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Random Vibrations

Ares I Zonal Random vibration environments due to acoustic impingement and combustion processes are develop for liftoff, ascent and reentry. Random Vibration test criteria for Ares I Upper Stage pyrotechnic components are developed by enveloping the applicable zonal environments where each component is located. Random vibration tests will be conducted to assure that these components will survive and function appropriately after exposure to the expected vibration environments. Methodology: Random Vibration test criteria for Ares I Upper Stage pyrotechnic components were desired that would envelope all the applicable environments where each component was located. Applicable Ares I Vehicle drawings and design information needed to be assessed to determine the location(s) for each component on the Ares I Upper Stage. Design and test criteria needed to be developed by plotting and enveloping the applicable environments using Microsoft Excel Spreadsheet Software and documenting them in a report Using Microsoft Word Processing Software. Conclusion: Random vibration liftoff, ascent, and green run design & test criteria for the Upper Stage Pyrotechnic Components were developed by using Microsoft Excel to envelope zonal environments applicable to each component. Results were transferred from Excel into a report using Microsoft Word. After the report is reviewed and edited by my mentor it will be submitted for publication as an attachment to a memorandum. Pyrotechnic component designers will extract criteria from my report for incorporation into the design and test specifications for components. Eventually the hardware will be tested to the environments I developed to assure that the components will survive and function appropriately after exposure to the expected vibration environments.

Messaro. Semma↗

Designing the Space Shuttle Propulsion System

The major elements of the Space Shuttle Main Propulsion System include two reusable solid rocket motors integrated into recoverable solid rocket boosters, an expendable external fuel and oxidizer tank, and three reusable Space Shuttle Main Engines. Both the solid rocket motors and space shuttle main engines ignite prior to liftoff, with the solid rocket boosters separating about two minutes into flight. The external tank separates after main engine shutdown and is safely expended in the ocean. The SSME's, integrated into the Space Shuttle Orbiter aft structure, are reused after post landing inspections. Both the solid rocket motors and the space shuttle main engine throttle during early ascent flight to limit aerodynamic loads on the structure. The configuration is called a stage and a half as all the propulsion elements are active during the boost phase, and the SSME's continue operation to achieve orbital velocity approximately eight and a half minutes after liftoff. Design and performance challenges were numerous, beginning with development work in the 1970 s. The solid rocket motors were large, and this technology had never been used for human space flight. The SSME s were both reusable and very high performance staged combustion cycle engines, also unique to the Space Shuttle. The multi body side mount configuration was unique and posed numerous integration and interface challenges across the elements. Operation of the system was complex and time consuming. This paper discusses a number of the system level technical challenges including development and operations.

Owen, James↗

Inclined Jet in Crossflow Interacting with a Vortex Generator

An experiment is conducted on the effectiveness of a vortex generator in preventing liftoff of a jet in crossflow, with possible relevance to film-cooling applications. The jet issues into the boundary layer at an angle of 20 degreees to the freestream. The effect of a triangular ramp-shaped vortex generator is studied while varying its geometry and location. Detailed flowfield properties are obtained for a case in which the height of the vortex generator and the diameter of the orifice are comparable with the approach boundary-layer thickness. The vortex generator produces a streamwise vortex pair with a vorticity magnitude 3 times larger (and of opposite sense) than that found in the jet in crossflow alone. Such a vortex generator appears to be most effective in keeping the jet attached to the wall. The effect of parametric variation is studied mostly from surveys 10 diameters downstream from the orifice. Results over a range of jet-to-freestream momentum flux ratio (1 < J < 11) show that the vortex generator has a significant effect even at the highest J covered in the experiment. When the vortex generator height is halved, there is a liftoff of the jet. On the other hand, when the height is doubled, the jet core is dissipated due to larger turbulence intensity. Varying the location of the vortex generator, over a distance of three diameters from the orifice, is found to have little impact. Rounding off the edges of the vortex generator with the increasing radius of curvature progressively diminishes its effect. However, allowing for a small radius of curvature may be quite tolerable in practice.

