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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 NTRS1989

Conjugate (solid/fluid) computational fluid dynamics analysis of the space shuttle solid rocket motor nozzle/case and case field joints

Three-dimensional, conjugate (solid/fluid) heat transfer analyses of new designs of the Solid Rocket Motor (SRM) nozzle/case and case field joints are described. The main focus was to predict the consequences of multiple rips (or debonds) in the ambient cure adhesive packed between the nozzle/case joint surfaces and the bond line between the mating field joint surfaces. The models calculate the transient temperature responses of the various materials neighboring postulated flow/leakpaths into, past, and out from the nozzle/case primary O-ring cavity and case field capture O-ring cavity. These results were used to assess if the design was failsafe (i.e., no potential O-ring erosion) and reusable (i.e., no excessive steel temperatures). The models are adaptions and extensions of the general purpose PHOENICS fluid dynamics code. A non-orthogonal coordinate system was employed and 11,592 control cells for the nozzle/case and 20,088 for the case field joints are used with non-uniform distribution. Physical properties of both fluid and solids are temperature dependent. A number of parametric studies were run for both joints with results showing temperature limits for reuse for the steel case on the nozzle joint being exceeded while the steel case temperatures for the field joint were not. O-ring temperatures for the nozzle joint predicted erosion while for the field joint they did not.

Doran, D.↗

NASA NTRS1993

Advanced composite fuselage technology

Boeing's ATCAS program has completed its third year and continues to progress towards a goal to demonstrate composite fuselage technology with cost and weight advantages over aluminum. Work on this program is performed by an integrated team that includes several groups within The Boeing Company, industrial and university subcontractors, and technical support from NASA. During the course of the program, the ATCAS team has continued to perform a critical review of composite developments by recognizing advances in metal fuselage technology. Despite recent material, structural design, and manufacturing advancements for metals, polymeric matrix composite designs studied in ATCAS still project significant cost and weight advantages for future applications. A critical path to demonstrating technology readiness for composite transport fuselage structures was created to summarize ATCAS tasks for Phases A, B, and C. This includes a global schedule and list of technical issues which will be addressed throughout the course of studies. Work performed in ATCAS since the last ACT conference is also summarized. Most activities relate to crown quadrant manufacturing scaleup and performance verification. The former was highlighted by fabricating a curved, 7 ft. by 10 ft. panel, with cocured hat-stiffeners and cobonded J-frames. In building to this scale, process developments were achieved for tow-placed skins, drape formed stiffeners, braided/RTM frames, and panel cure tooling. Over 700 tests and supporting analyses have been performed for crown material and design evaluation, including structural tests that demonstrated limit load requirements for severed stiffener/skin failsafe damage conditions. Analysis of tests for tow-placed hybrid laminates with large damage indicates a tensile fracture toughness that is higher than that observed for advanced aluminum alloys. Additional recent ATCAS achievements include crown supporting technology, keel quadrant design evaluation, and sandwich process development.

Ilcewicz, Larry B.↗

NASA NTRS1996

Nonlinear Response and Residual Strength of Damaged Stiffened Shells Subjected to Combined Loads

The results of an analytical study of the nonlinear response of stiffened fuselage shells with long cracks are presented. The shells are modeled with a hierarchical modeling strategy and analyzed with a nonlinear shell analysis code that maintains the shell in a nonlinear equilibrium state while the crack is grown. The analysis accurately accounts for global and local structural response phenomena. Fuselage skins, frames stringers and failsafe straps are included in the models. Results are presented for various combinations of internal pressure and mechanical bending, vertical shear and torsion loads, and the effects of crack orientation and location on the shell response are described. These results indicate that the nonlinear interaction between the in-plane stress resultants and the out-of-plane displacements near a crack can significantly affect the structural response of the shell, and the stress-intensity factors associated with a crack that are used to predict residual strength. The effects of representative combined loading conditions on the stress-intensity factors associated with a crack are presented. The effects of varying structural parameters on the stress-intensity factors associated with a crack, and on self-similar and non-self-similar crack-growth are also presented.

