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NASA NTRS2012

Modeling Programs Increase Aircraft Design Safety

Flutter may sound like a benign word when associated with a flag in a breeze, a butterfly, or seaweed in an ocean current. When used in the context of aerodynamics, however, it describes a highly dangerous, potentially deadly condition. Consider the case of the Lockheed L-188 Electra Turboprop, an airliner that first took to the skies in 1957. Two years later, an Electra plummeted to the ground en route from Houston to Dallas. Within another year, a second Electra crashed. In both cases, all crew and passengers died. Lockheed engineers were at a loss as to why the planes wings were tearing off in midair. For an answer, the company turned to NASA s Transonic Dynamics Tunnel (TDT) at Langley Research Center. At the time, the newly renovated wind tunnel offered engineers the capability of testing aeroelastic qualities in aircraft flying at transonic speeds near or just below the speed of sound. (Aeroelasticity is the interaction between aerodynamic forces and the structural dynamics of an aircraft or other structure.) Through round-the-clock testing in the TDT, NASA and industry researchers discovered the cause: flutter. Flutter occurs when aerodynamic forces acting on a wing cause it to vibrate. As the aircraft moves faster, certain conditions can cause that vibration to multiply and feed off itself, building to greater amplitudes until the flutter causes severe damage or even the destruction of the aircraft. Flutter can impact other structures as well. Famous film footage of the Tacoma Narrows Bridge in Washington in 1940 shows the main span of the bridge collapsing after strong winds generated powerful flutter forces. In the Electra s case, faulty engine mounts allowed a type of flutter known as whirl flutter, generated by the spinning propellers, to transfer to the wings, causing them to vibrate violently enough to tear off. Thanks to the NASA testing, Lockheed was able to correct the Electra s design flaws that led to the flutter conditions and return the aircraft to safe flight. Today, all aircraft must have a flutter boundary 15 percent beyond the aircraft s expected maximum speed to ensure that flutter conditions are not encountered in flight. NASA continues to support research in new aircraft designs to improve knowledge of aeroelasticity and flutter. Through platforms such as Dryden Flight Research Center s Active Aeroelastic Wing (AAW) research aircraft, the Agency researches methods for in-flight validation of predictions and for controlling and taking advantage of aeroelastic conditions to enhance aircraft performance.

Source record↗

NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human‐rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30‐sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post‐processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one‐way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, Tracie↗

NASA NTRS1990

The procedure safety system

Telerobotic operations, whether under autonomous or teleoperated control, require a much more sophisticated safety system than that needed for most industrial applications. Industrial robots generally perform very repetitive tasks in a controlled, static environment. The safety system in that case can be as simple as shutting down the robot if a human enters the work area, or even simply building a cage around the work space. Telerobotic operations, however, will take place in a dynamic, sometimes unpredictable environment, and will involve complicated and perhaps unrehearsed manipulations. This creates a much greater potential for damage to the robot or objects in its vicinity. The Procedural Safety System (PSS) collects data from external sensors and the robot, then processes it through an expert system shell to determine whether an unsafe condition or potential unsafe condition exists. Unsafe conditions could include exceeding velocity, acceleration, torque, or joint limits, imminent collision, exceeding temperature limits, and robot or sensor component failure. If a threat to safety exists, the operator is warned. If the threat is serious enough, the robot is halted. The PSS, therefore, uses expert system technology to enhance safety thus reducing operator work load, allowing him/her to focus on performing the task at hand without the distraction of worrying about violating safety criteria.

Obrien, Maureen E.↗

NASA NTRS2005

History of the Development of Liquid-Applied Coatings for Protection of Reinforced Concrete

