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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 415 records · Page 23

Uniform Dust Deposition System for Dust Tolerance Studies

Future missions to the Moon will require mechanisms and materials to effectively and reliably operate in the presences of lunar regolith. One of the challenges of developing such technologies is terrestrial testing with lunar dust simulants. Dust has a stochastic nature of depositing and it can be difficult to accurately apply it to surfaces of interest. Deposition density, particles size distribution, and percent coverage are all factors that affect the quality of dust mitigation testing. Therefore, to enable such testing the dust mitigation and seals teams at NASA Glenn Research Center (GRC) have developed a system that can uniformly and repeatably deposit lunar simulants on a range of surfaces. Testing of the Dust Deposition System (DDS) and an associatedsimulant preparation methodology have quantified the levels of uniformity and precision for this system. Furthermore, the deposition system has been paired with automated micrograph capturing and machine learning image analysis to correlate the images of dust on a surface to deposition density (in g/cm2). This correlation alleviates the need for tested samples to be accurately weighed with milligram precision and may be a useful tool for in-situ contamination evaluation on the Moon. This paper covers the design and validation testing for the DDS.

Stephen Gerdts↗

The Efficiency of Various Computers and Optimizations in Performing Finite Element Computations

With the advent of computers with many processors, it becomes unclear how to best exploit this advantage. For example, matrices can be inverted by applying several processors to each vector operation, or one processor can be applied to each matrix. The former approach has diminishing returns beyond a handful of processors, but how many processors depends on the computer architecture. Applying one processor to each matrix is feasible with enough ram memory and scratch disk space, but the speed at which this is done is found to vary by a factor of three depending on how it is done. The cost of the computer must also be taken into account. A computer with many processors and fast interprocessor communication is much more expensive than the same computer and processors with slow interprocessor communication. Consequently, for problems that require several matrices to be inverted, the best speed per dollar for computers is found to be several small workstations that are networked together, such as in a Beowulf cluster. Since these machines typically have two processors per node, each matrix is most efficiently inverted with no more than two processors assigned to it.

Marcus, Martin H.↗

Uniform Dust Deposition System for Dust Tolerance Studies

Future missions to the Moon will require mechanisms and materials to effectively and reliably operate in the presences of lunar regolith. One of the challenges of developing such technologies is terrestrial testing with lunar dust simulants. Dust has a stochastic nature of depositing and it can be difficult to accurately apply it to surfaces of interest. Deposition density, particles size distribution, and percent coverage are all factors that affect the quality of dust mitigation testing. Therefore, to enable such testing the dust mitigation and seals teams at NASA Glenn Research Center (GRC) have developed a system that can uniformly and repeatably deposit lunar simulants on a range of surfaces. Testing of the Dust Deposition System (DDS) and an associated simulant preparation methodology have quantified the levels of uniformity and precision for this system. Furthermore, the deposition system has been paired with automated micrograph capturing and machine learning image analysis to correlate the images of dust on a surface to deposition density (in g/cm2). This correlation alleviates the need for tested samples to be accurately weighed with milligram precision and may be a useful tool for in-situ contamination evaluation on the Moon. This paper covers the design and validation testing for the DDS.

Dust↗

Axial Fatigue Tests at Zero Mean Stress of 24S-T Aluminum-alloy Sheet with and Without a Circular Hole

Axial fatigue tests were made on 189 coupon specimens of 0.032-inch 24S-T aluminum-alloy sheet and a few supplementary specimens of 0.004-inch sheet. The mean load was zero. The specimens were restrained against lateral buckling by lubricated solid guides described in a previous report on this project. About two-thirds of the 0.032-inch specimens were plain coupons nominally free from stress raisers. The remainder contained a 0.1285-inch drilled hole at the center where the reduced section was 0.5 inch wide. S-N diagrams were obtained for cycles to failure between about 1000 and 10 to the 7th power cycles for the plain specimens and 17 and 10 to the 7th power cycles for the drilled specimens. The fatigue stress concentration factor increased from about 1.08 for a stress amplitude causing failure at 0.25 cycles (static) to a maximum of 1.83 at 15,000 cycles and then decreased gradually. The graph for the drilled specimens showed less scatter than that for the plain specimens.