Zaman, K. B. M. Q.↗

Lightweight Energy Absorbers for Blast Containers

Kinetic-energy-absorbing liners made of aluminum foam have been developed to replace solid lead liners in blast containers on the aft skirt of the solid rocket booster of the space shuttle. The blast containers are used to safely trap the debris from small explosions that are initiated at liftoff to sever frangible nuts on hold-down studs that secure the spacecraft to a mobile launch platform until liftoff.

Balles, Donald L.↗

Infrared Imagery of Solid Rocket Exhaust Plumes

The Ares I Scale Model Acoustic Test program consisted of a series of 18 solid rocket motor static firings, simulating the liftoff conditions of the Ares I five-segment Reusable Solid Rocket Motor Vehicle. Primary test objectives included acquiring acoustic and pressure data which will be used to validate analytical models for the prediction of Ares 1 liftoff acoustics and ignition overpressure environments. The test article consisted of a 5% scale Ares I vehicle and launch tower mounted on the Mobile Launch Pad. The testing also incorporated several Water Sound Suppression Systems. Infrared imagery was employed during the solid rocket testing to support the validation or improvement of analytical models, and identify corollaries between rocket plume size or shape and the accompanying measured level of noise suppression obtained by water sound suppression systems.

Moran, Robert P.↗

Automated Loads Analysis System (ATLAS)

ATLAS is a generalized solution that can be used for launch vehicles. ATLAS is used to produce modal transient analysis and quasi-static analysis results (i.e., accelerations, displacements, and forces) for the payload math models on a specific Shuttle Transport System (STS) flight using the shuttle math model and associated forcing functions. This innovation solves the problem of coupling of payload math models into a shuttle math model. It performs a transient loads analysis simulating liftoff, landing, and all flight events between liftoff and landing. ATLAS utilizes efficient and numerically stable algorithms available in MSC/NASTRAN.

Gardner, Stephen↗

Aeroacoustics of Space Vehicles

While for airplanes the subject of aeroacoustics is associated with community noise, for space vehicles it is associated with vibro-acoustics and structural dynamics. Surface pressure fluctuations encountered during launch and travel through lower part of the atmosphere create intense vibro-acoustics environment for the payload, electronics, navigational equipment, and a large number of subsystems. All of these components have to be designed and tested for flight-certification. This presentation will cover all three major sources encountered in manned and unmanned space vehicles: launch acoustics, ascent acoustics and abort acoustics. Launch pads employ elaborate acoustic suppression systems to mitigate the ignition pressure waves and rocket plume generated noise during the early part of the liftoff. Recently we have used large microphone arrays to identify the noise sources during liftoff and found that the standard model by Eldred and Jones (NASA SP-8072) to be grossly inadequate. As the vehicle speeds up and reaches transonic speed in relatively denser part of the atmosphere, various shock waves and flow separation events create unsteady pressure fluctuations that can lead to high vibration environment, and occasional coupling with the structural modes, which may lead to buffet. Examples of wind tunnel tests and computational simulations to optimize the outer mold line to quantify and reduce the surface pressure fluctuations will be presented. Finally, a manned space vehicle needs to be designed for crew safety during malfunctioning of the primary rocket vehicle. This brings the subject of acoustic environment during abort. For NASAs Multi-Purpose Crew Vehicle (MPCV), abort will be performed by lighting rocket motors atop the crew module. The severe aeroacoustics environments during various abort scenarios were measured for the first time by using hot helium to simulate rocket plumes in the Ames unitary plan wind tunnels. Various considerations used for the helium simulation and the final confirmation from a flight test will be presented.

launch vehicle↗

An Experimental and Computational Study on Soot Formation in a Coflow Jet Flame Under Microgravity and Normal Gravity

