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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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NASA NTRS2014

Space Launch System Implementation of Adaptive Augmenting Control

Given the complex structural dynamics, challenging ascent performance requirements, and rigorous flight certification constraints owing to its manned capability, the NASA Space Launch System (SLS) launch vehicle requires a proven thrust vector control algorithm design with highly optimized parameters to robustly demonstrate stable and high performance flight. On its development path to preliminary design review (PDR), the stability of the SLS flight control system has been challenged by significant vehicle flexibility, aerodynamics, and sloshing propellant dynamics. While the design has been able to meet all robust stability criteria, it has done so with little excess margin. Through significant development work, an adaptive augmenting control (AAC) algorithm previously presented by Orr and VanZwieten, has been shown to extend the envelope of failures and flight anomalies for which the SLS control system can accommodate while maintaining a direct link to flight control stability criteria (e.g. gain & phase margin). In this paper, the work performed to mature the AAC algorithm as a baseline component of the SLS flight control system is presented. The progress to date has brought the algorithm design to the PDR level of maturity. The algorithm has been extended to augment the SLS digital 3-axis autopilot, including existing load-relief elements, and necessary steps for integration with the production flight software prototype have been implemented. Several updates to the adaptive algorithm to increase its performance, decrease its sensitivity to expected external commands, and safeguard against limitations in the digital implementation are discussed with illustrating results. Monte Carlo simulations and selected stressing case results are shown to demonstrate the algorithm's ability to increase the robustness of the integrated SLS flight control system.

VanZwieten, Tannen S.↗
NASA NTRS2014

Space Launch System Implementation of Adaptive Augmenting Control

Given the complex structural dynamics, challenging ascent performance requirements, and rigorous flight certification constraints owing to its manned capability, the NASA Space Launch System (SLS) launch vehicle requires a proven thrust vector control algorithm design with highly optimized parameters to provide stable and high-performance flight. On its development path to Preliminary Design Review (PDR), the SLS flight control system has been challenged by significant vehicle flexibility, aerodynamics, and sloshing propellant. While the design has been able to meet all robust stability criteria, it has done so with little excess margin. Through significant development work, an Adaptive Augmenting Control (AAC) algorithm has been shown to extend the envelope of failures and flight anomalies the SLS control system can accommodate while maintaining a direct link to flight control stability criteria such as classical gain and phase margin. In this paper, the work performed to mature the AAC algorithm as a baseline component of the SLS flight control system is presented. The progress to date has brought the algorithm design to the PDR level of maturity. The algorithm has been extended to augment the full SLS digital 3-axis autopilot, including existing load-relief elements, and the necessary steps for integration with the production flight software prototype have been implemented. Several updates which have been made to the adaptive algorithm to increase its performance, decrease its sensitivity to expected external commands, and safeguard against limitations in the digital implementation are discussed with illustrating results. Monte Carlo simulations and selected stressing case results are also shown to demonstrate the algorithm's ability to increase the robustness of the integrated SLS flight control system.

Wall, John H.↗
NASA NTRS2004

Automating Structural Analysis of Spacecraft Vehicles

A major effort within NASA's vehicle analysis discipline has been to automate structural analysis and sizing optimization during conceptual design studies of advanced spacecraft. Traditional spacecraft structural sizing has involved detailed finite element analysis (FEA) requiring large degree-of-freedom (DOF) finite element models (FEM). Creation and analysis of these models can be time consuming and limit model size during conceptual designs. The goal is to find an optimal design that meets the mission requirements but produces the lightest structure. A structural sizing tool called HyperSizer has been successfully used in the conceptual design phase of a reusable launch vehicle and planetary exploration spacecraft. The program couples with FEA to enable system level performance assessments and weight predictions including design optimization of material selections and sizing of spacecraft members. The software's analysis capabilities are based on established aerospace structural methods for strength, stability and stiffness that produce adequately sized members and reliable structural weight estimates. The software also helps to identify potential structural deficiencies early in the conceptual design so changes can be made without wasted time. HyperSizer's automated analysis and sizing optimization increases productivity and brings standardization to a systems study. These benefits will be illustrated in examining two different types of conceptual spacecraft designed using the software. A hypersonic air breathing, single stage to orbit (SSTO), reusable launch vehicle (RLV) will be highlighted as well as an aeroshell for a planetary exploration vehicle used for aerocapture at Mars. By showing the two different types of vehicles, the software's flexibility will be demonstrated with an emphasis on reducing aeroshell structural weight. Member sizes, concepts and material selections will be discussed as well as analysis methods used in optimizing the structure. Analysis based on the HyperSizer structural sizing software will be discussed. Design trades required to optimize structural weight will be presented.

