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At least 1,045 records · Page 58

Rocketdyne - F-1 Saturn V First Stage Engine

Before I go into the history of F-1, I want to discuss the F-1 engine s role in putting man on the moon. The F-1 engine was used in a cluster of five on the first stage, and that was the only power during the first stage. It took the Apollo launch vehicle, which was 363 feet tall and weighed six million pounds, and threw it downrange fifty miles, threw it up to forty miles of altitude, at Mach 7. It took two and one-half minutes to do that and, in the process, burned four and one-half million pounds of propellant, a pretty sizable task. (See Slide 2, Appendix C) My history goes back to the same year I started working at Rocketdyne. That s where the F-1 had its beginning, back early in 1957. In 1957, there was no space program. Rocketdyne was busy working overtime and extra days designing, developing, and producing rocket engines for weapons of mass destruction, not for scientific reasons. The Air Force contracted Rocketdyne to study how to make a rocket engine that had a million pounds of thrust. The highest thing going at the time had 150,000 pounds of thrust. Rocketdyne s thought was the new engine might be needed for a ballistic missile, not that it was going to go on a moon shot.

Biggs, Robert↗

Re-Engineering Complex Legacy Systems at NASA

The Flight Production Process (FPP) Re-engineering project has established a Model-Based Systems Engineering (MBSE) methodology and the technological infrastructure for the design and development of a reference, product-line architecture as well as an integrated workflow model for the Mission Operations System (MOS) for human space exploration missions at NASA Johnson Space Center. The design and architectural artifacts have been developed based on the expertise and knowledge of numerous Subject Matter Experts (SMEs). The technological infrastructure developed by the FPP Re-engineering project has enabled the structured collection and integration of this knowledge and further provides simulation and analysis capabilities for optimization purposes. A key strength of this strategy has been the judicious combination of COTS products with custom coding. The lean management approach that has led to the success of this project is based on having a strong vision for the whole lifecycle of the project and its progress over time, a goal-based design and development approach, a small team of highly specialized people in areas that are critical to the project, and an interactive approach for infusing new technologies into existing processes. This project, which has had a relatively small amount of funding, is on the cutting edge with respect to the utilization of model-based design and systems engineering. An overarching challenge that was overcome by this project was to convince upper management of the needs and merits of giving up more conventional design methodologies (such as paper-based documents and unwieldy and unstructured flow diagrams and schedules) in favor of advanced model-based systems engineering approaches.

Ruszkowski, James↗

Rocket-Plume Spectroscopy Simulation for Hydrocarbon-Fueled Rocket Engines

The UV-Vis spectroscopic system for plume diagnostics monitors rocket engine health by using several analytical tools developed at Stennis Space Center (SSC), including the rocket plume spectroscopy simulation code (RPSSC), to identify and quantify the alloys from the metallic elements observed in engine plumes. Because the hydrocarbon-fueled rocket engine is likely to contain C2, CO, CH, CN, and NO in addition to OH and H2O, the relevant electronic bands of these molecules in the spectral range of 300 to 850 nm in the RPSSC have been included. SSC incorporated several enhancements and modifications to the original line-by-line spectral simulation computer program implemented for plume spectral data analysis and quantification in 1994. These changes made the program applicable to the Space Shuttle Main Engine (SSME) and the Diagnostic Testbed Facility Thruster (DTFT) exhaust plume spectral data. Modifications included updating the molecular and spectral parameters for OH, adding spectral parameter input files optimized for the 10 elements of interest in the spectral range from 320 to 430 nm and linking the output to graphing and analysis packages. Additionally, the ability to handle the non-uniform wavelength interval at which the spectral computations are made was added. This allowed a precise superposition of wavelengths at which the spectral measurements have been made with the wavelengths at which the spectral computations are done by using the line-by-line (LBL) code. To account for hydrocarbon combustion products in the plume, which might interfere with detection and quantification of metallic elements in the spectral region of 300 to 850 nm, the spectroscopic code has been enhanced to include the carbon-based combustion species of C2, CO, and CH. In addition, CN and NO have spectral bands in 300 to 850 nm and, while these molecules are not direct products of hydrocarbon-oxygen combustion systems, they can show up if nitrogen or a nitrogen compound is present as an impurity in the propellants and/or these can form in the boundary layer as a result of interaction of the hot plume with the atmosphere during the ground testing of engines. Ten additional electronic band systems of these five molecules have been included into the code. A comprehensive literature search was conducted to obtain the most accurate values for the molecular and the spectral parameters, including Franck-Cordon factors and electronic transition moments for all ten band systems. For each elemental transition in the RPSSC, six spectral parameters - Doppler broadened line width at half-height, pressure-broadened line width at half-height, electronic multiplicity of the upper state, electronic term energy of the upper state, Einstein transition probability coefficient, and the atomic line center - are required. Input files have been created for ten elements of Ni, Fe, Cr, Co, Cu, Ca, Mn, Al, Ag, and Pd, which retain only relatively moderate to strong transitions in 300 to 430 nm spectral range for each element. The number of transitions in the input files is 68 for Ni; 148 for Fe; 6 for Cr; 87 for Co; 1 for Ca; 3 for Mn; 2 each for Cu, Al, and Ag; and 11 for Pd.

