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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 577 records · Page 32

Design and Fabrication Development of J-2X Engine Metallic Nozzle Extension

Maximized rocket engine performance is in part derived from expanding combustion gasses through the rocket nozzle. For upper stage engines the nozzles can be quite large. On the J-2X engine, an uncooled extension of a regeneratively cooled nozzle is used to expand the combustion gasses to a targeted exit pressure which is defined by an altitude for the desired maximum performance. Creating a J-2X nozzle extension capable of surviving the loads of test and flight environments while meeting engine system performance requirements required development of new processes and facilities. Meeting the challenges of the development resulted in concurrent J-2X nozzle extension design and fabrication. This paper describes how some of the design and fabrication challenges were resolved.

Kopicz, C.↗

Nancy Grace Roman Space Telescope Observatory Implementation and Challenges

NASA’s Nancy Grace Roman Space Telescope (Roman), previously referred to as Wide Field Infrared Survey Telescope (WFIRST), was named after Dr. Nancy Grace Roman, an astronomer and NASA pioneer of modern space-based astronomy who is known as the “mother of the Hubble Space Telescope”. Roman is a deep space infrared observatory with a Hubble-sized telescope and wide field of view instrument (greater than 100 times that of Hubble’s) that will conduct a high latitude time-domain survey, a high latitude imaging and spectroscopic survey, and a galactic bulge time-domain survey to characterize dark energy and expand the census of exoplanets in our galaxy while allowing a broad range of astrophysics research. Roman will also demonstrate exoplanet coronagraphy with active wave front control technology and provide general investigator programs for the science community. Roman is finishing the critical design phase and is planning for launch in 2026. It will operate in a quasi-halo orbit about Sun-Earth L2, 1.5 million kilometers from Earth, for a five-year primary mission life. The Observatory features an Optical Telescope Assembly with an existing, repurposed 2.4m primary mirror, a Wide Field Instrument with a focal plane array comprised of 18 HgCdTe near-infrared detectors and a grism, prism and filter elements for imaging and spectroscopy in support of the primary surveys, as well as a Coronagraph instrument technology demonstration with starlight suppression technology for direct imaging and spectroscopy of exoplanets. The telescope is mounted to the Instrument Carrier composite truss structure which also optically meters each instrument, includes a Launch Load and Vibration Isolation System to provide passive isolation of spacecraft jitter sources while also supporting the payload during launch and is attached to the Spacecraft Bus. The Spacecraft also includes a Solar Array Sunshield ,Deployable Aperture Cover, Lower Instrument Sunshade, High Gain Antenna System, and Outer Barrel Assembly. Figure 1 shows an overview of the Roman Observatory. When fully integrated, Roman will be the largest Observatory assembled and tested at NASA’s Goddard Space Flight Center. Figure 1. Roman Observatory Overview Development of scientific satellites is challenging by nature, as the pursuit to broaden scientific knowledge always pushes the boundary of what has come before. The implementation of the Roman mission is a prime example and expected challenges have been augmented by the foundational decision to use the existing telescope components, developed in the early 2000s by another Government agency for a different application. Other unique aspects of the Roman mission, such as its survey nature, the vast amount of data required to meet science objectives, and packaging of the Observatory elements around the existing telescope components, create constrained design spaces that drive competing requirements across Observatory subsystems. Given these challenges, systems engineering has been a critical discipline in balancing implementation decisions for the Roman mission and will continue to play a key role going forward. This paper will discuss details of the Roman Observatory configuration, as well as some of the systems engineering challenges and the decision-making process used to mature the Roman Space Telescope preliminary design to implementation.

