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At least 757 records · Page 42

Cooled Ceramic Matrix Composite Propulsion Structures Demonstrated

NASA's Next Generation Launch Technology (NGLT) Program has successfully demonstrated cooled ceramic matrix composite (CMC) technology in a scramjet engine test. This demonstration represented the world s largest cooled nonmetallic matrix composite panel fabricated for a scramjet engine and the first cooled nonmetallic composite to be tested in a scramjet facility. Lightweight, high-temperature, actively cooled structures have been identified as a key technology for enabling reliable and low-cost space access. Tradeoff studies have shown this to be the case for a variety of launch platforms, including rockets and hypersonic cruise vehicles. Actively cooled carbon and CMC structures may meet high-performance goals at significantly lower weight, while improving safety by operating with a higher margin between the design temperature and material upper-use temperature. Studies have shown that using actively cooled CMCs can reduce the weight of the cooled flow-path component from 4.5 to 1.6 lb/sq ft and the weight of the propulsion system s cooled surface area by more than 50 percent. This weight savings enables advanced concepts, increased payload, and increased range. The ability of the cooled CMC flow-path components to operate over 1000 F hotter than the state-of-the-art metallic concept adds system design flexibility to space-access vehicle concepts. Other potential system-level benefits include smaller fuel pumps, lower part count, lower cost, and increased operating margin.

Jaskowiak, Martha H.↗

Acoustic Treatment Design Scaling Methods: Overview, Results, and Recommendations - Volume 1

Scale model fan rigs that simulate new generation ultra-high-bypass engines at about 1/5-scale are achieving increased importance as development vehicles for the design of low-noise aircraft engines. Testing at small scale allows the tests to be performed in existing anechoic wind tunnels, which provides an accurate simulation of the important effects of aircraft forward motion on the noise generation. The ability to design, build, and test miniaturized acoustic treatment panels on scale model fan rigs representative of the fullscale engine provides not only a cost-savings, but an opportunity to optimize the treatment by allowing tests of different designs. The primary objective of this study was to develop methods that will allow scale model fan rigs to be successfully used as acoustic treatment design tools. The study focuses on finding methods to extend the upper limit of the frequency range of impedance prediction models and acoustic impedance measurement methods for subscale treatment liner designs, and confirm the predictions by correlation with measured data. This phase of the program had as a goal doubling the upper limit of impedance measurement from 6 kHz to 12 kHz. The program utilizes combined analytical and experimental methods to achieve the objectives.

Kraft, R. E.↗

Space Launch System Spacecraft and Payload Elements: Progress Toward Crewed Launch and Beyond

