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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Thick thermal barrier coatings for diesel engines

Caterpillar's approach to applying Thick Thermal Barrier Coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective of Caterpillar's subcontract with ORNL is to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impede the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Beardsley, M. B.↗
NASA NTRS1995

Thick thermal barrier coatings for diesel engines

Caterpillar's approach to applying thick thermal barrier coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective Caterpillar's program to date has been to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impeded the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Beardsley, M. Brad↗
NASA NTRS1989

Iterative procedures for space shuttle main engine performance models

Performance models of the Space Shuttle Main Engine (SSME) contain iterative strategies for determining approximate solutions to nonlinear equations reflecting fundamental mass, energy, and pressure balances within engine flow systems. Both univariate and multivariate Newton-Raphson algorithms are employed in the current version of the engine Test Information Program (TIP). Computational efficiency and reliability of these procedures is examined. A modified trust region form of the multivariate Newton-Raphson method is implemented and shown to be superior for off nominal engine performance predictions. A heuristic form of Broyden's Rank One method is also tested and favorable results based on this algorithm are presented.

Santi, L. Michael↗
NASA NTRS1992

Feasibility of magnetic bearings for advanced gas turbine engines

The application of active magnetic bearings to advanced gas turbine engines will provide a product with major improvements compared to current oil lubricated bearing designs. A rethinking of the engine rotating and static structure design is necessary and will provide the designer with significantly more freedom to meet the demanding goals of improved performance, increased durability, higher reliability, and increased thrust to weight ratio via engine weight reduction. The product specific technology necessary for this high speed, high temperature, dynamically complex application has been defined. The resulting benefits from this approach to aircraft engine rotor support and the complementary engine changes and improvements have been assessed.

Hibner, David↗
NASA NTRS1994

Advanced diesel engine component development program, tasks 4-14

This report summarizes the Advanced Diesel Engine Component Development (ADECD) Program to develop and demonstrate critical technology needed to advance the heavy-duty low heat rejection engine concept. Major development activities reported are the design, analysis, and fabrication of monolithic ceramic components; vapor phase and solid film lubrication; electrohydraulic valve actuation; and high pressure common rail injection. An advanced single cylinder test bed was fabricated as a laboratory tool in studying these advanced technologies. This test bed simulates the reciprocator for a system having no cooling system, turbo compounding, Rankine bottoming cycle, common rail injection, and variable valve actuation to achieve fuel consumption of 160 g/kW-hr (.26 lb/hp-hr). The advanced concepts were successfully integrated into the test engine. All ceramic components met their functional and reliability requirements. The firedeck, cast-in-place ports, valves, valve guides, piston cap, and piston ring were made from silicon nitride. Breakthroughs required to implement a 'ceramic' engine included the fabrication of air-gap cylinder heads, elimination of compression gaskets, machining of ceramic valve seats within the ceramic firedeck, fabrication of cast-in-place ceramic port liners, implementation of vapor phase lubrication, and elimination of the engine coolant system. Silicon nitride valves were successfully developed to meet several production abuse test requirements and incorporated into the test bed with a ceramic valve guide and solid film lubrication. The ADECD cylinder head features ceramic port shields to increase insulation and exhaust energy recovery. The combustion chamber includes a ceramic firedeck and piston cap. The tribological challenge posed by top ring reversal temperatures of 550 C was met through the development of vapor phase lubrication using tricresyl phosphate at the ring-liner interface. A solenoid-controlled, variable valve actuation system that eliminated the conventional camshaft was demonstrated on the test bed. High pressure fuel injection via a common rail system was also developed to reduce particulate emissions.

