Design, manufacture, development, test, and evaluation of boron/aluminum structural components for space shuttle. Volume 2: Materials and processing
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Miller, M. F.↗
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NASA's Aero-Space Technology
This presentation reviews the three pillars and the associated goals of NASA's Aero-Space Technology Enterprise. The three pillars for success are: (1) Global Civil Aviation, (2) Revolutionary Technology Leaps, (3) Advanced Space Transportation. The associated goals of the first pillar are to reduce accidents, emissions, and cost, and to increase the aviation system capacity. The goals of the second pillar are to reduce transoceanic travel time, revolutionize general aviation aircraft, and improve development capacity. The goals associated with the third pillar are to reduce the launch cost for low earth orbit and to reduce travel time for planetary missions. In order to meet these goals NASA must provide next-generation design capability for new and or experimental craft which enable a balance between reducing components of the design cycle by up to 50% and or increasing the confidence in design by 50%. These next-generation design tools, concepts, and processes will revolutionize vehicle development. The presentation finally reviews the importance of modeling and simulation in achieving the goals.
Milstead, Phil↗
NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies
Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.
Filament Wound↗
Configurable Multi-Purpose Processor
Advancements in technology have allowed the miniaturization of systems used in aerospace vehicles. This technology is driven by the need for next-generation systems that provide reliable, responsive, and cost-effective range operations while providing increased capabilities such as simultaneous mission support, increased launch trajectories, improved launch, and landing opportunities, etc. Leveraging the newest technologies, the command and telemetry processor (CTP) concept provides for a compact, flexible, and integrated solution for flight command and telemetry systems and range systems. The CTP is a relatively small circuit board that serves as a processing platform for high dynamic, high vibration environments. The CTP can be reconfigured and reprogrammed, allowing it to be adapted for many different applications. The design is centered around a configurable field-programmable gate array (FPGA) device that contains numerous logic cells that can be used to implement traditional integrated circuits. The FPGA contains two PowerPC processors running the Vx-Works real-time operating system and are used to execute software programs specific to each application. The CTP was designed and developed specifically to provide telemetry functions; namely, the command processing, telemetry processing, and GPS metric tracking of a flight vehicle. However, it can be used as a general-purpose processor board to perform numerous functions implemented in either hardware or software using the FPGA s processors and/or logic cells. Functionally, the CTP was designed for range safety applications where it would ultimately become part of a vehicle s flight termination system. Consequently, the major functions of the CTP are to perform the forward link command processing, GPS metric tracking, return link telemetry data processing, error detection and correction, data encryption/ decryption, and initiate flight termination action commands. Also, the CTP had to be designed to survive and operate in a launch environment. Additionally, the CTP was designed to interface with the WFF (Wallops Flight Facility) custom-designed transceiver board which is used in the Low Cost TDRSS Transceiver (LCT2) also developed by WFF. The LCT2 s transceiver board demodulates commands received from the ground via the forward link and sends them to the CTP, where they are processed. The CTP inputs and processes data from the inertial measurement unit (IMU) and the GPS receiver board, generates status data, and then sends the data to the transceiver board where it is modulated and sent to the ground via the return link. Overall, the CTP has combined processing with the ability to interface to a GPS receiver, an IMU, and a pulse code modulation (PCM) communication link, while providing the capability to support common interfaces including Ethernet and serial interfaces boarding a relatively small-sized, lightweight package.
Valencia, J. Emilio↗
Altair Lander Life Support: Design Analysis Cycles 1, 2, and 3
NASA is working to develop a new lunar lander to support lunar exploration. The development process that the Altair project is using for this vehicle is unlike most others. In Lander Design Analysis Cycle 1 (LDAC-1), a single-string, minimum functionality design concept was developed, including life support systems for different vehicle configuration concepts, first for a combination of an ascent vehicle and a habitat with integral airlocks, and then for a combined ascent vehicle-habitat with a detachable airlock. In LDAC-2, the Altair team took the ascent vehicle-habitat with detachable airlock and analyzed the design for the components that were the largest contributors to the risk of loss of crew (LOC). For life support, the largest drivers were related to oxygen supply and carbon dioxide control. Integrated abort options were developed at the vehicle level. Many life support failures were not considered to result in LOC because they had a long enough time to effect that abort was considered a feasible option to safely end the mission before the situation became life threatening. These failures were then classified as loss of mission (LOM) failures. Many options to reduce LOC risk were considered, and mass efficient solutions to the LOC problems were added to the vehicle design at the end of LDAC-2. In LDAC-3, the new design was analyzed for large contributors to the risk of LOM. To avoid ending the mission early or being unable to accomplish goals like performing all planned extravehicular activities (EVAs), various options were assessed for their combination of risk reduction and mass cost. This paper outlines the major assumptions, design features, and decisions related to the development of the life support system for the Altair project through LDAC-3.
