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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 433 records · Page 24

Feasibility Investigation on the Development of a Structural Damage Diagnostic and Monitoring System for Rocket Engines

The research activity for this project is mainly to investigate the necessity and feasibility to develop a structural health monitoring system for rocket engines, and to carry out a research plan for further development of the system. More than one hundred technical papers have been searched and reviewed during the period. We concluded after this investigation that adding a new module in NASA's existing automated diagnostic system to monitor the healthy condition of rocket engine structures is a crucial task, and it's possible to develop such a system based upon the vibrational-based nondestructive damage assessment techniques. A number of such techniques have been introduced. Their advantages and disadvantages are also discussed. A global research plan has been figured out. As the first step of the overall research plan, a proposal for the next fiscal year has been submitted.

Shen, Ji Y.↗

Standards Advisor-Advanced Information Technology for Advanced Information Delivery

Developers of space systems must deal with an increasing amount of information in responding to extensive requirements and standards from numerous sources. Accessing these requirements and standards, understanding them, comparing them, negotiating them and responding to them is often an overwhelming task. There are resources to aid the space systems developer, such as lessons learned and best practices. Again, though, accessing, understanding, and using this information is often more difficult than helpful. This results in space systems that: 1. Do not meet all their requirements. 2. Do not incorporate prior engineering experience. 3. Cost more to develop. 4. Take longer to develop. The NASA Technical Standards Program (NTSP) web site at http://standards.nasa.gov has made significant improvements in making standards, lessons learned, and related material available to space systems developers agency-wide. The Standards Advisor was conceived to take the next steps beyond the current product, continuing to apply evolving information technology that continues to improve information delivery to space systems developers. This report describes the features of the Standards Advisor and suggests a technical approach to its development.

Hawker, J. Scott↗

Oxygen Compatibility Assessment of Components and Systems

Fire hazards are inherent in oxygen systems and a storied history of fires in rocket engine propulsion components exists. To detect and mitigate these fire hazards requires careful, detailed, and thorough analyses applied during the design process. The oxygen compatibility assessment (OCA) process designed by NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) can be used to determine the presence of fire hazards in oxygen systems and the likelihood of a fire. This process may be used as both a design guide and during the approval process to ensure proper design features and material selection. The procedure for performing an OCA is a structured step-by-step process to determine the most severe operating conditions; assess the flammability of the system materials at the use conditions; evaluate the presence and efficacy of ignition mechanisms; assess the potential for a fire to breach the system; and determine the reaction effect (the potential loss of life, mission, and system functionality as the result of a fire). This process should be performed for each component in a system. The results of each component assessment, and the overall system assessment, should be recorded in a report that can be used in the short term to communicate hazards and their mitigation and to aid in system/component development and, in the long term, to solve anomalies that occur during engine testing and operation.

Stoltzfus, Joel↗

Coal gasification systems engineering and analysis. Appendix E: Cost estimation and economic evaluation methodology

The cost estimation and economic evaluation methodologies presented are consistent with industry practice for assessing capital investment requirements and operating costs of coal conversion systems. All values stated are based on January, 1980 dollars with appropriate recognition of the time value of money. Evaluation of project economic feasibility can be considered a two step process (subject to considerable refinement). First, the costs of the project must be quantified and second, the price at which the product can be manufacturd must be determined. These two major categories are discussed. The summary of methodology is divided into five parts: (1) systems costs, (2)instant plant costs, (3) annual operating costs, (4) escalation and discounting process, and (5) product pricing.

Source record↗

Hardware-in-the-loop testing of a hydraulic wave energy power take-off system

This report describes testing conducted related to the development of a “hydrostatic power takeoff” (HPTO) system for a wave energy converter. Tests were conducted with an experimental electric motor rig to provide preliminary results and de-risk future testing. Efficiency mapping tests were conducted as well as hardware-in-the-loop (HIL) testing. The results of the efficiency mapping tests provide good insight into how to systematically perform efficiency mapping tests. The HIL testing indicates good overall performance of the system and provides a stepping stone towards more complete system tests in the future.

