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NASA NTRSDate not supplied

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

NASA NTRS2024

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

Electrified Aircraft Propulsion↗

DOE OSTI2020

Autoignition of CRC diesel surrogates at low temperature combustion conditions: Rapid compression machine experiments and modeling

As federal programs require increasingly stringent engine emissions and fuel economy standards, these ambitions can only be met if next-generation combustion technology is developed focusing on high-efficiency and low-emissions engines. Recent research has indicated the need to operate engines at higher compression ratios and with low temperature combustion (LTC) to achieve the needed gains in engine efficiency and reductions in emissions. Because there is a lack of understanding of the chemistry of diesel fuel components and their mixtures at these LTC conditions, this limits the ability to develop predictive chemical kinetic models that can be used to optimize engine combustion. The current study aims to fill in gaps in fundamental combustion data on surrogate fuel mixtures relevant to diesel fuels. Specifically, four multicomponent diesel surrogates formulated by the Coordinating Research Council (CRC) to emulate an ultra-low-sulfur research-grade #2 certification diesel fuel (CFA), namely V0a (4 components), V0b (5 components), V1 (8 components), and V2 (9 components), have been investigated in a rapid compression machine (RCM) through determination of total and first-stage ignition delay times. Autoignition characteristics of lean to rich fuel/O 2 /N 2 mixtures, for the four CRC surrogates and CFA, have been measured using an RCM at LTC relevant pressures and temperatures, in the ranges of 10–20 bar and 650–1000 K, respectively. The equivalence ratios have been varied by independently changing the oxygen mole fraction and the fuel mole fraction in the test mixtures, thereby illustrating the individual effects of oxygen concentration and fuel loading on diesel autoignition. Autoignition results of these four CRC surrogates are compared among them and with those of CFA. Some degree of agreement in autoignition response between each CRC surrogate and CFA is observed, while discrepancies are also identified and discussed. In addition, a detailed chemical kinetic model for diesel surrogates has been developed and validated against these newly-acquired RCM data. We find that this model shows reasonable agreement with the overall ignition delay time results of the current RCM experiments. Chemical kinetic analyses of the developed model were further conducted to help identify the reactions controlling the autoignition processes and the consumption of fuel components in CRC surrogates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

High Fidelity Adaptively Refined CFD and Reduced Order Models of a High Aspect Ratio Aeroelastic Wing Wind Tunnel Model

Robust adaptive mesh refinement for transonic conditions is one of the most difficult challenges to advancing CFD usage for certification by analysis. Transonic fluid-structure interaction cases represent an even more difficult challenge for adaptive mesh refinement. Production aircraft furthermore have structural models that have gaps and discontinuities that make the interdomain transfer of loads and deflections difficult. This adds to the challenge of adaptive mesh refinement. An initial attempt to create an adaptive mesh refinement process that refines regions of high flow gradient based around the HeldenMesh software is presented. The method is applied to the Integrated Adaptive Wing Technology Maturation (IAWTM) configuration. That has developed an aspect ratio 13.5 wing aeroelastic wind-tunnel model for testing in the Transonic Dynamics Tunnel (TDT). The high levels of deformation of this wing make the adaptation of meshes for the static shape difficult and has necessitated some creativity in how to efficiently adapt meshes. A time-domain identification of the unsteady system based on flexible modes using the adapted meshes is performed.

Robert E. Bartels↗

NASA NTRS2015

ASME Section VIII Recertification of a 33,000 Gallon Vacuum-jacketed LH2 Storage Vessel for Densified Hydrogen Testing at NASA Kennedy Space Center

The Ground Operations Demonstration Unit for Liquid Hydrogen (GODU-LH2) has been developed at NASA Kennedy Space Center in Florida. GODU-LH2 has three main objectives: zero-loss storage and transfer, liquefaction, and densification of liquid hydrogen. A cryogenic refrigerator has been integrated into an existing, previously certified, 33,000 gallon vacuum-jacketed storage vessel built by Minnesota Valley Engineering in 1991 for the Titan program. The dewar has an inner diameter of 9.5 and a length of 71.5; original design temperature and pressure ranges are -423 F to 100 F and 0 to 95 psig respectively. During densification operations the liquid temperature will be decreased below the normal boiling point by the refrigerator, and consequently the pressure inside the inner vessel will be sub-atmospheric. These new operational conditions rendered the original certification invalid, so an effort was undertaken to recertify the tank to the new pressure and temperature requirements (-12.7 to 95 psig and -433 F to 100 F respectively) per ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. This paper will discuss the unique design, analysis and implementation issues encountered during the vessel recertification process.