Anderson, Molly↗
Identification of multivariable high-performance turbofan engine dynamics from closed loop data
A typical engine control design cycle consists of developing a dynamic engine simulation from steady-state component performance data, designing a control based upon this simulation, and then testing and modifying the control in an engine test cell to meet performance requirements. This design cycle was successful for state-of-the-art engines. However, for more advanced multivariable engines that exhibit strong variable interactions, this procedure will result in substantial trial and error modification of the control during the testing phase. One method to automate the design process and reduce control modification testing and development cost would be to identify accurate dynamic models directly from the closed-loop test data. These identified models would then be used in conjunction with a synthesis procedure to systematically refine the control. Recent advances in closed-loop identifiability present a methodology for this direct identification of engine model dynamics from closed-loop test data. The application of an identification method to simulated and actual closed-loop F100 engine data is described. This study was undertaken to determine if useful dynamic engine models could be identified directly from closed-loop engine test data.
Merrill, W. C.↗
STAEBL: Structural tailoring of engine blades, phase 2
The Structural Tailoring of Engine Blades (STAEBL) program was initiated at NASA Lewis Research Center in 1980 to introduce optimal structural tailoring into the design process for aircraft gas turbine engine blades. The standard procedure for blade design is highly iterative with the engineer directly providing most of the decisions that control the design process. The goal of the STAEBL program has been to develop an automated approach to generate structurally optimal blade designs. The program has evolved as a three-phase effort with the developmental work being performed contractually by Pratt & Whitney Aircraft. Phase 1 was intended as a proof of concept in which two fan blades were structurally tailored to meet a full set of structural design constraints while minimizing DOC+I (direct operating cost plus interest) for a representative aircraft. This phase was successfully completed and was reported in reference 1 and 2. Phase 2 has recently been completed and is the basis for this discussion. During this phase, three tasks were accomplished: (1) a nonproprietary structural tailoring computer code was developed; (2) a dedicated approximate finite-element analysis was developed; and (3) an approximate large-deflection analysis was developed to assess local foreign object damage. Phase 3 is just beginning and is designed to incorporated aerodynamic analyses directly into the structural tailoring system in order to relax current geometric constraints.
Hirschbein, M. S.↗
Effect of Electron Beam Freeform Fabrication (EBF3) Processing Parameters on Composition of Ti-6-4
The Electron Beam Freeform Fabrication (EBF3) process developed at NASA Langley Research Center was evaluated using a design of experiments approach to determine the effect of processing parameters on the composition and geometry of Ti-6-4 deposits. The effects of three processing parameters: beam power, translation speed, and wire feed rate, were investigated by varying one while keeping the remaining parameters constant. A three-factorial, three-level, fully balanced mutually orthogonal array (L27) design of experiments approach was used to examine the effects of low, medium, and high settings for the processing parameters on the chemistry, geometry, and quality of the resulting deposits. Single bead high deposits were fabricated and evaluated for 27 experimental conditions. Loss of aluminum in Ti-6-4 was observed in EBF3 processing due to selective vaporization of the aluminum from the sustained molten pool in the vacuum environment; therefore, the chemistries of the deposits were measured and compared with the composition of the initial wire and base plate to determine if the loss of aluminum could be minimized through careful selection of processing parameters. The influence of processing parameters and coupling between these parameters on bulk composition, measured by Direct Current Plasma (DCP), local microchemistries determined by Wavelength Dispersive Spectrometry (WDS), and deposit geometry will also be discussed.
Lach, Cynthia L.↗
Towards a New Food System Assessment: AgMIP Coordinated Global and Regional Assessments of Climate Change
Agricultural stakeholders need more credible information on which to base adaptation and mitigation policy decisions. In order to provide this, we must improve the rigor of agricultural modelling. Ensemble approaches can be used to address scale issues and integrated teams can overcome disciplinary silos. The AgMIP Coordinated Global and Regional Assessments of Climate Change and Food Security (CGRA) has the goal to link agricultural systems models using common protocols and scenarios to significantly improve understanding of climate effects on crops, livestock and livelihoods across multiple scales. The AgMIP CGRA assessment brings together experts in climate, crop, livestock, economics, and food security to develop Protocols to guide the process throughout the assessment. Scenarios are designed to consistently combine elements of intertwined storylines of future society including, socioeconomic development, greenhouse gas concentrations, and specific pathways of agricultural sector development. Through these approaches, AgMIP partners around the world are providing an evidence base for their stakeholders as they make decisions and investments.
