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

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At least 325 records · Page 18

Safety Expertise and the Perils of Novelty

Emerging aviation markets such as urban air mobility are giving rise to new technologies and means of operation. However, novelty may hide ‘unknown unknowns,’ raising new hazards. This paper examines how expertise and safety techniques enable transformative technologies such as reduced crew operations, hybrid wing-borne and rotor-born flight, federated air traffic services, and urban operations. We explore how analysts use expertise to address common-cause failures, collect and interpret safety data, and perform exacting tradeoffs between dissimilarity, redundancy, independence, and diversity (human, process lifecycle, or otherwise) to ensure safety. When novelty is present, analysts might not possess the expertise needed to fully understand the implications of design decisions and tradeoffs being made, especially in early lifecycle phases, on emergent properties such as safety. Safety expertise must be carefully cultivated. The conflicting views of safety experts must be unpacked to identify the divergence in fundamental assumptions, models, means, and methods that may be causing them. Once systems venture beyond the basis of what safety expertise can reliably guarantee, projects take on risk that must be managed. The paper contains key takeaways and actionable recommendations for novel OEMs and regulators touching on topics such as robust monitoring; clear and transparent reporting; incremental approaches to fielding novel systems in hazard-rich, risk-tolerant environments; the cultivation of safety culture and expertise in an organization; and the use of scientific study to reduce epistemic uncertainty in novel operations with new technologies. Since excessive novelty in aviation can undermine the current foundation of safety, humility and incrementalism are necessary to enable emerging aviation markets safely.

safety expertise↗

Method Development for Experimental Characterization of Dynamic Strength of Aluminum Structures

Space Flight Hardware (SFH) experiences intense vibratory loading during flight, which only lasts a few minutes. When determining the appropriate size of these components to withstand such loading without becoming damaged (plastically deforming or breaking), standard design practice is to assume that the peak dynamic loads are applied statically. In doing so, the resulting stress is compared against a material strength parameter obtained from a quasi-static experiment. Since the near-peak stresses are only experienced over a small fraction of time in reality, this approach leads to design conservatism that unnecessarily increases structural mass as well as the associated inefficiency and financial cost. In an effort to modernize engineering design standards to appropriately consider the higher practical strength of dynamically loaded structures, this overarching research project seeks to develop an experimental test procedure for quantifying the dynamic strength of metallic alloys as a function of excitation frequency. In the ideal case, the characterization test would include an in-situ method for monitoring the onset and progression of plastic deformation of the test specimen undergoing vibratory loading. These new tests are designed to be high intensity (forcing amplitude), short term (60 seconds at full amplitude), and cyclic in nature (sinusoidal excitation via attached stinger to an otherwise cantilevered beam). In addition, the initial metallic alloy under investigation is 6061 aluminum, due to its wide use and applicability for SFH. Thus far, the most promising monitoring method under development with live-capacity is to track hysteresis behavior of the beam from power dissipation trends, calculated via force (from transducer on excitation stinger) and velocity (measurements from Laser Doppler Vibrometer) data and work to distinguish between elastic and plastic features. As a key component of this ongoing method development, any pseudo-live indication of plasticity can be corroborated against the outcome of a pre-post assessment of damage via macroscopic evaluation of beam geometry (i.e. assessing any permanent change in the beam’s tip deflection). Support for experimental design decisions as well as dynamic strength data from tests with excitation frequencies of 10, 40, and 55 Hz will be discussed. This work contributes to the foundation for a new type of vibration-based characterization experiments and generates initial data on the functional strength of 6061 aluminum under the conditions considered. Keywords: vibrations, plastic deformation, aluminum

vibrations↗

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was implemented to offer an efficient framework for determining material characteristics from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enable parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM). SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography or other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗

Hybrid CFD Engineering Model of Plume Induced Erosion and Crater Formation During Descent of Lunar Landers

