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NASA NTRS2010

Product Lifecycle Management and the Quest for Sustainable Space Exploration Solutions

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decisionmaking. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful tool to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting. Sustainable space exploration solutions demand that all lifecycle phases be optimized. Adopting PLM, which has been used by the automotive industry for many years, for aerospace applications provides a foundation for strong, disciplined systems engineering and accountable return on investment by making lifecycle considerations variables in an iterative decision-making process. This paper combines the perspectives of the founding father of PLM, along with the experience of Engineering leaders who are implementing these processes and practices real-time. As the nation moves from an industrial-based society to one where information is a valued commodity, future NASA programs and projects will benefit from the experience being gained today for the exploration missions of tomorrow.

Caruso, Pamela W.↗

DOE OSTI2025

Hydrogen Storage Engineering Center of Excellence Adsorbent (Final Report)

The Hydrogen Storage Engineering Center of Excellence (HSECoE) team would like to thank the U.S Department of Energy’s (DOE) Hydrogen and Fuel Cell Technologies Office for the funding to embark on such a large endeavor to develop the material and engineering science related to the use of adsorbents as the storage media for automotive applications. In addition, SRNL would like to thank the many partners of the HSECoE including U.S. automotive manufacturers, GM and Ford, potential component and materials suppliers, United Technologies Research Center, Hexagon Lincoln Composites, and BASF, Universities, Oregon State University, University of Michigan, and the University of Québec, Trois Reveres, along with the Jet Propulsion Laboratory, Pacific Northwest National Laboratory, Los Alamos National Laboratory and Savannah River National Laboratory. Individual specific contributions can be found in individual final reports submitted to DOE. No attempt is made here to attribute contributions to individual people or organizations, illustrating the cooperative arrangement of the team members.

08 HYDROGEN↗

NASA NTRS1978

Making aerospace technology work for the automotive industry - Introduction

In many cases it has been found that advances made in one technical field can contribute to other fields. An investigation is in this connection conducted concerning subjects from contemporary NASA programs and projects which might have relevance and potential usefulness to the automotive industry. Examples regarding aerospace developments which have been utilized by the automotive industry are related to electronic design, computer systems, quality control experience, a NASA combustion scanner and television display, exhaust gas analyzers, and a device for suppressing noise propagated through ducts. Projects undertaken by NASA's center for propulsion and power research are examined with respect to their value for the automotive industry. As a result of some of these projects, a gas turbine engine and a Stirling engine might each become a possible alternative to the conventional spark ignition engine.

Olson, W. T.↗

NASA NTRS1983

Advanced Gas Turbine (AGT): Power-train system development

Technical work on the design and effort leading to the testing of a 74.5 kW (100 hp) automotive gas turbine is described. The general effort was concentrated on building an engine for test starting in July. The buildup progressed with only routine problems and the engine was delivered to the test stand 9 July. In addition to the engine build effort, work continued in selected component areas. Ceramic turbine parts were built and tested. Burst tests of ceramic rotors show strengths are approaching that achieved in test bars; proof testing is required for acceptable strength ceramic vanes. Over 25 hours was accumulated on the combustor rig in three test modes: pilot nozzle only, start nozzle, and main nozzle operation. Satisfactory ignition was achieved for a wide range of starting speeds and the lean blowout limit was as low as 0.06 kg/b (0.14 lb/hr). Lean blowout was more a function of nozzle atomization than fuel/air ratio. A variety of cycle points were tested. Transition from start nozzle flow to main nozzle flow was done manually without difficulty. Regenerator parts were qualification tested without incident and the parts were assembled on schedule. Rig based performance matched first build requirements. Repeated failures in the harmonic drive gearbox during rig testing resulted in that concept being abandoned for an alternate scheme.