Upon the completion of the Structure and Liftoff in Combustion Experiment (SLICE) in March 2012, a comprehensive and unique set of microgravity coflow diffusion flame data was obtained. This data covers a range of conditions from weak flames near extinction to strong, highly sooting flames, and enabled the study of gravitational effects on phenomena such as liftoff, blowout and soot formation. The microgravity experiment was carried out in the Microgravity Science Glovebox (MSG) on board the International Space Station (ISS), while the normal gravity experiment was performed at Yale utilizing a copy of the flight hardware. Computational simulations of microgravity and normal gravity flames were also carried out to facilitate understanding of the experimental observations. This paper focuses on the different sooting behaviors of CH4 coflow jet flames in microgravity and normal gravity. The unique set of data serves as an excellent test case for developing more accurate computational models.Experimentally, the flame shape and size, lift-off height, and soot temperature were determined from line-of-sight flame emission images taken with a color digital camera. Soot volume fraction was determined by performing an absolute light calibration using the incandescence from a flame-heated thermocouple. Computationally, the MC-Smooth vorticity-velocity formulation was employed to describe the chemically reacting flow, and the soot evolution was modeled by the sectional aerosol equations. The governing equations and boundary conditions were discretized on an axisymmetric computational domain by finite differences, and the resulting system of fully coupled, highly nonlinear equations was solved by a damped, modified Newtons method. The microgravity sooting flames were found to have lower soot temperatures and higher volume fraction than their normal gravity counterparts. The soot distribution tends to shift from the centerline of the flame to the wings from normal gravity to microgravity.

microgravity↗

Variational Coupled Loads Analysis using the Hybrid Parametric Variation Method

Time-domain coupled loads analysis (CLA)is used to determine the response of a launch vehicle and payload system to transient forces, such as liftoff, engine ignitions and shutdowns, jettison events, and atmospheric flight loads, such as buffet. CLA, using Hurty/Craig-Bampton (HCB)component models, is the accepted method for the establishment of design-level loads for launch systems. However, uncertainty in the component models flows into uncertainty in predicted system results. Uncertainty in the structural responses during launch is a significant concern because small variations in launch vehicle and payload mode shapes and their interactions can result in significant variations in system loads. Uncertainty quantification (UQ)is used to determine statistical bounds on prediction accuracy based on model uncertainty. In this paper uncertainty is treated at the HCB component-model level. In an effort to account for model uncertainties and statistically bound their effect on CLA predictions, this work combines CLA with UQ in a process termed variational coupled loads analysis (VCLA). The modeling of uncertainty using a parametric approach, in which input parameters are represented by random variables, is common, but its major drawback is the resulting uncertainty is limited to the form of the nominal model. Uncertainty in model form is one of the biggest contributors to uncertainty in complex built-up structures. Model-form uncertainty can be represented using a nonparametric approach based on random matrix theory (RMT). In this work, UQ is performed using the hybrid parametric variation (HPV)method, which combines parametric with nonparametric uncertainty at the HCB component model level. The HPV method requires the selection of dispersion values for the HCB fixed-interface (FI)eigenvalues, and the HCB mass and stiffness matrices. The dispersions are based upon component test-analysis modal correlation results. During VCLA, random component models are assembled into an ensemble of random systems using a Monte Carlo (MC)approach. CLA is applied to each of the ensemble members to produce an ensemble of system-level responses for statistical analysis. The proposed methodology is demonstrated through its application to a buffet loads analysis of NASA’s Space Launch System (SLS)during the transonic regime fifty seconds after liftoff. Core stage (CS)section shears and moments are recovered, and statistics are computed.

