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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 541 records · Page 30

Integration of Mirror Design with Suspension System using NASA's New Mirror Modeling Software

Advances in mirror fabrication is making very large space based telescopes possible. In the many applications, only monolithic mirrors meet the performance requirements. The existing and near-term planned heavy launch vehicles place a premium on lowest possible mass. Again, available and planned payload shroud size limits near term designs to 4 meter class mirror. Practical 8 meter and beyond designs could encourage planners to include larger shrouds if it can be proven that such mirrors can be manufactured. These two factors lower mass and larger mirrors, presents the classic optimization problem. There is a practical upper limit to how large a mirror can be supported by a purely kinematic mount system and be launched. This paper shows how the design of the suspension system and mirror blank needs to be designed simultaneously. We will also explore the concepts of auxiliary support systems, which act only during launch and disengage on orbit. We will define required characteristics of these systems and show how they can substantially reduce the mirror mass. The AMTD project is developing and maturing the processes for future replacements for HUBBLE, creating the design tools, validating the methods and techniques necessary to manufacture, test and launch extremely large optical missions. This paper will use the AMTD 4 meter "design point" as an illustration of the typical use of the modeler in generating the multiple models of mirror and suspension systems used during the conceptual design phase of most projects. The influence of Hexapod geometry, mirror depth, cell size and construction techniques (Exelsis Deep Core Low Temperature Fusion (c) versus Corning Frit Bonded (c) versus Schott Pocket Milled Zerodur (c) in this particular study) are being evaluated. Due to space and time consideration we will only be able to present snippets of the study in this paper. The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond.

Arnold, William↗

Enabling Parametric Optimal Ascent Trajectory Modeling During Early Phases of Design

During the early phases of engineering design, the costs committed are high, costs incurred are low, and the design freedom is high. It is well documented that decisions made in these early design phases drive the entire design's life cycle. In a traditional paradigm, key design decisions are made when little is known about the design. As the design matures, design changes become more difficult -- in both cost and schedule -- to enact. Indeed, the current capability-based paradigm that has emerged because of the constrained economic environment calls for the infusion of knowledge acquired during later design phases into earlier design phases, i.e. bring knowledge acquired during preliminary and detailed design into pre-conceptual and conceptual design. An area of critical importance to launch vehicle design is the optimization of its ascent trajectory, as the optimal trajectory will be able to take full advantage of the launch vehicle's capability to deliver a maximum amount of payload into orbit. Hence, the optimal ascent trajectory plays an important role in the vehicle's affordability posture as the need for more economically viable access to space solutions are needed in today's constrained economic environment. The problem of ascent trajectory optimization is not a new one. There are several programs that are widely used in industry that allows trajectory analysts to, based on detailed vehicle and insertion orbit parameters, determine the optimal ascent trajectory. Yet, little information is known about the launch vehicle early in the design phase - information that is required of many different disciplines in order to successfully optimize the ascent trajectory. Thus, the current paradigm of optimizing ascent trajectories involves generating point solutions for every change in a vehicle's design parameters. This is often a very tedious, manual, and time-consuming task for the analysts. Moreover, the trajectory design space is highly non-linear and multi-modal due to the interaction of various constraints. Additionally, when these obstacles are coupled with The Program to Optimize Simulated Trajectories [1] (POST), an industry standard program to optimize ascent trajectories that is difficult to use, it requires expert trajectory analysts to effectively optimize a vehicle's ascent trajectory. As it has been pointed out, the paradigm of trajectory optimization is still a very manual one because using modern computational resources on POST is still a challenging problem. The nuances and difficulties involved in correctly utilizing, and therefore automating, the program presents a large problem. In order to address these issues, the authors will discuss a methodology that has been developed. The methodology is two-fold: first, a set of heuristics will be introduced and discussed that were captured while working with expert analysts to replicate the current state-of-the-art; secondly, leveraging the power of modern computing to evaluate multiple trajectories simultaneously, and therefore, enable the exploration of the trajectory's design space early during the pre-conceptual and conceptual phases of design. When this methodology is coupled with design of experiments in order to train surrogate models, the authors were able to visualize the trajectory design space, enabling parametric optimal ascent trajectory information to be introduced with other pre-conceptual and conceptual design tools. The potential impact of this methodology's success would be a fully automated POST evaluation suite for the purpose of conceptual and preliminary design trade studies. This will enable engineers to characterize the ascent trajectory's sensitivity to design changes in an arbitrary number of dimensions and for finding settings for trajectory specific variables, which result in optimal performance for a "dialed-in" launch vehicle design. The effort described in this paper was developed for the Advanced Concepts Office [2] at NASA Marshall Space Flight Center

