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Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗

NASA NTRS2003

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Hartley, Paula J.↗

NASA NTRS2022

Elevated Hot Gas and High-mass X-Ray Binary Emission in Low-metallicity Galaxies: Implications for Nebular Ionization and Intergalactic Medium Heating in the Early Universe

High-energy emission associated with star formation has been proposed as a significant source of interstellar medium (ISM) ionization in low-metallicity starbursts and an important contributor to the heating of the intergalactic medium (IGM) in the high-redshift (z ≳ 8) universe. Using Chandra observations of a sample of 30 galaxies at D ≈ 200–450 Mpc that have high specific star formation rates of 3–9 Gyr^(−1) and metallicities near Z ≈ 0.3Z_⊙, we provide new measurements of the average 0.5–8 keV spectral shape and normalization per unit star formation rate (SFR). We model the sample-combined X-ray spectrum as a combination of hot gas and high-mass X-ray binary (HMXB) populations and constrain their relative contributions. We derive scaling relations of log L^(HMXB)_(0.5-8keV) / SFR = 40.19 ± 0.06 and log L^(gas)_(0.5-2keV) / SFR = 39.58 ^(+0.17)_(-0.28), significantly elevated compared to local relations. The HMXB scaling is also somewhat higher than L^(HMXB)_(0.5-8keV) -SFR-Z relations presented in the literature, potentially due to our galaxies having relatively low HMXB obscuration and young and X-ray luminous stellar populations. The elevation of the hot gas scaling relation is at the level expected for diminished attenuation due to a reduction of metals; however, we cannot conclude that an L^(gas)_(0.5-2keV) -SFR-Z relation is driven solely by changes in ISM metal content. Finally, we present SFR-scaled spectral models (both emergent and intrinsic) that span the X-ray-to-IR band, providing new benchmarks for studies of the impact of ISM ionization and IGM heating in the early universe.

high-mass x-ray binary stars↗

NASA NTRS2013

Regression Verification Using Impact Summaries

Regression verification techniques are used to prove equivalence of syntactically similar programs. Checking equivalence of large programs, however, can be computationally expensive. Existing regression verification techniques rely on abstraction and decomposition techniques to reduce the computational effort of checking equivalence of the entire program. These techniques are sound but not complete. In this work, we propose a novel approach to improve scalability of regression verification by classifying the program behaviors generated during symbolic execution as either impacted or unimpacted. Our technique uses a combination of static analysis and symbolic execution to generate summaries of impacted program behaviors. The impact summaries are then checked for equivalence using an o-the-shelf decision procedure. We prove that our approach is both sound and complete for sequential programs, with respect to the depth bound of symbolic execution. Our evaluation on a set of sequential C artifacts shows that reducing the size of the summaries can help reduce the cost of software equivalence checking. Various reduction, abstraction, and compositional techniques have been developed to help scale software verification techniques to industrial-sized systems. Although such techniques have greatly increased the size and complexity of systems that can be checked, analysis of large software systems remains costly. Regression analysis techniques, e.g., regression testing [16], regression model checking [22], and regression verification [19], restrict the scope of the analysis by leveraging the differences between program versions. These techniques are based on the idea that if code is checked early in development, then subsequent versions can be checked against a prior (checked) version, leveraging the results of the previous analysis to reduce analysis cost of the current version. Regression verification addresses the problem of proving equivalence of closely related program versions [19]. These techniques compare two programs with a large degree of syntactic similarity to prove that portions of one program version are equivalent to the other. Regression verification can be used for guaranteeing backward compatibility, and for showing behavioral equivalence in programs with syntactic differences, e.g., when a program is refactored to improve its performance, maintainability, or readability. Existing regression verification techniques leverage similarities between program versions by using abstraction and decomposition techniques to improve scalability of the analysis [10, 12, 19]. The abstractions and decomposition in the these techniques, e.g., summaries of unchanged code [12] or semantically equivalent methods [19], compute an over-approximation of the program behaviors. The equivalence checking results of these techniques are sound but not complete-they may characterize programs as not functionally equivalent when, in fact, they are equivalent. In this work we describe a novel approach that leverages the impact of the differences between two programs for scaling regression verification. We partition program behaviors of each version into (a) behaviors impacted by the changes and (b) behaviors not impacted (unimpacted) by the changes. Only the impacted program behaviors are used during equivalence checking. We then prove that checking equivalence of the impacted program behaviors is equivalent to checking equivalence of all program behaviors for a given depth bound. In this work we use symbolic execution to generate the program behaviors and leverage control- and data-dependence information to facilitate the partitioning of program behaviors. The impacted program behaviors are termed as impact summaries. The dependence analyses that facilitate the generation of the impact summaries, we believe, could be used in conjunction with other abstraction and decomposition based approaches, [10, 12], as a complementary reduction technique. An evaluation of our regression verification technique shows that our approach is capable of leveraging similarities between program versions to reduce the size of the queries and the time required to check for logical equivalence. The main contributions of this work are: - A regression verification technique to generate impact summaries that can be checked for functional equivalence using an off-the-shelf decision procedure. - A proof that our approach is sound and complete with respect to the depth bound of symbolic execution. - An implementation of our technique using the LLVMcompiler infrastructure, the klee Symbolic Virtual Machine [4], and a variety of Satisfiability Modulo Theory (SMT) solvers, e.g., STP [7] and Z3 [6]. - An empirical evaluation on a set of C artifacts which shows that the use of impact summaries can reduce the cost of regression verification.