Uncertainty Quantification↗

A Deformed Geometry Synthesis Technique for Determining Stacking and Cryogenically Induced Preloads for the Space Launch System

The Space Launch System (SLS) stacking and Core Stage (CS) fueling induce significant preloads that contribute to the liftoff pad separation “twang”. To accurately capture this, an approach is required that can replicate the physics of all SLS physical stacking steps, CS cryogenic shrinkage, associated geometric nonlinearities, and the transient behavior and decay of the preloads with changing boundary conditions as the vehicle separates from the pad. The Deformed Geometry Synthesis (DGS) approach presented here satisfies the above requirements. DGS determines induced preloads by modeling components in their deformed geometry states and then enforcing compatibility by closing the resulting “deadbands”. DGS seamlessly integrates into the multibody modal synthesis framework and does not require the use of artificial external loads to enforce preloads or post-processing steps to remove their influence. Since DGS iterates to solve for the deformed state inclusive of geometric nonlinearities, running linearized parametrics to exercise different potential orientations of ball jointed struts that connect the CS to Boosters for cryo-shrinkage analyses is entirely avoided. Relative to the transient behavior and decay of stacking and cryo-induced preloads with SLS liftoff pad separation, this is an area of considerable interest to the SLS program. To capture this in the most accurate way possible, DGS algorithms are designed to work with Henkel-Mar nonlinear pad separation algorithms which operate on the separating longitudinal and lateral degrees of freedom (DoFs) between the vehicle and the pad. As the separating DoFs release, in whatever manner as dictated by the interface geometries, interface loads and interface flexibilities as well as the external loading on the vehicle, the subject preloads generate a complex twang/decay time-trace as dictated by the physics of the problem. This paper presents DGS numerical verification against the closed-form solution for Timoshenko’s 3 ball-jointed strut preload problem. This problem is then extended by the authors to the geometric nonlinear case where DGS is compared to the Newton-Raphson solution of the nonlinear equations. Next, DGS is utilized to solve the SLS stacking and cryogenic shrinkage coupled loads analyses. Finally, Henkel-Mar pad separation simulations are executed that isolate the impact of the induced preloads’ twang and decay characteristics.

Space Launch System↗

Artemis I Countdown 101

Before the Artemis I mission launches on its way around the Moon, the launch team at Kennedy Space Center and supporting teams across the country will begin the launch countdown about two days before liftoff. The launch countdown contains "L Minus” and "T Minus" times. "L minus" indicates how far away we are from liftoff in hours and minutes and does not include built-in holds. “T minus” time is a sequence of events that are built into the launch countdown where counting and holds are inserted. The 730,000 gallons of propellants that will be loaded into the rocket are liquid oxygen (LO2) and liquid hydrogen (LH2). Pauses in the countdown, or "holds," are built into the countdown to allow the launch team to target a precise launch window, and to provide a cushion of time for certain tasks and procedures without impacting the overall schedule. For the Artemis I countdown, planned built-in holds vary in length and occur at the following times: L-8 hours, 40 minutes, and L-40 minutes.