With rapidly increased worldwide interest in landing on the moon, the issue of Plume Surface Interactions (PSI) is gaining attention. Hazards posed by lander plume induced dust and debris, as well as landing site deformation can be mitigated when better understood through predictive simulations. As simulation enabling computational power continues to increase, hybrid Computational Fluid Dynamics (CFD)/Engineering models provide the immediate ability to conduct parametric/trade studies driving design decisions for landers. Reduced order erosion engineering models apply correlations of the surface erosion rate to the plume induced surface forces with the correlations anchored to flight observations from Apollo LM landings. The MSFC propulsion fluid dynamics branch has developed such a hybrid model for predicting the plume induced viscous erosive regression of the Lunar surface beneath a landing vehicle. The (Descent Interpolated Gas Granular Erosion Model) DIGGEM was originally implemented as a post processing tool to calculate induced erosion rates through vehicle descent using CFD solutions of the vehicle plume at several fixed altitudes. This capability has since been advanced in the Loci/Chem-DIGGEM model to allow transient, moving vehicle, fully coupled viscous erosion modeling of vehicle descent PSI. This model has recently been used to make preflight predictions of the erosive regression of the ground beneath a Commercial Lunar Payload Services (CLPS) vehicle in support of measurements to be made by the Stereo Cameras for Lunar Plume Surface Studies (SCALPSS) instrument.

Plume Surface Interaction↗

The Porous Microstructure Analysis (PuMA) software

The open-source Porous Microstructure Analysis (PuMA) software was created to offer an efficient framework for determining material properties from 3D microstructures. Its development was inspired by progress in X-ray microtomography, an imaging technology that captures the internal structure of materials in 3D, and even in a 4D temporal context. Over recent years, this method has transformed the domain of materials science due to its capability to non-destructively examine material microstructures while presenting digital data about their geometrical details. It has provided insights into materials relevant to several NASA missions, including heatshields, parachute fabrics, meteorites, and other advanced composites. PuMA, in its current version 3, delivers an array of features, spanning from basic geometric insights of a microstructure to intricate anisotropic thermo-elastic and chemical behavior. Specifically, the software evaluates morphological attributes (specific surface area, volume fractions, mean intercept lengths, orientation) and physical characteristics (conductivity, elasticity, permeability, and tortuosity). Additionally, it can model material degradation processes, such as oxidation and surface chemistry interactions. The software can generate synthetic microstructures, from straightforward geometrical designs to intricate woven and non-woven geometries. Coupling material generation and characterization enables parametric studies and sensitivity analysis to optimize the microstructural performance and inform design decisions and reliability assessment based on uncertainty quantification. A recent addition to PuMA includes the TomoSAM plugin, devised to incorporate the cutting-edge Segment Anything Model (SAM) into our image segmentation workflow. SAM is a promptable deep learning model that can identify objects and create image masks in a zero-shot manner, based only on a few user clicks. The synergy between these tools aids in the segmentation of complex 3D datasets from tomography and other imaging techniques, which would otherwise require a laborious manual segmentation process.

Tomography↗

Nonlinear Dynamic Analyses of STS-1 Forward RCS Oxidizer Tank Structural Failure

At liftoff of the first Space Shuttle mission, a strong ignition overpressure pulse excited the stack. The frequency of the experienced pressure wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. As result of this unexpected loading, an oxidizer tank support strut in the orbiter’s forward reaction control system module failed in buckling under axial compression, which could have led to loss of the mission, crew, and vehicle. This incident is investigated in more detail using linear and nonlinear finite element analyses, complementing previous analyses with classical structural mechanics. The results of these analyses are examined to provide additional insight into the accident and to better inform future design decisions for modern space vehicle systems and structures.

