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Report describes modifications of design of type of ball-screw linear actuator driven by dc motor, with linear-displacement feedback via linear variable-differential transformer (LVDT). Actuators used to position spacecraft engines to direct thrust. Modifications directed toward ensuring reliable and predictable operation during planned 12-year cruise and interval of hard use at end of cruise.
Thermal barrier coatings (TBC's) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBC's is of primary importance. Physical vapor deposition (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard powder or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increases upon exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as-fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicate that if these coatings reach a temperature above 1100 C during operation, they will begin to lose their effectiveness as a thermal barrier.
NASA has been researching new technology and system concepts to meet the requirements of aeropropulsion for 21st Century aircraft. The air transportation for the new millennium will require revolutionary solutions to meet public demand for improving safety, reliability, environmental compatibility, and affordability. Whereas the turbine engine revolution will continue during the next two decades, several new revolutions are required to achieve the dream of an affordable, emissionless, and silent aircraft. This paper reviews the continuing turbine engine revolution and explores the propulsion system impact of future revolutions in propulsion configuration, fuel infrastructure, and alternate energy systems. A number of promising concepts, ranging from the ultrahigh to fuel cell-powered distributed propulsion are also reviewed.
Requirements have always been acknowledged as the backbone of any system. However, in many past development efforts, requirements were paid little heed. At NASA, in recent years, the hue and cry for project development has been "Faster, Better, Cheaper and Safer". This has impacted the way we develop software; it has increased the risks to quality, safety and reliability. At NASA, the Software Assurance Technology Center (SATC) is working with projects to emphasize the criticality of requirements throughout development, not just in the initial phases. This emphasis is on requirements relationship to all aspects of quality, including reliability and safety. In this presentation, we will look at some of these relationships through the eyes of quality.
In designing a control for Bethany College's solar heating and cooling system, Apollo Energy Control, Inc. used Marshall Space Flight Center's doe solar and heating and cooling technology. The technology helped the company design a highly reliable, simply operated system with substantial savings in engineering time.
"Qualification" of fiber optic components holds a very different meaning than it did ten years ago. In the past, qualification meant extensive prolonged testing and screening that led to a programmatic method of reliability assurance. For space flight programs today, the combination of using higher performance commercial technology, with shorter development schedules and tighter mission budgets makes long term testing and reliability characterization unfeasible. In many cases space flight missions will be using technology within years of its development and an example of this is fiber laser technology. Although the technology itself is not a new product the components that comprise a fiber laser system change frequently as processes and packaging changes occur. Once a process or the materials for manufacturing a component change, even the data that existed on its predecessor can no longer provide assurance on the newer version. In order to assure reliability during a space flight mission, the component engineer must understand the requirements of the space flight environment as well as the physics of failure of the components themselves. This can be incorporated into an efficient and effective testing plan that "qualifies" a component to specific criteria defined by the program given the mission requirements and the component limitations. This requires interaction at the very initial stages of design between the system design engineer, mechanical engineer, subsystem engineer and the component hardware engineer. Although this is the desired interaction what typically occurs is that the subsystem engineer asks the components or development engineers to meet difficult requirements without knowledge of the current industry situation or the lack of qualification data. This is then passed on to the vendor who can provide little help with such a harsh set of requirements due to high cost of testing for space flight environments. This presentation is designed to guide the engineers of design, development and components, and vendors of commercial components with how to make an efficient and effective qualification test plan with some basic generic information about many space flight requirements. Issues related to the ~ physics of failure, acceptance criteria and lessons learned will also be discussed to assist with understanding how to approach a space flight mission in an ever changing commercial photonics industry.
AlliedSignal aerospace company is committed to significantly improving the reliabilities of air/oil seals in their gas turbine engines. One motivation for this is that aircraft cabin air quality can be affected by the performance of mainshaft air/oil seals. In the recent past, coking related failure modes have been the focus of air/oil seal R&D at AlliedSignal. Many significant advances have been made to combat coke related failures, with some more work continuing in this area. This years R&D begins to address other commin failure modes. Among them, carbon seal "blistering" has been a chronic problem facing the sealing industry for many decades. AlliedSignal has launched an aggressive effort this year to solve this problem for our aerospace rated carbon seals in a short (one to two year) timeframe. Work also continues in developing more user-friendly tools and data for seal analysis & design. Innovations in seal cooling continue. Nominally non-contacting hydropad sealing concept is being developed for aerospace applications. Finally, proprietary work is in planning stages for development of a seal with the aggressive aim of zero oil leakage.