Tejwani, Gopal D.↗

A Data Filter for Identifying Steady-State Operating Points in Engine Flight Data for Condition Monitoring Applications

This paper presents an algorithm that automatically identifies and extracts steady-state engine operating points from engine flight data. It calculates the mean and standard deviation of select parameters contained in the incoming flight data stream. If the standard deviation of the data falls below defined constraints, the engine is assumed to be at a steady-state operating point, and the mean measurement data at that point are archived for subsequent condition monitoring purposes. The fundamental design of the steady-state data filter is completely generic and applicable for any dynamic system. Additional domain-specific logic constraints are applied to reduce data outliers and variance within the collected steady-state data. The filter is designed for on-line real-time processing of streaming data as opposed to post-processing of the data in batch mode. Results of applying the steady-state data filter to recorded helicopter engine flight data are shown, demonstrating its utility for engine condition monitoring applications.

Simon, Donald L.↗

Affordability Engineering: Bridging the Gap Between Design and Cost

Affordability is a commonly used term that takes on numerous meanings depending on the context used. Within conceptual design of complex systems, the term generally implies comparisons between expected costs and expected resources. This characterization is largely correct, but does not convey the many nuances and considerations that are frequently misunderstood and underappreciated. In the most fundamental sense, affordability and cost directly relate to engineering and programmatic decisions made throughout development programs. Systems engineering texts point out that there is a temporal aspect to this relationship, for decisions made earlier in a program dictate design implications much more so than those made during latter phases. This paper explores affordability engineering and its many sub-disciplines by discussing how it can be considered an additional engineering discipline to be balanced throughout the systems engineering and systems analysis processes. Example methods of multidisciplinary design analysis with affordability as a key driver will be discussed, as will example methods of data visualization, probabilistic analysis, and other ways of relating design decisions to affordability results.

Reeves, J. D.↗

Predicting Noise From Aircraft Turbine-Engine Combustors

COMBUSTOR and CNOISE are computer codes that predict far-field noise that originates in the combustors of modern aircraft turbine engines -- especially modern, low-gaseous-emission engines, the combustors of which sometimes generate several decibels more noise than do the combustors of older turbine engines. COMBUSTOR implements an empirical model of combustor noise derived from correlations between engine-noise data and operational and geometric parameters, and was developed from databases of measurements of acoustic emissions of engines. CNOISE implements an analytical and computational model of the propagation of combustor temperature fluctuations (hot spots) through downstream turbine stages. Such hot spots are known to give rise to far-field noise. CNOISE is expected to be helpful in determining why low-emission combustors are sometimes noisier than older ones, to provide guidance for refining the empirical correlation model embodied in the COMBUSTOR code, and to provide insight on how to vary downstream turbinestage geometry to reduce the contribution of hot spots to far-field noise.