Madison Elizabeth Tuttle↗

Multiphase Simulations of the SLS Launch Environment

NASA’s Space Launch System (SLS), which will send astronauts back to the Moon in the next few years, is powered by four RS-25 engines and two RSRMV solid rocket boosters (SRBs). During launch the SLS propulsion system generates intense acoustics and other powerful waves, such as ignition overpressure (IOP) which, if unmitigated, have the potential to damage the vehicle and possibly cause loss of mission or crew. To protect the vehicle from these powerful waves, the SLS launch pad design includes an ignition overpressure/sound suppression (IOP/SS) system which sprays 270,000 gallons per minute of water very close to the SRB and RS-25 nozzles. The SRB and RS-25 engine plumes, and the proximity of the IOP/SS water, create a complex multiphase (gas and liquid) environment during the SLS ignition sequence. The interplay among these systems creates challenges related to water spray into/onto engine nozzles, potential debris transport, and additional transient loads due to strong plume-water interactions - all of which the SLS vehicle must be able to withstand. Prior to the Artemis I launch, the SLS multiphase liftoff environment was largely unknown due to differences from the Space Shuttle and other programs. Some data was available from tests of individual systems, but no integrated testing or analysis was available. Even post-launch analysis of Artemis I cannot provide a full understanding of the complex physics involved due to limited (or obstructed) camera views and instrumentation. Computational fluid dynamics (CFD) is being used to investigate the details of the multiphase environment which could not be measured, help comprehend the data gathered from the launch, and ultimately identify phenomena that are a concern for future flights. Project Details Engineers at NASA’s Marshall Space Flight Center (MSFC) have executed simulations using the Loci/STREAM-Volume of Fluid (VoF) multiphase CFD solver to understand this environment. Initial efforts successfully validated the CFD solver on various tests, giving confidence to simulate the SLS multiphase liftoff environment prior to the Artemis I launch. The CFD simulation of the SLS ignition sequence was conducted in three phases. First the IOP/SS water system was simulated for approximately 6 seconds to reach a quasi-steady state. Next, the RS-25 engine plumes were activated and held at full power for 1 second. Lastly, the SRB booster was activated and the simulation was carried out until just prior to vehicle motion. This simulation process mimics the conditions that exist at launch. Results and Impact The SLS ignition sequence simulation results provide deep understanding of the underlying physics occuring during launch. Observations from the simulation include reduction of water splashing into/onto the engine nozzles, change in angling of the dense water sheets, and the origin of the powerful ignition overpressure (IOP) wave. These observations directly inform the SLS program on subjects including plume-water induced side loads, debris transport, and the acoustic launch environment. Additionally, with post launch comparison of CFD observations to flight data, these tools can be applied to launch vehicles and environments other than SLS with confidence. Why HPC Matters The SLS ignition sequence CFD simulations are conducted on meshes up to hundreds of millions of cells on thousands of processors for weeks at a time. These simulations generate terabytes of data that must also be stored and archived for future use on HPC systems. Simply put, the CFD simulations would not be possible without NASA HPC resources. What’s Next Comparisons between the Artemis I flight data and the CFD simulations will be continued to both improve confidence in the CFD results and provide deeper understanding into the SLS multiphase launch environment. This will be used to provide insight for decision making for the first manned SLS flight, Artemis II. Future simulations will target new configurations of the SLS IOP/SS water required to support the more powerful variants of the SLS vehicle, such as Block 1B. Additionally, this capability provides NASA the ability to investigate launch environments for vehicles other than SLS to support other missions.

Travis Rivord↗

Preparations for the Launch, Cruise, and Orbital Operations Phases of the Psyche Mission

“Psyche: Journey to a Metal World” was selected in 2017 as the 14th mission in NASA’s Discovery program. The mission uses an electric propulsion (EP) system to rendezvous with and orbit the large metal asteroid (16) Psyche. Spacecraft development is a hybrid approach with deep-space avionics provided by the Jet Propulsion Laboratory (JPL) and a solar electric propulsion chassis based on Maxar’s 1300-series GEO communications satellites. The payload suite is comprised of a magnetometer, multispectral imager, and gamma ray & neutron spectrometer science instruments and the Deep Space Optical Communications advanced technology demonstration.The spacecraft is currently in the final integration and test phase to support a planned launch period open in August 2022. With under a year until liftoff, final pre-liftoff preparations are underway for the mission’s major in-flight Phases. The Launch Phase is the mission’s only critical event as the vehicle autonomously deploys the solar arrays and delivers the spacecraft to a safe state. Following a planned 70-day Initial Checkout Phase, the spacecraft thrusts with the EP system through the majority of a 3.5-year Cruise Phase, which includes a Mars gravity assist, to rendezvous with (16) Psyche. The Approach Phase uses optical navigation while continuing to thrust with the EP engines to deliver the spacecraft into orbit. Orbital Operations are baselined for 20 months as the spacecraft steps through four progressively lower orbital altitudes to study the largest M-type asteroid in the solar system.

Hart, William↗

Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor

NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.

