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NASA NTRS2012

Development and Testing of Propulsion Health Management

An Integrated Vehicle Health Management system aims to maintain vehicle health through detection, diagnostics, state awareness, prognostics, and lastly, mitigation of detrimental situations for each of the vehicle subsystems and throughout the vehicle as a whole. This paper discusses efforts to advance Propulsion Health Management technology for in-flight applications to provide improved propulsion sensors measuring a range of parameters, improve ease of propulsion sensor implementation, and to assess and manage the health of gas turbine engine flow-path components. This combined work is intended to enable real-time propulsion state assessments to accurately determine the vehicle health, reduce loss of control, and to improve operator situational awareness. A unique aspect of this work is demonstration of these maturing technologies on an operational engine.

Hunter, Gary W.↗

NASA NTRS2012

Testing of the NASA Hypersonics Project Combined Cycle Engine Large Scale Inlet Mode Transition Experiment (CCE LlMX)

Status on an effort to develop Turbine Based Combined Cycle (TBCC) propulsion is described. This propulsion technology can enable reliable and reusable space launch systems. TBCC propulsion offers improved performance and safety over rocket propulsion. The potential to realize aircraft-like operations and reduced maintenance are additional benefits. Among most the critical TBCC enabling technologies are: 1) mode transition from turbine to scramjet propulsion, 2) high Mach turbine engines and 3) TBCC integration. To address these TBCC challenges, the effort is centered on a propulsion mode transition experiment and includes analytical research. The test program, the Combined-Cycle Engine Large Scale Inlet Mode Transition Experiment (CCE LIMX), was conceived to integrate TBCC propulsion with proposed hypersonic vehicles. The goals address: (1) dual inlet operability and performance, (2) mode-transition sequences enabling a switch between turbine and scramjet flow paths, and (3) turbine engine transients during transition. Four test phases are planned from which a database can be used to both validate design and analysis codes and characterize operability and integration issues for TBCC propulsion. In this paper we discuss the research objectives, features of the CCE hardware and test plans, and status of the parametric inlet characterization testing which began in 2011. This effort is sponsored by the NASA Fundamental Aeronautics Hypersonics project

Saunders, J. D.↗

NASA NTRS2012

Configuration Effects on Liner Performance

The acoustic performance of a duct liner depends not only on the intrinsic properties of the liner but also on the configuration of the duct in which it is used. A series of experiments is performed in the NASA Langley Research Center Curved Duct Test Rig (at Mach 0.275) to evaluate the effect of duct configuration on the acoustic performance of single degree of freedom perforate-over-honeycomb liners. The liners form the sidewalls of the duct's test section. Variations of duct configuration include: asymmetric (liner on one side and hard wall opposite) and symmetric (liner on both sides) wall treatment; inlet and exhaust orientation, in which the sound propagates either against or with the flow; and straight and curved flow path. The effect that duct configuration has on the overall acoustic performance, particularly the shift in frequency and magnitude of peak attenuation, is quantified. The redistribution of incident mode content is shown. The liners constitute the side walls of the liner test section and the scatter of incident horizontal order 1 mode by the asymmetric treatment and order 2 mode by the symmetric treatment into order 0 mode is shown. Scatter of order 0 incident modes into higher order modes is also shown. This redistribution of mode content is significant because it indicates that the liner design can be manipulated such that energy is scattered into more highly attenuated modes, thus enhancing liner performance.

