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NASA NTRS2007

GVIPS Models and Software

Two reports discuss, respectively, (1) the generalized viscoplasticity with potential structure (GVIPS) class of mathematical models and (2) the Constitutive Material Parameter Estimator (COMPARE) computer program. GVIPS models are constructed within a thermodynamics- and potential-based theoretical framework, wherein one uses internal state variables and derives constitutive equations for both the reversible (elastic) and the irreversible (viscoplastic) behaviors of materials. Because of the underlying potential structure, GVIPS models not only capture a variety of material behaviors but also are very computationally efficient. COMPARE comprises (1) an analysis core and (2) a C++-language subprogram that implements a Windows-based graphical user interface (GUI) for controlling the core. The GUI relieves the user of the sometimes tedious task of preparing data for the analysis core, freeing the user to concentrate on the task of fitting experimental data and ultimately obtaining a set of material parameters. The analysis core consists of three modules: one for GVIPS material models, an analysis module containing a specialized finite-element solution algorithm, and an optimization module. COMPARE solves the problem of finding GVIPS material parameters in the manner of a design-optimization problem in which the parameters are the design variables.

Arnold, Steven M.↗

NASA NTRS2016

Optimization of a Hot Structure Aeroshell and Nose Cap for Mars Atmospheric Entry

The National Aeronautics and Space Administration (NASA) is preparing to send humans beyond Low Earth Orbit and eventually to the surface of Mars. As part of the Evolvable Mars Campaign, different vehicle configurations are being designed and considered for delivering large payloads to the surface of Mars. Weight and packing volume are driving factors in the vehicle design, and the thermal protection system (TPS) for planetary entry is a technology area which can offer potential weight and volume savings. The feasibility and potential benefits of a ceramic matrix composite hot structure concept for different vehicle configurations are explored in this paper, including the nose cap for a Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and an aeroshell for a mid lift-to-drag (Mid L/D) concept. The TPS of a planetary entry vehicle is a critical component required to survive the severe aerodynamic heating environment during atmospheric en- try. The current state-of-the-art is an ablative material to protect the vehicle from the heat load. The ablator is bonded to an underlying structure, which carries the mechanical loads associated with entry. The alternative hot structure design utilizes an advanced carbon-carbon material system on the outer surface of the vehicle, which is exposed to the severe heating and acts as a load carrying structure. The preliminary design using the hot structure concept and the ablative concept is determined for the spherical nose cap of the HIAD entry vehicle and the aeroshell of the Mid L/D entry vehicle. The results of the study indicate that the use of hot structures for both vehicle concepts leads to a feasible design with potential weight and volume savings benefits over current state-of-the-art TPS technology that could enable future missions.

Langston, Sarah L.↗

NASA NTRS2009

The Integrated Medical Model - Optimizing In-flight Space Medical Systems to Reduce Crew Health Risk and Mission Impacts

The Integrated Medical Model (IMM) is a decision support tool used by medical system planners and designers as they prepare for exploration planning activities of the Constellation program (CxP). IMM provides an evidence-based approach to help optimize the allocation of in-flight medical resources for a specified level of risk within spacecraft operational constraints. Eighty medical conditions and associated resources are represented in IMM. Nine conditions are due to Space Adaptation Syndrome. The IMM helps answer fundamental medical mission planning questions such as What medical conditions can be expected? What type and quantity of medical resources are most likely to be used?", and "What is the probability of crew death or evacuation due to medical events?" For a specified mission and crew profile, the IMM effectively characterizes the sequence of events that could potentially occur should a medical condition happen. The mathematical relationships among mission and crew attributes, medical conditions and incidence data, in-flight medical resources, potential clinical and crew health end states are established to generate end state probabilities. A Monte Carlo computational method is used to determine the probable outcomes and requires up to 25,000 mission trials to reach convergence. For each mission trial, the pharmaceuticals and supplies required to diagnose and treat prevalent medical conditions are tracked and decremented. The uncertainty of patient response to treatment is bounded via a best-case, worst-case, untreated case algorithm. A Crew Health Index (CHI) metric, developed to account for functional impairment due to a medical condition, provides a quantified measure of risk and enables risk comparisons across mission scenarios. The use of historical in-flight medical data, terrestrial surrogate data as appropriate, and space medicine subject matter expertise has enabled the development of a probabilistic, stochastic decision support tool capable of optimizing in-flight medical systems based on crew and mission parameters. This presentation will illustrate how to apply quantitative risk assessment methods to optimize the mass and volume of space-based medical systems for a space flight mission given the level of crew health and mission risk.