Space Shuttle↗

Hybrid CFD Engineering Model of Plume Induced Erosion and Crater Formation During Descent of Lunar Landers

With rapidly increased worldwide interest in landing on the moon, the issue of Plume Surface Interactions (PSI) is gaining attention. Hazards posed by lander plume induced dust and debris, as well as landing site deformation can be mitigated when better understood through predictive simulations. As simulation enabling computational power continues to increase, hybrid Computational Fluid Dynamics (CFD)/Engineering models provide the immediate ability to conduct parametric/trade studies driving design decisions for landers. Reduced order erosion engineering models apply correlations of the surface erosion rate to the plume induced surface forces with the correlations anchored to flight observations from Apollo LM landings. The MSFC propulsion fluid dynamics branch has developed such a hybrid model for predicting the plume induced viscous erosive regression of the Lunar surface beneath a landing vehicle. The (Descent Interpolated Gas Granular Erosion Model) DIGGEM was originally implemented as a post processing tool to calculate induced erosion rates through vehicle descent using CFD solutions of the vehicle plume at several fixed altitudes. This capability has since been advanced in the Loci/Chem-DIGGEM model to allow transient, moving vehicle, fully coupled viscous erosion modeling of vehicle descent PSI. This model has recently been used to make preflight predictions of the erosive regression of the ground beneath a Commercial Lunar Payload Services (CLPS) vehicle in support of measurements to be made by the Stereo Cameras for Lunar Plume Surface Studies (SCALPSS) instrument.

Plume Surface Interaction↗

Nonlinear Dynamic Analyses of STS-1 Forward RCS Oxidizer Tank Structural Failure

At liftoff of the first Space Shuttle mission, a strong ignition overpressure pulse excited the stack. The frequency of the experienced pressure wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. As result of this unexpected loading, an oxidizer tank support strut in the orbiter’s forward reaction control system module failed in buckling under axial compression, which could have led to loss of the mission, crew, and vehicle. This incident is investigated in more detail using linear and nonlinear finite element analyses, complementing previous analyses with classical structural mechanics. The results of these analyses are examined to provide additional insight into the accident and to better inform future design decisions for modern space vehicle systems and structures.

Space Shuttle↗

Reach Performance Using Touchscreens Under G and Vibration Conditions

This presentation summarizes prior results from human-in-the-loop experiments that measured the accuracy and precision of human reaches to a touchscreen under a range of altered gravitational and vibrational conditions. From the data, this presentation proposes a method for estimating the worst-case reach accuracy and precision during lunar landings with an eye towards supporting engineering design decisions about human control interfaces and crew operations for lunar missions.

human performance↗

Method Development for Experimental Characterization of Dynamic Strength of Aluminum Structures

Space Flight Hardware (SFH) experiences intense vibratory loading during flight, which only lasts a few minutes. When determining the appropriate size of these components to withstand such loading without becoming damaged, standard design practice is to assume that the peak dynamic loads are applied statically. In doing so, the resulting stress is compared against a material strength parameter obtained from a quasi-static experiment. Since the near-peak stresses are only experienced over a small fraction of time in reality, this approach leads to design conservatism that unnecessarily increases structural mass as well as the associated inefficiency and financial cost. In an effort to modernize engineering design standards to appropriately consider the higher practical strength of dynamically loaded structures, this overarching research project seeks to develop an experimental test procedure for quantifying the dynamic strength of metallic alloys as a function of excitation frequency. In the ideal case, the characterization test would include an in-situ method for monitoring the onset and progression of plastic deformation of the test specimen undergoing vibratory loading. These new tests are designed to be high intensity (forcing amplitude), short term (60 seconds at full amplitude), and cyclic in nature (sinusoidal excitation via attached stinger to an otherwise cantilevered beam). In addition, the initial alloy under investigation is 6061 aluminum, due to its wide use and applicability for SFH. Thus far, the primary candidate under development with live-capacity is to track hysteresis behavior of the beam from power dissipation trends, calculated via force (from transducer on excitation stinger) and velocity (measurements from Laser Doppler Vibrometer) data and work to distinguish between elastic and plastic features. As a key component of this ongoing method development, any pseudo-live indication of plasticity could be corroborated against the outcome of a pre-post assessment of damage via macroscopic evaluation of beam geometry (i.e. assessing any permanent change in the beam’s tip deflection). Support for experimental design decisions as well as dynamic strength data from tests with excitation frequencies of 10, 40, and 55 Hz will be discussed. This work contributes to the foundation for a new type of vibration-based characterization experiments and generates initial data on the functional strength of 6061 aluminum under the conditions considered.