Gerhold, Carl H.↗

NASA NTRS2013

Shock Position Control for Mode Transition in a Turbine Based Combined Cycle Engine Inlet Model

A dual flow-path inlet for a turbine based combined cycle (TBCC) propulsion system is to be tested in order to evaluate methodologies for performing a controlled inlet mode transition. Prior to experimental testing, simulation models are used to test, debug, and validate potential control algorithms which are designed to maintain shock position during inlet disturbances. One simulation package being used for testing is the High Mach Transient Engine Cycle Code simulation, known as HiTECC. This paper discusses the development of a mode transition schedule for the HiTECC simulation that is analogous to the development of inlet performance maps. Inlet performance maps, derived through experimental means, describe the performance and operability of the inlet as the splitter closes, switching power production from the turbine engine to the Dual Mode Scram Jet. With knowledge of the operability and performance tradeoffs, a closed loop system can be designed to optimize the performance of the inlet. This paper demonstrates the design of the closed loop control system and benefit with the implementation of a Proportional-Integral controller, an H-Infinity based controller, and a disturbance observer based controller; all of which avoid inlet unstart during a mode transition with a simulated disturbance that would lead to inlet unstart without closed loop control.

Csank, Jeffrey T.↗

NASA NTRS2012

Review and Assessment of JPL's Thermal Margins

JPL has captured its experience from over four decades of robotic space exploration into a set of design rules. These rules have gradually changed into explicit requirements and are now formally implemented and verified. Over an extended period of time, the initial understanding of intent and rationale for these rules has faded and rules are now frequently applied without further consideration. In the meantime, mission classes and their associated risk postures have evolved, coupled with resource constraints and growing design diversity, bringing into question the current "one size fits all" thermal margin approach. This paper offers a systematic review of the heat flow path from an electronic junction to the eventual heat rejection to space. This includes the identification of different regimes along this path and the associated requirements. The work resulted in a renewed understanding of the intent behind JPL requirements for hot thermal margins and a framework for relevant considerations, which in turn enables better decision making when a deviation to these requirements is considered.

derating↗

NASA NTRS2013

Investigation of a Cross-Correlation Based Optical Strain Measurement Technique for Detecting radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASA`s Fundamental Aeronautics Program is extremely interested in the development of novel measurement technologies, such as optical surface measurements in the internal parts of a flow path, for in situ health monitoring of gas turbine engines. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. In the present study, a cross-correlation imaging technique is investigated in a proof-of-concept study as a possible optical technique to measure the radial growth and strain field on an already cracked sub-scale turbine engine disk under loaded conditions in the NASA Glenn Research Center`s High Precision Rotordynamics Laboratory. The optical strain measurement technique under investigation offers potential fault detection using an applied high-contrast random speckle pattern and imaging the pattern under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds induces an external load, resulting in a radial growth of the disk of approximately 50.0-im in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will be undistorted; however, during rotation the cracked region will grow radially, thus causing the applied particle pattern to be .shifted`. The resulting particle displacements between the two images will then be measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. In order to develop and validate this optical strain measurement technique an initial proof-of-concept experiment is carried out in a controlled environment. Using PIV optimization principles and guidelines, three potential speckle patterns, for future use on the rotating disk, are developed and investigated in the controlled experiment. A range of known shifts are induced on the patterns; reference and data images are acquired before and after the induced shift, respectively, and the images are processed using the cross-correlation algorithms in order to determine the particle displacements. The effectiveness of each pattern at resolving the known shift is evaluated and discussed in order to choose the most suitable pattern to be implemented onto a rotating disk in the Rotordynamics Lab. Although testing on the rotating disk has not yet been performed, the driving principles behind the development of the present optical technique are based upon critical aspects of the future experiment, such as the amount of expected radial growth, disk analysis, and experimental design and are therefore addressed in the paper.

