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At least 325 records · Page 18

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

Limitations to the study of man in the United States space program

Research on humans conducted during space flight is fraught both with great opportunities and great obstacles. The purpose of this paper is to review some of the limitations to United States research in space in the hope that an informed scientific community may lead to more rapid and efficient solution of these problems. Limitations arise because opportunities to study the same astronauts in well-controlled situations on repeated space flights are practically non-existent. Human research opportunities are further limited by the necessity of avoiding simultaneous mutually-interfereing experiments. Environmental factors including diet and other physiological perturbations concomitant with space flight also complicates research design and interpretation. Technical limitations to research methods and opportunities further restrict the development of the knowledge base. Finally, earth analogues of space travel all suffer from inadequacies. Though all of these obstacles will eventually be overcome; creativity, diligence, and persistence are required to further our knowledge of humans in space.

Bishop, Phillip A.↗

GPS Ocean Reflection Experiment on Spartan 251

It has recently been demonstrated that the GPS signal which has reflected from the ocean surface contains useful geophysical data from which the sea surface wind speed and other parameters can be extracted. This can be used for remote sensing, similar to present day use of radar altimeters or scatterometers, but with significantly smaller instrumentation because of the utilization of the existing GPS broadcast signal for illumination. Several campaigns of aircraft experimentation have been completed demonstrating this technique and reflected GPS data has been reliably collected from 25 km altitude on a balloon. However, there has not yet been a demonstration that the reflected GPS signal can be detected from orbit with sufficient signal to noise ratio (SNR) to make useful remote sensing measurements. A technology demonstration experiment was planned for a Space Shuttle flight in the late 2000 using the Spartan 251 recoverable carrier. This experiment would also have been the first flight validation of the PiVoT GPS receiver developed in house at the Goddard Space Flight Center. The "open-architecture" design of this receiver would allow the software modifications to be made which control code-correlator spacing to map out the shape of the reflected signal waveform, which is the most basic data product generated by this instrumentation. A moderate gain left-hand circularly polarized antenna, constructed from an array of off-the-shelf hemispherical antennas was to be used to give approximately 3 to 6 dB of additional gain. Preliminary SNR predictions have been done indicating that this antenna would offer sufficient gain to record waveform measurements. A system level description of the experiment instrumentation, including the receiver, antenna and data storage and retrieval will be given. The visibility of GPS reflections over the mission duration of several hours will be studied, including the effects of the limited beamwidth of the antenna. Spartan 251 has now been postponed with the earliest opportunity in the year 2002. The results of this study however, have been 2 used to further the define the requirements and expected performance of reflected GPS receivers in orbit. Several other space flight opportunities are being considered based upon this new information.

Garrison, James L↗

2010 JANNAF Abstract Propulsion System Status: Ares First Stage

In November 2005, NASA created the Constellation Program to develop an entirely new fleet of spacecraft to include the Ares I Crew Launch Vehicle and the Ares V Cargo Launch vehicles. The Ares I First Stage Team has made significant progress on the design of a propulsion system capable of lofting that new fleet. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle served as a starting point in the design of a new motor that would meet the requirements of those new vehicles. By bringing in a fifth segment, this new propulsive element will provide greater total impulse to loft a safer, more powerful fleet of space flight vehicles. Additional modifications include the use of composite structures, new metallic forward structures, new parachutes, a new propellant grain design, and a new nozzle. Although still ongoing and in process, significant design, development and concept testing has already been conducted. This includes a full-scale motor firing, deceleration subsystem testing, and testing of several complete avionics line replaceable units. The suborbital development flight, Ares I-X, provided the opportunity to gather critical data about the flight dynamics of the integrated launch vehicle stack. The Ares I-X test flight has also informed our Ares First Stage design. It brought a more comprehensive understanding in a number of areas, which are now being analyzed. This paper will provide an overview of the design, development, challenges, and progress on the production of the new Ares First Stage propulsion system. Challenges and mitigation strategies will be addressed. An overview will also be included of testing to date.

