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NASA NTRS1992

Extensional and Flexural Waves in a Thin-Walled Graphite/Epoxy Tube

Simulated acoustic emission signals were induced in a thin-walled graphite/epoxy tube by means of lead breaks (Hsu-Neilsen source). The tube is of similar material and layup to be used by NASA in fabricating the struts of Space Station Freedom. The resulting waveforms were detected by broad band ultrasonic transducers and digitized. Measurements of the velocities of the extensional and flexural modes were made for propagation directions along the tube axis (0 degrees), around the tube circumference (90 degrees) and at an angle of 45 degrees. These velocities were found to be in agreement with classical plate theory.

Prosser, William H.↗

NASA NTRS2004

Issues on Fabrication and Evaluation of SiC/SiC Tubes With Various Fiber Architectures

SiC/SiC engine components, high-modulus Sylramic-iBN SiC fiber tows were used to form nine different tubular architectural preforms with 13 mm (0.5 in.) inner diameter and lengths of approx. 75 and 230 mm (approx. 3 and approx, 9 in.). The thin-walled preforms were then coated with a BN interphase and densified with a hybrid SiC matrix using nearly the same process steps previously established for slurry-cast melt-infiltrated Sylramic-iBN/BN/SiC flat panels. The as-fabricated CMC tubes were microstructurally evaluated and tested for tensile hoop and flexural behavior, and some of the tubes were also tested in a low-pressure burner rig test with a high thru-thickness thermal gradient. To date, four general tube scale-up issues have been identified: greater CVI deposits on outer wall than inner wall; increased ply thickness and reduced fiber fraction; poor test standards for accurately determining the hoop strength of a small-diameter tube; and poor hoop strength for architectures with seams or ply ends. The underlying mechanisms and possible methods for their minimization are discussed.

Yun, H. M.↗

NASA NTRS2004

Evaluation of High Temperature Knitted Spring Tubes for Structural Seal Applications

Control surface seals are crucial to current and future space vehicles, as they are used to seal the gaps surrounding body flaps, elevons, and other actuated exterior surfaces. During reentry, leakage of high temperature gases through these gaps could damage underlying lower temperature structures such as rudder drive motors and mechanical actuators, resulting in impaired vehicle control. To be effective, control surface seals must shield lower temperature structures from heat transfer by maintaining sufficient resiliency to remain in contact with opposing sealing surfaces through multiple compression cycles. The current seal exhibits significant loss of resiliency after a few compression cycles at elevated temperatures (i.e., 1900 F) and therefore would be inadequate for advanced space vehicles. This seal utilizes a knitted Inconel X-750 spring tube as its primary resilient element. As part of a larger effort to enhance seal resiliency, researchers at the NASA Glenn Research Center performed high temperature compression testing (up to 2000 F) on candidate spring tube designs employing material substitutions and modified geometries. These tests demonstrated significant improvements in spring tube resiliency (5.5x better at 1750 F) through direct substitution of heat treated Rene 41 alloy in the baseline knit design. The impact of geometry modification was minor within the range of parameters tested, however trends did suggest that moderate resiliency improvements could be obtained by optimizing the current spring tube geometry.

Taylor, Shawn C.↗

NASA NTRS2006

A Simple Test to Determine the Effectiveness of Different Braze Compositions for Joining Ti-Tubes to C/C Composite Plates

A simple tube-plate joint tensile test was implemented to compare the effectiveness of commercial brazes, namely, TiCuNi, TiCuSil, and Cu-ABA, used for bonding Ti-tubes joined to C-C composite plates. The different braze systems yielded different; yet, repeatable results. The Cu-ABA system proved to have about twice the load-carrying ability of the other two systems due to the fact that the bonded area between the braze material and the C-C plate was largest for this system. The orientation of the surface fiber tows also had a significant effect on load-carrying ability with tows oriented perpendicular to the tube axis displaying the highest failure loads. Increasing the process load and modifying the surface of the C-C plate by grooving out channels for the Ti-Tube to nest in resulted in increased load-carrying ability for the TiCuSil and Cu-ABA systems due to increased bonded area and better penetration of the braze material into the C-C composite.

