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575 records · Page 8

Summary of LDEF battery analyses

Tests and analyses of NiCd, LiSO2, and LiCf batteries flown on the Long Duration Exposure Facility (LDEF) includes results from NASA, Aerospace, and commercial labs. The LiSO2 cells illustrate six-year degradation of internal components acceptable for space applications, with up to 85 percent battery capacity remaining on discharge of some returned cells. LiCf batteries completed their mission, but lost any remaining capacity due to internal degradation. Returned NiCd batteries tested an GSFC showed slight case distortion due to pressure build up, but were functioning as designed.

Johnson, Chris

Nickel-hydrogen CPV battery update

The multicell common pressure vessel (CPV) nickel hydrogen battery manufactured by Johnson Controls Battery Group, Inc. has completed full flight qualification, including random vibration at 19.5 g for two minutes in each axis, electrical characterization in a thermal vacuum chamber, and mass-spectroscopy vessel leak detection. A first launch is scheduled for late in 1992 or early 1993 by the Naval Research Laboratory (NRL). Specifics of the launch date are not available at this time due to the classified nature of the program. Release of orbital data for the battery is anticipated following the launch.

Jones, Kenneth R.

Nickel-hydrogen bipolar battery systems

Nickel-hydrogen cells are currently being manufactured on a semi-experimental basis. Rechargeable nickel-hydrogen systems are described that more closely resemble a fuel cell system than a traditional nickel-cadmium battery pack. This has been stimulated by the currently emerging requirements related to large manned and unmanned low earth orbit applications. The resultant nickel-hydrogen battery system should have a number of features that would lead to improved reliability, reduced costs as well as superior energy density and cycle lives as compared to battery systems constructed from the current state-of-the-art nickel-hydrogen individual pressure vessel cells.

Thaller, L. H.

2005 NASA Seal/Secondary Air System Workshop

The 2005 NASA Seal/Secondary Air System workshop covered the following topics: (i) Overview of NASA’s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (ii) Overview of the NASA-sponsored Propulsion 21 Project; (iii) Overview of NASA Glenn’s seal project aimed at developing advanced seals for NASA’s turbomachinery, space, and reentry vehicle needs; (iv) Reviews of NASA prime contractor, vendor, and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. Turbine engine studies have shown that reducing high-pressure turbine (HPT) blade tip clearances will reduce fuel burn, lower emissions, retain exhaust gas temperature margin, and increase range. Several organizations presented development efforts aimed at developing faster clearance control systems and associated technology to meet future engine needs. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle. Seal technical challenges (including space environments, temperature variation, and seal-on-seal operation) as well as plans to develop the necessary “androgynous” seal technologies were reviewed. Researchers also reviewed tests completed for the shuttle main landing gear door seals.

Hypersonic

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

vaned diffuser

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

centrifugal compressor

Analytical Model for Steady Flow through a Finite Channel with One Porous Wall with Arbitrary Variable Suction or Injection

This paper presents an exact solution of two-dimensional laminar flow through a finite length channel with one porous wall. It improves upon previous solutions by (1) satisfying the no-slip boundary condition at the channel dead end, (2) adding a turbulent term to the porous wall boundary condition, (3) allowing for arbitrary variable suction or injection across the porous wall, and (4) model validation against new cryogenic liquid hydrogen and oxygen experimental data. Of particular interest in the current work is the modeling of cryogenic propellant flow through a porous liquid acquisition device (LAD) screen and channel inside a propellant tank. First, a detailed review of the literature is presented for previously attempted solutions to channel flow with one porous wall. Next, the governing equations, boundary conditions, and model assumptions are used to derive the analytical flow solution and present general model results for pressure and velocity fields within the channel. Then, the model solution is compared with horizontal LAD channel flow data in liquid oxygen as well as vertical LAD channel flow data in an inverted outflow configuration in liquid hydrogen. Model results are used to update the static cryogenic bubble point pressure model with a dynamic bubble point term which factors in enhanced convection and cooling at the screen during propellant outflow. Convective heat transfer at the LAD screen during outflow is also quantified by comparing model and data. The new analytical flow solution with the dynamic bubble point model is shown to compare well with available cryogenic experimental data

Navier Stokes Equations

Digitally-Engineered Impact Resistant Aerogel Composites for MMOD Protection (DIRAC-MP)

This project implemented a digital-engineering approach to optimize the impact absorption performance of polymer aerogels and aerogel-based composites for Micrometeoroids and Orbital Debris (MMOD) containment. We developed a curated materials database and a machine-learning framework to derive composition-response relationships, enabling predictive design and targeted material selection. In support of experimental validation, a split Hopkinson pressure bar (SHPB) test rig, specifically adapted for low-density aerogel materials, was designed and built in-house. This project accelerates the development of new aerogel formulations, producing candidate materials tailored for enhanced impact-absorption behavior.