Tiller, Bruce K.↗

Mechanistic studies of polymeric samples exposed aboard STS 8

The early Shuttle flights and the attendant opportunity to deploy material samples to the near-Earth space environment, along well-defined trajectories and accompanied by detailed characterization of these samples prior to and following the flight exposure, have brought to light several novel phenomena associated with interaction of these materials with the space environment. JPL, in coordination with other NASA Centers, has carried out a research program to study the degradation and oxidation processes caused by interaction of these materials with atomic oxygen at an energy of 5 eV. In addition, energetic atomic oxygen is believed to be responsible for the shuttle glow first observed during the flight of STS-3. The shuttle glow phenomenon has been extensively studied and modeled because of its long-range potential impact on optical communication schemes and its more immediate impact on the Space Telescope. This report summarizes the results of certian material degradation and erosion experiments carried out aboard STS-8 between August 30, 1983 and September 5, 1983. Based on these data, a generic degradation model has been developed for common structural polymers.

Liang, Ranty H.↗

New Air-Launched Small Missile (ALSM) Flight Testbed for Hypersonic Systems

The Phoenix Air-Launched Small Missile (ALSM) flight testbed was conceived and is proposed to help address the lack of quick-turnaround and cost-effective hypersonic flight research capabilities. The Phoenix ALSM testbed results from utilization of the United States Navy Phoenix AIM-54 (Hughes Aircraft Company, now Raytheon Company, Waltham, Massachusetts) long-range, guided air-to-air missile and the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center (Edwards, California) F-15B (McDonnell Douglas, now the Boeing Company, Chicago, Illinois) testbed airplane. The retirement of the Phoenix AIM-54 missiles from fleet operation has presented an opportunity for converting this flight asset into a new flight testbed. This cost-effective new platform will fill the gap in the test and evaluation of hypersonic systems for flight Mach numbers ranging from 3 to 5. Preliminary studies indicate that the Phoenix missile is a highly capable platform; when launched from a high-performance airplane, the guided Phoenix missile can boost research payloads to low hypersonic Mach numbers, enabling flight research in the supersonic-to-hypersonic transitional flight envelope. Experience gained from developing and operating the Phoenix ALSM testbed will assist the development and operation of future higher-performance ALSM flight testbeds as well as responsive microsatellite-small-payload air-launched space boosters.

Bui, Trong T.↗

Digital Flight: A New Cooperative Operating Mode to Complement VFR and IFR

Digital Flight is a proposed new operating mode for all airspace users, complementing and adding to the existing operating modes of visual and instrument flight rules (VFR and IFR) and providing for cooperative integration in controlled airspace. Under new regulations (Digital Flight Rules, DFR) that set requirements for its sustained use, qualified operators employ Digital Flight to enhance their airspace access and operational flexibility in all visibility conditions and eventually all airspace classes without requiring segregation from incumbent operations. Enabled by connected digital information and technologies, Digital Flight operators employ cooperative practices and self-separation to ensure flight path safety in lieu of visual procedures or receiving separation services from Air Traffic Control. Its distributed structure and automated functions enable traffic densities and operational tempos not achievable with the existing operating modes. Various ongoing and emerging industry initiatives for enabling new entrants (e.g., unmanned aircraft systems, urban air taxis) and enhanced use of underserved airspace (e.g., ultra-high altitude), are pursuing various alternative operating modes with significant similarities, creating a unique and time-limited opportunity for harmonization and convergence. Digital Flight is proposed to serve that harmonizing role, creating a common new paradigm for airspace operations. Such convergence would not only bring together these emerging market segments but will also bolster the existing operators with access to this new operating mode and its advantages. Digital Flight provides an opportunity to focus regulatory development and benefit the aviation industry. This paper describes Digital Flight in sufficient detail to initiate community engagement and deliberation on a common new operating mode. It describes the essential elements, principal capabilities, and operational integration of DFR in shared airspace. It describes the value proposition from multiple perspectives and presents initial thoughts on the path forward.

