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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
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NASA NTRS2020

Lessons Learned from Recent Space Flight Assessments

This paper highlights four space flight assessments, each with an important lesson. The first assessment points to the challenge of material substitution for weight saving. Space Shuttle’s external tank stringers were changed from Al 2024 to Al 2090 without comprehensive analysis. Lack of understanding the low Short-Transverse (S-T) strength associated with Al 2090 led to widespread cracking. The second assessment addresses the failure to understand that time-dependent relationships and loading interactions of multiple disciplines can lead to non-conservative results. An aerodynamic test article of the Orion Multi-Purpose Crew Vehicle (MPCV) Launch Abort System (LAS) was analyzed for worst-case single discipline loads, showing positive structural margins. When disciplines were combined with time dependent loading, the analysis resulted in negative margins. The third assessment highlights the pitfalls of putting blind trust in historical architecture. The MPCV re-entry heat shield adopted the Apollo design approach despite fundamental differences between the two designs (e.g., the underlying substructure design, material differences, scale, and geometry). Manufacturing resulted in cracking along seams of the cured MPCV heat shield and produced lower mechanical properties of the Avcoat witness panels. Subsequently, the design was changed to a block architecture, which introduced unperceived technical, cost, and schedule risk. The fourth assessment shows how the lack of a comprehensive investigation of design modifications and inappropriate Finite Element Analyses (FEA) can lead to trouble. A mass reduction campaign eliminated highly critical internal struts on the ISS Node-1 pressurized module based on inadequate and uncorrelated FEA. High strains were noted and ignored as a modeling aberration. A system level high fidelity FEA discovered large plastic strains in the gussets of all four radial ports. These findings initiated a full-scale test campaign, new test correlated assembly-level FEA, and significant design modifications.

James P Smith↗
NASA NTRSDate not supplied

H2 / DeCarbonization Studies: History and Ongoing

An ongoing study is collecting and reviewing hydrogen and low/zero carbon aircraft and related studies. In addition to previous NASA studies, international and as well as other US sponsored hydrogen, other fuels and infrastructure efforts supporting aviation aircraft are included. These reports and presentations are summarized here to develop further insight as well as help identify potential research areas to support reduction or elimination of harmful emissions from aviation aircraft. Although not all possible studies have been identified and included here, it is believed that sufficient information has been collected to help guide subsequent efforts. Efforts pertaining to aircraft emissions and assessing climate impact have only just started to be included.

fuel↗
NASA NTRSDate not supplied

Revisiting the Effectiveness of Debris Mitigation by Back-Dating Fragmentation Event

Since 1961, more than 250 satellites have fragmented while in orbit about the Earth, from very low Earth orbit out to the geostationary belt. The problem of orbital debris has been recognized since at least the late 1970s, with the institution of the NASA Orbital Debris Program Office (ODPO) in 1979 at the Johnson Space Center. Efforts to mitigate the growth of the orbital debris environment have mainly focused in two areas: the reduction and elimination of accidental explosions of spacecraft and rocket upper stages and the timely removal of spacecraft and rocket upper stages from orbit after completion of their missions. The ODPO continues to analyze the orbital population in orbit based on object type, mass, and other parameters of interest for characterizing the overall growth of objects in Earth’s orbit. Of the 268 known fragmentation events, 46 have occurred more than ten years after the affected satellites’ launch. These long-delayed breakups increase the population of orbital debris on the date of fragmentation, but we can also consider that the debris generated during that event could be attributed to the launch date of that satellite. We will present here an analysis of the historical growth of the low-Earth orbit debris environment, removing intentional fragmentation events, and examine the effectiveness of mitigation measures (such as passivation and reducing post-mission orbital lifetime).

Chris Ostrom↗
NASA NTRSDate not supplied

Alloy Evaluation and Flow Forming Process Modeling for Net Shape Aerospace Structures

Over the past decade, NASA Langley Research Center (LaRC) has led several manufacturing demonstration projects exploiting flow forming technology. The work has resulted in the commercial-scale manufacture of 10-ft. diameter single-piece, integrally stiffened cylinders. Near-net-shape flow forming offers simplified manufacturing schedules and cost savings through reduced part count. Reduction or elimination of machining, welding, and/or riveting can also lead to significant performance gains. NASA LaRC recently established a flow forming research facility to investigate new alloys and stiffener geometries for fuselage and launch vehicle cryotank applications. Candidate aluminum alloys and heat treatment combinations have been characterized through advanced mechanical testing and microscopy to maximize workability during flow forming trials. Elasto-plastic deformation simulations of the forming process have been performed using the finite element software DEFORM and correlated with forming trial results. The overall objective is to optimize structural performance through a combination of innovative materials, processes, and designs.

