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

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NASA NTRS1986

Load cell verification of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

Beatty, R. F.↗

NASA NTRS1995

High speed nozzles task

Supersonic cruise exhaust nozzles for advanced applications are optimized for a high nozzle pressure ratio (NPR) at design supersonic cruise Mach number and altitude. The performance of these nozzles with large expansion ratios are severely degraded for operations at subsonic speeds near sea level for NPR significantly less than the design values. The prediction of over-expanded 2DCD nozzles performance is critical to evaluating the internal losses and to the optimization of the integrated vehicle and propulsion system performance. The reported research work was aimed at validating and assessing existing computational methods and turbulence models for predicting the flow characteristics and nozzle performance at over-expanded conditions. Flow simulations in 2DCD nozzles were performed using five different turbulence models. The results are compared with the experimental data for the wall pressure distribution and thrust and flow coefficients at over-expanded static conditions.

Hamed, Awatef↗

NASA NTRS2016

Parametric Modeling Investigation of a Radially-Staged Low-Emission Aviation Combustor

Aviation gas-turbine combustion demands high efficiency, wide operability and minimal trace gas emissions. Performance critical design parameters include injector geometry, combustor layout, fuel-air mixing and engine cycle conditions. The present investigation explores these factors and their impact on a radially staged low-emission aviation combustor sized for a next-generation 24,000-lbf-thrust engine. By coupling multi-fidelity computational tools, a design exploration was performed using a parameterized annular combustor sector at projected 100% takeoff power conditions. Design objectives included nitrogen oxide emission indices and overall combustor pressure loss. From the design space, an optimal configuration was selected and simulated at 7.1, 30 and 85% part-power operation, corresponding to landing-takeoff cycle idle, approach and climb segments. All results were obtained by solution of the steady-state Reynolds-averaged Navier-Stokes equations. Species concentrations were solved directly using a reduced 19-step reaction mechanism for Jet-A. Turbulence closure was obtained using a nonlinear K-epsilon model. This research demonstrates revolutionary combustor design exploration enabled by multi-fidelity physics-based simulation.

design analysis↗

NASA NTRS1990

Radiation effect on rocket engine performance

Critical problem areas involving the effect of radiation on the combustion of bipropellants are addressed by formulating a universal scaling law in combination with a radiation-enhanced vaporization combustion model. Numerical algorithms are developed and data pertaining to the Variable Thrust Engine (VTE) and the Space Shuttle Main Engine (SSME) are used to conduct parametric sensitivity studies to predict the principal intercoupling effects of radiation. The analysis reveals that low-enthalpy engines, such as the VTE, are vulnerable to a substantial performance setback due to radiative loss, whereas the performance of high-enthalpy engines such as the SSME are hardly affected over a broad range of engine operation. Combustion enhancement by radiative heating of the propellant has a significant impact on propellants with high absorptivity.

Chiu, Huei-Huang↗

NASA NTRS1988

Radiation effect on rocket engine performance

The effects of radiation on the performance of modern rocket propulsion systems operating at high pressure and temperature were recognized as a key issue in the design and operation of various liquid rocket engines of the current and future generations. Critical problem areas of radiation coupled with combustion of bipropellants are assessed and accounted for in the formulation of a universal scaling law incorporated with a radiation-enhanced vaporization combustion model. Numerical algorithms are developed and the pertaining data of the Variable Thrust Engine (VTE) and Space Shuttle Main Engine (SSME) are used to conduct parametric sensitivity studies to predict the principal intercoupling effects of radiation. The analysis reveals that low enthalpy engines, such as the VTE, are vulnerable to a substantial performance set back by the radiative loss, whereas the performance of high enthalpy engines such as the SSME, are hardly affected over a broad range of engine operation. Additionally, combustion enhancement by the radiative heating of the propellant has a significant impact in those propellants with high absorptivity. Finally, the areas of research related with radiation phenomena in bipropellant engines are identified.