16 TIDAL AND WAVE POWER↗

Navy GTE seal development activity

Under the auspices of the Integrated High Performance Turbine Engine Technology Initiative, the Naval Air Warfare Center conducts advanced development programs for demonstration in the next generation of air-breathing propulsion systems. Among the target technologies are gas path and lube oil seals. Two development efforts currently being managed by NAWCAD are the High Performance Compressor Discharge Film-Riding Face Seal and the Subsonic Core High Speed Air/Oil Seal. The High Performance Compressor Discharge Film-Riding Face Seal Program aims at reducing parasitic leakage through application of a film-riding face sea concept to the compressor discharge location of a Phase 2 IHPTET engine. An order-of-magnitude leakage reduction relative to current labyrinth seal configurations is expected. Performance goals for these seals are (1) 1200 F air temperature, (2) 800 feet-per-second surface velocity, and (3) 600 SPI differential pressure. The two designs chosen for fabrication and rig test are a spiral groove and a Rayleigh step seal. Rig testing is currently underway. The Subsonic Core High Speed Air/Oil Seal Program is developing shaft-to-ground seals for next-generation propulsion systems that will minimize leakage and provide full life. Significantly higher rotor speeds and temperatures will be experienced. Technologies being exploited include, hydrodynamic lift assist features, ultra light weight designs, and improved cooling schemes. Parametric testing has been completed; a final seal design is entering the endurance test phase.

Grala, Carl P.↗

Systems engineering at the Jet Propulsion Laboratory.

Work at the JPL in systems engineering is surveyed with the emphasis on practical experience with large hardware and software systems. Systems concepts in lunar and planetary projects, in the Morgantown project, and in the Urban Health Systems Task are discussed. Goal definition, problem statement, objective and criteria development, and synthesis, analysis, selection and implementation of systems are considered as successive steps in the optimization of the overall system.-

Pickering, W. H.↗

Design and initial application of the extended aircraft interrogation and display system: Multiprocessing ground support equipment for digital flight systems

A pipelined, multiprocessor, general-purpose ground support equipment for digital flight systems has been developed and placed in service at the NASA Ames Research Center's Dryden Flight Research Facility. The design is an outgrowth of the earlier aircraft interrogation and display system (AIDS) used in support of several research projects to provide engineering-units display of internal control system parameters during development and qualification testing activities. The new system, incorporating multiple 16-bit processors, is called extended AIDS (XAIDS) and is now supporting the X-29A forward-swept-wing aircraft project. This report describes the design and mechanization of XAIDS and shows the steps whereby a typical user may take advantage of its high throughput and flexible features.

Glover, Richard D.↗

Definition and preliminary design of the Laser Atmospheric Wind Sounder (LAWS) phase 1. Volume 2

The steps and engineering trades and analyses used in establishing the initial requirements and in developing a concept and configuration for the laser atmospheric wind sounder (LAWS) instrument. A summary of the performance anticipated from the baseline configuration, and a bibliography are presented. LAWS, which is a facility instrument of the Earth observing system (EOS), is the culmination of over 20 years of effort in the field of laser Doppler wind sensing and will be the first instrument to fly in space capable of providing global-scale tropospheric wind profiles at high spatial resolutions. Global-scale wind profiles are necessary for: (1) more accurate diagnosis of large-scale circulation and climate dynamics; (2) improved numerical weather prediction; (3) improved understanding of mesoscale systems; and (4) improved understanding of global biogeochemical and hydrologic cycles. The objective of phase 1 was to define and perform a preliminary design for the LAWS instrument. The definition phase consisted of identifying realistic concepts for LAWS and analyzing them in sufficient detail to be able to choose the most promising one for the LAWS instrument. Systems and subsystems configurations were then developed for the chosen concept. The concept and subsequent configuration were to be compatible with two prospective platforms: the Japanese polar orbiting platform (JPOP) and as an attached payload on the Space Station Freedom. After a thorough and objective concept selection process, a heterodyne detection Doppler lidar using a CO2 laser transmitter operating a 9.1 micron over a 2.1 micron solid state system was chosen. A configuration for LAWS that meets the performance requirements was designed at the conclusion of phase 1.

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Summary of Liquid Propulsion System Needs in Support of the Constellation Program

In January 2004, the President of the United States established the Vision for Space Exploration (VSE) to complete the International Space Station, retire the Space Shuttle and develop its replacement, and expand the human presence on the Moon as a stepping stone to human exploration of Mars and worlds beyond. In response, NASA developed the Constellation Program, consisting of the components shown in Figure 1. This paper will summarize the manned spaceflight liquid propulsion system needs in support of the Constellation Program over the next 10 years. It will address all liquid engine needs to support human exploration from low Earth orbit (LEO) to the lunar surface, including an overview of engines currently under contract, those baselined but not yet under contract, and those propulsion needs that have yet to be initiated. There may be additional engine needs for early demonstrators, but those will not be addressed as part of this paper. Also, other portions of the VSE architecture, including the planned Orion abort test boosters and the Lunar Precursor Robotic Program, are not addressed here as they either use solid motors or are focused on unmanned elements of returning humans to the Moon.