Kaushal, Tony S.↗
NASA NTRS2019

Model Based Engineering for Software Assurance

NASA's successful development of next generation space vehicles, habitats, and robotic systems will require reliable hardware and software systems. The aim of this initiative is to develop modeling methodology and tools to support Model-Based Systems Engineering (MBSE) for software assurance and reliability analysis. This effort expands the Unified Modeling Language (UML) software design models to include fault data for the extraction of Failure Modes and Effects Criticality Analysis (FMECA) and Fault Tree Analysis (FTA) for software. We explored different modeling approaches to integrate the UML software design models with the Systems Modeling Language (SysML) system models to generate an integrated model and reliability tools that take into account software and hardware interfaces.The benefits of this concept directly affect the safety community with quick turnarounds to produce software assurance and reliability analysis artifacts and the ability to visualize failure effects, both hardware and software. The result is enhanced system design integrity and early identification of system risks. This initiative will enable software assurance activities early in the system design lifecycle, facilitating the discovery of design weaknesses and enhancing the capability to produce safe, hazard-free systems

Wang, Lui↗
NASA NTRS2008

Development Status of the CECE Cryogenic Deep Throttling Demonstrator Engine

As one of the first technology development programs awarded by NASA under the U.S. Space Exploration Policy (USSEP), the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA's Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RLI0, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy, cryogenic engine. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Two series of demonstrator engine tests, the first in April-May 2006 and the second in March-April 2007, have demonstrated in excess of 10:1 throttling of the hydrogen/oxygen expander cycle engine. Both test series have explored a combustion instability ("chug") environment at low throttled power levels. These tests have provided an early demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future CECE Demonstrator engine tests.

Source record↗
NASA NTRS1997

Rocket Ejector Studies for Application to RBCC Engines: An Integrated Experimental/CFD Approach

Recent interest in low cost, reliable access to space has generated increased interest in advanced technology approaches to space transportation systems. A key to the success of such programs lies in the development of advanced propulsion systems capable of achieving the performance and operations goals required for the next generation of space vehicles. One extremely promising approach involves the combination of rocket and air- breathing engines into a rocket-based combined-cycle engine (RBCC). A key element of that engine is the rocket ejector which is utilized in the zero to Mach two operating regime. Studies of RBCC engine concepts are not new and studies dating back thirty years are well documented in the literature. However, studies focused on the rocket ejector mode of the RBCC cycle are lacking. The present investigation utilizes an integrated experimental and computation fluid dynamics (CFD) approach to examine critical rocket ejector performance issues. In particular, the development of a predictive methodology capable of performance prediction is a key objective in order to analyze thermal choking and its control, primary/secondary pressure matching considerations, and effects of nozzle expansion ratio. To achieve this objective, the present study emphasizes obtaining new data using advanced optical diagnostics such as Raman spectroscopy and CFD techniques to investigate mixing in the rocket ejector mode. A new research facility for the study of the rocket ejector mode is described along with the diagnostic approaches to be used. The CFD modeling approach is also described along with preliminary CFD predictions obtained to date.

Pal, S.↗
NASA NTRS1988

Prototype thin-film thermocouple/heat-flux sensor for a ceramic-insulated diesel engine

A platinum versus platinum-13 percent rhodium thin-film thermocouple/heat-flux sensor was devised and tested in the harsh, high-temperature environment of a ceramic-insulated, low-heat-rejection diesel engine. The sensor probe assembly was developed to provide experimental validation of heat transfer and thermal analysis methodologies applicable to the insulated diesel engine concept. The thin-film thermocouple configuration was chosen to approximate an uninterrupted chamber surface and provide a 1-D heat-flux path through the probe body. The engine test was conducted by Purdue University for Integral Technologies, Inc., under a DOE-funded contract managed by NASA Lewis Research Center. The thin-film sensor performed reliably during 6 to 10 hr of repeated engine runs at indicated mean surface temperatures up to 950 K. However, the sensor suffered partial loss of adhesion in the thin-film thermocouple junction area following maximum cyclic temperature excursions to greater than 1150 K.

