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NASA NTRS1993

GRYPHON: Air launched space booster

The project chosen for the winter semester Aero 483 class was the design of a next generation Air Launched Space Booster. Based on Orbital Sciences Corporation's Pegasus concept, the goal of Aero 483 was to design a 500,000 pound air launched space booster capable of delivering 17,000 pounds of payload to Low Earth Orbit and 8,000 pounds of payload to Geosynchronous Earth Orbit. The resulting launch vehicle was named the Gryphon. The class of forty senior aerospace engineering students was broken down into eight interdependent groups. Each group was assigned a subsystem or responsibility which then became their field of specialization. Spacecraft Integration was responsible for ensuring compatibility between subsystems. This group kept up to date on subsystem redesigns and informed those parties affected by the changes, monitored the vehicle's overall weight and dimensions, and calculated the mass properties of the booster. This group also performed the cost/profitability analysis of the Gryphon and obtained cost data for competing launch systems. The Mission Analysis Group was assigned the task of determining proper orbits, calculating the vehicle's flight trajectory for those orbits, and determining the aerodynamic characteristics of the vehicle. The Propulsion Group chose the engines that were best suited to the mission. This group also set the staging configurations for those engines and designed the tanks and fuel feed system. The commercial satellite market, dimensions and weights of typical satellites, and method of deploying satellites was determined by the Payloads Group. In addition, Payloads identified possible resupply packages for Space Station Freedom and identified those packages that were compatible with the Gryphon. The guidance, navigation, and control subsystems were designed by the Mission Control Group. This group identified required tracking hardware, communications hardware telemetry systems, and ground sites for the location of the Gryphon's mission control center. The Structures group was responsible for ensuring the structural integrity of the vehicle. Their designs included the payload shroud, payload support structure, exterior hull and engine support struts. The Gryphon's power requirements were determined by the Power/Thermal/Attitude Control Group. This group then selected suitable batteries and other components to meet these requirements. The group also designed heat shielding and cooling systems to ensure subsystem performance. In addition to these responsibilities this group designed the attitude control methods and RCS components for the vehicle. The Aircraft Integration Group was responsible for all aspects of the booster aircraft connection. This included the design of the connection structure and the drop mechanism. This group also designed the vehicle assembly facility and identified possible ground bases for the plane.

Source record↗

NASA NTRS1988

Identification of large space structures on orbit : A survey

The Task Committee on Methods for Identification of Large Structures in Space was founded in Jul. 1984. The charter of the committee was to prepare a state-of-the-art report on methods of system identification applicable to large space structures (LSS). Funding to support preparation of the report was received in Aug. 1985 from the Air Force Rocket Propulsion Laboratory (now the Air Force Astronautics Laboratory), in the form of a contract to the ASCE. The report was completed, and published by AFRPL in Sep. 1986. The Task Committee consisted of ten members, including ASCE and AFRPL representatives. The membership represented Government, Industry, and Universities, and consisted of electrical, mechanical, and civil engineers, with backgrounds in Structural Dynamics, Optimization, and Controls. An effort was made to use consistent terminology and notation throughout the report which would be compatible with the terminology used in both the structures and controls communities.