Helms, H. E.↗

NASA NTRS1996

Silicon Carbide Epitaxial Films Studied by Atomic Force Microscopy

Silicon carbide (SiC) holds great potential as an electronic material because of its wide band gap energy, high breakdown electric field, thermal stability, and resistance to radiation damage. Possible aerospace applications of high-temperature, high-power, or high-radiation SiC electronic devices include sensors, control electronics, and power electronics that can operate at temperatures up to 600 C and beyond. Commercially available SiC devices now include blue light-emitting diodes (LED's) and high-voltage diodes for operation up to 350 C, with other devices under development. At present, morphological defects in epitaxially grown SiC films limit their use in device applications. Research geared toward reducing the number of structural inhomogeneities can benefit from an understanding of the type and nature of problems that cause defects. The Atomic Force Microscope (AFM) has proven to be a useful tool in characterizing defects present on the surface of SiC epitaxial films. The in-house High-Temperature Integrated Electronics and Sensors (HTIES) Program at the NASA Lewis Research Center not only extended the dopant concentration range achievable in epitaxial SiC films, but it reduced the concentration of some types of defects. Advanced structural characterization using the AFM was warranted to identify the type and structure of the remaining film defects and morphological inhomogeneities. The AFM can give quantitative information on surface topography down to molecular scales. Acquired, in part, in support of the Advanced High Temperature Engine Materials Technology Program (HITEMP), the AFM had been used previously to detect partial fiber debonding in composite material cross sections. Atomic force microscopy examination of epitaxial SiC film surfaces revealed molecular-scale details of some unwanted surface features. Growth pits propagating from defects in the substrate, and hillocks due, presumably, to existing screw dislocations in the substrates, were imaged. Away from local defects, step bunching was observed to yield step heights of hundreds of angstroms, with possible implications for the uniformity of dopants incorporated in SiC devices during fabrication. The quantitative topographic data from the AFM allow the relevant defect information to be extracted, such as the size and distribution of step bunching and the Burgers vector of screw dislocations. These atomic force microscopy results have furthered the understanding of the dynamic epitaxial SiC growth process. A model describing the observed hillock step bunching has been proposed. This cooperation between researchers involved in crystal growth, electronic device fabrication, and surface structural characterization is likely to continue as atomic force microscopy is used to improve SiC films for high-temperature electronic devices for NASA's advanced turbine engines and space power devices, as well as for future applications in the automotive industry.

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NASA NTRS1999

Ninth Thermal and Fluids Analysis Workshop Proceedings

The Ninth Thermal and Fluids Analysis Workshop (TFAWS 98) was held at the Ohio Aerospace Institute in Cleveland, Ohio from August 31 to September 4, 1998. The theme for the hands-on training workshop and conference was "Integrating Computational Fluid Dynamics and Heat Transfer into the Design Process." Highlights of the workshop (in addition to the papers published herein) included an address by the NASA Chief Engineer, Dr. Daniel Mulville; a CFD short course by Dr. John D. Anderson of the University of Maryland; and a short course by Dr. Robert Cochran of Sandia National Laboratories. In addition, lectures and hands-on training were offered in the use of several cutting-edge engineering design and analysis-oriented CFD and Heat Transfer tools. The workshop resulted in international participation of over 125 persons representing aerospace and automotive industries, academia, software providers, government agencies, and private corporations. The papers published herein address issues and solutions related to the integration of computational fluid dynamics and heat transfer into the engineering design process. Although the primary focus is aerospace, the topics and ideas presented are applicable to many other areas where these and other disciplines are interdependent.

Sakowski, Barbara↗

NASA NTRS2012

Alloy-Enhanced Fans Maintain Fresh Air in Tunnels

The Partnership for Next Generation Vehicles (PNGV) is not a NASA initiative to develop powerful new rockets and spacecraft, even though it may sound like one. PNGV was a partnership established by the Clinton administration between the Federal government and the U.S. Council for Automotive Research to develop technologies that improve fuel efficiency and reduce emissions from cars and trucks. More than 20 Federal laboratories from the Departments of Commerce, Energy, Transportation, and Defense; the Environmental Protection Agency; the National Science Foundation; and NASA were all involved in PNGV, in addition to more than 350 automotive suppliers, universities, and small businesses. In support of this tremendous effort, Jonathan Lee, a materials engineer at Marshall Space Flight Center, worked with a major automobile manufacturer in 1995 to develop a strong aluminum alloy for high temperature applications. The aim was to use the alloy for manufacturing parts for an internal combustion engine, as well as for NASA s propulsion applications. When funding from PNGV ended, Marshall continued to support the alloy s development with help from NASA s Innovative Partnerships Program (now the Office of the Chief Technologist). Together with PoShou Chen, a scientist with Morgan Research Corporation, Lee invented a highstrength aluminum alloy called MSFC-398 that, when tested, was three to four times stronger than conventional aluminum alloys at high temperatures. By the late 1990s, Lee says, NASA s scientists had successfully developed and patented this technology, which has great potential applications not for just automotive, but also for aerospace, marine, and commercial applications