Gliebe, P.↗

Automation of Design Engineering Processes

A method, and a computer program that helps to implement the method, have been developed to automate and systematize the retention and retrieval of all the written records generated during the process of designing a complex engineering system. It cannot be emphasized strongly enough that all the written records as used here is meant to be taken literally: it signifies not only final drawings and final engineering calculations but also such ancillary documents as minutes of meetings, memoranda, requests for design changes, approval and review documents, and reports of tests. One important purpose served by the method is to make the records readily available to all involved users via their computer workstations from one computer archive while eliminating the need for voluminous paper files stored in different places. Another important purpose served by the method is to facilitate the work of engineers who are charged with sustaining the system and were not involved in the original design decisions. The method helps the sustaining engineers to retrieve information that enables them to retrace the reasoning that led to the original design decisions, thereby helping them to understand the system better and to make informed engineering choices pertaining to maintenance and/or modifications of the system. The software used to implement the method is written in Microsoft Access. All of the documents pertaining to the design of a given system are stored in one relational database in such a manner that they can be related to each other via a single tracking number.

Torrey, Glenn↗

Software for Collaborative Engineering of Launch Rockets

The Rocket Evaluation and Cost Integration for Propulsion and Engineering software enables collaborative computing with automated exchange of information in the design and analysis of launch rockets and other complex systems. RECIPE can interact with and incorporate a variety of programs, including legacy codes, that model aspects of a system from the perspectives of different technological disciplines (e.g., aerodynamics, structures, propulsion, trajectory, aeroheating, controls, and operations) and that are used by different engineers on different computers running different operating systems. RECIPE consists mainly of (1) ISCRM a file-transfer subprogram that makes it possible for legacy codes executed in their original operating systems on their original computers to exchange data and (2) CONES an easy-to-use filewrapper subprogram that enables the integration of legacy codes. RECIPE provides a tightly integrated conceptual framework that emphasizes connectivity among the programs used by the collaborators, linking these programs in a manner that provides some configuration control while facilitating collaborative engineering tradeoff studies, including design to cost studies. In comparison with prior collaborative-engineering schemes, one based on the use of RECIPE enables fewer engineers to do more in less time.

Stanley, Thomas Troy↗

Foil Bearing Starting Considerations and Requirements for Rotorcraft Engine Applications

Foil gas bearings under development for rotorcraft-sized, hot core engine applications have been susceptible to damage from the slow acceleration and rates typically encountered during the pre-ignition stage in conventional engines. Recent laboratory failures have been assumed to be directly linked to operating foil bearings below their lift-off speed while following conventional startup procedures for the engines. In each instance, the continuous sliding contact between the foils and shaft was believed to thermally overload the bearing and cause the engines to fail. These failures highlight the need to characterize required acceleration rates and minimum operating speeds for these applications. In this report, startup experiments were conducted with a large, rotorcraft engine sized foil bearing under moderate load and acceleration rates to identify the proper start procedures needed to avoid bearing failure. The results showed that a bearing under a 39.4 kPa static load can withstand a modest acceleration rate of 500 rpm/s and excessive loitering below the bearing lift-off speed provided an adequate solid lubricant is present.

Radil, Kevin C.↗

Current Density Measurements of an Annular-Geometry Ion Engine

The concept of the annular-geometry ion engine, or AGI-Engine, has been shown to have many potential benefits when scaling electric propulsion technologies to higher power. However, the necessary asymmetric location of the discharge cathode away from thruster centerline could potentially lead to non-uniformities in the discharge not present in conventional geometry ion thrusters. In an effort to characterize the degree of this potential non-uniformity, a number of current density measurements were taken on a breadboard AGI-Engine. Fourteen button probes were used to measure the ion current density of the discharge along a perforated electrode that replaced the ion optics during conditions of simulated beam extraction. Three Faraday probes spaced apart in the vertical direction were also used in a separate test to interrogate the plume of the AGI-Engine during true beam extraction. It was determined that both the discharge and the plume of the AGI-Engine are highly uniform, with variations under most conditions limited to +/-10% of the average current density in the discharge and +/-5% of the average current density in the plume. Beam flatness parameter measured 30 mm from the ion optics ranged from 0.85 - 0.95, and overall uniformity was shown to generally increase with increasing discharge and beam currents. These measurements indicate that the plasma is highly uniform despite the asymmetric location of the discharge cathode.