Clem, Michelle M.↗

NASA NTRS2013

Micromachined Active Magnetic Regenerator for Low-Temperature Magnetic Coolers

A design of an Active Magnetic Regenerative Refrigeration (AMRR) system has been developed for space applications. It uses an innovative 3He cryogenic circulator to provide continuous remote/distributed cooling at temperatures in the range of 2 K with a heat sink at about 15 K. A critical component technology for this cooling system is a highly efficient active magnetic regenerator, which is a regenerative heat exchanger with its matrix material made of magnetic refrigerant gadolinium gallium garnet (GGG). Creare Inc. is developing a microchannel GGG regenerator with an anisotropic structured bed for high system thermal efficiency. The regenerator core consists of a stack of thin, single-crystal GGG disks alternating with thin polymer insulating layers. The insulating layers help minimize the axial conduction heat leak, since GGG has a very high thermal conductivity in the regenerator s operating temperature range. The GGG disks contain micro channels with width near 100 micrometers, which enhance the heat transfer between the circulating flow and the refrigerant bed. The unique flow configuration of the GGG plates ensures a uniform flow distribution across the plates. The main fabrication challenges for the regenerator are the machining of high-aspect-ratio microchannels in fragile, single-crystal GGG disks and fabrication and assembly of the GGG insulation layers. Feasibility demonstrations to date include use of an ultrashort- pulse laser to machine microchannels without producing unacceptable microcracking or deposition of recast material, as shown in the figure, and attachment of a thin insulation layer to a GGG disk without obstructing the flow paths. At the time of this reporting, efforts were focused on improving the laser machining process to increase machining speed and further reduce microcracking.

Chen, Weibo↗

NASA NTRS2013

Advanced Shock Position Control for Mode Transition in a Turbine Based Combined Cycle Engine Inlet Model

A dual flow-path inlet system is being tested to evaluate methodologies for a Turbine Based Combined Cycle (TBCC) propulsion system to perform a controlled inlet mode transition. Prior to experimental testing, simulation models are used to test, debug, and validate potential control algorithms. One simulation package being used for testing is the High Mach Transient Engine Cycle Code simulation, known as HiTECC. This paper discusses the closed loop control system, which utilizes a shock location sensor to improve inlet performance and operability. Even though the shock location feedback has a coarse resolution, the feedback allows for a reduction in steady state error and, in some cases, better performance than with previous proposed pressure ratio based methods. This paper demonstrates the design and benefit with the implementation of a proportional-integral controller, an H-Infinity based controller, and a disturbance observer based controller.

Csank, Jeffrey T.↗

NASA NTRS2013

Progress of a Cross-correlation Based Optical Strain Measurement Technique for Detecting Radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASAs Fundamental Aeronautics Program is extremely interested in the development of fault detection technologies, such as optical surface measurements in the internal parts of a flow path, for in situ health monitoring of gas turbine engines. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. In the present study, a cross-correlation imaging technique is investigated in a proof-of-concept study as a possible optical technique to measure the radial growth and strain field on an already cracked sub-scale turbine engine disk under loaded conditions in the NASA Glenn Research Centers High Precision Rotordynamics Laboratory. The optical strain measurement technique under investigation offers potential fault detection using an applied background consisting of a high-contrast random speckle pattern and imaging the background under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds induces an external load, resulting in a radial growth of the disk of approximately 50.8-m in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will appear shifted. The resulting background displacements between the two images will then be measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. In order to develop and validate this optical strain measurement technique an initial proof-of-concept experiment is carried out in a controlled environment. Using PIV optimization principles and guidelines, three potential backgrounds, for future use on the rotating disk, are developed and investigated in the controlled experiment. A range of known shifts are induced on the backgrounds; reference and data images are acquired before and after the induced shift, respectively, and the images are processed using the cross- correlation algorithms in order to determine the background displacements. The effectiveness of each background at resolving the known shift is evaluated and discussed in order to choose to the most suitable background to be implemented onto a rotating disk in the Rotordynamics Lab. Although testing on the rotating disk has not yet been performed, the driving principles behind the development of the present optical technique are based upon critical aspects of the future experiment, such as the amount of expected radial growth, disk analysis, and experimental design and are therefore addressed in the paper.

