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NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems in Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Mahzari, Milad↗

NASA NTRS1979

Development of the Space Shuttle Main Engine /May 1979/

During the last year, significant progress was made toward the development of the Space Shuttle Main Engine, which will provide propulsion for the Space Shuttle Orbiter vehicle. Engine system testing continued at the National Space Technology Laboratories on both single engines and a three-engine cluster. A third single engine test position was activated at the Rocketdyne Santa Susana Field Laboratory to provide additional capability for demonstrating increasing engine maturity and for solving problems. The results of engine system testing is discussed as well as the major problems identified and the design changes incorporated to solve those problems. A review of the program efforts toward the delivery of the first set of flight engines and the certification of the SSME for manned flight is included.

Colbo, H. I.↗

NASA NTRS1994

Flight service evaluation of composite helicopter components

This paper presents the results of a NASA funded contract and Sikorsky research and development programs to evaluate structural composite components in flight service on Sikorsky Model S-76 helicopters. Selected components were removed and tested at prescribed intervals over a nine year time frame. Four horizontal stabilizers and thirteen tail rotor spars were returned from commercial service in West Palm Beach, Florida and in the Gulf Coast region of Louisiana to determine the long term effects of operations in hot and humid climates on component performance. Concurrent with the flight component evaluation, panels of materials used in their fabrication were exposed to the environment in ground racks. Selected panels were tested annually to determine the effects of exposure on physical and mechanical properties. The results of 55,741 component flight hours and 911 months of field exposure are reported and compared with initial Federal Aviation Administration (FAA) certification data. The findings of this program have provided increased confidence in the long term durability of advanced composite materials used in helicopter structural applications.

Mardoian, George H.↗

NASA NTRS1999

Investigation of Dynamic Flight Maneuvers With an Iced Tailplane

A detailed analysis of two of the dynamic maneuvers, the pushover and elevator doublet, from the NASA/FAA Tailplane Icing Program are discussed. For this series of flight tests, artificial ice shapes were attached to the leading edge of the horizontal stabilizer of the NASA Lewis Research Center icing aircraft, a DHC-6 Twin Otter. The purpose of these tests was to learn more about ice-contaminated tailplane stall (ICTS), the known cause of 16 accidents resulting in 139 fatalities. The pushover has been employed by the FAA, JAA and Transport Canada for tailplane icing certification. This research analyzes the pushover and reports on the maneuver performance degradation due to ice shape severity and flap deflection. A repeatability analysis suggests tolerances for meeting the required targets of the maneuver. A second maneuver, the elevator doublet, is also studied.

VanZante, Judith Foss↗

NASA NTRS2006

Lightweight Ablative and Ceramic Thermal Protection System Materials for NASA Exploration Systems Vehicles

As a collaborative effort among NASA Centers, the "Lightweight Nonmetallic Thermal Protection Materials Technology" Project was set up to assist mission/vehicle design trade studies, to support risk reduction in thermal protection system (TPS) material selections, to facilitate vehicle mass optimization, and to aid development of human-rated TPS qualification and certification plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on advanced heatshields that allow reductions in spacecraft mass by minimizing propellant requirements. Information will be presented on candidate materials for such reentry approaches and on screening tests conducted (material property and space environmental effects tests) to evaluate viable candidates. Seventeen materials, in three classes (ablatives, tiles, and ceramic matrix composites), were studied. In additional to physical, mechanical, and thermal property tests, high heat flux laser tests and simulated-reentry oxidation tests were performed. Space environmental effects testing, which included exposures to electrons, atomic oxygen, and hypervelocity impacts, was also conducted.

Valentine, Peter G.↗

NASA NTRS2010

L(sub 1) Adaptive Flight Control System: Flight Evaluation and Technology Transition

Certification of adaptive control technologies for both manned and unmanned aircraft represent a major challenge for current Verification and Validation techniques. A (missing) key step towards flight certification of adaptive flight control systems is the definition and development of analysis tools and methods to support Verification and Validation for nonlinear systems, similar to the procedures currently used for linear systems. In this paper, we describe and demonstrate the advantages of L(sub l) adaptive control architectures for closing some of the gaps in certification of adaptive flight control systems, which may facilitate the transition of adaptive control into military and commercial aerospace applications. As illustrative examples, we present the results of a piloted simulation evaluation on the NASA AirSTAR flight test vehicle, and results of an extensive flight test program conducted by the Naval Postgraduate School to demonstrate the advantages of L(sub l) adaptive control as a verifiable robust adaptive flight control system.