Kerstman, Eric↗

NASA NTRS1997

On-Orbit and Ground Performance of the PGBA Plant Growth Facility

PGBA, a plant growth facility developed for commercial space biotechnology research, successfully grew a total of 30 plants (6 species) for 10 days on board the Space Shuttle Endeavour (STS-77) and is scheduled for reflight on board MSL-1 (STS-83) for a 16 day flight. The PGBA life support systems provide atmospheric, thermal, and humidity control as well as lighting and nutrient supply in a 23.6 liter chamber. Atmosphere treatment includes ethylene and other hydrocarbon removal, CO2 replenishment, and O2 control. The normally closed system uses controlled CO2 replenishment from the crew cabin as required by the plants. Temperature is controlled (1 C) at user-specified setpoints between 20-32 C, using water-filled coolant loops, solid state Peltier thermoelectric devices, and liquid heat exchangers. The thermoelectric cooling systems were optimized for low power consumption and high cooling efficiencies. Relative humidity is maintained between 60-100% using a cooled porous metal plate to remove water vapor from the air stream without cooling the bulk air below the dew point. The lighting system utilizes three compact fluorescent bi-axial lights with variable lighting control and light intensity (PAR) between 220 and 330 micromol/sq m/s at a distance of 20 cm in spaceflight configuration (on orbit power limited to 230 Watt for entire payload). A ground, up to 550 micromol/sq m/s light intensity can be achieved with 330 Watt payload power consumption. Plant water and nutrient support is sustained via the 'Nutrient Pack' system including the passive or active 'Water Replenishable Nutrient Pack.' The root matrix material (soil or Agar) and nutrient formulation of each pack is prepared according to plant species and experimental requirements. These systems were designed by NASA Ames personnel. Data acquisition and control systems provide 32 channels of environmental data as well as digitized or analog video signals for downlink.

Hoehn, A.↗

NASA NTRS1994

Uncertainty relations as Hilbert space geometry

Precision measurements involve the accurate determination of parameters through repeated measurements of identically prepared experimental setups. For many parameters there is a 'natural' choice for the quantum observable which is expected to give optimal information; and from this observable one can construct an Heinsenberg uncertainty principle (HUP) bound on the precision attainable for the parameter. However, the classical statistics of multiple sampling directly gives us tools to construct bounds for the precision available for the parameters of interest (even when no obvious natural quantum observable exists, such as for phase, or time); it is found that these direct bounds are more restrictive than those of the HUP. The implication is that the natural quantum observables typically do not encode the optimal information (even for observables such as position, and momentum); we show how this can be understood simply in terms of the Hilbert space geometry. Another striking feature of these bounds to parameter uncertainty is that for a large enough number of repetitions of the measurements all V quantum states are 'minimum uncertainty' states - not just Gaussian wave-packets. Thus, these bounds tell us what precision is achievable as well as merely what is allowed.

Braunstein, Samuel L.↗

NASA NTRS1997

Nonlinear Dynamic Analysis of Disordered Bladed-Disk Assemblies

In a effort to address current needs for efficient, air propulsion systems, we have developed some new analytical predictive tools for understanding and alleviating aircraft engine instabilities which have led to accelerated high cycle fatigue and catastrophic failures of these machines during flight. A frequent cause of failure in Jets engines is excessive resonant vibrations and stall flutter instabilities. The likelihood of these phenomena is reduced when designers employ the analytical models we have developed. These prediction models will ultimately increase the nation's competitiveness in producing high performance Jets engines with enhanced operability, energy economy, and safety. The objectives of our current threads of research in the final year are directed along two lines. First, we want to improve the current state of blade stress and aeromechanical reduced-ordered modeling of high bypass engine fans, Specifically, a new reduced-order iterative redesign tool for passively controlling the mechanical authority of shroudless, wide chord, laminated composite transonic bypass engine fans has been developed. Second, we aim to advance current understanding of aeromechanical feedback control of dynamic flow instabilities in axial flow compressors. A systematic theoretical evaluation of several approaches to aeromechanical feedback control of rotating stall in axial compressors has been conducted. Attached are abstracts of two .papers under preparation for the 1998 ASME Turbo Expo in Stockholm, Sweden sponsored under Grant No. NAG3-1571. Our goals during the final year under Grant No. NAG3-1571 is to enhance NASA's capabilities of forced response of turbomachines (such as NASA FREPS). We with continue our development of the reduced-ordered, three-dimensional component synthesis models for aeromechanical evaluation of integrated bladeddisk assemblies (i.e., the disk, non-identical bladeing etc.). We will complete our development of component systems design optimization strategies for specified vibratory stresses and increased fatigue life prediction of assembly components, and for specified frequency margins on the Campbell diagrams of turbomachines. Finally, we will integrate the developed codes with NASA's turbomachinery aeromechanics prediction capability (such as NASA FREPS).