While significant and substantial progress continues to be accomplished toward readying the Space Launch System (SLS) rocket for its first test flight, work is already underway on preparations for the second flight - using an upgraded version of the vehicle - and beyond. Designed to support human missions into deep space, SLS is the most powerful human-rated launch vehicle the United States has ever undertaken, and is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development division. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit (LEO), and the Ground Systems Development and Operations (GSDO) program is transforming Kennedy Space Center (KSC) into a next-generation spaceport capable of supporting not only SLS but also multiple commercial users. Together, these systems will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. For its first flight, SLS will deliver a near-term heavy-lift capability for the nation with its 70-metric-ton (t) Block 1 configuration. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS, which will propel Orion around the moon and back. Encompassing hardware qualification, structural testing to validate hardware compliance and analytical modeling, progress is on track to meet the initial targeted launch date. In Utah and Mississippi, booster and engine testing are verifying upgrades made to proven shuttle hardware. At Michoud Assembly Facility (MAF) in Louisiana, the world's largest spacecraft welding tool is producing tanks for the SLS core stage. Providing the Orion crew capsule/launch vehicle interface and in-space propulsion via a cryogenic upper stage, the Spacecraft/Payload Integration and Evolution (SPIE) element serves a key role in achieving SLS goals and objectives. The SPIE element marked a major milestone in 2014 with the first flight of original SLS hardware, the Orion Stage Adapter (OSA) which was used on Exploration Flight Test-1 with a design that will be used again on the first flight of SLS. The element has overseen production of the Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage, which was manufactured at United Launch Alliance (ULA) in Decatur, Alabama, prior to being shipped to Florida for flight preparations. Manufacture of the OSA and the Launch Vehicle Stage Adapter (LVSA) took place at the Friction Stir Facility located at Marshall Space Flight Center (MSFC) in Huntsville, Alabama. Marshall is also home to the Integrated Structural Test of the ICPS, LVSA, and OSA, subjecting the stacked components to simulated stresses of launch. The SPIE Element is also overseeing integration of 13 "CubeSat" secondary payloads that will fly on the first flight of SLS, providing access to deep space regions in a way currently not available to the science community. At the same time as this preparation work is taking place toward the first launch of SLS, however, the Space Launch System Program is actively working toward its second launch. For its second flight, SLS will be upgraded to the more-capable Block 1B configuration. While the Block 1 configuration is capable of delivering more than 70 t to LEO, the Block 1B vehicle will increase that capability to 105 t. For that flight, the new configuration introduces two major new elements to the vehicle - an Exploration Upper Stage (EUS) that will be used for both ascent and in-space propulsion, and a Universal Stage Adapter (USA) that serves as a "payload bay" for the rocket, allowing the launch of large exploration systems along with the Orion spacecraft. Already, flight hardware is being prepared for the Block 1B vehicle. Welding is taking place on the second rocket's core stage. Flight hardware production has begun on booster components. An RS-25 engine slated for that flight has been tested. Development work is taking place on the EUS, with contracts in place for both the stage and the RL10 engines which will power it. (The EUS will use four RL10 engines, an increase from one on the ICPS.) For the crew configuration of the Block 1B vehicle, the SLS SPIE element is managing the USA and accompanying Payload Adapter, which will accommodate both large payloads co-manifested with Orion and small-satellite secondary payloads. This co-manifested payload capacity will be instrumental for missions into the proving ground around the moon, where NASA will test new systems and demonstrate new capabilities needed for human exploration farther into deep space.

Schorr, Andrew A.↗

PMR Graphite Engine Duct Development

The objective was to demonstrate the cost and weight advantages that could be obtained by utilizing the graphite/PMR15 material system to replace titanium in selected turbofan engine applications. The first component to be selected as a basis for evaluation was the outer bypass duct of the General Electric F404 engine. The operating environment of this duct was defined and then an extensive mechanical and physical property test program was conducted using material made by processing techniques which were also established by this program. Based on these properties, design concepts to fabricate a composite version of the duct were established and two complete ducts fabricated. One of these ducts was proof pressure tested and then run successfully on a factory test engine for over 1900 hours. The second duct was static tested to 210 percent design limit load without failure. An improved design was then developed which utilized integral composite end flanges. A complete duct was fabricated and successfully proof pressure tested. The net results of this effort showed that a composite version of the outer duct would be 14 percent lighter and 30 percent less expensive that the titanium duct. The other type of structure chosen for investigation was the F404 fan stator assembly, including the fan stator vanes. It was concluded that it was feasible to utilize composite materials for this type structure but that the requirements imposed by replacing an existing metal design resulted in an inefficient composite design. It was concluded that if composites were to be effectively used in this type structure, the design must be tailored for composite application from the outset.

Stotler, C. L.↗

Space Launch System Spacecraft and Payload Elements: Progress Toward Crewed Launch and Beyond

