SEARCH · Search NASA

Results for “design and process development”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2

All sources NASA NTRS DOE OSTI

NASA NTRS2014

SLM Produced Hermetically Sealed Isolation Valve

Marshall Space Flight Center (MSFC) has developed a valve concept to replace traditional pyrotechnic-driven isolation valves. This paper will describe the valve design and development process. The valve design uses a stem/wedge to support a disk inside the valve. That disk hermetically seals the pressurized fluids. A release mechanism holds the stem/wedge and a large spring in place. When required to open, a solenoid is energized and pulls the release mechanism allowing the spring to pull the stem/wedge away from the disk. Now the disk is unsupported and the pressure ruptures the disk allowing flow to the outlet of the valve. This paper will provide details of this design, describe the development testing, and show the results from the valve level tests performed. Also, a trade study is presented to show the advantages of this design to a conventional pyrotechnic-based valve.

Richard, James↗

NASA NTRS1999

Launch Vehicle Design Process Description and Training Formulation

A primary NASA priority is to reduce the cost and improve the effectiveness of launching payloads into space. As a consequence, significant improvements are being sought in the effectiveness, cost, and schedule of the launch vehicle design process. In order to provide a basis for understanding and improving the current design process, a model has been developed for this complex, interactive process, as reported in the references. This model requires further expansion in some specific design functions. Also, a training course for less-experienced engineers is needed to provide understanding of the process, to provide guidance for its effective implementation, and to provide a basis for major improvements in launch vehicle design process technology. The objective of this activity is to expand the description of the design process to include all pertinent design functions, and to develop a detailed outline of a training course on the design process for launch vehicles for use in educating engineers whose experience with the process has been minimal. Building on a previously-developed partial design process description, parallel sections have been written for the Avionics Design Function, the Materials Design Function, and the Manufacturing Design Function. Upon inclusion of these results, the total process description will be released as a NASA TP. The design function sections herein include descriptions of the design function responsibilities, interfaces, interactive processes, decisions (gates), and tasks. Associated figures include design function planes, gates, and tasks, along with other pertinent graphics. Also included is an expanded discussion of how the design process is divided, or compartmentalized, into manageable parts to achieve efficient and effective design. A detailed outline for an intensive two-day course on the launch vehicle design process has been developed herein, and is available for further expansion. The course is in an interactive lecture/workshop format to engage the participants in active learning. The course addresses the breadth and depth of the process, requirements, phases, participants, multidisciplinary aspects, tasks, critical elements,as well as providing guidance from previous lessons learned. The participants are led to develop their own understanding of the current process and how it can be improved. Included are course objectives and a session-by-session outline of course content. Also included is an initial identification of visual aid requirements.

Atherton, James↗

NASA NTRS1978

Thermomechanical processing of HAYNES alloy No. 188 sheet to improve creep strength

Improvements in the low strain creep strength of HAYNES alloy No. 188 thin gauge sheet by means of thermomechanical processing were developed. Processing methods designed to develop a sheet with strong crystallographic texture after recrystallization and to optimize grain size were principally studied. The effects of thickness-to-grain diameter ratio and prestrain on low strain creep strength were also briefly examined. Results indicate that the most significant improvements were obtained in the sheets having a strong crystallographic texture. The low strain creep strength of the textured sheets was observed to be superior to that of standard production sheets in the 922 K to 1255 K temperature range. Tensile, stress rupture, fabricability, and surface stability properties of the experimental sheets were also measured and compared to property values reported for the baseline production sheets.