Denman, Eugene E.↗

NASA NTRS2008

Intelligent Integrated Health Management for a System of Systems

An intelligent integrated health management system (IIHMS) incorporates major improvements over prior such systems. The particular IIHMS is implemented for any system defined as a hierarchical distributed network of intelligent elements (HDNIE), comprising primarily: (1) an architecture (Figure 1), (2) intelligent elements, (3) a conceptual framework and taxonomy (Figure 2), and (4) and ontology that defines standards and protocols. Some definitions of terms are prerequisite to a further brief description of this innovation: A system-of-systems (SoS) is an engineering system that comprises multiple subsystems (e.g., a system of multiple possibly interacting flow subsystems that include pumps, valves, tanks, ducts, sensors, and the like); 'Intelligent' is used here in the sense of artificial intelligence. An intelligent element may be physical or virtual, it is network enabled, and it is able to manage data, information, and knowledge (DIaK) focused on determining its condition in the context of the entire SoS; As used here, 'health' signifies the functionality and/or structural integrity of an engineering system, subsystem, or process (leading to determination of the health of components); 'Process' can signify either a physical process in the usual sense of the word or an element into which functionally related sensors are grouped; 'Element' can signify a component (e.g., an actuator, a valve), a process, a controller, an actuator, a subsystem, or a system; The term Integrated System Health Management (ISHM) is used to describe a capability that focuses on determining the condition (health) of every element in a complex system (detect anomalies, diagnose causes, prognosis of future anomalies), and provide data, information, and knowledge (DIaK) not just data to control systems for safe and effective operation. A major novel aspect of the present development is the concept of intelligent integration. The purpose of intelligent integration, as defined and implemented in the present IIHMS, is to enable automated analysis of physical phenomena in imitation of human reasoning, including the use of qualitative methods. Intelligent integration is said to occur in a system in which all elements are intelligent and can acquire, maintain, and share knowledge and information. In the HDNIE of the present IIHMS, an SoS is represented as being operationally organized in a hierarchical-distributed format. The elements of the SoS are considered to be intelligent in that they determine their own conditions within an integrated scheme that involves consideration of data, information, knowledge bases, and methods that reside in all elements of the system. The conceptual framework of the HDNIE and the methodologies of implementing it enable the flow of information and knowledge among the elements so as to make possible the determination of the condition of each element. The necessary information and knowledge is made available to each affected element at the desired time, satisfying a need to prevent information overload while providing context-sensitive information at the proper level of detail. Provision of high-quality data is a central goal in designing this or any IIHMS. In pursuit of this goal, functionally related sensors are logically assigned to groups denoted processes. An aggregate of processes is considered to form a system. Alternatively or in addition to what has been said thus far, the HDNIE of this IIHMS can be regarded as consisting of a framework containing object models that encapsulate all elements of the system, their individual and relational knowledge bases, generic methods and procedures based on models of the applicable physics, and communication processes (Figure 2). The framework enables implementation of a paradigm inspired by how expert operators monitor the health of systems with the help of (1) DIaK from various sources, (2) software tools that assist in rapid visualization of the condition of the system, (3) analical software tools that assist in reasoning about the condition, (4) sharing of information via network communication hardware and software, and (5) software tools that aid in making decisions to remedy unacceptable conditions or improve performance.

Smith, Harvey↗

NASA NTRS1980

NASA's activities in the conservation of strategic aerospace materials

The United States imports 50-100 percent of certain metals critical to the aerospace industry, namely, cobalt, columbium, chromium, and tantalum. In an effort to reduce this dependence on foreign sources, NASA is planning a program called Conservation of Strategic Aerospace Materials (COSAM), which will provide technology minimizing strategic metal content in the components of aerospace structures such as aircraft engines. With a proposed starting date of October 1981, the program will consist of strategic element substitution, process technology development, and alternate materials research. NASA's two-fold pre-COSAM studies center on, first, substitution research involving nickel-base and cobalt-base superalloys (Waspaloy, Udimet-700, MAE-M247, Rene 150, HA-188) used in turbine disks, low-pressure blades, turbine blades, and combustors; and, second, alternate materials research devoted initially to investigating possible structural applications of the intermetallic alloys nickel aluminide and iron aluminide.

Stephens, J. R.↗

NASA NTRS1991

GRASP/Ada: Graphical Representations of Algorithms, Structures, and Processes for Ada. The development of a program analysis environment for Ada: Reverse engineering tools for Ada, task 2, phase 3

The main objective is the investigation, formulation, and generation of graphical representations of algorithms, structures, and processes for Ada (GRASP/Ada). The presented task, in which various graphical representations that can be extracted or generated from source code are described and categorized, is focused on reverse engineering. The following subject areas are covered: the system model; control structure diagram generator; object oriented design diagram generator; user interface; and the GRASP library.