Hrinda, Glenn A.↗
NASA NTRS1992

Evaluation of some significant issues affecting trajectory and control management for air-breathing hypersonic vehicles

Horizontal takeoff airbreathing-propulsion launch vehicles require near-optimal guidance and control which takes into account performance sensitivities to atmospheric characteristics while satisfying physically-derived operational constraints. A generic trajectory/control analysis tool that deepens insight into these considerations has been applied to two versions of a winged-cone vehicle model. Information that is critical to the design and trajectory of these vehicles is derived, and several unusual characteristics of the airbreathing propulsion model are shown to have potentially substantial effects on vehicle dynamics.

Hattis, Philip D.↗
NASA NTRS1993

Multidisciplinary Design Techniques Applied to Conceptual Aerospace Vehicle Design

Multidisciplinary design optimization (MDO) is an emerging discipline within aerospace engineering. Its goal is to bring structure and efficiency to the complex design process associated with advanced aerospace launch vehicles. Aerospace vehicles generally require input from a variety of traditional aerospace disciplines - aerodynamics, structures, performance, etc. As such, traditional optimization methods cannot always be applied. Several multidisciplinary techniques and methods were proposed as potentially applicable to this class of design problem. Among the candidate options are calculus-based (or gradient-based) optimization schemes and parametric schemes based on design of experiments theory. A brief overview of several applicable multidisciplinary design optimization methods is included. Methods from the calculus-based class and the parametric class are reviewed, but the research application reported focuses on methods from the parametric class. A vehicle of current interest was chosen as a test application for this research. The rocket-based combined-cycle (RBCC) single-stage-to-orbit (SSTO) launch vehicle combines elements of rocket and airbreathing propulsion in an attempt to produce an attractive option for launching medium sized payloads into low earth orbit. The RBCC SSTO presents a particularly difficult problem for traditional one-variable-at-a-time optimization methods because of the lack of an adequate experience base and the highly coupled nature of the design variables. MDO, however, with it's structured approach to design, is well suited to this problem. The result of the application of Taguchi methods, central composite designs, and response surface methods to the design optimization of the RBCC SSTO are presented. Attention is given to the aspect of Taguchi methods that attempts to locate a 'robust' design - that is, a design that is least sensitive to uncontrollable influences on the design. Near-optimum minimum dry weight solutions are determined for the vehicle. A summary and evaluation of the various parametric MDO methods employed in the research are included. Recommendations for additional research are provided.

Olds, John Robert↗
NASA NTRS2012

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth-to-Orbit Team (ETO) of the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) is considered the pre-eminent go-to group for pre-phase A and phase A concept definition. Over the past several years the ETO team has evaluated thousands of launch vehicle concept variations for a significant number of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Augustine Report, Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). The ACO ETO Team is called upon to address many needs in NASA s design community; some of these are defining extremely large trade-spaces, evaluating advanced technology concepts which have not been addressed by a large majority of the aerospace community, and the rapid turn-around of highly time critical actions. It is the time critical actions, those often limited by schedule or little advanced warning, that have forced the five member ETO team to develop a design process robust enough to handle their current output level in order to meet their customer s needs. Based on the number of vehicle concepts evaluated over the past year this output level averages to four completed vehicle concepts per day. Each of these completed vehicle concepts includes a full mass breakdown of the vehicle to a tertiary level of subsystem components and a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. A structural analysis of the vehicle to determine flight loads based on the trajectory output, material properties, and geometry of the concept is also performed. Due to working in this fast-paced and sometimes rapidly changing environment, the ETO Team has developed a finely tuned process to maximize their delivery capabilities. The objective of this paper is to describe the interfaces between the three disciplines used in the design process: weights and sizing, trajectory, and structural analysis. The tools used to perform such analysis are INtegrated Rocket Sizing (INTROS), Program to Optimize Simulated Trajectories (POST), and Launch Vehicle Analysis (LVA) respectively. The methods each discipline uses to streamline their particular part of the design process will also be discussed.

