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At least 541 records · Page 30

Standardization of Rocket Engine Pulse Time Parameters

Plumes of bipropellant thrusters are a source of contamination. Small bipropellant thrusters are often used for spacecraft attitude control and orbit correction. Such thrusters typically operate in a pulse mode, at various pulse lengths. Quantifying their contamination effects onto spacecraft external surfaces is especially important for long-term complex-geometry vehicles, e.g. International Space Station. Plume contamination tests indicated the presence of liquid phase contaminant in the form of droplets. Their origin is attributed to incomplete combustion. Most of liquid-phase contaminant is generated during the startup and shutdown (unsteady) periods of thruster pulse. These periods are relatively short (typically 10-50 ms), and the amount of contaminant is determined by the thruster design (propellant valve response, combustion chamber size, thruster mass flow rate, film cooling percentage, dribble volume, etc.) and combustion process organization. Steady-state period of pulse is characterized by much lower contamination rates, but may be lengthy enough to significantly conh'ibute to the overall contamination effect. Because there was no standard methodology for thruster pulse time division, plume contamination tests were conducted at various pulse durations, and their results do not allow quantifying contaminant amounts from each portion of the pulse. At present, the ISS plume contamination model uses an assumption that all thrusters operate in a pulse mode with the pulse length being 100 ms. This assumption may lead to a large difference between the actual amounts of contaminant produced by the thruster and the model predictions. This paper suggests a way to standardize thruster startup and shutdown period definitions, and shows the usefulness of this approach to better quantify thruster plume contamination. Use of the suggested thruster pulse time-division technique will ensure methodological consistency of future thruster plume contamination test programs, and allow accounting for thruster pulse length when modeling plume contamination and erosion effects.

Larin, Max E.↗

New ASTM Standards for Nondestructive Testing of Aerospace Composites

Problem: Lack of consensus standards containing procedural detail for NDE of polymer matrix composite materials: I. Flat panel composites. II. Composite components with more complex geometries a) Pressure vessels: 1) composite overwrapped pressure vessels (COPVs). 2) composite pressure vessels (CPVs). III. Sandwich core constructions. Metal and brittle matrix composites are a possible subject of future effort.

Waller, Jess M.↗

Enhancements to TetrUSS for NASA Constellation Program

The NASA Constellation program is utilizing Computational Fluid Dynamics (CFD) predictions for generating aerodynamic databases and design loads for the Ares I, Ares I-X, and Ares V launch vehicles and for aerodynamic databases for the Orion crew exploration vehicle and its launch abort system configuration. This effort presents several challenges to applied aerodynamicists due to complex geometries and flow physics, as well as from the juxtaposition of short schedule program requirements with high fidelity CFD simulations. NASA TetrUSS codes (GridTool/VGRID/USM3D) have been making extensive contributions in this effort. This paper will provide an overview of several enhancements made to the various elements of TetrUSS suite of codes. Representative TetrUSS solutions for selected Constellation program elements will be shown. Best practices guidelines and scripting developed for generating TetrUSS solutions in a production environment will also be described.

Pandya, Mohagna J.↗

Recommendations for Hypersonic Boundary Layer Transition Flight Testing

Much has been learned about the physics underlying the transition process at supersonic and hypersonic speeds through years of analysis, experiment and computation. Generally, the application of this knowledge has been restricted to simple shapes like plates, cones and spherical bodies. However, flight reentry vehicles are in reality never simple. They typically are highly complex geometries flown at angle of attack so three-dimensional effects are very important, as are roughness effects due to surface features and/or ablation. This paper will review our present understanding of the physics of the transition process and look back at some of the recent flight test programs for their successes and failures. The goal of this paper is to develop rationale for new hypersonic boundary layer transition flight experiments. Motivations will be derived from both an inward look at what we believe constitutes a good flight test program as well as an outward review of the goals and objectives of some recent US based unclassified proposals and programs. As part of our recommendations, this paper will address the need for careful experimental work as per the guidelines enunciated years ago by the U.S. Transition Study Group. Following these guidelines is essential to obtaining reliable, usable data for allowing refinement of transition estimation techniques.