Liquefaction↗

NASA NTRS2003

Using X-band Weather Radar Measurements to Monitor the Integrity of Digital Elevation Models for Synthetic Vision Systems

Synthetic Vision Systems (SVS) provide pilots with displays of stored geo-spatial data representing terrain, obstacles, and cultural features. As comprehensive validation is impractical, these databases typically have no quantifiable level of integrity. Further, updates to the databases may not be provided as changes occur. These issues limit the certification level and constrain the operational context of SVS for civil aviation. Previous work demonstrated the feasibility of using a realtime monitor to bound the integrity of Digital Elevation Models (DEMs) by using radar altimeter measurements during flight. This paper describes an extension of this concept to include X-band Weather Radar (WxR) measurements. This enables the monitor to detect additional classes of DEM errors and to reduce the exposure time associated with integrity threats. Feature extraction techniques are used along with a statistical assessment of similarity measures between the sensed and stored features that are detected. Recent flight-testing in the area around the Juneau, Alaska Airport (JNU) has resulted in a comprehensive set of sensor data that is being used to assess the feasibility of the proposed monitor technology. Initial results of this assessment are presented.

Young, Steve↗

NASA NTRS2019

Sextant Navigation on the International Space Station: A Human Space Exploration Demo

Astronauts on board the International Space Station (ISS) tested a hand-held sextant to demonstrate potential use on future human exploration missions such as Orion and Gateway. The investigation, designed to aid in the development of emergency navigation methods for future crewed spacecraft, took place from June-December 2018. A sextant provides manual capability to perform star/planet-limb sightings and estimate vehicle state during loss of communication or other contingencies. Its simplicity and independence from primary systems make it useful as an emergency survival backup or confirming measurement source. The concept of using a sextant has heritage in Gemini, Apollo, and Skylab. This paper discusses the instrument selection, flight certification, crew training, product development, experiment execution, and data analysis. Preflight training consisted of a hands-on session with the instrument and practice in a Cupola mock-up with star field projector dome. The experiment itself consisted of several sessions with sextant sightings in the ISS Cupola module by two crew members. Sightings were taken on star pairs, star/moon limb, and moon diameter. The sessions were designed to demonstrate star identification and acquisition, sighting stability, accuracy, and lunar sights. Results are presented which demonstrate sightings within the accuracy goal of 60 arcseconds, even in the presence of window refraction effects and minimal crew training. The crew members provided valuable feedback on sighting products and microgravity stability techniques.

Exploration↗

NASA NTRSDate not supplied

Computational Icing Analysis on NASA’s SIDRM Geometry to Investigate Collection Efficiency

Computational icing analysis results were compared to experimental icing tunnel data including aerothermal (e.g. dry air) and supercooled water droplet rime-ice conditions from tests conducted in early 2022 at the NASA Icing Research Tunnel (IRT). The Simulated Intercompressor Duct Research Model (SIDRM) test article was used in this study, and its geometry represents the inter-compressor duct region of a turbofan engine. The test article’s purpose is to study the physics of supercooled water icing and ice crystal icing. This study compared three different icing codes: FENSAP-ICE (Eulerian approach), LEWICE3D (Lagrangian approach), and GlennICE (Lagrangian approach). All three icing codes were conducted on SIDRM’s complex body flow-field and compared to different experimental supercooled water rime runs. The test article instrumentation (pressure taps, thermocouples, etc.) and 3D laser scans of final ice shapes were used to compare against the different icing code simulations. The overall objectives are to understand how the icing codes handle capturing collection efficiency on the complex test article’s unheated surfaces. In the aerothermal cases, pressure tap readings matched the CFD results, but dry air CFD underpredicted thermocouple readings. Collection efficiency results from all three icing codes matched well together on the main body leading edge, main body slope, and the strut leading edges. All three icing codes underpredicted the final ice shape using a single-shot constant ice density approach, with more difficulty coming from the strut leading edge ice shape due to the swept wing like flow field. NASA’s overall goal for this effort is to develop computational icing tools to assist in the design and certification of engines for flight in icing conditions.