Klarstrom, D. L.↗

NASA NTRS2018

SLS Navigation Model-Based Design Approach

The SLS Program chose to implement a Model-based Design and Model-based Requirements approach for managing component design information and system requirements. This approach differs from previous large-scale design efforts at Marshall Space Flight Center where design documentation alone conveyed information required for vehicle design and analysis and where extensive requirements sets were used to scope and constrain the design. The SLS Navigation Team has been responsible for the Program-controlled Design Math Models (DMMs) which describe and represent the performance of the Inertial Navigation System (INS) and the Rate Gyro Assemblies (RGAs) used by Guidance, Navigation, and Controls (GN&C). The SLS Navigation Team is also responsible for the navigation algorithms. The navigation algorithms are delivered for implementation on the flight hardware as a DMM. For the SLS Block 1-B design, the additional GPS Receiver hardware is managed as a DMM at the vehicle design level. This paper provides a discussion of the processes and methods used to engineer, design, and coordinate engineering trades and performance assessments using SLS practices as applied to the GN&C system, with a particular focus on the Navigation components. These include composing system requirements, requirements verification, model development, model verification and validation, and modeling and analysis approaches. The Model-based Design and Requirements approach does not reduce the effort associated with the design process versus previous processes used at Marshall Space Flight Center. Instead, the approach takes advantage of overlap between the requirements development and management process, and the design and analysis process by efficiently combining the control (i.e. the requirement) and the design mechanisms. The design mechanism is the representation of the component behavior and performance in design and analysis tools. The focus in the early design process shifts from the development and management of design requirements to the development of usable models, model requirements, and model verification and validation efforts. The models themselves are represented in C/C++ code and accompanying data files. Under the idealized process, potential ambiguity in specification is reduced because the model must be implementable versus a requirement which is not necessarily subject to this constraint. Further, the models are shown to emulate the hardware during validation. For models developed by the Navigation Team, a common interface/standalone environment was developed. The common environment allows for easy implementation in design and analysis tools. Mechanisms such as unit test cases ensure implementation as the developer intended. The model verification and validation process provides a very high level of component design insight. The origin and implementation of the SLS variant of Model-based Design is described from the perspective of the SLS Navigation Team. The format of the models and the requirements are described. The Model-based Design approach has many benefits but is not without potential complications. Key lessons learned associated with the implementation of the Model Based Design approach and process from infancy to verification and certification are discussed

Oliver, T. Emerson↗

NASA NTRS2009

Overview of the Altair Lunar Lander Thermal Control System Design

NASA's Constellation Program has been developed to successfully return humans to the Lunar surface prior to 2020. The Constellation Program includes several different project offices including Altair, which is the next generation Lunar Lander. The planned Altair missions are very different than the Lunar missions accomplished during the Apollo era. These differences have resulted in a significantly different thermal control system architecture. The Altair project has employed a rather unique development approach as compared with previous manned spacecraft programs. Altair started the design process by developing a single-string (no fault tolerance), minimum functionality design. This first design and analysis cycle resulted in the baseline design for the entire process. From this point of departure, Altair continued the development process by adding vehicle functionality for the purposes of minimizing the risk of Loss Of Crew (LOC) and Loss Of Mission (LOM). Through the subsequent design and analysis cycles, the project office compared the added mass associated with the reduction of LOC/LOM and selected the most mass efficient design solutions. The current paper will summarize the Altair mission profile, the operational phases, and the LOC/LOM decisions that were made during the various design cycles. The evolution of the thermal control system design through Lunar Design and Analysis Cycle 3 (LDAC-3) will also be described in this paper.

Stephan, Ryan A.↗

NASA NTRS2014

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Protz, Christopher↗

NASA NTRS1999

Analysis and Inverse Design of the HSR Arrow Wing Configuration with Fuselage, Wing, and Flow Through Nacelles

The design process for developing the natural flow wing design on the HSR arrow wing configuration utilized several design tools and analysis methods. Initial fuselage/wing designs were generated with inviscid analysis and optimization methods in conjunction with the natural flow wing design philosophy. A number of designs were generated, satisfying different system constraints. Of the three natural flow wing designs developed, the NFWAc2 configuration is the design which satisfies the constraints utilized by McDonnell Douglas Aerospace (MDA) in developing a series of optimized configurations; a wind tunnel model of the MDA designed OPT5 configuration was constructed and tested. The present paper is concerned with the viscous analysis and inverse design of the arrow wing configurations, including the effects of the installed diverters/nacelles. Analyses were conducted with OVERFLOW, a Navier-Stokes flow solver for overset grids. Inverse designs were conducted with OVERDISC, which couples OVERFLOW with the CDISC inverse design method. An initial system of overset grids was generated for the OPT5 configuration with installed diverters/nacelles. An automated regridding process was then developed to use the OPT5 component grids to create grids for the natural flow wing designs. The inverse design process was initiated using the NFWAc2 configuration as a starting point, eventually culminating in the NFWAc4 design-for which a wind tunnel model was constructed. Due to the time constraints on the design effort, initial analyses and designs were conducted with a fairly coarse grid; subsequent analyses have been conducted on a refined system of grids. Comparisons of the computational results to experiment are provided at the end of this paper.

