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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Application of Two-Phase CFD to the Design and Analysis of a Subscale Motor Experiment to Evaluate Propellant Slag Production

The redesigned solid rocket motor (RSRM) Pressure Perturbation Investigation Team concluded that the cause of recent pressure spikes during both static and flight motor burns was the expulsion of molten aluminum oxide slag from a pool which collects in the aft end of the motor around the submerged nozzle nose during the last half of motor operation. It is suspected that some motors produce more slag than others due to differences in aluminum oxide agglomerate particle sizes which may relate to subtle differences in propellant ingredient characteristics such as particle size distribution, contaminants, or processing variations. In order to determine the effect of suspect propellant ingredient characteristics on the propensity for slag production in a real motor environment, a subscale motor experiment was designed. An existing 5 inch ballistic test motor was selected as the basic test vehicle due to low cost and quick turn around times. The standard converging/diverging nozzle was replaced with a submerged nozzle nose design to provide a positive trap for the slag which would increase both the quantity and repeatability of measured slag weights. Computational fluid dynamics (CFD) was used to assess a variety of submerged nose configurations to identify the design which possessed the best capability to reliably collect slag. CFD also was used to assure that the final selected nozzle design would result in flow field characteristics such as dividing streamline location, nose attach point, and separated flow structure which would have similtude with the RSRM submerged nozzle nose flow field. It also was decided to spin the 5 inch motor about its longitudinal axis to further enhance slag collection quantities. Again, CFD was used to select an appropriate spin rate along with other considerations, including the avoidance of burn rate enhancement from radial acceleration effects.

Whitesides, R. Harold↗
NASA NTRS1996

Design of a Subscale Propellant Slag Evaluation Motor Using Two-Phase Fluid Dynamic Analysis

Small pressure perturbations in the Space Shuttle Reusable Solid Rocket Motor (RSRM) are caused by the periodic expulsion of molten aluminum oxide slag from a pool that collects in the aft end of the motor around the submerged nozzle nose during the last half of motor operation. It is suspected that some motors produce more slag than others due to differences in aluminum oxide agglomerate particle sizes that may relate to subtle differences in propellant ingredient characteristics such as particle size distributions or processing variations. A subscale motor experiment was designed to determine the effect of propellant ingredient characteristics on the propensity for slag production. An existing 5 inch ballistic test motor was selected as the basic test vehicle. The standard converging/diverging nozzle was replaced with a submerged nose nozzle design to provide a positive trap for the slag that would increase the measured slag weights. Two-phase fluid dynamic analyses were performed to develop a nozzle nose design that maintained similitude in major flow field features with the full scale RSRM. The 5 inch motor was spun about its longitudinal axis to further enhance slag collection and retention. Two-phase flow analysis was used to select an appropriate spin rate along with other considerations, such as avoiding bum rate increases due to radial acceleration effects. Aluminum oxide particle distributions used in the flow analyses were measured in a quench bomb for RSRM type propellants with minor variations in ingredient characteristics. Detailed predictions for slag accumulation weights during motor bum compared favorably with slag weight data taken from defined zones in the subscale motor and nozzle. The use of two-phase flow analysis proved successful in gauging the viability of the experimental program during the planning phase and in guiding the design of the critical submerged nose nozzle.

Whitesides, R. Harold↗
NASA NTRS1991

Comparison of impact results for several polymeric composites over a wide range of low impact velocities

Static indentation, falling weight, and ballistic impact tests were conducted in clamped plates made of AS4/3501-6 and IM7/8551-7 prepreg tape. The transversely isotropic plates were nominally 7-mm thick. Pendulum and ballistic tests were also conducted on simply supported plates braided with Celion 12000 fibers and 3501-6 epoxy. The 20 degree braided plates were about 5-mm thick. The impactors had spherical or hemispherical shapes with a 12.7 mm diameter. Residual compression strength and damage size were measured. For a given kinetic energy, damage size was least for IM7/8551-7 and greatest for the braided material. Strengths varied inversely with damage size. For a given damage size, strength loss as a fraction of original strength was least for the braided material and greatest for AS4/3501-6 and IM7/8551-7. Strength loss for IM7/8551-7 and AS4/3501-6 was nearly equal. No significant differences were noticed between damage sizes and residual compression strengths for the static indentation, falling weight, and ballistic tests of AS4/3501-6 and IM7/8551-7. For the braided material, sizes of damage were significantly less and compression strengths were significantly more for the falling weight tests than for the ballistic tests.

