hence, the thruster chamber can be operated without the need of any cooling techniques. This vortex flow also creates strong turbulence, which promotes the propellant mixing process. Consequently, the subject chamber concepts not only offer system simplicity, but also enhance the combustion performance. Test results have shown that chamber performance is markedly high even at a low chamber length-to-diameter ratio (LD). This incentive can be translated to a convenience in the thrust chamber packaging. Variations of the vortex chamber concepts have been introduced in the past few decades. These investigations include an ongoing work at Orbital Technologies Corporation (ORBITEC). By injecting the oxidizer tangentially at the chamber convergence and fuel axially at the chamber head end, Knuth et al. were able to keep the wall relatively cold. A recent investigation of the low L/D vortex chamber concept for gel propellants was conducted by Michaels. He used both triplet (two oxidizer orifices and one fuel orifice) and unlike impinging schemes to inject propellants tangentially along the chamber wall. Michaels called the subject injection scheme an Impinging Stream Vortex Chamber (ISVC). His preliminary tests showed that high performance, with an Isp efficiency of 9295, can be obtained. MSFC and the U. S. Army are jointly investigating an application of the ISVC concept for the cryogenic oxygen/hydrocarbon propellant system. This vortex chamber concept is currently tested with gel propellants at AMCOM at Redstone Arsenal, Alabama. A version of this concept for the liquid oxygen (LOX) hydrocarbon fuel (RP-1) system has been derived from the one for the gel propellant. An unlike impinging injector was employed to deliver the propellants to the chamber. MSFC is also conducting an alternative injection scheme, called the chasing injector, associated with this vortex chamber concept. In this injection technique, both propellant jets and their impingement point are in the same chamber cross-sectional plane. Long duration tests (approximately up to 15 seconds) will be conducted on the ISVC to study the thermal effects. This paper will report the progress of the subject efforts at NASA Marshall Space Flight Center. Thrust chamber performance and thermal wall compatibility will be evaluated. The chamber pressures, wall temperatures, and thrust will be measured as appropriate. The test data will be used to validate CFD models, which, in turn, will be used to design the optimum vortex chambers. Measurements in the previous tests showed that the chamber pressures vary significantly with radius. This is due to the existence of the vortices in the chamber flow field. Hence, the combustion efficiency may not be easily determined from chamber pressure. For this project, measured thrust data will be collected. The performance comparison will be in terms of specific impulse efficiencies. In addition to the thrust measurements, several pressure and temperature readings at various locations on the chamber head faceplate and the chamber wall will be made. The first injector and chamber were designed and fabricated based on the available data and experience gained during gel propellant system tests by the U.S. Army. The alternate injector for the ISVC was also fabricated. Hot-fire tests of the vortex chamber are about to start and are expected to complete in February of 2003 at the TS115 facility of MSFC.

Trinh, Huu P.↗
NASA NTRS1976

Experimental clean combustor program, phase 2

Combustor pollution reduction technology for commercial CTOL engines was generated and this technology was demonstrated in a full-scale JT9D engine in 1976. Component rig refinement of the two best combustor concepts were tested. These concepts are the vorbix combustor, and a hybrid combustor which combines the pilot zone of the staged premix combustor and the main zone of the swirl-can combustor. Both concepts significantly reduced all pollutant emissions relative to the JT9D-7 engine combustor. However, neither concept met all program goals. The hybrid combustor met pollution goals for unburned hydrocarbons and carbon monoxide but did not achieve the oxides of nitrogen goal. This combustor had significant performance deficiencies. The Vorbix combustor met goals for unburned hydrocarbons and oxides of nitrogen but did not achieve the carbon monoxide goal. Performance of the vorbix combustor approached the engine requirements. On the basis of these results, the vorbix combustor was selected for the engine demonstration program. A control study was conducted to establish fuel control requirements imposed by the low-emission combustor concepts and to identify conceptual control system designs. Concurrent efforts were also completed on two addendums: an alternate fuels addendum and a combustion noise addendum.