While significant and substantial progress continues to be accomplished toward readying the Space Launch System (SLS) rocket for its first test flight, work is already also underway on preparations for the second flight - using an upgraded version of the vehicle - and beyond. Designed to support human missions into deep space, Space Launch System (SLS), is the most powerful human-rated launch vehicle the United States has ever undertaken, and is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development division. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit (LEO), and the Ground Systems Development and Operations program is transforming Kennedy Space Center into a next-generation spaceport capable of supporting not only SLS but also multiple commercial users. Together, these systems will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. For its first flight, SLS will deliver a near-term heavy-lift capability for the nation with its 70-metric-ton (t) Block 1 configuration. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS, which will propel Orion around the moon and back. Encompassing hardware qualification, structural testing to validate hardware compliance and analytical modeling, progress in on track to meet the initial targeted launch date. In Utah and Mississippi, booster and engine testing are verifying upgrades made to proven shuttle hardware. At Michoud Assembly Facility in Louisiana, the world's largest spacecraft welding tool is producing tanks for the SLS core stage. Providing the Orion crew capsule/launch vehicle interface and in-space propulsion via a cryogenic upper stage, the Spacecraft/Payload Integration and Evolution (SPIE) element serves a key role in achieving SLS goals and objectives. The SPIE element marked a major milestone in 2014 with the first flight of original SLS hardware, the Orion Stage Adapter (OSA) which was used on Exploration Flight Test-1 with a design that will be used again on the first flight of SLS. The element has overseen production of the Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage, which was manufactured at United Launch Alliance in Decatur, Alabama, prior to being shipped to Florida for flight preparations. Manufacture of the Orion Stage Adapter and the Launch Vehicle Stage Adapter (LVSA) took place at the Friction Stir Facility located at Marshall Space Flight Center in Huntsville, Alabama. Marshall is also home to the Integrated Structural Test of the ICPS, LVSA, and OSA, subjecting the stacked components to simulated stresses of launch. The SPIE Element is also overseeing integration of 13 "CubeSat" secondary payloads that will fly on the first flight of SLS, providing access to deep space regions in a way currently not available to the science community. At the same time as this preparation work is taking place toward the first launch of SLS, however, the Space Launch System Program is actively working toward its second launch. For its second flight, SLS will be upgraded to the more-capable Block 1B configuration. While the Block 1 configuration is capable of delivering more than 70 metric tons to low Earth orbit, the Block 1B vehicle will increase that capability to 105 t. For that flight, the new configuration introduces two major new elements to the vehicle - an Exploration Upper Stage (EUS) that will be used for both ascent and in-space propulsion, and a Universal Stage Adapter (USA) that serves as a "payload bay" for the rocket, allowing the launch of large exploration systems along with the Orion spacecraft. Already, flight hardware is being prepared for the Block 1B vehicle. Welding is taking place on the second rocket's core stage. Flight hardware production has begun on booster components. An RS-25 engine slated for that flight has been tested. Development work is taking place on the Exploration Upper Stage, with contracts in place for both the stage and the RL10 engines which will power it. (The EUS will use four RL10 engines, an increase from one on the ICPS.) For the crew configuration of the Block 1B vehicle, the SLS SPIE element is managing the USA and accompanying Payload Adapter, which will accommodate both large payloads co-manifested with Orion and small-satellite secondary payloads. This co-manifested payload capacity will be instrumental for missions into the Proving Ground around the moon, where NASA will test new systems and demonstrate new capabilities needed for human exploration farther into deep space.

Schorr, Andrew A.↗

System reliability analysis through corona testing

A corona vacuum test facility for nondestructive testing of power system components was built in the Reliability and Quality Engineering Test Laboratories at the NASA Lewis Research Center. The facility was developed to simulate operating temperature and vacuum while monitoring corona discharges with residual gases. The facility is being used to test various high-voltage power system components.

Lalli, V. R.↗

Autoignition of hydrogen injected transverse to a supersonic airstream

A parametric study of autoignition characteristics of transverse fuel injector patterns for a hydrogen-fueled, supersonic-combustion ramjet was conducted in direct-connect tests over a range of simulated hypersonic flight conditions. Autoignition limits, defined directly by visual observations and indirectly by measured wall pressure and temperature, are compared with a semi-empirical ignition limit model which accounts for first order effects on autoignition. It is shown that to initiate combustion in the immediate region of the fuel injector, ignition must occur in the separation region ahead of the fuel jet. Autoignition within this separation zone exhibits strong dependence on flow pressure and temperature, injector diameter, local boundary layer energy thickness, wall temperature, and on fluid dynamic interactions with adjacent downstream facing steps (such as inlet isolation steps). Secondary effects are also discussed. The empirical model is used to define limits of test temperature, pressure, and scale required for autoignition in a current subscale engine test program.