Krist, Steven E.↗

NASA NTRS2004

Development of the Planar Inlet Design and Analysis Process (PINDAP)

The aerodynamic development of an engine inlet requires a comprehensive program of both wind tunnel testing and Computational Fluid Dynamics (CFD) simulations. To save time and resources, much "testing" is done using CFD before any design ever enters a wind tunnel. The focus of my project this summer is on CFD analysis tool development. In particular, I am working to further develop the capabilities of the Planar Inlet Design and Analysis Process (PINDAP). "PINDAP" is a collection of computational tools that allow for efficient and accurate design and analysis of the aerodynamics about and through inlets that can make use of a planar (two-dimensional or axisymmetric) geometric and flow assumption. PINDAP utilizes the WIND CFD flow solver, which is capable of simulating the turbulent, compressible flow field. My project this summer is a continuation of work that I performed for two previous summers. Two years ago, I used basic features of the PINDAP to design a Mach 5 hypersonic scramjet engine inlet and to demonstrate the feasibility of the PINDAP. The following summer, I worked to develop its geometry and grid generation capabilities to include subsonic and supersonic inlets, complete bodies and cowls, conic leading and trailing edges, as well as airfoils. These additions allowed for much more design flexibility when using the program.

Gruber, Christopher R.↗

NASA NTRS1999

High Reynolds Number Predictions for the Baseline Arrow Wing at Mach 2.48

The NASA High Speed Research (HSR) Program is intended to establish a technology base enabling industry development of an economically viable and environmentally acceptable second generation high speed civil transport (HSCT). The objective of the Configuration Aerodynamics task of the program is the development of aerodynamic drag reduction, stability and control, and propulsion airframe integration technologies required to support the HSCT development process. Aerodynamic design tools are being developed, evaluated, and validated through ground based experimental testing. In addition, methods for ground to flight scaling are being developed and refined.

Rivers, Melissa↗

NASA NTRS2003

Probabilistic Unsteady Aerodynamic Analysis

Probabilistic CFD design is needed because we are asked to do more with less. To cost effectively accomplish the design task, we need to formally quantify the effect of uncertainties (variables) in the design. Probabilistic design is one effective method to formally quantify the effect of uncertainties. Our objective is to establish a revolutionary new early design process, by developing non-deterministic physics-based probabilistic design tools, which will include all the life cycle processes. This work was concerned with the usefulness of parametric optimization method coupled with a Navier-Stokes analysis code for the aero-thermodynamic design of turbomachinery combustor liner. The interconnection between the CFD code and NESSUS codes will facilitate the coupling between the thermal profiles and structural design. We have developed new concepts for reducing the computational cost of unsteady, three-dimensional, compressible aerodynamic analyses for multistage turbomachinery flows. The flow was modeled by the three-dimensional Favre-Reynolds-averaged Navier-Stokes equations using the k-E turbulence closure, which was integrated using an implicit third-order upwind solver. The methodology developed in this work is expected to lead to the design optimization of turbomachinery blades.

