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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 NTRS2002

Survey of NASA V and V Processes/Methods

The purpose of this report is to describe current NASA Verification and Validation (V&V) techniques and to explain how these techniques are applicable to 2nd Generation RLV Integrated Vehicle Health Management (IVHM) software. It also contains recommendations for special V&V requirements for IVHM. This report is divided into the following three sections: 1) Survey - Current NASA V&V Processes/Methods; 2) Applicability of NASA V&V to 2nd Generation RLV IVHM; and 3) Special 2nd Generation RLV IVHM V&V Requirements.

Pecheur, Charles↗
NASA NTRS2002

A Plan for Advanced Guidance and Control Technology for 2nd Generation Reusable Launch Vehicles

Advanced guidance and control (AG&C) technologies are critical for meeting safety/reliability and cost requirements for the next generation of reusable launch vehicle (RLV). This becomes clear upon examining the number of expendable launch vehicle failures in the recent past where AG&C technologies would have saved a RLV with the same failure mode, the additional vehicle problems where this technology applies, and the costs associated with mission design with or without all these failure issues. The state-of-the-art in guidance and control technology, as well as in computing technology, is at the point where we can took to the possibility of being able to safely return a RLV in any situation where it can physically be recovered. This paper outlines reasons for AG&C, current technology efforts, and the additional work needed for making this goal a reality.

Hanson, John M.↗
NASA NTRS2002

Characterization of C/SiC Ceramic Matrix Composites (CMCs) with Novel Interface Fiber Coatings

Ceramic Matrix Composites (CMCs) are attractive candidate materials in the aerospace industry due to their high specific strength, low density and higher temperature capabilities. The National Aeronautics and Space Administration (NASA) is pursuing the use of CMC components in advanced Reusable Launch Vehicle (RLV) propulsion applications. Carbon fiber-reinforced silicon carbide (C/SiQ is the primary material of interest for a variety of RLV propulsion applications. These composites offer high-strength carbon fibers and a high modulus, oxidation-resistant matrix. For comparison, two types of carbon fibers were processed with novel types of interface coatings (multilayer and pseudoporous). For RLV propulsion applications, environmental durability will be critical. The coatings show promise of protecting the carbon fibers from the oxidizing environment. The strengths and microstructures of these composite materials are presented.

Petko, Jeanne F.↗
NASA NTRS2002

Characterization of C/SiC Ceramic Matrix Composites (CMCs) with Novel Interface Fiber Coatings

Ceramic Matrix Composites (CMCs) are attractive candidate aerospace materials due to their high specific strength, low density and high temperature capabilities. The National Aeronautics and Space Administration (NASA) is pursuing the use of CMC components in advanced Reusable Launch Vehicle (RLV) propulsion applications. Carbon fiber-reinforced silicon carbide (C/SiC) is the primary material of interest for a variety of RLV propulsion applications. These composites consist of high-strength carbon fibers and a high modulus, oxidation resistant matrix. For RLV propulsion applications, environmental durability will be critical. Two types of carbon fibers were processed with both standard (pyrolytic carbon) and novel (multilayer and pseudoporous) types of interface coatings as part of a study investigating various combinations of constituents. The benefit of protecting the composites with a surface sealant was also investigated. The strengths, durability in oxidizing environments, and microstructures of these developmental composite materials are presented. The novel interface coatings and the surface sealant show promise for protecting the carbon fibers from the oxidizing environment.

