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NASA NTRS2013

Ballistics Analysis of Orion Crew Module Separation Bolt Cover

NASA is currently developing a new crew module to replace capabilities of the retired Space Shuttles and to provide a crewed vehicle for exploring beyond low earth orbit. The crew module is a capsule-type design, which is designed to separate from the launch vehicle during launch ascent once the launch vehicle fuel is expended. The separation is achieved using pyrotechnic separation bolts, wherein a section of the bolt is propelled clear of the joint at high velocity by an explosive charge. The resulting projectile must be contained within the fairing structure by a containment plate. This paper describes an analytical effort completed to augment testing of various containment plate materials and thicknesses. The results help guide the design and have potential benefit for future similar applications.

Howard, Samuel A.↗
NASA NTRS2013

Multiphase Transport in Porous Media: Gas-Liquid Separation Using Capillary Pressure Gradients International Space Station (ISS) Flight Experiment Development

Advances in the understanding of multiphase flow characteristics under variable gravity conditions will ultimately lead to improved and as of yet unknown process designs for advanced space missions. Such novel processes will be of paramount importance to the success of future manned space exploration as we venture into our solar system and beyond. In addition, because of the ubiquitous nature and vital importance of biological and environmental processes involving airwater mixtures, knowledge gained about fundamental interactions and the governing properties of these mixtures will clearly benefit the quality of life here on our home planet. The techniques addressed in the current research involving multiphase transport in porous media and gas-liquid phase separation using capillary pressure gradients are also a logical candidate for a future International Space Station (ISS) flight experiment. Importantly, the novel and potentially very accurate Lattice-Boltzmann (LB) modeling of multiphase transport in porous media developed in this work offers significantly improved predictions of real world fluid physics phenomena, thereby promoting advanced process designs for both space and terrestrial applications.This 3-year research effort has culminated in the design and testing of a zero-g demonstration prototype. Both the hydrophilic (glass) and hydrophobic (Teflon) media Capillary Pressure Gradient (CPG) cartridges prepared during the second years work were evaluated. Results obtained from ground testing at 1-g were compared to those obtained at reduced gravities spanning Martian (13-g), Lunar (16-g) and zero-g. These comparisons clearly demonstrate the relative strength of the CPG phenomena and the efficacy of its application to meet NASAs unique gas-liquid separation (GLS) requirements in non-terrestrial environments.LB modeling software, developed concurrently with the zero-g test effort, was shown to accurately reproduce observed CPG driven gas-liquid separation phenomena. The design and fabrication of a micropost plate-lamina Hele-Shaw (HS) cell was performed which served as a computationally attainable geometric structure facilitating direct comparison between physical phenomena observed in our laboratory and the LB software predictions.

Wheeler, Richard R., Jr.↗
NASA NTRS2014

Determining the Source of Water Vapor in a Cerium Oxide Electrochemical Oxygen Separator to Achieve Aviator Grade Oxygen

More than a metric ton of water is transported to the International Space Station (ISS) each year to provide breathing oxygen for the astronauts. Water is a safe and compact form of stored oxygen. The water is electrolyzed on ISS and ambient pressure oxygen is delivered to the cabin. A much smaller amount of oxygen is used each year in spacesuits to conduct Extra Vehicular Activities (EVAs). Space suits need high pressure (>1000 psia) high purity oxygen (must meet Aviator Breathing Oxygen "ABO" specifications, >99.5% O2). The water / water electrolysis system cannot directly provide high pressure, high purity oxygen, so oxygen for EVAs is transported to ISS in high pressure gas tanks. The tanks are relatively large and heavy, and the majority of the system launch weight is for the tanks and not the oxygen. Extracting high purity oxygen from cabin air and mechanically compressing the oxygen might enable on-board production of EVA grade oxygen using the existing water / water electrolysis system. This capability might also benefit human spaceflight missions, where oxygen for EVAs could be stored in the form of water, and converted into high pressure oxygen on-demand. Cerium oxide solid electrolyte-based ion transport membranes have been shown to separate oxygen from air, and a supported monolithic wafer form of the CeO2 electrolyte membrane has been shown to deliver oxygen at pressures greater than 300 psia. These supported monolithic wafers can withstand high pressure differentials even though the membrane is very thin, because the ion transport membrane is supported on both sides (Fig 1). The monolithic supported wafers have six distinct layers, each with matched coefficients of thermal expansion. The wafers are assembled into a cell stack which allows easy air flow across the wafers, uniform current distribution, and uniform current density (Fig 2). The oxygen separation is reported to be "infinitely selective" to oxygen [1] with reported purity of 99.99% [2]. Combined with a mechanical compressor, a Solid Electrolyte Oxygen Separator (SEOS) should be capable of producing ABO grade oxygen at pressures >2400 psia, on the space station. Feasibility tests using a SEOS integrated with a mechanical compressor identified an unexpected contaminant in the oxygen: water vapour was found in the oxygen product, sometimes at concentrations higher than 40 ppm (the ABO limit for water vapour is 7 ppm). If solid electrolyte membranes are really "infinitely selective" to oxygen as they are reported to be, where did the water come from? If water is getting into the oxygen, what other contaminants might get into the oxygen? Microscopic analyses of wafers, welds, and oxygen delivery tubes were performed in an attempt to find the source of the water vapour contamination. Hot and cold pressure decay tests were performed. Measurements of water vapour as a function of O2 delivery rate, O2 delivery pressure, and process air humidity levels were the most instructive in finding the source of water contamination (Fig 3). Water contamination was directly affected by oxygen delivery rate (doubling the oxygen production rate cut the water level in half). Water was affected by process air humidity levels and delivery pressure in a way that indicates the water was diffusing into the oxygen delivery system.

