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NASA NTRS2008

Structural Design and Analysis of the Upper Pressure Shell Section of a Composite Crew Module

This paper presents the results of the structural design and analysis of the upper pressure shell section of a carbon composite demonstration structure for the Composite Crew Module (CCM) Project. The project is managed by the NASA Engineering and Safety Center with participants from eight NASA Centers, the Air Force Research Laboratory, and multiple aerospace contractors including ATK/Swales, Northrop Grumman, Lockheed Martin, Collier Research Corporation, Genesis Engineering, and Janicki Industries. The paper discusses details of the upper pressure shell section design of the CCM and presents the structural analysis results using the HyperSizer structural sizing software and the MSC Nastran finite element analysis software. The HyperSizer results showed that the controlling load case driving most of the sizing in the upper pressure shell section was the internal pressure load case. The regions around the cutouts were controlled by internal pressure and the main parachute load cases. The global finite element analysis results showed that the majority of the elements of the CCM had a positive margin of safety with the exception of a few hot spots around the cutouts. These hot spots are currently being investigated with a more detailed analysis. Local finite element models of the Low Impact Docking System (LIDS) interface ring and the forward bay gussets with greater mesh fidelity were created for local sizing and analysis. The sizing of the LIDS interface ring was driven by the drogue parachute loads, Trans-Lunar Insertion (TLI) loads, and internal pressure. The drogue parachute loads controlled the sizing of the gusset cap on the drogue gusset and TLI loads controlled the sizing of the other five gusset caps. The main parachute loads controlled the sizing of the lower ends of the gusset caps on the main parachute fittings. The results showed that the gusset web/pressure shell and gusset web/gusset cap interfaces bonded using Pi-preform joints had local hot spots in the Pi-preform termination regions. These regions require a detailed three-dimensional analysis, which is currently being performed, to accurately address the load distribution near the Pi-preform termination in the upper and lower gusset caps.

Sleight, David W.↗

NASA NTRS2011

NASA Tech Briefs, January 2011

The topics include: 1) Distributed Aerodynamic Sensing and Processing Toolbox; 2) Collaborative Supervised Learning for Sensor Networks; 3) Hazard Detection Software for Lunar Landing; 4) Onboard Nonlinear Engine Sensor and Component Fault Diagnosis and Isolation Scheme; 5) Network-Capable Application Process and Wireless Intelligent Sensors for ISHM; 6) Interface Supports Multiple Broadcast Transceivers for Flight Applications; 7) FPGA Sequencer for Radar Altimeter Applications; 8) Miniature Sapphire Acoustic Resonator - MSAR; 9) Process-Hardened, Multi-Analyte Sensor for Characterizing Rocket Plume Constituents; 10) SAD5 Stereo Correlation Line-Striping in an FPGA; 11) Hybrid Composite Cryogenic Tank Structure; 12) Nanoscale Deformable Optics; 13) Reliability-Based Design Optimization of a Composite Airframe Component; 14) Zinc Oxide Nanowire Interphase for Enhanced Lightweight Polymer Fiber Composites; 15) Plasma Igniter for Reliable Ignition of Combustion in Rocket Engines; 16) Wire Test Grip Fixture; 17) A Sub-Hertz, Low-Frequency Vibration Isolation Platform; 18) Carbon Nanofibers Synthesized on Selective Substrates for Nonvolatile Memory and 3D Electronics; 19) Nanoparticle/Polymer Nanocomposite Bond Coat or Coating; 20) High-Resolution Wind Measurements for Offshore Wind Energy Development; 21) Spring Tire; 22) Marsviewer 2008; 23) Mission Services Evolution Center Message Bus; 24) Major Constituents Analysis for the Vehicle Cabin Atmosphere Monitor; 25) Astronaut Health Participant Summary Application; 26) Adaption of the AMDIS Method to Flight Status on the VCAM Instrument; 27) Natural Language Interface for Safety Certification of Safety-Critical Software; 28) Cryogenic Caging for Science Instrumentation; 29) Wide-Range Neutron Detector for Space Nuclear Applications; 30) In Situ Guided Wave Structural Health Monitoring System; 31) Multiplexed Energy Coupler for Rotating Equipment; 32) Attitude Estimation in Fractionated Spacecraft Cluster Systems; 33) Full Piezoelectric Multilayer-Stacked Hybrid Actuation/Transduction Systems; 34) Active Flow Effectors for Noise and Separation Control; 35) Method and System for Temporal Filtering in Video Compression Systems; 36) Apparatus for Measuring Total Emissivity of Small, Low-Emissivity Samples; 37) Multiple-Zone Diffractive Optic Element for Laser Ranging Applications; 38) Simplified Architecture for Precise Aiming of a Deep-Space Communication Laser Transceiver; 39) Two-Photon-Absorption Scheme for Optical Beam Tracking; 40) High-Sensitivity, Broad-Range Vacuum Gauge Using Nanotubes for Micromachined Cavities; 41) Wide-Field Optic for Autonomous Acquisition of Laser Link; 42) Extracting Zero-Gravity Surface Figure of a Mirror; 43) Modeling Electromagnetic Scattering From Complex Inhomogeneous Objects; 44) Visual Object Recognition and Tracking of Tools; 45) Method for Implementing Optical Phase Adjustment; 46) Visual SLAM Using Variance Grid Maps; 47) Rapid Calculation of Spacecraft Trajectories Using Efficient Taylor Series Integration; 48) Efficient Kriging Algorithms; 49) Predicting Spacecraft Trajectories by the WeavEncke Method; 50) An Augmentation of G-Guidance Algorithms; 51) Comparison of Aircraft Icing Growth Assessment Software; 52) Silicon-Germanium Voltage-Controlled Oscillator at 105 GHz; 53) Estimation of Coriolis Force and Torque Acting on Ares-1; 54) Null Lens Assembly for X-Ray Mirror Segments; and 55) High-Precision Pulse Generator.