Petko, Jeanne F.↗
NASA NTRS2002

Preliminary Thermal-Mechanical Sizing of Metallic TPS: Process Development and Sensitivity Studies

The purpose of this research was to perform sensitivity studies and develop a process to perform thermal and structural analysis and sizing of the latest Metallic Thermal Protection System (TPS) developed at NASA LaRC (Langley Research Center). Metallic TPS is a key technology for reducing the cost of reusable launch vehicles (RLV), offering the combination of increased durability and competitive weights when compared to other systems. Accurate sizing of metallic TPS requires combined thermal and structural analysis. Initial sensitivity studies were conducted using transient one-dimensional finite element thermal analysis to determine the influence of various TPS and analysis parameters on TPS weight. The thermal analysis model was then used in combination with static deflection and failure mode analysis of the sandwich panel outer surface of the TPS to obtain minimum weight TPS configurations at three vehicle stations on the windward centerline of a representative RLV. The coupled nature of the analysis requires an iterative analysis process, which will be described herein. Findings from the sensitivity analysis are reported, along with TPS designs at the three RLV vehicle stations considered.

Poteet, Carl C.↗
NASA NTRS2003

Multi-Disciplinary Analysis for Future Launch Systems Using NASA's Advanced Engineering Environment (AEE)

A new engineering environment constructed for the purposes of analyzing and designing Reusable Launch Vehicles (RLVs) is presented. The new environment has been developed to allow NASA to perform independent analysis and design of emerging RLV architectures and technologies. The new Advanced Engineering Environment (AEE) is both collaborative and distributed. It facilitates integration of the analyses by both vehicle performance disciplines and life-cycle disciplines. Current performance disciplines supported include: weights and sizing, aerodynamics, trajectories, propulsion, structural loads, and CAD-based geometries. Current life-cycle disciplines supported include: DDT&E cost, production costs, operations costs, flight rates, safety and reliability, and system economics. Involving six NASA centers (ARC, LaRC, MSFC, KSC, GRC and JSC), AEE has been tailored to serve as a web-accessed agency-wide source for all of NASA's future launch vehicle systems engineering functions. Thus, it is configured to facilitate (a) data management, (b) automated tool/process integration and execution, and (c) data visualization and presentation. The core components of the integrated framework are a customized PTC Windchill product data management server, a set of RLV analysis and design tools integrated using Phoenix Integration's Model Center, and an XML-based data capture and transfer protocol. The AEE system has seen production use during the Initial Architecture and Technology Review for the NASA 2nd Generation RLV program, and it continues to undergo development and enhancements in support of its current main customer, the NASA Next Generation Launch Technology (NGLT) program.

Monell, D.↗
NASA NTRS2003

Advanced Guidance and Control for Hypersonics and Space Access

Advanced guidance and control (AG&C) technologies are critical for meeting safety, reliability, and cost requirements for the next generation of reusable launch vehicle (RLV), whether it is fully rocket-powered or has air- breathing components. This becomes clear upon examining the number of expendable launch vehicle failures in the recent past where AG&C technologies could have saved a RLV with the same failure mode, the additional vehicle problems where t h i s technology applies, and the costs and time associated with mission design with or without all these failure issues. The state-of-the-art in guidance and control technology, as well as in computing technology, is the point where we can look to the possibility of being able to safely return a RLV in any situation where it can physically be recovered. This paper outlines reasons for AWC, current technology efforts, and the additional work needed for making this goal a reality. There are a number of approaches to AG&C that have the potential for achieving the desired goals. For some of these methods, we compare the results of tests designed to demonstrate the achievement of the goals. Tests up to now have been focused on rocket-powered vehicles; application to hypersonic air-breathers is planned. We list the test cases used to demonstrate that the desired results are achieved, briefly describe an automated test scoring method, and display results of the tests. Some of the technology components have reached the maturity level where they are ready for application to a new vehicle concept, while others are not far along in development.