Corrosion of reinforcing steel in concrete is an insidious problem for structures at Kennedy Space Center (KSC). KSC is located on the coast of Florida in a highly corrosive atmosphere. Launch pads, highway bridge infrastructure, and buildings are strongly affected. To mitigate these problems, NASA initiated a development program for a Galvanic Liquid-Applied Coating System (GLACS). A breakthrough in this area would have great commercial value in transportation, marine and construction industry infrastructures. The patented NASA GLACS system has undergone considerable testing to meet the needs of commercialization. A moisture-cure coating gives excellent adhesion with ease of application compared to existing galvanic products on the market. The latest development, GalvaCori; can be sprayed or hand applied to almost any structure shape. A self-adhesive conductive tape system has been devised to simplify current collection within the coating areas. In testing programs, millivolt potential and milliamp output per square foot of anode have been closely studied at actual test sites. These two parameters are probably the most challenging items of a resin-based, room-temperature-applied, galvanic coating. Extensive re-formulation has resulted in a system that provides the needed polarization for catholic protection of reinforcing steel in concrete in a variety of structure environments. The rate of corrosion of rebar in concrete is greatly affected by the environment of the structure. In addition to this, for any given concrete structure; moisture level, carbonization, and chloride contamination influences the rate of rebar corrosion. Similarly, the cathodic protection level of galvanic systems is also dependent on the moisture level of the concrete. GalvaCorr is formulated to maintain galvanic activity as the moisture level of the structure declines. GalvaCorr is available as a three-part kit. The mixing step requires about ten minutes. The viscosity can be easily adjusted to meet the application needs. The pot or working life is four to six hours, depending on the temperature. GalvaCorr can be thought of as a spray-on coating, battery ready to provide up to -1.4 volts (relative to CSE) of cathodic protection (CP) potential.

Curran, Joseph J.↗

NASA NTRS2003

Microbatteries for Combinatorial Studies of Conventional Lithium-Ion Batteries

Integrated arrays of microscopic solid-state batteries have been demonstrated in a continuing effort to develop microscopic sources of power and of voltage reference circuits to be incorporated into low-power integrated circuits. Perhaps even more importantly, arrays of microscopic batteries can be fabricated and tested in combinatorial experiments directed toward optimization and discovery of battery materials. The value of the combinatorial approach to optimization and discovery has been proven in the optoelectronic, pharmaceutical, and bioengineering industries. Depending on the specific application, the combinatorial approach can involve the investigation of hundreds or even thousands of different combinations; hence, it is time-consuming and expensive to attempt to implement the combinatorial approach by building and testing full-size, discrete cells and batteries. The conception of microbattery arrays makes it practical to bring the advantages of the combinatorial approach to the development of batteries.

West, William↗

NASA NTRS1973

The Survey of Fires in Buildings. Third Report: The Use of Information Obtained From Fire Surveys

The previous two reports in this series gave details of the general. scope of the pilot exercise and methods by which it was carried out. In addition the nature of the information obtained was illustrated by preliminary analyses of the house and industrial fires surveyed. Some brief comments on the use of the information were made. This report indicates a method of assessing the nation wide effects of applying conclusions drawn from the results of limited numbers of surveys and considers the use of the information for specific purposes.

Silcock, A.↗

NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, T.↗

NASA NTRS2002

Program and Project Management Framework

The primary objective of this project was to develop a framework and system architecture for integrating program and project management tools that may be applied consistently throughout Kennedy Space Center (KSC) to optimize planning, cost estimating, risk management, and project control. Project management methodology used in building interactive systems to accommodate the needs of the project managers is applied as a key component in assessing the usefulness and applicability of the framework and tools developed. Research for the project included investigation and analysis of industrial practices, KSC standards, policies, and techniques, Systems Management Office (SMO) personnel, and other documented experiences of project management experts. In addition, this project documents best practices derived from the literature as well as new or developing project management models, practices, and techniques.