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NASA NTRS1995

Stellar Interferometer Technology Experiment (SITE)

The MIT Space Engineering Research Center and the Jet Propulsion Laboratory stand ready to advance science sensor technology for discrete-aperture astronomical instruments such as space-based optical interferometers. The objective of the Stellar Interferometer Technology Experiment (SITE) is to demonstrate system-level functionality of a space-based stellar interferometer through the use of enabling and enhancing Controlled-Structures Technologies (CST). SITE mounts to the Mission Peculiar Experiment Support System inside the Shuttle payload bay. Starlight, entering through two apertures, is steered to a combining plate where it is interferred. Interference requires 27 nanometer pathlength (phasing) and 0.29 archsecond wavefront-tilt (pointing) control. The resulting 15 milli-archsecond angular resolution exceeds that of current earth-orbiting telescopes while maintaining low cost by exploiting active optics and structural control technologies. With these technologies, unforeseen and time-varying disturbances can be rejected while relaxing reliance on ground alignment and calibration. SITE will reduce the risk and cost of advanced optical space systems by validating critical technologies in their operational environment. Moreover, these technologies are directly applicable to commercially driven applications such as precision matching, optical scanning, and vibration and noise control systems for the aerospace, medical, and automotive sectors. The SITE team consists of experienced university, government, and industry researchers, scientists, and engineers with extensive expertise in optical interferometry, nano-precision opto-mechanical control and spaceflight experimentation. The experience exists and the technology is mature. SITE will validate these technologies on a functioning interferometer science sensor in order to confirm definitely their readiness to be baselined for future science missions.

Crawley, Edward F.↗

NASA NTRS1981

AGT-102 automotive gas turbine

Development of a gas turbine powertrain with a 30% fuel economy improvement over a comparable S1 reciprocating engine, operation within 0.41 HC, 3.4 CO, and 0.40 NOx grams per mile emissions levels, and ability to use a variety of alternate fuels is summarized. The powertrain concept consists of a single-shaft engine with a ceramic inner shell for containment of hot gasses and support of twin regenerators. It uses a fixed-geometry, lean, premixed, prevaporized combustor, and a ceramic radial turbine rotor supported by an air-lubricated journal bearing. The engine is coupled to the vehicle through a widerange continuously variable transmission, which utilizes gearing and a variable-ratio metal compression belt. A response assist flywheel is used to achieve acceptable levels of engine response. The package offers a 100 lb weight advantage in a Chrysler K Car front-wheel-drive installation. Initial layout studies, preliminary transient thermal analysis, ceramic inner housing structural analysis, and detailed performance analysis were carried out for the basic engine.

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NASA NTRS1978

Review of JPL Automotive Technology Status and Projections (ATSP) project

The general objective was to make a continuing assessment of current automotive technology development programs and of the prospects for new concepts. The study embraced alternative engines, advanced powertrain components, and related energy conserving vehicle modifications which could be implemented by the end of this century. Vehicle level projections of the fuel economy and emissions potential of alternative power systems were key elements of this assessment.

Dowdy, M. W.↗

NASA NTRS1982

AGT101 automotive gas turbine system development

The AGT101 automotive gas turbine system consisting of a 74.6 kw regenerated single-shaft gas turbine engine, is presented. The development and testing of the system is reviewed, and results for aerothermodynamic components indicate that compressor and turbine performance levels are within one percent of projected levels. Ceramic turbine rotor development is encouraging with successful cold spin testing of simulated rotors to speeds over 12,043 rad/sec. Spin test results demonstrate that ceramic materials having the required strength levels can be fabricated by net shape techniques to the thick hub cross section, which verifies the feasibility of the single-stage radial rotor in single-shaft engines.