Hanson, John M.↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shockshock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates are highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shock-shock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates a r e highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS1999

Communications and Tracking of Visiting Vehicles near ISS: The Design of the Reusable Launch Vehicle Communications

The International Space Station (ISS) will provide for the visitation of various vehicles such as the Shuttle, Automated Transfer Vehicle (ATV), H-II Transfer Vehicle (HTV), Crew Return Vehicle (CRV), Reusable Launch Vehicle (RLV) and Soyuz. These vehicles will provide for crew replacement, consumables resupply, and equipment delivery. In order for these vehicles to approach and eventually dock with the ISS, there must be near continuous communications coverage between the visiting vehicle and the ISS, as well as communications between the vehicle and a Mission Control Center (MCC). Since the ISS communications systems are already designed and scheduled for ISS activation, the vehicles must either utilize these communications systems or provide their own. There are two means of two-way communications with the ISS. These are (1) S-Band communications using TDRSS, and (2) UHF communications using some form of the Space to Space Station Radio (SSSR) link. The RLV utilizes ISS compatible communications systems to communicate with both the ISS and a Mission Control Center. Since all vehicles must adhere to the Visiting Vehicle Interface requirements given in reference 1, the RLV communications system design must meet these requirements during entry into the ISS Approach Ellipsoid (AE) and during Proximity Operations. Included in this paper are descriptions of these communications approaches as well as their potential utilization in the ISS communications system.

Stillwagen, Frederic H.↗
NASA NTRS1999

Airframe Integration Trade Studies for a Reusable Launch Vehicle

Future launch vehicles must be lightweight, fully reusable and easily maintained if low-cost access to space is to be achieved. The goal of achieving an economically viable Single-Stage-to-Orbit (SSTO) Reusable Launch Vehicle (RLV) is not easily achieved and success will depend to a large extent on having an integrated and optimized total system. A series of trade studies were performed to meet three objectives. First, to provide structural weights and parametric weight equations as inputs to configuration-level trade studies. Second, to identify, assess and quantify major weight drivers for the RLV airframe. Third, using information on major weight drivers, and considering the RLV as an integrated thermal structure (composed of thrust structures, tanks, thermal protection system, insulation and control surfaces), identify and assess new and innovative approaches or concepts that have the potential for either reducing airframe weight, improving operability, and/or reducing cost.

Dorsey, John T.↗
NASA NTRS1995

Cooperative Testing of Rocket Injectors That Use Gaseous Oxygen and Hydrogen

Gaseous oxygen and hydrogen propellants used in a special engine energy cycle called Full-Flow Staged Combustion are believed to significantly increase the lifetime of a rocket engine's pumps. The cycle can also reduce the operating temperatures of the engine. Improving the lifetime of the hardware reduces its overall maintenance and operations costs, and is critical to reducing costs for the joint NASA/industry Reusable Launch Vehicle (RLV). The work in this project will demonstrate the performance and lifetime of one-element and many-element combustors with gaseous O2/H2 injectors. This work supporting the RLV program is a cooperative venture of the NASA Lewis Research Center, the NASA Marshall Space Flight Center, Rocketdyne, and the Pennsylvania State University. Information about gas-gas rocket injector performance with O2/H2 is very limited. Because of this paucity of data, new testing is needed to improve the knowledge base for testing and designing new injectors for the RLV and to improve computer models that predict the combusting gas flows of new injector designs. Therefore, detailed observations and measurements of the combusting flow from many-element injectors in a rocket engine are being sought. These observations and measurements will be done with three different tools: schlieren photography, ultraviolet imaging, and Raman spectroscopy. The schlieren system will take photos of the density differences in combusting flow, the ultraviolet movies will determine the location of the hydroxyl (OH) radical in the combustion flow, and the Raman spectroscopic measurements will provide the combustion temperature and amount of water (H2O), hydrogen (H2), and oxygen (O2) in the combustor. Marshall is providing overall program management, design and computational fluid dynamics (CFD) analyses, as well as funding for the work at Penn State. An existing, windowed combustor and several injectors will be provided by Rocketdyne--two injectors for the initial screening tests and one with an optimized design based on the best design found in the screening tests. Lewis will provide a nozzle and several injectors for the screening test program. The configuration of the injectors will be based on a design chosen by all the participants, and their elements will be based on the coaxial and impinging flow. Lewis also will provide the instrumentation for the flow-field measurements: schlieren, ultraviolet imaging, and Raman spectroscopy. In addition, thermocouples will measure heat flow on the injector face. Other traditional measurements of rocket performance will be made as well: chamber pressure, mass flow of each propellant, purge flow, and the barrier cooling gas flow. Penn State will conduct single-element testing with the injector elements from both the Rocketdyne and the jointly designed injectors. A wide variety of traditional and nontraditional injector designs will be tested in this program. The results will be valuable in computational fluid dynamics code validation and overall rocket combustion efficiency measurements. Correlations between combustion efficiency, laser measurements of species, and ultraviolet and visible light photography will also be made. Thus far, several different single-element injectors have been tested at Penn State and Lewis. The experimental setup of a rocket engine with a viewing window is shown. The combusting flow is shown. The results are helping engineers design the many element injectors.

