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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 NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗
NASA NTRS1988

Strain intensity factor approach for predicting the strength of continuously reinforced metal matrix composites

A method was previously developed to predict the fracture toughness (stress intensity factor at failure) of composites in terms of the elastic constants and the tensile failing strain of the fibers. The method was applied to boron/aluminum composites made with various proportions of 0 to + or - 45 deg plies. Predicted values of fracture toughness were in gross error because widespread yielding of the aluminum matrix made the compliance very nonlinear. An alternate method was developed to predict the strain intensity factor at failure rather than the stress intensity factor because the singular strain field was not affected by yielding as much as the stress field. Strengths of specimens containing crack-like slits were calculated from predicted failing strains using uniaxial stress-strain curves. Predicted strengths were in good agreement with experimental values, even for the very nonlinear laminates that contained only + or - 45 deg plies. This approach should be valid for other metal matrix composites that have continuous fibers.

Poe, C. C., Jr.↗
NASA NTRS1989

Strain intensity factor approach for predicting the strength of continuously reinforced metal matrix composites

A method was previously developed to predict the fracture toughness (stress intensity factor at failure) of composites in terms of the elastic constants and the tensile failing strain of the fibers. The method was applied to boron/aluminum composites made with various proportions of 0 deg and +/- 45 deg plies. Predicted values of fracture toughness were in gross error because widespread yielding of the aluminum matrix made the compliance very nonlinear. An alternate method was develolped to predict the strain intensity factor at failure rather than the stress intensity factor because the singular strain field was not affected by yielding as much as the stress field. Far-field strains at failure were calculated from the strain intensity factor, and then strengths were calculated from the far-field strains using uniaxial stress-strain curves. The predicted strengths were in good agreement with experimental values, even for the very nonlinear laminates that contained only +/- 45 deg plies. This approach should be valid for other metal matrix composites that have continuous fibers.

Poe, Clarence C., Jr.↗
NASA NTRS1985

Study of storm time fluxes of heavy ions

Ion composition data sets from Lockheed instruments on a variety of spacecraft were used in combination with each other and with data from other instruments to address a variety of problems regarding plasma sources, energization and transport within the magnetosphere. The availability of data from several differing orbits has given a highly flexible approach to attacking the continually evolving questions of magnetospheric physics. This approach is very successful and should be continued in the future.

Sharp, R. D.↗
NASA NTRS2013

Adoption of Test Driven Development and Continuous Integration for the Development of the Trick Simulation Toolkit

This paper describes the adoption of a Test Driven Development approach and a Continuous Integration System in the development of the Trick Simulation Toolkit, a generic simulation development environment for creating high fidelity training and engineering simulations at the NASA/Johnson Space Center and many other NASA facilities. It describes what was learned and the significant benefits seen, such as fast, thorough, and clear test feedback every time code is checked-in to the code repository. It also describes a system that encourages development of code that is much more flexible, maintainable, and reliable. The Trick Simulation Toolkit development environment provides a common architecture for user-defined simulations. Trick builds executable simulations using user-supplied simulation-definition files (S_define) and user supplied "model code". For each Trick-based simulation, Trick automatically provides job scheduling, checkpoint / restore, data-recording, interactive variable manipulation (variable server), and an input-processor. Also included are tools for plotting recorded data and various other supporting tools and libraries. Trick is written in C/C++ and Java and supports both Linux and MacOSX. Prior to adopting this new development approach, Trick testing consisted primarily of running a few large simulations, with the hope that their complexity and scale would exercise most of Trick's code and expose any recently introduced bugs. Unsurprising, this approach yielded inconsistent results. It was obvious that a more systematic, thorough approach was required. After seeing examples of some Java-based projects that used the JUnit test framework, similar test frameworks for C and C++ were sought. Several were found, all clearly inspired by JUnit. Googletest, a freely available Open source testing framework, was selected as the most appropriate and capable. The new approach was implemented while rewriting the Trick memory management component, to eliminate a fundamental design flaw. The benefits became obvious almost immediately, not just in the correctness of the individual functions and classes but also in the correctness and flexibility being added to the overall design. Creating code to be testable, and testing as it was created resulted not only in better working code, but also in better-organized, flexible, and readable (i.e., articulate) code. This was, in essence the Test-driven development (TDD) methodology created by Kent Beck. Seeing the benefits of Test Driven Development, other Trick components were refactored to make them more testable and tests were designed and implemented for them.