Shastry, Rohit↗

Current Density Measurements of an Annular-Geometry Ion Engine

The concept of the annular-geometry ion engine, or AGI-Engine, has been shown to have many potential benefits when scaling electric propulsion technologies to higher power. However, the necessary asymmetric location of the discharge cathode away from thruster centerline could potentially lead to non-uniformities in the discharge not present in conventional geometry ion thrusters. In an effort to characterize the degree of this potential nonuniformity, a number of current density measurements were taken on a breadboard AGI-Engine. Fourteen button probes were used to measure the ion current density of the discharge along a perforated electrode that replaced the ion optics during conditions of simulated beam extraction. Three Faraday probes spaced apart in the vertical direction were also used in a separate test to interrogate the plume of the AGI-Engine during true beam extraction. It was determined that both the discharge and the plume of the AGI-Engine are highly uniform, with variations under most conditions limited to 10% of the average current density in the discharge and 5% of the average current density in the plume. Beam flatness parameter measured 30 mm from the ion optics ranged from 0.85 0.95, and overall uniformity was shown to generally increase with increasing discharge and beam currents. These measurements indicate that the plasma is highly uniform despite the asymmetric location of the discharge cathode.

Shastry, Rohit↗

Elements of Engineering Excellence

The inspiration for this Contract Report (CR) originated in discussions with the director of Marshall Space Flight Center (MSFC) Engineering who asked that we investigate the question: "How do you achieve excellence in aerospace engineering?" Engineering a space system is a complex activity. Avoiding its inherent potential pitfalls and achieving a successful product is a challenge. This CR presents one approach to answering the question of how to achieve Engineering Excellence. We first investigated the root causes of NASA major failures as a basis for developing a proposed answer to the question of Excellence. The following discussions integrate a triad of Technical Understanding and Execution, Partnership with the Project, and Individual and Organizational Culture. The thesis is that you must focus on the whole process and its underlying culture, not just on the technical aspects. In addition to the engineering process, emphasis is given to the need and characteristics of a Learning Organization as a mechanism for changing the culture.

Blair, J. C.↗

Socio-Technical Perspective on Interdisciplinary Interactions During the Development of Complex Engineered Systems

This study investigates interdisciplinary interactions that take place during the research, development, and early conceptual design phases in the design of large-scale complex engineered systems (LaCES) such as aerospace vehicles. These interactions, that take place throughout a large engineering development organization, become the initial conditions of the systems engineering process that ultimately leads to the development of a viable system. This paper summarizes some of the challenges and opportunities regarding social and organizational issues that emerged from a qualitative study using ethnographic and survey data. The analysis reveals several socio-technical couplings between the engineered system and the organization that creates it. Survey respondents noted the importance of interdisciplinary interactions and their benefits to the engineered system as well as substantial challenges in interdisciplinary interactions. Noted benefits included enhanced knowledge and problem mitigation and noted obstacles centered on organizational and human dynamics. Findings suggest that addressing the social challenges may be a critical need in enabling interdisciplinary interactions

McGowan, Anna-Maria R.↗

STS-114: Engine Cut-Off Sensors Are a No-Go: Teaching Notes for NASA Case Study

This case study format is intended to simulate the experience of facing the same difficult challenges and making the same critical decisions as managers, engineers, and scientists in the Space Shuttle Program. It has been designed for use in the classroom setting to help students develop skills related to decision-making. Students will read about the engine cut-off sensor anomaly which created challenges during the STS-114 mission and have the opportunity to make decisions as lead NASA engineers and Mission Management Team members. Included within this document are three case study presentation options - class discussion, group activity, and open-ended research. Please read the full case prior to in-class presentation to allow ample time for students' analysis and reflection, as well as to prepare additional questions. activities or exercises, material selection, etc. Depending upon the setting of your presentation and the number of participants, please choose at least one presentation format beforehand and plan accordingly. You may expect the following learning objectives by using the proposed formats. Learning Objectives: To enable students to experience the responsibilities of NASA management, engineers, and analysis; to discover possible procedures for investigating system anomalies; to become familiar with the liquid hydrogen low level engine cut-off sensor, including its function, connecting components, and location within the Space Shuttle; and to encourage critical analysis and stimulating discussion of Space Shuttle mission challenges.