Supercooled icing, SIDRM, aerodynamics, computatio↗

NASA NTRS2000

Effects of Various Heat Treatments on the Ballistic Impact Properties of Inconel 718 Investigated

Uncontained failures of aircraft engine fan blades are serious events that can cause equipment damage and loss of life. Federal Aviation Administration (FAA) certification requires that all engines demonstrate the ability to contain a released fan blade with the engine running at full power. However, increased protection generally comes at the expense of weight. Proper choice of materials is therefore imperative to an optimized design. The process of choosing a good casing material is done primarily through trial and error. This costly procedure could be minimized if there was a better understanding of the relationships among static material properties, impact properties, and failure mechanisms. This work is part of a program being conducted at the NASA Glenn Research Center at Lewis Field to study these relationships. Ballistic impact tests were conducted on flat, square sheets of Inconel 718 that had been subjected to different heat treatments. Two heat treatments and the as-received condition were studied. In addition, results were compared with those from an earlier study involving a fourth heat treatment. The heat treatments were selected on the basis of their effects on the static tensile properties of the material. The impact specimens used in this study were 17.8-cm square panels that were centered and clamped over a 15.2-cm square hole in a 1.27-cm-thick steel plate. Three nominal plate thickness dimensions were studied, 1.0, 1.8, and 2.0 mm. For each thickness, all the specimens were taken from the same sheet of material. The projectile was a Ti-6Al-4V cylinder with a length of 25.4 mm, a diameter of 12.7 mm, and a mass ranging from 14.05 to 14.20 g. The projectiles were accelerated toward the specimens at normal incidence using a gas gun with a 2-m-long, 12.7-mm inner-diameter barrel. The ballistic limit for each heat treatment condition and thickness was determined by conducting a number of impact tests that bracketed as closely as possible the velocity required to penetrate the specimen.

Pereira, J. Michael↗

NASA NTRS2009

Low Cost Rapid Response Spacecraft, (LCRRS): A Research Project in Low Cost Spacecraft Design and Fabrication in a Rapid Prototyping Environment

The Low Cost Rapid Response Spacecraft (LCRRS) is an ongoing research development project at NASA Ames Research Center (ARC), Moffett Field, California. The prototype spacecraft, called Cost Optimized Test for Spacecraft Avionics and Technologies (COTSAT) is the first of what could potentially be a series of rapidly produced low-cost satellites. COTSAT has a target launch date of March 2009 on a SpaceX Falcon 9 launch vehicle. The LCRRS research system design incorporates use of COTS (Commercial Off The Shelf), MOTS (Modified Off The Shelf), and GOTS (Government Off The Shelf) hardware for a remote sensing satellite. The design concept was baselined to support a 0.5 meter Ritchey-Chretien telescope payload. This telescope and camera system is expected to achieve 1.5 meter/pixel resolution. The COTSAT team is investigating the possibility of building a fully functional spacecraft for $500,000 parts and $2,000,000 labor. Cost is dramatically reduced by using a sealed container, housing the bus and payload subsystems. Some electrical and RF designs were improved/upgraded from GeneSat-1 heritage systems. The project began in January 2007 and has yielded two functional test platforms. It is expected that a flight-qualified unit will be finished in December 2008. Flight quality controls are in place on the parts and materials used in this development with the aim of using them to finish a proto-flight satellite. For LEO missions the team is targeting a mission class requiring a minimum of six months lifetime or more. The system architecture incorporates several design features required by high reliability missions. This allows for a true skunk works environment to rapidly progress toward a flight design. Engineering and fabrication is primarily done in-house at NASA Ames with flight certifications on materials. The team currently employs seven Full Time Equivalent employees. The success of COTSATs small team in this effort can be attributed to highly cross trained engineering team. The engineers on the team are capable of functioning in two to three engineering disciplines which allows highly efficient interdisciplinary engineering collaboration. NASA Ames is actively proposing mission concepts to use the COTSAT platform to accomplish science. If the COTSAT team validates this approach, it will allow the possibility for remote sensing missions to produce a high science yield for minimal cost and reduced schedule. Another aim of this approach is to yield an accelerated pathway from a Phase A study to mission launch. Leaders in the aerospace industry have shown interest in this methodology. Several visits and tours have been given in the lab. Although the concept of low-cost development is initially met with skepticism from some within the prohibitive aerospace industry, the project's efforts have been highly praised for the accomplishments met within a limited time and budget. Overall the development has progressed tremendously well and the team is answering critical questions for current and future low-cost small satellite developments. COTSAT subsystems are not limited to a specific weight class and could be adapted to produce smaller platforms and to fit various launch vehicles.