Lisa Ml Bartusek↗

Nancy Grace Roman Space Telescope Observatory Implementation and Challenges

NASA’s Nancy Grace Roman Space Telescope (Roman) is a deep space infrared observatory with a Hubble-sized telescope and wide field of regard with a boresight view greater than 200 times that of the Hubble Wide Field Camera 3infrared field of view, that will conduct a suite of science surveys to characterize dark energy and expand the census of exoplanets in our galaxy. Roman will also demonstrate exoplanet coronagraphy with active wavefront control technology and provide general investigator opportunities for the science community. Roman is finishing the critical design phase and is planning for launch in 2026. It will operate at the second Sun-Earth-Moon Lagrange for a five-year primary mission life. The Observatory features a telescope with an existing, repurposed 2.4m primary mirror, a Wide Field Instrument with a near-infrared detector focal plane array and optical elements for imaging and spectroscopy, as well as a Coronagraph instrument technology demonstration for direct imaging and spectroscopy of exoplanets. The telescope and instruments are mounted to an Instrument Carrier for optical metering and isolation from Spacecraft-induced disturbances. The Spacecraft includes a Bus, Solar Array Sunshield, Deployable Aperture Cover, Outer Barrel Assembly, and Star Tracker/Inertial Reference Unit Bench. When fully integrated, Roman will be the largest Observatory assembled and tested at NASA’s Goddard Space Flight Center. The development of scientific satellites is challenging and pushes engineering boundaries to broaden scientific knowledge. The Roman mission implementation is a prime example and expected challenges have been amplified by the foundational decision to use existing, repurposed telescope components. Other unique aspects of the Roman mission, including its survey nature, large data volume, and Observatory packaging, create constrained design spaces that drive competing requirements across Observatory subsystems. Given these challenges, systems engineering has been a critical discipline in balancing implementation decisions and will continue to play a key role in the development of the Roman mission. This paper will discuss details of the Roman Observatory configuration, systems engineering challenges and the decision-making process used to mature the Roman Space Telescope from preliminary design to implementation.

Lisa M L Bartusek↗

Flat-plate solar array project: Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

The process technology for the manufacture of semiconductor-grade silicon in a large commercial plant by 1986, at a price less than $14 per kilogram of silicon based on 1975 dollars is discussed. The engineering design, installation, checkout, and operation of an Experimental Process System Development unit was discussed. Quality control of scaling-up the process and an economic analysis of product and production costs are discussed.

Source record↗

Application of High Speed Digital Image Correlation in Rocket Engine Hot Fire Testing

Hot fire testing of rocket engine components and rocket engine systems is a critical aspect of the development process to understand performance, reliability and system interactions. Ground testing provides the opportunity for highly instrumented development testing to validate analytical model predictions and determine necessary design changes and process improvements. To properly obtain discrete measurements for model validation, instrumentation must survive in the highly dynamic and extreme temperature application of hot fire testing. Digital Image Correlation has been investigated and being evaluated as a technique to augment traditional instrumentation during component and engine testing providing further data for additional performance improvements and cost savings. The feasibility of digital image correlation techniques were demonstrated in subscale and full scale hotfire testing. This incorporated a pair of high speed cameras to measure three-dimensional, real-time displacements and strains installed and operated under the extreme environments present on the test stand. The development process, setup and calibrations, data collection, hotfire test data collection and post-test analysis and results are presented in this paper.

Gradl, Paul R.↗

Physics and Process Modeling (PPM) and Other Propulsion R and T: Materials Processing, Characterization, and Modeling; Lifting Models - Volume 1

This CP contains the extended abstracts and presentation figures of 36 papers presented at the PPM and Other Propulsion R&T Conference. The focus of the research described in these presentations is on materials and structures technologies that are parts of the various projects within the NASA Aeronautics Propulsion Systems Research and Technology Base Program. These projects include Physics and Process Modeling; Smart, Green Engine; Fast, Quiet Engine; High Temperature Engine Materials Program; and Hybrid Hyperspeed Propulsion. Also presented were research results from the Rotorcraft Systems Program and work supported by the NASA Lewis Director's Discretionary Fund. Authors from NASA Lewis Research Center, industry, and universities conducted research in the following areas: material processing, material characterization, modeling, life, applied life models, design techniques, vibration control, mechanical components, and tribology. Key issues, research accomplishments, and future directions are summarized in this publication.

Source record↗

Situation Awareness of Onboard System Autonomy

We have developed intelligent agent software for onboard system autonomy. Our approach is to provide control agents that automate crew and vehicle systems, and operations assistants that aid humans in working with these autonomous systems. We use the 3 Tier control architecture to develop the control agent software that automates system reconfiguration and routine fault management. We use the Distributed Collaboration and Interaction (DCI) System to develop the operations assistants that provide human services, including situation summarization, event notification, activity management, and support for manual commanding of autonomous system. In this paper we describe how the operations assistants aid situation awareness of the autonomous control agents. We also describe our evaluation of the DCI System to support control engineers during a ground test at Johnson Space Center (JSC) of the Post Processing System (PPS) for regenerative water recovery.

Schreckenghost, Debra↗

Thermal system engineering experiment

The technical feasibility of a solar thermal collector to provide process steam in an industrial environment was determined. The form of the experiment was an industrial field test.

Source record↗

Modular digital holographic fringe data processing system

A software architecture suitable for reducing holographic fringe data into useful engineering data is developed and tested. The results, along with a detailed description of the proposed architecture for a Modular Digital Fringe Analysis System, are presented.