McGee, Oliver G., III↗

NASA NTRSDate not supplied

Gateway Autonomy for Enabling Deep Space Exploration

The Gateway spacecraft is an important stepping-stone to exploration of the solar system, integrating commercial and international partners into a tightly coupled system, enabling cislunar activities, and implementing key technologies for missions to Mars. Autonomy is a capability area necessary to handle long communication outages where intervention from Earth is impossible, to prepare to operate with long communication delays that will be common in interplanetary travel, and to make spaceflight more affordable and accessible by reducing sustaining operations costs. The Gateway Concept of Operations states that one of Gateway’s goals is to “focus on infrastructure and systems that will allow autonomous operations aboard the Gateway with robotics, automated systems, advanced communications, and distributed computing.” Gateway’s Vehicle Systems Manager (VSM) and associated Autonomous Spacecraft Management Architecture (ASMA) are key products towards delivering autonomous capability. The primary functions of the control architecture are Mission Management and Timeline Execution, Resource Management, Fault Management, and Vehicle Control and Operation (VCO). In each of these areas, there is an initial level of capability to be delivered at launch, with plans to continue development and grow to greater capability. The initial deployment of VSM will focus on maintaining vehicle safety by focusing on full fault management capabilities and deploying only enough resource and timeline planning functionality to support that. The final deployment of VSM will add significant planning and control optimization functionality to support nominal operations for up to 21 days without ground support, even accommodating fault and failure conditions. While the VSM is the vehicle-level representation of autonomous reasoning, distributed automation is essential to provide the right scope and abstraction of information to process. Module and system support of automation and simplicity of interfaces are two important design paradigms that Gateway is focusing on to garner a systems approach to autonomy. Distribution of reasoning can increase complexity, so Gateway is also taking a strict hierarchical approach to information flow and decision making. VSM is not the only capability necessary to achieve an autonomous spacecraft. Robotics support for maintenance of the spacecraft will be essential to provide continued vehicle functionality even when crew is not present. Technical and programmatic challenges exist when implementing autonomous robotics operations. These challenges include sufficient network flexibility to support data transfer to the rest of the vehicle to coordinate module-to-module robotic walk-offs and finding the proper interfaces to allow sufficient dexterity. Communication system upgrades planned for Gateway include Delay Tolerant Networking to best utilize the complex network of relays that will be part of mature cislunar operations. Distributed computing and management will provide failure tolerance, robustness, and growth of capabilities while still allowing significant reuse of heritage software on heritage systems as well as reuse of common applications across a spacecraft to minimize new development, but this requires adherence to key standards and interfaces. The Gateway program has demonstrated significant progress towards these capabilities and has identified challenges other spacecraft developers should be aware of from the start.

Molly Anderson↗

NASA NTRSDate not supplied

Gateway Autonomy for Enabling Deep Space Exploration

Molly Anderson↗

NASA NTRS2003

Flame Spray Strain Gages with Improved Durability and Lifetimes

The focus of this APP research program was to improve the bond coats used in the fabrication of flame sprayed instrumentation. Typically. a bond coat is applied to a superalloy surface prior to the application of a thin dielectric coating onto which instrumentation is placed. After affixing the instrumentation, a much thicker ceramic topcoat is typically applied to protect the instrumentation from harsh environments. The fatigue life of NiCoCrAlY coated superalloys was extended beyond current state-of-the-art by relatively simple and cost effective means. Heat treatment in reduced oxygen partial pressures at 1750 to 1800 F effectively doubled the fatigue life of NiCoCrAlY coated substrates relative to as-sprayed substrates and when used in conjunction with platinum diffusion barriers yielded a four fold increase in the fatigue life of NiCoCrAlY coated substrates. Further improvements in the fatigue life of thermally sprayed coatings were made by employing intermediate coatings, which minimized thermal expansion differences between the bond coat and top coat. Combinatorial chemistry experiments yielded an optimum composition for an intermediate TCE matching coating that showed considerable promise in extending the fatigue life of thermal spray instrumentation. The intermediate coating had two functions: to reduce the surface roughness of the peaks and valleys associated with the as-sprayed NiCoCrAlY bond coat, and to produce a thin layer of a mixture of Al2O3 and NiCoCrAlY that exhibited an intermediate TCE. The optimal composition of the intermediate coating consisted of 60 wt% Al2O3 and 40 wt% NiCoCrAlY, as determined by energy dispersive analysis of x-rays (EDS). Intermediate coatings having this composition were prepared by physical vapor deposition and the resulting coating systems are being evaluated in our test facility.