single-piece↗
NASA NTRS2023

Revisiting the Effectiveness of Debris Mitigation by Back-Dating Fragmentation Events

Since 1961, more than 250 satellites have fragmented while in orbit about the Earth, from very low Earth orbit out to the geostationary belt. The problem of orbital debris has been recognized since at least the late 1970s, with the institution of the NASA Orbital Debris Program Office (ODPO) in 1979 at the Johnson Space Center. Efforts to mitigate the growth of the orbital debris environment have mainly focused in two areas: the reduction and elimination of accidental explosions of spacecraft and rocket upper stages and the timely removal of spacecraft and rocket upper stages from orbit after completion of their missions. The ODPO continues to analyze the orbital population in orbit based on object type, mass, and other parameters of interest for characterizing the overall growth of objects in Earth’s orbit. Of the 268 known fragmentation events, 46 have occurred more than ten years after the affected satellites’ launch. These long-delayed breakups increase the population of orbital debris on the date of fragmentation, but we can also consider that the debris generated during that event could be attributed to the launch date of that satellite. We will present here an analysis of the historical growth of the low-Earth orbit debris environment, removing intentional fragmentation events, and examine the effectiveness of mitigation measures (such as passivation and reducing post-mission orbital lifetime).

Chris Ostrom↗
NASA NTRS2016

Additive Manufacturing for Affordable Rocket Engines

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch labor required, and increases reliability. When certification is achieved, NASA missions will be able to realize these benefits.

West, Brian↗
NASA NTRSDate not supplied

Investigation of the 30P30N Slat Flow Field with Passive Control Devices Using Particle Image Velocimetry

The leading-edge slat of a high-lift wing is one of the main noise contributors during approach and landing. This paper describes an experimental investigation of the velocity field associated with multiple passive noise treatments, including slat-cusp extensions, a cove filler, and a gap filler, on a two-dimensional multi-element high-lift 30P30N airfoil. Previous work documented comparisons of both surface and far field pressure fluctuations in the presence of these devices with those for a baseline case at different flow conditions. However, important information related to the velocity fields was missing from the previous measurements, hindering our ability to elucidate the changes in the flow physics associated with the noise treatments. Therefore, two-component Particle Image Velocity has been used to investigate the influence of passive noise treatments on the flow fields. All measurements are taken at an effective, free-air angle of attack of 5.5 degrees and a stowed-chord-based Reynolds number of 1.71 × 10e6. The measurements show that the slat extensions shorten the slat-cove shear layer trajectory, resulting in reduced growth of disturbances within the slat-cove shear layer. This leads to a shift of tonal peaks to higher frequencies and a reduction in the tonal amplitudes. The gap filler blocks the flow path through the gap, causing the reattachment location to shift to the main wing leading edge lower surface. Consequently, the feedback loop associated with the flow-acoustic interaction in the baseline case is eliminated, and the turbulent kinetic energy in the slat-cove shear layer is significantly reduced. However, extensive flow separation is observed on the suction side of the gap filler, which does not eliminate the noise reduction benefit due to the gap filler, but does degrade the aerodynamic performance of the high-lift configuration. Finally, the overall flow field in the presence of the cove filler is similar to that in the baseline case at the design angle of attack, but the slat-cove shear layer is eliminated leading to a suppression of the cavity tones associated with the shear layer. This change accounts for the reduction in slat noise as measured in previous work.