Digital flight↗

Analysis of Multi-Flight Common Routes for Traffic Flow Management

This paper presents an approach for creating common weather avoidance reroutes for multiple flights and the associated benefits analysis, which is an extension of the single flight advisories generated using the Dynamic Weather Routes (DWR) concept. These multiple flight advisories are implemented in the National Airspace System (NAS) Constraint Evaluation and Notification Tool (NASCENT), a nation-wide simulation environment to generate time- and fuel-saving alternate routes for flights during severe weather events. These single flight advisories are clustered together in the same Center by considering parameters such as a common return capture fix. The clustering helps propose routes called, Multi-Flight Common Routes (MFCR), that avoid weather and other airspace constraints, and save time and fuel. It is expected that these routes would also provide lower workload for traffic managers and controllers since a common route is found for several flights, and presumably the route clearances would be easier and faster. This study was based on 30-days in 2014 and 2015 each, which had most delays attributed to convective weather. The results indicate that many opportunities exist where individual flight routes can be clustered to fly along a common route to save a significant amount of time and fuel, and potentially reducing the amount of coordination needed.

weather uncertainty↗

Global Infrared Observations of Roughness Induced Transition on the Space Shuttle Orbiter

High resolution infrared observations made from a mobile ground based optical system captured the laminar-to-turbulent boundary layer transition process as it occurred during Space Shuttle Endeavour's return to earth following its final mission in 2011. The STS-134 imagery was part of a larger effort to demonstrate an emerging and reliable non-intrusive global thermal measurement capability and to complement a series of boundary layer transition flight experiments that were flown on the Shuttle. The STS-134 observations are believed to be the first time that the development and movement of a hypersonic boundary layer transition front has been witnessed in flight over the entire vehicle surface and in particular, at unprecedented spatial resolution. Additionally, benchmark surface temperature maps of the Orbiter lower surface collected over multiple flights and spanning a Mach range of 18 to 6 are now available and represent an opportunity for collaborative comparison with computational techniques focused on hypersonic transition and turbulence modeling. The synergy of the global temperature maps with the companion in-situ thermocouple measurements serve as an example of the effective leveraging of resources to achieve a common goal of advancing our understanding of the complex nature of high Mach number transition. It is shown that quantitative imaging can open the door to a multitude of national and international opportunities for partnership associated with flight-testing and subsequent validation of numerical simulation techniques. The quantitative imaging applications highlighted in this paper offer unique and complementary flight measurement alternatives and suggest collaborative instrumentation opportunities to advance the state of the art in transition prediction and maximize the return on investment in terms of developmental flight tests for future vehicle designs.

Horvath, Thomas J.↗

Crew Factors in Flight Operations XII: A Survey of Sleep Quantity and Quality in On-Board Crew Rest Facilities

Many aircraft operated on long-haul commercial airline flights are equipped with on-board crew rest facilities, or bunks, to allow crewmembers to rest during the flight. The primary objectives of this study were to gather data on how the bunks were used, the quantity and quality of sleep obtained by flight crewmembers in the facilities, and the factors that affected their sleep. A retrospective survey comprising 54 questions of varied format addressed demographics, home sleep habits, and bunk sleep habits. Crewmembers from three airlines with long-haul fleets carrying augmented crews consisting of B747-100/200, B747-400, and MD-11 aircraft equipped with bunks returned a total of 1404 completed surveys (a 37% response rate). Crewmembers from the three carriers were comparable demographically, although one carrier had older, more experienced flight crewmembers. Each group, on average, rated themselves as "good" or "very good" sleepers at home, and all groups obtained about the same average amount of sleep each night. Most were able to sleep in the bunks, and about two thirds indicated that these rest opportunities benefited their subsequent flight deck alertness and performance. Comfort, environment, and physiology (e.g., being ready for sleep) were identified as factors that most promoted sleep. Factors cited as interfering with sleep included random noise, thoughts, heat, and the need to use the bathroom. These factors, in turn, suggest potential improvements to bunk facilities and their use. Ratings of the three aircraft types suggested differences among facilities. Bunks in the MD-11 were rated significantly better than either of the B747 types, and the B747-400 bunks received better ratings than did the older, B747-100/200 facilities.