Butler, Cassandra D.↗

NASA NTRS2007

Multijunction Solar Cell Development and Production at Spectrolab

Development of multijunction space solar cells is much like that for any high technology product. New products face two major pressures from the market: improving performance while maintaining heritage. This duality of purpose is not new and has been represented since ancient times by the Roman god Janus.[1] This deity was typically represented as two faces on a single head: one facing forward and the other to the rear. The image of Janus has been used as symbolism for many combined forces of dual purpose, such as the balance in life between beginnings and endings, or between art and science. For our purposes, Janus represents our design philosophy balance between looking to the future for improvement while simultaneously blending past heritage. In the space photovoltaics industry there are good reasons for both purposes. Looking to the past, a product must have a space flight heritage to gain widespread use. The main reason being that this is an unforgiving business. Spacecraft are expensive to build, launch and operate. Typically once a satellite is launched, in-field service for a power systems problem is near impossible.[2Balanced with this is looking forward. New missions typically require more power than previous programs or attempt new objectives such as a new orbit. And there is always the cost pressure for both the satellite itself as well as the launch costs. Both of which push solar technology to improve power density at a lower cost. The consequence of this balance in a high-risk environment is that space PV develops as a series of infrequent large technology steps or generational changes interspersed with more frequent small technology steps or evolutionary changes. Figure 1 gives a bit of clarification on this point. It depicts the historical progress in space solar cells tracked by efficiency against first launch date for most major products introduced by Spectrolab. The first generation is the Si-based technology reaching a peak values near 15% AM0 (herein denoted for max. power, AM0, 1.353 W/cm2, 28 C). The GaAs single junction device generation supplanted this technology with first flight of GaAs on GaAs substrate in 1982.[3] More recently this generation has been supplanted by the multijunction solar cell GaInP/GaAs/Ge generation. The first launch of a commercial satellite powered by multijunction technology was in 1997 (Hughes HS 601HP) using solar arrays based on Spectrolab s dual junction (DJ) cells. The cells at that time were an impressive 21.5% efficient at beginning-of-life (BOL).[4] Eight years later, the multijunction device has evolved through several versions. The incorporation of an active Ge subcell formed the Triple Junction (TJ) product line at 25.1% efficient, on orbit since November 2001. The evolution of the TJ into the Improved Triple Junction (ITJ) at 26.8% efficient has been on orbit since June of 2002.[5]

Fetzer, Chris↗

NASA NTRS1983

Is structural interface standardization beneficial?

Factors applicable to fixed angle, large field and fixed angle, large building flat plate photovoltaic (PV) generator arrays are discussed in the context of standardization. It is concluded that structural interface standardization may be highly desirable in any one major project, but not at this time in the overall PV industry. Attempts to mandate such standardization will act as a deterrent to long-range improvements. In specific projects, structural standardization should be defined at the largest practical interface, leaving the maximum possible freedom to the module and array manufacturer. There is a corollary area, however, where detailed standards would benefit the industry; the matter of Standard Practices. Work being done towards definition of acceptable/desirable practices in materials, finishes, fastening and locking methods, grounding techniques, lightning protection, etc., and in handling the environmental ranges, should be continued.

Dombert, W. E.↗

NASA NTRS1967

Design of Liquid Propellant Rocket Engines Second Edition

This book intends to build a bridge for the student and the young engineer: to link the rocket propulsion fundamentals and elements (which are well covered in the literature) with the actual rocket engine design and development work as it is carried out in industry (which is very little, if at all covered in literature). The book attempts to further the understanding of the realistic application of liquid rocket propulsion theories, and to help avoid or at least reduce time and money consuming errors and disappointments. In so doing, it also attempts to digest and consolidate numerous closely related subjects, hitherto often treated as separate, bringing them up to date at the same time. The book was written "on the job" for use by those active in all phases of engine systems design, development, and application, in industry as well as government agencies. Since it addresses itself to human beings set out to create new machines, rather than describing machines about to dominate man, the language chosen may not always be "functional" in the strict sense of the word. The book presents sufficient detail to familiarize and educate thoroughly those responsible for various aspects of liquid propellant rocketry, including engine systems design, engine development, and flight vehicle application. It should enable the rocket engineer to conduct, independently, complete or partial engine systems preliminary detail designs and to understand and judge the activities in, and the problems, limitations, and "facts of life~ of the various subsystems making up a complete engine system. It also attempts to educate those ultimately interested in specialized subsystems and component design (thrust chamber, turbopump, control valves, etc.) about their own as well as neighboring subsystems and about the complete engine system. This should enable the student to prepare realistic analytical calculations and design layouts with a long headstart toward the final specialized designs for subsystem production release. Special emphasis has been placed on engine flight application to stimulate engine systems and subsystem designers to think in these terms from the outset. The book is intended as a textbook, with specific consideration of the teacher without industry experience. We hope it will stimulate those desiring to specialize in the area of a rocket engine subsystem by supplying adequate information to enable them to benefit fully from the specialized literature. Thus, it provides a realistic expert introduction for those joining the liquid propellant rocket engine field.

Dieter K Huzel↗

NASA NTRS1999

Airbreathing Hypersonic Technology Vision Vehicles and Development Dreams

Significant advancements in hypersonic airbreathing vehicle technology have been made in the country's research centers and industry over the past 40 years. Some of that technology is being validated with the X-43 flight tests. This paper presents an overview of hypersonic airbreathing technology status within the US, and a hypersonic technology development plan. This plan builds on the nation's large investment in hypersonics. This affordable, incremental plan focuses technology development on hypersonic systems, which could be operating by the 2020's.