Poe, C. C., Jr.↗
NASA NTRS2004

Material Modeling of Space Shuttle Leading Edge and External Tank Materials For Use in the Columbia Accident Investigation

Upon the commencement of the analytical effort to characterize the impact dynamics and damage of the Space Shuttle Columbia leading edge due to External Tank insulating foam, the necessity of creating analytical descriptions of these materials became evident. To that end, material models were developed of the leading edge thermal protection system, Reinforced Carbon Carbon (RCC), and a low density polyurethane foam, BX-250. Challenges in modeling the RCC include its extreme brittleness, the differing behavior in compression and tension, and the anisotropic fabric layup. These effects were successfully included in LS-DYNA Material Model 58, *MAT_LAMINATED_ COMPOSITE_ FABRIC. The differing compression and tension behavior was modeled using the available damage parameters. Each fabric layer was given an integration point in the shell element, and was allowed to fail independently. Comparisons were made to static test data and coupon ballistic impact tests before being utilized in the full scale analysis. The foam's properties were typical of elastic automotive foams; and LS-DYNA Material Model 83, *MAT_FU_CHANG_FOAM, was successfully used to model its behavior. Material parameters defined included strain rate dependent stress-strain curves for both loading and un-loading, and for both compression and tension. This model was formulated with static test data and strain rate dependent test data, and was compared to ballistic impact tests on load-cell instrumented aluminum plates. These models were subsequently utilized in analysis of the Shuttle leading edge full scale ballistic impact tests, and are currently being used in the Return to Flight Space Shuttle re-certification effort.

Carney, Kelly↗
NASA NTRS1999

Current Testing Capabilities at the NASA Ames Ballistic Ranges

Capabilities for designing and performing ballistic range tests at the NASA Ames Research Center are presented. Computational tools to assist in designing and developing ballistic range models and to predict the flight characteristics of these models are described. A CFD code modeling two-stage gun performance is available, allowing muzzle velocity, maximum projectile base pressure, and gun erosion to be predicted. Aerodynamic characteristics such as drag and stability can be obtained at speeds ranging from 0.2 km/s to 8 km/s. The composition and density of the test gas can be controlled, which allows for an assessment of Reynolds number and specific heat ratio effects under conditions that closely match those encountered during planetary entry. Pressure transducers have been installed in the gun breech to record the time history of the pressure during launch, and pressure transducers have also been installed in the walls of the range to measure sonic boom effects. To illustrate the testing capabilities of the Ames ballistic ranges, an overview of some of the recent tests is given.

Ramsey, Alvin↗
NASA NTRS1988

The ballistic range and aerothermodynamic testing

A renewed interest in hypervelocity vehicles requires an increase in our knowledge of aerothermodynamic phenomena. Tests conducted in our ground-based facilities can be used both to better understand the physics of hypervelocity flight, and to calibrate and validate computer codes designed to predict vehicle performance in the hypervelocity environment. This paper reviews the requirements for aerothermodynamic testing and discusses the ballistic range and its capabilities. Examples of the kinds of testing performed in typical high-performance ballistic ranges are described; we draw heavily on experience obtained in the ballistics facilities at NASA Ames. Prospects for improving the capabilities of the ballistic range by using advanced instrumentation are discussed. Finally, recent developments in gun technology and their application to extend the capability of the ballistic range are summarized.

Strawa, A. W.↗
NASA NTRS1974

Fabrication and testing of prestressed composite rotor blade spar specimens

Prestressed composite spar specimens were fabricated and evaluated by crack propagation and ballistic penetration tests. The crack propagation tests on flawed specimens showed that the prestressed composite spar construction significantly suppresses crack growth. Damage from three high velocity 30 caliber projectile hits was confined to three small holes in the ballistic test specimen. No fragmentation or crack propagation was observed indicating good ballistic damage resistance. Rotor attachment approaches and improved structural performance configurations were identified. Design theory was verified by tests. The prestressed composite spar configuration consisted of a compressively prestressed high strength ARDEFORM 301 stainless steel liner overwrapped with pretensioned S-994 fiberglass.

Gleich, D.↗
NASA NTRS2019

Aerodynamics for the ADEPT SR-1 Flight Experiment

Adaptable, Deployable, Entry, and Placement Technology (ADEPT) is a combination of a heatshield and an aerodynamic decelerator for atmospheric entry applications. The ADEPT Sounding Rocket (SR)-1 mission was a suborbital flight experiment of an 0.7 m-diameter ADEPT to verify system-level performance and to characterize dynamic stability behavior. The aerodynamic database for ADEPT SR-1 was constructed from non-continuum and continuum flowfield computations, along with data from recent ADEPT ground testing and the IRVE-3 flight test vehicle. High-altitude (free-molecular and transitional regimes) data were generated using DSMC methods. Pre-flight predictions of continuum static aerodynamics coefficients were derived from Reynolds-Averaged Navier-Stokes solutions at conditions along a design trajectory, with comparisons to available ground test data of the nano-ADEPT geometry. Dynamic pitch damping characteristics were taken from functional forms developed for the IRVE-3 flight test vehicle through ballistic range testing. Comparison of pre-flight predictions to post-flight reconstruction of aerodynamic force and moment coefficients is presented.