Gorla, Rama S. R.↗

NASA NTRS2002

Probabilistic Study of Fluid Structure Interaction

Probabilistic CFD design is needed because we are asked to do more with less. To cost effectively accomplish the design task, we need to formally quantify the effect of uncertainties (variables) in the design. Probabilistic design is one effective method to formally quantify the effect of uncertainties. Our objective is to establish a revolutionary new early design process, by developing non-deterministic physics-based probabilistic design tools, which will include all the life cycle processes. Breakthroughs will be sought in speed, accuracy, intelligence, and usability of the system. This paper is concerned with the usefulness of parametric optimization method coupled with a Navier-Stokes analysis code for the aero-thermodynamic design of turbomachinery combustor liner. The interconnection between the CFD code and NESSUS codes facilitated the coupling between the thermal profiles and structural design. We have developed new concepts for reducing the computational cost of unsteady, three-dimensional, compressible aerodynamic analyses for multistage turbomachinery flows. The flow was modeled by the three-dimensional Favre-Reynolds-averaged Navier-Stokes equations using the k-epsilon turbulence closure, which was integrated using an implicit third-order upwind solver. The methodology developed in this paper is expected to lead to the design optimization of turbomachinery blades.

Gorla, Rama S. R.↗

NASA NTRS2014

Recipe for Success: Digital Viewables

The Engineering Services Contract (ESC) and Information Management Communication Support contract (IMCS) at Kennedy Space Center (KSC) provide services to NASA in respect to flight and ground systems design and development. These groups provides the necessary tools, aid, and best practice methodologies required for efficient, optimized design and process development. The team is responsible for configuring and implementing systems, software, along with training, documentation, and administering standards. The team supports over 200 engineers and design specialists with the use of Windchill, Creo Parametric, NX, AutoCAD, and a variety of other design and analysis tools.

design and process development↗

NASA NTRS2005

The Systems Engineering Process for Human Support Technology Development

Systems engineering is designing and optimizing systems. This paper reviews the systems engineering process and indicates how it can be applied in the development of advanced human support systems. Systems engineering develops the performance requirements, subsystem specifications, and detailed designs needed to construct a desired system. Systems design is difficult, requiring both art and science and balancing human and technical considerations. The essential systems engineering activity is trading off and compromising between competing objectives such as performance and cost, schedule and risk. Systems engineering is not a complete independent process. It usually supports a system development project. This review emphasizes the NASA project management process as described in NASA Procedural Requirement (NPR) 7120.5B. The process is a top down phased approach that includes the most fundamental activities of systems engineering - requirements definition, systems analysis, and design. NPR 7120.5B also requires projects to perform the engineering analyses needed to ensure that the system will operate correctly with regard to reliability, safety, risk, cost, and human factors. We review the system development project process, the standard systems engineering design methodology, and some of the specialized systems analysis techniques. We will discuss how they could apply to advanced human support systems development. The purpose of advanced systems development is not directly to supply human space flight hardware, but rather to provide superior candidate systems that will be selected for implementation by future missions. The most direct application of systems engineering is in guiding the development of prototype and flight experiment hardware. However, anticipatory systems engineering of possible future flight systems would be useful in identifying the most promising development projects.

Jones, Harry↗

NASA NTRS1999

Human Modeling Evaluations in Microgravity Workstation and Restraint Development

The International Space Station (ISS) will provide long-term missions which will enable the astronauts to live and work, as well as, conduct research in a microgravity environment. The dominant factor in space affecting the crew is "weightlessness" which creates a challenge for establishing workstation microgravity design requirements. The crewmembers will work at various workstations such as Human Research Facility (HRF), Microgravity Sciences Glovebox (MSG) and Life Sciences Glovebox (LSG). Since the crew will spend considerable amount of time at these workstations, it is critical that ergonomic design requirements are integral part of design and development effort. In order to achieve this goal, the Space Human Factors Laboratory in the Johnson Space Center Flight Crew Support Division has been tasked to conduct integrated evaluations of workstations and associated crew restraints. Thus, a two-phase approach was used: 1) ground and microgravity evaluations of the physical dimensions and layout of the workstation components, and 2) human modeling analyses of the user interface. Computer-based human modeling evaluations were an important part of the approach throughout the design and development process. Human modeling during the conceptual design phase included crew reach and accessibility of individual equipment, as well as, crew restraint needs. During later design phases, human modeling has been used in conjunction with ground reviews and microgravity evaluations of the mock-ups in order to verify the human factors requirements. (Specific examples will be discussed.) This two-phase approach was the most efficient method to determine ergonomic design characteristics for workstations and restraints. The real-time evaluations provided a hands-on implementation in a microgravity environment. On the other hand, only a limited number of participants could be tested. The human modeling evaluations provided a more detailed analysis of the setup. The issues identified during the real-time testing were investigated in the human modeling analyses. In some cases, the opposite was true where preliminary human modeling analyses provided the design engineers with critical issues that needed to be addressed further. This extensive approach provided an effective means to fully address ergonomic design considerations and accurately identify critical issues.

