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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2015

FJET Database Project: Extract, Transform, and Load

The Data Mining & Knowledge Management team at Kennedy Space Center is providing data management services to the Frangible Joint Empirical Test (FJET) project at Langley Research Center (LARC). FJET is a project under the NASA Engineering and Safety Center (NESC). The purpose of FJET is to conduct an assessment of mild detonating fuse (MDF) frangible joints (FJs) for human spacecraft separation tasks in support of the NASA Commercial Crew Program. The Data Mining & Knowledge Management team has been tasked with creating and managing a database for the efficient storage and retrieval of FJET test data. This paper details the Extract, Transform, and Load (ETL) process as it is related to gathering FJET test data into a Microsoft SQL relational database, and making that data available to the data users. Lessons learned, procedures implemented, and programming code samples are discussed to help detail the learning experienced as the Data Mining & Knowledge Management team adapted to changing requirements and new technology while maintaining flexibility of design in various aspects of the data management project.

excel vba↗
NASA NTRS1990

Current limiting remote power control module

The power source for the Space Station Freedom will be fully utilized nearly all of the time. As such, any loads on the system will need to operate within expected limits. Should any load draw an inordinate amount of power, the bus voltage for the system may sag and disrupt the operation of other loads. To protect the bus and loads some type of power interface between the bus and each load must be provided. This interface is most crucial when load faults occur. A possible system configuration is presented. The proposed interface is the Current Limiting Remote Power Controller (CL-RPC). Such an interface should provide the following power functions: limit overloading and resulting undervoltage; prevent catastrophic failure and still provide for redundancy management within the load; minimize cable heating; and provide accurate current measurement. A functional block diagram of the power processing stage of a CL-RPC is included. There are four functions that drive the circuit design: rate control of current; current sensing; the variable conductance switch (VCS) technology; and the algorithm used for current limiting. Each function is discussed separately.

Hopkins, Douglas C.↗
NASA NTRS1995

Description of a MIL-STD-1553B Data Bus Ada Driver for the LeRC EPS Testbed

This document describes the software designed to provide communication between control computers in the NASA Lewis Research Center Electrical Power System Testbed using MIL-STD-1553B. The software drivers are coded in the Ada programming language and were developed on a MSDOS-based computer workstation. The Electrical Power System (EPS) Testbed is a reduced-scale prototype space station electrical power system. The power system manages and distributes electrical power from the sources (batteries or photovoltaic arrays) to the end-user loads. The electrical system primary operates at 120 volts DC, and the secondary system operates at 28 volts DC. The devices which direct the flow of electrical power are controlled by a network of six control computers. Data and control messages are passed between the computers using the MIL-STD-1553B network. One of the computers, the Power Management Controller (PMC), controls the primary power distribution and another, the Load Management Controller (LMC), controls the secondary power distribution. Each of these computers communicates with two other computers which act as subsidiary controllers. These subsidiary controllers are, in turn, connected to the devices which directly control the flow of electrical power.

Mackin, Michael A.↗
NASA NTRS1982

Capillary Pump Loop (CPL) heat pipe development status report

The capillary pump loop (CPL) was re-introduced as a potential candidate for the management of large heat loads. It is currently being evaluated for application in the thermal management of large space structures. Test efforts were conducted to establish the feasibility of the CPL heat pipe design.

Source record↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗
NASA NTRS1983

Specification for a Program for an Interative Aeroelastic Solution (PIAS)

An engineering and software specification which was written for a computer program to calculate aeroelastic structural loads including the effects of nonlinear aerodynamics is presented. The procedure used in the program for an iterative aeroelastic solution (PIAS) is to alternately execute two computer codes: one to calculate aerodynamic loads for a specific wing shape, and another to calculate the deflected shape caused by this loading. A significant advantage to the design of PIAS is that the initial aerodynamic module can be replaced with others. The leading edge vortex (LEV) program is used as the aerodynamic module in PIAS. This provides the capability to calculate aeroelastic loads, including the effects of a separation induced leading edge vortex. The finite element method available in ATLAS Integrated structural analysis and design system is used to determine the deflected wing shape for the applied aerodynamics and inertia loads. The data management capabilities in ATLAS are used by the execution control monitor (ECM) of PIAS to control the solution process.