Starnes, James H., Jr.↗

NASA NTRS1998

SLR2000: a microlaser-based single photoelectron satellite laser ranging system

SLR2000 is an autonomous and eyesafe satellite laser ranging (SLR) station with an expected single shot range precision of about one centimeter and a normal point (time-averaged) precision better than 3 mm. The system wil provide continuous 24 hour tracking coverage for a constellation of over twenty artificial satellites. Replication costs are expected to be roughly an order of magnitude less than current operational systems, and the system will be about 75% less expensive to operate and maintain relative to manned systems. Computer simulations have predicted a daylight tracking capability to GPS and lower satellites with telescope apertures of 40 cm and have demonstrated the ability of our current autotracking algorithm to extract mean signal strengths below .001 photoelectrons per pulse from daytime background noise. The dominant cost driver in present SLR systems is the onsite and central infrastructure manpower required to operate the system, to service and maintain the complex subsystems, and to ensure that the transmitted laser beam is not a hazard to onsite personnel or to overflying aircraft. To keep development, fabrication, and maintenance costs at a minimum, we adopted the following design philosophies: (1) use off the shelf commercial components wherever possible; this allows rapid component replacement and "outsourcing" of engineering support; (2) use smaller telescopes (less than 50 cm) since this constrains the cost, size, and weight of the telescope and tracking mount; and (3) for low maintenance and failsafe reliability, choose simple versus complex technical approaches and, where possible, use passive techniques and components rather than active ones. Adherence to these philosophies has led to the SLR2000 design described here.

Degnan, John J.↗

NASA NTRS1996

A Risk Assessment Model for Reduced Aircraft Separation: A Quantitative Method to Evaluate the Safety of Free Flight

As new technologies and procedures are introduced into the National Airspace System, whether they are intended to improve efficiency, capacity, or safety level, the quantification of potential changes in safety levels is of vital concern. Applications of technology can improve safety levels and allow the reduction of separation standards. An excellent example is the Precision Runway Monitor (PRM). By taking advantage of the surveillance and display advances of PRM, airports can run instrument parallel approaches to runways separated by 3400 feet with the same level of safety as parallel approaches to runways separated by 4300 feet using the standard technology. Despite a wealth of information from flight operations and testing programs, there is no readily quantifiable relationship between numerical safety levels and the separation standards that apply to aircraft on final approach. This paper presents a modeling approach to quantify the risk associated with reducing separation on final approach. Reducing aircraft separation, both laterally and longitudinally, has been the goal of several aviation R&D programs over the past several years. Many of these programs have focused on technological solutions to improve navigation accuracy, surveillance accuracy, aircraft situational awareness, controller situational awareness, and other technical and operational factors that are vital to maintaining flight safety. The risk assessment model relates different types of potential aircraft accidents and incidents and their contribution to overall accident risk. The framework links accident risks to a hierarchy of failsafe mechanisms characterized by procedures and interventions. The model will be used to assess the overall level of safety associated with reducing separation standards and the introduction of new technology and procedures, as envisaged under the Free Flight concept. The model framework can be applied to various aircraft scenarios, including parallel and in-trail approaches. This research was performed under contract to NASA and in cooperation with the FAA's Safety Division (ASY).

Cassell, Rick↗

NASA NTRS1999

Three-Dimensional Gear Crack Propagation Studied

Gears used in current helicopters and turboprops are designed for light weight, high margins of safety, and high reliability. However, unexpected gear failures may occur even with adequate tooth design. To design an extremely safe system, the designer must ask and address the question, "What happens when a failure occurs?" With gear-tooth bending fatigue, tooth or rim fractures may occur. A crack that propagates through a rim will be catastrophic, leading to disengagement of the rotor or propeller, loss of an aircraft, and possible fatalities. This failure mode should be avoided. A crack that propagates through a tooth may or may not be catastrophic, depending on the design and operating conditions. Also, early warning of this failure mode may be possible because of advances in modern diagnostic systems. One concept proposed to address bending fatigue fracture from a safety aspect is a splittooth gear design. The prime objective of this design would be to control crack propagation in a desired direction such that at least half of the tooth would remain operational should a bending failure occur. A study at the NASA Lewis Research Center analytically validated the crack-propagation failsafe characteristics of a split-tooth gear. It used a specially developed three-dimensional crack analysis program that was based on boundary element modeling and principles of linear elastic fracture mechanics. Crack shapes as well as the crack-propagation life were predicted on the basis of the calculated stress intensity factors, mixed-mode crack-propagation trajectory theories, and fatigue crack-growth theories. The preceding figures show the effect of the location of initial cracks on crack propagation. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth was simulated in a case study to evaluate crack-propagation paths. Tooth fracture was predicted from the crackgrowth simulation for an initial crack in the tooth fillet region. This was the desired failure mode for an ultrasafe design. Lastly, tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. This effect needs to be considered in the design of a split-tooth configuration. This work was done in-house at Lewis in support of the National Rotorcraft Technology Center project, Ultra-Safe Gear Design, with the Boeing Defense and Space Group. The crack-propagation package was developed by the Cornell Fracture Group at Cornell University. The reported results, which are the initial findings of Lewis gear-crackpropagation research for the Rotorcraft Base Program, will be further investigated to develop generalized gear design guidelines.