TESTING MACHINES, FATIGUE↗

Life and Reliability Characteristics of TurboBrayton Coolers

Wear and internal contaminants are two of the primary factors that influence reliable, long-life operation of turbo-Brayton cryocoolers. This paper describes tests that have been conducted and methods that have been developed for turbo-Brayton components and systems to assure reliable operation. The turbomachines used in these coolers employ self-acting gas bearings to support the miniature high-speed shafts, thus providing vibration-free operation. Because the bearings are self-acting, rubbing contact occurs during initial start-up and shutdown of the machines. Bearings and shafts are designed to endure multiple stop/start cycles without producing particles or surface features that would impair the proper operation of the machines. Test results are presented for a variety of turbomachines used in these systems. The tests document extended operating life and start/stop cycling behavior for machines over a range of time and temperature scales. Contaminants such as moisture and other residual gas impurities can be a source of degraded operation if they freeze out in sufficient quantities to block flow passages or if they mechanically affect the operation of the machines. A post-fabrication bakeout procedure has been successfully used to reduce residual internal contamination to acceptable levels in a closed cycle system. The process was developed during space qualification tests on the NICMOS cryocooler. Moisture levels were sampled over a six-month time interval confirming the effectiveness of the technique. A description of the bakeout procedure is presented.

Breedlove, Jeff J.↗

Micro-Cracking Detection in Laminated Composites

Porosity and fatigue cracking are two critical factors that affect the performance and safety of cryogenic fuel tanks and feedlines made from unlined laminated or weaved carbon/epoxy materials. This paper presents the experiments to induce fatigue cracking of laminated composites through thermal cycling as well as the feasibility of using Thermography and Ultrasound Spectroscopy technology (UT) to detect and measure such micro-cracking. Carbon/epoxy laminated composite panels were built and cut into strips. These specimens were partially submerged in liquid nitrogen while subjected to various loads on a test machine. Edges of some specimens were polished and etched to determine the degree of micro-cracking. The rest of specimens were then examined with Thermography and Ultrasound Spectroscopy NDE systems to investigate the feasibility of finding such micro-cracking in the laminated composites. Thermography is utilized to determine changes in thermal diffusivity. The degree of cracking may reduce the apparent thermal diffusivity and therefore change the thermal response on the surface. Thermography testing was conducted on a group of specimens where it is desired to have some correlation between the predetermined stress and the thermography data. Ultrasound Spectroscopy was used to determine peak changes between the pre-stressed and stressed samples. Data from the inspections were analyzed and the results are presented in this paper.

Chu, Tsuchin↗

New Integrated Modeling Capabilities: MIDAS' Recent Behavioral Enhancements

The Man-machine Integration Design and Analysis System (MIDAS) is an integrated human performance modeling software tool that is based on mechanisms that underlie and cause human behavior. A PC-Windows version of MIDAS has been created that integrates the anthropometric character "Jack (TM)" with MIDAS' validated perceptual and attention mechanisms. MIDAS now models multiple simulated humans engaging in goal-related behaviors. New capabilities include the ability to predict situations in which errors and/or performance decrements are likely due to a variety of factors including concurrent workload and performance influencing factors (PIFs). This paper describes a new model that predicts the effects of microgravity on a mission specialist's performance, and its first application to simulating the task of conducting a Life Sciences experiment in space according to a sequential or parallel schedule of performance.