Chiu, Huei-Huang↗

NASA NTRS1998

A Spaceflight Magnetic Bearing Equipped Optical Chopper with Six-Axis Active Control

This paper describes the development of an ETU (Engineering Test Unit) rotary optical chopper with magnetic bearings. An ETU is required to be both flight-like, nearly identical to a flight unit without the need for material certifications, and demonstrate structural and performance integrity. A prototype breadboard design previously demonstrated the feasibility of meeting flight performance requirements using magnetic bearings. The chopper mechanism is a critical component of the High Resolution Dynamics Limb Sounder (HIRDLS) which will be flown on EOS-CHEM (Earth Observing System-Chemistry). Particularly noteworthy are the science requirements which demand high precision positioning and minimal power consumption along with full redundancy of coils and sensors in a miniature, lightweight package. The magnetic bearings are unique in their pole design to minimize parasitic losses and utilize collocated optical sensing. The motor is of an unusual disk-type ironless stator design. The ETU design has evolved from the breadboard design. A number of improvements have been incorporated into the ETU design. Active thrust control has been added along with changes to improve sensor stability, motor efficiency, and touchdown and launch survivability. It was necessary to do all this while simultaneously reducing the mechanism volume. Flight-like electronics utilize a DSP (Digital Signal Processor) and contain all sensor electronics and drivers on a single five inch by nine inch circuit board. Performance test results are reported including magnetic bearing and motor rotational losses.

Blumenstock, Kenneth A.↗

NASA NTRS1998

A Spaceflight Magnetic Bearing Equipped Optical Chopper with Six-Axis Active Control

Blumenstock, K. A.↗

NASA NTRS1998

A Spaceflight Magnetic Bearing Equipped Optical Chopper with Six-Axis Active Control

Blumenstock, Kenneth A.↗

NASA NTRS1987

Space Station: Leadership for the Future

No longer limited to occasional spectaculars, space has become an essential, almost commonplace dimension of national life. Among other things, space is an arena of competition with our allies and adversaries, a place of business, a field of research, and an avenue of cooperation with our allies. The space station will play a critical role in each of these endeavors. Perhaps the most significant feature of the space station, essential to its utility for science, commerce, and technology, is the permanent nature of its crew. The space station will build upon the tradition of employing new capabilities to explore further and question deeper, and by providing a permanent presence, the station should significantly increase the opportunities for conducting research in space. Economic productivity is, in part, a function of technical innovation. A major thrust of the station design effort is devoted to enhancing performance through advanced technology. The space station represents the commitment of the United States to a future in space. Perhaps most importantly, as recovery from the loss of Challenger and its crew continues, the space station symbolizes the national determination to remain undeterred by tragedy and to continue exploring the frontiers of space.

Martin, Franklin D.↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the ascent thrust vector control actuator subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The independent analysis results for the Ascent Thrust Vector Control (ATVC) Actuator hardware are documented. The function of the Ascent Thrust Vector Control Actuators (ATVC) is to gimbal the main engines to provide for attitude and flight path control during ascent. During first stage flight, the SRB nozzles provide nearly all the steering. After SRB separation, the Orbiter is steered by gimbaling of its main engines. There are six electrohydraulic servoactuators, one pitch and one yaw for each of the three main engines. Each servoactuator is composed of four electrohydraulic servovalve assemblies, one second stage power spool valve assembly, one primary piston assembly and a switching valve. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Critical failures resulting in loss of ATVC were mainly due to loss of hydraulic fluid, fluid contamination and mechanical failures.

Wilson, R. E.↗

NASA NTRS2020

Autonomous Assessment and Predictive Capabilities for Low-Altitude Urban Flight Operations

