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NASA NTRS2005

Lunar and Martian Sub-surface Habitat Structure Technology Development and Application

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Subsidace structures such as caves and lava tubes offer readily available and existing in-situ habitat options. Sub-surface dwellings can provide complete radiation, micro-meteorite and exhaust plume shielding and a moderate and constant temperature environment; they are, therefore, excellent pre-existing habitat risk mitigation elements. Technical challenges to subsurface habitat structure development include surface penetration (digging and mining equipment), environmental pressurization, and psychological environment enhancement requirements. Lunar and Martian environments and elements have many beneficial similarities. This will allow for lunar testing and design development of subsurface habitat structures for Martian application; however, significant differences between lunar and Martian environments and resource elements will mandate unique application development. Mars is NASA's ultimate exploration goal and is known to have many very large lava tubes. Other cave types are plausible. The Moon has unroofed rilles and lava tubes, but further research will, in the near future, define the extent of Lunar and Martian differences and similarities. This paper will discuss Lunar and Martian subsurface habitation technology development challenges and opportunities.

Boston, Penelope J.↗
NASA NTRS2004

Lunar Contour Crafting: A Novel Technique for ISRU-Based Habitat Development

As the nation prepares to return to the Moon, it is apparent that the viability of long duration visits with appropriate radiation shielding/crew protection, hinges on the development of Lunar structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. Contour Crafting is a USC-patented technique for automated development of terrestrial concrete-based structures. The process is relatively fast, completely automated, and supports the incorporation of various infrastructure elements such as plumbing and electrical wiring. This paper will present a conceptual design of a Lunar Contour Crafting system designed to autonomously fabricate integrated structures on the Lunar surface using high-strength concrete based on Lunar regolith, including glass reinforcement rods or fibers fabricated from melted regolith. Design concepts will be presented, as well as results of initial tests aimed at concrete and glass production using Lunar regolith simulant. Key issues and concerns will be presented, along with design concepts for an LCC testbed to be developed at MSFC's Prototype Development Laboratory (PDL).

Khoshnevis, Behrokh↗
NASA NTRS2005

Development of High Altitude UAV Weather Radars for Hurricane Research

A proposed effort within NASA called (ASHE) over the past few years was aimed at studying the genesis of tropical disturbances off the east coast of Africa. This effort was focused on using an instrumented Global Hawk UAV with high altitude (%Ok ft) and long duration (30 h) capability. While the Global Hawk availability remains uncertain, development of two relevant instruments, a Doppler radar (URAD - UAV Radar) and a backscatter lidar (CPL-UAV - Cloud Physics Lidar), are in progress. The radar to be discussed here is based on two previous high-altitude, autonomously operating radars on the NASA ER-2 aircraft, the ER-2 Doppler Radar (EDOP) at X-band (9.6 GHz), and the Cloud Radar System (CRS) at W- band (94 GHz). The nadir-pointing EDOP and CRS radars profile vertical reflectivity structure and vertical Doppler winds in precipitation and clouds, respectively. EDOP has flown in all of the CAMEX flight series to study hurricanes over storms such as Hurricanes Bonnie, Humberto, Georges, Erin, and TS Chantal. These radars were developed at Goddard over the last decade and have been used for satellite algorithm development and validation (TRMM and Cloudsat), and for hurricane and convective storm research. We describe here the development of URAD that will measure wind and reflectivity in hurricanes and other weather systems from a top down, high-altitude view. URAD for the Global Hawk consists of two subsystems both of which are at X-band (9.3-9.6 GHz) and Doppler: a nadir fixed-beam Doppler radar for vertical motion and precipitation measurement, and a Conical scanning radar for horizontal winds in cloud and at the surface, and precipitation structure. These radars are being designed with size, weight, and power consumption suitable for the Global Hawk and other UAV's. The nadir radar uses a magnetron transmitter and the scanning radar uses a TWT transmitter. With conical scanning of the radar at a 35" incidence angle over an ocean surface in the absence of precipitation, the surface return over a single 360 degree sweep over -25 h-diameter region provides information on the surface wind speed and direction within the scan circle. In precipitation regions, the conical scan with appropriate mapping and analysis provides the 3D structure of reflectivity beneath the plane and the horizontal winds. The use of conical scanning in hurricanes has recently been demonstrated for measuring inner core winds with the IWRAP system flying on the NOAA P3's. In this presentation, we provide a description of the URAD system hardware, status, and future plans. In addition to URAD, NASA SBIR activity is supporting a Phase I study by Remote Sensing Solutions and the University of Massachusetts for a dual-frequency IWRAP for a high altitude UAV that utilizes solid state transmitters at 14 and 35 GHz, the same frequencies that are planned for the radar on the Global Precipitation System satellite. This will be discussed elsewhere at the meeting.