Morscher, Gregory N.↗

NASA NTRS2006

Parametric Investigation of Thrust Augmentation by Ejectors on a Pulsed Detonation Tube

A parametric investigation has been made of thrust augmentation of a 1 in. diameter pulsed detonation tube by ejectors. A set of ejectors was used which permitted variation of the ejector length, diameter, and nose radius, according to a statistical design of experiment scheme. The maximum augmentation ratios for each ejector were fitted using a polynomial response surface, from which the optimum ratios of ejector diameter to detonation tube diameter, and ejector length and nose radius to ejector diameter, were found. Thrust augmentation ratios above a factor of 2 were measured. In these tests, the pulsed detonation device was run on approximately stoichiometric air-hydrogen mixtures, at a frequency of 20 Hz. Later measurements at a frequency of 40 Hz gave lower values of thrust augmentation. Measurements of thrust augmentation as a function of ejector entrance to detonation tube exit distance showed two maxima, one with the ejector entrance upstream, and one downstream, of the detonation tube exit. A thrust augmentation of 2.5 was observed using a tapered ejector.

Wilson, Jack↗

NASA NTRS2006

Further Investigations of High Temperature Knitted Spring Tubes for Advanced Control Surface Seal Applications

Knitted metallic spring tubes are the structural backbones that provide resiliency in control surface seals for use on current and future reusable space launch vehicles. Control surface seals fill the space between movable control surfaces such as body flaps, rudders and elevons, and the static body structures to which they are attached. These seals must remain in continuous contact with opposing surfaces to prevent the ingestion of damaging hot gases encountered during atmospheric re-entry. The Inconel X-750 (Special Metals Corporation) spring tube utilized in the baseline control surface seal shows significant resiliency loss when compressed at temperatures as low as 1200 F. High temperature compression testing and microstructural analysis show that creep is the dominant deformation mechanism leading to permanent set and resiliency loss in tested spring tube samples. Additional evaluation using a structured design of experiments approach shows that spring tube performance, primarily high temperature resiliency, can be enhanced through material substitution of Rene 41 (Allvac) alloy (for the baseline Inconel X-750 material) when coupled with specialized thermal processing.

Taylor, Shawn C.↗

NASA NTRS2008

Parametric Study of High Frequency Pulse Detonation Tubes

This paper describes development of high frequency pulse detonation tubes similar to a small pulse detonation engine (PDE). A high-speed valve injects a charge of a mixture of fuel and air at rates of up to 1000 Hz into a constant area tube closed at one end. The reactants detonate in the tube and the products exit as a pulsed jet. High frequency pressure transducers are used to monitor the pressure fluctuations in the device and thrust is measured with a balance. The effects of injection frequency, fuel and air flow rates, tube length, and injection location are considered. Both H2 and C2H4 fuels are considered. Optimum (maximum specific thrust) fuel-air compositions and resonant frequencies are identified. Results are compared to PDE calculations. Design rules are postulated and applications to aerodynamic flow control and propulsion are discussed.

Cutler, Anderw D.↗

NASA NTRS2011

Miniature, low-power X-ray tube using a microchannel electron generator electron source

Embodiments of the invention provide a novel, low-power X-ray tube and X-ray generating system. Embodiments of the invention use a multichannel electron generator as the electron source, thereby increasing reliability and decreasing power consumption of the X-ray tube. Unlike tubes using a conventional filament that must be heated by a current power source, embodiments of the invention require only a voltage power source, use very little current, and have no cooling requirements. The microchannel electron generator comprises one or more microchannel plates (MCPs), Each MCP comprises a honeycomb assembly of a plurality of annular components, which may be stacked to increase electron intensity. The multichannel electron generator used enables directional control of electron flow. In addition, the multichannel electron generator used is more robust than conventional filaments, making the resulting X-ray tube very shock and vibration resistant.