Manro, M. E.↗
NASA NTRS1984

Aerospace Safety Advisory Panel

An assessment of NASA's safety performance for 1983 affirms that NASA Headquarters and Center management teams continue to hold the safety of manned flight to be their prime concern, and that essential effort and resources are allocated for maintaining safety in all of the development and operational programs. Those conclusions most worthy of NASA management concentration are given along with recommendations for action concerning; product quality and utility; space shuttle main engine; landing gear; logistics and management; orbiter structural loads, landing speed, and pitch control; the shuttle processing contractor; and the safety of flight operations. It appears that much needs to be done before the Space Transportation System can achieve the reliability necessary for safe, high rate, low cost operations.

Source record↗
NASA NTRS1988

Space Station battery system design and development

The Space Station Electric Power System will rely on nickel-hydrogen batteries in its photovoltaic power subsystem for energy storage to support eclipse and contingency operations. These 81-Ah batteries will be designed for a 5-year life capability and are configured as orbital replaceable units (ORUs), permitting replacement of worn-out batteries over the anticipated 30-year Station life. This paper describes the baseline design and the development plans for the battery assemblies, the battery ORUs and the battery system. Key elements reviewed are the cells, mechanical and thermal design of the assembly, the ORU approach and interfaces, and the electrical design of the battery system. The anticipated operational approach is discussed, covering expected performance as well as the processor-controlled charge management and discharge load allocation techniques. Development plans cover verification of materials, cells, assemblies and ORUs, as well as system-level test and analyses.

Haas, R. J.↗
NASA NTRS1992

Lunar base thermal management/power system analysis and design

A compilation of several lunar surface thermal management and power system studies completed under contract and IR&D is presented. The work includes analysis and preliminary design of all major components of an integrated thermal management system, including loads determination, active internal acquisition and transport equipment, external transport systems (active and passive), passive insulation, solar shielding, and a range of lunar surface radiator concepts. Several computer codes were utilized in support of this study, including RADSIM to calculate radiation exchange factors and view factors, RADIATOR (developed in-house) for heat rejection system sizing and performance analysis over a lunar day, SURPWER for power system sizing, and CRYSTORE for cryogenic system performance predictions. Although much of the work was performed in support of lunar rover studies, any or all of the results can be applied to a range of surface applications. Output data include thermal loads summaries, subsystem performance data, mass, and volume estimates (where applicable), integrated and worst-case lunar day radiator size/mass and effective sink temperatures for several concepts (shielded and unshielded), and external transport system performance estimates for both single and two-phase (heat pumped) transport loops. Several advanced radiator concepts are presented, along with brief assessments of possible system benefits and potential drawbacks. System point designs are presented for several cases, executed in support of the contract and IR&D studies, although the parametric nature of the analysis is stressed to illustrate applicability of the analysis procedure to a wide variety of lunar surface systems. The reference configuration(s) derived from the various studies will be presented along with supporting criteria. A preliminary design will also be presented for the reference basing scenario, including qualitative data regarding TPS concerns and issues.

Mcghee, Jerry R.↗
NASA NTRS1996

Supersonic Channel Concept for Enhancement of Lift/Drag Ratio

The concept studied during the summer NASA/ASEE Fellowship provides a means of lowering drag and a means for directional control of supersonic and hypersonic vehicles. Low drag and efficient directional control are essential for the success of aircraft, atmospheric entry vehicles, missiles, and other vehicles in supersonic and hypersonic flight. Drag reduction can result in increased vehicle range, increased speed, improved fuel efficiency, increased lift/drag ratio, and increased climb rate. For high supersonic and hypersonic vehicles heat transfer considerations dictate the design of the nose and leading edge. The heat transfer to such vehicles is most severe at stagnation points which occur on the leading edges and nose of the vehicle. Theoretical formulations, experimental data, and semi-empirical formulas all agree in the fact that stagnation point heat transfer is inversely proportional to the square root of the nose or leading edge radius. Thus, the noses and leading edges of supersonic and hypersonic vehicles are typically blunted so that the heat transfer and structural loads will be manageable. However, much of the wave drag experienced by these vehicles is due to nose blunting.

