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Optimization of base thermal protection system for advanced Saturn II boosters employing strap-on solid propellant motors
The High-Speed Research (HSR) Airfoil Alloy program developed fourth-generation single-crystal superalloys with up to an 85 F increase in creep rupture capability over current production airfoil alloys. Recent results have been generated at the NASA Glenn Research Center on these fourth-generation alloys, but in coated form, for subsonic turbine blade applications under NASA's Ultra-Efficient Engine Technology (UEET) Program. One goal for UEET is to optimize the airfoil alloy/thermal barrier coating system for 3100 F turbine inlet temperatures. The state-of-the art turbine blade airfoil system consists of a superalloy single crystal that provides the basic mechanical performance of the airfoil. A thermal barrier coating is used to reduce the temperature of the base superalloy, and a bondcoat is deposited between the base material and the thermal barrier coating. The bondcoat improves the oxidation and corrosion resistance of the base superalloy and improves the spallation resistance of the thermal barrier coating. A commercial platinum aluminide bondcoat was applied to the HSR-developed alloys, and a diffusion zone developed as a result of interaction between the bondcoat and the superalloy. Optimized strength is obtained for superalloys when the refractory element content is high and the limits of microstructural stability are approached or exceeded slightly. For fourthgeneration alloys, instability leads to the formation of topologically close packed (TCP) phases, which form internally in the superalloy, and a secondary reaction zone (SRZ), which forms under the diffusion zone. There was a concern that excessive quantities of either TCP or SRZ might decrease the mechanical properties of the superalloy, with SRZ thought to be particularly detrimental and its formation unpredictable. Thus, an SRZreduction effort was initiated in the NASA UEET Program so that methods developed during the HSR project could be optimized further to reduce or eliminate the SRZ. An SRZ is a three-phase constituent composed of TCP and stringers of gamma phase in a matrix of gamma prime. An incoherent grain boundary separates the SRZ from the gammagamma prime microstructure of the superalloy. The SRZ is believed to form as a result of local chemistry changes in the superalloy due to the application of the diffusion aluminide bondcoat. Locally high surface stresses also appear to promote the formation of the SRZ. Thus, techniques that change the local alloy chemistry or reduce surface stresses have been examined for their effectiveness in reducing SRZ. These SRZ-reduction steps are performed on the test specimen or the turbine blade before the bondcoat is applied. Stressrelief heat treatments developed at NASA Glenn have been demonstrated to reduce significantly the amount of SRZ that develops during subsequent high-temperature exposures. Stress-relief heat treatments reduce surface stresses by recrystallizing a thin surface layer of the superalloy. However, in alloys with very high propensities to form SRZ, stress relief heat treatments alone do not eliminate SRZ entirely. Thus, techniques that modify the local chemistry under the bondcoat have been emphasized and optimized successfully at Glenn. One such technique is carburization, which changes the local chemistry by forming submicron carbides near the surface of the superalloy. Detailed characterizations have demonstrated that the depth and uniform distribution of these carbides are enhanced when a stress relief treatment and an appropriate surface preparation are employed in advance of the carburization treatment. Even in alloys that have the propensity to develop a continuous SRZ layer beneath the diffusion zone, the SRZ has been completely eliminated or reduced to low, manageable levels when this combination of techniques is utilized. Now that the techniques to mitigate SRZ have been established at Glenn, TCP phase formation is being emphasized in ongoing work under the UEET Program. The limitsf stability of the fourth-generation alloys with respect to TCP phase formation are currently being defined along with high-temperature creep rupture properties. In addition, a regression model is being developed at Glenn for the prediction of the presence of TCP phase in the microstructure and SRZ under the diffusion zone. The model is based on a design-of-experiments methodology with emphasis on the potential synergistic effects of alloying elements.
A probabilistic optimal design methodology for complex structures modelled with finite element methods is presented. The main emphasis is on developing probabilistic analysis tools suitable for optimization. An advanced second-moment method is employed to evaluate the failure probability of the performance function. The safety indices are interpolated using the information at mean and most probable failure point. The minimum weight design with an improved safety index limit is achieved by using the extended interior penalty method of optimization. Numerical examples covering beam and plate structures are presented to illustrate the design approach. The results obtained by using the proposed approach are compared with those obtained by using the existing probabilistic optimization techniques.