Orbital debris is a real concern for the safe operations of satellites. In general, the hazard of debris impact is a function of the size and spatial distributions of the debris populations. To describe and characterize the debris environment as reliably as possible, the current NASA Orbital Debris Engineering Model (ORDEM2000) is being upgraded to a new version based on new and better quality data. The data-driven ORDEM model covers a wide range of object sizes from 10 microns to greater than 1 meter. This paper reviews the statistical process for the estimation of the debris populations in the new ORDEM upgrade, and discusses the representation of large-size (greater than or equal to 1 m and greater than or equal to 10 cm) populations by SSN catalog objects and the validation of the statistical approach. Also, it presents results for the populations with sizes of greater than or equal to 3.3 cm, greater than or equal to 1 cm, greater than or equal to 100 micrometers, and greater than or equal to 10 micrometers. The orbital debris populations used in the new version of ORDEM are inferred from data based upon appropriate reference (or benchmark) populations instead of the binning of the multi-dimensional orbital-element space. This paper describes all of the major steps used in the population-inference procedure for each size-range. Detailed discussions on data analysis, parameter definition, the correlation between parameters and data, and uncertainty assessment are included.
Version 3.31 of Modeling and Analysis for Controlled Optical Systems (MACOS) has been released. MACOS is an easy-to-use computer program for modeling and analyzing the behaviors of a variety of optical systems, including systems that have large, segmented apertures and are aligned with the technology of wavefront sensing and control. Two previous versions were described in "Improved Software for Modeling Controlled Optical Systems" (NPO-19841) NASA Tech Briefs, Vol. 21, No. 12 (December 1997), page 42 and "Optics Program Modified for Multithreaded Parallel Computing" (NPO-40572) NASA Tech Briefs, Vol. 30, No. 1 (January 2006) page 13a. The present version incorporates the following enhancements over prior versions: a) A powerful system-optimization facility includes algorithms for linear, nonlinear, unconstrained, and constrained optimization of optical systems under a variety of settings. b) There is now enhanced capability to perturb optical components individually and on subsystem levels, and to optimize system performance by adjusting selected individual components as well as subsystems. c) Capabilities for modeling a variety of new optical aperture types have been added. d) Effects of multilayer thin-film coats on optical surfaces can now be taken into account when tracing polarized rays. e) Major software-engineering work was performed to make MACOS more reliable, flexible, and manageable for purposes of maintenance and further development.
Ball bearing design is critical to the success of aerospace mechanisms. Key bearing performance parameters, such as load capability, stiffness, torque, and life all depend on accurate determination of the internal load distribution. Hence, a good analytical bearing tool that provides both comprehensive capabilities and reliable results becomes a significant asset to the engineer. This paper introduces the ORBIS bearing tool. A discussion of key modeling assumptions and a technical overview is provided. Numerous validation studies and case studies using the ORBIS tool are presented. All results suggest the ORBIS code closely correlates to predictions on bearing internal load distributions, stiffness, deflection and stresses.
Frequently it is necessary to distribute spacecraft telemetry to multiple destinations on Internet Protocol (IP) networks. There are various methods of delivering this data, but when the data is high rate and there are many destinations IP multicast provides the best solution from a network perspective. However, IP multicast only supports the User Datagram Protocol (UDP) which is connectionless and unreliable. This nature of UDP and by extension the low priority treatment of UDP packets by some network hardware creates a difficult environment for distribution of high rate telemetry to a number of recipients over IP networks. NACK (Negative ACKnowledgment) Oriented Reliable Multicast (NORM) is defined by IETF (Internet Engineering Task Force) RFC (Request for Comments) 5740 in 2009 by B. Adamson et al. NORM provides a mechanism of retransmission and or forward error correction for UDP packets, potentially overcoming the limits of UDP for the transmission of spacecraft telemetry. Marshall Space Flight Center’s (MSFC) Huntsville Operations Support Center (HOSC) manages the delivery of the International Space Station (ISS) payload science and health data. The ISS IP Ground Routed (IIGoR) network provides the delivery of the data from the ground stations to the control centers. HOSC personnel have been experimenting with the use of NORM on the link between the ground stations and the front end processor equipment in Huntsville, AL.