Gore, Brian F.↗

Optimal Estimation Framework for Ocean Color Atmospheric Correction and Pixel-level Uncertainty Quantification

Ocean color remote sensing requires compensation for atmospheric scattering and absorption (aerosol, Rayleigh, and trace gases), referred to as atmospheric correction (AC). AC allows inference of parameters such as spectrally resolved remote sensing reflectance ( R rs )(λ) ; sr 1 ) at the ocean surface from the top-of-atmosphere reflectance. Often, the uncertainty of this process is not fully explored. Bayesian inference techniques provide a simultaneous AC and uncertainty assessment via a full posterior distribution of the relevant variables, given the prior distribution of those variables and the radiative transfer (RT) likelihood function. Given uncertainties in the algorithm inputs, the Bayesian framework enables better constraints on the AC process by using the complete spectral information compared to traditional approaches that use only a subset of bands for AC. This paper investigates a Bayesian inference research method (Optimal Estimation, OE) for ocean color AC by simultaneously retrieving atmospheric and ocean properties using all visible and near-infrared spectral bands. The OE algorithm analytically approximates the posterior distribution of parameters based on normality assumptions and provides a potentially viable operational algorithm with a reduced computational expense. We developed a Neural Network (NN) RT forward model look-up-table-based emulator to increase algorithm efficiency further and thus speed up the likelihood computations. We then applied the OE algorithm to synthetic data and observations from the MODerate resolution Imaging Spectroradiometer (MODIS) on NASA’s Aqua spacecraft. We compared the R rs )(λ) retrieval and its uncertainty estimates from the OE method with in-situ validation data from the SeaWiFS Bio-optical Archive and Storage System (SeaBASS) and Aerosol Robotic Network Ocean Color (AERONET-OC) datasets. The OE algorithm improved R rs )(λ) estimates relative to the NASA standard operational algorithm by improving all statistical metrics at 443, 555, and 667 nm. Unphysical negative R rs )(λ) , which often appear in complex water conditions, was reduced by a factor of 3. The OE-derived pixel-level R rs )(λ) uncertainty estimates were also assessed relative to in-situ data and were shown to have skill.

Atmospheric correction↗

Pushing the Limits of Aquatic Remote Sensing: Synthetic Data and Deep Learning for Fast Inverse Emulation of A Coupled Ocean-Atmosphere Radiative Transfer Model

The inversion of electromagnetic information to physical and biological properties of the water column is a notoriously difficult problem, yet fundamental to our ability of understanding aquatic processes on large time and space scales. There is now a growing necessity to develop pragmatic approaches that allow timely and effective extrapolation of local processes, to spatially resolved global products, and to promote operational and sustainable resource policy management. This presentation will discuss research integrating advanced biological and radiative modeling, high-end computation, and machine learning to develop a portable global processor for simultaneous retrieval of atmosphere and water optics for diverse aquatic systems from the open and coastal ocean to optically extreme inland waters and harmful algal blooms. We will discuss some of the basic concepts behind the forward modeling approach including DEAP, the novel Distributed Equivalent Algal Populations model, for developing large spectral libraries of aquatic particle optics to aid in our ability to distinguish phytoplankton functional types (PFTs) and inorganic material, as well as other factors which enable comprehensive modeling from the benthos to top-of-atmosphere (TOA). This information is being used to understand how we can leverage next-generation deep learning methods for maximum information retrieval and rapid image processing, while also providing capabilities to identify minimum sensor spectral requirements necessary for certain aquatic applications. Further, I will touch on how we envision this research to enable the aquatic community for science discovery and how we are moving closer towards the capability for high-fidelity global analysis of aquatic ecosystems.

Jeremy Alan Kravitz↗

Research and Technology Challenges for Human Data Analysts in Future Safety Management Systems

Enabling new and novel concepts of operations for Advanced Air Mobility poses an important need to evolve current safety management systems (SMS) and is posited to be realized through advances in Machine Learning (ML) Data Sciences and Artificial Intelligence. The “In-time Aviation Safety Management System” (IASMS) concept of operations supports the need to evolve today’s SMS to become more tailorable, scalable, and interoperable in response to forecasted changes expected for the future airspace system. Key to IASMS is integration of proactive and predictive ML algorithms trained to provide “in time” detection and mitigation of hazards and emergent risks through new methods and novel data types. IASMS research and technology development includes human factors design considerations for these systems to include human-system teaming, innovations in human interfaces and management of complex digital data information, human-system interaction/model-based system engineering, and verification and validation for data assurance and trust.