The beginning of the 21st century is marked by a rapid growth of land surface satellite data and model sophistication. This offers new opportunities to estimate multiple components of the water cycle via satellite-based land data assimilation (DA) across multiple scales. By resolving more processes in land surface models and by coupling the land, the atmosphere, and other Earth system compartments, the observed information can be propagated to constrain additional unobserved variables. Furthermore, access to more satellite observations enables the direct constraint of more and more components of the water cycle that are of interest to end users. However, the finer level of detail in models and data is also often accompanied by an increase in dimensions, with more state variables, parameters, or boundary conditions to estimate, and more observations to assimilate. This requires advanced DA methods and efficient solutions. One solution is to target specific observations for assimilation based on a sensitivity study or coupling strength analysis, because not all observations are equally effective in improving subsequent forecasts of hydrological variables, weather, agricultural production, or hazards through DA. This paper offers a perspective on current and future land DA development, and suggestions to optimally exploit advances in observing and modeling systems.
Taking advantage of a novel approach to the design of the orbital transfer optimization problem and advanced non-linear programming algorithms, several optimal transfer trajectories are found for problems with and without known analytic solutions. This method treats the fixed known gravitational constants as optimization variables in order to reduce the need for an advanced initial guess. Complex periodic orbits are targeted with very simple guesses and the ability to find optimal transfers in spite of these bad guesses is successfully demonstrated. Impulsive transfers are considered for orbits in both the 2-body frame as well as the circular restricted three-body problem (CRTBP). The results with this new approach demonstrate the potential for increasing robustness for all types of orbit transfer problems.
NASA's future missions demand high energy density batteries. Current state-of-the-art lithium-ion batteries (LIBs) reach the specific energy capacity limits (<250 Wh/kg), thus new electrochemical storage technologies are needed to meet NASA's future mission requirement of >400 Wh/kg. Battery chemistries with higher theoretical energy densities in particular, Li-metal based battery chemistries such as Li-air, are being actively pursued, but there remains a number of issues to be solved. Development of advanced and optimized air cathodes will be crucial for improving capacity retention and cycle life of Li-air battery. The microstructure of carbon substrates and the catalytic oxygen reduction of the air-cathode play critical roles in the electrochemical performance in Li-air batteries. With the development and proper design of air cathodes, the energy efficiency and energy density can be enhanced significantly. In this presentation, the results of advanced permeable air cathodes design with different substrates such as 2D carbon paper or carbon cloth, vs 3D graphene or metal foam, different high surface area carbon materials and incorporation with catalysts on oxygen reduction reactions, different porosity controlling of air cathode as well the additives in electrolyte will be presented. The cycling and rate capability performance of these air-cathodes in the Li-air cells will be discussed as well.
A vertical flow loop was designed and assembled to determine the local (circumferential and axial) and mean wall temperature distributions for single-phase and two-phase (subcooled and saturated) downward flow in both uniformly-heated and single-side heated vertical channels. Freon-11 was used as the working fluid in order to directly relate and compare the results with a previous experimental campaign which employed this same working fluid. For a given steady-state experiment, the following parameters were held constant: (1) exit pressure, (2) inlet temperature, and (3) mass velocity. For a given configuration of the 2.2 m long cylindrical channel test section, which had a 1.2 m long heated section, the applied heat rate was varied from zero through successive quasi-steady states to a level which corresponded to localized film boiling in the test section. The measurements showed that the boiling curve changes significantly at higher mass velocities with respect to both the circumferential and axial directions. The slope of the boiling curve changes in a non-monotonic fashion with respect to the circumferential directions. The slope of the boiling curve changes in a non-monotonic fashion with respect to the circumferential direction. The measurements point to the existence of a dry-out phenomenon occurring at multiple levels of the applied heat for the single-side heated channel. In comparing the heat transfer for horizontal channel flow with a vertically downward flow, the results show that significantly lower heat transfer occurs in the horizontal flow. However, this trend reverses as both the Reynolds number and the applied heat rate increase. Both the Liu-Winterton and Shah correlations were compared with the experimental data. The Shah correlation predicted the uniformly heated tube data better. When a thermal hydraulic diameter approach was used for the single-side heated case, the data at upstream locations for Z/L less than 0.5 was bounded above by the Liu-Winterton correlation and below by the Shah correlation. At Z/L = 0.5, the Shah correlation bounded the data; and for Z/L greater than 0.5, both correlations overpredicted the data with the Shah correlation being closest to the data. The present results indicate that additional correlational development is needed. In addressing some of the advanced space thermal management objectives concerning accommodating high heat fluxes in non-uniformly heated systems, a large battery of experiments 88 have been completed where local two-dimensional wall temperature variations were measured for both single-phase and two-phase flow in a single-side heated circular tube. As noted above, the results show significant axial and circumferential variations. Accurately accounting for such variations can result in optimized future advanced space, enhanced (high heat flux) thermal management systems.