Accurate and reliable prediction of noise emitted from turbofan aircraft engines is an ongoing challenge. For continued progress, it is necessary to assess the performance of the most recent prediction methods in the NASA Aircraft NOise Prediction Program (ANOPP), and to examine the effects of flight condition on fan noise. The assessment is based on an extensive acoustic dataset acquired as part of the Propulsion Airframe Aeroacoustics and Aircraft System Noise (PAA&ASN) Flight Test conducted on a Boeing 787-10 aircraft. Engine operating condition was varied to study the characteristics of fan noise in flight. In a subset of the flight test matrix, the influence of the aft duct acoustic liner was studied by covering the lined area with aluminum tape to simulate a hardwall duct. The combination of test data at different flight conditions, along with rigorous predictions of jet noise, is used in this paper to extract fan noise from the measured total aircraft noise levels. The measured fan noise levels are compared with those predicted using the latest methods for fan source noise, liner attenuation, and PAA effect prediction. Detailed analyses are undertaken to understand agreement between data and various aspects of the prediction models, including spectral shape, directivity, and response to throttle setting. An additional investigation was undertaken to study the effect of aircraft speed on fan noise, as current models do not directly account for this parameter.
As a foundational element of the National Aeronautics and Space Administration (NASA) Artemis Campaign, the Gateway is an incrementally built cislunar spacecraft that will serve as a platform for deep space human exploration, science, and technology demonstration. The Gateway will be a unifying catalyst for international partners around the world to establish sustained deep space scientific investigations, lunar surface access, and missions to Mars. As human exploration moves farther away from Earth, spacecraft designs must prioritize and optimize mass and volume allocations, while minimizing human and spacecraft risk. To accomplish this objective, the Gateway Program Safety and Mission Assurance functions develop, implement, and ensure compliance with requirements, in concert with the accurate characterization and transparent communication of residual hazard risks, for integrated safety, reliability and maintainability and quality assurance. Safety and Mission Assurance was a key contributor during Gateway program pre-formulation and formulation activities where safety and reliability analysis was embedded in the Gateway Systems Engineering and Integration team. During these early program stages, a preliminary Gateway Integrated Hazard Analysis and Preliminary Gateway Probabilistic Risk Assessment assisted in Gateway architectural and operational definition as part of a risk-informed design process. As the deep space architecture has matured, the integrated Safety and Mission Assurance analyses have matured, new safety review processes have been developed, and requirements have been refined to ensure compliance with integrated safety and mission assurance objectives. The Gateway Program is currently concluding the preliminary design review informed milestone, where the primary objectives included: - Ensured completeness and consistency of the preliminary design, including the meeting of all requirements within appropriate margins and acceptable risk posture. - Identification of any major issues moving forward to the Critical Design phase. At this milestone, Safety and Mission Assurance provided numerous products, including Gateway Top Risks and Risk Mitigation Plans, updated integrated hazard analyses, updated probabilistic risk assessment, Crew Survival Analysis Report, and updated Safety and Mission Assurance Requirements and Plans. These products provide a many-faceted perspective on the inherent risk and available mitigations involved in flying the current proposed vehicle design and anticipated stack configurations. In addition, Safety and Mission Assurance identified top technical, process and workforce concerns to be addressed as the program progresses toward the critical design phase. This paper will detail the evolution of the Gateway Program Safety and Mission Assurance integration functions, provide its current status and lessons learned for future human spaceflight programs. Throughout this paper the key tenets of the Gateway Program Safety and Mission Assurance will be discussed: - Application of a risk-informed approach to identify and mitigate areas of highest risk. - Leverage of valuable processes and lessons learned from earlier spaceflight programs. - Development of Safety and Mission Assurance products to inform design risk trades. - Utilization of common Safety and Mission Assurance practices to identify safety risks for multiple perspectives: top-down, bottom-up, and across lines of integration. - Approval of safety hazards at the appropriate level of authority, keeping most deliberation closest to design expertise and elevating risks of greatest concern for program-level consideration. - Championing of Safety and Mission Assurance processes and forums to foster a pervasive safety culture that is transparent, inclusive, and collaborative between all partners. These tenets have allowed the Gateway Safety and Mission Assurance function to play a key role in optimized vehicle design evolution, and early identification and mitigation of Gateway program and Artemis mission risk.
Scientists at NASA's Glenn Research Center developed a high-temperature, solid lubricant coating material that is saving the manufacturing industry millions of dollars. The material came out of 3 decades of tribological research, work studying high-temperature friction, lubrication, and the wearing of interacting surfaces that are in relative motion. It was developed as a shaft coating deposited by thermal spraying to protect foil air bearings used in oil-free turbomachinery, like gas turbines, and is meant to be part of a larger project: an oil-free aircraft engine capable of operating at high temperatures with increased reliability, lowered weight, reduced maintenance requirements, and increased power. This advanced coating, PS300, is a self-lubricating bearing material containing chromium oxide, with additions of a low-temperature start up lubricant (silver) and a high-temperature lubricant, making it remarkably stable at high temperatures, and better suited than previously available materials for high-stress conditions. It improves efficiency, lowers friction, reduces emissions, and has been used by NASA in advanced aeropropulsion engines, refrigeration compressors, turbochargers, and hybrid electrical turbogenerators. PS300 is ideal in any application where lowered weight and reduced maintenance are desired, and high-temperature uses and heavy operating speeds are expected. It has notable uses for the Space Agency, but it has even further-reaching potential for the industrial realm.