Source record↗
NASA NTRS2004

Propulsion Integrated Vehicle Health Management Technology Experiment (PITEX) Conducted

The Propulsion Integrated Vehicle Health Management (IVHM) Technology Experiment (PITEX) is a continuing NASA effort being conducted cooperatively by the NASA Glenn Research Center, the NASA Ames Research Center, and the NASA Kennedy Space Center. It was a key element of a Space Launch Initiative risk-reduction task performed by the Northrop Grumman Corporation in El Segundo, California. PITEX's main objectives are the continued maturation of diagnostic technologies that are relevant to second generation reusable launch vehicle (RLV) subsystems and the assessment of the real-time performance of the PITEX diagnostic solution. The PITEX effort has considerable legacy in the NASA IVHM Technology Experiment for X-vehicles (NITEX) that was selected to fly on the X-34 subscale RLV that was being developed by Orbital Sciences Corporation. NITEX, funded through the Future-X Program Office, was to advance the technology-readiness level of selected IVHM technologies within a flight environment and to begin the transition of these technologies from experimental status into RLV baseline designs. The experiment was to perform realtime fault detection and isolation and suggest potential recovery actions for the X-34 main propulsion system (MPS) during all mission phases by using a combination of system-level analysis and detailed diagnostic algorithms.

Maul, William A.↗
NASA NTRS2002

Characterization on C/SiC Ceramic Matrix Composites with Novel Fiber Coatings

Ceramic Matrix Composites (CMCs) are attractive candidate materials in the aerospace industry due to their high specific strength, low density and higher temperature capabilities. The National Aeronautics and Space Administration (NASA) is pursuing the use of CMC components in advanced Reusable Launch Vehicle (RLV) propulsion applications. Carbon fiber-reinforced silicon carbide (C/SiC) is the primary material of interest for a variety of RLV propulsion applications. These composites offer high- strength carbon fibers and a high modulus, oxidation-resistant matrix. For comparison, two types of carbon fibers were processed with novel types of interface coatings (multilayer and pseudoporous). For RLV propulsion applications, environmental durability will be critical. The coatings show promise of protecting the carbon fibers from the oxidizing environment. The strengths and microstructures of these composite materials are presented.

Petko, Jeanne↗
NASA NTRS2006

Generic Environment for Simulating Launch Operations

GEM-FLO (A Generic Simulation Environment for Modeling Future Launch Operations) is a computer program that facilitates creation of discrete-event simulation models of ground processes in which reusable or expendable launch vehicles (RLVs) are prepared for flight. GEM-FLO includes a component, developed in Visual Basic, that generates a graphical user interface (GUI) and a component, developed in the Arena simulation language, that creates a generic discrete-event simulation model. Through the GUI, GEM-FLO elicits RLV design information from the user. The design information can include information on flight hardware elements, resources, and ground processes. GEM-FLO translates the user s responses into mathematical variables and expressions that populate the generic simulation model. The variables and expressions can represent processing times, resource capacities, status variables, and other process parameters needed to configure a simulation model that reflects the ground processing flow and requirements of a specific RLV. Upon execution of the model, GEMFLO puts out data on many measures of performance, including the flight rate, turnaround time, and utilization of resources. This information can serve as the basis for determining whether design goals can be met, and for comparing characteristics of competing RLV designs