Fralick, Gustave↗

NASA NTRS2010

NASA's Soil Moisture Active and Passive (SMAP) Mission

The Soil Moisture Active-Passive (SMAP) Mission is one of the first Earth observation satellites being formulated by NASA in response to the 2007 National Research Council s Decadal Survey. SMAP will make global measurements of soil moisture at the Earth's land surface and its freeze-thaw state. These measurements will allow significantly improved estimates of water, energy and carbon transfers between the land and atmosphere. Soil moisture measurements are also of great importance in assessing flooding and monitoring drought. Knowledge gained from SMAP observations can help mitigate these natural hazards, resulting in potentially great economic and social benefits. SMAP observations of soil moisture and freeze/thaw timing over the boreal latitudes will also reduce a major uncertainty in quantifying the global carbon balance and help to resolve an apparent missing carbon sink over land. The SMAP mission concept will utilize an L-band radar and radiometer sharing a rotating 6-meter mesh reflector antenna flying in a 680 km polar orbit with an 8-day exact ground track repeat aboard a 3-axis stabilized spacecraft to provide high-resolution and high-accuracy global maps of soil moisture and freeze/thaw state every two to three days. In addition, the SMAP project will use these surface observations with advanced modeling and data assimilation to provide estimates of deeper root-zone soil moisture and net ecosystem exchange of carbon. SMAP recently completed its Phase A Mission Concept Study Phase for NASA and transitioned into Phase B (Formulation and Detailed Design). A number of significant accomplishments occurred during this initial phase of mission development. The SMAP project held several open meetings to solicit community feedback on possible science algorithms, prepared preliminary draft Algorithm Theoretical Basis Documents (ATBDs) for each mission science product, and established a prototype algorithm testbed to enable testing and evaluation of the performance of candidate algorithms. SMAP conducted an Applications Workshop in September 2009 to coordinate with potential application users interested in the mission data. A draft Applications Plan describing the Project s planned outreach to potential applications users has been prepared and will be updated during Phase B. SMAP made a significant evaluation of the potential terrestrial radio frequency interference (RFI) source environment and established radiometer and radar flight hardware and ground processing mitigation approaches. SMAP finalized its science orbit and orbit injection approach to optimize launch mass and prepared launch and commissioning scenarios and timeline. A science data communications approach was developed to maximize available science data volume to improve science margins while maintaining moderately short data product latencies to support many potential applications using existing ground assets and with minimum impact to the flight system. SMAP developed rigid multi-body and flexible body dynamics and control models and system designs for the 6-meter rotating instrument reflector-boom assembly (RBA) and flight system to confirm pointing and control performance, and devised strategies to efficiently implement on-orbit balancing if needed. Industry partners were selected for the spin mechanism assembly (SMA) and RBA. Preliminary designs for the radar and radiometer were initiated, including constructing breadboards of key assemblies.

Kellogg, Kent↗

NASA NTRS2010

An Integrated, Evidence-Based Approach to Transitioning to Operations: Specifications for Future Replacement Lights on ISS