Clem, Michelle M.↗

NASA NTRS2013

Modeling Commercial Turbofan Engine Icing Risk With Ice Crystal Ingestion

The occurrence of ice accretion within commercial high bypass aircraft turbine engines has been reported under certain atmospheric conditions. Engine anomalies have taken place at high altitudes that have been attributed to ice crystal ingestion, partially melting, and ice accretion on the compression system components. The result was degraded engine performance, and one or more of the following: loss of thrust control (roll back), compressor surge or stall, and flameout of the combustor. As ice crystals are ingested into the fan and low pressure compression system, the increase in air temperature causes a portion of the ice crystals to melt. It is hypothesized that this allows the ice-water mixture to cover the metal surfaces of the compressor stationary components which leads to ice accretion through evaporative cooling. Ice accretion causes a blockage which subsequently results in the deterioration in performance of the compressor and engine. The focus of this research is to apply an engine icing computational tool to simulate the flow through a turbofan engine and assess the risk of ice accretion. The tool is comprised of an engine system thermodynamic cycle code, a compressor flow analysis code, and an ice particle melt code that has the capability of determining the rate of sublimation, melting, and evaporation through the compressor flow path, without modeling the actual ice accretion. A commercial turbofan engine which has previously experienced icing events during operation in a high altitude ice crystal environment has been tested in the Propulsion Systems Laboratory (PSL) altitude test facility at NASA Glenn Research Center. The PSL has the capability to produce a continuous ice cloud which are ingested by the engine during operation over a range of altitude conditions. The PSL test results confirmed that there was ice accretion in the engine due to ice crystal ingestion, at the same simulated altitude operating conditions as experienced previously in flight. The computational tool was utilized to help guide a portion of the PSL testing, and was used to predict ice accretion could also occur at significantly lower altitudes. The predictions were qualitatively verified by subsequent testing of the engine in the PSL. The PSL test has helped to calibrate the engine icing computational tool to assess the risk of ice accretion. The results from the computer simulation identified prevalent trends in wet bulb temperature, ice particle melt ratio, and engine inlet temperature as a function of altitude for predicting engine icing risk due to ice crystal ingestion.

Jorgenson, Philip C. E.↗

NASA NTRS2014

Space Launch System Base Heating Test: Sub-Scale Rocket Engine/Motor Design, Development and Performance Analysis

The Space Launch System (SLS) base heating test is broken down into two test programs: (1) Pathfinder and (2) Main Test. The Pathfinder Test Program focuses on the design, development, hot-fire test and performance analyses of the 2% sub-scale SLS core-stage and booster element propulsion systems. The core-stage propulsion system is composed of four gaseous oxygen/hydrogen RS-25D model engines and the booster element is composed of two aluminum-based model solid rocket motors (SRMs). The first section of the paper discusses the motivation and test facility specifications for the test program. The second section briefly investigates the internal flow path of the design. The third section briefly shows the performance of the model RS-25D engines and SRMs for the conducted short duration hot-fire tests. Good agreement is observed based on design prediction analysis and test data. This program is a challenging research and development effort that has not been attempted in 40+ years for a NASA vehicle.

Mehta, Manish↗

NASA NTRS2013

Advanced Seal Sessions I and II

As aircraft operators continue to seek higher fuel efficiency, lower emissions, and longer on-wing performance, turbine engine designers are scrutinizing all components for areas of improvement. To achieve overall goals, turbine pressure ratios and by-pass ratios continue to climb. Also, designers are seeking to minimize parasitic and cooling flows to extract the most useful work out of the flow stream, placing a renewed interest on seal technology and secondary flow path management. In the area of future manned spacecraft, advancements are being examined for both habitat seals and re-entry thermal protection system thermal barrierseals. For long duration space craft, designers are continuing to look for savings in parasitic losses to reduce the amount of cabin re-supply air that needs to be brought along. This is placing greater demands on seal designs and materials to exhibit low leakage and be resistant to space environments. For future missions to and from distant planets, the re-entry heating will be higher than for low-earth orbit or lunar return motivating advanced thermal barrier development. This presentation will provide an overview of the seal challenges and opportunities in these diverse areas.