Lorier, Terry↗

Active Learning for Directed Exploration of Complex Systems

Physics-based simulation codes are widely used in science and engineering to model complex systems that would be infeasible to study otherwise. Such codes provide the highest-fidelity representation of system behavior, but are often so slow to run that insight into the system is limited. For example, conducting an exhaustive sweep over a d-dimensional input parameter space with k-steps along each dimension requires k(sup d) simulation trials (translating into k(sup d) CPU-days for one of our current simulations). An alternative is directed exploration in which the next simulation trials are cleverly chosen at each step. Given the results of previous trials, supervised learning techniques (SVM, KDE, GP) are applied to build up simplified predictive models of system behavior. These models are then used within an active learning framework to identify the most valuable trials to run next. Several active learning strategies are examined including a recently-proposed information-theoretic approach. Performance is evaluated on a set of thirteen synthetic oracles, which serve as surrogates for the more expensive simulations and enable the experiments to be replicated by other researchers.

oracles↗

The Value of SysML Modeling During System Operations: A Case Study

System models are often touted as engineering tools that promote better understanding of systems, but these models are typically created during system design. The Ground Data System (GDS) team for the Dawn spacecraft took on a case study to see if benefits could be achieved by starting a model of a system already in operations. This paper focuses on the four steps the team undertook in modeling the Dawn GDS: defining a model structure, populating model elements, verifying that the model represented reality, and using the model to answer system-level questions and simplify day-to-day tasks. Throughout this paper the team outlines our thought processes and the system insights the model provided.

Dutenhoffer, Chelsea↗

LOTO Training Flow Simulator Design

The LOTO Training Flow Simulator Design poster discusses the intended purpose of the simulator along with the steps taken in the design process. It highlights the two main systems designed in the primary flow loop and the bubbler system, along with a brief description of the flow calculations made to ensure the functionality of the system.