The objective of this program is to develop a thermal data transfer computer program module for the burner liner thermal structural load modeling program. This will be accomplished by (1) reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program; (2) evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes; (3) developing the automated thermal load transfer module; and (4) verifying and documenting the module. In aircraft turbine engine hot section components, cyclic thermal stresses are the most important damage mechanism. Consequently, accurate and reliable prediction of thermal loads is essential to improving durability. To achieve this goal, a considerable effort over the past 20 years has been devoted to the acquisition of engine temperature test data, as well as the development of accurate, reliable, and efficient computer codes for the prediction of steady state and transient temperatures and for the calculation of elastic and inelastic cyclic stresses and strains in hot section components. There is a need for continued development of these codes, because the availability of more accurate analysis techniques for complex configurations has enabled engine designers to use more sophisticated designs to achieve higher cycle efficiency and reduce weight.
Under the Department of Energy's (DOE) Solar Thermal Technology Program, Sandia National Laboratories is evaluating heat engines for terrestrial Solar Distributed Heat Receivers. The Stirling engine has been identified by Sandia as one of the most promising engines for terrestrial applications. The Stirling engine also has the potential to meet DOE's performance and cost goals. The NASA Lewis Research Center is conducting Stirling engine technology development activities directed toward a dynamic power source for space applications. Space power systems requirements include high reliability, very long life, low vibration and high efficiency. The free-piston Stirling engine has the potential for future high power space conversion systems, either nuclear or solar powered. Although both applications appear to be quite different, their requirements complement each other. Preliminary designs feature a free-piston Stirling engine, a liquid metal heat transport system, and a means to provide nominally 25 kW electric power to a utility grid while meeting DOE's performance and long term cost goals. The Cummins design incorporates a linear alternator to provide the electrical output, while the STC design generates electrical power indirectly through a hydraulic pump/motor coupled to an induction generator. Both designs for the ASCS's will use technology which can reasonably be expected to be available in the early 1990's
Under the Department of Energy's (DOE) Solar Thermal Technology Program, Sandia National Laboratories is evaluating heat engines for terrestrial Solar Distributed Heat Receivers. The Stirling engine has been identified by Sandia as one of the most promising engines for terrestrial applications. The Stirling engine also has the potential to meet DOE's performance and cost goals. The NASA Lewis Research Center is conducting Stirling engine technology development activities directed toward a dynamic power source for space applications. Space power systems requirements include high reliability, very long life, low vibration and high efficiency. The free-piston Stirling engine has the potential for future high power space conversion systems, either nuclear or solar powered. Although both applications appear to be quite different, their requirements complement each other. Preliminary designs feature a free-piston Stirling engine, a liquid metal heat transport system, and a means to provide nominally 25 kW electric power to a utility grid while meeting DOE's performance and long term cost goals. The Cummins design incorporates a linear alternator to provide the electrical output, while the STC design generates electrical power indirectly through a hydraulic pump/motor coupled to an induction generator. Both designs for the ASCS's will use technology which can reasonably be expected to be available in the early 1990's.
In recent years, there has been an increased emphasis in developing NiAl-based alloys for high- temperature applications in aircraft engines. In comparison to commercial superalloys, binary NiAl has a higher melting temperature, lower density, larger thermal conductivity, and better oxidation resistance. These properties make it a desirable material to replace superalloys as blades and vanes in aircraft engines. Despite this attractive combination of properties, binary NiAl cannot be used as a reliable structural material because of its low-temperature brittleness and poor high-temperature creep strength. GE Aircraft Engines in Cincinnati, Ohio, has recently developed NiAl(Hf) alloys that have creep strengths comparable to commercial superalloys while maintaining the other desirable properties of binary NiAl. The microstructures of these alloys consist of finely distributed G-phase (Ni_(16)Hf_(6)Si_(7)) precipitates, which strengthen the NiAl matrix. However, while the creep properties of these alloys were being evaluated, considerable scatter was observed in the creep lives of specimens tested under identical stress and temperature conditions. Although these alloys had nominally the same composition, the test specimens were obtained from four different ingots (A, B, C, and D) that had been heat treated under similar conditions. The NASA Lewis Research Center began the present study at the request of GE Aircraft Engines under a Space Act Agreement to identify the source of this scatter.