turbine engines↗

NASA NTRS2014

Progress of a Cross-Correlation Based Optical Strain Measurement Technique for Detecting Radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASA's Fundamental Aeronautics Program is interested in the development of novel measurement technologies, such as optical surface measurements for the in situ health monitoring of critical constituents of the internal flow path. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. The present study, aims to further validate and develop an optical strain measurement technique to measure the radial growth and strain field of an already cracked disk, mimicking the geometry of a sub-scale turbine engine disk, under loaded conditions in the NASA Glenn Research Center's High Precision Rotordynamics Laboratory. The technique offers potential fault detection by imaging an applied high-contrast random speckle pattern under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds (loaded conditions) induces an external load, resulting in a radial growth of the disk of approximately 50.0-μm in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will be undistorted; however, during rotation the cracked region will grow radially, thus causing the applied particle pattern to be 'shifted'. The resulting particle displacements between the two images is measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. A random particle distribution is adhered onto the surface of the cracked disk and two bench top experiments are carried out to evaluate the technique's ability to measure the induced particle displacements. The disk is shifted manually using a translation stage equipped with a fine micrometer and a hotplate is used to induce thermal growth of the disk, causing the particles to become shifted. For both experiments, reference and test images are acquired before and after the induced shifts, respectively, and then processed using PIV software. The controlled manual translation of the disk resulted in detection of the particle displacements accurate to ~1.75% of full scale and the thermal expansion experiment resulted in successful detection of the disk's thermal growth as compared to the calculated thermal expansion results. After validation of the technique through the induced shift experiments, the technique is implemented in the Rotordynamics Lab for preliminary assessment in a simulated engine environment. The discussion of the findings and plans for future work to improve upon the results are addressed in the paper.

rotordynamics↗

NASA NTRS2014

NASA Bioculture System: From Experiment Definition to Flight Payload

Starting in 2015, the NASA Bioculture System will be available to the science community to conduct cell biology and microbiology experiments on ISS. The Bioculture System carries ten environmentally independent Cassettes, which house the experiments. The closed loop fluids flow path subsystem in each Cassette provides a perfusion-based method for maintain specimen cultures in a shear-free environment by using a biochamber based on porous hollow fiber bioreactor technology. Each Cassette contains an incubator and separate insulated refrigerator compartment for storage of media, samples, nutrients and additives. The hardware is capable of fully automated or manual specimen culturing and processing, including in-flight experiment initiation, sampling and fixation, up to BSL-2 specimen culturing, and the ability to up to 10 independent cultures in parallel for statistical analysis. The incubation and culturing of specimens in the Bioculture System is a departure from standard laboratory culturing methods. Therefore, it is critical that the PI has an understanding the pre-flight test required for successfully using the Bioculture System to conduct an on-orbit experiment. Overall, the PI will conduct a series of ground tests to define flight experiment and on-orbit implementation requirements, verify biocompatibility, and determine base bioreactor conditions. The ground test processes for the utilization of the Bioculture System, from experiment selection to flight, will be reviewed. Also, pre-flight test schedules and use of COTS ground test equipment (CellMax and FiberCell systems) and the Bioculture System will be discussed.

Bioculture System↗

NASA NTRS2015

A Tool for the Automated Collection of Space Utilization Data: Three Dimensional Space Utilization Monitor

Space Human Factors and Habitability (SHFH) Element within the Human Research Program (HRP), in collaboration with the Behavioral Health and Performance (BHP) Element, is conducting research regarding Net Habitable Volume (NHV), the internal volume within a spacecraft or habitat that is available to crew for required activities, as well as layout and accommodations within that volume. NASA is looking for innovative methods to unobtrusively collect NHV data without impacting crew time. Data required includes metrics such as location and orientation of crew, volume used to complete tasks, internal translation paths, flow of work, and task completion times. In less constrained environments methods for collecting such data exist yet many are obtrusive and require significant post‐processing. Example technologies used in terrestrial settings include infrared (IR) retro‐reflective marker based motion capture, GPS sensor tracking, inertial tracking, and multiple camera filmography. However due to constraints of space operations many such methods are infeasible, such as inertial tracking systems which typically rely upon a gravity vector to normalize sensor readings, and traditional IR systems which are large and require extensive calibration. However multiple technologies have not yet been applied to space operations for these explicit purposes. Two of these include 3‐Dimensional Radio Frequency Identification Real‐Time Localization Systems (3D RFID‐RTLS) and depth imaging systems which allow for 3D motion capture and volumetric scanning (such as those using IR‐depth cameras like the Microsoft Kinect or Light Detection and Ranging / Light‐Radar systems, referred to as LIDAR).