The integration of unmanned aerial vehicles in the national airspace will introduce new vehicle types, technologies, and operational paradigms for which safety must be maintained and hazards mitigated. One approach is to attempt to design for possible hazards and unsafe incidents that can occur at different phases of flight (pre-flight, in-flight, and post-flight) and during ground operations. Another is to mitigate safety incidents by implementing changes to policies, procedures, regulations, and design to cover personnel, equipment, and aircraft during operations. These and other techniques, not described herein, are typically conservative or adhoc in that they reduce the likelihood of risk after safety incidents have occurred. In this work, the goal is to develop a more predictive capability to monitor and mitigate risk and hazards to safety “in-time” enough for decisions to be made. In line with NASA’s Aeronautics Mission Directorate Strategic Thrust 5 [1] (In-Time System-Wide Safety Assurance), the System-Wide Safety (SWS) project under which this work falls, is developing and demonstrating innovative and safety-oriented solutions that enable modernization and aviation transformation. To that effect, this work will detail data-driven efforts on the SWS project to develop a number of safety-critical services for in-time monitoring and mitigation of hazards to low-altitude flight operations. First, hazards to these operations are identified based on previous work by NASA [2,3] and others in the aerospace industry. These hazards include (i) unsafe proximity to other vehicles, property, and people on the ground, (ii) critical system failures such as communication signal/GPS loss, unexpected propulsion system degradation, engine/power failure, and (iii) operational/environmental issues such as severe weather and gusty winds. For these hazards, safety metrics, which can be quantified and assessed are defined, models to monitor and predict them are developed, and flight test data is generated to develop, validate, and test these models, considering the complex interplay of the different hazards that define them [4-6]. In addition, the uncertainty in the non-deterministic effects that cannot be modeled nor predicted and unknown unknowns that arise after design/testing and during operations must be handled in rigorous manner. As a result, for each of the developed safety metrics, their dependencies on one another are characterized and a framework for handling the uncertainties inherent in the modeling, algorithms, and measurements required for prediction is also developed [7]. To that effect, this presentation will describe the safety metrics and services already developed and underway under the System-Wide Safety project that utilize data-driven techniques for the identification of anomalies, precursors, and trends (APTs) to monitor and mitigate hazards to safety, in-time, for urban flight operations in low-altitude airspace.

Okolo, Wendy A.↗

NASA NTRS1993

Space propulsion

Lewis Research Center is developing broad-based new technologies for space chemical engines to satisfy long-term needs of ETO launch vehicles and other vehicles operating in and beyond Earth orbit. Specific objectives are focused on high performance LO2/LH2 engines providing moderate thrusts of 7,5-200 klb. This effort encompasses research related to design analysis and manufacturing processes needed to apply advanced materials to subcomponents, components, and subsystems of space-based systems and related ground-support equipment. High-performance space-based chemical engines face a number of technical challenges. Liquid hydrogen turbopump impellers are often so large that they cannot be machined from a single piece, yet high stress at the vane/shroud interface makes bonding extremely difficult. Tolerances on fillets are critical on large impellers. Advanced materials and fabricating techniques are needed to address these and other issues of interest. Turbopump bearings are needed which can provide reliable, long life operation at high speed and high load with low friction losses. Hydrostatic bearings provide good performance, but transients during pump starts and stops may be an issue because no pressurized fluid is available unless a separate bearing pressurization system is included. Durable materials and/or coatings are needed that can demonstrate low wear in the harsh LO2/LH2 environment. Advanced materials are also needed to improve the lifetime, reliability and performance of other propulsion system elements such as seals and chambers.

Kazaroff, John M.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the reaction control system, volume 1

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results for the Reaction Control System (RCS). The purpose of the RCS is to provide thrust in and about the X, Y, Z axes for External Tank (ET) separation; orbit insertion maneuvers; orbit translation maneuvers; on-orbit attitude control; rendezvous; proximity operations (payload deploy and capture); deorbit maneuvers; and abort attitude control. The RCS is situated in three independent modules, one forward in the orbiter nose and one in each OMS/RCS pod. Each RCS module consists of the following subsystems: Helium Pressurization Subsystem; Propellant Storage and Distribution Subsystem; Thruster Subsystem; and Electrical Power Distribution and Control Subsystem. Of the failure modes analyzed, 307 could potentially result in a loss of life and/or loss of vehicle.

Burkemper, V. J.↗

NASA NTRS2020

Evolution of the Preliminary Fault Management Architecture and Design for the Psyche Mission