Holt, James B.↗

Considerations When Building Thermal Models that Require Conversion Between Formats

At times, it is inevitable to require conversion of thermal models from one software format to another. This most often occurs for missions with international partners where not all parties utilize the same software packages for thermal analysis. Mandating a single tool for all parties is one possible solution, but this approach can introduce problems if significant effort is required to overcome inexperience with the designated tool and may result in difficulty meeting analysis schedule requirements. Alternatively, allowing all parties to use their own familiar tools minimizes the impact to analysis schedules but does introduce the need to convert the models later to a common format for analysis at a higher level of assembly. External conversion tools and formats have been developed through the years to aid in this process, but have had limited success in fully converting models seamlessly. Having a basic familiarity with tool capabilities on both sides of the conversion process allows for models to be built in a manner to better facilitate conversion by avoiding features and capabilities which are unsupported by the destination tool or for which no workarounds exist. Also, the effort to convert a model is often neglected when developing the schedules for analysis at the higher assembly levels; delivery of models preconditioned for convertibility minimizes the schedule risk. This paper seeks to provide some guidance on modeling techniques to avoid when developing Geometrical Math Models (GMM) and Thermal Math Models (TMM) when conversion is required. The recommendations are based on GMM conversion experiences between TSS/ThermalDesktop/ESARAD and TMM conversions between SINDA-FLUINT/ESATAN.

Modeling↗

Blending Pipeline Analysis Tool for Hydrogen (BlendPATH) Documentation and User Manual

The Blending Pipeline Analysis Tool for Hydrogen (BlendPATH) is a flexible, open-source Python tool designed to provide users with case-by-case analysis capabilities to identify the necessary modifications to repurpose existing natural gas transmission pipeline networks to transport hydrogen as a blend of a user-specified volume fraction of hydrogen or as a pure stream and to estimate the associated capital and operating expenditures resulting from those modifications. This tool is intended to be applied during the initial screening stage of a prospective project when pipeline developers compile transmission pipeline technical documentation and history but prior to performing detailed pipeline inspections. Performing analysis with BlendPATH during this initial screening stage can provide the user with an understanding of promising opportunities and probable economic outcomes of repurposing their pipeline network for hydrogen before proceeding with detailed pipeline materials testing and pipeline inspections. BlendPATH consists of multiple modules to simulate, assess, and modify existing natural gas transmission pipeline network designs to be compatible with hydrogen as a blend or pure stream. The tool employs an open-source gas network hydraulic model to simulate existing, user-specified transmission pipeline networks, and it applies ASME B31.12 to assess the pipe segments within these networks for compatibility with hydrogen and to modify the networks to achieve compatibility where the existing infrastructure is inadequate. Users can specify ASME B31.12 design options for pipeline assessment and can select from multiple methods for pipeline modification. This report details the functionalities of BlendPATH Version 2.0.2 and demonstrates an example of applying BlendPATH to a case study. Potential and intended users of this framework include natural gas pipeline developers and operators and researchers at both public and private institutions. BlendPATH is publicly available at https://github.com/NREL/BlendPATH.

08 HYDROGEN↗

Collaborative Software Development in Support of Fast Adaptive AeroSpace Tools (FAAST)

A collaborative software development approach is described. The software product is an adaptation of proven computational capabilities combined with new capabilities to form the Agency's next generation aerothermodynamic and aerodynamic analysis and design tools. To efficiently produce a cohesive, robust, and extensible software suite, the approach uses agile software development techniques; specifically, project retrospectives, the Scrum status meeting format, and a subset of Extreme Programming's coding practices are employed. Examples are provided which demonstrate the substantial benefits derived from employing these practices. Also included is a discussion of issues encountered when porting legacy Fortran 77 code to Fortran 95 and a Fortran 95 coding standard.