Ruffin, Stephen M.↗
NASA NTRS2001

Phased-Array Satcom Antennas Developed for Aeronautical Applications

The Advanced Communications (AC) for Aeronautics research at the NASA Glenn Research Center integrates both aeronautics and space communications technologies to achieve the national objective of upgrading the present National Airspace System infrastructure by responding to the agency's aviation capacity and safety goals. One concept for future air traffic management, free flight, presents a significantly increased demand for communications systems capacity and performance in comparison to current air traffic management practices. Current aeronautical communications systems are incapable of supporting the anticipated demands, and the new digital data communications links that are being developed, or are in the early stages of implementation, are not primarily designed to carry the data-intensive free flight air traffic management (ATM) communications loads. Emerging satellite communications technologies are the best potential long-term solution to provide the capacity and performance necessary to enable a mature free flight concept to be deployed. NASA AC/ATM funded the development of a Boeing-designed Ku-band transmit phased-array antenna, a combined in-house and contract effort. Glenn designed and integrated an Aeronautical Mobile Satellite Communications terminal based on the transmit phased-array antenna and a companion receive phased-array antenna previously developed by Boeing.

Kerczewski, Robert J.↗
NASA NTRS2010

Handling Qualities of a Capsule Spacecraft During Atmospheric Entry

A piloted simulation was conducted to study handling qualities for capsule spacecraft entering the Earth s atmosphere. Eight evaluation pilots, including six pilot astronauts, provided Cooper-Harper ratings, workload ratings, and qualitative comments. The simulation began after descending through the atmospheric entry interface point and continued until the drogue parachutes deployed. There were two categories of piloting tasks, both of which required bank angle control. In one task category, the pilot followed a closed-loop bank angle command computed by the backup guidance system to manage g-loads during entry. In the other task category, the pilot used intuitive rules to determine the desired bank angle independently, based on an open-loop schedule of vertical speed, Mach, and total energy specified at several range-to-target gates along the entry trajectory. Pilots were able to accurately track the bank angle guidance commands and steered the capsule toward the recovery site with essentially the same range error as the benchmark autopilot trajectory albeit with substantially higher propellant usage, and the handling qualities for this task were satisfactory. Another key result was that the complex piloting task of atmospheric entry could be performed satisfactorily, even in the presence of large dispersions, by controlling bank angle to follow a simple open-loop schedule.

Bilimoria, Karl D.↗
NASA NTRS2011

A Human-in-the-Loop Evaluation of Multi-Sector Planning in Mixed Equipage Airspace (MSP III)

A human-in-the-loop (HITL) simulation was conducted in May 2010 to determine the feasibility and value 01 conducting multi-sector planning (MSP) operations in a mixed equipage environment. Aircraft were categorized as equipped or unequipped based on the presence or absence of an air-ground data communications (Data Comm) capability for receiving auto-loadable clearances and transfer of communication messages from the air navigation service provider (ANSP). The purpose of the study was to determine the feasibility and possible benefits of introducing multi-sector planning in a mixed equipage context, or whether Data Comm equipage was required for MSP operations. Each test scenario presented one of three different equipage levels to the controllers (10%, 50% or 90% equipped aircraft), so that the operational impact of different equipage levels could be observed. Operational feasibility assessment addressed two related questions: (1) are MSP operations feasible for unequipped aircraft, and (2) are they feasible in a mixed equipage context. Similarly, two categories of potential benefits were explored: (1) system performance improvements (e.g., throughput, workload) associated with MSP at different equipage levels, and (2) the possibility of providing differential service for equipage through MSP operations. Tool requirements (for both planning and controller stations), as well as planning and coordination procedures - within facility (traffic management unit/operational area) and within sector (R-Side/D-Side) - were two other topics addressed in the study. Overall, results suggested that MSP operations were feasible in a mixed equipage environment and that the tools were effective with both equipped and unequipped aircraft. Using the MSP tools, traffic management coordinators were able to manage controller task load, effectively balancing throughput with complexity and controller task load at each of the three equipage levels tested.

