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NASA NTRS2010

LISA Technology Development and Risk Reduction at NASA

The Laser Interferometer Space Antenna (LISA) is a joint ESA-NASA project to design, build and operate a space-based gravitational wave detector based on a laser interferometer. LISA relies on several technologies that are either new to spaceflight or must perform at levels not previously demonstrated in a spaceflight environment. The ESA-led LISA Pathfinder mission is the main effort to demonstrate LISA technology. NASA also supports complementary ground-based technology development and risk reduction activities. This presentation will report the status of NASA work on micronewton thrusters, the telescope, the optical pointing subsystem and mission formulation. More details on some of these topics will be given in posters. Other talks and posters will describe NASA-supported work on the laser subsystem, the phasemeter, and aspects of the interferometry. Two flight-qualified clusters of four colloid micronewton thrusters, each capable of thrust Levels between 5 and 30 microNewton with a resolution less than 0.l microNewton and a thrust noise less than 0.1 microNewton/vHz (0.001 to 4 Hz), have been integrated onto the LISA Pathfinder spacecraft. The complementary ground-based development focuses on lifetime demonstration. Laboratory verification of failure models and accelerated life tests are just getting started. LISA needs a 40 cm diameter, afocal telescope for beam expansion/reduction that maintains an optical pathlength stability of approximately 1 pm/vHz in an extremely stable thermal environment. A mechanical prototype of a silicon carbide primary-secondary structure has been fabricated for stability testing. Two optical assemblies must point at different distant spacecraft with nanoradian accuracy over approximately 1 degree annual variation in the angle between the distant spacecraft. A candidate piezo-inchworm actuator is being tested in a suitable testbed. In addition to technology development, NASA has carried out several studies in support of the mission formulation. The results of systems engineering work on flight software, avionics and reliability will be summarized.

Stebbins, Robin T.↗

NASA NTRS2010

Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS) Independent Design Reliability Assessment

This report documents the activities, findings, and NASA Engineering and Safety Center (NESC) recommendations of a multidiscipline team to independently assess the Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS). This assessment occurred during a period of 15 noncontiguous months between December 2008 and April 2010, prior to the CPAS Project's Preliminary Design Review (PDR) in August 2010.

Kelly, Michael J.↗

NASA NTRS1973

An airline study of advanced technology requirements for advanced high speed commercial transport engines. 2: Engine preliminary design assessment

The advanced technology requirements for an advanced high speed commercial transport engine are presented. The results of the phase 2 study effort cover the following areas: (1) general review of preliminary engine designs suggested for a future aircraft, (2) presentation of a long range view of airline propulsion system objectives and the research programs in noise, pollution, and design which must be undertaken to achieve the goals presented, (3) review of the impact of propulsion system unreliability and unscheduled maintenance on cost of operation, (4) discussion of the reliability and maintainability requirements and guarantees for future engines.

Sallee, G. P.↗

NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗

DOE OSTI2024

Current Practices in Distribution Utility Resilience Planning for Winter Storms

This report is part of a series of hazard-focused case studies examining common practices in electric utility resilience planning. We use standard terminology defining resilience as the ability to anticipate, withstand, absorb, and recover from hazards that cause long duration outages. We distinguish between reliability and resilience using Institute of Electrical and Electronics Engineers (IEEE) 1366-2022, which defines major events as an event that exceeds reasonable design and/or operational limits of the electric power system. Resilience planning is focused on major event days and reliability planning is focused on nonmajor event days. Utility resilience plans are assessed according to common resilience components identified in existing resilience frameworks. The focus of this report is on winter storms in which the primary hazards are heavy snowfall, freezing rain, ice, extreme cold, severe wind, and flooding. These hazards can also contribute to generation shortages, resulting in bulk power system impacts that have consequences for the distribution system, such as load shedding. Stand-alone reports focusing on wildfires and nonwinter storms have been published in parallel with this report. This report can be used as a starting point for understanding potential investment prioritization processes and investment options. This report is intended to improve utility resilience planning by supporting constructive dialogue among utilities, regulators, and other stakeholders.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2024