Downward, J. G.↗

Design and Data Management System

The Design and Data Management System (DDMS) was developed to automate the NASA Engineering Order (EO) and Engineering Change Request (ECR) processes at the Propulsion Test Facilities at Stennis Space Center for efficient and effective Configuration Management (CM). Prior to the development of DDMS, the CM system was a manual, paper-based system that required an EO or ECR submitter to walk the changes through the acceptance process to obtain necessary approval signatures. This approval process could take up to two weeks, and was subject to a variety of human errors. The process also requires that the CM office make copies and distribute them to the Configuration Control Board members for review prior to meetings. At any point, there was a potential for an error or loss of the change records, meaning the configuration of record was not accurate. The new Web-based DDMS eliminates unnecessary copies, reduces the time needed to distribute the paperwork, reduces time to gain the necessary signatures, and prevents the variety of errors inherent in the previous manual system. After implementation of the DDMS, all EOs and ECRs can be automatically checked prior to submittal to ensure that the documentation is complete and accurate. Much of the configuration information can be documented in the DDMS through pull-down forms to ensure consistent entries by the engineers and technicians in the field. The software also can electronically route the documents through the signature process to obtain the necessary approvals needed for work authorization. The workflow of the system allows for backups and timestamps that determine the correct routing and completion of all required authorizations in a more timely manner, as well as assuring the quality and accuracy of the configuration documents.

Messer, Elizabeth↗

Thermophysical and Thermomechanical Properties of Thermal Barrier Coating Systems

Thermal barrier coatings have been developed for advanced gas turbine and diesel engine applications to improve engine reliability and fuel efficiency. However, the issue of coating durability under high temperature cyclic conditions is still of major concern. The coating failure is closely related to thermal stresses and oxidation in the coating systems. Coating shrinkage cracking resulting from ceramic sintering and creep at high temperatures can further accelerate the coating failure process. The purpose of this paper is to address critical issues such as ceramic sintering and creep, thermal fatigue and their relevance to coating life prediction. Novel test approaches have been established to obtain critical thermophysical and thermomechanical properties of the coating systems under near-realistic temperature and stress gradients encountered in advanced engine systems. Emphasis is placed on the dynamic changes of the coating thermal conductivity and elastic modulus, fatigue and creep interactions, and resulting failure mechanisms during the simulated engine tests. Detailed experimental and modeling results describing processes occurring in the thermal barrier coating systems provide a framework for developing strategies to manage ceramic coating architecture, microstructure and properties.

Zhu, Dongming↗

The Vehicle Integrated Performance Analysis Experience: Reconnecting With Technical Integration

Very early in the Space Launch Initiative program, a small team of engineers at MSFC proposed a process for performing system-level assessments of a launch vehicle. Aimed primarily at providing insight and making NASA a smart buyer, the Vehicle Integrated Performance Analysis (VIPA) team was created. The difference between the VIPA effort and previous integration attempts is that VIPA a process using experienced people from various disciplines, which focuses them on a technically integrated assessment. The foundations of VIPA s process are described. The VIPA team also recognized the need to target early detailed analysis toward identifying significant systems issues. This process is driven by the T-model for technical integration. VIPA s approach to performing system-level technical integration is discussed in detail. The VIPA process significantly enhances the development and monitoring of realizable project requirements. VIPA s assessment validates the concept s stated performance, identifies significant issues either with the concept or the requirements, and then reintegrates these issues to determine impacts. This process is discussed along with a description of how it may be integrated into a program s insight and review process. The VIPA process has gained favor with both engineering and project organizations for being responsive and insightful

McGhee, D. S.↗

PSL Icing Facility Upgrade Overview

The NASA Glenn Research Center Propulsion Systems Lab (PSL) was recently upgraded to perform engine inlet ice crystal testing in an altitude environment. The system installed 10 spray bars in the inlet plenum for ice crystal generation using 222 spray nozzles. As an altitude test chamber, the PSL is capable of simulating icing events at altitude in a groundtest facility. The system was designed to operate at altitudes from 4,000 to 40,000 ft at Mach numbers up to 0.8M and inlet total temperatures from -60 to +15 degF. This paper and presentation will be part of a series of presentations on PSL Icing and will cover the development of the icing capability through design, developmental testing, installation, initial calibration, and validation engine testing. Information will be presented on the design criteria and process, spray bar developmental testing at Cox and Co., system capabilities, and initial calibration and engine validation test. The PSL icing system was designed to provide NASA and the icing community with a facility that could be used for research studies of engine icing by duplicating in-flight events in a controlled ground-test facility. With the system and the altitude chamber we can produce flight conditions and cloud environments to simulate those encountered in flight. The icing system can be controlled to set various cloud uniformities, droplet median volumetric diameter (MVD), and icing water content (IWC) through a wide variety of conditions. The PSL chamber can set altitudes, Mach numbers, and temperatures of interest to the icing community and also has the instrumentation capability of measuring engine performance during icing testing. PSL last year completed the calibration and initial engine validation of the facility utilizing a Honeywell ALF502-R5 engine and has duplicated in-flight roll back conditions experienced during flight testing. This paper will summarize the modifications and buildup of the facility to accomplish these tests.