Xargay, Enric↗

NASA NTRS2010

Handheld White Light Interferometer for Measuring Defect Depth in Windows

Accurate quantification of defects (scratches and impacts) is vital to the certification of flight hardware and other critical components. The amount of damage to a particular component contributes to the performance, reliability, and safety of a system, which ultimately affects the success or failure of a mission or test. The launch-commit criteria on a Space Shuttle Orbiter window are governed by the depth of the defects that are identified by a visual inspection. This measurement of a defect is not easy to obtain given the environment, size of the defect, and location of the window(s). The determination of depth has typically been performed by taking a mold impression and measuring the impression with an optical profiling instrument. Another method of obtaining an estimate of the depth is by using a refocus microscope. To use a refocus microscope, the surface of the glass and bottom of the defect are, in turn, brought into focus by the operator. The amount of movement between the two points corresponds to the depth of the defect. The refocus microscope requires a skilled operator and has been proven to be unreliable when used on Orbiter windows. White light interferometry was chosen as a candidate to replace the refocus microscope. The White Light Interferometer (WLI) was developed to replace the refocus microscope as the instrument used for measuring the depth of defects in Orbiter windows. The WLI consists of a broadband illumination source, interferometer, detector, motion control, displacement sensor, mechanical housing, and support electronics. The illumination source for the WLI is typically a visible light emitting diode (LED) or a near-infrared superluminescent diode (SLD) with power levels of less than a milliwatt. The interferometer is a Michelson configuration consisting of a 1-in. (2.5-cm) cube beam splitter, a 0.5-in. (1.3-cm) optical window as a movable leg (used to closely match the return intensity of the fixed leg from the window), and a mirrored prism to fold the optics into the mechanical housing. The detector may be one of many C-mount CCD (charge-coupled device) cameras. Motion is provided by a commercial nanostepping motor with a serial interface. The displacement sensor is a custom device specifically designed for this application. The mechanical housing and support electronics were designed to integrate the various components into an instrument that could be physically handled by a technician and easily transported.

Youngquist, Robert↗

NASA NTRS2017

Validation of Minimum Display Requirements for a UAS Detect and Avoid System

The full integration of Unmanned Aircraft Systems (UAS) into the National Airspace System (NAS), a prerequisite for enabling a broad range of public and commercial UAS operations, presents several technical challenges to UAS developers, operators and regulators. A primary barrier is the inability for UAS pilots (situated at a ground control station, or GCS) to comply with Title 14 Code of Federal Regulations sections 91.111 and 91.113, which require pilots to “see and avoid” other aircraft in order to maintain well clear. UAS pilots’ removal from the flight deck of the aircraft necessitates the development of a UAS-specific system for detecting nearby traffic and displaying traffic information to the pilot to support their ability to maintain an objectively defined “DAA well clear” threshold from other aircraft. This new UAS-specific function of remaining DAA well clear is called traffic avoidance. The resulting Detect and Avoid (DAA) system, however, will be subject to a collection of requirements that manufacturers will be obligated to meet in order to certify their equipment. RTCA Special Committee 228 (SC-228), a consortium of representatives from government, industry and academia, is responsible for developing and documenting the Minimum Operational Performance Standards (MOPS) for UAS DAA systems. The present study is the final in a series of human-in-the-loop (HITL) experiments designed to explore and test the various display and alerting requirements being incorporated into the DAA MOPS. Whereas the prior DAA HITLs examined a wide variety of DAA display features and concepts, the current experiment aims to validate the latest minimum display requirements for Phase 1 of the DAA MOPS. Rather than test different display concepts, this study tests two configurations of a MOPS-compatible DAA display: a version that is integrated into the primary navigation and control display of the GCS and a version that is physically separated from the primary display. This manipulation tests the draft minimum requirement that allows the DAA traffic display to be a separate, or standalone, configuration. This type of configuration is a more achievable near-term technology solution since it does not stipulate additional certification or integration requirements on UAS manufacturers. However, a standalone display configuration has the potential to result in pilot performance issues resulting from the cognitive costs of switching between the primary DAA display and the primary navigation and control display. This configuration is also particularly susceptible to errors if the displays are in different orientations (e.g., north-up versus track-up). Both the integrated and standalone display configurations were presented to 16 active UAS pilots in a medium-fidelity simulation, which included confederate air traffic controllers and pseudo pilots operating simulated manned traffic. Pilots were tasked with navigating two different mission routes while maintaining DAA well clear with scripted conflicts. Pilot response times (i.e., measured response) and ability to remain DAA well clear are reported. Primary results indicate that both display configurations resulted in favorable response times and well clear rates. While there were clear trends of pilots objectively performing better in the integrated display condition, with several measured response metrics reaching statistical significance, the differences between the two displays were typically moderate. While the primary variable of DAA display location did not have an especially large impact on pilot performance on its own, when examined alongside the type of DAA threat the pilot was facing (a caution-level versus a warning-level alert), the response time benefits associated with the integrated display were amplified. The implications of these American Institute of Aeronautics and Astronautics 2 results on the Phase 1 DAA MOPS and the connection of this data to previous studies is also discussed.