Waters, Eric D.↗
NASA NTRS2013

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth-to-Orbit Team (ETO) of the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) is considered the pre-eminent "go-to" group for pre-phase A and phase A concept definition. Over the past several years the ETO team has evaluated thousands of launch vehicle concept variations for a significant number of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Augustine Report, Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). The ACO ETO Team is called upon to address many needs in NASA's design community; some of these are defining extremely large trade-spaces, evaluating advanced technology concepts which have not been addressed by a large majority of the aerospace community, and the rapid turn-around of highly time critical actions. It is the time critical actions, those often limited by schedule or little advanced warning, that have forced the five member ETO team to develop a design process robust enough to handle their current output level in order to meet their customer's needs. Based on the number of vehicle concepts evaluated over the past year this output level averages to four completed vehicle concepts per day. Each of these completed vehicle concepts includes a full mass breakdown of the vehicle to a tertiary level of subsystem components and a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. A structural analysis of the vehicle to determine flight loads based on the trajectory output, material properties, and geometry of the concept is also performed. Due to working in this fast-paced and sometimes rapidly changing environment, the ETO Team has developed a finely tuned process to maximize their delivery capabilities. The objective of this paper is to describe the interfaces between the three disciplines used in the design process: weights and sizing, trajectory, and structural analysis. The tools used to perform such analysis are INtegrated Rocket Sizing (INTROS), Program to Optimize Simulated Trajectories (POST), and Launch Vehicle Analysis (LVA) respectively. The methods each discipline uses to streamline their particular part of the design process will also be discussed.

Waters, Eric D.↗
NASA NTRS2010

Modified Universal Design Survey: Enhancing Operability of Launch Vehicle Ground Crew Worksites

Operability is a driving requirement for next generation space launch vehicles. Launch site ground operations include numerous operator tasks to prepare the vehicle for launch or to perform preflight maintenance. Ensuring that components requiring operator interaction at the launch site are designed for optimal human use is a high priority for operability. To promote operability, a Design Quality Evaluation Survey based on Universal Design framework was developed to support Human Factors Engineering (HFE) evaluation for NASA s launch vehicles. Universal Design per se is not a priority for launch vehicle processing however; applying principles of Universal Design will increase the probability of an error free and efficient design which promotes operability. The Design Quality Evaluation Survey incorporates and tailors the seven Universal Design Principles and adds new measures for Safety and Efficiency. Adapting an approach proven to measure Universal Design Performance in Product, each principle is associated with multiple performance measures which are rated with the degree to which the statement is true. The Design Quality Evaluation Survey was employed for several launch vehicle ground processing worksite analyses. The tool was found to be most useful for comparative judgments as opposed to an assessment of a single design option. It provided a useful piece of additional data when assessing possible operator interfaces or worksites for operability.

Blume, Jennifer L.↗
NASA NTRS2012

Space Launch System Mission Flexibility Assessment

The Space Launch System (SLS) is envisioned as a heavy lift vehicle that will provide the foundation for future beyond low Earth orbit (LEO) missions. While multiple assessments have been performed to determine the optimal configuration for the SLS, this effort was undertaken to evaluate the flexibility of various concepts for the range of missions that may be required of this system. These mission scenarios include single launch crew and/or cargo delivery to LEO, single launch cargo delivery missions to LEO in support of multi-launch mission campaigns, and single launch beyond LEO missions. Specifically, we assessed options for the single launch beyond LEO mission scenario using a variety of in-space stages and vehicle staging criteria. This was performed to determine the most flexible (and perhaps optimal) method of designing this particular type of mission. A specific mission opportunity to the Jovian system was further assessed to determine potential solutions that may meet currently envisioned mission objectives. This application sought to significantly reduce mission cost by allowing for a direct, faster transfer from Earth to Jupiter and to determine the order-of-magnitude mass margin that would be made available from utilization of the SLS. In general, smaller, existing stages provided comparable performance to larger, new stage developments when the mission scenario allowed for optimal LEO dropoff orbits (e.g. highly elliptical staging orbits). Initial results using this method with early SLS configurations and existing Upper Stages showed the potential of capturing Lunar flyby missions as well as providing significant mass delivery to a Jupiter transfer orbit.

Monk, Timothy↗
NASA NTRS1994

Launch-pad abort capabilities of the HL-20 lifting body

The capability of the HL-20 lifting body to perform an abort maneuver from the launch pad to a horizontal landing was studied. The study involved both piloted and batch simulation models of the vehicle. A point-mass model of the vehicle was used for trajectory optimization studies. The piloted simulation was performed in the Langley Visual/Motion Simulator in the fixed-base mode. A candidate maneuver was developed and refined for the worst-case launch-pad-to-landing-site geometry with an iterative procedure of off-line maneuver analysis followed by piloted evaluations and heuristic improvements to the candidate maneuver. The resulting maneuver demonstrates the launch-site abort capability of the HL-20 and dictates requirements for nominal abort-motor performance. The sensitivity of the maneuver to variations in several design parameters was documented.