Heymsfield, Gerald↗
NASA NTRS2005

Development Status of the Advanced Life Support On-Line Project Information System

The Advanced Life Support Program has recently accelerated an effort to develop an On-line Project Information System (OPIS) for research project and technology development data centralization and sharing. The core functionality of OPIS will launch in October of 2005. This paper presents the current OPIS development status. OPIS core functionality involves a Web-based annual solicitation of project and technology data directly from ALS Principal Investigators (PIS) through customized data collection forms. Data provided by PIs will be reviewed by a Technical Task Monitor (TTM) before posting the information to OPIS for ALS Community viewing via the Web. The data will be stored in an object-oriented relational database (created in MySQL(R)) located on a secure server at NASA ARC. Upon launch, OPIS can be utilized by Managers to identify research and technology development gaps and to assess task performance. Analysts can employ OPIS to obtain.

Levri, Julie A.↗
NASA NTRS2005

Risk Management for Human Support Technology Development

NASA requires continuous risk management for all programs and projects. The risk management process identifies risks, analyzes their impact, prioritizes them, develops and carries out plans to mitigate or accept them, tracks risks and mitigation plans, and communicates and documents risk information. Project risk management is driven by the project goal and is performed by the entire team. Risk management begins early in the formulation phase with initial risk identification and development of a risk management plan and continues throughout the project life cycle. This paper describes the risk management approach that is suggested for use in NASA's Human Support Technology Development. The first step in risk management is to identify the detailed technical and programmatic risks specific to a project. Each individual risk should be described in detail. The identified risks are summarized in a complete risk list. Risk analysis provides estimates of the likelihood and the qualitative impact of a risk. The likelihood and impact of the risk are used to define its priority location in the risk matrix. The approaches for responding to risk are either to mitigate it by eliminating or reducing the effect or likelihood of a risk, to accept it with a documented rationale and contingency plan, or to research or monitor the risk, The Human Support Technology Development program includes many projects with independently achievable goals. Each project must do independent risk management, considering all its risks together and trading them against performance, budget, and schedule. Since the program can succeed even if some projects fail, the program risk has a complex dependence on the individual project risks.

jones, Harry↗
NASA NTRS2005

Proposed Project Selection Method for Human Support Research and Technology Development (HSR&TD)

The purpose of HSR&TD is to deliver human support technologies to the Exploration Systems Mission Directorate (ESMD) that will be selected for future missions. This requires identifying promising candidate technologies and advancing them in technology readiness until they are acceptable. HSR&TD must select an may of technology development projects, guide them, and either terminate or continue them, so as to maximize the resulting number of usable advanced human support technologies. This paper proposes an effective project scoring methodology to support managing the HSR&TD project portfolio. Researchers strongly disagree as to what are the best technology project selection methods, or even if there are any proven ones. Technology development is risky and outstanding achievements are rare and unpredictable. There is no simple formula for success. Organizations that are satisfied with their project selection approach typically use a mix of financial, strategic, and scoring methods in an open, established, explicit, formal process. This approach helps to build consensus and develop management insight. It encourages better project proposals by clarifying the desired project attributes. We propose a project scoring technique based on a method previously used in a federal laboratory and supported by recent research. Projects are ranked by their perceived relevance, risk, and return - a new 3 R's. Relevance is the degree to which the project objective supports the HSR&TD goal of developing usable advanced human support technologies. Risk is the estimated probability that the project will achieve its specific objective. Return is the reduction in mission life cycle cost obtained if the project is successful. If the project objective technology performs a new function with no current cost, its return is the estimated cash value of performing the new function. The proposed project selection scoring method includes definitions of the criteria, a project evaluation questionnaire, and a scoring formula.