The Psyche Mission presents the first opportunity toexplore the largest metal asteroid in the solar system, (16)Psyche, which is believed to be the exposed core of a largerplanetesimal that was stripped of its rocky mantle throughmultiple collisions during early solar system formation. Themission was selected in January 2017 for a 2022 launch as partof NASA’s Discovery Program and is uniquely enabled by theintegration of a Solar Electric Propulsion (SEP) Chassisdelivered by Maxar Space Solutions with JPL’s core deepspace avionics, flight software, and fault managementarchitectures. One of the key design tasks is the development ofa fault management system capable of being responsive to theunique elements of the combined JPL and Maxar spacecraftarchitecture. This new design leverages the strengths of eachorganization, with Maxar delivering its well-proven highvoltage power bus and low-thrust electric propulsionsubsystem from its GEO communications satellite product line,and JPL delivering its deep space mission expertise and thehardware and software most critical to deep space missiondesign. The development of a robust low-thrust mission andthe integration of design philosophies and hardware from twoorganizations is not without its challenges though.A key challenge in the development of the Psyche faultmanagement architecture and design is in the integration ofdesign philosophies and hardware from JPL and Maxar. Atthe architecture level, Maxar GEO communications satellitesare developed under the premise of highly responsive groundin the loop for the resolution of anomalies, and theimplementation takes a fail-operational approach to minimizedown time for its customers. In contrast, a deep space missionmust be able to maintain safety with long periods of groundcommunication outage. Additionally, with no time-criticalevents after launch, the Psyche spacecraft will generally failsafe in the presence of anomalous conditions; specialconsideration is being given to this approach, however, tominimize the loss of electric propulsion thrust time, which iscritical to low-thrust missions. At the hardware level, thedetailed definition of interfaces between JPL and Maxarhardware presents a unique challenge in the development andflowdown of fault management requirements, the developmentand implementation of fault monitors and responses, and thedevelopment and verification of fault containment boundaries.This paper describes the evolution of the Psyche faultmanagement architecture and design from the concept studyinto the preliminary design phase, with a focus on the uniquechallenges associated with flying GEO communicationssatellite hardware in deep space, implementing a robust lowthrust mission, and the integration of design philosophies andhardware from JPL and Maxar. Details regarding how thesechallenges are addressed in the fault management design inorder to maximize heritage, leverage the strengths of eachorganization, and minimize risk across the design are alsodiscussed.

Marsh, Danielle↗

NASA NTRS2006

GOES-R STATIONKEEPING AND MOMENTUM MANAGEMENT

The NOAA Geostationary Operational Environmental Satellites (GOES) fire thrusters to remain within a 1deg longitude-latitude box and to dump accumulated angular momentum. In the past, maneuvers have disrupted GOES imaging due to attitude transients and the loss of orbit knowledge. If the R-series of spacecraft to be launched starting in 2012 were to follow current practice, maneuvers would still fail to meet Image Navigation and Registration (INR) specifications during and after thruster firings. Although maneuvers and recovery take only one percent of spacecraft lifetime, they sometimes come at inopportune times, such as hurricane season, when coverage is critical. To alleviate this problem, thruster firings small enough not to affect imaging are being considered. Eliminating post-maneuver recovery periods increases availability and facilitates autonomous operation. Frequent maneuvers also reduce 1ongitudeAatitude variation and allow satellite co-location. Improved orbit observations come from a high-altitude GPS receiver, and improved attitude control comes from thruster torque compensation. This paper reviews the effects of thruster firings on position knowledge and pointing control and suggests that low-thrust burns plus GPS and feedforward control offer a less disruptive approach to GOES-R stationkeeping and momentum management.

Chu, Donald↗

NASA NTRS2005

Trial by Fire

The NASa/ATK Thiokol space shuttle solid rocket motor program has doubled ground test firings and enhanced manufacturing quality and process control to increase safety for Discovery's return to flight. There are a number of places where we've strengthened our engineering and our processes, says Mike Kahn, ATK Thiokol vice president of space launch systems. Protecting the booster against corrosion in the humid Florida environment is one area that has been addressed. Since the loss of Columbia, ATK Thiokol and the Marshall Space Flight Center have completely reevaluated the shuttle solid rocket motor's design certification and found no major problems, Kahn said. The Thiokol solid motors did not play a role in the 2003 Columbia accident, but the motor's older field joint design (since replaced) was the primary cause of the 1986 Challenger accident that killed seven astronauts. The 129 X 12-ft. ATK Thiokol reusable solid rocket motor forms the core of the shuttle's two solid rocket boosters (SRBs). United Space Alliance (USA) has overall responsibility for the booster's nose-mounted systems such as recovery parachutes and aft-mounted thrust vector control systems that increase the length to 149 ft. USA and its subcontractors have also reaffirmed quality control on systems such as the booster's Hamilton Sundstrand hydraulic power units for critical thrust vector control. And to ensure greater safeguards against booster debris jeopardizing the orbiter, a bolt-catcher system to restrain the large bolts, severed at booster separation, was also redesigned.