Source record↗

NASA NTRS2011

Composite Crew Module: Primary Structure

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center to design, build, and test a full-scale crew module primary structure, using carbon fiber reinforced epoxy based composite materials. The overall goal of the Composite Crew Module project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project's baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. This report discusses the project management aspects of the project including team organization, decision making, independent technical reviews, and cost and schedule management approach.

Kirsch, Michael T.↗

NASA NTRS1990

TRANSTRAIN: A program to compute strain transformations in composite materials

Over the years, the solid rocket motor community has made increasing use of composite materials for thermal and structural applications. This is particularly true of solid rocket nozzles, which have used carbon phenolic and, increasingly, carbon-carbon materials to provide structural integrity and thermal protection at the high temperatures encountered during motor burn. To evaluate the degree of structural performance of nozzles and their materials and to verify analysis models, many subscale and full-scale tests are run. These provide engineers with valuable data needed to optimize design and to analyze nozzle hardware. Included among these data are strains, pressures, thrust, temperatures, and displacements. Recent nozzle test hardware has made increasing use of strain gauges embedded in the carbon composite material to measure internal strains. In order to evaluate strength, these data must be transformed into strains along the fiber directions. The fiber-direction stresses can then be calculated. A computer program written to help engineers correctly manipulate the strain data into a form that can be used to evaluate structural integrity of the nozzle is examined.

Ahmed, Rafiq↗

NASA NTRS1992

Composite materials for the extravehicular mobility unit

The extravehicular mobility unit (EMU), commonly known as the astronaut space suit assembly (SSA) and primary life support system (PLSS), has evolved through the years to incorporate new and innovative materials in order to meet the demands of the space environment. The space shuttle program which is seeing an increasing level of extravehicular activity (EVA), also called space walks, along with interest in an EMU for Lunar-Mars missions means even more demanding conditions are being placed on the suit and PLSS. The project for this NASA-ASEE Summer Program was to investigate new materials for these applications. The focus was to emphasize the use of composite materials for every component of the EMU to enhance the properties while reducing the total weight of the EMU. To accomplish this, development of new materials called fullerene reinforced materials (FRM's) was initiated. Fullerenes are carbon molecules which when added to a material significantly reduce the weight of that material. The Faculty Fellow worked directly on the development of the fullerene reinforced materials. A chamber for fullerene production was designed and assembled and first generation samples were processed. He also supervised with the JSC Colleague, a study of composite materials for the EMU conducted by the student participant in the NASA-ASEE Program, Hector Tello a Rice University graduate student, and by a NASA Aerospace Technologist (Materials Engineer) Evelyne Orndoff, in the Systems Engineering Analysis Office (EC7), also a Rice University graduate student. Hector Tello conducted a study on beryllium and Be alloys and initiated a study of carbon and glass reinforced composites for space applications. Evelyne Orndoff compiled an inventory of the materials on the SSA. Ms. Orndoff also reviewed SSA material requirements and cited aspects of the SSA design where composite materials might be further considered. Hector Tello spent part of his time investigating the solar radiation sensitivity of anodic coatings. This project was directed toward the effects of ultra-violet radiation on high emissivity anodic coatings. The work of both Evelyne Orndoff and Hector Tello is of interest to the Engineering Directorate at NASA/JSC and is also directed toward their research as Rice University graduate students.