Fault Diagnosis of Power Components with Reliability Assessment in Extraterrestrial Microgrids

This research investigates the possible failures caused by aging and other environmental and external factors that could significantly impact the performance of extraterrestrial power systems. Additionally, it presents a reliability assessment model for the space microgrid based on fault tree analysis (FTA). The reliability assessment model developed in this paper represents a tool that can be used by engineers to harden the system design for operational and economic benefits. To improve the reliability of the system, this work provides a broad review of the different fault detection and diagnosis (FDD) algorithms used for power microgrids and space applications. Using data sets from the Habitat Simulator developed through the NASA-funded Resilient Extraterrestrial Habitat Institute, this paper compares the applicability and accuracy of the different FDD methods. The primary FDD approach proposed and assessed in this work is based on the Markov reliability model. It predicts and detects future faults in the space microgrids by using past data samples and categorizing them into different classes. Data-driven-based models such as artificial neural networks are also investigated, tested, and evaluated using simulation data sets. According to the simulation results and the broad FDD algorithm comparison, this study provides the crew or maintenance engineers with a clear methodology to detect and localize power system failures.

Leila Chebbo↗

NASA NTRS2006

Advanced Health Management System for the Space Shuttle Main Engine

Pratt & Whitney Rocketdyne, Inc., in cooperation with NASA-Marshall Space Flight Center (MSFC), has developed a new Advanced Health Management System (AHMS) controller for the Space Shuttle Main Engine (SSME) that will increase the probability of successfully placing the shuttle into the intended orbit and increase the safety of the Space Transportation System (STS) launches. The AHMS is an upgrade o the current Block II engine controller whose primary component is an improved vibration monitoring system called the Real-Time Vibration Monitoring System (RTVMS) that can effectively and reliably monitor the state of the high pressure turbomachinery and provide engine protection through a new synchronous vibration redline which enables engine shutdown if the vibration exceeds predetermined thresholds. The introduction of this system required improvements and modification to the Block II controller such as redesigning the Digital Computer Unit (DCU) memory and the Flight Accelerometer Safety Cut-Off System (FASCOS) circuitry, eliminating the existing memory retention batteries, installation of the Digital Signal Processor (DSP) technology, and installation of a High Speed Serial Interface (HSSI) with accompanying outside world connectors. Test stand hot-fire testing along with lab testing have verified successful implementation and is expected to reduce the probability of catastrophic engine failures during the shuttle ascent phase and improve safely by about 23% according to the Quantitative Risk Assessment System (QRAS), leading to a safer and more reliable SSME.

Davidson, Matt↗

NASA NTRS2019

Program Promotion Can Distort Space Systems Engineering and Deny Risk

NASA's spectacular success in the Apollo moon landings was achieved against the odds by an obsessive dedication to reducing the great risk. But risk analysis predicted so many astronaut fatalities that it was thought to be unreasonably pessimistic and potentially damaging to the Apollo program. Risk analysis was discontinued, risk was neglected in space shuttle engineering, and so the space shuttle design was unnecessarily dangerous. Since the Apollo era it has been understood that long human space missions would recycle oxygen and water to avoid the very high launch cost of directly supplying them. The development of recycling systems was justified by the need to increase material closure and reduce launch mass. When it was recognized that increasing closure leads to rapidly diminishing returns, the program goal was changed to reducing launch mass and reliability, cost, and risk were considered irrelevant. Systems engineering and especially the discouraging problems of risk and cost have been deliberately ignored because they detract from program promotion, with unfortunate results. Current human launch system design does account for risk and the result strongly resembles Apollo. Current life support design continues to assume recycling, even though the recent great reduction in launch cost now allows direct supply of oxygen and water with significantly better quality, reliability, cost, and risk.