Backes, John↗

NASA NTRS1998

Versatile Software Package For Near Real-Time Analysis of Experimental Data

This paper provides an overview of a versatile software package developed for time- and frequency-domain analyses of experimental wind-tunnel data. This package, originally developed for analyzing data in the NASA Langley Transonic Dynamics Tunnel (TDT), is applicable for analyzing any time-domain data. A Matlab-based software package, TDT-analyzer, provides a compendium of commonly-required dynamic analysis functions in a user-friendly interactive and batch processing environment. TDT-analyzer has been used extensively to provide on-line near real-time and post-test examination and reduction of measured data acquired during wind tunnel tests of aeroelastically-scaled models of aircraft and rotorcraft as well as a flight test of the NASA High Alpha Research Vehicle (HARV) F-18. The package provides near real-time results in an informative and timely manner far exceeding prior methods of data reduction at the TDT.

Wieseman, Carol D.↗

NASA NTRS2006

Flight Test Results for Uniquely Tailored Propulsion-Airframe Aeroacoustic Chevrons: Community Noise

The flow/acoustic environment around the jet exhaust of an engine when installed on an airplane, say, under the wing, is highly asymmetric due to the pylon, the wing and the high-lift devices. Recent scale model tests have shown that such Propulsion Airframe Aeroacoustic (PAA) interactions and the jet mixing noise can be reduced more than with conventional azimuthally uniform chevrons by uniquely tailoring the chevrons to produce enhanced mixing near the pylon. This paper describes the community noise results from a flight test on a large twin-engine airplane using this concept of azimuthally varying chevrons for engines installed under the wing. Results for two different nozzle configurations are described: azimuthally varying "PAA T-fan" chevrons on the fan nozzle with a baseline no-chevron core nozzle and a second with PAA T-fan chevrons with conventional azimuthally uniform chevrons on the core nozzle. We analyze these test results in comparison to the baseline no-chevron nozzle on both spectral and integrated power level bases. The study focuses on the peak jet noise reduction and the effects at high frequencies for typical take-off power settings. The noise reduction and the absolute noise levels are then compared to model scale results. The flight test results verify that the PAA T-fan nozzles in combination with standard core chevron nozzles can, indeed, give a reasonable amount of noise reduction at low frequencies without high-frequency lift during take-off conditions and hardly any impact on the cruise thrust coefficient.

Nesbitt, Eric↗

NASA NTRS2012

Verification of Ares I Liftoff Acoustic Environments via the Ares I Scale Model Acoustic Test

The Ares I Scale Model Acoustic Test (ASMAT) program was implemented to verify the predicted Ares I liftoff acoustic environments and to determine the acoustic reduction gained by using an above deck water sound suppression system. The test article included a 5% scale Ares I vehicle model and Mobile Launcher with tower. Acoustic and pressure data were measured by over 200 instruments. The ASMAT results are compared to Ares I-X flight data.