Barrera, Enrique V.↗

NASA NTRS2000

Development and Characterization of Laser-Induced Incandescence Towards Nanoparticle (Soot) Detection

The production of particulates, notably soot, during combustion has both positive and negative ramifications. Exhaust from diesel engines under load (for example, shifting gears), flickering candle flames and fireplaces all produce soot leaving a flame. From an efficiency standpoint, emission of soot from engines, furnaces or even a simple flickering candle flame represents a loss of useful energy. The emission of soot from diesel engines, furnaces, power generation facilities, incinerators and even simple flames poses a serious environmental problem and health risk. Yet some industries intentionally produce soot as carbon black for use in inks, copier toner, tires and as pigments. Similarly, the presence of soot within flames can act both positively and negatively. Energy transfer from a combustion process is greatly facilitated by the radiative heat transfer from soot yet radiative heat transfer also facilitates the spread of unwanted fires. To understand soot formation and develop control strategies for soot emission/formation, measurements of soot concentration in both practical devices such as engines and controlled laboratory flames are necessary. Laser-induced incandescence (LII) has been developed and characterized to address this need, as described here.

VanderWal, Randy L.↗

NASA NTRS1974

Mainshaft seals for small gas turbine engines

An experimental evaluation of mainshaft seals for small gas turbine engines was conducted with shaft speeds to 213 m/s (700 ft/sec), air pressures to 148 Newtons per square centimeter abs. (215 psia), and air temperatures to 412k(282 F). A radial face seal incorporating self-acting geometry for lift augmentation was evaluated. In addition, three conventional carbon seal types (face, circumferential segmented, and rotating ring) were run for comparison. Test results indicated that the conventional seals used in this evaluation may not be satisfactory in future advanced engines because of excessive air leakage. On the other hand, the self-acting face seal was shown to have the potential capability of limiting leakages to one-half that of the conventional face seals and one-fifth that of conventional ring seals. A 150-hour endurance test of the self-acting face seal was conducted.

Ludwig, L. P.↗

NASA NTRS2011

In-Space Propulsion Engine Architecture Based on Sublimation of Planetary Resources: From Exploration Robots to NED Mitigation

Volatile solids occur naturally on most planetary bodies including the Moon, Mars, asteroids and comets. Examples of recent discoveries include water ice, frozen carbon dioxide and hydrocarbons. The ability to utilize readily available resources for in-space propulsion and for powering surface systems during a planetary mission will help minimize the overall cost and extend the op.erational life of a mission. The utilization of volatile solids to achieve these goals is attractive for its simplicity. We have investigated the potential of subliming in situ volatiles and silicate minerals to power propulsion engines for a wide range of in-space applications where environmental conditions are favorable. This paper addresses the' practicality of using planetary solid volatiles as a power source for propulsion and surface systems by presenting results of modeling involving thermodynamic and physical mechanics calculations, and laboratory testing to measure the thrust obtained from ,a volatile solid engine (VSE). Applications of a VSE for planetary exploration are discussed as a means for propulsion and for mechanical actuators and surface mobility platforms.

Sibille, Laurent↗

NASA NTRS1976

Emissions data by category of engines

Exhaust gas pollutant emissions data under test stand conditions were obtained for the following: (1) full-rich baseline test (7-mode cycle), (2) lean-out tests for each power mode, and (3) different spark settings. The test data were also used to create a theoretical 5-mode cycle baseline. The emissions data in the framework of the theoretical 5-mode cycle were emphasized. There is no significant difference in the test results produced by data exhibited on the 7-mode cycle or 5-mode cycle. The 5-mode cycle was slightly more conservative for the carbon monoxide pollutant than the 7-mode cycle. The data were evaluated to determine which mode(s) had the greatest influence on improving general aviation piston engine emissions. Improvements that were achieved as a result of making lean-out adjustments to the fuel metering device were: (1) taxi mode only, (2) taxi and approach modes combined, and (3) leaning-out of the climb mode to best power.