vibrations, plastic deformation, aluminum, testing↗

Historical Retrospective on Orion GNC Design

On November 16, 2022, Artemis I successfully launched and began a nearly 26-day journey returning a human-rated spacecraft to the Moon for the first time in fifty years. The mission was a huge success and once again the world's attention was focused on the Moon. This paper will take a step back in time over the seventeen-plus years of design and development of the Orion Guidance Navigation and Control (GNC) system that carried the spacecraft 1.4 million miles around the Moon and landed safely back on earth off the coast of San Diego California. Key design decisions (good and not so good) and "first-ever" capabilities will be chronicled. This paper will explore such things as the most advanced on-board targeting system ever flown on a spacecraft, never-been-done-before autonomous planetary Optical Navigation, and the first-ever truly skip entry guided to the desired target within a few miles.

Guidance Navigation and Control↗

Historical Retrospective on Orion GNC Design

On November 16, 2022, Artemis I successfully launched and began a nearly 26-day journey returning a human-rated spacecraft to the Moon for the first time in fifty years. The mission was a huge success and once again the world's attention was focused on the Moon. This paper will take a step back in time over the seventeen-plus years of design and development of the Orion Guidance Navigation and Control (GNC) system that carried the spacecraft 1.4 million miles around the Moon and landed safely back on earth off the coast of San Diego California. Key design decisions (good and not so good) and "first-ever" capabilities will be chronicled. This paper will explore such things as the most advanced on-board targeting system ever flown on a spacecraft, never-been-done-before autonomous planetary Optical Navigation, and the first-ever truly skip entry guided to the desired target within a few miles.

Guidance Navigation and Control↗

Qualitative Data Coding of User Experience with an Urban Air Mobility Fleet Manager Interface

The NASA Aeronautics Research Mission Directorate created the High Density Vertiplex (HDV) project to integrate and evaluate a prototype Urban Air Mobility (UAM) ecosystem. Part of the HDV testing environment included a prototype operator user interface called the Fleet Manager Interface (FMI). In 2023, HDV conducted flight testing with the FMI during which a user experience (UX) study was performed to assess the quality of UX and elicit design recommendations. As a result, a large database of open-ended, qualitative responses was generated and then coded using a new qualitative data coding technique called Directive String Coding, which used a blended coding approach to generate actionable heuristics that stakeholders (e.g., researchers, UI designers, software developers) could use to answer specific research questions and make future design decisions. The key themes that arose from the coded responses showed that the UX was pleasant, system notifications should be more salient, and information across multiple screens should be integrated into a central display. As the Fleet Manger operational role is still being defined, it is vital to increase our understanding of the tools and capabilities needed for such a role. The results from HDV work will eventually feed into standards for vertiport operations that will enable safe and scalable UAM operations in the United States.

high density vertiplex↗

Design Implications of Rotordynamics and Mass Balancing on a 1.4 MW Partially Superconducting Machine

To ensure that rotating machines operate without excessive bearing loads, vibration, and dynamic stresses, their design must consider rotordynamic response and provisions for mass balancing of rotors, even when their rotational speeds are modest. This paper presents a rotordynamics design study for a 1.4 MW, partially superconducting electric machine proposed for electrified aircraft propulsion – NASA’s High Efficiency Megawatt Motor (HEMM). The study includes the selection of mass balancing grade and mount and bearing stiffnesses to yield satisfactory critical speeds, deflection, and unbalance force, and predictions of the expected mass unbalance caused by the superconducting rotor coils. The impact of the machine’s number of rotor poles on expected mass unbalance is also quantified. Design decisions and lessons learned are discussed.

hybrid electric aircraft↗

Design Implications of Rotordynamics and Mass Balancing on a 1.4 MW Partially Superconducting Machine