Mcclinton, C. R.↗

Thermal finite-element analysis of space shuttle main engine turbine blade

Finite-element, transient heat transfer analyses were performed for the first-stage blades of the space shuttle main engine (SSME) high-pressure fuel turbopump. The analyses were based on test engine data provided by Rocketdyne. Heat transfer coefficients were predicted by performing a boundary-layer analysis at steady-state conditions with the STAN5 boundary-layer code. Two different peak-temperature overshoots were evaluated for the startup transient. Cutoff transient conditions were also analyzed. A reduced gas temperature profile based on actual thermocouple data was also considered. Transient heat transfer analyses were conducted with the MARC finite-element computer code.

Abdul-Aziz, Ali↗

High Speed PC Based Data Acquisition and Instrumentation for Measurement of Simulated Low Earth Orbit Thermally Induced Disturbances

The Hubble Space Telescope (HST) Disturbance Verification Test (DVT) was conducted to characterize responses of the Observatory's new set of rigid solar array's (SA3) to thermally induced 'creak' or stiction releases. The data acquired in the DVT were used in verification of the HST Pointing Control System on-orbit performance, post-Servicing Mission 3B (SM3B). The test simulated the on-orbit environment on a deployed SA3 flight wing. Instrumentation for this test required pretest simulations in order to select the correct sensitivities. Vacuum compatible, highly accurate accelerometers and force gages were used for this test. The complexity of the test, as well as a short planning schedule, required a data acquisition system that was easy to configure, highly flexible, and extremely robust. A PC Windows oriented data acquisition system meets these requirements, allowing the test engineers to minimize the time required to plan and perform complex environmental test. The SA3 DVT provided a direct practical and complex demonstration of the versatility that PC based data acquisition systems provide. Two PC based data acquisition systems were assembled to acquire, process, distribute, and provide real time processing for several types of transducers used in the SA3 DVT. A high sample rate digital tape recorder was used to archive the sensor signals. The two systems provided multi-channel hardware and software architecture and were selected based on the test requirements. How these systems acquire and processes multiple data rates from different transducer types is discussed, along with the system hardware and software architecture.

Sills, Joel W., Jr.↗

Activation of the E1 Ultra High Pressure Propulsion Test Facility at Stennis Space Center

After a decade of construction and a year of activation the El Ultra High Pressure Propulsion Test Facility at NASA's Stennis Space Center is fully operational. The El UHP Propulsion Test Facility is a multi-cell, multi-purpose component and engine test facility . The facility is capable of delivering cryogenic propellants at low, high, and ultra high pressures with flow rates ranging from a few pounds per second up to two thousand pounds per second. Facility activation is defined as a series of tasks required to transition between completion of construction and facility operational readiness. Activating the El UHP Propulsion Test Facility involved independent system checkouts, propellant system leak checks, fluid and gas sampling, gaseous system blow downs, pressurization and vent system checkouts, valve stability testing, valve tuning cryogenic cold flows, and functional readiness tests.

Messer, Bradley↗

Phased Array Noise Source Localization Measurements of an F404 Nozzle Plume at Both Full and Model Scale

A 48-microphone planar phased array system was used to acquire jet noise source localization data on both a full-scale F404-GE-F400 engine and on a 1/4th scale model of a F400 series nozzle. The full-scale engine test data show the location of the dominant noise sources in the jet plume as a function of frequency for the engine in both baseline (no chevron) and chevron configurations. Data are presented for the engine operating both with and without afterburners. Based on lessons learned during this test, a set of recommendations are provided regarding how the phased array measurement system could be modified in order to obtain more useful acoustic source localization data on high-performance military engines in the future. The data obtained on the 1/4th scale F400 series nozzle provide useful insights regarding the full-scale engine jet noise source mechanisms, and document some of the differences associated with testing at model-scale versus fullscale.