McClinton, C. R.↗

NASA NTRS2009

Embedded passives emulator FY2003 interim report

The National Aeronautics and Space Administration Electronic Parts and Packaging (NEPP) Program has been evaluating state-of-the-art Embedded Passive Technology for the printed circuit board (PCB) industry for the past several years and has conducted its own testing on embedded passive coupons (resistors and capacitors). This document is a progress report of the work performed through fiscal year 2008 by NASA and the Navy to convert an existing PWB (printed wiring board) design to a design that incorporates embedded passive components. The work is being performed through a memorandum of understanding (MOU) between the NEPP Program (NASA) and the Naval Surface Warfare Center (NSWC) Crane Emerging Critical Interconnect Technology (ECIT) Program. NSWC Crane’s ECIT Program has funding to convert two PCB designs from the military and aerospace industry to a PCB design with embedded passives. ECIT will provide a design team that will take a well characterized design and convert it to an embedded design. They will also provide electrical modeling and layout expertise as well as build the PWB in their facility in Indiana. NEPP, through the Jet Propulsion Laboratory (JPL), will assemble any passives deemed not suitable for embedding and the active components and electrically test the new design to the existing (non-embedded) design

Gerke, David↗

NASA NTRS2004

Research and Technology 2003

The NASA Glenn Research Center at Lewis Field, in partnership with U.S. industries, universities, and other Government institutions, is responsible for developing critical technologies that address national priorities in aeropropulsion and space applications. Our work is focused on research for new aeropropulsion technologies, aerospace power, microgravity science (fluids and combustion), electric propulsion, and communications technologies for aeronautics, space, and aerospace applications. As NASA s premier center for aeropropulsion, aerospace power, and turbomachinery, our role is to conduct world-class research and to develop key technologies. We contribute to economic growth and national security through safe, superior, and environmentally compatible U.S. civil and military aircraft propulsion systems. Our Aerospace Power Program supports all NASA Enterprises and major programs, including the International Space Station, Advanced Space Transportation, and new initiatives in human and robotic exploration. Glenn Research Center leads NASA s research in the microgravity science disciplines of fluid physics, combustion science, and acceleration measurement. Almost every space shuttle science mission has had an experiment managed by NASA Glenn, and we have conducted a wide array of similar experiments on the International Space Station. The Glenn staff consists of over 3200 civil service employees and support service contractor personnel. Scientists and engineers comprise more than half of our workforce, with technical specialists, skilled workers, and an administrative staff supporting them. We aggressively strive for technical excellence through continuing education, increased diversity in our workforce, and continuous improvement in our management and business practices so that we can expand the boundaries of aeronautics, space, and aerospace technology. Glenn Research Center is a unique facility located in northeast Ohio. Situated on 350 acres of land adjacent to the Cleveland Hopkins International Airport, Glenn comprises more than 140 buildings, including 24 major facilities and over 500 specialized research and test facilities. Additional facilities are located at Plum Brook Station, which is about 50 miles west of Cleveland. Plum Brook Station has four large, major, world-class facilities for space research available for Government and industry programs. Knowledge is the end product of our activities. The R&T reports help make this knowledge fully available to potential users the aircraft engine industry, the space industry, the energy industry, the automotive industry, the aerospace industry, and others. It is organized so that a broad cross section of the community can readily use it. Each article begins with a short introductory paragraph that should prove valuable for the layperson. These articles summarize the progress made during the year in various technical areas and portray the technical and administrative support associated with Glenn s technology programs. We hope that this information is useful to all. If additional information is desired, readers are encouraged to contact the researchers identified at the end of each article and to visit Glenn on the World Wide Web at http://www.grc.nasa.gov.