Whitmore, Mihriban↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2009

Ares I-X Flight Test Vehicle Similitude to the Ares I Crew Launch Vehicle

The Ares I-X Flight Test Vehicle is the first in a series of flight test vehicles that will take the Ares I Crew Launch Vehicle design from development to operational capability. Ares I-X is scheduled for a 2009 flight date, early enough in the Ares I design and development process so that data obtained from the flight can impact the design of Ares I before its Critical Design Review. Decisions on Ares I-X scope, flight test objectives, and FTV fidelity were made prior to the Ares I systems requirements being baselined. This was necessary in order to achieve a development flight test to impact the Ares I design. Differences between the Ares I-X and the Ares I configurations are artifacts of formulating this experimental project at an early stage and the natural maturation of the Ares I design process. This paper describes the similarities and differences between the Ares I-X Flight Test Vehicle and the Ares I Crew Launch Vehicle. Areas of comparison include the outer mold line geometry, aerosciences, trajectory, structural modes, flight control architecture, separation sequence, and relevant element differences. Most of the outer mold line differences present between Ares I and Ares I-X are minor and will not have a significant effect on overall vehicle performance. The most significant impacts are related to the geometric differences in Orion Crew Exploration Vehicle at the forward end of the stack. These physical differences will cause differences in the flow physics in these areas. Even with these differences, the Ares I-X flight test is poised to meet all five primary objectives and six secondary objectives. Knowledge of what the Ares I-X flight test will provide in similitude to Ares I - as well as what the test will not provide - is important in the continued execution of the Ares I-X mission leading to its flight and the continued design and development of Ares I.

Huebner, Lawrence D.↗

NASA NTRS1993

The use of designed experiments in the process development of continuous propellant mixing

A continuous mix pilot plant was constructed at Aerojet Propulsion Division in Sacramento, California to develop a robust propellant mixing process for the full scale plant that was to be built at the NASA Advanced Solid Rocket Motor facility Yellow Creek, Mississippi. The plant was used to conduct dozens of subsystem and full system mixing tests for evaluation of equipment, processing methods, and control schemes for later use at the production plant. As a culmination to this work, a series of designed experiments were conducted using an eight run Taguchi analysis with four factors at two levels each to determine the primary effect of processing parameters on propellant ballistic and mechanical properties. The factors examined in these runs included the propellant production rate (454 (1000) and 622 kg/hr (1371 Ib/hr)), the product temperature out of the mixer (49 (120) and 63 deg C (145 deg F)), mixer screw speed (75 and 90 rpm), and the deaerator excess capacity (20 and 80 percent). Measured response variables included the uncured and cured density, Crawford Bomb liquid strand burning rates, and selected mechanical properties. The experiment revealed that several of the response variables displayed significant changes from run-to-run with the product temperature being the single most important factor. After concluding this experiment, a twenty-six hour confirmation run was conducted to verify the conclusions reached in the designed experiment. The extended run produced over 12,250 kgs (27,000 lbs) of propellant meeting all of the pre-run targeted properties including density (1.803 g/cc (0.065 lb/in(exp 3)) with a 0.12 percent coefficient of variation (CV) at 25 deg C (77 deg F)), liquid strand burn rate (0.889 cm/s (0.350 in/s) with a 0.69 percent CV at 4210 KPa (610 psig), 15.6 deg C (60 deg F)), nominal maximum stress (828 KPa (120 psig) with a 2.84 percent CV, S&E at 25 deg C (77 deg F), 5.08 cm/min (2 in/min)), strain at nominal maximum (47.4 percent with a 3.96 percent CV), and initial tangent modulus (5349 KPa (775 psig) with a 7.26 percent CV).

Campbell, J. A.↗