Lewicki, David G.↗

NASA NTRS2005

System-Level Design of a Shape Memory Alloy Actuator for Active Clearance Control in the High-Pressure Turbine

This paper describes results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 inches. Design results show that an actuator comprised of 10 wires 2 inches in length is adequate for control at critical engine operating points and still exhibits acceptable failsafe operability and cycle life. A proportional-integral-derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

DeCastro, Jonathan A.↗

NASA NTRS2006

Progress on Shape Memory Alloy Actuator Development for Active Clearance Control

Results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine has been conducted. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 in. Design results show that an actuator comprised of 10 wires 2 in. in length is adequate for control at critical engine operating points and still exhibit acceptable failsafe operability and cycle life. A proportional-integral-derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

DeCastro, Jonathan↗

NASA NTRS2009

NASA Tech Briefs, October 2009

Topics covered include: Light-Driven Polymeric Bimorph Actuators; Guaranteeing Failsafe Operation of Extended-Scene Shack-Hartmann Wavefront Sensor Algorithm; Cloud Water Content Sensor for Sounding Balloons and Small UAVs; Pixelized Device Control Actuators for Large Adaptive Optics; T-Slide Linear Actuators; G4FET Implementations of Some Logic Circuits; Electrically Variable or Programmable Nonvolatile Capacitors; System for Automated Calibration of Vector Modulators; Complementary Paired G4FETs as Voltage-Controlled NDR Device; Three MMIC Amplifiers for the 120-to-200 GHz Frequency Band; Low-Noise MMIC Amplifiers for 120 to 180 GHz; Using Ozone To Clean and Passivate Oxygen-Handling Hardware; Metal Standards for Waveguide Characterization of Materials; Two-Piece Screens for Decontaminating Granular Material; Mercuric Iodide Anticoincidence Shield for Gamma-Ray Spectrometer; Improved Method of Design for Folding Inflatable Shells; Ultra-Large Solar Sail; Cooperative Three-Robot System for Traversing Steep Slopes; Assemblies of Conformal Tanks; Microfluidic Pumps Containing Teflon[Trademark] AF Diaphragms; Transparent Conveyor of Dielectric Liquids or Particles; Multi-Cone Model for Estimating GPS Ionospheric Delays; High-Sensitivity GaN Microchemical Sensors; On the Divergence of the Velocity Vector in Real-Gas Flow; Progress Toward a Compact, Highly Stable Ion Clock; Instruments for Imaging from Far to Near; Reflectors Made from Membranes Stretched Between Beams; Integrated Risk and Knowledge Management Program -- IRKM-P; LDPC Codes with Minimum Distance Proportional to Block Size; Constructing LDPC Codes from Loop-Free Encoding Modules; MMICs with Radial Probe Transitions to Waveguides; Tests of Low-Noise MMIC Amplifier Module at 290 to 340 GHz; and Extending Newtonian Dynamics to Include Stochastic Processes.