Counter, Douglas↗

NASA NTRS1993

Structural similitude and design of scaled down laminated models

The excellent mechanical properties of laminated composite structures make them prime candidates for wide variety of applications in aerospace, mechanical and other branches of engineering. The enormous design flexibility of advanced composites is obtained at the cost of large number of design parameters. Due to complexity of the systems and lack of complete design based informations, designers tend to be conservative in their design. Furthermore, any new design is extensively evaluated experimentally until it achieves the necessary reliability, performance and safety. However, the experimental evaluation of composite structures are costly and time consuming. Consequently, it is extremely useful if a full-scale structure can be replaced by a similar scaled-down model which is much easier to work with. Furthermore, a dramatic reduction in cost and time can be achieved, if available experimental data of a specific structure can be used to predict the behavior of a group of similar systems. This study investigates problems associated with the design of scaled models. Such study is important since it provides the necessary scaling laws, and the factors which affect the accuracy of the scale models. Similitude theory is employed to develop the necessary similarity conditions (scaling laws). Scaling laws provide relationship between a full-scale structure and its scale model, and can be used to extrapolate the experimental data of a small, inexpensive, and testable model into design information for a large prototype. Due to large number of design parameters, the identification of the principal scaling laws by conventional method (dimensional analysis) is tedious. Similitude theory based on governing equations of the structural system is more direct and simpler in execution. The difficulty of making completely similar scale models often leads to accept certain type of distortion from exact duplication of the prototype (partial similarity). Both complete and partial similarity are discussed. The procedure consists of systematically observing the effect of each parameter and corresponding scaling laws. Then acceptable intervals and limitations for these parameters and scaling laws are discussed. In each case, a set of valid scaling factors and corresponding response scaling laws that accurately predict the response of prototypes from experimental models is introduced. The examples used include rectangular laminated plates under destabilizing loads, applied individually, vibrational characteristics of same plates, as well as cylindrical bending of beam-plates.

Simitses, G. J.↗

NASA NTRS1971

The NASA Quiet Engine.

The NASA Quiet Engine Program will incorporate all available noise-reduction technology into a propulsion system suitable for subsonic civil transport aircraft. Full-scale experimental hardware is being built and tested primarily for noise performance. The program is in process, and component tests to date indicate that it is possible to achieve or exceed noise reduction objectives of 15-20 PNdB below the levels of 707/DC-8 long-range transport aircraft.

Kramer, J. J.↗

NASA NTRS1987

What happens to the large eddies when net drag reduction is achieved by outer flow manipulators?

The tandem-arranged parallel plate manipulator (TAPPM) presently used to generate a flow with net drag reduction is conditionally sampled and found to exhibit significant changes of the boundary layer's large-scale motions at 20 delta(0), where delta(0) is the boundary layer thickness at the upstream plate of the TAPPM. Flow fields in the 'valleys' are equally affected. Both turbulent and irrotational flows then reestablish themselves by 50 delta(0). Flow visualization indicates that the TAPPM wake is very coherent at 20 delta(0), and has not yet spread into the wall region, while large scale motions and the ambient response flow continue to exhibit dynamic changes. This indicates that the shielding effect of the TAPPM's wake prolongs suppression of large-scale motions, thereby reducing skin friction over a sufficiently long extent of the boundary layer to overcome device drag and yield net drag reductions.

Falco, R. E.↗

NASA NTRS2008

Analysis of Thermal and Reaction Times for Hydrogen Reduction of Lunar Regolith

System analysis of oxygen production by hydrogen reduction of lunar regolith has shown the importance of the relative time scales for regolith heating and chemical reaction to overall performance. These values determine the sizing and power requirements of the system and also impact the number and operational phasing of reaction chambers. In this paper, a Nusselt number correlation analysis is performed to determine the heat transfer rates and regolith heat up times in a fluidized bed reactor heated by a central heating element (e.g., a resistively heated rod, or a solar concentrator heat pipe). A coupled chemical and transport model has also been developed for the chemical reduction of regolith by a continuous flow of hydrogen. The regolith conversion occurs on the surfaces of and within the regolith particles. Several important quantities are identified as a result of the above analyses. Reactor scale parameters include the void fraction (i.e., the fraction of the reactor volume not occupied by the regolith particles) and the residence time of hydrogen in the reactor. Particle scale quantities include the particle Reynolds number, the Archimedes number, and the time needed for hydrogen to diffuse into the pores of the regolith particles. The analysis is used to determine the heat up and reaction times and its application to NASA s oxygen production system modeling tool is noted.