Vos, Gordon A.↗

NASA NTRS2016

Metallic Thin-Film Bonding and Alloy Generation

Diffusion bonding a stack of aluminum thin films is particularly challenging due to a stable aluminum oxide coating that rapidly forms on the aluminum thin films when they are exposed to atmosphere and the relatively low meting temperature of aluminum. By plating the individual aluminum thin films with a metal that does not rapidly form a stable oxide coating, the individual aluminum thin films may be readily diffusion bonded together using heat and pressure. The resulting diffusion bonded structure can be an alloy of choice through the use of a carefully selected base and plating metals. The aluminum thin films may also be etched with distinct patterns that form a microfluidic fluid flow path through the stack of aluminum thin films when diffusion bonded together.

Fryer, Jack Merrill↗

NASA NTRS2017

A Tool for the Automated Collection of Space Utilization Data: Three Dimensional Space Utilization Monitor

Space Human Factors and Habitability (SHFH) Element within the Human Research Program (HRP) and the Behavioral Health and Performance (BHP) Element are conducting research regarding Net Habitable Volume (NHV), the internal volume within a spacecraft or habitat that is available to crew for required activities, as well as layout and accommodations within the volume. NASA needs methods to unobtrusively collect NHV data without impacting crew time. Data required includes metrics such as location and orientation of crew, volume used to complete tasks, internal translation paths, flow of work, and task completion times. In less constrained environments methods exist yet many are obtrusive and require significant post-processing. Examplesused in terrestrial settings include infrared (IR) retro-reflective marker based motion capture, GPS sensor tracking, inertial tracking, and multi-camera methods Due to constraints of space operations many such methods are infeasible. Inertial tracking systems typically rely upon a gravity vector to normalize sensor readings,and traditional IR systems are large and require extensive calibration. However, multiple technologies have not been applied to space operations for these purposes. Two of these include: 3D Radio Frequency Identification Real-Time Localization Systems (3D RFID-RTLS) Depth imaging systems which allow for 3D motion capture and volumetric scanning (such as those using IR-depth cameras like the Microsoft Kinect or Light Detection and Ranging / Light-Radar systems, referred to as LIDAR)

Vos, Gordon A.↗

NASA NTRS2017

Summary of Martian Dust Filtering Challenges and Current Filter Development

Traditional air particulate filtering in manned spaceflight (Apollo, Shuttle, ISS, etc.) has used cleanable or replaceable catch filters such as screens and High-Efficiency Particulate Arrestance (HEPA) filters. However, the human mission to Mars architecture will require a new approach. It is Martian dust that is the particulate of concern but the need also applies to particulates generated by crew. The Mars Exploration Program Analysis Group (MEPAG) high-lighted this concern in its Mars Science, Goals, Objectives, Investigations and Priorities document [7], by saying specifically that one high priority investigation will be to "Test ISRU atmospheric processing systems to measure resilience with respect to dust and other environmental challenge performance parameters that are critical to the design of a full-scale system." By stating this as high priority the MEPAG is acknowledging that developing and adequately verifying this capability is critical to success of a human mission to Mars. This architecture will require filtering capabilities that are highly reliable, will not restrict the flow path with clogging, and require little to no maintenance. This paper will summarize why this is the case, the general requirements for developing the technology, and the status of the progress made in this area.

O'Hara, William J., IV↗