Spremo, Stevan↗

NASA NTRS2016

Tethered Space Satellite-1 (TSS-1): Wound About a Bolt

In the early 1990's US and Italian scientists collaborated to study the electrodynamics on a long tether between two satellites as it moved through the electrically charged portion of Earth's atmosphere called the ionosphere. Potential uses for the electrical current induced in the long wire include power and thrust generation for a satellite, momentum exchange, artificial gravity, deployment of sensors or antennas, and gravity-gradient stabilization. The Tethered Space Satellite (TSS) was a first-of-its-kind experiment with long tethers in space. It consisted of a satellite with science experiments attached to a 12.5 mile long, very thin (0.10 inch diameter) copper wire assembly wound around a spool in the deployer reel mechanism. The whole mechanism sits on a pallet that is installed into the Shuttle bay. At an altitude of 160 nautical miles above earth, the satellite would be deplodeployed from the Shuttle bay by raising it on a boom facing away from Earth. Once cleared of the bay, the deployer mechanism would slowly feed out the 12-plus miles of tether. Scientific data would be collected throughout the operation, after which the satellite would be reeled back in. A receiver spool to catch the 12.5 mile tether as it was being unwound by the deployer reel mechanism was set up to do the system-level test of deployer real mechanism prior to installing the loaded pallet into the Shuttle bay. The system level tests were required before the pallet could be installed into the Space Shuttle cargo bay. A few months before flight, the system level tests, including unreeling and reeling the tether, were completed at Kennedy Space Center (KSC) and the TSS payload was installed onto the Spacelab pallet. Some of this testing equipment was then shipped back to the contractor, Martin Marietta. Integration with the Shuttle began. Systems-level load analyses, which cannot be run until all information about each payload is finalized, was run in parallel with the physical integration of the hardware into the Shuttle payload bay. An analysis, called Coupled loads analysis, incorporates any updates to the model due to system level tests of all the different payloads, and any changes that were found during integration. Engineering analysis examines the worst case scenarios for the loads the hardware will see. The two times during the mission where the dynamic loads are the worst were 1) the first 10-second portion of Shuttle lift off, and 2) a 2-second time during landing when the landing gears hit the ground. The coupled loads analysis using the final verification loads showed that a single bolt attaching the deployer reel mechanism to the support structure had a "negative margin" - which is an indication that it might fail - during touch down. Hardware certification rules do not allow for hardware to fly with negative margins. A structural failure of one payload could have serious or catastrophic consequences to other payloads, or may significantly damage the Orbiter. The issue had to be resolved before the flight.

O'Connor, Brian↗

DOE OSTI2020

Quantifying CTFE content in FK-800 using ATR-FTIR and time to peak crystallization

The chlorotrifluoroethylene (CTFE) content in vinylidene fluoride (VDF)-CTFE copolymers greatly influences the chemical and physical properties and ultimately determines the application. The copolymer known as FK-800 has a VDF:CTFE ratio of ~1:3 and is used almost exclusively as the binder in the insensitive high explosive (HE) formulation PBX 9502. Due to the dangerous nature of HE work and the effect CTFE content variations have, the ability to quickly and easily quantify CTFE content is of interest. Two techniques, attenuated total reflectance-Fourier transform infrared spectroscopy (ATR-FTIR) and time to peak crystallization measured by heat flow calorimetry, were evaluated here as potential means for quantifying CTFE content. Based on the certificate of analyses (COAs), FK-800 lots with varied CTFE content encompassing the range historically used in HE applications were used as standards for both methodologies. For FTIR, a linear regression was performed on the peak area of the C-Cl IR stretch and the CTFE content; the methodology was then demonstrated on four samples, two lots of unadulterated material and material recovered from two HE samples. The calculated CTFE content and COAs were in good agreement for all four samples. Heat flow calorimetry revealed the relationship between time to peak crystallization and CTFE content was best fit by a power regression; the methodology was then tested on two different FK-800 lots. Only one sample showed good agreement between the calculated CTFE content and the COA. This discrepancy indicates the method developed is not suitable for quantifying CTFE, but provides valuable insight regarding the crystallization behavior of VDF-CTFE copolymers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2007