Cross, James H., II↗

NASA NTRS1991

Space shuttle with common fuel tank for liquid rocket booster and main engines (supertanker space shuttle)

An operation and schedule enhancement is shown that replaces the four-body cluster (Space Shuttle Orbiter (SSO), external tank, and two solid rocket boosters) with a simpler two-body cluster (SSO and liquid rocket booster/external tank). At staging velocity, the booster unit (liquid-fueled booster engines and vehicle support structure) is jettisoned while the remaining SSO and supertank continues on to orbit. The simpler two-bodied cluster reduces the processing and stack time until SSO mate from 57 days (for the solid rocket booster) to 20 days (for the liquid rocket booster). The areas in which liquid booster systems are superior to solid rocket boosters are discussed. Alternative and future generation vehicles are reviewed to reveal greater performance and operations enhancements with more modifications to the current methods of propulsion design philosophy, e.g., combined cycle engines, and concentric propellant tanks.

Thorpe, Douglas G.↗

NASA NTRS1985

Adhesives for Aerospace

The industry is hereby challenged to integrate adhesive technology with the total structure requirements in light of today's drive into automation/mechanization. The state of the art of adhesive technology is fairly well meeting the needs of the structural designers, the processing engineer, and the inspector, each on an individual basis. The total integration of these needs into the factory of the future is the next collective hurdle to be achieved. Improved processing parameters to fit the needs of automation/mechanization will necessitate some changes in the adhesive forms, formulations, and chemistries. Adhesives have, for the most part, kept up with the needs of the aerospace industry, normally leading the rest of the industry in developments. The wants of the aerospace industry still present a challenge to encompass all elements, achieving a totally integrated joined and sealed structural system. Better toughness with hot-wet strength improvements is desired. Lower cure temperatures, longer out times, and improved corrosion inhibition are desired.

Meade, L. E.↗

NASA NTRS2015

Ballistic and Cyclic Rig Testing of Braided Composite Fan Case Structures

FAA fan blade-out certification testing on turbofan engines occurs very late in an engine's development program and is very costly. It is of utmost importance to approach the FAA Certification engine test with a high degree of confidence that the containment structure will not only contain the high-energy debris, but that it will also withstand the cyclic loads that occur with engine spooldown and continued rotation as the non-running engine maintains a low rotor RPM due to forced airflow as the engine-out aircraft returns to an airport. Accurate rig testing is needed for predicting and understanding material behavior of the fan case structure during all phases of this fan blade-out event.

spooldown↗

NASA NTRS2002

Multidisciplinary Analysis of a Hypersonic Engine

This paper describes implementation of a technique used to obtain a high fidelity fluid-thermal-structural solution of a combined cycle engine at its scram design point. Single-discipline simulations are insufficient here since interactions from other disciplines are significant. Using off-the-shelf, validated solvers for the fluid, chemistry, thermal, and structural solutions, this approach couples together their results to obtain consistent solutions.

Stewart, M. E. M.↗

NASA NTRS1977

Integrated gas turbine engine-nacelle

A nacelle for use with a gas turbine engine is presented. An integral webbed structure resembling a spoked wheel for rigidly interconnecting the nacelle and engine, provides lightweight support. The inner surface of the nacelle defines the outer limits of the engine motive fluid flow annulus while the outer surface of the nacelle defines a streamlined envelope for the engine.