Advocacy↗

NASA NTRS1973

Apollo experience report: Reliability and quality assurance

The reliability of the Apollo spacecraft resulted from the application of proven reliability and quality techniques and from sound management, engineering, and manufacturing practices. Continual assessment of these techniques and practices was made during the program, and, when deficiencies were detected, adjustments were made and the deficiencies were effectively corrected. The most significant practices, deficiencies, adjustments, and experiences during the Apollo Program are described in this report. These experiences can be helpful in establishing an effective base on which to structure an efficient reliability and quality assurance effort for future space-flight programs.

Sperber, K. P.↗

NASA NTRS1979

Safety considerations in the design and operation of large wind turbines

The engineering and safety techniques used to assure the reliable and safe operation of large wind turbine generators utilizing the Mod 2 Wind Turbine System Program as an example is described. The techniques involve a careful definition of the wind turbine's natural and operating environments, use of proven structural design criteria and analysis techniques, an evaluation of potential failure modes and hazards, and use of a fail safe and redundant component engineering philosophy. The role of an effective quality assurance program, tailored to specific hardware criticality, and the checkout and validation program developed to assure system integrity are described.

Reilly, D. H.↗

NASA NTRS2002

Risk-Based Probabilistic Approach to Aeropropulsion System Assessment

In an era of shrinking development budgets and resources, where there is also an emphasis on reducing the product development cycle, the role of system assessment, performed in the early stages of an engine development program, becomes very critical to the successful development of new aeropropulsion systems. A reliable system assessment not only helps to identify the best propulsion system concept among several candidates, it can also identify which technologies are worth pursuing. This is particularly important for advanced aeropropulsion technology development programs, which require an enormous amount of resources. In the current practice of deterministic, or point-design, approaches, the uncertainties of design variables are either unaccounted for or accounted for by safety factors. This could often result in an assessment with unknown and unquantifiable reliability. Consequently, it would fail to provide additional insight into the risks associated with the new technologies, which are often needed by decision makers to determine the feasibility and return-on-investment of a new aircraft engine. In this work, an alternative approach based on the probabilistic method was described for a comprehensive assessment of an aeropropulsion system. The statistical approach quantifies the design uncertainties inherent in a new aeropropulsion system and their influences on engine performance. Because of this, it enhances the reliability of a system assessment. A technical assessment of a wave-rotor-enhanced gas turbine engine was performed to demonstrate the methodology. The assessment used probability distributions to account for the uncertainties that occur in component efficiencies and flows and in mechanical design variables. The approach taken in this effort was to integrate the thermodynamic cycle analysis embedded in the computer code NEPP (NASA Engine Performance Program) and the engine weight analysis embedded in the computer code WATE (Weight Analysis of Turbine Engines) with the fast probability integration technique (FPI). FPI was developed by Southwest Research Institute under contract with the NASA Glenn Research Center. The results were plotted in the form of cumulative distribution functions and sensitivity analyses and were compared with results from the traditional deterministic approach. The comparison showed that the probabilistic approach provides a more realistic and systematic way to assess an aeropropulsion system. The current work addressed the application of the probabilistic approach to assess specific fuel consumption, engine thrust, and weight. Similarly, the approach can be used to assess other aspects of aeropropulsion system performance, such as cost, acoustic noise, and emissions. Additional information is included in the original extended abstract.

Tong, Michael T.↗

NASA NTRS2012

Requirements Flowdown for Prognostics and Health Management

Prognostics and Health Management (PHM) principles have considerable promise to change the game of lifecycle cost of engineering systems at high safety levels by providing a reliable estimate of future system states. This estimate is a key for planning and decision making in an operational setting. While technology solutions have made considerable advances, the tie-in into the systems engineering process is lagging behind, which delays fielding of PHM-enabled systems. The derivation of specifications from high level requirements for algorithm performance to ensure quality predictions is not well developed. From an engineering perspective some key parameters driving the requirements for prognostics performance include: (1) maximum allowable Probability of Failure (PoF) of the prognostic system to bound the risk of losing an asset, (2) tolerable limits on proactive maintenance to minimize missed opportunity of asset usage, (3) lead time to specify the amount of advanced warning needed for actionable decisions, and (4) required confidence to specify when prognosis is sufficiently good to be used. This paper takes a systems engineering view towards the requirements specification process and presents a method for the flowdown process. A case study based on an electric Unmanned Aerial Vehicle (e-UAV) scenario demonstrates how top level requirements for performance, cost, and safety flow down to the health management level and specify quantitative requirements for prognostic algorithm performance.