Aero-acoustics of Drag Generating Swirling Exhaust Flows

Aircraft on approach in high-drag and high-lift configuration create unsteady flow structures which inherently generate noise. For devices such as flaps, spoilers and the undercarriage there is a strong correlation between overall noise and drag such that, in the quest for quieter aircraft, one challenge is to generate drag at low noise levels. This paper presents a rigorous aero-acoustic assessment of a novel drag concept. The idea is that a swirling exhaust flow can yield a steady, and thus relatively quiet, streamwise vortex which is supported by a radial pressure gradient responsible for pressure drag. Flows with swirl are naturally limited by instabilities such as vortex breakdown. The paper presents a first aero-acoustic assessment of ram pressure driven swirling exhaust flows and their associated instabilities. The technical approach combines an in-depth aerodynamic analysis, plausibility arguments to qualitatively describe the nature of acoustic sources, and detailed, quantitative acoustic measurements using a medium aperture directional microphone array in combination with a previously established Deconvolution Approach for Mapping of Acoustic Sources (DAMAS). A model scale engine nacelle with stationary swirl vanes was designed and tested in the NASA Langley Quiet Flow Facility at a full-scale approach Mach number of 0.17. The analysis shows that the acoustic signature is comprised of quadrupole-type turbulent mixing noise of the swirling core flow and scattering noise from vane boundary layers and turbulent eddies of the burst vortex structure near sharp edges. The exposed edges are the nacelle and pylon trailing edge and the centerbody supporting the vanes. For the highest stable swirl angle setting a nacelle area based drag coefficient of 0.8 was achieved with a full-scale Overall Sound Pressure Level (OASPL) of about 40dBA at the ICAO approach certification point.

Shah, P. N.↗

NASA NTRSDate not supplied

Comparison of Inlet Broadband Acoustic Liner Predictions to Quiet Technology Demonstrator 3 Flight Data

Companion acoustic liner attenuation predictions and flight data representative of certification conditions are analyzed to determine the validation quality and gain an understanding of current prediction shortcomings. These comparisons are limited to the inlet broadband component of fan noise. Two prediction methods are assessed: a traditional, semiempirical model, and a computational approach with a parabolic duct propagation code coupled with a Ffowcs Williams-Hawkings solver for free-field propagation. The semiempirical method is widely used for aircraft system noise predictions, but does not explicitly account for several physical parameters important for sound attenuation. The computational approach includes these effects, but requires a significant increase in cycle time. For the three-degree-of-freedom (3DOF) liner tested, both methods have a bias error less than 0.5 dB for cutback and takeoff power settings, and a much larger 3–4 dB bias for approach power setting. The standard deviation of each method varies between 1–2 dB for different conditions. The similar performance of both approaches illustrates that, in this instance, the additional complexity of the computational approach does not provide a clear improvement over the semiempirical method. Planned improvements to the numerical grid and source assumptions may result in reevaluation of this conclusion in later work.

aircraft system noise↗

DOE OSTI2020

Efficient, Predictive Tomography of Multi-Qubit Quantum Processors

After decades of R&D, quantum computers comprising more than 2 qubits are appearing. If this progress is to continue, the research community requires a capability for precise characterization (“tomography”) of these enlarged devices, which will enable benchmarking, improvement, and finally certification as mission-ready. As world leaders in characterization -- our gate set tomography (GST) method is the current state of the art – the project team is keenly aware that every existing protocol is either (1) catastrophically inefficient for more than 2 qubits, or (2) not rich enough to predict device behavior. GST scales poorly, while the popular randomized benchmarking technique only measures a single aggregated error probability. This project explored a new insight: that the combinatorial explosion plaguing standard GST could be avoided by using an ansatz of few-qubit interactions to build a complete, efficient model for multi-qubit errors. We developed this approach, prototyped it, and tested it on a cutting-edge quantum processor developed by Rigetti Quantum Computing (RQC), a US-based startup. We implemented our new models within Sandia’s PyGSTi open-source code, and tested them experimentally on the RQC device by probing crosstalk. We found two major results: first, our schema worked and is viable for further development; second, while the Rigetti device is indeed a “real” 8-qubit quantum processor, its behavior fluctuated significantly over time while we were experimenting with it and this drift made it difficult to fit our models of crosstalk to the data.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2014