Smith, Nancy↗
NASA NTRS2012

Automation of Hubble Space Telescope Mission Operations

On June 13, 2011, after more than 21 years, 115 thousand orbits, and nearly 1 million exposures taken, the operation of the Hubble Space Telescope successfully transitioned from 24x7x365 staffing to 815 staffing. This required the automation of routine mission operations including telemetry and forward link acquisition, data dumping and solid-state recorder management, stored command loading, and health and safety monitoring of both the observatory and the HST Ground System. These changes were driven by budget reductions, and required ground system and onboard spacecraft enhancements across the entire operations spectrum, from planning and scheduling systems to payload flight software. Changes in personnel and staffing were required in order to adapt to the new roles and responsibilities required in the new automated operations era. This paper will provide a high level overview of the obstacles to automating nominal HST mission operations, both technical and cultural, and how those obstacles were overcome.

Burley, Richard↗
NASA NTRS2017

Cooling the Origins Space Telescope

The NASA Astrophysics Division has commissioned 4 studies for consideration by the 2020 Decadal Survey to be the next flagship mission following WFIRST (Wide Field Infrared Survey Telescope). One of the four studies is the Origins Space Telescope (OST), which will cover wavelengths from 6 microns to 600 microns. To perform at the level of the zodiacal, galactic, and cosmic background, the telescope must be cooled to 4 degrees Kelvin. 4 degrees Kelvin multi-stage mechanical cryocoolers will be employed along with a multilayer sunshield/thermal shield to achieve this temperature with a manageable parasitic heat load. Current state-of-the-art cryocoolers can achieve close to 4 degrees Kelvin, providing about 50 megawatts of cooling at 4 degrees Kelvin with an input power of 500 watts. Multiple coolers at this power level will be used in parallel. These coolers also provide extra cooling power at intermediate temperature stages of 15-20 degrees Kelvin and 50-70 degrees Kelvin . This upper stage cooling will be used to limit the heat conducted to 4 degrees Kelvin . The multi-layer sunshield will limit the radiated thermal energy to the 4 degrees Kelvin volume. This paper will describe the architecture of the cryogenic system for OST along with preliminary thermal models.

cryogenics↗
NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Project

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes up to 5000 watts per square centimeter and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufactruing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU and will be discussed. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature, to sub-component level testing such as 4-pt bend testing at sub-ambient and elevated temperature. ETU test results are used to validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4-pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are intended to establish the system's structural capability during entry. A broad range of aerothermal tests (arcjet tests) are being performed to develop material response models for predicting the required TPS thickness to meet a mission's needs and to evaluate failure modes. These tests establish the capability of the system and assure robustness of the system during entry. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview and status of the project and describe the status of the tehnology maturation level for the inner and outer planet as well as earth entry sample return missions.

Ellerby, Don↗
NASA NTRS2019

Overview of Heatshield for Extreme Entry Environment Technology (HEEET)

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes > 3500 W/cm2 and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufacturing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high-density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature to sub-component level testing such as 4pt bend testing at sub-ambient and elevated temperature and culminates in testing of the ETU results from which will validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are being utilized to establish the systems structural capability during entry.A broad range of aerothermal tests (arcjet tests) were performed to develop material response models for predicting the required TPS thickness to meet a missions needs and to evaluate failure modes and establish the capability of the system. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview for each of these areas and argue that HEEET has successfully achieved TRL 6.

HEEET↗