Optimization of base thermal protection system for advanced Saturn II boosters employing strap-on solid propellant motors
In support of the NASA Human Research Program Exploration Medical Capability (ExMC) Element, NASA Ames Research Center (ARC) established a collaborative effort with the Canadian Space Agency (CSA). The collaboration focuses on leveraging CSA capability in the areas of biosensors and decision support that will augment future development of such components for Exploration Missions. The CSA advancement of biosensors enables NASA to focus on the integration and data management associated with these types of components through the system currently under development by the Medical Data Architecture (MDA) project. This approach has enabled the establishment of a successful collaborative working relationship between ExMC and CSA.Applying lessons learned from the fiscal year 2016 (FY16) Human Exploration Research Analog (HERA) campaign, CSA and NASA ARC developed a solution to provide real-time feedback to researchers who monitor the collection of vital signs data from a wearable Astroskin garment. The advances in the interfaces included the development of an iPad application (by CSA) to wirelessly forward the vital signs data to the MDA system, which collected the vital signs data through a receiver developed by NASA ARC. The development of these interfaces aims to provide communications between the Astroskin and the MDA system such that data may be seamlessly collected, stored and retrieved by the MDA. The first steps towards this goal were demonstrated in FY16. In FY17, ExMC will complete the first in a series of test beds that establishes a system to automate collection and management of vital sign data from the Astroskin, and other sources of data, to provide information for a crewmember to make medical decisions. In addition, the MDA Test Bed 1 will enable CSA to evaluate and optimize biosensor advancement and facilitate decision support algorithm development.
In support of the NASA Human Research Program Exploration Medical Capability (ExMC) Element, NASA Ames Research Center (ARC) established a collaborative effort with the Canadian Space Agency (CSA). The collaboration focuses on leveraging CSA capability in the areas of biosensors and decision support that will augment future development of such components for Exploration Missions. The CSA advancement of biosensors enables NASA to focus on the integration and data management associated with these types of components through the system currently under development by the Medical Data Architecture (MDA) project. This approach has enabled the establishment of a successful collaborative working relationship between ExMC and CSA.Applying lessons learned from the fiscal year 2016 (FY16) Human Exploration Research Analog (HERA) campaign, CSA and NASA ARC developed a solution to provide real-time feedback to researchers who monitor the collection of vital signs data from a wearable Astroskin garment. The advances in the interfaces included the development of an iPad application (by CSA) to wirelessly forward the vital signs data to the MDA system, which collected the vital signs data through a receiver developed by NASA ARC. The development of these interfaces aims to provide communications between the Astroskin and the MDA system such that data may be seamlessly collected, stored and retrieved by the MDA. The first steps towards this goal were demonstrated in FY16. In FY17, ExMC will complete the first in a series of test beds that establishes a system to automate collection and management of vital sign data from the Astroskin, and other sources of data, to provide information for a crewmember to make medical decisions. In addition, the MDA Test Bed 1 will enable CSA to evaluate and optimize biosensor advancement and facilitate decision support algorithm development.
Recent advances in optimal control have brought design techniques based on optimization of H(2) and H(infinity) norm criteria, closer to be attractive alternatives to single-loop design methods for linear time-variant systems. Significant steps forward in this technology are the deeper understanding of performance and robustness issues of these design procedures and means to perform design trade-offs. However acceptance of the technology is hindered by the lack of convenient design tools to exercise these powerful multivariable techniques, while still allowing single-loop design formulation. Presented is a unique computer tool for designing arbitrary low-order linear time-invarient controllers than encompasses both performance and robustness issues via the familiar H(2) and H(infinity) norm optimization. Application to disturbance rejection design for a commercial transport is demonstrated.