Jones, Harry↗
NASA NTRS1995

Concept Designed and Developed for Distortion- Tolerant, High-Stability Engine Control

Engine Control Future aircraft turbine engines, both commercial and military, must be able to successfully accommodate expected increased levels of steady-state and dynamic engine-face distortion. Advanced tactical aircraft are likely to use thrust vectoring to enhance their maneuverability. As a result, the engines will see more extreme aircraft angles-of-attack and sideslip levels than are currently encountered with present-day aircraft. Also, the mixed-compression inlets needed for the High Speed Civil Transport will likely encounter disturbances similar to those seen by tactical aircraft, in addition to planar pulse, inlet buzz, and high distortion levels at low flight speed and off-design operation. The current approach of incorporating a sufficient component design stall margin to tolerate these increased levels of distortion would significantly reduce performance. The objective of the High Stability Engine Control (HISTEC) program is to design, develop, and flight demonstrate an advanced, high-stability, integrated engine-control system that uses measurement-based, real-time estimates of distortion to enhance engine stability. The resulting distortion-tolerant control reduces the required design stall margin, with a corresponding increase in performance and decrease in fuel burn. The HISTEC concept has been designed and developed, and the software implementing the concept has successfully accommodated time-varying distortion. The NASA Lewis Research Center is currently overseeing the development and validation of the hardware and software necessary to flight test the HISTEC concept. HISTEC is a contracted effort with Pratt & Whitney of West Palm Beach, Florida. The HISTEC approach includes two major systems: A Distortion Estimation System (DES) and Stability Management Control (SMC). DES is an aircraft-mounted, high-speed processor that estimates the amount and type of distortion present and its effect on the engine. It uses high-response pressure measurements at the engine face to calculate indicators of the type and extent of distortion in real time. From these indicators, DES determines the effects of distortion on the propulsion systems and the corresponding engine match point necessary to accommodate it. DES output consists of fan and compressor pressure ratio trim commands that are passed to the SMC. In addition, DES uses maneuver information, consisting of angle-of-attack and sideslip from the flight control, to anticipate high inlet distortion conditions. The SMC, which is contained in the engine-mounted, Improved Digital Electronic Engine Control (IDEEC), includes advanced control laws to directly control the fan and compressor transient operating line (pressure ratio). These advanced control laws, with a multivariable design, have the potential for higher bandwidth and the resulting more precise control of engine match. The ability to measure and assess the distortion effects in real time coupled with a high-response controller improves engine stability at high levels of distortion. The software algorithms implementing DES have been designed, developed, and demonstrated, and integration testing of the DES and SMC software has been completed. The results show that the HISTEC system will be able to sense inlet distortion, determine the effect on engine stability, and accommodate distortion by maintaining an adequate margin for engine surge. The Pratt &Whitney Comprehensive Engine Diagnostic Unit was chosen as the DES processor. An instrumented inlet case for sensing distortion was designed and fabricated. HISTEC is scheduled for flight test on the ACTIVE F-15 aircraft at the NASA Dryden Flight Research Center in Edwards, California, in late 1996.

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NASA NTRS1996

Potential Market for Satellite Technology in Meeting Telecommunication Needs of Developing Nations

A recent study examined the potential for satellite technology to meet the telecommunication needs of developing nations. The growth of these nations depends on their attracting and holding the industrial investments of developed nations. This will not be likely with the antiquated telecommunications infrastructure typical of developing nations. On the contrary, it will require an infrastructure that is compatible with international standards. Most of the developing nations perceive this necessity and are pursuing the necessary upgrades. The rate of replacement, types of technology, services affected, and the terrestrial/satellite mix differ by each nation's priorities and gross national product (GNP).

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NASA NTRS1996

User Interface Developed for Controls/CFD Interdisciplinary Research

The NASA Lewis Research Center, in conjunction with the University of Akron, is developing analytical methods and software tools to create a cross-discipline "bridge" between controls and computational fluid dynamics (CFD) technologies. Traditionally, the controls analyst has used simulations based on large lumping techniques to generate low-order linear models convenient for designing propulsion system controls. For complex, high-speed vehicles such as the High Speed Civil Transport (HSCT), simulations based on CFD methods are required to capture the relevant flow physics. The use of CFD should also help reduce the development time and costs associated with experimentally tuning the control system. The initial application for this research is the High Speed Civil Transport inlet control problem. A major aspect of this research is the development of a controls/CFD interface for non-CFD experts, to facilitate the interactive operation of CFD simulations and the extraction of reduced-order, time-accurate models from CFD results. A distributed computing approach for implementing the interface is being explored. Software being developed as part of the Integrated CFD and Experiments (ICE) project provides the basis for the operating environment, including run-time displays and information (data base) management. Message-passing software is used to communicate between the ICE system and the CFD simulation, which can reside on distributed, parallel computing systems. Initially, the one-dimensional Large-Perturbation Inlet (LAPIN) code is being used to simulate a High Speed Civil Transport type inlet. LAPIN can model real supersonic inlet features, including bleeds, bypasses, and variable geometry, such as translating or variable-ramp-angle centerbodies. Work is in progress to use parallel versions of the multidimensional NPARC code.

