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

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At least 397 records · Page 22

Fault detection, isolation and reconfiguration in FTMP Methods and experimental results

The Fault-Tolerant Multiprocessor (FTMP) is a highly reliable computer designed to meet a goal of 10 to the -10th failures per hour and built with the objective of flying an active-control transport aircraft. Fault detection, identification, and recovery software is described, and experimental results obtained by injecting faults in the pin level in the FTMP are presented. Over 21,000 faults were injected in the CPU, memory, bus interface circuits, and error detection, masking, and error reporting circuits of one LRU of the multiprocessor. Detection, isolation, and reconfiguration times were recorded for each fault, and the results were found to agree well with earlier assumptions made in reliability modeling.

Lala, J. H.↗

An analysis code for the Rapid Engineering Estimation of Momentum and Energy Losses (REMEL)

Nonideal behavior has traditionally been modeled by defining efficiency (a comparison between actual and isentropic processes), and subsequent specification by empirical or heuristic methods. With the increasing complexity of aeropropulsion system designs, the reliability of these more traditional methods is uncertain. Computational fluid dynamics (CFD) and experimental methods can provide this information but are expensive in terms of human resources, cost, and time. This report discusses an alternative to empirical and CFD methods by applying classical analytical techniques and a simplified flow model to provide rapid engineering estimates of these losses based on steady, quasi-one-dimensional governing equations including viscous and heat transfer terms (estimated by Reynold's analogy). A preliminary verification of REMEL has been compared with full Navier-Stokes (FNS) and CFD boundary layer computations for several high-speed inlet and forebody designs. Current methods compare quite well with more complex method results and solutions compare very well with simple degenerate and asymptotic results such as Fanno flow, isentropic variable area flow, and a newly developed, combined variable area duct with friction flow solution. These solution comparisons may offer an alternative to transitional and CFD-intense methods for the rapid estimation of viscous and heat transfer losses in aeropropulsion systems.

Dechant, Lawrence J.↗

Combined bending-torsion fatigue reliability of AISI 4340 steel shafting with K sub t = 2.34

Results generated by three, unique fatigue reliability research machines which can apply reversed bending loads combined with steady torque are presented. Six-inch long, AISI 4340 steel, grooved specimens with a stress concentration factor of 2.34 and R sub C 35/40 hardness were subjected to various combinations of these loads and cycled to failure. The generated cycles-to-failure and stress-to-failure data are statistically analyzed to develop distributional S-N and Goodman diagrams. Various failure theories are investigated to determine which one represents the data best. The effect of the groove and of the various combined bending-torsion loads on the S-N and Goodman diagrams are determined. Three design applications are presented. The third one illustrates the weight savings that may be achieved by designing for reliability.

Kececioglu, D.↗

Thermostructural applications of heat pipes for cooling leading edges of high-speed aerospace vehicles

Heat pipes have been considered for use on wing leading edge for over 20 years. Early concepts envisioned metal heat pipes cooling a metallic leading edge. Several superalloy/sodium heat pipes were fabricated and successfully tested for wing leading edge cooling. Results of radiant heat and aerothermal testing indicate the feasibility of using heat pipes to cool the stagnation region of shuttle-type space transportation systems. The test model withstood a total seven radiant heating tests, eight aerothermal tests, and twenty-seven supplemental radiant heating tests. Cold-wall heating rates ranged from 21 to 57 Btu/sq ft-s and maximum operating temperatures ranged from 1090 to 1520 F. Follow-on studies investigated the application of heat pipes to cool the stagnation regions of single-stage-to-orbit and advanced shuttle vehicles. Results of those studies indicate that a 'D-shaped' structural design can reduce the mass of the heat-pipe concept by over 44 percent compared to a circular heat-pipe geometry. Simple analytical models for heat-pipe startup from the frozen state (working fluid initially frozen) were adequate to approximate transient, startup, and steady-state heat-pipe performance. Improvement in analysis methods has resulted in the development of a finite-element analysis technique to predict heat-pipe startup from the frozen state. However, current requirements of light-weight design and reliability suggest that metallic heat pipes embedded in a refractory composite material should be used. This concept is the concept presently being evaluated for NASP. A refractory-composite/heat-pipe-cooled wing leading edge is currently being considered for the National Aero-Space Plane (NASP). This concept uses high-temperature refractory-metal/lithium heat pipes embedded within a refractory-composite structure and is significantly lighter than an actively cooled wing leading edge because it eliminates the need for active cooling during ascent and descent. Since the NASP vehicle uses cryogenic hydrogen to cool structural components and then burns this fuel in the combustor, hydrogen necessary for descent cooling only, when the vehicle is unpowered, is considered to be a weight penalty. Details of the design of the refractory-composite/heat-pipe-cooled wing leading edge are currently being investigated. Issues such as thermal contact resistance and thermal stress are also being investigated.