Penn, John M.↗
NASA NTRS1976

Helios mission support

The successful flight of the Helios-1 spacecraft continues as it approaches its third aphelion. The Helios-2 spacecraft has entered its first superior conjunction and continues in excellent health. Much valuable scientific information about the solar corona and its effects on electromagnetic waves is expected to be learned from data gathered during this superior conjunction.

Goodwin, P. S.↗
NASA NTRSDate not supplied

Cooperative Clustering Techniques Applied to Contact Graph Routing

Routing in the space internet has to face many unique challenges - from unplanned disconnections and interruptions to predictable intermittent connectivity due to high network mobility and long propagation delays. NASA’s current approach to such routing is Contact Graph Routing (CGR), using a graph formed of prescheduled communication contacts to compute routes through the network. While this approach manages to tackle issues of connectivity and propagation delays, it is a global approach that requires continuous knowledge of the entire network. In a potential future Solar Space Internet (SSI) such an approach on its own cannot scale to large networks with thousands of members. In this presentation we propose clustering as a solution to CGR scalability. Clustering has been used in many networking problems as a way to subdivide the network and allow for localized routing and better scalability. Using techniques from graph theory and game theory, we explore various existing clustering algorithms and adapt them to the Contact Graph Routing setting. Finally, we propose a way to combine multiple algorithms to create a Delay Tolerant Clustering Protocol.

Yael Kirkpatrick↗
NASA NTRSDate not supplied

Cooperative Clustering Techniques For Space Network Scalability

Routing in the space internet must face many unique challenges - from unplanned disconnections and interruptions to predictable intermittent connectivity due to high network mobility and long propagation delays. NASA’s current approach to such routing is Contact Graph Routing (CGR), using a graph formed of prescheduled communication contacts to compute routes through the network. While this approach manages to tackle issues of connectivity and propagation delays, it is a global approach that requires continuous knowledge of the entire network. In a potential future Solar Space Internet (SSI) such an approach on its own cannot scale to large networks with thousands of members. In this paper we propose clustering as a solution to CGR scalability. Clustering has been used in many networking problems as a way to subdivide the network and allow for localized routing and better scalability. Using techniques from graph theory and game theory, we explore various existing clustering algorithms and adapt them to the Contact Graph Routing setting. We propose a way to combine multiple algorithms to create a Delay Tolerant Clustering Protocol (DTCP). In addition, we explore the underlying networking mechanisms such as multicast, neighbor discovery, and software defined networking that may be used to enable DTCP.

Delay Tolerant Networking↗
NASA NTRS2002

A Method of Efficient Inclination Changes for Low-thrust Spacecraft

The evolution of low-thrust propulsion technologies has reached a point where such systems have become an economical option for many space missions. The development of efficient, low trip time control laws has received an increasing amount of attention in recent years, though few studies have examined the subject of inclination changing maneuvers in detail. A method for performing economical inclination changes through the use of an efficiency factor is derived front Lagrange's planetary equations. The efficiency factor can be used to regulate propellant expenditure at the expense of trip time. Such a method can be used for discontinuous-thrust transfers that offer reduced propellant masses and trip-times in comparison to continuous thrust transfers, while utilizing thrusters that operate at a lower specific impulse. Performance comparisons of transfers utilizing this approach with continuous-thrust transfers are generated through trajectory simulation and are presented in this paper.

Falck, Robert↗
NASA NTRS1992

Life extending control for rocket engines

The concept of life extending control is defined. A brief discussion of current fatigue life prediction methods is given and the need for an alternative life prediction model based on a continuous functional relationship is established. Two approaches to life extending control are considered: (1) the implicit approach which uses cyclic fatigue life prediction as a basis for control design; and (2) the continuous life prediction approach which requires a continuous damage law. Progress on an initial formulation of a continuous (in time) fatigue model is presented. Finally, nonlinear programming is used to develop initial results for life extension for a simplified rocket engine (model).