The International Space Station (ISS) currently uses General Luminaire Assemblies (GLAs) as its primary light source. These GLAs are composed of fluorescent lighting and are integrated into the electrical system on Station. Seventy seven of these units are distributed throughout the vehicle, and many of the lights, having reached their lifespan, are no longer functional; while backup panels are available on orbit, it is anticipated that the supplies of fluorescents on the station will be exhausted by 2015. The ISS vehicle office is therefore preparing to replace all of the GLAs, with Solid State Light Assemblies (SSLAs) composed of white Light Emitting Diodes (LEDs). In the Spring of 2010, an announcement for the replacement lights was released. The announcement specified that proposed lighting systems should use LED technology, given certain power draw restrictions and no changes to how the lights are currently controlled (a central on/off switch per node, and a dial to turn on/off and increase brightness on each lighting unit). The replacement lights are to follow current specifications for brightness levels (lux) and color temperature (degrees Kelvin, or K). Reportedly, the lighting on orbit is dim and suboptimal. The average brightness of the lights (given all lights within a node are operational) is 291 lux; by comparison, recommended office lighting ranges from 200 to 500 lux, and daylight ranges on a typical overcast day, consists of 10,000 to 25,000 lux. Representatives from NASA Behavioral Health and Performance Element (BHP) and Human Factors and Habitability identified that maintaining current brightness levels limits visual acuity, work space, and the use of light as a countermeasure for improving circadian entrainment, hastening phase shifting, evoking acute alertness and enhancing performance. Revised lighting specifications are therefore needed to optimize the replacement lights for the ISS.

Leveton, Lauren↗

NASA NTRS2008

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗

NASA NTRS1999

Strategies and Technologies for In Situ Mineralogical Investigations on Mars

Surface landers on Mars (Viking and Pathfinder) have not revealed satisfying answers to the mineralogy and lithology of the planet's surface. In part, this results from their prime directives: Viking focused on exobiology, Pathfinder focused on technology demonstration. The analytical instruments on board the landers made admirable attempts to extract the mineralogy and geology of Mars, as did countless modeling efforts after the missions. Here we suggest a framework for elucidating martian, or any other planetary geology, through an approach that defines (a) type of information required, (b) explorational strategy harmonious with acquisition of these data, (c) interpretation approach to the data, (d) compatible mission architecture, (e) instrumentation for interrogating rocks and soil. (a) Data required: The composition of a planet is ordered at scales ranging from molecules to minerals to rocks, and from geological units to provinces to planetary-scale systems. The largest ordering that in situ compositional instruments can attempt to interrogate is rock type "aggregate" information. This is what the geologist attempts to identify first. From this, mineralogy can be either directly seen or inferred. From mineralogy can be determined elemental abundances and perhaps the state of the compounds as being crystalline or amorphous. Knowledge of rock type and mineralogy is critical for elucidating geologic process. Mars landers acquired extremely valuable elemental data, but attempted to move from elements to aggregates, but this can only be done by making many assumptions and sometimes giant leaps of faith. Data we believe essential are elements, minerals, degree of ordering of compounds, and the aggregate or rock type that these materials compose. (b) Explorational strategy: A lander should function as a surrogate geologist. Of the total landscape, a geologist sees much, but gives detailed attention to an infinitesimally small amount of what is seen. To acquire samples worth detailed scrutiny, as many samples as possible need examining at a cursory or reconnaissance level. A representative, statistically-meaningful sample number cannot be overemphasized. This maxim still applies to geological exploration of our own planet of which we have abundant knowledge. Analysis of many samples mandates low-power consumption per sample. (c) Data interpretation: No single instrument can analyze the full spectrum of the x-axis. An instrument is optimized for detecting certain material characteristics and must therefore affix itself to some point on the x-axis. Any conclusions drawn about data to the left or right of the instrument's position on this axis must necessarily be derived by inference. Hence, it seems logical to include on a mission, instruments that are not closely spaced in their x-axis-position, and if only two analytical methods are used, as shown, they should start at opposite ends of the axis and work towards the center. As examples, we depict a high-resolution camera to evaluate rock type ("aggregate" state) and mineralogy, and an x-ray diffractometer-fluorescence spectrometer (XRD-XRF) to determine elements, minerals, and the degree of order of materials. (d) Mission architecture: No instrument or suite of instruments can be relied upon to always give truly unequivocal analyses. The suite of instruments should therefore permit conclusions of one instrument to be checked against those of another through closed analytical loops. These "loops" can be structured by a combination of orbital imagery, descent imagery, broad-band site viewing/analysis, and data that cover both x and y axes. For example, the detection of a basaltic-looking rock with a microscope should be checked against the elements detected, the appearance of the rock as a lava flow from descent imagery, and so forth. (e) Instrumentation: To satisfy the above criteria, it is necessary to: (i) See the rock or soil with high resolution + magnification, (ii) Examine many samples, (iii) Consume little power per analysis, (iv) Determine elemental species, (v) Determine mineralogy directly (not inferentially) and the degree of ordering of compounds, (vi) Start analyzing from both ends of the x-axis. Every geologist wants to see the hand sample first, and apply a hand lens to its surface. This has not been the starting point for missions to Mars. Thus, our technology satisfies all these criteria . This XRD-XRF-Optical instrument currently being developed, analyses rock or soil surfaces without the need for sample acquisition or preparation; this satisfies the power criterion, and enables many analyses. The device acquires direct mineralogy and determines elemental species. The embedded endoscopic camera satisfies the critical criterion of close inspection of samples; the fiber optic cable can also be used for IR, LTV, or laser sample analysis. Additional information is contained in the original (Figures).