42 - ENGINEERING↗

Autonomous Ocean World Exploration: Advancement of a Virtual Testbed

The search for life (extinct or extant) and potentially habitable bodies in our solar system and beyond is one of the 12 priority science questions outlined in the National Acadamies’ 2022 decadal survey [5]. Extraterrestrial destinations containing liquid water present an opportunity to search for life as we know it, and in recent years an increasing number of such locations have been discovered within our solar system. Several Jovian moons—Europa, Ganymede, and Callisto [10]—and the Saturnian moons Enceladus [8] and Titan [9] are known or suspected to harbor massive subsurface oceans. Of these "ocean worlds", Europa is the focus of at least one planned NASA orbiter mission, Europa Clipper [4], and an early lander mission concept, the Europa Lander [2, 3]. Whereas most robotic missions to the Moon and Mars (e.g. orbiters, rovers, landers) to date have had ground controllers on Earth tightly involved in mission operations, missions to more distant worlds will require a high degree of onboard autonomy due to long communication lags and blackouts, harsh environments (radiation, cold), and more limited battery and hardware life. The past decade has seen great advances in both AI technologies and computing scalability and performance that offer promising solutions for spacecraft autonomy and motivate the software system and research programs described in this paper. The Ocean Worlds Autonomy Testbed for Exploration, Research, and Simulation (OceanWATERS) [1], which has been in development at the NASA Ames Research Center since 2018, is a virtual environment for testing lander autonomy solutions. It is built on the Robot Operating System (ROS), runs on consumer-grade Linux workstations, and was released as open source in 2020. OceanWATERS provides a physical and visual simulation of a prototypical lander in a Europa-like environment (Figure 1). The lander was modeled after requirements and specifications made in JPL’s Europa Lander Study of 2016 [3]. Simulated lander systems include stereo cameras and spotlights mounted on an antenna mast that pans and tilts, a 6 degrees of freedom (DoF) robotic arm with a force-torque sensor and two interchangeable end effectors, and a battery pack power system. The environment consists of multiple terrain models including a highly detailed model sourced from the FROST dataset [11], simulation of surrounding planetary bodies based on an ephemeris model, and lighting from the sun with associated surface illumination, reflectance, and shadows. Operations supported by OceanWATERS include panoramic and directed imaging of the environment and lander workspace, Cartesian and joint-level arm commanding, grinding of the terrain surface (e.g. digging a trench), and scooping of ground material (Figure 2) which can be discarded or collected as science samples in a receptacle that can be emptied (science operations themselves are not simulated). These operations are realized as ROS Actions and are complimented by a wide selection of telemetry that is continually produced by each lander subsystem. The power system model is driven by the open-source Generic Software Architecture for Prognostics (GSAP) [11] that predicts the battery’s remaining useful life and other characteristics. As a testbed for high-level autonomy, OceanWATERS provides an execution framework based on PLEXIL [12], an open-source plan specification language and execution engine developed largely at Ames. NASA's initial development of OceanWATERS, as well the Ocean Worlds Lander Autonomy Testbed (OWLAT) [6], a complimentary physical testbed developed at JPL, was the first step in a plan for realizing candidate onboard autonomy solutions for such planetary landers. In 2020 NASA solicited applications for its Autonomous Robotics Research for Ocean Worlds (ARROW) program, and in 2021 the similar Concepts for Ocean worlds Life Detection Technology (COLDTech) program. Collectively six research teams, based in universities and companies across the United States, were awarded grants to develop and demonstrate autonomy solutions on OceanWATERS and OWLAT. These 1–2-year projects have now finished or are nearing completion, and a wide variety of autonomy challenges in ocean world surface missions were addressed. Prototyped and demonstrated solutions have included autonomous discovery, response and adaptation to system faults and unexpected environmental events, world model synthesis through perception, plan synthesis using learned models, methods to optimize sample target selection and prioritize science data transmission, extension of PLEXIL for stochastic decision-making, and an integration of a model of JPL’s mission-ready COLDArm [7]. Technologies used in these projects include many forms of machine learning, causal reasoning, automated planning, Markov decision processes, formal methods, and other advanced techniques. A more detailed summary of the ARROW and COLDTech projects is given herein. OceanWATERS has had significant enhancements since its open-source release in 2020. Many of its new features were driven or shaped by feedback from the ARROW and COLDTech teams and requirements of their projects. In support of enabling autonomous adaptation to spacecraft faults (a specific capability solicited by both programs), a fault injection and detection framework was developed that supports a wide and growing range of fault types such as locked joints, image loss, and battery failures. The power system model was completed and integrated into the simulator, starting as a single-cell battery model and later upgraded to a multi-cell model with associated faults such as cell disconnection. Arm/terrain interaction was improved by adding a force-torque sensor and associated faults, and an analytic dig force model based on the Balovnev bucket force equations. Environment fidelity was increased by modeling terrain deformation resulting from digging and scooping; visual improvements were made in textures, lighting, and shadows. To facilitate interoperation with OWLAT, a unified command and telemetry interface between the testbeds was developed at the ROS level, along with a PLEXIL interface. The number of lander operations was greatly expanded (e.g. with Cartesian-based arm and antenna movement), and a framework was designed for users to build their own lander actions. A GUI for PLEXIL plan selection was created (Figure 3), and an expansive set of plans were added, such as those that illustrate patterns for fault handling. This paper provides a self-contained high-level description of OceanWATERS, focusing on more detailed coverage of the aforementioned enhancements. It provides a high-level summary of the projects undertaken by participants in the ARROW and COLDTech programs and how these efforts have helped shape OceanWATERS. Finally, potential future work and directions for the testbed are listed, as likely informed by the recent planetary science decadal survey [5].