Berry, Scott A.↗

Gas Dynamic Spray Technology Demonstration Project Management

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 Air Force Space Command (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 (GOS) technology (also known as Cold Spray) was 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 GOS coatings also have no VOCs and are environmentally preferable coatings. The primary objective of this effort was to demonstrate GDS technology as a repair method for TSCs. The aim was that successful completion of this project would result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations to 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↗

Turbulence Modeling for Shock Wave/Turbulent Boundary Layer Interactions

Accurate aerodynamic computational predictions are essential for the safety of space vehicles, but these computations are of limited accuracy when large pressure gradients are present in the flow. The goal of the current project is to improve the state of compressible turbulence modeling for high speed flows with shock wave / turbulent boundary layer interactions (SWTBLI). Emphasis will be placed on models that can accurately predict the separated region caused by the SWTBLI. These flows are classified as nonequilibrium boundary layers because of the very large and variable adverse pressure gradients caused by the shock waves. The lag model was designed to model these nonequilibrium flows by incorporating history effects. Standard one- and two-equation models (Spalart Allmaras and SST) and the lag model will be run and compared to a new lag model. This new model, the Reynolds stress tensor lag model (lagRST), will be assessed against multiple wind tunnel tests and correlations. The basis of the lag and lagRST models are to preserve the accuracy of the standard turbulence models in equilibrium turbulence, when the Reynolds stresses are linearly related to the mean strain rates, but create a lag between mean strain rate effects and turbulence when nonequilibrium effects become important, such as in large pressure gradients. The affect this lag has on the results for SWBLI and massively separated flows will be determined. These computations will be done with a modified version of the OVERFLOW code. This code solves the RANS equations on overset grids. It was used for this study for its ability to input very complex geometries into the flow solver, such as the Space Shuttle in the full stack configuration. The model was successfully implemented within two versions of the OVERFLOW code. Results show a substantial improvement over the baseline models for transonic separated flows. The results are mixed for the SWBLI assessed. Separation predictions are not as good as the baseline models, but the over prediction of the peak heat flux downstream of the reattachment shock that plagues many models is reduced.

Lillard, Randolph P.↗

CFD Validation with LDV Test Data for Payload/Fairing Internal Flow

Flowfield testing of a 1/5th scale model of a payload/fairing configuration, typical of an expendable launch vehicle, has been performed. Two-dimensional (planar) velocity measurements were carried out in four planes with the aid of Laser Doppler Velocimetry (LDV). Computational Fluid Dynamics (CFD) analysis results for the scale model flowfleld are compared with the test data. The CFD results are in general agreement with the test data. The ability of the CFD methodology in identifying the global flow features (including critical points such as vortex, saddle point, etc.) has been demonstrated. Practical problems and difficulties associated with the LDV method applied to the complex geometry under consideration have been summarized.

Kandula, max↗

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↗

OpTIIX: An ISS-Based Testbed Paving the Roadmap Toward a Next Generation Large Aperture UV/Optical Space Telescope

The next generation large aperture UV/Optical space telescope will need a diameter substantially larger than even that of JWST in order to address some of the most compelling unanswered scientific quests. These quests include understanding the earliest phases of the Universe and detecting life on exo-planets by studying spectra of their atmospheres. Such 8-16 meter telescopes face severe challenges in terms of cost and complexity and are unlikely to be affordable unless a new paradigm is adopted for their design and construction. The conventional approach is to use monolithic or preassembled segmented mirrors requiring complicated and risky deployments and relying on future heavy-lift vehicles, large fairings and complex geometry. The new paradigm is to launch component modules on relatively small vehicles and then perform in-orbit robotic assembly of those modules. The Optical Testbed and Integration on ISS eXperiment (OpTIIX) is designed to demonstrate, at low cost by leveraging the infrastructure provided by ISS, telescope assembly technologies and end-to-end optical system technologies. The use of ISS as a testbed permits the concentration of resources on reducing the technical risks associated with robotically integrating the components. These include laser metrology and wavefront sensing and control (WFS&C) systems, an imaging instrument, lightweight, low-cost deformable primary mirror segments and the secondary mirror. These elements are then aligned to a diffraction-limited optical system in space. The capability to assemble the optical system and remove and replace components via the existing ISS robotic systems like the Special Purpose Dexterous Manipulator (SPDM), or by the ISS flight crew, allows for future experimentation, as well as repair.