Camarda, Charles J.↗

NASA Crew Launch Vehicle Approach Builds on Lessons from Past and Present Missions

The United States Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with a new human-rated system suitable for missions to the Moon and Mars. The Crew Exploration Vehicle (CEV) that the new Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station and be capable of carrying crews back to lunar orbit and of supporting missions to Mars orbit. NASA is using its extensive experience gained from past and ongoing launch vehicle programs to maximize the CLV system design approach, with the objective of reducing total lifecycle costs through operational efficiencies. To provide in-depth data for selecting this follow-on launch vehicle, the Exploration Systems Architecture Study was conducted during the summer of 2005, following the confirmation of the new NASA Administrator. A team of aerospace subject matter experts used technical, budget, and schedule objectives to analyze a number of potential launch systems, with a focus on human rating for exploration missions. The results showed that a variant of the Space Shuttle, utilizing the reusable Solid Rocket Booster as the first stage, along with a new upper stage that uses a derivative of the RS-25 Space Shuttle Main Engine to deliver 25 metric tons to low-Earth orbit, was the best choice to reduce the risks associated with fielding a new system in a timely manner. The CLV Project, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operation of this new human-rated system. The CLV Project works closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch system . leveraging a wealth of lessons learned from Shuttle operations. The CL V is being designed to reduce costs through a number of methods, ranging from validating requirements to conducting trades studies against the concept design. Innovations such as automated processing will build on lessons learned from the Shuttle, other launch systems, Department of Defense operations experience, and subscale flight tests such as the Delta Clipper-Experimental Advanced (DCXA) vehicle operations that utilized minimal touch labor, automated cryogen ic propellant loading , and an 8-hour turnaround for a cryogenic propulsion system. For the CLV, the results of hazard analyses are contributing to an integrated vehicle health monitoring system that will troubleshoot anomalies and determine which ones can be solved without human intervention. Such advances will help streamline the mission operations process for pilots and ground controllers alike. In fiscal year 2005, NASA invested approximately $4.5 billion of its $16 bill ion budget on the Space Shuttle. The ultimate goal of the CLV Project is to deliver a safe, reliable system designed to minimize lifecycle costs so that NASA's budget can be invested in missions of scientific discovery. Lessons learned from developing the CLV will be applied to the growth path for future systems, including a heavy lift launch vehicle.

Dumbacher, Daniel L.↗

Ionizing Radiation Environment on the International Space Station: Performance vs. Expectations for Avionics and Material