Hegde, U.↗

NASA NTRS2009

Analysis of Thermal and Reaction Times for Hydrogen Reduction of Lunar Regolith

Hegde, U.↗

NASA NTRS1977

Obstacle detection by rapid estimation scheme with data scaling

A data scaling technique is proposed to improve the performance of a rapid estimation scheme for analyzing rover rangefinder data in the specific area of obstacle outline characterization. The scaling transformation involves multiplying the measured beam length times a scale factor and taking the logarithm in a certain base. Although analysis shows that introducing the scaling transformation has no primary effect on the detection ability and that there is no apparent signal-to-noise ratio improvement, computer simulations show a reduction in the number of false jumps. In the 40-m range the use of data scaling cleared the foreground of obstacles of noise and obtained definition of the near edge of a crater.

Marynowski, R. C.↗

NASA NTRS2011

Flight Test Results of a GPS-Based Pitot-Static Calibration Method Using Output-Error Optimization for a Light Twin-Engine Airplane

As part of the NASA Aviation Safety Program (AvSP), a novel pitot-static calibration method was developed to allow rapid in-flight calibration for subscale aircraft while flying within confined test areas. This approach uses Global Positioning System (GPS) technology coupled with modern system identification methods that rapidly computes optimal pressure error models over a range of airspeed with defined confidence bounds. This method has been demonstrated in subscale flight tests and has shown small 2- error bounds with significant reduction in test time compared to other methods. The current research was motivated by the desire to further evaluate and develop this method for full-scale aircraft. A goal of this research was to develop an accurate calibration method that enables reductions in test equipment and flight time, thus reducing costs. The approach involved analysis of data acquisition requirements, development of efficient flight patterns, and analysis of pressure error models based on system identification methods. Flight tests were conducted at The University of Tennessee Space Institute (UTSI) utilizing an instrumented Piper Navajo research aircraft. In addition, the UTSI engineering flight simulator was used to investigate test maneuver requirements and handling qualities issues associated with this technique. This paper provides a summary of piloted simulation and flight test results that illustrates the performance and capabilities of the NASA calibration method. Discussion of maneuver requirements and data analysis methods is included as well as recommendations for piloting technique.

Martos, Borja↗

NASA NTRS1972

The NASA quiet engine program.

The NASA quiet engine program will incorporate all available noise-reduction technology into a propulsion system suitable for subsonic civil transport aircraft. Full-scale experimental hardware is being built and tested primarily for noise performance. The program is in process, and component and engine tests to date indicate that it is possible to achieve or exceed noise reduction objectives of 15-20 PNdB below the levels of 707/DC-8 long-range transport aircraft.

Kramer, J. J.↗

NASA NTRS1972

Use of leaning vanes for fan noise reduction.

The obliquity of blade-vane interactions in an axial fan and its influence on noise generation are examined. Analysis indicates that leaning vanes decrease the amplitudes of the fluctuating pressures at the rotor-stator plane and modify the radial distribution. These changes lead to considerable cancellation in the near field and consequent reduction in radiated acoustic power. Acoustic measurements on a small scale fan with radial and leaning vanes compare favorably with analytical predictions.

Rao, G. V. R.↗

NASA NTRS1981

The design and development of a mixer compound exhaust system for a quiet clean general aviation turbofan

Lower engine fuel consumption has become a dominant factor in turbofan engine design due to rapidly increasing fuel costs. One engine component with a large impact on engine performance is the exhaust system. Previous exhaust system studies have demonstrated the significant exhaust system efficiency gains available through mixing of the core and bypass flows. Typically, a large, costly rig and engine program are required to develop and optimize these gains. The purpose of this paper is to present the results of the low-cost design system used for the quiet, clean general aviation turbofan mixer nozzle design and development. The scale model and full-scale engine test results confirm the predicted 3 to 5% reduction in cruise fuel consumption. This unique design system, which is based on integrating advanced three-dimensional viscous numerical methods with empirical optimization techniques, is summarized and detailed comparisons with test data are presented. The ability to accurately predict relative performance of mixer systems with substantially reduced development time and cost savings is demonstrated.

Blackmore, W. L.↗

NASA NTRS1984

Reduction of astrometric plates

A rapid and accurate method for the reduction of comet or asteroid plates is described. Projection equations, scale length correction, rotation of coordinates, linearization, the search for additional reference stars, and the final solution are examined.

Stock, J.↗