Korzun, Ashley M.↗
NASA NTRS2009

Dynamic Stability Testing of the Mars Science Laboratory Entry Capsule

Results from a 26 shot ballistic range test of the Mars Science Laboratory (MSL) entry capsule are presented. The supersonic pitch damping properties of the MSL capsule were characterized between Mach 1.35 and Mach 3.5 and total angles-of-attack from 0 to 30 degrees. In flight, the MSL entry capsule will utilize a radial center-of-gravity offset to produce a non-zero trim angle-of-attack. This offset trim angle will produce lift, enabling the capsule to fly a guided entry and reducing the landing footprint dimensions to within 10 km of the desired landing site. A lifting configuration could not be tested at the ballistic range used for this test as the models would swerve into the range walls, possibly damaging cameras, the coordinate reference system or other facility assets. Ballistic (non-lifting) data was extracted and will be implemented in a conservative fashion to ensure that the dynamic stability characteristics of the flight vehicle are bounded. A comparison between the MSL pitch damping results and the dynamic model of the Mars Exploration Rover capsule shows generally close agreement with no significant differences in damping characteristics due to the change in backshell geometry. Dynamic moments are also compared to the MSL reaction control system (RCS) control authority to show the controller has sufficient margin to easily damp any dynamic stability effects.

Schroenenberger, Mark↗
NASA NTRS2017

Aerodynamic Coefficients from Aeroballistic Range Testing of Deployed- and Stowed-SIAD SFDT Models

This report documents a ballistic-range test campaign conducted in 2012 in order to estimate the aerodynamic stability characteristics of two configurations of the Supersonic Flight Dynamics Test (SFDT) vehicle prior to its initial flight in 2014. The SFDT vehicle was a test bed for demonstrating several new aerodynamic decelerator technologies then being developed under the Low-Density Supersonic Decelerator (LDSD) Project. Of particular interest here is the Supersonic Inflatable Aerodynamic Decelerator (SIAD), an inflatable attached torus used to increase the drag surface area of an entry vehicle during the supersonic portion of the entry trajectory. Two model configurations were tested in the ballistic range: one representing the SFDT vehicle prior to deployment of the SIAD, and the other representing the nominal shape with the SIAD inflated. Both models were fabricated from solid metal, and therefore, the effects of the flexibility of the inflatable decelerator were not considered. The test conditions were chosen to match, as close as possible, the Mach number, Reynolds number, and motion dynamics expected for the SFDT vehicle in flight, both with the SIAD stowed and deployed. For SFDT models with the SIAD stowed, 12 shots were performed covering a Mach number range of 3.2 to 3.7. For models representing the deployed SIAD, 37 shots were performed over a Mach number range of 2.0 to 3.8. Pitch oscillation amplitudes covered a range from 0.7 to 20.6 degrees RMS. Portions of this report (data analysis approach, aerodynamic modeling, and resulting aerodynamic coefficients) were originally published as an internal LDSD Project report [1] in 2012. In addition, this report provides a description of the test design approach, the test facility, and experimental procedures. Estimated non-linear aerodynamic coefficients, including pitch damping, for both model configurations are reported, and the shot-by-shot trajectory measurements, plotted in comparison with calculated trajectories based on the derived non-linear aerodynamic coefficients, are provided as appendices. Since the completion of these tests, two full-scale SFDT flights have been successfully conducted: one in June 2014 [2, 3], and one in June 2015 [3].

Ground Test↗
NASA NTRS1962

Simplified Free-Flight Testing in a Conventional Wind Tunnel

In order to incorporate the advantages of ballistic range testing with the convenience of wind tunnel testing, simplified techniques have been developed at the Jet Propulsion Laboratory (JPL) for free-flight testing of models in a conventional wind tunnel. So far, only a small number of the many possibilities have been investigated, but the preliminary results indicate that such techniques are both practical and useful. The model to be investigated is suspended on a single traverse wire at the upstream end of the test section window, then is released from this position by causing the wire to break within the model. High speed motion pictures taken of the model oscillating during its travel across the viewing area make it possible to determine various aerodynamic parameters such as drag, lift, pitching moment, and pitch damping in much the same manner as is done in ballistic range testing. Also, a spark schlieren photograph can be taken of the model in flight in order to observe details of an undisturbed (from support interference) wake.