detect and avoid↗

DOE OSTI2020

Cost Efficient and Highly Weather-Resistant Solar Panel Backsheet Produced through Continuous Co-Extrusion Processing

The efficient generation and delivery of ‘clean energy” through photovoltaic (PV) technology relies heavily on the cost, performance and reliability of solar panels, along with the individual components used in assembly of those panels. In order to continue towards the Department of Energy’s (DOE) goals of driving costs down, the lifetime of high-output power generation equipment (i.e. solar modules) must be extended to reduce costs associated with power output degradation and replacement of failed or degraded panels. One of the major sources of module failures in the past 30 years has been the failure of the solar panel backsheet. Failure of this component causes severe output losses due to oxidation and yellowing of the module while creating safety concerns as the major electrical insulation of the module is compromised. Tomark-Worthen LLC was formed in 2012 with the goal of designing and manufacturing novel PV backsheets and encapsulants that would be produced in the United States of America and exceed expectations of domestic and international module producers. These backsheets would improve upon known backsheet design failures (i.e. Isovoltaic’s AAA backsheet) and create domestic manufacturing jobs in the PV sector. This goal became a reality with a first-generation product in 2018 and now, with the support of the DOE, Tomark-Worthen has launched a second-generation product known as PhotoMark® Reflections™ 205-3 and 360-3. This 2+ year effort began in late 2017 with a screening of potential polymeric materials and backsheet structural designs. Performance evaluations of each material provided the necessary data needed to select the proper material combinations and move forward into the design of the manufacturing process. These decisions were made by teaming with a local university, well-respected government laboratories, and private research organizations who provided the tools necessary to predict long-term performance of these materials in much shorter periods of time. Once the go/no-go criteria were met at the mid-point of the project, the effort transitioned to predicting 30+ year performance, achieving certifications, and improving manufacturing efficiencies designed to lower costs in order to be competitive in a cost-driven market. Major project accomplishments include recognition of the new backsheet by Underwriters Laboratories (UL) and international certification for 1000V and 1500V modules by TUV Sud. Both 1000V and 1500V products have been proven on several module manufacturing lines and initial customer orders have been received by both domestic and international module producers. Accelerated exposure testing has shown that the performance of this backsheet exceeds the prior polyamide-based backsheet known to fail in the field. Cost-models and initial customer orders have shown the ability to produce this backsheet at a cost acceptable to many domestic manufacturers, while International costs for standard backsheet remains extremely low. Tomark-Worthen remains one of the only U.S. companies manufacturing backsheet domestically and this has drawn interest from many domestic module manufacturers looking to improve their material supply logistics by avoiding long lead times and custom’s headaches while avoiding current tariffs on Chinese-made components. Along with the launch of a new PV backsheet, this project has provided a critical deliverable to the PV R&D community. This deliverable is the knowledge that not all polyamide-containing backsheets are doomed to failure as the earlier versions did. There has been a fear amongst the PV community to consider these materials due to the failure of one design. This effort has brought a new level of interest to the scientific community as it has been shown that polyamides can be used successfully in a well-designed backsheet. As we move forward from this project, we are excited to see how backsheet technology and manufacturing in the U.S. will continue to progress and grow.

14 SOLAR ENERGY↗

NASA NTRS1977

Ground development and flight correlation of the vortex attenuating spline device

Data presented indicate that the wing-mounted spline is a effective vortex-attenuating device. A comparison of the vortex induced rolling moment results at a separation scale distance of 0.70 km with those measured in full scale flight indicate good agreement for the unattenuated vortex configuration. The comparison also indicates that the spline effectiveness in flight was greater than in the ground facility test. The results of an applications study show that, for the heavy commercial jet aircraft studied, use of the splines does result in some degradation of the climb gradient and rate of climb, but the aircraft should meet certification requirements.

Patterson, J. C., Jr.↗

NASA NTRS1990

GCS programmer's manual

A variety of instructions to be used in the development of implementations of software for the Guidance and Control Software (GCS) project is described. This document fulfills the Radio Technical Commission for Aeronautics RTCA/DO-178A guidelines, 'Software Considerations in Airborne Systems and Equipment Certification' requirements for document No. 4, which specifies the information necessary for understanding and programming the host computer, and document No. 12, which specifies the software design and implementation standards that are applicable to the software development and testing process. Information on the following subjects is contained: activity recording, communication protocol, coding standards, change management, error handling, design standards, problem reporting, module testing logs, documentation formats, accuracy requirements, and programmer responsibilities.