Rackley, R. A.↗

NASA NTRS1992

Advanced Turbine Technology Applications Project (ATTAP)

This report is the fourth in a series of Annual Technical Summary Reports for the Advanced Turbine Technology Applications Project (ATTAP). This report covers plans and progress on ceramics development for commercial automotive applications over the period 1 Jan. - 31 Dec. 1991. Project effort conducted under this contract is part of the DOE Gas Turbine Highway Vehicle System program. This program is directed to provide the U.S. automotive industry the high-risk, long-range technology necessary to produce gas turbine engines for automobiles with reduced fuel consumption, reduced environmental impact, and a decreased reliance on scarce materials and resources. The program is oriented toward developing the high-risk technology of ceramic structural component design and fabrication, such that industry can carry this technology forward to production in the 1990s. The ATTAP test bed engine, carried over from the previous AGT101 project, is being used for verification testing of the durability of next-generation ceramic components, and their suitability for service at Reference Powertrain Design conditions. This document reports the technical effort conducted by GAPD and the ATTAP subcontractors during the fourth year of the project. Topics covered include ceramic processing definition and refinement, design improvements to the ATTAP test bed engine and test rigs and the methodology development of ceramic impact and fracture mechanisms. Appendices include reports by ATTAP subcontractors in the development of silicon nitride and silicon carbide families of materials and processes.

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NASA NTRS1993

Advanced Turbine Technology Applications Project (ATTAP)

This report is the fifth in a series of Annual Technical Summary Reports for the Advanced Turbine Technology Applications Project (ATTAP), sponsored by the U.S. Department of Energy (DOE). The report was prepared by Garrett Auxiliary Power Division (GAPD), a unit of Allied-Signal Aerospace Company, a unit of Allied Signal, Inc. The report includes information provided by Garrett Ceramic Components, and the Norton Advanced Ceramics Company, (formerly Norton/TRW Ceramics), subcontractors to GAPD on the ATTAP. This report covers plans and progress on ceramics development for commercial automotive applications over the period 1 Jan. through 31 Dec. 1992. Project effort conducted under this contract is part of the DOE Gas Turbine Highway Vehicle System program. This program is directed to provide the U.S. automotive industry the high-risk, long-range technology necessary to produce gas turbine engines for automobiles with reduced fuel consumption, reduced environmental impact, and a decreased reliance on scarce materials and resources. The program is oriented toward developing the high-risk technology of ceramic structural component design and fabrication, such that industry can carry this technology forward to production in the 1990's. The ATTAP test bed engine, carried over from the previous AGT101 project, is being used for verification testing of the durability of next generation ceramic components, and their suitability for service at Reference Powertrain Design conditions. This document reports the technical effort conducted by GAPD and the ATTAP subcontractors during the fifth year of the project. Topics covered include ceramic processing definition and refinement, design improvements to the ATTAP test bed engine and test rigs, and the methodology development of ceramic impact and fracture mechanisms. Appendices include reports by ATTAP subcontractors in the development of silicon nitride materials and processes.

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NASA NTRS1996

Propulsion Selection for 85kft Remotely Piloted Atmospheric Science Aircraft

This paper describes how a 3 stage turbocharged gasoline engine was selected to power NASA's atmospheric science unmanned aircraft now under development. The airplane, whose purpose is to fly sampling instruments through targeted regions of the upper atmosphere at the exact location and time (season, time of day) where the most interesting chemistry is taking place, must have a round trip range exceeding 1000 km, carry a payload of about 500 lb to altitudes exceeding 80 kft over the site, and be able to remain above that altitude for at least 30 minutes before returning to base. This is a subsonic aircraft (the aerodynamic heating and shock associated with supersonic flight could easily destroy the chemical species that are being sampled) and it must be constructed so it will operate out of small airfields at primitive remote sites worldwide, under varying climate and weather conditions. Finally it must be low cost, since less than $50 M is available for its development. These requirements put severe constraints on the aircraft design (for example, wing loading in the vicinity of 10 psf) and have in turn limited the propulsion choices to already-existing hardware, or limited adaptations of existing hardware. The only candidate that could emerge under these circumstances was a propeller driven aircraft powered by spark ignited (SI) gasoline engines, whose intake pressurization is accomplished by multiple stages of turbo-charging and intercooling. Fortunately the turbocharged SI powerplant, owing to its rich automotive heritage and earlier intensive aero powerplant development during WWII, enjoys in addition to its potentially low development costs some subtle physical advantages (arising from its near-stochiometric combustion) that may make it smaller and lighter than either a turbine engine or a diesel for these altitudes. Just as fortunately, the NASA/industry team developing this aircraft includes the same people who built multi-stage turbocharged SI powerplants for unmanned military spyplanes in the early 1980's. Now adapting hardware developed for reconaissance at 65-70 kft to the interests of atmospheric science at 80-90 kft, their efforts should yield an aero powerplant that pushes the altitude limits of subsonic air breathing propulsion.