FREE FLIGHT↗
NASA NTRS2013

Dynamic Stability Analysis of Blunt Body Entry Vehicles Using Time-Lagged Aftbody Pitching Moments

This analysis defines an analytic model for the pitching motion of blunt bodies during atmospheric entry. The proposed model is independent of the pitch damping sum coefficient present in the standard formulation of the equations of motion describing pitch oscillations of a decelerating blunt body, instead using the principle of a time-lagged aftbody moment as the forcing function for oscillation divergence. Four parameters, all with intuitive physical relevance, are introduced to fully define the aftbody moment and the associated time delay. It is shown that the dynamic oscillation responses typical to blunt bodies can be produced using hysteresis of the aftbody moment in place of the pitch damping coefficient. The approach used in this investigation is shown to be useful in understanding the governing physical mechanisms for blunt body dynamic stability and in guiding vehicle and mission design requirements. A validation case study using simulated ballistic range test data is conducted. From this, parameter identification is carried out through the use of a least squares optimizing routine. Results show good agreement with the limited existing literature for the parameters identified, suggesting that the model proposed could be validated by an experimental ballistic range test series. The trajectories produced by the identified parameters were found to match closely those from the MER ballistic range tests for a wide array of initial conditions and can be identified with a reasonable number of ballistic range shots and computational effort.

Supersonic↗
NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗
NASA NTRS2015

Impact and Penetration of Thin Aluminum 2024 Flat Panels at Oblique Angles of Incidence

The U.S. Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA) are actively involved in improving the predictive capabilities of transient finite element computational methods for application to safety issues involving unintended impacts on aircraft and aircraft engine structures. One aspect of this work involves the development of an improved deformation and failure model for metallic materials, known as the Tabulated Johnson-Cook model, or MAT224, which has been implemented in the LS-DYNA commercial transient finite element analysis code (LSTC Corp., Livermore, CA) (Ref. 1). In this model the yield stress is a function of strain, strain rate and temperature and the plastic failure strain is a function of the state of stress, temperature and strain rate. The failure criterion is based on the accumulation of plastic strain in an element. The model also incorporates a regularization scheme to account for the dependency of plastic failure strain on mesh size. For a given material the model requires a significant amount of testing to determine the yield stress and failure strain as a function of the three-dimensional state of stress, strain rate and temperature. In addition, experiments are required to validate the model. Currently the model has been developed for Aluminum 2024 and validated against a series of ballistic impact tests on flat plates of various thicknesses (Refs. 1 to 3). Full development of the model for Titanium 6Al-4V is being completed, and mechanical testing for Inconel 718 has begun. The validation testing for the models involves ballistic impact tests using cylindrical projectiles impacting flat plates at a normal incidence (Ref. 2). By varying the thickness of the plates, different stress states and resulting failure modes are induced, providing a range of conditions over which the model can be validated. The objective of the study reported here was to provide experimental data to evaluate the model under more extreme conditions, using a projectile with a more complex shape and sharp contacts, impacting flat panels at oblique angles of incidence.

Ruggeri, Charles R.↗
NASA NTRS2019

Free-Flight CFD Simulations of Ballistic Range and Flight Tests

Free-Flight CFD capability has been implemented into the finite-volume solver US3D under the Entry Systems Modeling project. Several simulations of ballistic range experiments have been performed in order to validate the simulation software and methodology. Extension of the software to flight scale trajectories with varying freestream conditions has been carried out. Results show promising ability to predict vehicle behavior as compared to flight. Finally, a multi-body free-flight capability has been developed to generalize the single-body free-flight solver to study multiple bodies in proximal flight.

Brock, Joseph M.↗
NASA NTRS1988

Experimental investigation of hypersonic aerodynamics

An extensive series of ballistic range tests were conducted at the Ames Research Center to determine precisely the aerodynamic characteristics of the Galileo entry probe vehicle. Figures and tables are presented which summarize the results of these ballistic range tests. Drag data were obtained for both a nonablated and a hypothesized ablated Galileo configuration at Mach numbers from about 0.7 to 14 and at Reynolds numbers from 1000 to 4 million. The tests were conducted in air and the experimental results were compared with available Pioneer Venus data since these two configurations are similar in geometry. The nonablated Galileo configuration was also tested with two different center-of-gravity positions to obtain values of pitching-moment-curve slope which could be used in determining values of lift and center-of-pressure location for this configuration. The results indicate that the drag characteristics of the Galileo probe are qualitatively similar to that of Pioneer Venus, however, the drag of the nonablated Galileo is about 3 percent lower at the higher Mach numbers and as much as 5 percent greater at transonic Mach numbers of about 1.0 to 1.5. Also, the drag of the hypothesized ablated configuration is about 3 percent lower than that of the nonablated configuration at the higher Mach numbers but about the same at the lower Mach numbers. Additional tests are required at Reynolds numbers of 1000, 500, and 250 to determine if the dramatic rise in drag coefficient measured for Pioneer Venus at these low Reynolds numbers also occurs for Galileo, as might be expected.

Intrieri, Peter F.↗