The role of structural shielding mass in the design, verification, and in-flight performance of International Space Station (ISS), in both the natural and induced orbital ionizing radiation (IR) environments, is reported. Detailed consideration of the effects of both the natural and induced ionizing radiation environment during ISS design, development, and flight operations has produced a safe, efficient manned space platform that is largely immune to deleterious effects of the LEO ionizing radiation environment. The assumption of a small shielding mass for purposes of design and verification has been shown to be a valid worst-case approximation approach to design for reliability, though predicted dependences of single event effect (SEE) effects on latitude, longitude, SEP events, and spacecraft structural shielding mass are not observed. The Figure of Merit (FOM) method over predicts the rate for median shielding masses of about 10g/cm(exp 2) by only a factor of 3, while the Scott Effective Flux Approach (SEFA) method overestimated by about one order of magnitude as expected. The Integral Rectangular Parallelepiped (IRPP), SEFA, and FOM methods for estimating on-orbit (Single Event Upsets) SEU rates all utilize some version of the CREME-96 treatment of energetic particle interaction with structural shielding, which has been shown to underestimate the production of secondary particles in heavily shielded manned spacecraft. The need for more work directed to development of a practical understanding of secondary particle production in massive structural shielding for SEE design and verification is indicated. In contrast, total dose estimates using CAD based shielding mass distributions functions and the Shieldose Code provided a reasonable accurate estimate of accumulated dose in Grays internal to the ISS pressurized elements, albeit as a result of using worst-on-worst case assumptions (500 km altitude x 2) that compensate for ignoring both GCR and secondary particle production in massive structural shielding.

Koontz, Steven L.↗

Combining Data with Physical Knowledge for Uncertainty Quantification in Certification and Reliability Analysis

Unifying empirical data with predictive models can enable engineering cost-savings through certification by analysis and reliability-based design. Both concepts require rigorous uncertainty quantification (UQ) and robust understanding and treatment of relevant physics. Combining sampling-based UQ algorithms with high-fidelity simulations creates a computational bottleneck that is often alleviated through the use of machine learning (ML). ML can be used to create computationally efficient surrogates for simulations of complex or high-dimensional physical interactions (e.g., multi-phase interactions associated with melt pools in laser powder bed fusion or spatially-dependent material properties in functionally graded materials). However, negative side effects of ML may include a lack of interpretability and negative correlation between event rarity and simulation accuracy due to a lack of training data. As such, it is important to infuse ML algorithms with physics-based guardrails to provide confidence in their predictions. This talk will provide a brief review of recent NASA research at this intersection of physics-based simulation, ML, and UQ with a focus on certification and reliability analysis.

uncertainty quantification↗

The Goddard Space Flight Center (GSFC) robotics technology testbed

Much of the technology planned for use in NASA's Flight Telerobotic Servicer (FTS) and the Demonstration Test Flight (DTF) is relatively new and untested. To provide the answers needed to design safe, reliable, and fully functional robotics for flight, NASA/GSFC is developing a robotics technology testbed for research of issues such as zero-g robot control, dual arm teleoperation, simulations, and hierarchical control using a high level programming language. The testbed will be used to investigate these high risk technologies required for the FTS and DTF projects. The robotics technology testbed is centered around the dual arm teleoperation of a pair of 7 degree-of-freedom (DOF) manipulators, each with their own 6-DOF mini-master hand controllers. Several levels of safety are implemented using the control processor, a separate watchdog computer, and other low level features. High speed input/output ports allow the control processor to interface to a simulation workstation: all or part of the testbed hardware can be used in real time dynamic simulation of the testbed operations, allowing a quick and safe means for testing new control strategies. The NASA/National Bureau of Standards Standard Reference Model for Telerobot Control System Architecture (NASREM) hierarchical control scheme, is being used as the reference standard for system design. All software developed for the testbed, excluding some of simulation workstation software, is being developed in Ada. The testbed is being developed in phases. The first phase, which is nearing completion, and highlights future developments is described.

Schnurr, Rick↗

Space-Hardware Design for Long Life With High Reliability

In 1991, the Cassini Project, NASA's planetary project to place a spacecraft in orbit about Saturn, funded a study at the Jet Propulsion Laboratory (JPL) to identify rules for design and test of hardware required to function reliably in space for very long lifetimes. Twenty-nine subjects were considered comprising 130 specific rules related to long-life issues such as accelerated life testing, cycling of mechanical devices, selection and application of parts, semiconductor junction temperatures, and worst-case analysis for long life. The study was subsequently published as a JPL document. One major conclusion of the workshop was that unattended space missions extending out to 25 years or more are feasible.