Rosekind, Mark R.↗

MoonRIDERS: NASA and Hawaiis Innovative Lunar Surface Flight Experiment for Landing in Late 2017

Recently, NASA Kennedy Space Center, Hawaii's state aerospace agency PISCES, and two Hawaii high schools Iolani and Kealakehe have come together in a unique collaboration called MoonRIDERS. This strategic partnership will allow Hawaii students to participate directly in sending a science experiment to the surface of the moon. The MoonRIDERS project started in the spring of 2014, with each institution responsible for its own project costs and activities. PISCES, given its legislative direction in advancing planetary surface systems, saw this collaboration as an important opportunity to inspire a young generation and encourage STEM (Science, Technology, Engineering, and Mathematics) learning. Under the guidance of PISCES and NASA, the students will be involved hands-on from start to finish in the engineering, testing, and validation of a space technology called the Electrodynamic Dust Shield (EDS). Dust is a critical issue for space exploration, as evidenced by the Apollo lunar missions and Mars rovers and landers. Dust creates a number of problems for humans and hardware, including inhalation, mechanical interference, wear and tear on spacesuits, inhibition of heat transfer on radiators, and reduced efficiency of solar panels. To address this, the EDS is designed to work on a variety of materials, and functions by generatingelectrodynamic fields to clear away the dust. The Google Lunar XPRIZE (GLXP), a space competition "designed to inspire pioneers to do robotic space transport on a budget," serves as a likely method for the MoonRIDERS to get their project to the moon. The EDS would potentially be flown as a hosted payload on a competitor's lander (still to be chosen). This briefing will provide an overview of the technology, the unique partnership, progress update and testing leading to this flight opportunity.

Payload experiment↗

Radiation Hardening by Software Techniques on FPGAs: Flight Experiment Evaluation and Results

We present our work on implementing Radiation Hardening by Software (RHBSW) techniques on the Xilinx Virtex5 FPGAs PowerPC 440 processors on the SpaceCube 2.0 platform. The techniques have been matured and tested through simulation modeling, fault emulation, laser fault injection and now in a flight experiment, as part of the Space Test Program- Houston 4-ISS SpaceCube Experiment 2.0 (STP-H4-ISE 2.0). This work leverages concepts such as heartbeat monitoring, control flow assertions, and checkpointing, commonly used in the High Performance Computing industry, and adapts them for use in remote sensing embedded systems. These techniques are extremely low overhead (typically <1.3%), enabling a 3.3x gain in processing performance as compared to the equivalent traditionally radiation hardened processor. The recently concluded STP-H4 flight experiment was an opportunity to upgrade the RHBSW techniques for the Virtex5 FPGA and demonstrate them on-board the ISS to achieve TRL 7. This work details the implementation of the RHBSW techniques, that were previously developed for the Virtex4-based SpaceCube 1.0 platform, on the Virtex5-based SpaceCube 2.0 flight platform. The evaluation spans the development and integration with flight software, remotely uploading the new experiment to the ISS SpaceCube 2.0 platform, and conducting the experiment continuously for 16 days before the platform was decommissioned. The experiment was conducted on two PowerPCs embedded within the Virtex5 FPGA devices and the experiment collected 19,400 checkpoints, processed 253,482 status messages, and incurred 0 faults. These results are highly encouraging and future work is looking into longer duration testing as part of the STP-H5 flight experiment.

Hybrid Flight Architectures↗

Effects of Self-Instructional Methods and Above Real Time Training (ARTT) for Maneuvering Tasks on a Flight Simulator

Personal computer based flight simulators are expanding opportunities for providing low-cost pilot training. One advantage of these devices is the opportunity to incorporate instructional features into training scenarios that might not be cost effective with earlier systems. Research was conducted to evaluate the utility of different instructional features using a coordinated level turn as an aircraft maneuvering task. In study I, a comparison was made between automated computer grades of performance with certified flight instructors grades. Every one of the six student volunteers conducted a flight with level turns at two different bank angles. The automated computer grades were based on prescribed tolerances on bank angle, airspeed and altitude. Two certified flight instructors independently examined the video tapes of heads up and instrument displays of the flights and graded them. The comparison of automated grades with the instructors grades ms based on correlations between them. In study II, a 2x2 between subjects factorial design was used to devise and conduct an experiment. Comparison was made between real time training and above real time training and between feedback and no feedback in training. The performance measure to monitor progress in training was based on deviations in bank angle and altitude. The performance measure was developed after completion of the experiment including the training and test flights. It was not envisaged before the experiment. The experiment did not include self-instructions as it was originally planned, although feedback by experimenter to the trainee was included in the study.