Adamson, A. P.↗

NASA NTRS1998

A Geometry Based Infra-Structure for Computational Analysis and Design

The computational steps traditionally taken for most engineering analysis suites (computational fluid dynamics (CFD), structural analysis, heat transfer and etc.) are: (1) Surface Generation -- usually by employing a Computer Assisted Design (CAD) system; (2) Grid Generation -- preparing the volume for the simulation; (3) Flow Solver -- producing the results at the specified operational point; (4) Post-processing Visualization -- interactively attempting to understand the results. For structural analysis, integrated systems can be obtained from a number of commercial vendors. These vendors couple directly to a number of CAD systems and are executed from within the CAD Graphical User Interface (GUI). It should be noted that the structural analysis problem is more tractable than CFD; there are fewer mesh topologies used and the grids are not as fine (this problem space does not have the length scaling issues of fluids). For CFD, these steps have worked well in the past for simple steady-state simulations at the expense of much user interaction. The data was transmitted between phases via files. In most cases, the output from a CAD system could go to Initial Graphics Exchange Specification (IGES) or Standard Exchange Program (STEP) files. The output from Grid Generators and Solvers do not really have standards though there are a couple of file formats that can be used for a subset of the gridding (i.e. PLOT3D data formats). The user would have to patch up the data or translate from one format to another to move to the next step. Sometimes this could take days. Specifically the problems with this procedure are:(1) File based -- Information flows from one step to the next via data files with formats specified for that procedure. File standards, when they exist, are wholly inadequate. For example, geometry from CAD systems (transmitted via IGES files) is defined as disjoint surfaces and curves (as well as masses of other information of no interest for the Grid Generator). This is particularly onerous for modern CAD systems based on solid modeling. The part was a proper solid and in the translation to IGES has lost this important characteristic. STEP is another standard for CAD data that exists and supports the concept of a solid. The problem with STEP is that a solid modeling geometry kernel is required to query and manipulate the data within this type of file. (2) 'Good' Geometry. A bottleneck in getting results from a solver is the construction of proper geometry to be fed to the grid generator. With 'good' geometry a grid can be constructed in tens of minutes (even with a complex configuration) using unstructured techniques. Adroit multi-block methods are not far behind. This means that a million node steady-state solution can be computed on the order of hours (using current high performance computers) starting from this 'good' geometry. Unfortunately, the geometry usually transmitted from the CAD system is not 'good' in the grid generator sense. The grid generator needs smooth closed solid geometry. It can take a week (or more) of interaction with the CAD output (sometimes by hand) before the process can begin. One way Communication. (3) One-way Communication -- All information travels on from one phase to the next. This makes procedures like node adaptation difficult when attempting to add or move nodes that sit on bounding surfaces (when the actual surface data has been lost after the grid generation phase). Until this process can be automated, more complex problems such as multi-disciplinary analysis or using the above procedure for design becomes prohibitive. There is also no way to easily deal with this system in a modular manner. One can only replace the grid generator, for example, if the software reads and writes the same files. Instead of the serial approach to analysis as described above, CAPRI takes a geometry centric approach. This makes the actual geometry (not a discretized version) accessible to all phases of the analysis. The connection to the geometry is made through an Application Programming Interface (API) and NOT a file system. This API isolates the top-level applications (grid generators, solvers and visualization components) from the geometry engine. Also this allows the replacement of one geometry kernel with another, without effecting these top-level applications. For example, if UniGraphics is used as the CAD package then Parasolid (UG's own geometry engine) can be used for all geometric queries so that no solid geometry information is lost in a translation. This is much better than STEP because when the data is queried, the same software is executed as used in the CAD system. Therefore, one analyzes the exact part that is in the CAD system. CAPRI uses the same idea as the commercial structural analysis codes but does not specify control. Software components of the CAD system are used, but the analysis suite, not the CAD operator, specifies the control of the software session. This also means that the license issues (may be) minimized and individuals need not have to know how to operate a CAD system in order to run the suite.

Haimes, Robert↗

NASA NTRS1978

Thermal-structural design study of an airframe-integrated Scramjet

Design concepts are developed and evaluated for a cooled structures assembly for the Scramjet engine, for engine subsystems mass, volume, and operating requirements, and for the aircraft/engine interface. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 12.4 KN/sq m. The total weight of a six-module engine assembly including the fuel system is 14.73 KN.