design↗

Truncated ARQ Statistical Link Analysis for Dynamic Links

The future deep space links are migrating towards higher frequency bands such as Ka band and optical. These links are susceptible to non Gaussian and non linear effects such as atmospheric turbulence, scintillation, antenna mis-pointing, jitter, etc. These dynamic links thus will experience various degrees of fading loss, and some of these link disruptions cannot be effectively mitigated by forward error correction coding and/or interleaving. One effective way to ensure reliable communication is by using Automatic Repeat Request (ARQ) protocol, where the receiver acknowledges to the transmitter whether or not a data unit is successfully received. If a data unit is not successfully received (such as after a pre-set time-out), the transmitter would then re-transmit the lost data unit to the receiver. In a previous paper, we derived a statistical link analysis method of finding the optimal operating Signal-to-Noise Ratio (SNR) and estimating the latency of an ARQ scheme. In a more recent paper, we demonstrated the above method using the SNR distribution constructed from the Ka-band (32 GHz) flight data. To simplify the discussion, we considered the academic approach that the ARQ scheme allows for an infinite number of retransmissions. In this paper, we consider the more practical case of a truncated ARQ scheme, where there is a limit on the number of retransmissions. We derive the error probability, the optimal SNR setting, and the latency statistics of the correctly received frames of the truncated ARQ schemes. We first discuss the truncated ARQ link analysis principles using the Gaussian assumption for SNR distribution with a large variance. Next, we demonstrate the statistical truncated ARQ link analysis using the SNR distribution constructed from the Ka-band flight data. The results in this paper can be applied in the design of reliable communication systems such as the Consultative Committee for Space Data System (CCSDS) File Transfer Protocol (CFTP) and the Delay Tolerant Network (DTN).

Morabito, David↗

A reliability and mass perspective of SP-100 Stirling cycle lunar-base powerplant designs

The purpose was to obtain reliability and mass perspectives on selection of space power system conceptual designs based on SP-100 reactor and Stirling cycle power-generation subsystems. The approach taken was to: (1) develop a criterion for an acceptable overall reliability risk as a function of the expected range of emerging technology subsystem unit reliabilities; (2) conduct reliability and mass analyses for a diverse matrix of 800-kWe lunar-base design configurations employing single and multiple powerplants with both full and partial subsystem redundancy combinations; and (3) derive reliability and mass perspectives on selection of conceptual design configurations that meet an acceptable reliability criterion with the minimum system mass increase relative to reference powerplant design. The developed perspectives provided valuable insight into the considerations required to identify and characterize high-reliability and low-mass lunar-base powerplant conceptual design.

Bloomfield, Harvey S.↗

Spacecraft failure rates - Where are we?

OGO program failure rate analysis with respect to cost, schedule and performance tradeoffs, considering component and systems design and reliability, prelaunch feedback, etc

Bloomquist, C. E.↗

Saturn component failure rate and failure rate modifiers

Failure mode frequency ratios, environmental adjustment factors, and failure rates for mechanical and electromechanical component families are presented. The failure rates and failure rate modifiers resulted from a series of studies whose purpose was to provide design, tests, reliability, and systems engineers with accurate, up-to-date failure rate information. The results of the studies were achieved through an extensive engineering analysis of the Saturn Program test data and Unsatisfactory Condition Reports (UCR's) and the application of mathematical techniques developed for the studies.

Source record↗

Premium quality 5A1-2.5 Sn ELI titanium production

Preliminary design and reliability analysis conducted on the turbopump for the NERVA 75,000 full flow cycle engine, indicated that the turbopump bearings were the most critical turbopump parts in meeting the 10 hour life at the required turbopump reliability of .99978. The analysis revealed that significant reductions (approximately a factor of 3.25) in bearing loads would be achieved by fabricating the rotating parts from titanium in lieu of A286 or 718. This is basically due to the difference in density of the materials and the resulting mass effect on the location of the first and second stick mode critical speeds. For the selected rotor configuration, the lighter material has a first critical speed at approximately 36,000 rpm, while that of the heavier material has a first critical at approximately 27,000 rpm. As the operating range of the turbopump is from 0 to 30,000 rpm, the heavier material would have a stick mode critical in the operating range.

Dessau, P. P.↗