video acuity↗

NASA NTRS2011

Uncertainty Quantification and Statistical Engineering for Hypersonic Entry Applications

NASA has invested significant resources in developing and validating a mathematical construct for TPS margin management: a) Tailorable for low/high reliability missions; b) Tailorable for ablative/reusable TPS; c) Uncertainty Quantification and Statistical Engineering are valuable tools not exploited enough; and d) Need to define strategies combining both Theoretical Tools and Experimental Methods. The main reason for this lecture is to give a flavor of where UQ and SE could contribute and hope that the broader community will work with us to improve in these areas.

Cozmuta, Ioana↗

DOE OSTI2026

Assessing and Enabling Trustworthy Predictions for High-Consequence Decisions

Predictions from physics-based computational models provide critical information to inform high consequence decisions, e.g., engineering design decisions. The ability to assess the reliability of such predictions is therefore critical. However, to date, reliability assessment rely heavily on expert judgment and qualitative arguments. This report details the efforts of LDRD 233072 to develop quantitative methods to assess reliability of model predictions, especially in the context of simplifying assumptions that can impact their reliability.

42 ENGINEERING↗

NASA NTRS1980

Orbit transfer vehicle engine study. Volume 2: Technical report

The orbit transfer vehicle (OTV) engine study provided parametric performance, engine programmatic, and cost data on the complete propulsive spectrum that is available for a variety of high energy, space maneuvering missions. Candidate OTV engines from the near term RL 10 (and its derivatives) to advanced high performance expander and staged combustion cycle engines were examined. The RL 10/RL 10 derivative performance, cost and schedule data were updated and provisions defined which would be necessary to accommodate extended low thrust operation. Parametric performance, weight, envelope, and cost data were generated for advanced expander and staged combustion OTV engine concepts. A prepoint design study was conducted to optimize thrust chamber geometry and cooling, engine cycle variations, and controls for an advanced expander engine. Operation at low thrust was defined for the advanced expander engine and the feasibility and design impact of kitting was investigated. An analysis of crew safety and mission reliability was conducted for both the staged combustion and advanced expander OTV engine candidates.

Source record↗

NASA NTRS1977

Continuation of surge life of transient voltage suppressor

Efforts expended in testing, analyzing and the development of a meaningful definition of the mean number of peak pulses before failure (mp2bf) levels of a family of transient voltage suppressor devices were documented. Tests were done to determine the ability of the transient suppressor to effectively and reliably protect against severe short term, millisecond range, and transient voltages of the types resulting from inductive load switching and induced lightning. Existing pulse testing instrumentation was utilized, interfaced to an automatic sequencing test rack accommodating up to 50 devices. Tests were performed in step stress increments of 25% beginning at 25% and extending thru 100% rated I(pp) for each voltage category. The four voltage types test were the 6.8V, 33V, 91V, and 190V. Engineering efforts addressed the problem of improving the reliability of the 190V types.

Clark, O. M.↗

NASA NTRS2005

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗

NASA NTRS1984

Considerations for damage analysis of gas turbine hot section components

The hot flowpath of a gas turbine engine contains static and rotating components operating in a very hostile environment. Since the reliable operation of these components is critical to the safe and efficient performance of the engine, structural life analysis of these members is carried out with great care. However, the complex nature of the strain-temperature-time cycle affecting the engine makes a general analysis procedure difficult and usually leads to separating the damage into regimes where one damage mode dominates. In particular, cycle dependent, time dependent, and thermomechanical fatigue regimes have been identified and some general considerations of each region are discussed. This discussion includes both the damage models themselves and the application of the models. Specific examples of several models are given and important factors affecting each are presented.

Cook, T. S.↗