Sadeq Malakooti

The Operational NASA Anomaly Gas Analyzer and Exploration Follow-Ons

The NASA Anomaly Gas Analyzer (AGA) is the culmination of nearly ten years of advancement of core technology originally developed by Vista Photonics through the Small Business Innovation Research (SBIR) program and expanded using NASA program funding. The AGA is a portable, battery operated, optical gas detection instrument for continuous monitoring of H 2 O, CO 2 , O 2 , CO, NH 3 , HCN, HF, HCl in the spacecraft environment. Real time, in-situ monitored, gas concentrations are communicated at 1 Hz through a built-in display on-orbit and additionally through a serial interface on the ground. The instruments function over the typical range of temperatures and pressures required for the spacecraft environment. A ten-year operational life is targeted. Seven AGA instruments are currently deployed on the International Space Station and two Orion-specific units are manifested for Artemis 2. A variation of the operational AGA is under development for lunar Human Landing Systems. A wider calibrated operating pressure envelope is required in this application. Otherwise, the instruments straightforwardly address lessons learned from the original AGA by improving aspects of thermal control, ruggedness, and ease-of-use. A subset of AGA-developed sensed gases (H 2 O, CO 2 , O 2 ) is the subject of the Primary Constituent Monitor (PCM) development for the Habitation and Logistics Outpost (HALO) destined for lunar orbit. Two PCMs will be installed in HALO as part of the environmental control loop where they will interface with vehicle power and communications. While the basic sensor techniques are unchanged from the AGA, these instruments have been radiation hardened to survive for many years in the harsh target environment. Current development status for these instruments will be presented along with recent developments of a naval submarine variant.

ECLSS

NASA Hybrid Thermally Efficient Core (HyTEC) Phase 2 Q3’GFY25 to Q2’GFY26 Unlimited Rights Annual Report for CLIN 1 and 2

The HyTEC Phase 2 Project focuses on the development and demonstration of high-power density, small engine core gas turbine engine technologies. The focus of HyTEC on these small engine core technologies will provide direct benefits to the next single-aisle class aircraft in terms of thermal efficiency, as well as integrate with other technologies, through increased hybridization, as they mature to provide substantial continuous fuel burn reductions during the aircraft lifecycle. These advances will strengthen the US position in the commercial aviation engine market and enable cost benefits in commercial aviation. In Government fiscal year 26 the HyTEC Project was closed and contract moved to the Subsonic Vehicle Technologies and Tools Project. GE Aerospace is executing two major work plans as part of the HyTEC Phase 2 contract. The first is Contract Line-Item Number (CLIN) 001 and its objective is to mature High Pressure Turbine (HPT) aerodynamics technology to TRL 5 through multiple rigs so that it may be incorporated into a complete TRL 6 evaluation and unlock learnings for the engine core demonstration as applicable. CLIN 002, the second work plan, is to design, procure and test a cost shared portion of technologies on the TRL6 Compact Core test vehicle. The compact core demonstrated through HyTEC Phase 2 along with the HPT rig TRL advancement directly matures the technologies being developed as part of the CFM RISE demonstrator program which is targeting a more than 20% fuel burn reduction at the engine level versus today’s state of the art. The RISE program’s objective is to advance both the novel Open Fan architecture, compact core technologies and advanced systems such as hybrid electric needed to achieve the desired fuel burn reduction to TRL6 ahead of a new product introduction in the single-aisle class aircraft in the 2030s timeframe.