K Michael Dalal↗

Affordable Fiber-Reinforced Ceramic Composites Win 1995 R and D 100 Award

Affordable fiber-reinforced ceramic matrix composites (AFReCC) with high strength and toughness, good thermal conductivity, thermal shock resistance, and oxidation resistance are needed for high-temperature structural applications. AFReCC materials will have various applications in advanced high-efficiency and high-performance engines: that is, the High Speed Civil Transport (HSCT), space propulsion components, and land-based systems. For example, silicon-carbide-fiber-reinforced silicon carbide matrix composites show promise for meeting the criteria of high strength, thermal conductivity, and toughness required for the HSCT combustor liner. AFReCC received R&D Magazine's prestigious R&D 100 Award in 1995. The fabrication process for these composites has three steps. In the first step, fiber preforms are made and chemical vapor infiltration is used to apply the desired interface coating on the fibers. This step also rigidizes the preform. The second step consists of resin infiltration, which after pyrolysis, yields an interconnected network of porous carbon as the matrix. In the final step of the process, the carbon-containing preform is infiltrated with molten silicon or silicon alloys in a furnace. This converts the carbon to silicon carbide leaving as little as 5 percent residual free silicon or refractory disilicide phase. This process is suitable for any type of small-diameter fiber (e.g., carbon, alumina, or silicon carbide) woven into a two- or three-dimensional architecture. This processing approach leads to dense composites where matrix microstructure and composition can be tailored for optimum properties. It has much lower processing cost (less than 50 percent) in comparison to other approaches to fabricating silicon-carbide-based composites. The photograph shows the various AFReCC components. Thermomechanical and thermochemical characterization of these composites under the hostile environments that will be encountered in engine applications is underway.

Source record↗

Evaluation of a Process to Separate Ensiled Corn Grain and Stover for Improved Utilization as a Biomass Feedstock

Corn grain and chopped stover were stored anaerobically at 37% to 50% (w.b.) aggregate moisture content to create a unique biomass feedstock. However, after storage, the two fractions must be separated to accommodate different conversion pathways. In this work, a modified cleaning system from a grain combine harvester was evaluated to investigate its effectiveness in separating the grain from the stover. While this system has been purposefully built for this task, there is no previous literature on separating grain at high material other than grain (MOG) to grain ratios. Using this system, material was separated into four fractions: Grain, Tailings, Heavy MOG, and Light MOG. Subsamples were collected, oven dried, and then hydrodynamically separated to quantify the grain content in the four fractions. Several different configurations of air velocities, mass flow rate, material MOG: grain ratios, and sieve types and openings were investigated. Grain capture was defined as the fraction of the total grain dry mass collected in the grain and tailings fractions. In five experiments, the grain capture effectiveness varied from 89.2% to 99.4% on a dry basis. The dry basis foreign matter (FM) in the clean grain was 0.6% to 10.8%. As a result, the use of a modified combine cleaning system has the potential to be one step in a system to fractionate corn grain from stover (i.e., MOG) in a biorefinery that uses both starch and cellulose as biomass feedstocks.

09 BIOMASS FUELS↗

Development of High Temperature (>700°C) Molten Salt Pump Technology for Generation 3 Solar Power Tower Systems

Bearings are required for long-shafted pumps historically used in concentrating solar thermal power applications. For molten chloride salts, bearings for such service conditions are not commercially available, nor has a design been demonstrated to work. Therefore, a project was sponsored by the Department of Energy’s Solar Energy Technologies Office for the development and demonstration of a submerged bearing for use in chloride salt pumps. This project’s tasks covered the tribological testing of candidate materials and the design, fabrication, testing, and post-test analysis of full-scale salt-compatible bearings. This work expands upon previous work. The effects of potential particulate in the salt were investigated through tribological bench testing. Through 11 tests, the MgO particulate size and concentration in a molten chloride salt were varied, and the effects on friction, wear rate, and wear characteristics were recorded. Novel journal bearings for chloride salt service were designed and fabricated based on these results. The bearings were of a relevant scale (i.e., for a 1.5 in. pump shaft) to demonstrate the technology with respect to further scale-up. The bearings were made of Haynes 244 and Yttria Partially Stabilized Zirconia. A custom bearing test rig, salt tanks, and associated infrastructure (e.g., heaters, tanks, transfer lines, gas flow control) were designed, procured, and installed. A few issues were encountered in the system fabrication process, resulting in delay of the project schedule. The system was successfully fabricated and assembled. Heating, cover gas, and pump motor systems were integrated into the control logic. This progress of the bearing test system represents a significant step forward towards demonstrating this promising technology. Nevertheless, the project ended before testing of the full-scale bearings could be performed.

14 SOLAR ENERGY↗

Structured prototyping as risk management

A methodology is presented for integrating the systems-engineering management recommendation of prototyping into the traditional project-management process for developing large-scale systems. The suggested methodology begins with the identification of life-cycle risk areas, outlines the structure and conduct of the prototyping process, and defines the composition of the prototyping team. The methodology includes a step-by-step procedure for creating, executing, and documenting a prototyping test plan to evaluate design alternatives. It is argued that managers who adopt this methodology and apply it rigorously will increase the likelihood that the systems they build will be operationally effective and will be accepted by the intended users.

Hornstein, Rhoda SH.↗