Marshall, J. R.↗

NASA NTRS2001

Numerical Simulation of One- and Two-Phase Flows in Propulsion Systems

In this report, we present some results of problems investigated during joint research between the Hampton University Fluid Mechanics and Acoustics Laboratory (HU/FM&AL), NASA GRC, and the LaRC Hyper-X Program. This work is supported by joint research between the NASA GRC and the Institute of Mechanics at Moscow State University (IM/MSU) in Russia under a CRDF grant. The main areas of current scientific interest of the HU/FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. These methods are based on nontraditional 3D corrugated and composite nozzle, inlet, propeller and screw designs such as a Bluebell and Telescope nozzle, Mobius-shaped screw, etc. This is the main subject of our other projects, of which one is presented at the current conference. Here we analyze additional methods for exhaust jet noise reduction without essential thrust loss and even with thrust augmentation. Such additional approaches are: (1) to add some solid, fluid, or gas mass at discrete locations to the main supersonic gas stream to minimize the negative influence of strong shock waves formed in propulsion systems. This mass addition may be accompanied by heat addition to the main stream as a result of the fuel combustion or by cooling of this stream as a result of the liquid mass evaporation and boiling; (2) Use of porous or permeable nozzles and additional shells at the nozzle exit for preliminary cooling of the hot jet exhaust and pressure compensation for off-design conditions (so-called continuous ejector with small mass flow rate); and (3) to propose and analyze new effective methods of fuel injection into the flow stream in air-breathing engines. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The FM&AL Team uses analytical methods, numerical simulations, and experimental tests at the Hampton University campus, NASA, and IM/MSU. The main outcomes during this reporting period are: (1) Publications: The AIAA Paper #01-1893 has been accepted for the AIAA/NAL-NASDA-ISAS 10th International Space Planes and Hypersonic Systems and Technologies Conference, 24-27 April 2001, Kyoto, Japan. The AIAA Paper #01-3204 has been accepted for presentation at the 37th AIAA/ASME/SAE/ASEE Joint Propulsion Conference being held on 08-11 July, in Salt Lake City, UT; (2) Grants and proposals: The HU/FM&AL was awarded the NASA grant NAG3-2495 in October 2000 and the CRDF award was granted to the NASA GRC-HU FM&AL and IM/MSU (Russia) in July 2000. A solicited proposal was submitted for the NASA NRA-01GRC-02 competition and two unsolicited proposals to NASA are in preparation; (3) Theory and numerical simulations: Analytical theory, numerical simulation, comparison of theoretical with experimental results, and modification of theoretical approaches, models, grids, etc. Such investigations have been conducted for three main problems: (a) Combustion efficiency optimization in the half-duct combustor system; (b) Drag reduction effects for blunt bodies with solid needles; and (c) Solid particle injection from the butt-end against a supersonic flow. The NASA CFL3D, HU/FM&AL, and IM/MSU GODUNOV codes were used and modified for solution of these problems. The codes are based on full Euler and Navier-Stokes solvers with and without nonequilibrium oxygen-nitrogen and air-hydrogen chemical reactions in laminar and turbulent gas flow regimes; (4) Experimental tests: In the IM/MSU supersonic wind tunnel, experimental tests were conducted with different number, location, and geometric parameters of solid needles mounted at the front of the butt-end in supersonic flow. Optimal parameters were determined that provide minimal butt-end drag in the stationary flow regime. Experimental and numerical simulation results are in good agreement; (5) Student Research Activity: Involvement of one graduate and two undergraduate students as research assistants in the current project.

Gilinsky, Mikhail↗

NASA NTRS2002

Techniques Optimized for Reducing Instabilities in Advanced Nickel-Base Superalloys for Turbine Blades

The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.

MacKay, Rebecca A.↗