Source record↗

NASA NTRS2012

Expanding AirSTAR Capability for Flight Research in an Existing Avionics Design

The NASA Airborne Subscale Transport Aircraft Research (AirSTAR) project is an Unmanned Aerial Systems (UAS) test bed for experimental flight control laws and vehicle dynamics research. During its development, the test bed has gone through a number of system permutations, each meant to add functionality to the concept of operations of the system. This enabled the build-up of not only the system itself, but also the support infrastructure and processes necessary to support flight operations. These permutations were grouped into project phases and the move from Phase-III to Phase-IV was marked by a significant increase in research capability and necessary safety systems due to the integration of an Internal Pilot into the control system chain already established for the External Pilot. The major system changes in Phase-IV operations necessitated a new safety and failsafe system to properly integrate both the Internal and External Pilots and to meet acceptable project safety margins. This work involved retrofitting an existing data system into the evolved concept of operations. Moving from the first Phase-IV aircraft to the dynamically scaled aircraft further involved restructuring the system to better guard against electromagnetic interference (EMI), and the entire avionics wiring harness was redesigned in order to facilitate better maintenance and access to onboard electronics. This retrofit and harness re-design will be explored and how it integrates with the evolved Phase-IV operations.

Laughter, Sean A.↗

NASA NTRS2014

Preliminary Study on Acoustic Detection of Faults Experienced by a High-Bypass Turbofan Engine

The vehicle integrated propulsion research (VIPR) effort conducted by NASA and several partners provided an unparalleled opportunity to test a relatively low TRL concept regarding the use of far field acoustics to identify faults occurring in a high bypass turbofan engine. Though VIPR Phase II ground based aircraft installed engine testing wherein a multitude of research sensors and methods were evaluated, an array of acoustic microphones was used to determine the viability of such an array to detect failures occurring in a commercially representative high bypass turbofan engine. The failures introduced during VIPR testing included commanding the engine's low pressure compressor (LPC) exit and high pressure compressor (HPC) 14th stage bleed values abruptly to their failsafe positions during steady state

acoustics↗

NASA NTRS2013

4DoF Drift Free Navigation Using Inertial Cues and Optical Flow

In this paper, we describe a novel approach in fusing optical flow with inertial cues (3D acceleration and 3D angular velocities) in order to navigate a Micro Aerial Vehicle (MAV) drift free in 4DoF and metric velocity. Our approach only requires two consecutive images with a minimum of three feature matches. It does not require any (point) map nor any type of feature history. Thus it is an inherently failsafe approach that is immune to map and feature-track failures. With these minimal requirements we show in real experiments that the system is able to navigate drift free in all angles including yaw, in one metric position axis, and in 3D metric velocity. Furthermore, it is a power-on-and-go system able to online self-calibrate the inertial biases, the visual scale and the full 6DoF extrinsic transformation parameters between camera and IMU.

reconnissance↗

NASA NTRS2008

Dependence of Adaptive Cross-correlation Algorithm Performance on the Extended Scene Image Quality

Recently, we reported an adaptive cross-correlation (ACC) algorithm to estimate with high accuracy the shift as large as several pixels between two extended-scene sub-images captured by a Shack-Hartmann wavefront sensor. It determines the positions of all extended-scene image cells relative to a reference cell in the same frame using an FFT-based iterative image-shifting algorithm. It works with both point-source spot images as well as extended scene images. We have demonstrated previously based on some measured images that the ACC algorithm can determine image shifts with as high an accuracy as 0.01 pixel for shifts as large 3 pixels, and yield similar results for both point source spot images and extended scene images. The shift estimate accuracy of the ACC algorithm depends on illumination level, background, and scene content in addition to the amount of the shift between two image cells. In this paper we investigate how the performance of the ACC algorithm depends on the quality and the frequency content of extended scene images captured by a Shack-Hatmann camera. We also compare the performance of the ACC algorithm with those of several other approaches, and introduce a failsafe criterion for the ACC algorithm-based extended scene Shack-Hatmann sensors.