Chad L Stephens↗

Storage and computationally efficient permutations of factorized covariance and square-root information matrices

A unified method to permute vector-stored upper-triangular diagonal factorized covariance (UD) and vector stored upper-triangular square-root information filter (SRIF) arrays is presented. The method involves cyclical permutation of the rows and columns of the arrays and retriangularization with appropriate square-root-free fast Givens rotations or elementary slow Givens reflections. A minimal amount of computation is performed and only one scratch vector of size N is required, where N is the column dimension of the arrays. To make the method efficient for large SRIF arrays on a virtual memory machine, three additional scratch vectors each of size N are used to avoid expensive paging faults. The method discussed is compared with the methods and routines of Bierman's Estimation Subroutine Library (ESL).

Muellerschoen, R. J.↗

Turbomachine Sealing and Secondary Flows: Review of Rotordynamics Issues in Inherently Unsteady Flow Systems With Small Clearances - Part 2

Today's computational methods enable the determination of forces in complex systems, but without field validation data, or feedback, there is a high risk of failure when the design envelope is challenged. The data of Childs and Bently and field data reported in NASA Conference Proceedings serve as sources of design information for the development of these computational codes. Over time all turbomachines degrade and instabilities often develop, requiring responsible, accurate, turbomachine diagnostics with proper decisions to prevent failures. Tam et al. (numerical) and Bently and Muszynska (analytical) models corroborate and implicate that destabilizing factors are related through increases in the fluid-force average circumferential velocity. The stability threshold can be controlled by external swirl and swirl brakes and increases in radial fluid film stiffness (e.g., hydrostatic and ambient pressures) to enhance rotor stability. Also cited are drum rotor self-excited oscillations, where the classic fix is to add a split or severed damper ring or cylindrical damper drum, and the Benkert-Wachter work that engendered swirl brake concepts. For a smooth-operating, reliable, long-lived machine, designers must pay very close attention to sealing dynamics and diagnostic methods. Correcting the seals enabled the space shuttle main engine high-pressure fuel turbopump (SSME HPFTP) to operate successfully.

Hendricks, R. C.↗

Multidisciplinary Design Optimization and Analysis of an Open Rotor Stage: Part 1

Successful design of open rotor propulsors requires effective analysis across multiple disciplines, including aerodynamics, acoustics, and structures. A viable design must not only be efficient but must also produce an acceptable level of noise and meet all static and dynamic structural requirements. For design and optimization, this is especially challenging because running high fidelity analyses is resource-intensive, and optimizing a design may require many thousands of cases to be analyzed. For this reason, the NASA team has applied design methodology that utilizes low-cost aerodynamic methods, machine learning models, and high-fidelity analyses when necessary. This includes standard two-dimensional methods such as throughflow analysis and quasi-3D blade-to-blade CFD, as well as some newly developed methods. Optimization using 3D CFD is necessary to maximize performance, and this is considered as well. All optimizations are carried out subject to structural constraints evaluated using finite element analysis. Doing this accurately requires a robust trunnion design, capable of pitching the blade between cruise and takeoff conditions while maintaining acceptable factor of safety. Hot to cold analysis must also be applied in order to correctly determine the as-manufactured shape. For acoustics, the unsteady pressures on the blade surfaces must be predicted, and this can be done either through full-annulus unsteady CFD or through a nonlinear harmonic method (NLH). NLH can run much faster, allowing some acoustic considerations to be made earlier in the design process. The design process is ongoing, and this presentation will review the current status and planned next steps. This part of the talk will focus on aerodynamic performance and be followed by a talk on structures and acoustics.