NASA Unmanned Aircraft (UA) Control and Non-Payload Communication (CNPC) System Waveform Trade Studies

Unmanned Aircraft Systems (UAS) represent a new capability that will provide a variety of services in the government (public) and commercial (civil) aviation sectors. The growth of this potential industry has not yet been realized due to the lack of a common understanding of what is required to safely operate UAS in the National Airspace System (NAS). To address this deficiency, NASA has established a project called UAS Integration in the NAS (UAS in the NAS), under the Integrated Systems Research Program (ISRP) of the Aeronautics Research Mission Directorate (ARMD). This project provides an opportunity to transition concepts, technology, algorithms, and knowledge to the Federal Aviation Administration (FAA) and other stakeholders to help them define the requirements, regulations, and issues for routine UAS access to the NAS. The safe, routine, and efficient integration of UAS into the NAS requires new radio frequency (RF) spectrum allocations and a new data communications system which is both secure and scalable with increasing UAS traffic without adversely impacting the Air Traffic Control (ATC) communication system. These data communications, referred to as Control and Non-Payload Communications (CNPC), whose purpose is to exchange information between the unmanned aircraft and the ground control station to ensure safe, reliable, and effective unmanned aircraft flight operation. A Communications Subproject within the UAS in the NAS Project has been established to address issues related to CNPC development, certification and fielding. The focus of the Communications Subproject is on validating and allocating new RF spectrum and data link communications to enable civil UAS integration into the NAS. The goal is to validate secure, robust data links within the allocated frequency spectrum for UAS. A vision, architectural concepts, and seed requirements for the future commercial UAS CNPC system have been developed by RTCA Special Committee 203 (SC-203) in the process of determining formal recommendations to the FAA in its role provided for under the Federal Advisory Committee Act. NASA intends to conduct its research and development in keeping with this vision and associated architectural concepts. The prototype communication systems developed and tested by NASA will be used to validate and update the initial SC-203 requirements in order to provide a foundation for SC-203's Minimum Aviation System Performance Standards (MASPS).

Aircraft Communications↗

NASA NTRS1988

Center for Advanced Space Propulsion (CASP)

With a mission to initiate and conduct advanced propulsion research in partnership with industry, and a goal to strengthen U.S. national capability in propulsion technology, the Center for Advanced Space Propulsion (CASP) is the only NASA Center for Commercial Development of Space (CCDS) which focuses on propulsion and associated technologies. Meetings with industrial partners and NASA Headquarters personnel provided an assessment of the constraints placed on, and opportunities afforded commercialization projects. Proprietary information, data rights, and patent rights were some of the areas where well defined information is crucial to project success and follow-on efforts. There were five initial CASP projects. At the end of the first year there are six active, two of which are approaching the ground test phase in their development. Progress in the current six projects has met all milestones and is detailed. Working closely with the industrial counterparts it was found that the endeavors in expert systems development, computational fluid dynamics, fluid management in microgravity, and electric propulsion were well received. One project with the Saturn Corporation which dealt with expert systems application in the assembly process, was placed on hold pending further direction from Saturn. The Contamination Measurment and Analysis project was not implemented since CASP was unable to identify an industrial participant. Additional propulsion and related projects were investigated during the year. A subcontract was let to a small business, MicroCraft, Inc., to study rocket engine certification standards. The study produced valuable results; however, based on a number of factors it was decided not to pursue this project further.

Source record↗

NASA NTRS2016

Additive Manufacturing for Affordable Rocket Engines

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch labor required, and increases reliability. When certification is achieved, NASA missions will be able to realize these benefits.

West, Brian↗