wave-front sensing and control↗

NASA NTRS2016

NH11B-1726: FrankenRaven: A New Platform for Remote Sensing

Small, modular aircraft are an emerging technology with a goal to maximize flexibility and enable multi-mission support. This reports the progress of an unmanned aerial system (UAS) project conducted at the NASA Ames Research Center (ARC) in 2016. This interdisciplinary effort builds upon the success of the 2014 FrankenEye project to apply rapid prototyping techniques to UAS, to develop a variety of platforms to host remote sensing instruments. In 2016, ARC received AeroVironment RQ-11A and RQ-11B Raven UAS from the US Department of the Interior, Office of Aviation Services. These aircraft have electric propulsion, a wingspan of roughly 1.3m, and have demonstrated reliability in challenging environments. The Raven airframe is an ideal foundation to construct more complex aircraft, and student interns using 3D printing were able to graft multiple Raven wings and fuselages into FrankenRaven aircraft. Aeronautical analysis shows that the new configuration has enhanced flight time, payload capacity, and distance compared to the original Raven. The FrankenRaven avionics architecture replaces the mil-spec avionics with COTS technology based upon the 3DR Pixhawk PX4 autopilot with a safety multiplexer for failsafe handoff to 2.4 GHz RC control and 915 MHz telemetry. This project demonstrates how design reuse, rapid prototyping, and modular subcomponents can be leveraged into flexible airborne platforms that can host a variety of remote sensing payloads and even multiple payloads. Modularity advances a new paradigm: mass-customization of aircraft around given payload(s). Multi-fuselage designs are currently under development to host a wide variety of payloads including a zenith-pointing spectrometer, a magnetometer, a multi-spectral camera, and a RGB camera. After airworthiness certification, flight readiness review, and test flights are performed at Crows Landing airfield in central California, field data will be taken at Kilauea volcano in Hawaii and other locations.

remote sensing↗

NASA NTRS2019

Progressive Damage and Failure Analysis of Bonded Composite Joints at High Energy Dynamic Impacts

Both wing and fuselage structures utilize bonded composite joints for structural efficiency in modern commercial and military aircraft. To ensure compliance with certification requirements mechanical fasteners are typically used as a failsafe mechanism for appropriate strength in the event of complete stiffener disbond. However, the use of fasteners decreases the structural efficiency of the structure by adding weight. This establishes the requirement to better exploit the efficiency of bonded structures and fully understand the failure behavior of adhesively bonded composite structures, particularly when subjected to elevated loading rates due to high energy dynamic impacts (HEDI). For this reason, the NASA Advanced Composite Consortium (ACC) HEDI team developed an experimentation and numerical modeling program for high rate loading of composite joints. In the present work, the response of adhesively bonded composite joints subjected to elevated loading rates is studied numerically and validated against experimental results. Due to dynamic considerations of experiments, the idea of wedge insert was extended to use with Split Hopkinson Pressure Bar (SHPB) testing techniques. Mode-I and Mode-II test configurations were simulated to evaluate the capability of two continuum damage material (CDM) models in LS-DYNA, namely MAT162 and MAT261. Three different levels of fidelity were considered to investigate the level of detail required to numerically predict the failure behavior and the results from high fidelity analysis are presented.

MAT261↗

NASA NTRS2018

Assurance of Autonomy for Robotic Space Missions

While there have been meetings on assurance of autonomy in other application areas, this meeting seeks to develop a roadmap for assurance of autonomy specifically for robotic space missions. Key characteristics that distinguish this application area include: the lack of detailed prior knowledge of the environments in which those missions are to operate; the challenges of mimicking deep space operating conditions for purposes of testing; the need to be highly assured of failsafe operation; limited and delayed (due to speed of light over solar system distances) communication; and the one/few-of-a-kind, must-work-the-first-time nature of most space missions.

Feather, Martin↗

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 NTRS2010

The Certification of Environmental Chambers for Testing Flight Hardware

The JPL chamber certification process for ensuring that test chambers used to test flight hardware meet a minimum standard is critical to the safety of the hardware and personnel. Past history has demonstrated that this process is important due to the catastrophic incidents that could occur if the chamber is not set up correctly. Environmental testing is one of the last phases in the development of a subsystem, and it typically occurs just before integration of flight hardware into the fully assembled flight system. A seemingly insignificant -miscalculation or missed step can necessitate rebuilding or replacing a subsystem due to over-testing or damage from the test chamber. Conversely, under-testing might fail to detect weaknesses that might cause failure when the hardware is in service. This paper describes the process that identifies the many variables that comprise the testing scenario and screening of as built chambers, the training of qualified operators, and a general "what-to-look-for" in minimum standards.

Vacuum Chamber↗