Killackey, J. J.↗

NASA NTRS1987

STA-2A NDT testing

The nondestructive testing (NDT) on the Space Shuttle Solid Rocket Booster (SRB) filament wound case (FWC) short stact structural test articles 2 (STA-2A) during test of phases 1B-9C is described. The primary objective of this testing was to verify the structural integrity of the SRB-FWC for critical design loads. Another objective was to quantify the effect of load distributions in the aft skirt. The NDT objectives were to determine the acoustic emission characteristics of the FWC-SRB and to identify possible design deficiencies or defect growth. The results from the posttest inspection of the samples shows the depth measurements taken were accurate until exceeding .260 inches thickness. The data then show that pulse echo measurements exceeded actual part thickness by 10 to 14 percent. The mapping of forward boundaries of delaminations proved to be within the tolerance of the equipment. Using the ZIP probe, the maximum difference between the pulse echo boundary and the visual boundary was expected to be no greater than one half the diameter of the probe. The NDT performance on STA-2A shows how NDT can be used to assist design engineering in evaluating the structural integrity of composite test articles.

Lewis, T. J.↗

NASA NTRS1982

Crashworthy airframe design concepts: Fabrication and testing

Crashworthy floor concepts applicable to general aviation aircraft metal airframe structures were investigated. Initially several energy absorbing lower fuselage structure concepts were evaluated. Full scale floor sections representative of a twin engine, general aviation airplane lower fuselage structure were designed and fabricated. The floors featured an upper high strength platform with an energy absorbing, crushable structure underneath. Eighteen floors were fabricated that incorporated five different crushable subfloor concepts. The floors were then evaluated through static and dynamic testing. Computer programs NASTRAN and KRASH were used for the static and dynamic analysis of the floor section designs. Two twin engine airplane fuselages were modified to incorporate the most promising crashworthy floor sections for test evaluation.

Cronkhite, J. D.↗

NASA NTRS2011

Lightweight, Ultra-High-Temperature, CMC-Lined Carbon/Carbon Structures

Carbon/carbon (C/C) is an established engineering material used extensively in aerospace. The beneficial properties of C/C include high strength, low density, and toughness. Its shortcoming is its limited usability at temperatures higher than the oxidation temperature of carbon . approximately 400 C. Ceramic matrix composites (CMCs) are used instead, but carry a weight penalty. Combining a thin laminate of CMC to a bulk structure of C/C retains all of the benefits of C/C with the high temperature oxidizing environment usability of CMCs. Ultramet demonstrated the feasibility of combining the light weight of C/C composites with the oxidation resistance of zirconium carbide (ZrC) and zirconium- silicon carbide (Zr-Si-C) CMCs in a unique system composed of a C/C primary structure with an integral CMC liner with temperature capability up to 4,200 F (.2,315 C). The system effectively bridged the gap in weight and performance between coated C/C and bulk CMCs. Fabrication was demonstrated through an innovative variant of Ultramet fs rapid, pressureless melt infiltration processing technology. The fully developed material system has strength that is comparable with that of C/C, lower density than Cf/SiC, and ultra-high-temperature oxidation stability. Application of the reinforced ceramic casing to a predominantly C/C structure creates a highly innovative material with the potential to achieve the long-sought goal of long-term, cyclic high-temperature use of C/C in an oxidizing environment. The C/C substructure provided most of the mechanical integrity, and the CMC strengths achieved appeared to be sufficient to allow the CMC to perform its primary function of protecting the C/C. Nozzle extension components were fabricated and successfully hot-fire tested. Test results showed good thermochemical and thermomechanical stability of the CMC, as well as excellent interfacial bonding between the CMC liner and the underlying C/C structure. In particular, hafnium-containing CMCs on C/C were shown to perform well at temperatures exceeding 3,500 F (.1,925 C). The melt-infiltrated CMC-lined C/C composites offered a lower density than Cf/SiC. The melt-infiltrated composites offer greater use temperature than Cf/SiC because of the more refractory ceramic matrices and the C/C substructure provides greater high-temperature strength. The progress made in this work will allow multiple high-temperature components used in oxidizing environments to take advantage of the low density and high strength of C/C combined with the high-temperature oxidation resistance of melt-infiltrated CMCs.