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NASA NTRS1996

Spherical Joint Piston and Connecting Rod Developed

Under an interagency agreement with the Department of Energy, the NASA Lewis Research Center manages a Heavy-Duty Diesel Engine Technology (HDET) research program. The overall program objectives are to reduce fuel consumption through increased engine efficiency, reduce engine exhaust emissions, and provide options for the use of alternative fuels. The program is administered with a balance of research contracts, university research grants, and focused in-house research. The Cummins Engine Company participates in the HDET program under a cost-sharing research contract. Cummins is researching and developing in-cylinder component technologies for heavy-duty diesel engines. An objective of the Cummins research is to develop technologies for a low-emissions, 55-percent thermal efficiency (LE-55) engine. The best current-production engines in this class achieve about 46-percent thermal efficiency. Federal emissions regulations are driving this technology. Regulations for heavy duty diesel engines were tightened in 1994, more demanding emissions regulations are scheduled for 1998, and another step is planned for 2002. The LE-55 engine emissions goal is set at half of the 1998 regulation level and is consistent with plans for 2002 emissions regulations. LE-55 engine design requirements to meet the efficiency target dictate a need to operate at higher peak cylinder pressures. A key technology being developed and evaluated under the Cummins Engine Company LE-55 engine concept is the spherical joint piston and connecting rod. Unlike conventional piston and connecting rod arrangements which are joined by a pin forming a hinged joint, the spherical joint piston and connecting rod use a ball-and-socket joint. The ball-and-socket arrangement enables the piston to have an axisymmetric design allowing rotation within the cylinder. The potential benefits of piston symmetry and rotation are reduced scuffing, improved piston ring sealing, improved lubrication, mechanical and thermal load symmetry, reduced bearing stresses, reduced running clearances, and reduced oil consumption. The spherical joint piston is a monolithic, squeeze-cast, fiber-reinforced aluminum piston. The connecting rod has a ball end that seats on a spherical saddle within the piston and is retained by a pair of aluminum bronze holder rings. The holder rings are secured by a threaded ring that mates with the piston. As part of the ongoing research and development activity, the Cummins Engine Company successfully completed a 100-hr test of the spherical joint piston and connecting rod at LE- 55 peak steady-state engine conditions. In addition, a 100-hr transient cycle test that varied engine conditions between LE-55 no-load and LE-55 full-load was successfully completed.

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NASA NTRS2005

Experiences with a Requirements-Based Programming Approach to the Development of a NASA Autonomous Ground Control System

Requirements-to-Design-to-Code (R2D2C) is an approach to the engineering of computer-based systems that embodies the idea of requirements-based programming in system development. It goes further; however, in that the approach offers not only an underlying formalism, but full formal development from requirements capture through to the automatic generation of provably-correct code. As such, the approach has direct application to the development of systems requiring autonomic properties. We describe a prototype tool to support the method, and illustrate its applicability to the development of LOGOS, a NASA autonomous ground control system, which exhibits autonomic behavior. Finally, we briefly discuss other areas where the approach and prototype tool are being considered for application.

Hinchey, Michael G.↗
NASA NTRS2005

Challenges of Developing New Classes of NASA Self-Managing Mission

NASA is proposing increasingly complex missions that will require a high degree of autonomy and autonomicity. These missions pose hereto unforeseen problems and raise issues that have not been well-addressed by the community. Assuring success of such missions will require new software development techniques and tools. This paper discusses some of the challenges that NASA and the rest of the software development community are facing in developing these ever-increasingly complex systems. We give an overview of a proposed NASA mission as well as techniques and tools that are being developed to address autonomic management and the complexity issues inherent in these missions.

Hinchey, M. G.↗
NASA NTRS2005

You Can't Get There From Here! Problems and Potential Solutions in Developing New Classes of Complex Systems

The explosion of capabilities and new products within the sphere of Information Technology (IT) has fostered widespread, overly optimistic opinions regarding the industry, based on common but unjustified assumptions of quality and correctness of software. These assumptions are encouraged by software producers and vendors, who at this late date have not succeeded in finding a way to overcome the lack of an automated, mathematically sound way to develop correct systems from requirements. NASA faces this dilemma as it envisages advanced mission concepts that involve large swarms of small spacecraft that will engage cooperatively to acheve science goals. Such missions entail levels of complexity that beg for new methods for system development far beyond today's methods, which are inadequate for ensuring correct behavior of large numbers of interacting intelligent mission elements. New system development techniques recently devised through NASA-led research will offer some innovative approaches to achieving correctness in complex system development, including autonomous swarm missions that exhibit emergent behavior, as well as general software products created by the computing industry.