gas turbine engine

The Operational NASA Anomaly Gas Analyzer and Exploration Follow-Ons

The NASA Anomaly Gas Analyzer (AGA) is the culmination of nearly ten years of advancement of core technology originally developed by Vista Photonics through the Small Business Innovation Research (SBIR) program and expanded using NASA program funding. The AGA is a portable, battery operated, optical gas detection instrument for continuous monitoring of H 2 O, CO 2 , O 2 , CO, NH 3 , HCN, HF, HCl in the spacecraft environment. Real time, in-situ monitored, gas concentrations are communicated at 1 Hz through a built-in display on-orbit and additionally through a serial interface on the ground. The instruments function over the typical range of temperatures and pressures required for the spacecraft environment. A ten-year operational life is targeted. Seven AGA instruments are currently deployed on the International Space Station and two Orion-specific units are manifested for Artemis 2. A variation of the operational AGA is under development for lunar Human Landing Systems. A wider calibrated operating pressure envelope is required in this application. Otherwise, the instruments straightforwardly address lessons learned from the original AGA by improving aspects of thermal control, ruggedness, and ease-of-use. A subset of AGA-developed sensed gases (H 2 O, CO 2 , O 2 ) is the subject of the Primary Constituent Monitor (PCM) development for the Habitation and Logistics Outpost (HALO) destined for lunar orbit. Two PCMs will be installed in HALO as part of the environmental control loop where they will interface with vehicle power and communications. While the basic sensor techniques are unchanged from the AGA, these instruments have been radiation hardened to survive for many years in the harsh target environment. Current development status for these instruments will be presented along with recent developments of a naval submarine variant.

Air Monitoring

Manned Mars Systems Study

A study is underway to determine attractive system options, perform trade studies, and provide comparative data for astronaut missions to Mars. Because of an emphasis in this work on deriving requirements and candidates for the transportation and facility infrastructure for such missions, all relevant technologies and mission constraints are also being considered. These include on-orbit assembly, trajectory type, launch opportunities, propellant storage, crew size, cabin pressure, artificial gravity, life-support systems, radiation hazards, power/energy storage, thermal control, human factors, communications, abort scenarios, landing techniques, exploration strategies and science activities. It is planned to scope several example missions and to identify enabling and significantly enhancing technologies for accomplishing the goals of the human exploration of Mars.

Benton C Clark

Improved Treatment of Global Positioning System Force Parameters in Precise Orbit Determination Applications

Data collected from a worldwide 1992 experiment have been processed at JPL to determine precise orbits for the satellites of the Global Positioning System (GPS). A filtering technique has been tested to improve modeling of solar-radiation pressure force parameters for GPS satellites. The new approach improves orbit quality for eclipsing satellites by a factor of two, with typical results in the 25- to 50-cm range. The resultant GPS-based estimates for geocentric coordinates of the tracking sites, which include the three DSN sites, are accurate to 2 to 8 cm, roughly equivalent to 3 to 10 nrad of angular measure.

Y Vigue

Ulysses navigation

Ulysses, a cooperative NASA and ESA project, measures charged and neutral particles, magnetic fields, and electromagnetic wave emissions from the Sun's polar regions and the out of elliptic heliospheric environment. ESA supplied the spacecraft and one half of the instruments, and is in control of the spacecraft and its attitude. NASA supplied the power supply, one half of the instruments, the launch vehicle, and tracks the spacecraft and performs the navigation. Orbit determination results mapped to the time of Jupiter's arrival show improved accuracy and consistency over the course of the mission to date. Solar radiation pressure model uncertainties are major contributors to orbit determination errors, but are being estimated more accurately as data are accumulated.

H. J. Gordon

Three-Dimensional, Multi-Phase Unsteady Flow of Water Undergoing Multiple Flow Regimes (Free Surface, Droplet, and Fluid Film)

Upgrades to the Mobile Launcher Rainbird nozzles were implemented for the Artemis II launch to increase water flow rates and improve the mobile launcher deck water coverage while minimizing the water throw distance to avoid impacting the Space Launch System (SLS) rocket nozzles. This analysis describes the use of a three-dimensional, multi-phase, free surface transient computational fluid dynamics (CFD) model to simulate the water flowing out through the Rainbird nozzle and ensure compliance with current Artemis requirements. Flow rates, pressures, velocities, nozzle throw distances and coverage areas were analyzed to ensure that system requirements are met. The completed results were used to make necessary modifications to the Ignition Overpressure Protection and Sound Suppression (IOP/SS) system Rainbird design by reshaping the nozzle used in the system.