Julian Earls↗

NASA NTRS2010

Inflatable Tubular Structures Rigidized with Foams

Inflatable tubular structures that have annular cross sections rigidized with foams, and the means of erecting such structures in the field, are undergoing development. Although the development effort has focused on lightweight structural booms to be transported in compact form and deployed in outer space, the principles of design and fabrication are also potentially applicable to terrestrial structures, including components of ultralightweight aircraft, lightweight storage buildings and shelters, lightweight insulation, and sales displays. The use of foams to deploy and harden inflatable structures was first proposed as early as the 1960s, and has been investigated in recent years by NASA, the U.S. Air Force Research Laboratory, industry, and academia. In cases of deployable booms, most of the investigation in recent years has focused on solid cross sections, because they can be constructed relatively easily. However, solid-section foam-filled booms can be much too heavy for some applications. In contrast, booms with annular cross sections according to the present innovation can be tailored to obtain desired combinations of stiffness and weight through choice of diameters, wall thicknesses, and foam densities. By far the most compelling advantage afforded by this innovation is the possibility of drastically reducing weights while retaining or increasing the stiffnesses, relative to comparable booms that have solid foamfilled cross sections. A typical boom according to this innovation includes inner and outer polyimide film sleeves to contain foam that is injected between them during deployment.

Tinker, Michael L.↗

NASA NTRS2016

Lateral Cutoff Analysis and Results from NASA's Farfield Investigation of No-Boom Thresholds

In support of the ongoing effort by the National Aeronautics and Space Administration (NASA) to bring supersonic commercial travel to the public, the NASA Armstrong Flight Research Center (AFRC) and the NASA Langley Research Center (LaRC), in partnership with other industry organizations and academia, conducted a flight research experiment to analyze acoustic propagation at the lateral edge of the sonic boom carpet. The name of the effort was the Farfield Investigation of No-boom Thresholds (FaINT). The test helped to build a dataset that will go toward further understanding of the unique acoustic propagation characteristics near the sonic boom carpet extremity. The FaINT was an effort that collected finely-space sonic boom data across the entire lateral cutoff transition region. A major objective of the effort was to investigate the acoustic phenomena that occur at the audible edge of a sonic boom carpet, including the transition and shadow zones. A NASA F-18B aircraft made supersonic passes such that its sonic boom carpet transition zone would intersect a linear 60-microphone, 7500-ft long array. A TG-14 motor glider equipped with a microphone on its wing also attempted to capture the same sonic boom rays that were measured on the ground, at altitudes of 3000 - 6000 ft above ground level. This paper determined an appropriate metric for sonic boom waveforms in the transition and shadow zones called Perceived Sound Exposure Level, and established a value of 65 dB as a limit for the acoustic levels defining the lateral extent of a sonic boom's noise region; analyzed the change in sonic boom levels as a function of distance from flight path both on the ground and 4500 ft above the ground; and compared between sonic boom measurements and numerical predictions.

acoustics↗

NASA NTRS2017

Achieving And Sustaining Human Exploration of Mars The Fourth Community Workshop (AM IV)

About a half decade ago, several professionals working mainly in industry on scenarios for initial human exploration of Mars exploration together recognized that, under generally similar assumptions, there was a fair degree of similarity among these scenarios. Moreover, opportunities should be sought for greater community input into NASAs own scenario-building for the future of human space flight. A series of focused community workshops were considered to be effective to critically assess the increasingly sophisticated scenarios. Explore Mars, Inc. the American Astronautical Society agreed to support them. Four workshops to date each involve about sixty professional scientists, engineers, technologists, and strategists from NASA, academia, aerospace corporations, the National Academies, consulting organizations, and potential international partners. Each workshop produced a series of presentations and reports briefed to NASA leadership and other stakeholders.

Achieving Sustaining Human Exploration of Mars The↗

NASA NTRS1996

(Re)inventing Government-Industry R and D Collaboration

This paper describes the lessons learned in developing and operating a large-scale strategic alliance whose organization and coordination is U.S. Government-led using new means for R&D collaboration. Consortia in the United States counter a century of 1884 Sherman Anti-Trust Law-based governmental and legal policy and a longstanding business tradition of unfettered competition. Success in public-private collaboration in America requires compelling vision and motivation by both partners to reinvent our ways of doing business. The foundations for reinventing government and alliance building were laid in 1994 with Vice President Al Gore's mandates for Federal Lab Reviews and other examinations of the roles and missions for the nation's more than 700 government labs. In addition, the 1984 National Cooperative Research Act (NCRA) set in motion the abilities for U.S. companies to collaborate in pre-competitive technology development. The budget realities of the 1990's for NASA and other government agencies demand that government discover the means to accomplish its mission by leveraging resources through streamlining as well as alliances. Federal R&D investments can be significantly leveraged for greater national benefit through strategic alliances with industry and university partners. This paper presents early results from one of NASA's first large-scale public/private joint R&D ventures.

Holmes, Bruce J.↗