Barriage, J.↗

NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗

NASA NTRS1987

A 2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

The technological readiness of a long-life multipropellant resistojet for space station auxiliary propulsion is demonstrated. A laboratory model resistojet made from grain-stabilized platinum served as a test bed to evaluate the design characteristics, fabrication methods, and operating strategies for an engineering model multipropellant resistojet developed under contract by the Rocketdyne Division of Rockwell International and Technion Incorporated. The laboratory model thruster was subjected to a 2000-hr, 2400-thermal-cycle endurance test using carbon dioxide propellant. Maximum thruster temperatures were approximately 1400 C. The post-test analyses of the laboratory model thruster included an investigation of component microstructures. Significant observations from the laboratory model thruster are discussed as they relate to the design of the engineering model thruster.

Morren, W. Earl↗

NASA NTRS1987

2000-hour cyclic endurance test of a laboratory model multipropellant resistojet

Morren, W. Earl↗

NASA NTRS1971

A study of alternative methods for reclaiming oxygen from carbon dioxide and water by a solid-electrolyte process for spacecraft applications

Two alternative technical approaches were studied for application of an electrochemical process using a solid oxide electrolyte (zirconia stabilized by yttria or scandia) to oxygen reclamation from carbon dioxide and water, for spacecraft life support systems. Among the topics considered are the advisability of proceeding to engineering prototype development and fabrication of a full scale model for the system concept, the optimum choice of method or approach to be carried into prototype development, and the technical problem areas which exist.

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NASA NTRS1976

Solid electrolyte oxygen regeneration system

A program to design, develop, fabricate and assemble a one-man, self-contained, solid electrolyte oxygen regeneration system (SX-1) incorporating solid electrolyte electrolyzer drums was completed. The SX-1 is a preprototype engineering model designed to produce 0.952 kg (2.1 lb)/day of breathable oxygen (O2) from the electrolysis of metabolic carbon dioxide (CO2) and water vapor. The CO2 supply rate was established based on the metabolic CO2 generation rate for one man of 0.998 kg (2.2 lb)/day. The water supply rate (0.254 kg (0.56 lb)/day) was designed to be sufficient to make up the difference between the 0.952 kg (2.1 lb)/day O2 generation specification and the O2 available through CO2 electrolysis, 0.726 kg (1.6 lb)/day. The SX-1 was successfully designed, fabricated and assembled. Design verification tests (DVT) or the CO Disproportionators, H2 separators, control instrumentation, monitor instrumentation, water feed mechanism were successfully completed. The erratic occurrence of electrolyzer drum leakage prevented the completion of the CO2 electrolyzer module and water electrolyzer module DVT's and also prevented the performance of SX-1 integrated testing. Further development work is required to improve the solid electrolyte cell high temperature seals.

Shumar, J. W.↗

NASA NTRS1980

Experimental evaluation of combustor concepts for burning broad property fuels

A baseline CF6-50 combustor and three advanced combustor designs were evaluated to determine the effects of combustor design on operational characteristics using broad property fuels. Three fuels were used in each test: Jet A, a broad property 13% hydrogen fuel, and a 12% hydrogen fuel blend. Testing was performed in a sector rig at true cruise and simulated takeoff conditions for the CF6-50 engine cycle. The advanced combustors (all double annular, lean dome designs) generally exhibited lower metal temperatures, exhaust emissions, and carbon buildup than the baseline CF6-50 combustor. The sensitivities of emissions and metal temperatures to fuel hydrogen content were also generally lower for the advanced designs. The most promising advanced design used premixing tubes in the main stage. This design was chosen for additional testing in which fuel/air ratio, reference velocity, and fuel flow split were varied.