Hinchey, Michael G.↗
NASA NTRS2005

Development of the Surface Management System Integrated with CTAS Arrival Tools

The Surface Management System (SMS) developed by NASA Ames Research Center in coordination with the Federal Aviation Administration (FAA) is a decision support tool to help tower traffic coordinators and Ground/Local controllers in managing and controlling airport surface traffic in order to increase capacity, efficiency, and flexibility. SMS provides common situation awareness to personnel at various air traffic control facilities such as airport traffic control towers (ATCT s), airline ramp towers, Terminal Radar Approach Control (TRACON), and Air Route Traffic Control Center (ARTCC). SMS also provides a traffic management tool to assist ATCT traffic management coordinators (TMCs) in making decisions such as airport configuration and runway load balancing. The Build 1 of the SMS tool was installed and successfully tested at Memphis International Airport (MEM) and received high acceptance scores from ATCT controllers and coordinators, as well as airline ramp controllers. NASA Ames Research Center continues to develop SMS under NASA s Strategic Airspace Usage (SAU) project in order to improve its prediction accuracy and robustness under various modeling uncertainties. This paper reports the recent development effort performed by the NASA Ames Research Center: 1) integration of Center TRACON Automation System (CTAS) capability with SMS and 2) an alternative approach to obtain airline gate information through a publicly available website. The preliminary analysis results performed on the air/surface traffic data at the DFW airport have shown significant improvement in predicting airport arrival demand and IN time at the gate. This paper concludes with recommendations for future research and development.

Jung, Yoon C.↗
NASA NTRS2004

Development of the Planar Inlet Design and Analysis Process (PINDAP)

The aerodynamic development of an engine inlet requires a comprehensive program of both wind tunnel testing and Computational Fluid Dynamics (CFD) simulations. To save time and resources, much "testing" is done using CFD before any design ever enters a wind tunnel. The focus of my project this summer is on CFD analysis tool development. In particular, I am working to further develop the capabilities of the Planar Inlet Design and Analysis Process (PINDAP). "PINDAP" is a collection of computational tools that allow for efficient and accurate design and analysis of the aerodynamics about and through inlets that can make use of a planar (two-dimensional or axisymmetric) geometric and flow assumption. PINDAP utilizes the WIND CFD flow solver, which is capable of simulating the turbulent, compressible flow field. My project this summer is a continuation of work that I performed for two previous summers. Two years ago, I used basic features of the PINDAP to design a Mach 5 hypersonic scramjet engine inlet and to demonstrate the feasibility of the PINDAP. The following summer, I worked to develop its geometry and grid generation capabilities to include subsonic and supersonic inlets, complete bodies and cowls, conic leading and trailing edges, as well as airfoils. These additions allowed for much more design flexibility when using the program.

Gruber, Christopher R.↗
NASA NTRS2004

Soft-Fault Detection Technologies Developed for Electrical Power Systems

The NASA Glenn Research Center, partner universities, and defense contractors are working to develop intelligent power management and distribution (PMAD) technologies for future spacecraft and launch vehicles. The goals are to provide higher performance (efficiency, transient response, and stability), higher fault tolerance, and higher reliability through the application of digital control and communication technologies. It is also expected that these technologies will eventually reduce the design, development, manufacturing, and integration costs for large, electrical power systems for space vehicles. The main focus of this research has been to incorporate digital control, communications, and intelligent algorithms into power electronic devices such as direct-current to direct-current (dc-dc) converters and protective switchgear. These technologies, in turn, will enable revolutionary changes in the way electrical power systems are designed, developed, configured, and integrated in aerospace vehicles and satellites. Initial successes in integrating modern, digital controllers have proven that transient response performance can be improved using advanced nonlinear control algorithms. One technology being developed includes the detection of "soft faults," those not typically covered by current systems in use today. Soft faults include arcing faults, corona discharge faults, and undetected leakage currents. Using digital control and advanced signal analysis algorithms, we have shown that it is possible to reliably detect arcing faults in high-voltage dc power distribution systems (see the preceding photograph). Another research effort has shown that low-level leakage faults and cable degradation can be detected by analyzing power system parameters over time. This additional fault detection capability will result in higher reliability for long-lived power systems such as reusable launch vehicles and space exploration missions.

Button, Robert M.↗
NASA NTRS2004

Erosion Coatings Developed to Increase the Life and Durability of Composites

Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Sutter, James K.↗
NASA NTRS2004

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