Roberts, R.↗
NASA NTRS1994

Fast Track NTR Systems Assessment for NASA's First Lunar Outpost Scenario

Integrated systems and mission study results are presented which quantify the rationale and benefits for developing and using nuclear thermal rocket (NTR) technology for returning humans to the moon in the early 2000's. At present, the Exploration Program Office (ExPO) is considering chemical propulsion for its 'First Lunar Outpost' (FLO) mission, and NTR propulsion for the more demanding Mars missions to follow. The use of an NTR-based lunar transfer stage, capable of evolving to Mars mission applications, could result in an accelerated schedule, reduced cost approach to moon/Mars exploration. Lunar mission applications would also provide valuable operational experience and serve as a 'proving ground' for NTR engine and stage technologies. In terms of performance benefits, studies indicate that an expendable NTR stage powered by two 50 klbf engines can deliver approximately 96 metric tons (t) to trans-lunar injection (TLI) conditions for an initial mass in low earth orbit (IMLEO) of approximately 199 t compared to 250 t for a cryogenic chemical TLI stage. The NTR stage liquid hydrogen (LH2) tank has a 10 m diameter, 14.8 m length, and 68 t LH2 capacity. The NTR utilizes a 'graphite' fuel form consisting of coated UC2 particles in a graphite substrate, and has a specific impulse capability of approximately 870 s, and an engine thrust-to-weight ratio of approximately 4.8. The NTR stage and its piloted FLO lander has a total length of approximately 38 m and can be launched by a single Saturn V-derived heavy lift launch vehicle (HLLV) in the 200 to 250 t-class range. The paper summarizes NASA's First Lunar Outpost scenario, describes characteristics for representative engine/stage configurations, and examines the impact on engine selection and vehicle design resulting from a consideration of alternative NTR fuel forms and lunar mission profiles.

Borowski, Stanley K.↗
NASA NTRS2007

Possible Applications of Photoautotrophic Biotechnologies at Lunar Settlements

The most ambitious goal of the Vision of Space Exploration is to extend human presence across the solar system. Today, however, missions would have to bring all of the propellant, air, food, water, habitable volumes and shielding needed to sustain settlers beyond Earth. That is why resources for propellants, life support and construction of support systems and habitats must be found in space and utilized if humans hope to ever explore and colonize the solar system. The life support, fuel production and material processing systems currently proposed for spaceflight are essentially disconnected. Only traditional crop production has been proposed as a segment for bioregenerative life support systems, although the efficiency of higher plants for air regeneration is generally low. Thus, the investigation of air bioregeneration techniques based on the activity of photosynthetic organisms with higher rates of CO2 scrubbing and O2 release is very timely and important. Future systems for organic waste utilization in space may also benefit from the use of specific microorganisms. This janitorial job is efficiently carried out by microbes on Earth, which drive and connect different elemental cycles. It is likely that environmental control and life support systems based on bioregeneration will be capable of converting both organic and inorganic components of the waste at lunar settlements into edible biomass. The most challenging technologies for future lunar settlements are the extraction of elements (e.g. Fe, O, Si, etc) from local rocks for industrial feedstocks and the production of propellants. While such extraction can be accomplished by purely inorganic processes, the high energy requirements of such processes motivates the search for alternative technologies with lower energy requirements and appropriate efficiency. Well-developed terrestrial industrial biotechnologies for metals extraction and conversion could therefore be the prototypes for extraterrestrial biometallurgy.

McKay, David S.↗
NASA NTRS2000

Burning in Outer Space: Microgravity

A better understanding of combustion can lead to significant technological advances, such as less polluting, more fuel-efficient vehicles. Unfortunately, gravity can interfere with the study of combustion. Gravity drags down gases that are cooler- and, therefore, denser-than heated gases. This movement mixes the fuel and the oxidizer substance that promotes burning. Because of this mixing, an observer cannot necessarily distinguish what is happening as a result of the natural combustion process and what is caused, by the pull of gravity. To remove this uncertainty, scientists can conduct experiments that simulate the negation of gravity through freefall. This condition is known as a microgravity environment. A micro-gravity experiment may take place in a chamber that is dropped down a hole or from a high-speed drop tower. The experiment also be conducted in an airplane or a rocket during freefall in a parabolic flight path. This method provides less than a minute of microgravity at most. An experiment that requires the prolonged absence of gravity may necessitate the use of an orbiting spacecraft as a venue. However, access to an orbital laboratory is difficult to acquire. High-end computing centers such as the NCCS can provide a practical alternative to operating in microgravity. Scientists can model phenomena such as combustion without gravitys observational interference. The study of microgravity combustion produces important benefits beyond increased observational accuracy. Certain valuable materials that are produced through combustion can be formed with a more uniform crystal structure-and, therefore, improved structural quality-when the pull of gravity is removed. Furthermore, understanding how fires propagate in the absence of gravity can improve fire safety aboard spacecraft.