Lorenzo, C. F.↗
NASA NTRS1991

Sensor-actuator placement for flexible structures with actuator dynamics

A novel approach for placement of sensors and actuators in control of flexible space structures is developed. Using an approximation of the control forces and output measurements by spatially continuous functions, the approach follows a nonlinear programming technique to determine optimal locations for sensors and actuators. Two different criteria are considered for the placement of sensors and actuators. The first criterion optimizes the location of the sensors and actuators in order to move the transmission zeros of the system farther to the left of the imaginary axis. The second criterion, however, places the sensors and actuators to optimize a function of the singular values of the Hankel matrix, which includes both measures of controllability and observability. Moreover, the effect of actuator dynamics in the placement of sensors and actuators is investigated.

Maghami, P. G.↗
NASA NTRS2012

Numerical Predictions of Sonic Boom Signatures for a Straight Line Segmented Leading Edge Model

A sonic boom wind tunnel test was conducted on a straight-line segmented leading edge (SLSLE) model in the NASA Langley 4- by 4- Foot Unitary Plan Wind Tunnel (UPWT). The purpose of the test was to determine whether accurate sonic boom measurements could be obtained while continuously moving the SLSLE model past a conical pressure probe. Sonic boom signatures were also obtained using the conventional move-pause data acquisition method for comparison. The continuous data acquisition approach allows for accurate signatures approximately 15 times faster than a move-pause technique. These successful results provide an incentive for future testing with greatly increased efficiency using the continuous model translation technique with the single probe to measure sonic boom signatures. Two widely used NASA codes, USM3D (Navier-Stokes) and CART3D-AERO (Euler, adjoint-based adaptive mesh), were used to compute off-body sonic boom pressure signatures of the SLSLE model at several different altitudes below the model at Mach 2.0. The computed pressure signatures compared well with wind tunnel data. The effect of the different altitude for signature extraction was evaluated by extrapolating the near field signatures to the ground and comparing pressure signatures and sonic boom loudness levels.

Elmiligui, Alaa A.↗
NASA NTRS1980

An airport wind shear detection and warning system using Doppler radar

Two numerical models of aircraft performance are developed to relate atmospheric wind signals in wind-shear situations to aircraft response. Both models produce time histories of pitch angle, airspeed, height above the ground, and other parameters for simulating aircraft making precision approaches along a 3-deg glide slope to the runway. Simulations conducted using thunderstorm environment wind data indicate that the horizontal wind component is at least as important as the vertical component in determining aircraft response to wind shear. Obtaining quantitative measurements of aircraft approach or departure quality is found to depend on several factors, including the knowledge of winds along the expected flight track, clear-air detection in a quasi-horizontal path, and a near continuous estimate of approach deterioration due to shear conditions.

Mccarthy, J.↗
NASA NTRS2003

Using Bond Graphs for Articulated, Flexible Multi-bodies, Sensors, Actuators, and Controllers with Application to the International Space Station

Conceptually, modeling of flexible, multi-body systems involves a formulation as a set of time-dependent partial differential equations. However, for practical, engineering purposes, this modeling is usually done using the method of Finite Elements, which approximates the set of partial differential equations, thus generalizing the approach to all continuous media. This research investigates the links between the Bond Graph method and the classical methods used to develop system models and advocates the Bond Graph Methodology and current bond graph tools as alternate approaches that will lead to a quick and precise understanding of a flexible multi-body system under automatic control. For long endurance, complex spacecraft, because of articulation and mission evolution the model of the physical system may change frequently. So a method of automatic generation and regeneration of system models that does not lead to implicit equations, as does the Lagrange equation approach, is desirable. The bond graph method has been shown to be amenable to automatic generation of equations with appropriate consideration of causality. Indeed human-interactive software now exists that automatically generates both symbolic and numeric system models and evaluates causality as the user develops the model, e.g. the CAMP-G software package. In this paper the CAMP-G package is used to generate a bond graph model of the International Space Station (ISS) at an early stage in its assembly, Zvezda. The ISS is an ideal example because it is a collection of bodies that are articulated, many of which are highly flexible. Also many reaction jets are used to control translation and attitude, and many electric motors are used to articulate appendages, which consist of photovoltaic arrays and composite assemblies. The Zvezda bond graph model is compared to an existing model, which was generated by the NASA Johnson Space Center during the Verification and Analysis Cycle of Zvezda.