Steele, Martin↗
NASA NTRS2001

Potential Future Shuttle Improvements

NASA has just recently completed the 104th flight of the Space Shuttle. Each of the four Orbiters in the Shuttle fleet have a design life of 100 flights each. Thus the fleet is capable of almost 300 more flights, and at current flight rates could potentially operate well past 2020 if necessary. This paper addresses some of the potential Shuttle system improvements that could be considered if the decision is made to continue operations of this vehicle for such an extended period. The national space transportation policy envisions a decision around 2005-2006 concerning readiness to start development of a Shuttle replacement system. Leading up to that decision point NASA is investing in the Space Launch Initiative (SLI) to reduce the development risks associated with key technologies needed for the next generation reusable launch vehicle (RLV). The Shuttle replacement could be a new design RLV or could be based on a Shuttle derived design: i.e., a vehicle based on the current Shuttle but with major design changes. The technology investment strategy of SLI is supportive of either approach. However, if NASA and industry are not ready to develop a replacement vehicle in the 2006-2012 timeframe, then another option would be to continue to make important, but evolutionary changes, to the existing Shuttle fleet. The overall strategy for next generation RLV planning, including possible Shuttle evolution, is captured in Figure 1.

Henderson, Edward↗
NASA NTRS1994

Program test objectives milestone 3

The following conclusions have been developed relative to propulsion system technology adequacy for efficient development and operation of recoverable and expendable launch vehicles (RLV and ELV) and the benefits which the integrated propulsion technology demonstrator will provide for enhancing technology: (1) Technology improvements relative to propulsion system design and operation can reduce program cost. Many features or improvement needs to enhance operability, reduce cost, and improve payload are identified. (2) The Integrated Propulsion Technology Demonstrator (IPTD) Program provides a means of resolving the majority of issues associated with improvement needs. (3) The IPTD will evaluate complex integration of vehicle and facility functions in fluid management and propulsion control systems, and provides an environment for validating improved mechanical and electrical components. (4) The IPTD provides a mechanism for investigating operational issues focusing on reducing manpower and time to perform various functions at the launch site. These efforts include model development, collection of data to validate subject models, and ultimate development of complex time line models. (5) The IPTD provides an engine test bed for tri/bi-propellant engine development firings which is representative of the actual vehicle environment. (6) The IPTD provides for only a limited multiengine configuration integration environment for RLV. Multiengine efforts may be simulated for a number of subsystems and a number of subsystems are relatively independent of the multiengine influences.

Gaynor, T. L.↗
NASA NTRS1995

Design of launch systems using continuous improvement process

The purpose of this paper is to identify a systematic process for improving ground operations for future launch systems. This approach is based on the Total Quality Management (TQM) continuous improvement process. While the continuous improvement process is normally identified with making incremental changes to an existing system, it can be used on new systems if they use past experience as a knowledge base. In the case of the Reusable Launch Vehicle (RLV), the Space Shuttle operations provide many lessons. The TQM methodology used for this paper will be borrowed from the United States Air Force 'Quality Air Force' Program. There is a general overview of the continuous improvement process, with concentration on the formulation phase. During this phase critical analyses are conducted to determine the strategy and goals for the remaining development process. These analyses include analyzing the mission from the customers point of view, developing an operations concept for the future, assessing current capabilities and determining the gap to be closed between current capabilities and future needs and requirements. A brief analyses of the RLV, relative to the Space Shuttle, will be used to illustrate the concept. Using the continuous improvement design concept has many advantages. These include a customer oriented process which will develop a more marketable product and a better integration of operations and systems during the design phase. But, the use of TQM techniques will require changes, including more discipline in the design process and more emphasis on data gathering for operational systems. The benefits will far outweigh the additional effort.

Brown, Richard W.↗