Elam, Wm. Timothy↗

NASA NTRS2012

Calibration of PCB-132 Sensors in a Shock Tube

While PCB-132 sensors have proven useful for measuring second-mode instability waves in many hypersonic wind tunnels, they are currently limited by their calibration. Until now, the factory calibration has been all that was available, which is a single-point calibration at an amplitude three orders of magnitude higher than a second-mode wave. In addition, little information has been available about the frequency response or spatial resolution of the sensors, which is important for measuring high-frequency instability waves. These shortcomings make it difficult to compare measurements at different conditions and between different sensors. If accurate quantitative measurements could be performed, comparisons of the growth and breakdown of instability waves could be made in different facilities, possibly leading to a method of predicting the amplitude at which the waves break down into turbulence, improving transition prediction. A method for calibrating the sensors is proposed using a newly-built shock tube at Purdue University. This shock tube, essentially a half-scale version of the 6-Inch shock tube at the Graduate Aerospace Laboratories at Caltech, has been designed to attain a moderate vacuum in the driven section. Low driven pressures should allow the creation of very weak, yet still relatively thin shock waves. It is expected that static pressure rises within the range of second-mode amplitudes should be possible. The shock tube has been designed to create clean, planar shock waves with a laminar boundary layer to allow for accurate calibrations. Stronger shock waves can be used to identify the frequency response of the sensors out to hundreds of kilohertz.

Berridge, Dennis C.↗

NASA NTRS2016

A Multi-Dimensional Heat Transfer Model of a Tie-Tube and Hexagonal Fuel Element for Nuclear Thermal Propulsion

The Space Capable Cryogenic Thermal Engine (SCCTE) effort considers a nuclear thermal rocket design based around a Low-Enriched Uranium (LEU) design fission reactor. The reactor core is comprised of bundled hexagonal fuel elements that directly heat hydrogen for expansion in a thrust chamber and hexagonal tie-tubes that house zirconium hydride moderator mass for the purpose of thermalizing fast neutrons resulting from fission events. Created 3D steady state Hex fuel rod model with 1D flow channels. Hand Calculation were used to set up initial conditions for fluid flow. The Hex Fuel rod uses 1D flow paths to model the channels using empirical correlations for heat transfer in a pipe. Created a 2-D axisymmetric transient to steady state model using the CFD turbulent flow and Heat Transfer module in COMSOL. This model was developed to find and understand the hydrogen flow that might effect the thermal gradients axially and at the end of the tie tube where the flow turns and enters an annulus. The Hex fuel rod and Tie tube models were made based on requirements given to us by CSNR and the SCCTE team. The models helped simplify and understand the physics and assumptions. Using pipe correlations reduced the complexity of the 3-D fuel rod model and is numerically more stable and computationally more time-efficient compared to the CFD approach. The 2-D axisymmetric tie tube model can be used as a reference "Virtual test model" for comparing and improving 3-D Models.

Gomez, C. F.↗

NASA NTRS2018

One-Dimensional Modeling Methodology for Shock Tubes: Application to the EAST Facility

In this work, a one-dimensional methodology for simulating shock tubes is developed. The model accounts for the viscous interactions of the shock with the shock tube wall by adding an area change source term in the 1-D conservation equations corresponding to the boundary layer growth. This source term corresponds to the mass and energy going into the boundary layer. The boundary layer growth is computed using a simple model with a scaling factor. This scale factor is used to tailor a solution to match the deceleration profile of a shock tube test. In doing so, not only will the source term take into account boundary layer losses, it will also cover any effect due to radiative cooling loses from the gas. For this study, the Electric Arc Shock Tube(EAST) facility at NASA Ames Research Center is modeled for Earth reentry conditions. The purpose of this paper is to investigate if anomalies identified for certain conditions in the EAST data are due to shock deceleration. These anomalies include measuring electron number density above equilibrium predictions and observing that radiance profiles can continually increase behind the shock, never reach steady state, for certain shots (typically those less than 10 km/s). An eleven species air mixture is chosen to study the chemistry of the flow. Comparisons of the simulations to the experimental results are presented. Good agreement with the shock deceleration profiles was achieved by tuning in the boundary layer scale factor. The temperature as well as electron number density increases behind the shock, as has also been observed in the experiments. Finally, radiance comparisons between results from NEQAIR and experiments also show good agreement for some shots, but significant discrepancies are still observed for others.