Ransom, Khadijah S.↗

Surface Temperature Measurements from a Stator Vane Doublet in a Turbine Engine Afterburner Flame using Ultra-Bright Cr-Doped GdAlO3 Thermographic Phosphor

Luminescence-based surface temperature measurements from an ultra-bright Cr-doped GdAlO3 perovskite (GAP:Cr) coating were successfully conducted on an air-film-cooled stator vane doublet exposed to the afterburner flame of a J85 test engine at University of Tennessee Space Institute (UTSI). The objective of the testing at UTSI was to demonstrate that reliable thermal barrier coating (TBC) surface temperatures based on luminescence decay of a thermographic phosphor could be obtained from the surface of an actual engine component in an aggressive afterburner flame environment and to address the challenges of a highly radiant background and high velocity gases. A high-pressure turbine vane doublet from a Honeywell TECH7000 turbine engine was coated with a standard electron-beam physical vapor deposited (EB-PVD) 200-m-thick TBC composed of yttria-stabilized zirconia (YSZ) onto which a 25-m-thick GAP:Cr thermographic phosphor layer was deposited by EB-PVD. The ultra-bright broadband luminescence from the GAP:Cr thermographic phosphor is shown to offer the advantage of over an order-of-magnitude greater emission intensity compared to rare-earth-doped phosphors in the engine test environment. This higher emission intensity was shown to be very desirable for overcoming the necessarily restricted probe light collection solid angle and for achieving high signal-to-background levels. Luminescence-decay-based surface temperature measurements varied from 500 to over 1000C depending on engine operating conditions and level of air film cooling.

Eldridge, Jeffrey I.↗

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗

Male and Female Summer Interns in Engineering from 2007-2012

The purpose of this study was to ascertain the colleges and universities from which engineering interns were chosen for the Langley Aerospace Research Student Scholars (LARSS) internship program over a six year period. While the initial question was where the interns were from, information was also obtained on these colleges and universities' rankings with respect to female faculty in tenure/tenure-track positions as well as research expenditures according to the American Society for Engineering Education's (ASEE) 2012 Annual Report. The majority of interns were selected from 14 institutions. Eight of the institutions for female interns and 7 for male interns were also cited as having the largest percentages/numbers of female faculty according to ASEE data. In 10 of the 14 institutions for male interns and 9 of 14 for female interns, the institutions were cited as having some of the highest research expenditures. Last, data from ASEE's report on bachelor degrees awarded in 2011 was assessed with respect to the 21 institutions listed as having higher numbers of women in tenure/tenure-track positions. The majority of these institutions represented larger engineering programs with a sizeable number of engineering faculty. These 21institutions accounted for 24.4% of the total engineering bachelor degrees awarded in 2011, with 27.4% of all female and 23.8% of all male graduates in the U.S.

Hall, Cathy W.↗

CMC Technology Advancements for Gas Turbine Engine Applications

CMC research at NASA Glenn is focused on aircraft propulsion applications. The objective is to enable reduced engine emissions and fuel consumption for more environmentally friendly aircraft. Engine system studies show that incorporation of ceramic composites into turbine engines will enable significant reductions in emissions and fuel burn due to increased engine efficiency resulting from reduced cooling requirements for hot section components. This presentation will describe recent progress and challenges in developing fiber and matrix constituents for 2700 F CMC turbine applications. In addition, ongoing research in the development of durable environmental barrier coatings, ceramic joining integration technologies and life prediction methods for CMC engine components will be reviewed.

Grady, Joseph E.↗