To ensure that rotating machines operate without excessive bearing loads, vibration, and dynamic stresses, their design must consider rotordynamic response and provisions for mass balancing of rotors, even when their rotational speeds are modest. This paper presents a rotordynamics design study for a 1.4 MW, partially superconducting electric machine proposed for electrified aircraft propulsion – NASA’s High Efficiency Megawatt Motor (HEMM). The study includes the selection of mass balancing grade and mount and bearing stiffnesses to yield satisfactory critical speeds, deflection, and unbalance force, and predictions of the expected mass unbalance caused by the superconducting rotor coils. The impact of the machine’s number of rotor poles on expected mass unbalance is also quantified. Design decisions and lessons learned are discussed.

hybrid electric aircraft↗

TBIRD, a rapid prototyping approach for design, assembly, and test of a LEO-to-ground lasercom CubeSat

The TeraByte InfraRed Delivery (TBIRD) system is a 3U payload on a 6U CubeSat launched in May 2022 which has now demonstrated space to ground links of >1 Terabyte (TB) per pass at a max data rate of 200Gbps. As a CubeSat mission, the development of the TBIRD payload was focused on low SWaP and a “rapid prototyping” approach which accepted higher risks to accelerate the schedule and reduce costs. The optomechanical design process followed standard in-house processes to develop a system that would be robust to LEO environmental loads, with a focus on the stability of the transmit (Tx) and receive (Rx) channel performance metrics. The driving requirement of maintaining 20μrad pointing error between the TX and Rx channels forced specific attention to thermal and mechanical load changes over operational conditions, which drove major design decisions. This paper describes some of engineering challenges overcome and approaches used to make TBIRD a successful program, as well as some of the tradeoffs of rapid prototyping precision optical payloads. TBIRD successfully met and exceeded the total downlink requirements listed above, with a bandwidth of 200Gbps and a total downlink of 4.8TB of information in a single pass.

TBIRD↗

Qualitative Data Coding of User Experience with an Urban Air Mobility Fleet Manager Interface

The NASA Aeronautics Research Mission Directorate created the High Density Vertiplex (HDV) project to integrate and evaluate a prototype Urban Air Mobility (UAM) ecosystem. Part of the HDV testing environment included a prototype operator user interface called the Fleet Manager Interface (FMI). In 2023, HDV conducted flight testing with the FMI during which a user experience (UX) study was performed to assess the quality of UX and elicit design recommendations. As a result, a large database of open-ended, qualitative responses was generated and then coded using a new qualitative data coding technique called Directive String Coding, which used a blended coding approach to generate actionable heuristics that stakeholders (e.g., researchers, UI designers, software developers) could use to answer specific research questions and make future design decisions. The key themes that arose from the coded responses showed that the UX was pleasant, system notifications should be more salient, and information across multiple screens should be integrated into a central display. As the Fleet Manger operational role is still being defined, it is vital to increase our understanding of the tools and capabilities needed for such a role. The results from HDV work will eventually feed into standards for vertiport operations that will enable safe and scalable UAM operations in the United States.

high density veriplex↗

Preliminary Design of Robotic Control Software for Mars Sample Return - Capture, Containment, and Return System

The Mars Sample Return (MSR) campaign aims to acquire and return to Earth a set of Mars samples for investigation in terrestrial laboratories. Mars 2020 has collected an adequate number of samples and deposited them in sealed sample tubes at a designated Martian depot. Sample tubes will be placed in cylindrical containers called Orbiting Samples (OS) by the Perseverance Rover, and later brought to Earth by the Earth Return Orbiter (ERO) and the MSR - Capture, Containment, and Return System (CCRS). Robot Software (RSW) is a set of software processes for commanding and monitoring the avionics that controls robotic mechanisms designed to sterilize and install OS into Earth Entry System (EES) for return to Earth. This paper describes a preliminary design of RSW including motion modes, architecture, and finite state machine. Additionally, software engineering procedures and testing of RSW is provided. A preliminary performance analysis is presented and the paper concludes with future work and a discussion of design decisions.

MSR↗