Montgomery, Raymond C.↗
NASA NTRS1992

Comparison of specificity and information for fuzzy domains

This paper demonstrates how an integrated theory can be built on the foundation of possibility theory. Information and uncertainty were considered in 'fuzzy' literature since 1982. Our departing point is the model proposed by Klir for the discrete case. It was elaborated axiomatically by Ramer, who also introduced the continuous model. Specificity as a numerical function was considered mostly within Dempster-Shafer evidence theory. An explicity definition was given first by Yager, who has also introduced it in the context of possibility theory. Axiomatic approach and the continuous model have been developed very recently by Ramer and Yager. They also establish a close analytical correspondence between specificity and information. In literature to date, specificity and uncertainty are defined only for the discrete finite domains, with a sole exception. Our presentation removes these limitations. We define specificity measures for arbitrary measurable domains.

Ramer, Arthur↗
NASA NTRSDate not supplied

Validation of a Probabilistic Continuity Assessment Method for Earth Observation Portfolios

With the increased reliance on spaceborne Earth observation data among the Earth science community and other end users, it is important that efforts are made to promote data continuity for a range of parameters of interest. Continuity gaps may occur between missions measuring like parameters due to mission development delays or early termination and introduce the potential of increased uncertainty for retrieved parameters. To inform portfolio-level decisions for Earth observing missions, Ivanco et al. developed a method that enables the assessment of the probability of continuity gaps for multi-mission architectures and provides a framework to assess this probability in the context of multiple scenarios that represent possible future states of the architecture [Ivanco et al., “A Scenario-Based Approach to Assess Continuity Gaps in Earth Observations,” IEEE Aerospace Conf., 2024]. While this method was previously applied to assess continuity gaps for a specific multi-mission architecture, it had not yet been validated with historical data. This paper outlines the process of validating the probabilistic gap assessment method by utilizing data obtained from past NASA Earth Science mission formulation documents and provides a discussion of the results and takeaways from the validation. Future areas of improvement pertaining to both the modeling and simulation methodologies and underlying assumptions are identified and discussed.

Katharine Burn↗
NASA NTRS2010

Characterization of MODIS Solar Diffuser On-Orbit Degradation

MODIS reflective solar bands (RSB) are calibrated using a solar diffuser (SD). The SD on-orbit degradation is determined by a solar diffuser stability monitor (SDSM) at 9 wavelengths from 0.41 to 0.94 microns via alternate observations of its sunlight reflected from the SD (SD view) and direct sunlight through an attenuation screen (Sun view). For each SDSM detector, a time series of ratios of its SD view to its Sun view responses tracks on-orbit changes in the SD bidirectional reflectance factor (BRF) at its wavelength. Due to an SDSM component design error, however, there exist large ripples in its Sun view responses, which have made it extremely difficult to use the original ratio approach for accurate characterization of SD on-orbit degradation. In order to mitigate the impact due to unexpected ripples, MODIS Characterization Support Team (MCST) developed a normalization approach. It relies on the fact that all SDSM detectors (D1 to D9) experience similar ripples and assumes that the SD degradation at its D9 wavelength (0.94 micron) is extremely small and can be ignored. As mission continues, the normalization approach becomes inadequate since the accumulated SD degradation at 0.94[tm can no longer be ignored. This paper presents a new approach to further improve on-orbit characterization of SD degradation. It uses a took-up table (LUT) with parameters derived from D9 observations made over a short period. Compared to other approaches, this approach can significantly reduce the impact due to ripples and that due to accumulated SD degradation at the reference detector wavelength.

Xiong, X.↗
NASA NTRS2014

Testability, Test Automation and Test Driven Development for the Trick Simulation Toolkit

This paper describes the adoption of a Test Driven Development approach and a Continuous Integration System in the development of the Trick Simulation Toolkit, a generic simulation development environment for creating high fidelity training and engineering simulations at the NASA Johnson Space Center and many other NASA facilities. It describes the approach, and the significant benefits seen, such as fast, thorough and clear test feedback every time code is checked into the code repository. It also describes an approach that encourages development of code that is testable and adaptable.

Penn, John↗