Griffin, Thomas A.↗

The Application of V&V within Reuse-Based Software Engineering

Verification and Validation (V&V) is performed during application development for many systems, especially safety-critical and mission-critical systems. The V&V process is intended to discover errors as early as possible during the development process. Early discovery is important in order to minimize the cost and other impacts of correcting these errors. In reuse-based software engineering, decisions on the requirements, design and even implementation of domain assets can can be made prior to beginning development of a specific system. in order to bring the effectiveness of V&V to bear within reuse-based software engineering. V&V must be incorporated within the domain engineering process.

Addy, Edward↗

Rocket engine nozzle photographic system

Protective enclosure for a camera, located on the exhaust stream of a rocket engine, permits continuous recording of erosion processes of materials used in nozzle throat structures. The system uses a standard camera in a water-cooled, pressurized enclosure having a unique, inert gas-swept viewing duct.

Bailey, R. L.↗

Lean Model-Based Systems Engineering on the NASA High-Density Vertiplex Subproject

The High Density Vertiplex (HDV) subproject of NASA’s Advanced Air Mobility (AAM) project adopted Model-Based Systems Engineering (MBSE) in July of 2020, prior to subproject formulation. A small and lean team of HDV Systems Engineers (SE) are utilizing MagicDraw to execute NASA SE processes via MBSE. The SEs learned how to use MagicDraw from scratch and HDV is the first project for which the SEs have utilized MagicDraw. This presentation will demonstrate project technical execution via MBSE, utilizing the digital elements built into the SysML (Systems Modeling Language). SysML provides a model-centric means of carrying out the NASA SE common technical processes by providing tools for complete system modeling, including requirements and interface management and design capture. The authors also leverage and extend SysML to perform other SE tasks, such as Verification and Validation (V&V) tracking. MBSE has two main purposes for HDV: 1) documenting the subproject’s logical architecture for distribution outside of the subproject, 2) capturing the subproject’s physical architecture in a single-source-of-truth for use by the subproject’s members. This presentation details the challenges, lessons learned, and solutions that were encountered in implementing MBSE in the first iteration on a multi-iteration, full-lifecycle design, build, fly project.

systems engineering↗

NSTAR Ion Propulsion System Power Electronics

The NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) program, managed by the Jet Propulsion Laboratory (JPL), is currently developing a high performance, simplified ion propulsion system. This propulsion system, which is throttleable from 0.5- to 2.3-kW output power to the thruster, targets primary propulsion applications for planetary and Earth-space missions and has been baselined as the primary propulsion system for the first New Millennium spacecraft. The NASA Lewis Research Center is responsible for the design and delivery of a breadboard power processing unit (PPU) and an engineering model thruster (EMT) for this system and will manage the contract for the delivery of the flight hardware to JPL. The PPU requirements, which dictate a mass of less than 12 kg with an efficiency of 0.9 or greater at a 2.3-kW output, forced a departure from the state-of-the-art ion thruster PPU design. Several innovations--including dual-use topologies, simplified thruster control, and the use of ferrite magnetic materials--were necessary to meet these requirements.

Source record↗

Achieving Maximum Integration Utilizing Requirements Flow Down

A robust and experienced systems engineering team is essential for a successful program. It is often a challenge to build a core systems engineering team early enough in a program to maximize integration and assure a common path for all supporting teams in a project. Ares I was no exception. During the planning of IVGVT, the team had many challenges including lack of: early identification of stakeholders, team training in NASA s system engineering practices, solid requirements flow down and a top down documentation strategy. The IVGVT team started test planning early in the program before the systems engineering framework had been matured due to an aggressive schedule. Therefore the IVGVT team increased their involvement in the Constellation systems engineering effort. Program level requirements were established that flowed down to IVGVT aligning all stakeholders to a common set of goals. The IVGVT team utilized the APPEL REQ Development Management course providing the team a NASA focused model to follow. The IVGVT team engaged directly with the model verification and validation process to assure that a solid set of requirements drove the need for the test event. The IVGVT team looked at the initial planning state, analyzed the current state and then produced recommendations for the ideal future state of a wide range of systems engineering functions and processes. Based on this analysis, the IVGVT team was able to produce a set of lessons learned and to provide suggestions for future programs or tests to use in their initial planning phase.

Archiable, Wes↗