Podboy, Gary G.↗

Lift-fan aircraft: Lessons learned-the pilot's perspective

This paper is written from an engineering test pilot's point of view. Its purpose is to present lift-fan 'lessons learned' from the perspective of first-hand experience accumulated during the period 1962 through 1988 while flight testing vertical/short take-off and landing (V/STOL) experimental aircraft and evaluating piloted engineering simulations of promising V/STOL concepts. Specifically, the scope of the discussions to follow is primarily based upon a critical review of the writer's personal accounts of 30 hours of XV-5A/B and 2 hours of X-14A flight testing as well as a limited simulator evaluation of the Grumman Design 755 lift-fan aircraft. Opinions of other test pilots who flew these aircraft and the aircraft simulator are also included and supplement the writer's comments. Furthermore, the lessons learned are presented from the perspective of the writer's flying experience: 10,000 hours in 100 fixed- and rotary-wing aircraft including 330 hours in 5 experimental V/STOL research aircraft. The paper is organized to present to the reader a clear picture of lift-fan lessons learned from three distinct points of view in order to facilitate application of the lesson principles to future designs. Lessons learned are first discussed with respect to case histories of specific flight and simulator investigations. These principles are then organized and restated with respect to four selected design criteria categories in Appendix I. Lastly, Appendix Il is a discussion of the design of a hypothetical supersonic short take-off vertical landing (STOVL) fighter/attack aircraft.

Gerdes, Ronald M.↗

Update on the NASA Glenn Propulsion Systems Lab Ice Crystal Cloud Characterization (2015, 2016)

NASA Glenn's Propulsion Systems Lab, an altitude engine test facility, was outfitted with a spray system to generate ice crystals in 2011. Turbine engines and driven rigs can experience ice crystal icing at flight altitudes, temperatures and Mach numbers. To support these tests, four ice crystal characterizations have been conducted in two different facility configurations. In addition, super-cooled liquid and mixed phase clouds have also been generated. This paper represents a work in progress. It will describe some of the 11-parameter calibration space, and how those parameters interact with each other, the instrumentation used to characterize the cloud and present a sample of the cloud characterization results.

Engine Icing↗

Advanced Turbine Technology Applications Project (ATTAP)

ATTAP activities during the past year were highlighted by an extensive materials assessment, execution of a reference powertrain design, test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, component rig design and fabrication, test-bed engine fabrication, and hot gasifier rig and engine testing. Materials assessment activities entailed engine environment evaluation of domestically supplied radial gasifier turbine rotors that were available at the conclusion of the Advanced Gas Turbine (AGT) Technology Development Project as well as an extensive survey of both domestic and foreign ceramic suppliers and Government laboratories performing ceramic materials research applicable to advanced heat engines. A reference powertrain design was executed to reflect the selection of the AGT-5 as the ceramic component test-bed engine for the ATTAP. Test-bed engine development activity focused on upgrading the AGT-5 from a 1038 C (1900 F) metal engine to a durable 1371 C (2500 F) structural ceramic component test-bed engine. Ceramic component design activities included the combustor, gasifier turbine static structure, and gasifier turbine rotor. The materials and component characterization efforts have included the testing and evaluation of several candidate ceramic materials and components being developed for use in the ATTAP. Ceramic component process development and fabrication activities were initiated for the gasifier turbine rotor, gasifier turbine vanes, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Component rig development activities included combustor, hot gasifier, and regenerator rigs. Test-bed engine fabrication activities consisted of the fabrication of an all-new AGT-5 durability test-bed engine and support of all engine test activities through instrumentation/build/repair. Hot gasifier rig and test-bed engine testing activities were performed.

Source record↗

A US History of Airbreathing/Rocket Combined-Cycle (RBCC) Propulsion for Powering Future Aerospace Transports, with a Look Ahead to the Year 2020