03 NATURAL GAS↗

Photonic devices fabricated from (111)‐oriented single crystal diamond

Abstract Diamond is a material of choice in the pursuit of integrated quantum photonic technologies. So far, the majority of photonic devices fabricated from diamond are made from (100)‐oriented crystals. In this work, we demonstrate a methodology for the fabrication of optically active membranes from (111)‐oriented diamond. We use a liftoff technique to generate membranes, followed by chemical vapor deposition of diamond in the presence of silicon to generate homogenous silicon vacancy color centers with emission properties that are superior to those in (100)‐oriented diamond. We further use the diamond membranes to fabricate microring resonators with quality factors exceeding ~ 3000. Supported by finite‐difference time‐domain calculations, we discuss the advantages of (111)‐oriented structures as building blocks for quantum nanophotonic devices. image

Regan, Blake↗

Molecular beam epitaxy of GaAs templates on water soluble NaCl thin films

Expensive III-V substrates are cost limiting for the adoption of many technologies. Consequently, being able to reuse the original substrate is highly desirable. Existing substrate reuse techniques have significant drawbacks, but this work discusses a new method using molecular beam epitaxy deposition of water soluble NaCl thin films on commonly employed (0 0 1) GaAs substrates. Single-crystal GaAs templates are grown on continuous NaCl layers utilizing careful exposure of the NaCl to an in-situ electron beam and a low temperature nucleation layer. The template layers can be quickly removed from the substrate via dissolution of the NaCl. After liftoff, the original wafer shows an increase in rms surface roughness of only 0.2 nm.

14 SOLAR ENERGY↗

A gas dynamic perspective on particle lifting in electrostatic discharge-like devices using multiphase particle-in-cell approach

Although particle–laden electrostatic discharges are widely used in laboratories as well as in industrial applications, the mechanism of particle lifting for particles initially at rest in such highly unsteady systems is not well understood. A multiphase gas–particle solver is developed using the multiphase particle-in-cell (MP-PIC) approach to emulate the interaction of a compressible shock-dominated gas phase with the dense particle phase. First, the two-way coupled solver is initially used to study the interaction of a planar traveling shock with a vertical curtain of particulates. The gas and particle phase evolution was found to be in good agreement with a similar experimental study in Ling et al. [Phys. Fluids 24, 113301 (2012)]. Second, the MP-PIC code is used to study the interaction of an expanding blast wave with a thick bed of particles. The simulation considered forces such as quasi-steady drag, pressure-gradient, added-mass, Saffman, and Magnus forces. We observe that the vertical liftoff particles close to the shock impingement point in this configuration are associated with the quasi-steady drag, pressure gradient, and added-mass forces. Also, the Saffman lift and Magnus forces contribute to lifting particles located radially farther away from the shock impingement point. In addition, the study finds a decrease in particle lifting efficiency with decreasing plasma kernel length and shock strength.

42 ENGINEERING↗

Data-driven Detection and Early Prediction of Thermoacoustic Instability in a Multi-nozzle Combustor

Thermoacoustic instability (TAI) is a critical issue in modern lean-burn gas-turbine combustors, which is induced by a strong coupling between the resonant combustor acoustics and fluctuations in the heat release rate. This instability may lead to high-amplitude pressure waves that generate undesirable noise levels as well as fatigue stresses in mechanical structures of the combustor. The intense pressure fluctuations due to TAI may also cause large flow perturbations and possibly flow reversal that may lead to flame oscillations, flame liftoff, and even flame blow-out. Hence, there is a strong need for exercising control actions in a timely fashion to mitigate the TAI phenomena. Anomaly detection is an essential prerequisite to the design of a good controller and such a detector must be able to reliably predict a forthcoming TAI. To detect and predict the onset of a TAI from an ensemble of pressure time series, this paper investigates three data-driven methods: Fast Fourier transform (FFT), symbolic time series analysis (STSA), and hidden Markov modeling (HMM). The main focus of the paper is to make a comparative evaluation of these three anomaly detection methods for classification of the current regime of operation into stable and unstable categories as well as for real-time identification of precursors to impending instabilities with short-length time series of measured variables (e.g., pressure oscillations). Finally, the results, generated on experimental data from a multi-nozzle combustor apparatus, have been compared to evaluate the performance of FFT, STSA, and HMM methods for TAI analysis.

42 ENGINEERING↗