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NASA NTRS2010

Design Considerations for Human Rating of Liquid Rocket Engines

I.Human-rating is specific to each engine; a. Context of program/project must be understood. b. Engine cannot be discussed independently from vehicle and mission. II. Utilize a logical combination of design, manufacturing, and test approaches a. Design 1) It is crucial to know the potential ways a system can fail, and how a failure can propagate; 2) Fault avoidance, fault tolerance, DFMR, caution and warning all have roles to play. b. Manufacturing and Assembly; 1) As-built vs. as-designed; 2) Review procedures for assembly and maintenance periodically; and 3) Keep personnel trained and certified. c. There is no substitute for test: 1) Analytical tools are constantly advancing, but still need test data for anchoring assumptions; 2) Demonstrate robustness and explore sensitivities; 3) Ideally, flight will be encompassed by ground test experience. III. Consistency and repeatability is key in production a. Maintain robust processes and procedures for inspection and quality control based upon development and qualification experience; b. Establish methods to "spot check" quality and consistency in parts: 1) Dedicated ground test engines; 2) Random components pulled from the line/lot to go through "enhanced" testing.

Parkinson, Douglas↗

NASA NTRS2019

Design Guide for Bearings Used in Cryogenic Turbopumps and Test Rigs

Cryogenic bearings are a unique and specialized area of the overall group of bearings that are used every day in industrial and aerospace applications. Cryogenic bearings operate in a unique environment that is not experienced by most bearing applications. The high speeds of turbomachinery, flow of cryogenic coolants, use of nonstandard materials, and lack of lubrication place unique demands on cryogenic bearings that must be met for the safety and success of the mission. To meet the goals of safety and success, requirements are put on the designer, manufacturer, and user that are not normally applied to off-the-shelf bearings. The designer has to have knowledge of the operating conditions, rotational speeds, loads, stresses, installation methods, inspection criteria, dimensional requirements, and design and analytical tools. The manufacturer needs to be aware of the materials used for cryogenic bearings, special heat treatments required, cleanliness of the processes, and inspection techniques to ensure a good product. The user needs to be aware of the safe handling practices to eliminate corrosion and debris, correct installation and removal procedures, pre- and post-test inspections, and the documentation that follow the bearings. This guide is based on the experiences of engineers at NASA Marshall Space Flight Center (MSFC) that have been involved in bearing research and testing along with specific bearing references that have been written. It is not meant to be a bearing design textbook for cryogenic bearing applications. These are available from many authors. Its purpose is to help the designer, manufacturer, or user in the application of cryogenic bearings to better understand the requirements placed on these bearings.

H. G. Gibson↗

NASA NTRS2016

CubeSub - A CubeSat Based Submersible Testbed for Space Technology

This report is a Master's Thesis in Aerospace Engineering, performed at the NASA Ames Research Center. It describes the development of the CubeSub, a submersible testbed compatible with the CubeSat form factor. The CubeSub will be used to mature technology and operational procedures to be used in space exploration, and possibly also as a tool for exploration of Earthly environments. CubeSats are carried as payloads, either containing technology to be tested or experiments and sensors for scientific use. The CubeSub is designed to be built up by modules, which can be assembled in different configurations to fulfill different needs. Each module is powered individually and intermodular communication is wireless, reducing the need for wiring. The inside of the hull is flooded with ambient water to simplify the interaction between payloads and surrounding environment. The overall shape is similar to that of a conventional AUV, slender and smooth. This is to make for a low drag, reduce the risk of snagging on surrounding objects and make it possible to deploy through an ice sheet via a narrow borehole. Rapid prototyping is utilized to a large extent, with full-scale prototypes being constructed through 3D-printing and with COTS (Commercial Off-The-Shelf) components. Arduino boards are used for control and internal communication. Modules required for basic operation have been designed, manufactured and tested. Each module is described with regards to its function, design and manufacturability. By performing tests in a pool it was found that the basic concept is sound and that future improvements include better controllability, course stability and waterproofing of electrical components. Further development is needed to make the CubeSub usable for its intended purposes. The largest gains are expected to be found by developing the software and improving controllability.