Lowman, Douglas S.↗

NASA NTRS1982

Stability and control flight test results of the space transportation system's orbiter

Flight testing of the Space Shuttle Orbiter is in progress and current results of the post-flight aerodynamic analyses are discussed. The purpose of these analyses is to reduce the pre-flight aerodynamic uncertainties, thereby leading to operational certification of the Orbiter flight envelope relative to the integrated airframe and flight control system. Primary data reduction is accomplished with a well documented maximum likelihood system identification techniques.

Culp, M. A.↗

NASA NTRS2005

Investigations of Shuttle Main Landing Gear Door Environmental Seals

The environmental seals for the main landing gear doors of the Shuttle Orbiters were raised by the Columbia Accident Investigation Board as a potential safety concern. Inspections of seals installed on the Shuttle Discovery revealed that they were permanently deformed and no longer met certified seal compression requirements. Replacement of the seals led to the inability to fully close the main landing gear doors. Johnson Space Center requested that Glenn Research Center conduct tests on the main landing gear door environmental seals to assist in installing the seals in a manner to allow the main landing gear doors to fully close. Further testing was conducted to fill out the seal performance database. Results from the testing indicated that the method of bonding the seals was important in reducing seal loads on the main landing gear doors. Also, the replacement seals installed in Shuttle Discovery were found to have leakage performance sufficient to meet the certification requirements.

Finkbeiner, Joshua↗

NASA NTRSDate not supplied

Ice Shape Analysis of an eVTOL Propeller in Forward Flight at the NASA Glenn Icing Research Tunnel

Advanced Air Mobility (AAM) introduces many novel electric vertical takeoff and landing (eVTOL) aircraft configurations for which the effect of icing is not well understood. While icing computational tools have often aided in the design and certification of conventional aircraft, experimental data is needed to support the development and validation of such tools for eVTOL applications. To investigate the icing phenomenon relevant to eVTOL aircraft, NASA Glenn Research Center developed a general-purpose propeller test stand for conducting fundamental icing research on electrically driven propellers in the Icing Research Tunnel (IRT). A 10-day test entry in the IRT was completed in March, 2023, with the goal of generating ice accretions on a non-proprietary propeller geometry under well-characterized conditions. Three carbon fiber propellers of diameters 0.610, 0.711, and 0.914 m (24, 28, and 36 in) were used during the test. Various parametric sweeps of cloud and operating conditions were performed to evaluate the sensitivity of the parameters on the resulting ice accretion characteristics such as ice thickness, mass, location (impingement limits), and type (glaze vs rime). Ice shapes were reviewed for their repeatability, correctness of trends, and sensitivity to parameter variations. The data from the test is being used to support the development of the ice accretion solver, GlennICE.

Icing↗

NASA NTRS2024

Ice Shape Analysis of an eVTOL Propeller in Forward Flight at the NASA Glenn Icing Research Tunnel

Icing↗

NASA NTRS1978

Development of advanced composite structures

Composite structure programs: the L-1011 Advanced Composite Vertical Fin (ACVF), the L-1011 Advanced Composite Aileron, and a wing study program were reviewed. These programs were structured to provide the technology and confidence for the use of advanced composite materials for primary and secondary structures of future transport aircraft. The current status of the programs is discussed. The results of coupon tests for both material systems are presented as well as the ACVF environmental (moisture and temperature) requirements. The effect of moisture and temperature on the mechanical properties of advanced composite materials is shown. The requirements set forth in the FAA Certification Guidelines for Civil Composite Aircraft Structures are discussed as they relate to the ACVF.

Stauffer, W. A.↗

NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗

DOE OSTI2017

Safety software release options to support plant start-up and commissioning activities - 285

The schedule demands on new nuclear power plant site testing and commissioning programs challenge the plant's Instrumentation and Control (I and C) supplier's ability to provide certified safety software releases to meet the needs of these programs. This paper outlines the typical certified safety software development and certification process which follows a Waterfall software life-cycle model. The conflicts that result between supporting the site program and the safety software supplier's internal certification program are identified. An adapted 'functional' safety release process is presented that supports the site program's needs for software changes and in parallel enables the safety software certification process to proceed. Comparisons between the two safety software release processes are examined and the benefits realized through the use of the adapted 'functional' safety software release process are discussed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