Carpenter, Kenneth G.↗

Ballistic Impact Testing of Aluminum 2024 and Titanium 6Al-4V for Material Model Development

An experimental program is underway to develop a consistent set of material property and impact test data, and failure analysis, for a variety of materials that can be used to develop improved impact failure and deformation models. Unique features of this set of data are that all material property information and impact test results are obtained using identical materials, the test methods and procedures are extensively documented and all of the raw data is available. This report describes ballistic impact testing which has been conducted on aluminum (Al) 2024 and titanium (Ti) 6Al-4vanadium (V) sheet and plate samples of different thicknesses and with different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade.

Pereira, J. Michael↗

Performance of an Advanced Stirling Convertor Based on Heat Flux Sensor Measurements

The U.S. Department of Energy (DOE) and Lockheed Martin Space Systems Company (LMSSC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. This generator would use two highefficiency Advanced Stirling Convertors (ASCs), developed by Sunpower, Inc., and NASA Glenn Research Center. The ASCs convert thermal energy from a radioisotope heat source into electricity. As part of ground testing of these ASCs, different operating conditions are used to simulate expected mission conditions. These conditions require achieving a particular operating frequency, hot-end and cold-end temperatures, and specified electrical power output for a given heat input. It is difficult to measure heat input to Stirling convertors due to the complex geometries of the hot components, temperature limits of sensor materials, and invasive integration of sensors. A thin-film heat flux sensor was used to directly measure heat input to an ASC. The effort succeeded in designing and fabricating unique sensors, which were integrated into a Stirling convertor ground test and exposed to test temperatures exceeding 700 C in air for 10,000 hr. Sensor measurements were used to calculate thermal efficiency for ASC-E (Engineering Unit) #1 and #4. The post-disassembly condition of the sensors is also discussed.

Wilson, Dcott D.↗

Axisymmetric Plume Simulations with NASA's DSMC Analysis Code

A comparison of axisymmetric Direct Simulation Monte Carlo (DSMC) Analysis Code (DAC) results to analytic and Computational Fluid Dynamics (CFD) solutions in the near continuum regime and to 3D DAC solutions in the rarefied regime for expansion plumes into a vacuum is performed to investigate the validity of the newest DAC axisymmetric implementation. This new implementation, based on the standard DSMC axisymmetric approach where the representative molecules are allowed to move in all three dimensions but are rotated back to the plane of symmetry by the end of the move step, has been fully integrated into the 3D-based DAC code and therefore retains all of DAC s features, such as being able to compute flow over complex geometries and to model chemistry. Axisymmetric DAC results for a spherically symmetric isentropic expansion are in very good agreement with a source flow analytic solution in the continuum regime and show departure from equilibrium downstream of the estimated breakdown location. Axisymmetric density contours also compare favorably against CFD results for the R1E thruster while temperature contours depart from equilibrium very rapidly away from the estimated breakdown surface. Finally, axisymmetric and 3D DAC results are in very good agreement over the entire plume region and, as expected, this new axisymmetric implementation shows a significant reduction in computer resources required to achieve accurate simulations for this problem over the 3D simulations.

Stewart, B. D.↗

Performance of an Advanced Stirling Convertor Based on Heat Flux Sensor Measurements

The U.S. Department of Energy (DOE) and Lockheed Martin Space Systems Company (LMSSC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. This generator would use two high-efficiency Advanced Stirling Convertors (ASCs), developed by Sunpower, Inc., and NASA Glenn Research Center. The ASCs convert thermal energy from a radioisotope heat source into electricity. As part of ground testing of these ASCs, different operating conditions are used to simulate expected mission conditions. These conditions require achieving a particular operating frequency, hot-end and cold-end temperatures, and specified electrical power output for a given heat input. It is difficult to measure heat input to Stirling convertors due to the complex geometries of the hot components, temperature limits of sensor materials, and invasive integration of sensors. A thin-film heat flux sensor was used to directly measure heat input to an ASC. The effort succeeded in designing and fabricating unique sensors, which were integrated into a Stirling convertor ground test and exposed to test temperatures exceeding 700 C in air for 10,000 hr. Sensor measurements were used to calculate thermal efficiency for ASC-E (Engineering Unit) #1 and #4. The post-disassembly condition of the sensors is also discussed.