Kleb, William L.↗

On-Line Tool for the Assessment of Radiation in Space - Deep Space Mission Enhancements

The On-Line Tool for the Assessment of Radiation in Space (OLTARIS, https://oltaris.nasa.gov) is a web-based set of tools and models that allows engineers and scientists to assess the effects of space radiation on spacecraft, habitats, rovers, and spacesuits. The site is intended to be a design tool for those studying the effects of space radiation for current and future missions as well as a research tool for those developing advanced material and shielding concepts. The tools and models are built around the HZETRN radiation transport code and are primarily focused on human- and electronic-related responses. The focus of this paper is to highlight new capabilities that have been added to support deep space (outside Low Earth Orbit) missions. Specifically, the electron, proton, and heavy ion design environments for the Europa mission have been incorporated along with an efficient coupled electron-photon transport capability to enable the analysis of complicated geometries and slabs exposed to these environments. In addition, a neutron albedo lunar surface environment was also added, that will be of value for the analysis of surface habitats. These updates will be discussed in terms of their implementation and on how OLTARIS can be used by instrument vendors, mission designers, and researchers to analyze their specific requirements.12

Sandridge, Chris a.↗

New Tools for Tour Design: Swiss Cheese Plot, Invariant Funnel, and Resonant Encounter Map

We define a new set of tools for tour design introduced in previous work: the”Swiss Cheese Plot,” ”Invariant Funnel,” and ”Resonant Encounter Map.” These tools promise to be useful in designing, analyzing, and navigating low-energy trajectories through multi-body systems. We review and clarify methods for generating the swiss cheese plot and invariant funnels in the Circular Restricted Three-Body Problem. We introduce the resonant encounter map as a graphical representation of the three-body design space, similar to the pork-chop plot for the two-body problem. We also discuss some interesting characteristics of the resonant encounter map and its connection to the invariant manifolds of periodic libration orbit

Close, Sigrid↗

50 MW Segmented Ultralight Morphing Rotors for Wind Energy

A multi-institutional team designed a 50 Megawatt (MW) rated wind turbine featuring downwind aeroelastic morphing to reduce blade loads and allow an ultralight segmented rotor (mass reduction of about 25% compared to a conventional upwind rotor). The team used a control co-design approach with state-of-the art simulations including for the rotor and tower design using non-linear fluid-structure interactions and control algorithms, and the team also designed, built, and field-tested an aeroelastically-scaled downwind rotor to demonstrate this novel technology and validate the design tool fidelity. In a follow-on phase, these results were used along with an updated Levelized Cost Of Energy (LCOE) methodology to co-design a more detailed set of 25 MW rated turbine designs (including individual pitch control) based on minimum LCOE with highly flexible blades for an Atlantic Ocean offshore fixed-bottom design targeted towards market technology evaluation. A set of upwind and downwind designs at 25 MW rated scales were found to provide the best LCOE, with strong improvements over all previous offshore reference turbines (NREL 5MW, DTU 10 MW and IEA 15 MW). The optimized design would represent the world’s largest offshore turbine design, which combines several state-of-the-art structural, aerodynamic, and control technologies into a new and optimized system concept.

17 WIND ENERGY↗

Centrifugal and Axial Pump Design and Off-Design Performance Prediction

A meanline pump-flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump-flow code PUMPA was written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design-point rotor efficiency and slip factors are obtained from empirical correlations to rotor-specific speed and geometry. The pump code can model axial, inducer, mixed-flow, and centrifugal pumps and can model multistage pumps in series. The rapid input setup and computer run time for this meanline pump flow code make it an effective analysis and conceptual design tool. The map-generation capabilities of the code provide the information needed for interfacing with a rocket engine system modeling code. The off-design and multistage modeling capabilities of PUMPA permit the user to do parametric design space exploration of candidate pump configurations and to provide head-flow maps for engine system evaluation.

Veres, Joseph P.↗

Mean Line Pump Flow Model in Rocket Engine System Simulation

A mean line pump flow modeling method has been developed to provide a fast capability for modeling turbopumps of rocket engines. Based on this method, a mean line pump flow code PUMPA has been written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The pump code can model axial flow inducers, mixed-flow and centrifugal pumps. The code can model multistage pumps in series. The code features rapid input setup and computer run time, and is an effective analysis and conceptual design tool. The map generation capability of the code provides the map information needed for interfacing with a rocket engine system modeling code. The off-design and multistage modeling capabilities of the code permit parametric design space exploration of candidate pump configurations and provide pump performance data for engine system evaluation. The PUMPA code has been integrated with the Numerical Propulsion System Simulation (NPSS) code and an expander rocket engine system has been simulated. The mean line pump flow code runs as an integral part of the NPSS rocket engine system simulation and provides key pump performance information directly to the system model at all operating conditions.