A technohistorical and forward-planning overview of U.S. developments in combined airbreathing/rocket propulsion for advanced aerospace vehicle applications is presented. Such system approaches fall into one of two categories: (1) Combination propulsion systems (separate, non-interacting engines installed), and (2) Combined-Cycle systems. The latter, and main subject, comprises a large family of closely integrated engine types, made up of both airbreathing and rocket derived subsystem hardware. A single vehicle-integrated, multimode engine results, one capable of operating efficiently over a very wide speed and altitude range, atmospherically and in space. While numerous combination propulsion systems have reached operational flight service, combined-cycle propulsion development, initiated ca. 1960, remains at the subscale ground-test engine level of development. However, going beyond combination systems, combined-cycle propulsion potentially offers a compelling set of new and unique capabilities. These capabilities are seen as enabling ones for the evolution of Spaceliner class aerospace transportation systems. The following combined-cycle hypersonic engine developments are reviewed: (1) RENE (rocket engine nozzle ejector), (2) Cryojet and LACE, (3) Ejector Ramjet and its derivatives, (4) the seminal NASA NAS7-377 study, (5) Air Force/Marquardt Hypersonic Ramjet, (6) Air Force/Lockheed-Marquardt Incremental Scramjet flight-test project, (7) NASA/Garrett Hypersonic Research Engine (HRE), (8) National Aero-Space Plane (NASP), (9) all past projects; and such current and planned efforts as (10) the NASA ASTP-ART RBCC project, (11) joint CIAM/NASA DNSCRAM flight test,(12) Hyper-X, (13) Trailblazer,( 14) W-Vehicle and (15) Spaceliner 100. Forward planning programmatic incentives, and the estimated timing for an operational Spaceliner powered by combined-cycle engines are discussed.

Escher, William J. D.↗

Liquid Rocket Booster (LRB) for the Space Transportation System (STS) systems study. Appendix E: Pressure-fed booster test bed for the liquid rocket booster study

The stress analysis/structural design of the Pressure-Fed Booster Engine Test Bed using the existing F-1 Test Facility Test Stand at Huntsville, Alabama is described. The analysis has been coded and set up for solution on NASTRAN. A separate stress program was established to take the NASTRAN output and perform stress checks on the members. Joint checks and other necessary additional checks were performed by hand. The notes include a brief description of other programs which assist in reproducing and reviewing the NASTRAN results. The redesign of the test stand members and the stress analysis was performed per the A.I.S.C. Code. Loads on the stand consist of the loaded run tanks; wind loads; seismic loads; live loads consisting of snow and ice: live and dead loads of steel; and loaded pressurant bottle. In combining loads, wind loads and seismic loads were each combined with full live loads. Wind and seismic loads were not combined. No one third increase in allowables was taken for the environmental loads except at decks 147 and 214, where the increase was used when considering the stay rods, brackets and stay beams. Wind and seismic loads were considered from each of the four coordinate directions (i.e. N,S,E,W) to give eight basic conditions. The analysis was run with the pressurant tank mounted at level 125. One seismic condition was also run with the tank mounted at levels 169 and 214. No failures were noted with mounting at level 169, but extensive deck failure with mounting at level 214 (the loadsets used are included on the tape, but no detailed results are included in the package). Decking support beams at levels 147 and 214 are not included in the model. The stress program thus does not reduce strut lengths to the length between support beams (the struts are attached to the beams at intersection points) and gives stress ratios larger than one for some of the struts. The affected members were therefore checked by hand.

Source record↗

Pratt and Whitney/Boeing Engine Validation of Noise Reduction Concepts: Final Report for NASA Contract NAS3-97144, Phase 1

Major airports in the world's air transportation systems face a serious problem in providing greater capacity to meet the ever increasing demands of air travel. This problem could be relieved if airports are allowed to increase their operating time, now restricted by curfews and by relaxing present limits on takeoffs and landings. The key operational issue in extending the present curfews is noise. In response to these increasing restrictive noise regulations, NASA has launched a program to validate through engine testing, noise reduction concepts and technologies that have evolved from the Advanced Subsonic Technologies (AST) Noise Reduction Program. The goal of this AST program was to develop and validate technology that reduces engine noise and improves nacelle suppression effectiveness relative to 1992 technology. Contract NAS3-97144 titled "Engine Validation of Noise Reduction Concepts" (EVNRC) was awarded to P&W on August 12, 1997 to conduct full scale noise reduction tests in two Phases on a PW4098 engine. The following Section 1.2 provides a brief description of the overall program. The remainder of this report provides a detailed documentation of Phase I of the program.

Mathews, Douglas↗