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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Feasibility of mapping velocity flowfields in an SSME powerhead using laser anemometry techniques

Nonintrusive anemometry measurement techniques are investigated for a NASA study of steady and unsteady aerothermal flow phenomena present in three engine component flow environments in the Space Shuttle Main Engine powerhead, the: (1) high-pressure fuel turbopump preburner; (2) turbine; and (3) turnaround duct. Issues considered include identification of feasible means of optical access to the high-pressure high-temperature measurement flow regions, and measurement system compatibility with the test environment. Descriptions of the two-component LDV and Laser Two Focus measurement systems are given whose capabilities include measurements of the time-averaged values of velocity magnitude and flow direction, turbulence intensity, and velocity component correlations.

Pelaccio, D. G.↗
NASA NTRS1988

Fiber reinforced superalloys for rocket engines

High-pressure turbopumps for advanced reusable liquid-propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several-fold increase in life and over a 200C increase in temperature capability over current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗
NASA NTRS1989

Fiber reinforced superalloys for rocket engines

High pressure turbopumps for advanced reusable liquid propellant rocket engines such as that for the Space Shuttle Main Engine (SSME) require turbine blade materials that operate under extreme conditions of temperature, hydrogen environment, high-cycle fatigue loading, thermal fatigue and thermal shock. Such requirements tax the capabilities of current blade materials. Based on projections of properties for tungsten fiber reinforced superalloy (FRS) composites, it was concluded that FRS turbine blades offer the potential of a several fold increase in life and over a 200 C increase in temperature capability over the current SSME blade material. FRS composites were evaluated with respect to mechanical property requirements for SSME blade applications. Compared to the current blade material, the thermal shock resistance of FRS materials is excellent, two to nine times better, and their thermal fatigue resistance is equal to or higher than the current blade material. FRS materials had excellent low and high-cycle fatigue strengths, and thermal shock-induced surface microcracks had no influence on their fatigue strength. The material also exhibited negligible embrittlement when exposed to a hydrogen environment.

Petrasek, Donald W.↗
NASA NTRS1992

SSME improved characterization using highly instrumented engine test data

This paper discusses the analysis of Space Shuttle Main Engine (SSME) 3001 test data and its applications to steady-state models. Engine 3001 is a highly instrumented Phase II (current configuration) SSME that was tested at the Technology Test Bed facility located at Marshall Space Flight Center. A test series covering a carefully selected range of operating conditions was performed during 1991. An analysis of pressure, temperature and flowrate data was performed to evaluate the ability of steady-state models to accurately characterize the internal system of an SSME. Much of the special instrumentation was used to acquire data never before measured at the engine level prior to Engine 3001 testing. The analysis revealed that modifications are needed to improve model calculations of internal Hydrogen and Oxygen flows. Modifying steady-state models to more accurately simulate the internal flow system of an SSME should improve both engine performance evaluations and prediction capabilities.

Piekarski, Brian↗
NASA NTRS1998

Summer Work Experience: Determining Methane Combustion Mechanisms and Sub-Scale Diffuser Properties for Space Transporation System Engine Testing

To assess engine performance during the testing of Space Shuttle Main Engines (SSMEs), the design of an optimal altitude diffuser is studied for future Space Transportation Systems (STS). For other Space Transportation Systems, rocket propellant using kerosene is also studied. Methane and dodecane have similar reaction schemes as kerosene, and are used to simulate kerosene combustion processes at various temperatures. The equations for the methane combustion mechanism at high temperature are given, and engine combustion is simulated on the General Aerodynamic Simulation Program (GASP). The successful design of an altitude diffuser depends on the study of a sub-scaled diffuser model tested through two-dimensional (2-D) flow-techniques. Subroutines given calculate the static temperature and pressure at each Mach number within the diffuser flow. Implementing these subroutines into program code for the properties of 2-D compressible fluid flow determines all fluid characteristics, and will be used in the development of an optimal diffuser design.

Williams, Powtawche N.↗
NASA NTRS1972

Space shuttle: Directional and lateral stability and interference effects of cruise engine location on a 0.015 scale space shuttle

The results are presented that were obtained from a wind tunnel tests to improve space shuttle booster baseline lateral-directional stability, control characteristics, and cruise engine location optimization. Tests were conducted in a 7 x 10-foot transonic wind tunnel. The model employed was a 0.015-scale replica of a space shuttle booster. The three major objectives of this test were to determine the following: (1) force, static stability, and control effectiveness characteristics for varying angles of positive and negative wing dihedral and various combinations of wing tip and centerline dorsal fins; (2) force and static stability characteristics of cruise engines location on the body below the high aerodynamic canard; and (3) control effectiveness for the low-mounted wing configuration. The wing dihedral study was conducted at a cruise Mach number of 0.40 and simulated altitude of 10,000 feet. Portions of the test were conducted to determine the control surfaces stability and control characteristics over the Mach number range of 0.4 to 1.2. The aerodynamic characteristics determined are based on a unit Reynolds number of approximately 2 million per foot. Boundary layer trip strips were employed to induce boundary layer transition.