Veres, Joseph P.↗

Development of an Inertia Relief Method for Aircraft with Dissimilar Engines in LEAPS

Weight estimation is a critical element of the aircraft conceptual design process. The Layered and Extensible Aircraft Performance System (LEAPS) is an aircraft conceptual design tool that is under development by the Systems Analysis and Concepts Directorate (SACD) at the NASA Langley Research Center. LEAPS includes modules that represent aircraft design disciplines. This work presents an update to the LEAPS wing weight estimation method to allow for engine inertia relief to be accurately accounted for when analyzing aircraft with multiple dissimilar engines.

LEAPS↗

Development of an Inertia Relief Method for Aircraft with Dissimilar Engines in LEAPS

Weight estimation is a critical element of the aircraft conceptual design process. The Layered and Extensible Aircraft Performance System (LEAPS) is an aircraft conceptual design tool that is under development by the Systems Analysis and Concepts Directorate (SACD) at the NASA Langley Research Center. LEAPS includes modules that represent aircraft design disciplines. This work presents an update to the LEAPS wing weight estimation method to allow for engine inertia relief to be accurately accounted for when analyzing aircraft with multiple dissimilar engines.

LEAPS↗

DENNIS: a design and analysis tool for dynamic material x-ray diffraction experiments

We present DENNIS (Diffraction Experiment desigN and aNalysiS): a graphical software tool useful for the design and analysis of dynamic x-ray diffraction experiments, such as those performed on the Z Pulsed Power Facility, Thor Pulsed Power Generator, and Dynamic Compression Sector (DCS) of the Advanced Photon Source. DENNIS provides rapid powder and single-crystal diffraction pattern predictions and powder diffraction pattern image integration in three-dimensional geometries. Additional features include crystallographic information file reading, image processing, and synthetic diffraction pattern image generation. We overview the software's capabilities, detail the prediction and integration methodologies, and provide example implementations on Z and DCS experiments.

47 OTHER INSTRUMENTATION↗

Advanced composite vertical stabilizer for DC-10 transport aircraft

Structural design, tooling, fabrication, and test activities are reported for a program to develop an advanced composite vertical stabilizer (CVS) for the DC 10 Commercial Transport Aircraft. Structural design details are described and the status of structural and weight analyses are reported. A structural weight reduction of 21.7% is currently predicted. Test results are discussed for sine wave stiffened shear webs containing representative of the CVS spar webs and for lightning current transfer and tests on a panel representative of the CVS skins.

Stephens, C. O.↗

Composite intermediate case manufacturing scale-up for advanced engines

This Manufacturing Technology for Propulsion Program developed a process to produce a composite intermediate case for advanced gas turbine engines. The method selected to manufacture this large, complex part uses hard tooling for surfaces in the airflow path and trapped rubber to force the composite against the mold. Subelements were manufactured and tested to verify the selected design, tools, and processes. The most significant subelement produced was a half-scale version of a composite intermediate case. The half-scale subelement maintained the geometry and key dimensions of the full-scale case, allowing relevant process development and structural verification testing to be performed on the subelement before manufacturing the first full-scale case.

Ecklund, Rowena H.↗

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas↗

Segmented, Pleat-Folded and Rib-Supported Thin-Shell Composite Antenna Reflector

A new architecture scalable to sizes greater than 10 m for a deployable solid surface reflector antenna is presented. The design makes use of radially and circumferentially segmented thin-shell composite gores interconnected on the back side by a series of flexible shape memory composite elements. The reflector surface stows like an umbrella by creating serpentine-shaped pleats in the thin shell while being supported by a simple-hinged metering rib structure. A parametric study assessed how design features affect the deployed stiffness of the reflector and are used to identify a test matrix for manufacturing, foldability, and shape accuracy assessments. Various manufacturing tooling designs and dedicated folding fixtures were built to increase the fidelity and confidence of the test articles produced. An overview of the development effort is provided.

Deployable antennas↗