Aeroacoustics↗
NASA NTRS2023

AMORE-Isoprene v1.0: A New Reduced Mechanism for Gas-Phase Isoprene Oxidation

Gas-phase oxidation of isoprene by ozone (O 3 ) and the hydroxyl (OH) and nitrate (NO 3 ) radicals significantly impacts tropospheric oxidant levels and secondary organic aerosol formation. The most comprehensive and up-to-date chemical mechanism for isoprene oxidation consists of several hundred species and over 800 reactions. Therefore, the computational expense of including the entire mechanism in large-scale atmospheric chemical transport models is usually prohibitive, and most models employ reduced isoprene mechanisms ranging in size from ∼ 10 to ∼ 200 species. We have developed a new reduced isoprene oxidation mechanism using a directed-graph path-based automated model reduction approach, with minimal manual adjustment of the output mechanism. The approach takes as inputs a full isoprene oxidation mechanism, the environmental parameter space, and a list of priority species which are protected from elimination during the reduction process. Our reduced mechanism, AMORE-Isoprene (where AMORE stands for Automated Model Reduction), consists of 12 species which are unique to the isoprene mechanism as well as 22 reactions. We demonstrate its performance in a box model in comparison with experimental data from the literature and other current isoprene oxidation mechanisms. AMORE-Isoprene's performance with respect to predicting the time evolution of isoprene oxidation products, including isoprene epoxydiols (IEPOX) and formaldehyde, is favorable compared with other similarly sized mechanisms. When AMORE-Isoprene is included in the Community Regional Atmospheric Chemistry Multiphase Mechanism 1.0 (CRACMM1AMORE) in the Community Multiscale Air Quality Model (CMAQ, v5.3.3), O 3 and formaldehyde agreement with Environmental Protection Agency (EPA) Air Quality System observations is improved. O 3 bias is reduced by 3.4 ppb under daytime conditions for O 3 concentrations over 50 ppb. Formaldehyde bias is reduced by 0.26 ppb on average for all formaldehyde measurements compared with the base CRACMM1. There was no significant change in computation time between CRACMM1AMORE and the base CRACMM. AMORE-Isoprene shows a 35 % improvement in agreement between simulated IEPOX concentrations and chamber data over the base CRACMM1 mechanism when compared in the Framework for 0-D Atmospheric Modeling (F0AM) box model framework. This work demonstrates a new highly reduced isoprene mechanism and shows the potential value of automated model reduction for complex reaction systems.

Automated Model Reduction↗
NASA NTRS1979

Bosch - An alternate CO2 reduction technology

The Bosch process is the most promising CO2 reduction concept for future prolonged space missions. The paper presents the design of a three-person-capacity preprototype B-CRS (Bosch-based CO2 Reduction Subsystem). It is sized to reduce 3.0 kg/d CO2 generated by the crew and to supply the product water to an O2 generation subsystem to obtain O2. The design supports future development of the B-CRS as an alternative CO2 reduction subsystem to the Sabatier-based process presently under test at NASA. The discussion covers the Bosch CO2 reduction concept, process and hardware description, performance parameters, design specifications, subsystem schematic and operation, mechanical subsystem summary, control/monitor instrumentation, and subsystem packaging. A B-CRS with a proven technological base is an attractive CO2 reduction subsystem that eliminates overboard venting.

Heppner, D. B.↗
NASA NTRS1991

Measurement of surface microtopography

Acquisition of ground truth data for use in microwave interaction modeling requires measurement of surface roughness sampled at intervals comparable to a fraction of the microwave wavelength and extensive enough to adequately represent the statistics of a surface unit. Sub-centimetric measurement accuracy is thus required over large areas, and existing techniques are usually inadequate. A technique is discussed for acquiring the necessary photogrammetric data using twin film cameras mounted on a helicopter. In an attempt to eliminate tedious data reduction, an automated technique was applied to the helicopter photographs, and results were compared to those produced by conventional stereogrammetry. Derived root-mean-square (RMS) roughness for the same stereo-pair was 7.5 cm for the automated technique versus 6.5 cm for the manual method. The principal source of error is probably due to vegetation in the scene, which affects the automated technique but is ignored by a human operator.

Wall, S. D.↗
NASA NTRS1943

Drag Measurements of a Protruding .50-caliber Machine Gun with Barrel Jacket Removed

Tests were made in 8-ft high-speed wind tunnel to determine the drag reduction possible by eliminating the barrel jacket of a protruding 50-caliber aircraft gun. It was found that the drag of a standard aircraft gun protruding into the air stream at right angles to the flow can be reduced by 23% by discarding the barrel jacket. At 300 mph and sea-level conditions, this amounts to a decrease in drag of from 83 to 64 pounds. A rough surface finish on the barrel was found to have no adverse effects on the drag of the barrel, the drag being actually less at high Mach Numbers.

GUNS - DRAG↗
NASA NTRS2001

Testing of Environmentally Preferable Aluminum Pretreatments and Coating Systems for Use on Space Shuttle Solid Rocket Boosters (SRB)

The solid rocket booster (SRB) has historically used a chromate conversion coating prior to protective finish application. After conversion coating, an organic paint system consisting of a chromated epoxy primer and polyurethane topcoat is applied. An overall systems approach was selected to reduce waste generation from the coatings application and removal processes. While the most obvious waste reduction opportunity involved elimination of the chromate conversion coating, several other coating system configurations were explored in an attempt to reduce the total waste. This paper will briefly discuss the use of a systems view to reduce waste generation from the coating process and present the results of the qualification testing of nonchromated aluminum pretreatments and alternate coating systems configurations.