Design↗

Micro-Slit Collimators for X-Ray/Gamma-Ray Imaging

A hybrid photochemical-machining process is coupled with precision stack lamination to allow for the fabrication of multiple ultra-high-resolution grids on a single array substrate. In addition, special fixturing and etching techniques have been developed that allow higher-resolution multi-grid collimators to be fabricated. Building on past work of developing a manufacturing technique for fabricating multi-grid, high-resolution coating modulation collimators for arcsecond and subarcsecond x-ray and gamma-ray imaging, the current work reduces the grid pitch by almost a factor of two, down to 22 microns. Additionally, a process was developed for reducing thin, high-Z (tungsten or molybdenum) from the thinnest commercially available foil (25 microns thick) down to approximately equal to 10 microns thick using precisely controlled chemical etching

Appleby, Michael↗

OH detection by Ford Motor Company

Two different methods for detection of OH are presented: a low pressure flow cell system and a frequency modulation absorption measurement. Using conventional absorption spectroscopy, detection limits were quoted of 1,000,000 OH molecules per cu cm using a 30-minute averaging time on the ground, and a 3-hour averaging time in the air for present apparatus in use. With the addition of FM spectroscopy at 1 GHz, a double-beam machine should permit detectable absorption of and an OH limit of 100,000 per cu cm in a 30-minute averaging time. In the low pressure system on which experiments are ongoing nonexponential time behavior was observed after the decay had progressed to about 0.3 of its original level; this was attributed to ion emission in the photomultiplier. A flame source with OH present at high concentration levels was used as a calibration. It was estimated that within the sampling chamber, 400,000 OH could be measured. With a factor-of-2 loss at the sampling orifice, this means detectability of 5 to 8 x 100,000 cu cm at the present time. This could be reduced by a factor of 2 in one hour averaging time; improvements in laser bandwidth and energy should provide another factor of 2 in sensitivity.

Wang, Charles C.↗

Analysis and modification of a single-mesh gear fatigue rig for use in diagnostic studies

A single-mesh gear fatigue rig was analyzed and modified for use in gear mesh diagnostic research. The fatigue rig allowed unwanted vibration to mask the test-gear vibration signal, making it difficult to perform diagnostic studies. Several possible sources and factors contributing to the unwanted components of the vibration signal were investigated. Sensor mounting location was found to have a major effect on the content of the vibration signal. In the presence of unwanted vibration sources, modal amplification made unwanted components strong. A sensor location was found that provided a flatter frequency response. This resulted in a more useful vibration signal. A major network was performed on the fatigue rig to reduce the influence of the most probable sources of the noise in the vibration signal. The slave gears were machined to reduce weight and increase tooth loading. The housing and the shafts were modified to reduce imbalance, looseness, and misalignment in the rotating components. These changes resulted in an improved vibration signal, with the test-gear mesh frequency now the dominant component in the signal. Also, with the unwanted sources eliminated, the sensor mounting location giving the most robust representation of the test-gear meshing energy was found to be at a point close to the test gears in the load zone of the bearings.

Zakrajsek, James J.↗

Scheduling revisited workstations in integrated-circuit fabrication

The cost of building new semiconductor wafer fabrication factories has grown rapidly, and a state-of-the-art fab may cost 250 million dollars or more. Obtaining an acceptable return on this investment requires high productivity from the fabrication facilities. This paper describes the Photo Dispatcher system which was developed to make machine-loading recommendations on a set of key fab machines. Dispatching policies that generally perform well in job shops (e.g., Shortest Remaining Processing Time) perform poorly for workstations such as photolithography which are visited several times by the same lot of silicon wafers. The Photo Dispatcher evaluates the history of workloads throughout the fab and identifies bottleneck areas. The scheduler then assigns priorities to lots depending on where they are headed after photolithography. These priorities are designed to avoid starving bottleneck workstations and to give preference to lots that are headed to areas where they can be processed with minimal waiting. Other factors considered by the scheduler to establish priorities are the nearness of a lot to the end of its process flow and the time that the lot has already been waiting in queue. Simulations that model the equipment and products in one of Texas Instrument's wafer fabs show the Photo Dispatcher can produce a 10 percent improvement in the time required to fabricate integrated circuits.

Kline, Paul J.↗

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