Jackson, E. Bruce↗
NASA NTRS1976

Nozzle selection for optimized single-stage shuttles

A computerized preliminary design procedure has been used to determine rocket-engine bell-nozzle configurations which achieve either minimum gross mass or minimum dry mass on an advanced technology winged single-stage-to-orbit launch vehicle. This procedure evaluates the trade offs between the optimized ascent flight trajectory performance and the flight vehicle sizing driven by the engine mass and propellant requirements. Numerous mission, flight, and vehicle related requirements and constraints are satisfied in this process. Propulsion system configurations which incorporate dual-position nozzles are evaluated and compared to configurations using all fixed nozzles.

Eldred, C. H.↗
NASA NTRS1993

Investigation of the launch pad abort capabilities of the HL-20 lifting body

The capability of the HL-20 lifting body spacecraft to perform an abort maneuver from the launch pad to a horizontal landing was studied at NASA Langley Research Center. This study involved both piloted and batch simulation models of the vehicle. A point-mass model of the vehicle was used for trajectory optimization studies. The piloted simulation was performed in the Visual Motion Simulator in fixed-base mode. A candidate maneuver was developed and refined for the worst-case launch-pad-to-landing-site geometry using an iterative procedure of off-line maneuver analysis followed by piloted evaluations and heuristic improvements to the candidate maneuver. The resulting maneuver demonstrates the launch site abort capability of the HL-20 and dictates requirements for nominal abort motor performance. The sensitivity of the maneuver to variations in several design parameters was documented.

Jackson, E. B.↗
NASA NTRS1992

A hybrid approach to near-optimal launch vehicle guidance

This paper evaluates a proposed hybrid analytical/numerical approach to launch-vehicle guidance for ascent to orbit injection. The feedback-guidance approach is based on a piecewise nearly analytic zero-order solution evaluated using a collocation method. The zero-order solution is then improved through a regular perturbation analysis, wherein the neglected dynamics are corrected in the first-order term. For real-time implementation, the guidance approach requires solving a set of small dimension nonlinear algebraic equations and performing quadrature. Assessment of performance and reliability are carried out through closed-loop simulation for a vertically launched 2-stage heavy-lift capacity vehicle to a low earth orbit. The solutions are compared with optimal solutions generated from a multiple shooting code. In the example the guidance approach delivers over 99.9 percent of optimal performance and terminal constraint accuracy.

Leung, Martin S. K.↗
NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗
NASA NTRS2010

ACT Payload Shroud Structural Concept Analysis and Optimization

Aerospace structural applications demand a weight efficient design to perform in a cost effective manner. This is particularly true for launch vehicle structures, where weight is the dominant design driver. The design process typically requires many iterations to ensure that a satisfactory minimum weight has been obtained. Although metallic structures can be weight efficient, composite structures can provide additional weight savings due to their lower density and additional design flexibility. This work presents structural analysis and weight optimization of a composite payload shroud for NASA s Ares V heavy lift vehicle. Two concepts, which were previously determined to be efficient for such a structure are evaluated: a hat stiffened/corrugated panel and a fiber reinforced foam sandwich panel. A composite structural optimization code, HyperSizer, is used to optimize the panel geometry, composite material ply orientations, and sandwich core material. HyperSizer enables an efficient evaluation of thousands of potential designs versus multiple strength and stability-based failure criteria across multiple load cases. HyperSizer sizing process uses a global finite element model to obtain element forces, which are statistically processed to arrive at panel-level design-to loads. These loads are then used to analyze each candidate panel design. A near optimum design is selected as the one with the lowest weight that also provides all positive margins of safety. The stiffness of each newly sized panel or beam component is taken into account in the subsequent finite element analysis. Iteration of analysis/optimization is performed to ensure a converged design. Sizing results for the hat stiffened panel concept and the fiber reinforced foam sandwich concept are presented.

Zalewski, Bart B.↗
NASA NTRS1976

A rapid method for optimization of the rocket propulsion system for single-stage-to-orbit vehicles

A rapid analytical method for the optimization of rocket propulsion systems is presented for a vertical take-off, horizontal landing, single-stage-to-orbit launch vehicle. This method utilizes trade-offs between propulsion characteristics affecting flight performance and engine system mass. The performance results from a point-mass trajectory optimization program are combined with a linearized sizing program to establish vehicle sizing trends caused by propulsion system variations. The linearized sizing technique was developed for the class of vehicle systems studied herein. The specific examples treated are the optimization of nozzle expansion ratio and lift-off thrust-to-weight ratio to achieve either minimum gross mass or minimum dry mass. Assumed propulsion system characteristics are high chamber pressure, liquid oxygen and liquid hydrogen propellants, conventional bell nozzles, and the same fixed nozzle expansion ratio for all engines on a vehicle.

Eldred, C. H.↗