Norlin, Ken↗

Effects of Self-Instructional Methods and Above Real Time Training (ARTT) for Maneuvering Tasks on a Flight Simulator

Personal computer based flight simulators are expanding opportunities for providing low-cost pilot training. One advantage of these devices is the opportunity to incorporate instructional features into training scenarios that might not be cost effective with earlier systems. Research was conducted to evaluate the utility of different instructional features using a coordinated level turn as an aircraft maneuvering task. In study I, a comparison was made between automated computer grades of performance with certified flight instructors grades. Every one of the six student volunteers conducted a flight with level turns at two different bank angles. The automated computer grades were based on prescribed tolerances on bank angle, airspeed and altitude. Two certified flight instructors independently examined the video tapes of heads up and instrument displays of the flights and graded them. The comparison of automated grades with the instructors grades was based on correlations between them. In study II, a 2x2 between subjects factorial design was used to devise and conduct an experiment. Comparison was made between real time training and above real time training and between feedback and no feedback in training. The performance measure to monitor progress in training was based on deviations in bank angle and altitude. The performance measure was developed after completion of the experiment including the training and test flights. It was not envisaged before the experiment. The experiment did not include self- instructions as it was originally planned, although feedback by experimenter to the trainee was included in the study.

Ali, Syed Firasat↗

The Shuttle and its importance to space medicine

The physiological effects of space flights on humans are reviewed, and the opportunities offered by frequent and repetitive Space Shuttle flights for space medical research are discussed. The most significant changes encountered in the vestibular, cardiopulmonary, musculoskeletal and hematopoietic systems during and after past space missions are indicated, and the time courses of the physiological shifts associated with space acclimatization and readaptation to a 1-g environment are summarized. Effects directly attributable to the absence of gravity, including postural changes and fluid shifts, are considered, and additional contributing factors to physiological changes imposed by the spacecraft operational environment are pointed out. Differences between the Space Shuttle missions and all previous missions in the areas of reentry profiles and varied crew composition are discussed, and results of experiments on the relative acceleration tolerances of men and women of different ages and the usefulness of the anti-g suit are presented. Directions for future research in space medicine available with the Shuttle are examined, with particular emphasis on the neurovestibular system cardiopulmonary dynamics, calcium metabolism, the erythropoietic system and the effects of space radiation.

Nicogossian, A.↗

MGS and Odyssey - Relay Satellites for the MER Mission

Both Mars Global Surveyor (MGS) and Mars Odyssey are currently in low altitude, nearly circular and highly inclined orbits about Mars. Thus, they are available and compatible to serve as relay satellites for the Mars Exploration Rover (MER) mission. Consequently, the MER project developed requirements for MGS to be overhead, at a specific time with a 30 second tolerance, during the atmospheric entry, descent and landing (EDL) phase of both MER vehicles. The result, after execution of a single orbit synchronization maneuver (OSM) on 10/03/03, 92.4 days or 1130 orbits before Spirit's EDL, was that MGS was over Spirit 8 seconds past the required time. This maneuver, with a delta-velocity of 0.534 m/s, caused the orbital period to change by 3.34 s and resulted in a time-phasing change of 62 min 19 s in order to achieve the EDL overflight. Based on the navigation and execution of an OSM on 01/04/04, MGS was overhead for the Opportunity EDL on 01/25/04,3.5 seconds after the required epoch. Requirements also existed for the Odyssey over-flight of the MER rovers after landing and various equipment deployments had been completed. Thus, these requirements were that Odyssey should rise no earlier than specified times with respect to each of the landing sites. The Odyssey over-flights of both Spirit and Opportunity on sol 1 were equally successful. This paper will present the navigation plan, trajectory propagation accuracy and maneuver execution for the successful MGS and Odyssey over-flights of both the MER rovers.

Mars Global Surveyor (MGS)↗

Far ultraviolet wide field imaging with a SPARTAN /Experiment of Opportunity/ Payload

A wide-field electrographic Schmidt camera, sensitive in the far UV (1230-2000 A), has been developed and utilized in three sounding rocket flights. It is now being prepared for Shuttle flight as an Experiment of Opportunity Payload (EOP) (recently renamed as the SPARTAN program). In this paper, we discuss (1) design of the instrument and payload, particularly as influenced by our experience in rocket flights; (2) special problems of EOP in comparison to sounding rocket missions; (3) relationship of this experiment to, and special capabilities in comparison to, other space astronomy instruments such as Space Telescope; and (4) a tentative observing plan for an EOP mission.

Carruthers, G. R.↗