Wilson, Scott D.↗

Extension of the Time-Spectral Approach to Overset Solvers for Arbitrary Motion

Forced periodic flows arise in a broad range of aerodynamic applications such as rotorcraft, turbomachinery, and flapping wing configurations. Standard practice involves solving the unsteady flow equations forward in time until the initial transient exits the domain and a statistically stationary flow is achieved. It is often required to simulate through several periods to remove the initial transient making unsteady design optimization prohibitively expensive for most realistic problems. An effort to reduce the computational cost of these calculations led to the development of the Harmonic Balance method [1, 2] which capitalizes on the periodic nature of the solution. The approach exploits the fact that forced temporally periodic flow, while varying in the time domain, is invariant in the frequency domain. Expanding the temporal variation at each spatial node into a Fourier series transforms the unsteady governing equations into a steady set of equations in integer harmonics that can be tackled with the acceleration techniques afforded to steady-state flow solvers. Other similar approaches, such as the Nonlinear Frequency Domain [3,4,5], Reduced Frequency [6] and Time-Spectral [7, 8, 9] methods, were developed shortly thereafter. Additionally, adjoint-based optimization techniques can be applied [10, 11] as well as frequency-adaptive methods [12, 13, 14] to provide even more flexibility to the method. The Fourier temporal basis functions imply spectral convergence as the number of harmonic modes, and correspondingly number of time samples, N, is increased. Some elect to solve the equations in the frequency domain directly, while others choose to transform the equations back into the time domain to simplify the process of adding this capability to existing solvers, but each harnesses the underlying steady solution in the frequency domain. These temporal projection methods will herein be collectively referred to as Time-Spectral methods. Time-Spectral methods have demonstrated marked success in reducing the computational costs associated with simulating periodic forced flows, but have yet to be fully applied to overset or Cartesian solvers for arbitrary motion with dynamic hole-cutting. Overset and Cartesian grid methodologies are versatile techniques capable of handling complex geometry configurations in practical engineering applications, and the combination of the Time-Spectral approach with this general capability potentially provides an enabling new design and analysis tool. In an arbitrary moving-body scenario for these approaches, a Lagrangian body moves through a fixed Eulerian mesh and mesh points in the Eulerian mesh interior to the solid body are removed (cut or blanked), leaving a hole in the Eulerian mesh. During the dynamic motion some gridpoints in the domain are blanked and do not have a complete set of time-samples preventing a direct implementation of the Time-Spectral method. Murman[6] demonstrated the Time-Spectral approach for a Cartesian solver with a rigid domain motion, wherein the hole cutting remains constant. Similarly, Custer et al. [15, 16] used the NASA overset OVERFLOW solver and limited the amount of relative motion to ensure static hole-cutting and interpolation. Recently, Mavriplis and Mundis[17] demonstrated a qualitative method for applying the Time-Spectral approach to an unstructured overset solver for arbitrary motion. The goal of the current work is to develop a robust and general method for handling arbitrary motion with the Time-Spectral approach within an overset or Cartesian mesh method, while still approaching the spectral convergence rate of the original Time-Spectral approach. The viscous OVERFLOW solver will be augmented with the new Time-Spectral algorithm and the capability of the method for benchmark problems in rotorcraft and turbomachinery will be demonstrated. This abstract begins with a brief synopsis of the Time-Spectral approach for overset grids and provides details of e current approach to allow for arbitrary motion. Model problem results in one and two dimensions are included to demonstrate the viability of the method and the convergence properties. Section IV briefly outlines the implementation into the OVERFLOW solver, and the abstract closes with a description of the benchmark test cases which will be included in the final paper.