Sharma, Maitreyee↗

NASA NTRS2018

One-Dimensional Modeling Methodology for Shock Tubes: Application to the EAST Facility

Sharma, Maitreyee↗

NASA NTRS2019

Numerical Modeling of Boiling in a Heated Tube

This paper presents numerical models of boiling in a heated tube using the Generalized Fluid System Simulation Program (GFSSP), a finite-volume-based general-purpose flow network code developed at NASA/Marshall Space Flight Center. The heated tube is discretized into a one-dimensional array of nodes and branches to represent the flow of liquid and vapor in a tube with a prescribed pressure differential. The solid wall is also discretized into solid nodes and conductors to allow for heat transfer between the wall and the fluid. The conservation equations of mass, momentum, and energy of the fluid are solved simultaneously with the energy conservation equation for the solid wall. Two experimental configurations of fluid flowing in a vertical tube have been simulated, one with water and the other with liquid hydrogen. This paper compares experimental data with numerical predictions based on four different published correlations for boiling heat transfer coefficients. Three of these correlations are applicable to the saturated vertical flow conditions of the experiments. One of them is applicable to film boiling and has been used for the liquid hydrogen experiment, which was in film boiling regime. For the case of boiling water, the predictions of wall temperatures using the boiling heat transfer correlations agreed well with the experimental results. However, in the case of boiling hydrogen larger discrepancies were observed between the experimental data and numerical predictions.

Majumdar, Alok↗

NASA NTRSDate not supplied

TO252: Parabolic Flight Demonstration of Fluid Dispensing Tube Performance Limits for Drop Delivery

Ring Shear Drop (RSD) ISS flight hardware failed to pin sample fluid drops between two rings, likely due to dynamic instability inherent to the dispensing tube (D-Tube) design. The first parabolic flight tested 5 D-tube tip designs with two bounding surface tension fluids, enabling an engineering design decision. D-tube Tip Cage Design was selected based on the November 2020 parabolic flight test data. Flight Operations Program (FOP) approved a reflight proposal to include 2 parabolic flight days during the April/May 2021 campaign with following objectives: • Validate ISS hardware flight design with actual flight fluids (test as you fly), demonstrating the ability to deliver 1” fluid drops in near-microgravity conditions. • Demonstrate pinning of 1” flight fluid drops: a secondary pinning ring is planned to be installed in the parabolic flight hardware to meet this objective. Fluid flow rates will also be varied as needed and as possible. • Provide data to validate computational models used to guide ISS operational deployment decisions and demonstrate the viability of the redesigned hardware to accommodate a range of future flight investigations. This presentation introduces highlights and lessons learned during this recent flight campaign for discussion in the Flight Opportunities Program Panel, “Leveraging Suborbital Flight Tests to Advance Science and Technology."

Sridhar Gorti↗

NASA NTRSDate not supplied

Proof Testing Aluminum and Titanium Thin-Walled Tubes for Aerospace Applications

Proof testing aerospace components aids in verifying the structural integrity of flight hardware. This process is often an important step in the certification process for critical parts. Though proof testing is a common practice at NASA and in industry, there is often a need to understand better the effectiveness of proof testing pressure systems discovering cracklike flaws or defects. Often proof tests are used in requirements and in practice as technical rationale for screening critical defects in a part in lieu of performing a non-destructive inspection. The intent of this work is to define proof test failure envelopes for thin-walled tubes composed of two materials: aluminum and titanium. Both materials are common in aerospace thin-walled tubing applications which is why these were the materials chosen for this study. The fracture mechanics software NASGRO was used to perform a parametric study on the effect of defects in thin-walled tubes subjected to proof testing. For both materials, the parameters varied in the NASGRO analyses were aspect ratio, proof test pressure, thickness, diameter, and flaw multiplier. With each case defined as a through crack or failure, the results were then pulled into MATLAB in order to parse through the data and produce failure envelope plots. Failure envelopes were created by meshing a surface in between the minimum proof pressure failing data points. As expected, based on material properties, the plots indicated the aluminum material would fail at much lower proof tests than the titanium. The parametric data and failure envelopes may be used as general qualitative insight on the effectiveness of proof testing thin-walled tubes of similar alloys.