Clayton, C.↗
NASA NTRS2001

Review of Concepts and Applications for Multispectral/Hyperspectral Focal Plane Array (FPA) Technology

Multispectral, and ultimately hyperspectral, focal plane arrays (FPAs) represent the logical extension of two-color FPA technology, which has already shown its utility in military applications. Incorporating the spectral discrimination function directly in the FPA would offer the potential for orders-of-magnitude increase in remote sensor system performance. It would allow reduction or even elimination of optical components currently required to provide spectral discrimination in atmospheric remote sensors. The result would be smaller, simpler instruments with higher performance than exist today.

McAdoo, James A.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-15304-DND

The Subsonic Fixed Wing Project conducts research to improve prediction methods and technologies that will produce lower noise, lower emissions, and higher performing subsonic aircraft for the Next Generation Air Transportation System. Subproject: FW Structural Efficiency: Lightweight, multi-objective and multifunctional structures (e.g., structures that can carry load and attenuate noise at the same time) are being developed to reduce the weight of both airframes and engines. Adaptive and flexible wing structures with aeroelastic tailoring offer significant weight reduction due to the elimination of a heavy actuation system. Extensive use of polymer matrix composites (PMCs) in airframe and engine structures (where applicable) will offer significant weight reduction opportunities. Research on composite technology is focused on developing alternate processes that will enable fabrication of large structures, increasing the temperature capability toward greater usage in engine and supersonic airframe structures, developing advanced structural concepts, and modeling damage initiation and progression in composite structures.

Jason P Moore↗
NASA NTRS1980

A mass reduction effort of the electric and hybrid vehicle

Weight reduction, cost competitiveness, and elimination of the intrusion beam resulted from the redesign and fabrication using composite materials of the door outer panel and intrusion beam from a Chevrolet Impala. The basis of the redesign involved replacing these two steel parts with a single compression molding using the unique approach of simultaneously curing a sheet molding compound outside panel with a continuous glass fiber intrusion strap. A weight reduction of nearly 11 pounds per door was achieved. Additional weight savings are possible by taking advantage of the elimination of the intrusion beam to design thinner door structures. The parts consolidation approach allows the composite structure to be cost competitive with the original steel design for both the lower production car models and for the near to midterm production vehicles using current state of the art composite production techniques. The design, prototype fabrication, costing, material, properties and compression molding production requirements are discussed.

Freeman, R. B.↗
NASA NTRS1972

Reduction of near-in sidelobes using phase reversal aperture rings

A technique is described for reducing near-in sidelobes in spacecraft antennas by cancellation. This technique takes a small portion of the radiation from the antenna aperture and generates the near-in lobes, which are then fed out of phase relative to the main signal. Results of sample cases indicate that the first three lobes can be nearly eliminated at a 40% reduction in aperture efficiency.

Williams, W. F.↗
NASA NTRS2012

The Advanced X-ray Spectroscopy and Imaging Observatory (AXSIO)

Following recommendations from the 2010 "New Worlds, New Horizons" (NWNH) report, the Advanced X-ray Spectroscopy and Imaging Observatory (AXSIO) concept streamlines the International X-ray Observatory (IXO) mission to concentrate on the science objectives that are enabled by high-resolution spectroscopic capabilities. AXSIO will trace orbits close to the event horizon of black holes, measure black hole spin for tens of supermassive black holes (SMBH), use spectroscopy to characterize outflows and the environment of AGN during their peak activity, observe 5MBH out to redshift z=6, map bulk motions and turbulence in galaxy clusters, find the missing baryons in the cosmic web using background quasars, and observe the process of cosmic feedback where black holes and supernovae inject energy on galactic and intergalactic scales. These measurements are enabled by a 0.9 sq m collecting area at 1.25 keV, a micro calorimeter array providing high-resolution spectroscopic imaging and a deployable high efficiency grating spectrometer. AXSIO delivers a 30-fold increase in effective area for high resolution spectroscopy. The key simplifications are guided by recommendations in the NWNH panel report include a reduction in focal length from 20m to 10m, eliminating the extendable optical bench, and a reduction in the instrument complement from six to two, avoiding a movable instrument platform. A focus on spectroscopic science allows the spatial resolution requirement to be relaxed to 10 arc sec (with a 5 arc sec goal). These simplifications decrease the total mission cost to under the $2B cost to NASA recommended by NWNH. AXSIO will be available to the entire astronomical community with observing allocations based on peer-review.

White, Nicholas E.↗