Wright, Matthew J.↗

NASA NTRS2013

Aircraft Turbine Engine Control Research at NASA Glenn Research Center

This paper provides an overview of the aircraft turbine engine control research at the NASA Glenn Research Center (GRC). A brief introduction to the engine control problem is first provided with a description of the state-of-the-art control law structure. A historical aspect of engine control development since the 1940s is then provided with a special emphasis on the contributions of GRC. With the increased emphasis on aircraft safety, enhanced performance, and affordability, as well as the need to reduce the environmental impact of aircraft, there are many new challenges being faced by the designers of aircraft propulsion systems. The Controls and Dynamics Branch (CDB) at GRC is leading and participating in various projects to develop advanced propulsion controls and diagnostics technologies that will help meet the challenging goals of NASA Aeronautics Research Mission programs. The rest of the paper provides an overview of the various CDB technology development activities in aircraft engine control and diagnostics, both current and some accomplished in the recent past. The motivation for each of the research efforts, the research approach, technical challenges, and the key progress to date are summarized.

Garg, Sanjay↗

NASA NTRS1993

Nonlinear dynamic simulation of single- and multi-spool core engines

In this paper a new computational method for accurate simulation of the nonlinear dynamic behavior of single- and multi-spool core engines, turbofan engines, and power generation gas turbine engines is presented. In order to perform the simulation, a modularly structured computer code has been developed which includes individual mathematical modules representing various engine components. The generic structure of the code enables the dynamic simulation of arbitrary engine configurations ranging from single-spool thrust generation to multi-spool thrust/power generation engines under adverse dynamic operating conditions. For precise simulation of turbine and compressor components, row-by-row calculation procedures were implemented that account for the specific turbine and compressor cascade and blade geometry and characteristics. The dynamic behavior of the subject engine is calculated by solving a number of systems of partial differential equations, which describe the unsteady behavior of the individual components. In order to ensure the capability, accuracy, robustness, and reliability of the code, comprehensive critical performance assessment and validation tests were performed. As representatives, three different transient cases with single- and multi-spool thrust and power generation engines were simulated. The transient cases range from operating with a prescribed fuel schedule, to extreme load changes, to generator and turbine shut down.

Schobeiri, T.↗

NASA NTRS2002

Buckling Design Studies of Inverted, Oblate Bulkheads for a Propellant Tank

An investigation of the deformation and buckling characteristics of a composite, oblate bulkhead that has an inverted geometry and is subjected to pressure-only loading is presented for three bulkhead geometries and thicknesses. The effects of a stiffening support ring at the bulkhead to cylinder interface are also evaluated. Buckling analyses conducted using the axisymmetric shell code BOSOR4 are discussed for several bulkhead configurations. These results are analytically verified using results from the Structural Analysis of General Shells (STAGS) code for a selected bulkhead configuration. The buckling characterization of an inverted, oblate bulkhead requires careful attention as small changes in bulkhead parameters can have a significant effect on the critical buckling load. Comparison of BOSOR4 and STAGS results provided a very good correlation between the two analysis methods. In addition, the analysis code BOSOR4 was found to be an efficient sizing tool that is useful during the preliminary design stage of a practical shell structure. Together, these two aspects should give the design engineer confidence in sizing these stability critical structures. Additional characterization is warranted, especially for a composite tank structure, since only one bulkhead configuration was examined closely.

Smeltzer, Stanley S., III↗