Europa↗

NASA NTRS1979

Manufacturing development of DC-10 advanced rudder

The design, manufacture, and ground test activities during development of production methods for an advanced composite rudder for the DC-10 transport aircraft are described. The advanced composite aft rudder is satisfactory for airline service and a cost saving in a full production manufacturing mode is anticipated.

Cominsky, A.↗

NASA NTRS2004

Simulation Based Acquisition for NASA's Office of Exploration Systems

In January 2004, President George W. Bush unveiled his vision for NASA to advance U.S. scientific, security, and economic interests through a robust space exploration program. This vision includes the goal to extend human presence across the solar system, starting with a human return to the Moon no later than 2020, in preparation for human exploration of Mars and other destinations. In response to this vision, NASA has created the Office of Exploration Systems (OExS) to develop the innovative technologies, knowledge, and infrastructures to explore and support decisions about human exploration destinations, including the development of a new Crew Exploration Vehicle (CEV). Within the OExS organization, NASA is implementing Simulation Based Acquisition (SBA), a robust Modeling & Simulation (M&S) environment integrated across all acquisition phases and programs/teams, to make the realization of the President s vision more certain. Executed properly, SBA will foster better informed, timelier, and more defensible decisions throughout the acquisition life cycle. By doing so, SBA will improve the quality of NASA systems and speed their development, at less cost and risk than would otherwise be the case. SBA is a comprehensive, Enterprise-wide endeavor that necessitates an evolved culture, a revised spiral acquisition process, and an infrastructure of advanced Information Technology (IT) capabilities. SBA encompasses all project phases (from requirements analysis and concept formulation through design, manufacture, training, and operations), professional disciplines, and activities that can benefit from employing SBA capabilities. SBA capabilities include: developing and assessing system concepts and designs; planning manufacturing, assembly, transport, and launch; training crews, maintainers, launch personnel, and controllers; planning and monitoring missions; responding to emergencies by evaluating effects and exploring solutions; and communicating across the OExS enterprise, within the Government, and with the general public. The SBA process features empowered collaborative teams (including industry partners) to integrate requirements, acquisition, training, operations, and sustainment. The SBA process also utilizes an increased reliance on and investment in M&S to reduce design risk. SBA originated as a joint Industry and Department of Defense (DoD) initiative to define and integrate an acquisition process that employs robust, collaborative use of M&S technology across acquisition phases and programs. The SBA process was successfully implemented in the Air Force s Joint Strike Fighter (JSF) Program.

Hale, Joe↗

NASA NTRS1984

Parabolic Dish Stirling Module

The design, manufacture, and assembly of a commercially designed parabolic dish Stirling 25 kWe module is examined. The cost, expected performance, design uniquenesses, and future commercial potential of this module, which is regarded as the most technically advanced in the parabolic dish industry is discussed.

Washom, B.↗

NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗

NASA NTRS1989

Involute composite design evaluation using global design sensitivity derivatives

An optimization capability for involute structures has been developed. Its key feature is the use of global material geometry variables which are so chosen that all combinations of design variables within a set of lower and upper bounds correspond to manufacturable designs. A further advantage of global variables is that their number does not increase with increasing mesh density. The accuracy of the sensitivity derivatives has been verified both through finite difference tests and through the successful use of the derivatives by an optimizer. The state of the art in composite design today is still marked by point design algorithms linked together using ad hoc methods not directly related to a manufacturing procedure. The global design sensitivity approach presented here for involutes can be applied to filament wound shells and other composite constructions using material form features peculiar to each construction. The present involute optimization technology is being applied to the Space Shuttle SRM nozzle boot ring redesigns by PDA Engineering.