Matkowsky, Bernard↗
NASA NTRS2002

Pulse Detonation Engine Test Bed Developed

A detonation is a supersonic combustion wave. A Pulse Detonation Engine (PDE) repetitively creates a series of detonation waves to take advantage of rapid burning and high peak pressures to efficiently produce thrust. NASA Glenn Research Center's Combustion Branch has developed a PDE test bed that can reproduce the operating conditions that might be encountered in an actual engine. It allows the rapid and cost-efficient evaluation of the technical issues and technologies associated with these engines. The test bed is modular in design. It consists of various length sections of both 2- and 2.6- in. internal-diameter combustor tubes. These tubes can be bolted together to create a variety of combustor configurations. A series of bosses allow instrumentation to be inserted on the tubes. Dynamic pressure sensors and heat flux gauges have been used to characterize the performance of the test bed. The PDE test bed is designed to utilize an existing calorimeter (for heat load measurement) and windowed (for optical access) combustor sections. It uses hydrogen as the fuel, and oxygen and nitrogen are mixed to simulate air. An electronic controller is used to open the hydrogen and air valves (or a continuous flow of air is used) and to fire the spark at the appropriate times. Scheduled tests on the test bed include an evaluation of the pumping ability of the train of detonation waves for use in an ejector and an evaluation of the pollutants formed in a PDE combustor. Glenn's Combustion Branch uses the National Combustor Code (NCC) to perform numerical analyses of PDE's as well as to evaluate alternative detonative combustion devices. Pulse Detonation Engine testbed.

Breisacher, Kevin J.↗
NASA NTRSDate not supplied

Experimental Studies of Open Rotor Installation Effects

Open rotor propulsion technologies offer an opportunity for reducing fuel burn. At the same time, great challenges arise from this radically different engine architecture in terms of aircraft system integration. The aeroacoustic effects of integration are one of those key challenges and, furthermore, can offer the possibility for total aircraft system noise reduction. The inter-relationship of the aerodynamic and aeroacoustic system integration effects is particularly important to enable future application. An extensive model scale test campaign was conducted to investigate a broad range of these open rotor installation effects for both a conventional and an unconventional airframe. The experimental campaign was conducted in the Boeing Low Speed Aeroacoustic Facility with specially designed modifications for efficient positioning of the open rotor rig relative to the airframe. The airframe was traversed remotely relative to the fixed open rotor rig providing for the investigation of a large number of installation positions. Eight positions around the main wing of the conventional airframe and eleven positions above the hybrid wing body airframe were documented. Other parameters investigated in the test campaign included forward flight simulation Mach number, angle of attack, rotor speed, and airframe control surface deployment. In addition, both airframes were modified for alternate configurations. The conventional airframe was configured with both a T and a U tail while the unconventional hybrid wing body airframe was configured with different vertical control surfaces. An extensive instrumentation package was deployed. The acoustics were documented with a fixed array of far field microphones, a traversing array of in-flow microphones, an out-of-flow traversing phased array, and unsteady pressure transducers mounted flush on the surface of the airframes. In addition, mean flow surveys were measured with an articulating arm traversing system. The flow field surveys were particularly valuable in documenting flow distortion effects for the various installation positions and those created by angle of attack. This presentation will report the key results obtained for open rotor installation effects and discuss future prospects with the perspective of these results.

Michael J Czech↗
NASA NTRS2002

Numerical Propulsion System Simulation (NPSS): An Award Winning Propulsion System Simulation Tool

The Numerical Propulsion System Simulation (NPSS) is a full propulsion system simulation tool used by aerospace engineers to predict and analyze the aerothermodynamic behavior of commercial jet aircraft, military applications, and space transportation. The NPSS framework was developed to support aerospace, but other applications are already leveraging the initial capabilities, such as aviation safety, ground-based power, and alternative energy conversion devices such as fuel cells. By using the framework and developing the necessary components, future applications that NPSS could support include nuclear power, water treatment, biomedicine, chemical processing, and marine propulsion. NPSS will dramatically reduce the time, effort, and expense necessary to design and test jet engines. It accomplishes that by generating sophisticated computer simulations of an aerospace object or system, thus enabling engineers to "test" various design options without having to conduct costly, time-consuming real-life tests. The ultimate goal of NPSS is to create a numerical "test cell" that enables engineers to create complete engine simulations overnight on cost-effective computing platforms. Using NPSS, engine designers will be able to analyze different parts of the engine simultaneously, perform different types of analysis simultaneously (e.g., aerodynamic and structural), and perform analysis in a more efficient and less costly manner. NPSS will cut the development time of a new engine in half, from 10 years to 5 years. And NPSS will have a similar effect on the cost of development: new jet engines will cost about a billion dollars to develop rather than two billion. NPSS is also being applied to the development of space transportation technologies, and it is expected that similar efficiencies and cost savings will result. Advancements of NPSS in fiscal year 2001 included enhancing the NPSS Developer's Kit to easily integrate external components of varying fidelities, providing the initial Visual-Based Syntax (VBS) capability, and developing additional capabilities to support space transportation. NPSS was supported under NASA's High Performance Computing and Communications Program. Through the NASA/Industry Cooperative Effort agreement, NASA Glenn and its industry and Government partners are developing NPSS. The NPSS team consists of propulsion experts and software engineers from GE Aircraft Engines, Pratt & Whitney, The Boeing Company, Honeywell, Rolls-Royce Corporation, Williams International, Teledyne Continental Motors, Arnold Engineering Development Center, Wright Patterson Air Force Base, and the NASA Glenn Research Center. Glenn is leading the way in developing NPSS--a method for solving complex design problems that's faster, better, and cheaper.