Buchholz, R. E.↗
NASA NTRS1986

Grid generation for turbomachinery problems

The development of a computer code to generate numerical grids for complex internal flow systems such as the fluid flow inside the space shuttle main engine is outlined. The blending technique for generating a grid for stator-rotor combination at a particular radial section is examined. The computer programs which generate these grids are listed in the Appendices. These codes are capable of generating grids at different cross sections and thus providng three dimensional stator-rotor grids for the turbomachinery of the space shuttle main engine.

Steinhoff, J.↗
NASA NTRSDate not supplied

Gimbal Bearing Friction in the SLS Core Stage Thrust Vector Control System

The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.

Friction↗
NASA NTRSDate not supplied

Gimbal Bearing Friction in the SLS Core Stage Thrust Vector Control System

The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.

Friction↗
NASA NTRS1987

The NESSUS finite element code

The objective of this development is to provide a new analysis tool which integrates the structural modeling versatility of a modern finite element code with the latest advances in the area of probabilistic modeling and structural reliability. Version 2.0 of the NESSUS finite element code was released last February, and is currently being exercised on a set of problems which are representative of typical Space Shuttle Main Engine (SSME) applications. NESSUS 2.0 allows linear elastostatic and eigenvalue analysis of structures with uncertain geometry, material properties and boundary conditions, which are subjected to a random mechanical and thermal loading environment. The NESSUS finite element code is a key component in a broader software system consisting of five major modules. NESSUS/EXPERT is an expert system under development at Southwest Research Institute, with the objective of centralizing all component-specific knowledge useful for conducting probabilistic analysis of typical Space Shuttle Main Engine (SSME) components. NESSUS/FEM contains the finite element code used for the structural analysis and parameter sensitivity evaluation of these components. The task of parametrizing a finite element mesh in terms of the random variables present is facilitated with the use of the probabilistic data preprocessor in NESSUS/PRE. An external database file is used for managing the bulk of the data generated by NESSUS/FEM.

Dias, J. B.↗
NASA NTRS2010

Main Propulsion Test Article (MPTA)

Scope: The Main Propulsion Test Article integrated the main propulsion subsystem with the clustered Space Shuttle Main Engines, the External Tank and associated GSE. The test program consisted of cryogenic tanking tests and short- and long duration static firings including gimbaling and throttling. The test program was conducted on the S1-C test stand (Position B-2) at the National Space Technology Laboratories (NSTL)/Stennis Space Center. 3 tanking tests and 20 hot fire tests conducted between December 21 1 1977 and December 17, 1980 Configuration: The main propulsion test article consisted of the three space shuttle main engines, flightweight external tank, flightweight aft fuselage, interface section and a boilerplate mid/fwd fuselage truss structure.

Snoddy, Cynthia↗
NASA NTRS1994

Mission Evaluation Room Intelligent Diagnostic and Analysis System (MIDAS)

The role of Mission Evaluation Room (MER) engineers is to provide engineering support during Space Shuttle missions, for Space Shuttle systems. These engineers are concerned with ensuring that the systems for which they are responsible function reliably, and as intended. The MER is a central facility from which engineers may work, in fulfilling this obligation. Engineers participate in real-time monitoring of shuttle telemetry data and provide a variety of analyses associated with the operation of the shuttle. The Johnson Space Center's Automation and Robotics Division is working to transfer advances in intelligent systems technology to NASA's operational environment. Specifically, the MER Intelligent Diagnostic and Analysis System (MIDAS) project provides MER engineers with software to assist them with monitoring, filtering and analyzing Shuttle telemetry data, during and after Shuttle missions. MIDAS off-loads to computers and software, the tasks of data gathering, filtering, and analysis, and provides the engineers with information which is in a more concise and usable form needed to support decision making and engineering evaluation. Engineers are then able to concentrate on more difficult problems as they arise. This paper describes some, but not all of the applications that have been developed for MER engineers, under the MIDAS Project. The sampling described herewith was selected to show the range of tasks that engineers must perform for mission support, and to show the various levels of automation that have been applied to assist their efforts.

Pack, Ginger L.↗
NASA NTRS1991

Sensor failure detection and recovery by neural networks

A new method of sensor failure detection, isolation, and accommodation is described using a neural network approach. In a propulsion system such as the Space Shuttle Main Engine, the dynamics are usually much higher than the order of the system. This built-in redundancy of the sensors can be utilized to detect and correct sensor failure problems. The goal of the proposed scheme is to train a neural network to identify the sensor whose measurement is not consistent with other sensor outputs. Another neural network is trained to recover the value of critical variables when their measurements fail. Techniques for training the network with a limited amount of data are developed. The proposed scheme is tested using the simulated data of the Space Shuttle Main Engine (SSME) inflight sensor group.