Kim, Walter S.↗
NASA NTRS1985

Energy Efficient Engine integrated core/low spool design and performance report

The Energy Efficient Engine (E3) is a NASA program to create fuel saving technology for future transport aircraft engines. The E3 technology advancements were demonstrated to operate reliably and achieve goal performance in tests of the Integrated Core/Low Spool vehicle. The first build of this undeveloped technology research engine set a record for low fuel consumption. Its design and detailed test results are herein presented.

Stearns, E. Marshall↗
NASA NTRS1994

Pip pin reliability and design

Pip pins are used in many engineering applications. Of particular interest to the aerospace industry is their use in various mechanism designs. Many payloads that fly aboard our nation's Space Shuttle have at least one actuated mechanism. Often these mechanisms incorporate pip pins in their design in order to fasten interfacing parts or joints. Pip pins are most often used when an astronaut will have a direct interface with the mechanism. This interfacing can be done during Space Shuttle mission EVA's (ExtraVehicular Activity). The main reason for incorporating pip pins is convenience and their ability to provide a quick release for interfacing parts. However, there are some issues that must be taken into account when using them in a design. These issues include documented failures and quality control problems when using substandard pip pins. A history of pip pins as they relate to the aerospace industry as well as general design features is discussed.

Skyles, Lane P.↗
NASA NTRS2001

Probabilistic Structural Analysis and Reliability Using NESSUS With Implemented Material Strength Degradation Model

This project included both research and education objectives. The goal of this project was to advance innovative research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction for improved reliability and safety of structural components of aerospace and aircraft propulsion systems. Research and education partners included Glenn Research Center (GRC) and Southwest Research Institute (SwRI) along with the University of Texas at San Antonio (UTSA). SwRI enhanced the NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) code and provided consulting support for NESSUS-related activities at UTSA. NASA funding supported three undergraduate students, two graduate students, a summer course instructor and the Principal Investigator. Matching funds from UTSA provided for the purchase of additional equipment for the enhancement of the Advanced Interactive Computational SGI Lab established during the first year of this Partnership Award to conduct the probabilistic finite element summer courses. The research portion of this report presents the cumulation of work performed through the use of the probabilistic finite element program, NESSUS, Numerical Evaluation and Structures Under Stress, and an embedded Material Strength Degradation (MSD) model. Probabilistic structural analysis provided for quantification of uncertainties associated with the design, thus enabling increased system performance and reliability. The structure examined was a Space Shuttle Main Engine (SSME) fuel turbopump blade. The blade material analyzed was Inconel 718, since the MSD model was previously calibrated for this material. Reliability analysis encompassing the effects of high temperature and high cycle fatigue, yielded a reliability value of 0.99978 using a fully correlated random field for the blade thickness. The reliability did not change significantly for a change in distribution type except for a change in distribution from Gaussian to Weibull for the centrifugal load. The sensitivity factors determined to be most dominant were the centrifugal loading and the initial strength of the material. These two sensitivity factors were influenced most by a change in distribution type from Gaussian to Weibull. The education portion of this report describes short-term and long-term educational objectives. Such objectives serve to integrate research and education components of this project resulting in opportunities for ethnic minority students, principally Hispanic. The primary vehicle to facilitate such integration was the teaching of two probabilistic finite element method courses to undergraduate engineering students in the summers of 1998 and 1999.

Bast, Callie C.↗
NASA NTRS1984

Aerojet advanced engine concept

The future orbit transfer vehicle (OTV) requirements which dictate the need for a highly versatile, highly reliable, reusable propulsion module are discussed. To attain maximum operational economy, space-basing is essential. This requires a reusable, maintenance free engine. The design features of this space based engine are defined. A new engine cycle and its advantages allow all the maintenance goals to be attained. Rubbing contact and interpropellant seals and purges are eliminated when GO2 is used to drive the LO2 pump. The TPA design has only one moving part. The use of both GH2 and GO2 to drive the turbines lowers the turbine temperatures in addition lower GH2 temperatures and pressures improve chamber cooling and longer life. The use of GO2 as a turbine drive fluid is addressed. Space based engines require an integrated control and health monitoring system to improve system reliability and eliminate all scheduled maintenance. It is concluded that all OTV propulsion requirements can be fulfilled with a single engine. The technological developments required to demonstrate that engine are outlined.