The Copernicus spacecraft, to be launched on May 4, 2009, is designed for scientific exploration of the planet Pluto. The main objectives of this exploration is to accurately determine the mass, density, and composition of the two bodies in the Pluto-Charon system. A further goal of the exploration is to obtain precise images of the system. The spacecraft will be designed for three axis stability control. It will use the latest technological advances to optimize the performance, reliability, and cost of the spacecraft. Due to the long duration of the mission, nominally 12.6 years, the spacecraft will be powered by a long lasting radioactive power source. Although this type of power may have some environmental drawbacks, currently it is the only available source that is suitable for this mission. The planned trajectory provides flybys of Jupiter and Saturn. These flybys provide an opportunity for scientific study of these planets in addition to Pluto. The information obtained on these flybys will supplement the data obtained by the Voyager and Galileo missions. The topics covered include: (1) scientific instrumentation; (2) mission management, planning, and costing; (3) power and propulsion system; (4) structural subsystem; (5) command, control, and communication; and (6) attitude and articulation control.
A methodology for design of helicopter control systems is proposed that can account for various types of concurrent specifications: stability, decoupling between longitudinal and lateral motions, handling qualities, and physical limitations of the swashplate motions. This is achieved by synergistic use of analytical techniques (Q-parameterization of all stabilizing controllers, transfer function interpolation) and advanced numerical optimization techniques. The methodology is used to design a controller for the UH-60 helicopter in hover. Good results are achieved for decoupling and handling quality specifications.
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A reliable algorithm for the evaluation of a quadratic performance index and its gradients with respect to the controller design parameters is presented. The algorithm is part of a design algorithm for an optimal linear dynamic output feedback controller that minimizes a finite time quadratic performance index. The numerical scheme is particularly robust when it is applied to the control law synthesis for systems with densely packed modes and where there is a high likelihood of encountering degeneracies in the closed loop eigensystem. This approach through the use of a accurate Pade series approximation does not require the closed loop system matrix to be diagonalizable. The algorithm has been included in a control design package for optimal robust low order controllers. Usefulness of the proposed numerical algorithm has been demonstrated using numerous practical design cases where degeneracies occur frequently in the closed loop system under an arbitrary controller design initialization and during the numerical search.
NASA maintains an applications oriented computational fluid dynamics (CFD) efforts complementary to and in support of the aerodynamic-propulsion design and test activities. This is especially true at NASA/MSFC where the goal is to advance and optimize present and future liquid-fueled rocket engines. Numerical grid generation plays a significant role in the fluid flow simulations utilizing CFD. An overall goal of the current project was to develop a geometry-grid generation tool that will help engineers, scientists and CFD practitioners to analyze design problems involving complex geometries in a timely fashion. This goal is accomplished by developing the Computer Aided Grid Interface system (CAGI). The CAGI system is developed by integrating CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) geometric system output and / or Initial Graphics Exchange Specification (IGES) files (including all the NASA-IGES entities), geometry manipulations and generations associated with grid constructions, and robust grid generation methodologies. This report describes the development process of the CAGI system.
NASA maintains an applications oriented computational fluid dynamics (CFD) efforts complementary to and in support of the aerodynamic-propulsion design and test activities. This is especially true at NASA/MSFC where the goal is to advance and optimize present and future liquid-fueled rocket engines. Numerical grid generation plays a significant role in the fluid flow simulations utilizing CFD. An overall goal of the current project was to develop a geometry-grid generation tool that will help engineers, scientists and CFD practitioners to analyze design problems involving complex geometries in a timely fashion. This goal is accomplished by developing the CAGI: Computer Aided Grid Interface system. The CAGI system is developed by integrating CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) geometric system output and/or Initial Graphics Exchange Specification (IGES) files (including all the NASA-IGES entities), geometry manipulations and generations associated with grid constructions, and robust grid generation methodologies. This report describes the development process of the CAGI system.
Since its inception in December 1999, the program has provided support for a total of 11 Graduate Research Scholar Assistants, of these, 6 have completed their MS degree program. The program has generated 3 MS theses and a total of 4 publications/presentations.