Stauber, Laurel J.↗
NASA NTRS2012

Influence of Alternative Engine Concepts on LCTR2 Sizing and Mission Profile

The Large Civil Tiltrotor (LCTR) was developed as part of the NASA Heavy Lift Rotorcraft Systems Investigation in order to establish a consistent basis for evaluating the benefits of advanced technology for large tiltrotors. The concept has since evolved into the second-generation LCTR2, designed to carry 90 passengers for 1,000 nm at 300 knots, with vertical takeoff and landing. This paper examines the impact of advanced propulsion system concepts on LCTR2 sizing. Two concepts were studied: an advanced, single-speed engine with a conventional power turbine layout (Advanced Conventional Engine, or ACE), and a variable-speed power turbine engine (VSPT). The ACE is the lighter engine, but requires a multi-speed (shifting) gearbox, whereas the VSPT uses a lighter, fixed-ratio gearbox. The NASA Design and Analysis of Rotorcraft (NDARC) design code was used to study the trades between rotor and engine efficiency and weight. Rotor performance was determined by Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD II), and engine performance was estimated with the Numerical Propulsion System Simulation (NPSS). Design trades for the ACE vs. VSPT are presented in terms of vehicle weight empty for variations in mission altitude and range; the effect of different One Engine Inoperative (OEI) criteria are also examined. Because of its strong effect on gearbox weight and on both rotor and engine efficiency, rotor speed was chosen as the reference design variable for comparing design trades. The two propulsion concepts had nearly identical vehicle weights and mission fuel consumption, and their relative advantages varied little with cruise altitude, mission range, or OEI criteria; high cruise altitude and low cruise tip speed were beneficial for both concepts.

Acree, C. W., Jr.↗
NASA NTRS2016

Developing the Water Supply System for Travel to Mars

What water supply method should be used on a trip to Mars? Two alternate approaches are using fuel cell and stored water, as was done for short missions such as Apollo and the Space Shuttle, or recycling most of the water, as on long missions including the International Space Station (ISS). Stored water is inexpensive for brief missions but its launch mass and cost become very large for long missions. Recycling systems have much lower total mass and cost for long missions, but they have high development cost and are more expensive to operate than storage. A Mars transit mission would have an intermediate duration of about 450 days out and back. Since Mars transit is about ten times longer than a brief mission but probably less than one-tenth as long as ISS, it is not clear if stored or recycled water would be best. Recycling system design is complicated because water is used for different purposes, drinking, food preparation, washing, and flushing the urinal, and because wastewater has different forms, humidity condensate, dirty wash water, and urine and flush water. The uses have different requirements and the wastewater resources have different contaminants and processing requirements. The most cost-effective water supply system may recycle some wastewater sources and also provide safety reserve water from storage. Different water supply technologies are compared using mass, cost, reliability, and other factors.

water supply↗
NASA NTRS2005

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗
NASA NTRS2008

Fiber Optic Sensing Monitors Strain and Reduces Costs

In applications where stress on a structure may vary widely and have an unknown impact on integrity, a common engineering strategy has been overbuilding to ensure a sufficiently robust design. While this may be appropriate in applications where weight concerns are not paramount, space applications demand a bare minimum of mass, given astronomical per-pound launch costs. For decades, the preferred solution was the tactic of disassembly and investigation between flights. Knowing there must be a better way, Dr. Mark Froggatt, of Langley Research Center, explored alternate means of monitoring stresses and damage to the space shuttle. While a tear-it-apart-and-have-a-look strategy was effective, it was also a costly and time consuming process that risked further stresses through the very act of disassembly and reassembly. An alternate way of monitoring the condition of parts under the enormous stresses of space flight was needed. Froggatt and his colleagues at Langley built an early-warning device to provide detailed information about even minuscule cracks and deformations by etching a group of tiny lines, or grating, on a fiber optic cable five-thousandths of an inch thick with ultraviolet light. By then gluing the fiber to the side of a part, such as a fuel tank, and shining a laser beam down its length, reflected light indicated which gratings were under stress. Inferring this data from measurements in light rather than in bonded gauges saved additional weight. Various shuttle components now employ the ultrasonic dynamic vector stress sensor (UDVSS), allowing stress detection by measuring light beamed from a built-in mini-laser. By measuring changes in dynamic directional stress occurring in a material or structure, and including phase-locked loop, synchronous amplifier, and contact probe, the UDVSS proved especially useful among manufacturers of aerospace and automotive structures for stress testing and design evaluation. Engineers could ensure safety in airplanes and spaceships with a narrower, not overbuilt, margin of safety. For this development, in 1997, Discover Magazine named Froggatt a winner in the "Eighth Annual Awards for Technological Innovation" from more than 4,000 entries.

Source record↗