Leffell, Joshua Isaac↗

Studies of Inviscid Flux Schemes for Acoustics and Turbulence Problems

The last two decades have witnessed tremendous growth in computational power, the development of computational fluid dynamics (CFD) codes which scale well over thousands of processors, and the refinement of unstructured grid-generation tools which facilitate rapid surface and volume gridding of complex geometries. Thus, engineering calculations of 10(exp 7) - 10(exp 8) finite-volume cells have become routine for some types of problems. Although the Reynolds Averaged Navier Stokes (RANS) approach to modeling turbulence is still in extensive and wide use, increasingly large-eddy simulation (LES) and hybrid RANS-LES approaches are being applied to resolve the largest scales of turbulence in many engineering problems. However, it has also become evident that LES places different requirements on the numerical approaches for both the spatial and temporal discretization of the Navier Stokes equations than does RANS. In particular, LES requires high time accuracy and minimal intrinsic numerical dispersion and dissipation over a wide spectral range. In this paper, the performance of both central-difference and upwind-biased spatial discretizations is examined for a one-dimensional acoustic standing wave problem, the Taylor-Green vortex problem, and the turbulent channel fl ow problem.

Morris, C. I.↗

Studies of Inviscid Flux Schemes for Acoustics and Turbulence Problems

The last two decades have witnessed tremendous growth in computational power, the development of computational fluid dynamics (CFD) codes which scale well over thousands of processors, and the refinement of unstructured grid-generation tools which facilitate rapid surface and volume gridding of complex geometries. Thus, engineering calculations of 10(exp 7) - 10(exp 8) finite-volume cells have become routine for some types of problems. Although the Reynolds Averaged Navier Stokes (RANS) approach to modeling turbulence is still in extensive and wide use, increasingly large-eddy simulation (LES) and hybrid RANS-LES approaches are being applied to resolve the largest scales of turbulence in many engineering problems. However, it has also become evident that LES places different requirements on the numerical approaches for both the spatial and temporal discretization of the Navier Stokes equations than does RANS. In particular, LES requires high time accuracy and minimal intrinsic numerical dispersion and dissipation over a wide spectral range. In this paper, the performance of both central-difference and upwind-biased spatial discretizations is examined for a one-dimensional acoustic standing wave problem, the Taylor-Green vortex problem, and the turbulent channel ow problem.

Morris, Christopher I.↗

An Overview of Modifications Applied to a Turbulence Response Analysis Method for Flexible Aircraft Configurations

A software program and associated methodology to study gust loading on aircraft exists for a classification of geometrically simplified flexible configurations. This program consists of a simple aircraft response model with two rigid and three flexible symmetric degrees of freedom and allows for the calculation of various airplane responses due to a discrete one-minus-cosine gust as well as continuous turbulence. Simplifications, assumptions, and opportunities for potential improvements pertaining to the existing software program are first identified, then a revised version of the original software tool is developed with improved methodology to include more complex geometries, additional excitation cases, and output data so as to provide a more useful and accurate tool for gust load analysis. Revisions are made in the categories of aircraft geometry, computation of aerodynamic forces and moments, and implementation of horizontal tail mode shapes. In order to improve the original software program to enhance usefulness, a wing control surface and horizontal tail control surface is added, an extended application of the discrete one-minus-cosine gust input is employed, a supplemental continuous turbulence spectrum is implemented, and a capability to animate the total vehicle deformation response to gust inputs in included. These revisions and enhancements are implemented and an analysis of the results is used to validate the modifications.

Funk, Christie J.↗

Impact Testing of Aluminum 2024 and Titanium 6Al-4V for Material Model Development

One of the difficulties with developing and verifying accurate impact models is that parameters such as high strain rate material properties, failure modes, static properties, and impact test measurements are often obtained from a variety of different sources using different materials, with little control over consistency among the different sources. In addition there is often a lack of quantitative measurements in impact tests to which the models can be compared. To alleviate some of these problems, a project is underway to develop a consistent set of material property, impact test data and failure analysis for a variety of aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the FAA William J. Hughes Technical Center. Unique features of this set of data are that all material property data and impact test data are obtained using identical material, the test methods and procedures are extensively documented and all of the raw data is available. Four parallel efforts are currently underway: Measurement of material deformation and failure response over a wide range of strain rates and temperatures and failure analysis of material property specimens and impact test articles conducted by The Ohio State University; development of improved numerical modeling techniques for deformation and failure conducted by The George Washington University; impact testing of flat panels and substructures conducted by NASA Glenn Research Center. This report describes impact testing which has been done on aluminum (Al) 2024 and titanium (Ti) 6Al-4vanadium (V) sheet and plate samples of different thicknesses and with different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.

Pereira, J. Michael↗