Guo, Ten-Huei↗
NASA NTRS1986

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

Jones, C. S.↗
NASA NTRS2003

Blind Leak Detection for Closed Systems

The current inspection technique for locating interstitial leaking in the Space Shuttle Main Engine nozzles is the application of a liquid leak check solution in the openings where the interstitials space between the tubing and the structural jacket vent out the aft end of the nozzle, while its cooling tubes are pressurized to 25 psig with Helium. When a leak is found, it is classified, and if the leak is severe enough the suspect tube is cut open so that a boroscope can be inserted to find the leak point. Since the boroscope can only cover a finite tube length and since it is impossible to identify which tube (to the right or left of the identified interstitial) is leaking, many extra and undesired repairs have been made to fix just one leak. In certain instances when the interstitials are interlinked by poor braze bonding, many interstitials will show indications of leaking from a single source. What is desired is a technique that can identify the leak source so that a single repair can be performed. Dr, Samuel Russell and James Walker, both with NASA/MSFC have developed a thermographic inspection system that addresses a single repair approach. They have teamed with Boeing/Rocketdyne to repackage the inspection processes to be suitable to address full scale Shuttle development and flight hardware and implement the process at NASA centers. The methods and results presented address the thermographic identification of interstitial leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera (capable of detecting a delta temperature difference of 0.025 C) is used to record the cooling effects associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner hot wall surface as the nozzle is pressurized, These images are enhanced by digitally subtracting a thermal reference image taken before pressurization. The method provides a non-intrusive way of locating the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation. Other applications for this thermographic inspection system are the Reinforced-Carbon-Carbon (RCC) leading edge of the Space Shuttle orbiter and braze joint integrity.

Oelgoetz, Peter↗
NASA NTRS1988

Statistical analysis of SSME system data

A statistical methodology to enhance the Space Shuttle Main Engine (SSME) performance prediction accuracy is proposed. This methodology was to be used in conjunction with existing SSME performance prediction computer codes to improve parameter prediction accuracy and to quantify that accuracy. However, after a review of related literature, researchers concluded that the proposed problem required a coverage of areas such as linear and nonlinear system theory, measurement theory, statistics, and stochastic estimation. Since state space theory is the foundation for a more complete study of each of the before mentioned areas, these researchers chose to refocus emphasis to cover the more specialized topic of state vector estimation procedures. State vector estimation was also selected because of current and future concerns by NASA for SSME performance evaluation; i.e., there is a current interest in an improved evaluation procedure for actual SSME post flight performance as well as for post static test performance of a single SSME. A current investigation of analytical methods may be used to improve test stand failure detection. This paper considers the issue of post flight/test state variable reconstruction through the application of observations made on the output of the Space Shuttle propulsion system. Rogers used the Kalman filtering procedure to reconstruct the state variables of the Space Shuttle propulsion system. An objective of this paper is to give the general setup of the Kalman filter and its connection to linear regression. A second objective is to examine the reconstruction methodology for application to the reconstruction of the state vector of a single Space Shuttle Main Engine (SSME) by using static test firing data.

Temple, Enoch C.↗
NASA NTRS1992

Lunar Transportation Facilities and Operations Study, option 2

During the Option 2 period of the Lunar Transportation Facilities and Operations Study (LTFOS), a joint McDonnell Douglas Space Systems Company Kennedy Space Center (MDSSC-KSC) and National Aeronautics and Space Administration Kennedy Space Center (NASA-KSC) Study team conducted a comparison of the functional testing of the RL-10 and Space Shuttle Main Engine, a quick-look impact assessment of the Synthesis Group Report, and a detailed assessment of the Synthesis Group Report. The results of these KSC LTFOS team efforts are included. The most recent study task effort was a detailed assessment of the Synthesis Group Report. The assessment was conducted to determine the impact on planetary launch and landing facilities and operations. The result of that effort is a report entitled 'Analysis of the Synthesis Group Report, its Architectures and their Impacts on PSS Launch and Landing Operations' and is contained in Appendix A. The report is structured in a briefing format with facing pages as opposed to a narrative style. A quick-look assessment of the Synthesis Group Report was conducted to determine the impact of implementing the recommendations of the Synthesis Group on KSC launch facilities and operations. The data was documented in a presentation format as requested by Kennedy Space Center Technology and Advanced Projects Office and is included in Appendix B. Appendix C is a white paper on the comparison of the functional testing of the RL-10 and Space Shuttle Main Engine. The comparison was undertaken to provide insight regarding common test requirements that would be applicable to Lunar and Mars Excursion Vehicles (LEV and MEV).

Source record↗