Covault, Craig↗

NASA NTRS2007

Emergency Flight Control of a Twin-Jet Commercial Aircraft using Manual Throttle Manipulation

The Department of Homeland Security (DHS) created the PCAR (Propulsion-Controlled Aircraft Recovery) project in 2005 to mitigate the ManPADS (man-portable air defense systems) threat to the commercial aircraft fleet with near-term, low-cost proven technology. Such an attack could potentially cause a major FCS (flight control system) malfunction or other critical system failure onboard the aircraft, despite the extreme reliability of current systems. For the situations in which nominal flight controls are lost or degraded, engine thrust may be the only remaining means for emergency flight control [ref 1]. A computer-controlled thrust system, known as propulsion-controlled aircraft (PCA), was developed in the mid 1990s with NASA, McDonnell Douglas and Honeywell. PCA's major accomplishment was a demonstration of an automatic landing capability using only engine thrust [ref 11. Despite these promising results, no production aircraft have been equipped with a PCA system, due primarily to the modifications required for implementation. A minimally invasive option is TOC (throttles-only control), which uses the same control principles as PCA, but requires absolutely no hardware, software or other aircraft modifications. TOC is pure piloting technique, and has historically been utilized several times by flight crews, both military and civilian, in emergency situations stemming from a loss of conventional control. Since the 1990s, engineers at NASA Dryden Flight Research Center (DFRC) have studied TOC, in both simulation and flight, for emergency flight control with test pilots in numerous configurations. In general, it was shown that TOC was effective on certain aircraft for making a survivable landing. DHS sponsored both NASA Dryden Flight Research Center (Edwards, CA) and United Airlines (Denver, Colorado) to conduct a flight and simulation study of the TOC characteristics of a twin-jet commercial transport, and assess the ability of a crew to control an aircraft down to a survivable runway landing using TOC. The PCAR project objective was a set of pilot procedures for operation of a specific aircraft without hydraulics that (a) have been validated in both simulation and flight by relevant personnel, and (b) mesh well with existing commercial operations, maintenance, and training at a minimum cost. As a result of this study, a procedure has been developed to assist a crew in making a survivable landing using TOC. In a simulation environment, line pilots with little or no previous TOC experience performed survivable runway landings after a few practice TOC approaches. In-flight evaluations put line pilots in a simulated emergency situation where TOC was used to recover the aircraft, maneuver to a landing site, and perform an approach down to 200 feet AGL. The results of this research, including pilot observations, procedure comments, recommendations, future work and lessons learned, will he discussed. Flight data and video footage of TOC approaches may also be shown.

Cole, Jennifer H.↗

NASA NTRSDate not supplied

Computational Assessment of Inlet Backflow Effects on Rotating Detonation Engine Performance and Operability

The performance impact of flow reversal at the inlet of an airbreathing rotating detonation engine (RDE) is investigated using 2 and 3-dimensional computational fluid dynamic (CFD) simulations. Flow reversal, or backflow, occurs in RDE inlets in the high-pressure region directly behind the rotating detonation front. This is also where most of the engine thrust or pressure gain is produced. The amount of backflow relative to throughflow depends on the inlet design. For the present work, a simple annular ‘slit’ design is used. The simulations are idealized in several ways, including that fuel and air are premixed, but prevented from reacting when within the inlet region. The results indicate that even with idealizations, the impact of inlet backflow on pressure gain can be substantial. The simulations also reveal an intriguing instability that develops in certain configurations. The mass flow rate into the RDE begins to oscillate at a regular frequency that is substantially less than the detonation rotational frequency. This is accompanied by oscillations in the detonation height. The oscillation amplitude grows over time until the detonation ultimately fails. Both the performance and instability results emphasize the need for carefully designed RDE inlets that provide low loss when flow is in the forward direction, but high resistance when the flow is reversed. Development of such high-diodicity inlets is critical to achieving pressure gain in airbreathing RDE’s.

Detonation↗