Ensembles↗
Low-Mass, Low-Power Hall Thruster System
NASA is developing an electric propulsion system capable of producing 20 mN thrust with input power up to 1,000 W and specific impulse ranging from 1,600 to 3,500 seconds. The key technical challenge is the target mass of 1 kg for the thruster and 2 kg for the power processing unit (PPU). In Phase I, Busek Company, Inc., developed an overall subsystem design for the thruster/cathode, PPU, and xenon feed system. This project demonstrated the feasibility of a low-mass power processing architecture that replaces four of the DC-DC converters of a typical PPU with a single multifunctional converter and a low-mass Hall thruster design employing permanent magnets. In Phase II, the team developed an engineering prototype model of its low-mass BHT-600 Hall thruster system, with the primary focus on the low-mass PPU and thruster. The goal was to develop an electric propulsion thruster with the appropriate specific impulse and propellant throughput to enable radioisotope electric propulsion (REP). This is important because REP offers the benefits of nuclear electric propulsion without the need for an excessively large spacecraft and power system.
Pote, Bruce↗
Improving Reliability and Maintainability (R&M) in Space Life Support
This paper considers how to improve the reliability and maintainability (R&M) of future NASA space life support systems. If these systems are procured under an industry contract, defining the R&M requirements would take precedence over providing technical guidance on designing the system. Imposing a specific R&M design could be over constraining. However, the mission may define the overall R&M approach, as the International Space Station (ISS) did by requiring Orbital Replacement Units (ORUs). Before defining the R&M requirements for the next mission, the life support research program should understand and plan the R&M approach. The recent NASA technical standard on R&M has moved away from requiring specific R&M activities during each of the traditional project phases to instead developing and planning to implement the R&M requirements to meet the top level project R&M objectives. The emphasis is on providing the evidence to show that the R&M requirements are met, rather than on conducting specific prescribed R&M activities. The technical standard on R&M defines a comprehensive hierarchy of specific R&M objectives and identifies particular strategies to implement them at each level. That is, the top level R&M objective is defined and then one or more design strategies to implement it are developed immediately, before the next lower objectives are defined and the strategies to achieve those are designed. This step-by-step, top-down approach is similar to the axiomatic design method. The objectives are the R&M requirements, and the strategies are the hardware designs or operations plans developed to meet these requirements. The new R&M process is aligned with the systems design process and helps ensure that the methods to meet the R&M requirements are built into the design.
Jones, Harry W.↗
Expert systems for superalloy studies
There are many areas in science and engineering which require knowledge of an extremely complex foundation of experimental results in order to design methodologies for developing new materials or products. Superalloys are an area which fit well into this discussion in the sense that they are complex combinations of elements which exhibit certain characteristics. Obviously the use of superalloys in high performance, high temperature systems such as the Space Shuttle Main Engine is of interest to NASA. The superalloy manufacturing process is complex and the implementation of an expert system within the design process requires some thought as to how and where it should be implemented. A major motivation is to develop a methodology to assist metallurgists in the design of superalloy materials using current expert systems technology. Hydrogen embrittlement is disasterous to rocket engines and the heuristics can be very complex. Attacking this problem as one module in the overall design process represents a significant step forward. In order to describe the objectives of the first phase implementation, the expert system was designated Hydrogen Environment Embrittlement Expert System (HEEES).
Workman, Gary L.↗
Development and fabrication of improved power transistor switches
A new class of high-voltage power transistors was achieved by adapting present interdigitated thyristor processing techniques to the fabrication of npn Si transistors. Present devices are 2.3 cm in diameter and have V sub CEO (sus) in the range of 400 to 600V. V sub CEO (sus) = 450V devices were made with an (h sub FE)(I sub C) product of 900A at V sub CE = 2.5V. The electrical performance obtained was consistent with the predictions of an optimum design theory specifically developed for power switching transistors. The device design, wafer processing, and assembly techniques are described. Experimental measurements of the dc characteristics, forward SOA, and switching times are included. A new method of characterizing the switching performance of power transistors is proposed.
Hower, P. L.↗
Design of closed-cycle MHD generator with nonequilibrium ionization and system
A method is developed to include the nonequilibrium ionization process in the MHD generator duct design equations, and these equations are coupled to the thermodynamic conditions of the closed cycle system. This is used to relate MHD generator size, configuration and gas conditions to the overall thermodynamic efficiency of the system. The system studied consists of an MHD loop (Ar + Cs or He + Cs) topping a steam bottoming plant.
Voshall, R. E.↗
Dynamic Analysis of Capture Devices for Momentum Exchange with Tethers
One of the significant challenges in developing a momentum exchange / electrodynamic reboost tether system is in the analysis and design of the capture device and its effects on the overall dynamics of the system. The goal of this work is to develop appropriate tether momentum exchange models that can simulate and evaluate the requirements of such a system, and be used to create specifications on the design of a capture device. This report briefly describes dynamic model development, simulation of the momentum exchange process, evaluation of dynamic effects of errors in the momentum exchange process, and the development of guidelines in selecting dynamic properties in the design of a capture device.
Stephen Canfield↗
Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System (HT-SSEP) to Enable Lower Cost NASA Science Missions
Discusses progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kilograms at a minimum thruster efficiency of 50 percent was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.
Benavides, Gabriel↗
Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions
This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.
Benavides, Gabriel F.↗
Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions
This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.
Benavides, Gabriel F.↗