Kasper, J. M.↗

NASA NTRS2005

The Spaceflight Revolution Revisited

This essay will first consider whether technological breakthroughs in space technology and the rational motives of ordinary institutions have the capacity to break out of this relatively static situation. Then we will survey the roles that social movements of various kinds might play and conclude with an examination of one particular nascent movement that might possibly build the foundation for a spacefaring civilization. A third of a century ago, practical nuclear fission rockets were under development, but this approach now seems environmentally unacceptable. It is hard to devise a more environmentally benign propellant than the hydrogen and oxygen used by the main engines of the Space Shuttle. There is some hope that nanotechnology will save the day with materials based on carbon nanotubes that are vastly stronger yet lighter than metals.6 However, the X-33 failure shows that it is not easy to work with radically new structural materials in demanding aerospace applications, and we may be many decades away from being able to manufacture propellant tanks, wings, and other large structures from carbon nanotubes. Satellites in low-Earth and synchronous orbit are of great importance in the collection and distribution of information, thus essential to the information economy. The wide range of civilian applications includes telephone, data transmission, television, navigation, weather observation, agriculture monitoring, and prospecting for natural resources.8 The technology is largely perfected, and incremental progress can be achieved by improvement in information systems and simply by investing in more relatively small satellites of the kinds we already have.

Bainbridge, William Sims↗

NASA NTRSDate not supplied

Research Activities in High Voltage (HV) Materials for Aerospace Systems

This presentation gives an overview of recent materials research activities carried out at NASA Glenn Research Center. The background and motivation for the development of thermally conductive electrical insulation for a high voltage (HV) turboelectric aircraft concept is briefly discussed. A summary of the challenges and technology gap associated with HV aerospace electrical systems is also covered as well as the development of electrical insulation and engineered ceramic fillers and HV test capabilities. The research has expanded to include the development of a lightweight copper/ carbon nanotube composite conductor. Applications for these materials include hybrid electric aircraft, all electric aircraft, spacecraft, electric propulsion systems, and future power transmission systems for Lunar and Martian destinations.

Composite conductors↗

NASA NTRS1961

Post University On-the-Job Training for Engineers

Our national need for qualified scientists and engineers is greater now than at any other time in our history. Fortunately, we can point with pride to this need as a measure of the impact of science and technology on our way of life. In effect, we have made such rapid strides In advancing established sciences and in opening new technological fields that we have proved the value of the scientist and engineer to society, and, as a-result, have created an expanding demand for their services which we must now attempt to satisfy. This demand we face is also due to the changing skills and high degree of specialization required to perform in these new technological fields. The colleges and universities are doing their part to provide current graduates with a modern technical foundation, but we cannot afford to ignore the thousands of experienced engineers and scientists already employed by private industry and government. As employers, we have an obligation to these men and women to see that they are provided with an understanding of the latest advances that modern technology has to offer; that we develop them in particular specialty areas characteristic of a given field of work; and, equally important, that we assist them in the transition from one field to another as the technological emphasis shifts. Practically all technological industries have experienced and continue to experience rapid changes in their activities. The aerospace business, in particular, has been characterized by extremely rapid, in fact revolutionary, changes during the relatively short period of its existence0 At the National Aeronautics and Space Administration, successor to the National Advisory Committee for Aeronautics, for example, we have encountered the fun impact of a changing science and technology. Indeed, as a research organization, we have undoubtedly contributed, in some measure, to this change. Within the NASAs Lewis Research Center, we have approximately 800 research scientists and engineers who have matured professionally in an environment which is essentially one of continuous learning - an experience which comes close to being a form of post graduate training in itself. This environment, in addition to providing continuous evolutionary changes, has also provided two major revolutions which have made this development picture more complex. We will describe these environmental changes which have occurred at the Lewis Research Center and discuss the various techniques and programs we have employed to provide for the professional development of our staff. The Lewis Research Center has had an Interesting and exciting l8-year history of aerospace propulsion research and development. It began during the early years of World War II as an expansion of the Power Plant Division of the NCA Langley Center with the mission of conducting research required for the development of improved reciprocating engines and to study the associated problems of subsonic propulsion aerodynamics, It was only a few years later, however, that turbojet and ramjet propulsion and supersonic flight research became our main concern. This transition to jet type engines and higher speeds was our first major technological change. The aerodynamics of propellers became the aerodynamics of high speed turbine and compressor blades; the fuel ignition and carbon deposition problems were transferred from a cyclical or Intermittent high compression combustion chamber to a continuous combustion zone within a thin-walled metal shell; aerodynamics problems were thrust into the supersonic range; and high temperature materials began to play an increasingly critical role. Although this transition still required the same basic knowledge and principles as before, the new engine types did involve a different emphasis and variety of consideration not generally familiar to our scientists and engineers.

Manganiello, Eugene J.↗