CFD

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity

High Efficiency Centrifugal Compressor for Rotorcraft Applications

The report "High Efficiency Centrifugal Compressor for Rotorcraft Applications" documents the work conducted at UTRC under the NRA Contract NNC08CB03C, with cost share 2/3 NASA, and 1/3 UTRC, that has been extended to 4.5 years. The purpose of this effort was to identify key technical barriers to advancing the state-of-the-art of small centrifugal compressor stages; to delineate the measurements required to provide insight into the flow physics of the technical barriers; to design, fabricate, install, and test a state-of-the-art research compressor that is representative of the rear stage of an axial-centrifugal aero-engine; and to acquire detailed aerodynamic performance and research quality data to clarify flow physics and to establish detailed data sets for future application. The design activity centered on meeting the goal set outlined in the NASA solicitation-the design target was to increase efficiency at higher work factor, while also reducing the maximum diameter of the stage. To fit within the existing Small Engine Components Test Facility at NASA Glenn Research Center (GRC) and to facilitate component re-use, certain key design parameters were fixed by UTRC, including impeller tip diameter, impeller rotational speed, and impeller inlet hub and shroud radii. This report describes the design effort of the High Efficiency Centrifugal Compressor stage (HECC) and delineation of measurements, fabrication of the compressor, and the initial tests that were performed. A new High-Efficiency Centrifugal Compressor stage with a very challenging reduction in radius ratio was successfully designed, fabricated and installed at GRC. The testing was successful, with no mechanical problems and the running clearances were achieved without impeller rubs. Overall, measured pressure ratio of 4.68, work factor of 0.81, and at design exit corrected flow rate of 3 lbm/s met the target requirements. Polytropic efficiency of 85.5 percent and stall margin of 7.5 percent were measured at design flow rate and speed. The measured efficiency and stall margin were lower than pre-test CFD predictions by 2.4 percentage points (pt) and 4.5 pt, respectively. Initial impressions from the experimental data indicated that the loss in the efficiency and stall margin can be attributed to a design shortfall in the impeller. However, detailed investigation of experimental data and post-test CFD simulations of higher fidelity than pre-test CFD, and in particular the unsteady CFD simulations and the assessment with a wider range of turbulence models, have indicated that the loss in efficiency is most likely due to the impact of unfavorable unsteady impeller/diffuser interactions induced by diffuser vanes, an impeller/diffuser corrected flow-rate mismatch (and associated incidence levels), and, potentially, flow separation in the radial-to-axial bend. An experimental program with a vaneless diffuser is recommended to evaluate this observation. A subsequent redesign of the diffuser (and the radial-to-axial bend) is also recommended. The diffuser needs to be redesigned to eliminate the mismatching of the impeller and the diffuser, targeting a slightly higher flow capacity. Furthermore, diffuser vanes need to be adjusted to align the incidence angles, to optimize the splitter vane location (both radially and circumferentially), and to minimize the unsteady interactions with the impeller. The radial-to-axial bend needs to be redesigned to eliminate, or at least minimize, the flow separation at the inner wall, and its impact on the flow in the diffuser upstream. Lessons were also learned in terms of CFD methodology and the importance of unsteady CFD simulations for centrifugal compressors was highlighted. Inconsistencies in the implementation of a widely used two-equation turbulence model were identified and corrections are recommended. It was also observed that unsteady simulations for centrifugal compressors require significantly longer integration times than what is current practice in industry.

Gorazd Medic

Development of a Thermal Radiator Optimization Tool with Alternate Coolants

The development of a modeling tool to optimize the design of a thermal radiator based on capacity, rejection temperature, geometry, type and coolant is presented. The radiator size is determined from the desired capacity, environmental conditions and rejection temperature. Flow through the radiator is derived from the overall heat load and prescribed inlet to outlet delta temperature for a given coolant. The tool considers radiator geometry (i.e., tube spacing and diameter, face-sheet thickness, overall size, etc.) and general type (i.e., parallel/manifold versus serpentine) in the optimization. Selection from a handful of potential coolants is also available in the tool which primarily affects necessary tube diameter to maintain turbulent flow and minimize pressure drop. An Equivalent System Mass (ESM) approach is utilized to include pump power in the optimization. Results from the tool and potential future enhancements are also discussed.

Coolant