Hart, J. K.↗

NASA NTRS1994

Agile manufacturing: The factory of the future

The factory of the future will require an operating methodology which effectively utilizes all of the elements of product design, manufacturing and delivery. The process must respond rapidly to changes in product demand, product mix, design changes or changes in the raw materials. To achieve agility in a manufacturing operation, the design and development of the manufacturing processes must focus on customer satisfaction. Achieving greatest results requires that the manufacturing process be considered from product concept through sales. This provides the best opportunity to build a quality product for the customer at a reasonable rate. The primary elements of a manufacturing system include people, equipment, materials, methods and the environment. The most significant and most agile element in any process is the human resource. Only with a highly trained, knowledgeable work force can the proper methods be applied to efficiently process materials with machinery which is predictable, reliable and flexible. This paper discusses the affect of each element on the development of agile manufacturing systems.

Loibl, Joseph M.↗

NASA NTRS1997

Virtual Collaborative Simulation Environment for Integrated Product and Process Development

Deneb Robotics is a leader in the development of commercially available, leading edge three- dimensional simulation software tools for virtual prototyping,, simulation-based design, manufacturing process simulation, and factory floor simulation and training applications. Deneb has developed and commercially released a preliminary Virtual Collaborative Engineering (VCE) capability for Integrated Product and Process Development (IPPD). This capability allows distributed, real-time visualization and evaluation of design concepts, manufacturing processes, and total factory and enterprises in one seamless simulation environment.

Gulli, Michael A.↗

NASA NTRS2013

Multi-Step Ka/Ka Dichroic Plate with Rounded Corners for NASA's 34m Beam Waveguide Antenna

A multi-step Ka/Ka dichroic plate Frequency Selective Surface (FSS structure) is designed, manufactured and tested for use in NASA's Deep Space Network (DSN) 34m Beam Waveguide (BWG) antennas. The proposed design allows ease of manufacturing and ability to handle the increased transmit power (reflected off the FSS) of the DSN BWG antennas from 20kW to 100 kW. The dichroic is designed using HFSS and results agree well with measured data considering the manufacturing tolerances that could be achieved on the dichroic.

antenna↗

NASA NTRS1980

Future integrated design process

The design process is one of the sources used to produce requirements for a computer system to integrate and manage product design data, program management information, and technical computation and engineering data management activities of the aerospace design process. Design activities were grouped chronologically and explored for activity type, activity interface, data quantity, and data flow. The work was based on analysis of the design process of several typical aerospace products, including both conventional and supersonic airplanes and a hydrofoil design. Activities examined included research, preliminary design, detail design, manufacturing interface, product verification, and product support. The design process was then described in an IPAD environment--the future.

Meyer, D. D.↗

NASA NTRS1975

Applications of Computer Graphics in Engineering

Various applications of interactive computer graphics to the following areas of science and engineering were described: design and analysis of structures, configuration geometry, animation, flutter analysis, design and manufacturing, aircraft design and integration, wind tunnel data analysis, architecture and construction, flight simulation, hydrodynamics, curve and surface fitting, gas turbine engine design, analysis, and manufacturing, packaging of printed circuit boards, spacecraft design.

Source record↗

NASA NTRS1975

Engineering computer graphics in gas turbine engine design, analysis and manufacture

A time-sharing and computer graphics facility designed to provide effective interactive tools to a large number of engineering users with varied requirements was described. The application of computer graphics displays at several levels of hardware complexity and capability is discussed, with examples of graphics systems tracing gas turbine product development, beginning with preliminary design through manufacture. Highlights of an operating system stylized for interactive engineering graphics is described.