Leah B Davis↗

NASA NTRSDate not supplied

MARS 2020 Backshell Radiative Heating Measurement and Shock Tube Verification

In February 2021, the Perseverance rover was brought to the surface of Mars by the Mars 2020 mission. A feature of the Mars 2020 capsule was instrumentation to measure its entry, descent and landing (EDL) with the so-called Mars EDL Instrumentation 2 (MEDLI2) [1]. The MEDLI2 introduced, among other things, backshell instrumentation, including a broadband radiometer. The radiometer was mounted on the leeside of the vehicle next to thermocouple plugs and a heat flux gauge. The data returned by the leeside MEDLI2 heat flux gauge is largely analogous to that measured by the COMARS gauge flown on the ExoMars Schiaparelli [2] entry in that it is measuring heat flux in an area that is entirely dominated by radiative heating. The COMARS measurement provided excellent validation of backshell radiative heating models for Mars entry, albeit at a limited number of points [3]. The MEDLI2 heat flux gauge measurement effectively confirmed the quality of the prediction, extended over the full trajectory, as will be presented in this paper. The MEDLI2 radiometer,however, was blocked by ablation products and suffered a loss of half of its signal. The second backshell heat flux gauge installed on the windside of the vehicle was also well predicted, although the heating had both radiative and convective contributions. It was desired to reproduce the conditions of the Mars 2020 entry via ground testing in the Electric Arc Shock Tube (EAST) at NASA Ames. Tests to verify stagnation line heating were previously reported in EAST, confirming the presence of shock layer radiation as the major discrepancy in heatshield temperature modelling [4]. Therefore, tests for stagnation line heating were not repeated. Instead, the shock tube informed bias method [5, 6] was used to identify test conditions that may produce similarity to streamlines that pass around the backside of the vehicle and are responsible for the radiation observed at the two heat flux gauge locations. This method was used to identify a range of velocities and densities in the shock tube that are relevant for confirming the radiative environment encountered. This paper reports the results obtained in the 10 cm diameter EAST shock tube, corresponding to later trajectory points at ambient pressures of 1.1-2.0 Torr and velocities from 1.2-3.5 km/s. The test series employed two primary diagnostics: emission spectroscopy and tunable diode laser absorption spectroscopy (TDLAS). The emission spectroscopy performed broadband measurements of the radiative emission of the 4.3 and 2.7 m bands of CO2 at flight similar conditions, obtaining both spectral and spatial data corresponding to the relaxation behind the shock front. The TDLAS measured the absorption of several lines of CO and CO2 and obtains species number densities and temperatures as a function of time behind the shock front. This paper will review highlights of this test series and analyses of the emission and absorption data. While the datasets generally show good agreement with predictions, a few discrepancies and items for additional investigation are identified and will be discussed

Brett A Cruden↗

NASA NTRSDate not supplied

PlanetarY Telemetric Helicopter for Investigation and Analysis (PYTHIA): A Rotorcraft for Martian Lava Tube Exploration

The PlanetarY Telemetric Helicopter for Investigation and Analysis (PYTHIA) project presents an early feasibility study into future Mars rotorcraft. With the success of Ingenuity and the current development of the Mars Sample Retrieval Helicopters, there is motivation to explore additional vehicle concepts for Mars exploration. This work presents an early conceptual design of a lava tube exploring quadrotor. The nominal mission for the PYTHIA quadrotor includes a two-phase in-depth exploration of one or mutliple lava tubes in the area of interest, Arsia Mons. A sizing analysis was completed using the NASA Design and Analysis of Rotorcraft (NDARC) tool. An eight-bladed quadrotor was selected based on the NDARC sizing sweeps. With preliminary vehicle and blade sizing completed, a flow visualization study was conducted. Two simulations were completed in Rotorcraft Computational Fluid Dynamics (RotCFD): one of the quadrotor alone and another in a lava tube. This paper introduces a baseline reference mission, preliminary vehicle design, and initial sizing analysis of a rotorcraft to explore Martian lava tubes.

PlanetarY↗

DOE OSTI2026

Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers

Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