Schoenman, L.↗
NASA NTRS1972

Space shuttle orbit maneuvering engine reusable thrust chamber

A data dump is presented containing space shuttle orbiter maneuvering engine performance, weight, envelope, and interface pressure requirements for candidate propellant combinations (NTO/MMH, NTO50-50, LOX/MMH, LOX/50-50, LOX/N2H4, LOX/C3H8, and LOX/RP-1) and cooling concepts (regenerative and dump/film). These data are presented parametrically for the thrust, chamber pressure, nozzle expansion ratio, and engine mixture ratio ranges of interest. Also included is information describing sensitivity to system changes; reliability, maintainability and safety; development programs and associated critical technology areas; engine cost comparisons during development and operation; and ecological effects.

Source record↗
NASA NTRS1991

Reliable fusion of control and sensing in intelligent machines

Although robotics research has produced a wealth of sophisticated control and sensing algorithms, very little research has been aimed at reliably combining these control and sensing strategies so that a specific task can be executed. To improve the reliability of robotic systems, analytic techniques are developed for calculating the probability that a particular combination of control and sensing algorithms will satisfy the required specifications. The probability can then be used to assess the reliability of the design. An entropy formulation is first used to quickly eliminate designs not capable of meeting the specifications. Next, a framework for analyzing reliability based on the first order second moment methods of structural engineering is proposed. To ensure performance over an interval of time, lower bounds on the reliability of meeting a set of quadratic specifications with a Gaussian discrete time invariant control system are derived. A case study analyzing visual positioning in robotic system is considered. The reliability of meeting timing and positioning specifications in the presence of camera pixel truncation, forward and inverse kinematic errors, and Gaussian joint measurement noise is determined. This information is used to select a visual sensing strategy, a kinematic algorithm, and a discrete compensator capable of accomplishing the desired task. Simulation results using PUMA 560 kinematic and dynamic characteristics are presented.

Mcinroy, John E.↗
NASA NTRS1994

Hydrogen-oxygen Torch Ignitor

The hydrogen-oxygen torch igniter described herein has been successfully used for many years at various NASA Lewis Research Center rocket test facilities to provide ignition for rocket engine research hardware. This igniter is inexpensive, simple to operate, and has demonstrated very good reliability. It has been used as an ignition source for rocket engines that utilized a variety of propellant combinations; some of these engines developed up to 40,000 lb of thrust.

Repas, George A.↗
NASA NTRS1992

Computational fluid dynamic design of rocket engine pump components

Integration of computational fluid dynamics (CFD) for design and analysis of turbomachinery components is needed as the requirements of pump performance and reliability become more stringent for the new generation of rocket engine. A fast grid generator, designed specially for centrifugal pump impeller, which allows a turbomachinery designer to use CFD to optimize the component design will be presented. The CFD grid is directly generated from the impeller blade G-H blade coordinates. The grid points are first generated on the meridional plane with the desired clustering near the end walls. This is followed by the marching of grid points from the pressure side of one blade to the suction side of a neighboring blade. This fast grid generator has been used to optimize the consortium pump impeller design. A grid dependency study has been conducted for the consortium pump impeller. Two different grid sizes, one with 10,000 grid points and one with 80,000 grid points were used for the grid dependency study. The effects of grid resolution on the turnaround time, including the grid generation and completion of the CFD analysis, is discussed. The impeller overall mass average performance is compared for different designs. Optimum design is achieved through systematic change of the design parameters. In conclusion, it is demonstrated that CFD can be effectively used not only for flow analysis but also for design and optimization of turbomachinery components.

Chen, Wei-Chung↗