Lopatka, R. S.↗

NASA NTRS2004

TiAl Scramjet Inlet Flap Subelement Designed and Fabricated

Next-generation launch vehicles are being designed with turbine-based combined cycle (TBCC) propulsion systems having very aggressive thrust/weight targets and long lives. Achievement of these goals requires advanced materials in a wide spectrum of components. TiAl has been identified as a potential backstructure material for maintainable composite panel heat exchangers (HEX) in the inlet, combustor, and nozzle section of a TBCC propulsion system. Weight reduction is the primary objective of this technology. Design tradeoff studies have assessed that a TiAl structure, utilizing a high-strength, hightemperature TiAl alloy called Gamma MET PX,1 reduce weight by 41 to 48 percent in comparison to the baseline Inconel 718 configuration for the TBCC propulsion system inlet, combustor, and nozzle. A collaborative effort between the NASA Glenn Research Center, Pratt & Whitney, Engineering Evaluation & Design, PLANSEE AG (Austria), and the Austrian Space Agency was undertaken to design, manufacture, and validate a Gamma-MET PX TiAl structure for scramjet applications. The TiAl inlet flap was designed with segmented flaps to improve manufacturability, to better control thermal distortion and thermal stresses, and to allow for maintainable HEX segments. The design philosophy was to avoid excessively complicated shapes, to minimize the number of stress concentrations, to keep the part sizes reasonable to match processing capabilities, and to avoid risky processes such as welding. The conceptual design used a standard HEX approach with a double-pass coolant concept for centrally located manifolds. The flowpath side was actively cooled, and an insulation package was placed on the external side to save weight. The inlet flap was analyzed structurally, and local high-stress regions were addressed with local reinforcements.

Draper, Susan L.↗

NASA NTRS1984

Development of laminar flow control wing surface composite structures

The dramatic increases in fuel costs and the potential for periods of limited fuel availability provided the impetus to explore technologies to reduce transport aircraft fuel consumption. NASA sponsored the Aircraft Energy Efficiency (ACEE) program beginning in 1976 to develop technologies to improve fuel efficiency. This report documents the Lockheed-Georgia Company accomplishments under NAS1-16235 LFC Laminar-Flow-Control Wing Panel Structural Design And Development (WSSD); Design, manufacturing, and testing activities. An in-depth preliminary design of the baseline 1993 LFC wing was accomplished. A surface panel using the Lockheed graphite/epoxy integrated LFC wing box structural concept was designed. The concept was shown by analysis to be structurally efficient and cost effective. Critical details of the surface and surface joints were demonstrated by fabricating and testing complex, concept selection specimens. Cost of the baseline LFC aircraft was estimated and compared to the turbulent aircraft. The mission fuel weight was 21.7 percent lower for the LFC aircraft. The calculation shows that the lower fuel costs for LFC offset the higher incremental costs of LFC in less than six months.

Lineberger, L. B.↗

NASA NTRS1984

Structural tests and development of a laminar flow control wing surface composite chordwise joint

The dramatic increases in fuel costs and the potential for periods of limited fuel availability provided the impetus to explore technologies to reduce transport aircraft fuel consumption. NASA sponsored the Aircraft Energy Efficiency (ACEE) program beginning in 1976 to develop technologies to improve fuel efficiency. The Lockheed-Georgia Company accomplished under NAS1-16235 Laminar-Flow-Control (LFC) Wing Panel Structural Design and Development (WSSD); design, manufacturing, and testing activities. An in-depth preliminary design of the baseline 1993 LFC wing was accomplished. A surface panel using the Lockheed graphite/epoxy integrated LFC wing box structural concept was designed. The concept was shown by analysis to be structurally efficient and cost effective. Critical details of the surface and surface joint was demonstrated by fabricating and testing complex, concept selection specimens. The Lockheed-Georgia Company accomplishments, Development of LFC Wind Surface Composite Structures (WSCS), are documented. Tests were conducted on two CV2 panels to verify the static tension and fatigue strength of LFC wing surface chordwise joints.

Lineberger, L. B.↗

NASA NTRS1988

The design of aircraft using the decision support problem technique

The Decision Support Problem Technique for unified design, manufacturing and maintenance is being developed at the Systems Design Laboratory at the University of Houston. This involves the development of a domain-independent method (and the associated software) that can be used to process domain-dependent information and thereby provide support for human judgment. In a computer assisted environment, this support is provided in the form of optimal solutions to Decision Support Problems.

Mistree, Farrokh↗