Bents, David J.↗

NASA NTRS2007

New Lubricants Protect Machines and the Environment

In 1994, NASA and Lockheed Martin Space Operations commissioned Sun Coast Chemicals of Daytona Inc to develop a new type of lubricant that would be safe for the environment and help "grease the wheels" of the shuttle-bearing launcher platform. Founded in 1989, Sun Coast Chemicals is known amongst the racing circuit for effective lubricants that help overcome engine and transmission problems related to heat and wear damage. In a matter of weeks, Sun Coast Chemical produced the biodegradable, high-performance X-1R Crawler Track Lube. In 1996, Sun Coast Chemical determined there was a market for this new development, and introduced three derivative products, Train Track Lubricant, Penetrating Spray Lubricant, and Biodegradable Hydraulic Fluid, and then quickly followed with a gun lubricant/cleaner and a fishing rod and reel lubricant. Just recently, Sun Coast introduced the X-1R Corporation, which folds the high-performance, environmentally safe benefits into a full line of standard automotive and specially formulated racing products. The entire X-1R automotive product line has stood up to rigorous testing by groups such as the American Society of Mechanical Engineers, the Swedish National Testing and Research Institute, the Department of Mechanical Engineering at Oakland University (Rochester, Michigan), and Morgan-McClure Motorsports (Abingdon, Virginia). The X-1R Corporation also markets "handy packs" for simple jobs around the house, consisting of a multi-purpose, multi-use lubricant and grease. In 2003, The X-1R Corporation teamed up with Philadelphia-based Penn Tackle Manufacturing Co., a leading manufacturer of fishing tackle since 1932, to jointly develop and market a line of advanced lubrication products for saltwater and freshwater anglers

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NASA NTRS1983

Multiaxial Cyclic Thermoplasticity Analysis with Besseling's Subvolume Method

A modification was formulated to Besseling's Subvolume Method to allow it to use multilinear stress-strain curves which are temperature dependent to perform cyclic thermoplasticity analyses. This method automotically reproduces certain aspects of real material behavior important in the analysis of Aircraft Gas Turbine Engine (AGTE) components. These include the Bauschinger effect, cross-hardening, and memory. This constitutive equation was implemented in a finite element computer program called CYANIDE. Subsequently, classical time dependent plasticity (creep) was added to the program. Since its inception, this program was assessed against laboratory and component testing and engine experience. The ability of this program to simulate AGTE material response characteristics was verified by this experience and its utility in providing data for life analyses was demonstrated. In this area of life analysis, the multiaxial thermoplasticity capabilities of the method have proved a match for the actual AGTE life experience.

Mcknight, R. L.↗

NASA NTRS1983

Overview of State-Of-The-Art Flywheel Technology

The technology and applications evaluation task focuses on defining performance and cost requirements for flywheels in the various areas of application. To date the DOE program has focused on automotive applications. The composite materials effort entails the testing of new commercial composites to determine their engineering properties. The rotor and containment development work uses data from these program elements to design and fabricate flywheels. The flywheels are then tested and their performance is evaluated to indicate possible areas for improvement. Once a rotor was fully developed it is transferred to the private sector.

Olszewski, M.↗

NASA NTRS1984

Summary results of the DOE flywheel development effort

The technology and applications evaluation task focuses on defining performance and cost requirements for flywheels in the various areas of application. To date the DOE program has focused on automotive applications. The composite materials effort entails the testing of new commercial composites to determine their engineering properties. The rotor and containment development work uses data from these program elements to design and fabricate flywheels. The flywheels are then tested at the Oak Ridge Flywheel Evaluation Laboratory and their performance is evaluated to indicate possible areas for improvement. Once a rotor has been fully developed it is transferred to the private sector.

Olszewski, M.↗