Graf, John↗
NASA NTRS2014

Active Flow Separation Control on a NACA 0015 Wing Using Fluidic Actuators

Results are presented from a recent set of wind tunnel experiments using sweeping jet actuators to control ow separation on the 30% chord trailing edge ap of a 30 deg. swept wing model with an aspect ratio (AR) of 4.35. Two sweeping jet actuator locations were examined, one on the flap shoulder and one on the trailing edge flap. The parameters that were varied included actuator momentum, freestream velocity, and trailing edge flap deflection (Delta f ) angle. The primary focus of this set of experiments was to determine the mass flow and momentum requirements for controlling separation on the flap, especially at large flap deflection angles which would be characteristic of a high lift system. Surface pressure data, force and moment data, and stereoscopic particle image velocimetry (PIV) data were acquired to evaluate the performance benefits due to applying active flow control. Improvements in lift over the majority of the wing span were obtained using sweeping jet actuator control. High momentum coefficient, Cu, levels were needed when using the actuators on the ap because they were located downstream of separation. Actuators on the flap shoulder performed slightly better but actuator size, orientation, and spacing still need to be optimized.

Melton, Latunia P.↗
NASA NTRS2014

Forward Bay Cover Separation Modeling and Testing for the Orion Multi-Purpose Crew Vehicle

Spacecraft multi‐body separation events during atmospheric descent require complex testing and analysis to validate the flight separation dynamics model and to verify no recontact. NASA Orion Multi‐Purpose Crew Vehicle (MPCV) teams examined key model parameters and risk areas to develop a robust but affordable test campaign in order to validate and verify the Forward Bay Cover (FBC) separation event for Exploration Flight Test‐1 (EFT‐1). The FBC jettison simulation model is highly complex, consisting of dozens of parameters varied simultaneously, with numerous multi‐parameter interactions (coupling and feedback) among the various model elements, and encompassing distinct near‐field, mid‐field, and far‐field regimes. The test campaign was composed of component‐level testing (for example gas‐piston thrusters and parachute mortars), ground FBC jettison tests, and FBC jettison air‐drop tests that were accomplished by a highly multi‐disciplinary team. Three ground jettison tests isolated the testing of mechanisms and structures to anchor the simulation models excluding aerodynamic effects. Subsequently, two air‐drop tests added aerodynamic and parachute parameters, and served as integrated system demonstrations, which had been preliminarily explored during the Orion Pad Abort‐1 (PA‐1) flight test in May 2010. Both ground and drop tests provided extensive data to validate analytical models and to verify the FBC jettison event for EFT‐1, but more testing is required to support human certification, for which NASA and Lockheed Martin are applying knowledge from Apollo and EFT‐1 testing and modeling to develop a robust but affordable human spacecraft capability.

Ali, Yasmin↗
NASA NTRS2015

Flow Separation Control on A Full-Scale Vertical Tail Model Using Sweeping Jet Actuators

This paper describes test results of a joint NASA/Boeing research effort to advance Active Flow Control (AFC) technology to enhance aerodynamic efficiency. A full-scale Boeing 757 vertical tail model equipped with sweeping jets AFC was tested at the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel at NASA Ames Research Center. The flow separation control optimization was performed at 100 knots, a maximum rudder deflection of 30deg, and sideslip angles of 0deg and -7.5deg. Greater than 20% increments in side force were achieved at the two sideslip angles with a 31-actuator AFC configuration. Flow physics and flow separation control associated with the AFC are presented in detail. AFC caused significant increases in suction pressure on the actuator side and associated side force enhancement. The momentum coefficient (C sub mu) is shown to be a useful parameter to use for scaling-up sweeping jet AFC from sub-scale tests to full-scale applications. Reducing the number of actuators at a constant total C(sub mu) of approximately 0.5% and tripling the actuator spacing did not significantly affect the flow separation control effectiveness.

Andino, Marlyn Y.↗
NASA NTRS2013

Separation-Compliant, Optimal Routing and Control of Scheduled Arrivals in a Terminal Airspace

We address the problem of navigating a set (fleet) of aircraft in an aerial route network so as to bring each aircraft to its destination at a specified time and with minimal distance separation assured between all aircraft at all times. The speed range, initial position, required destination, and required time of arrival at destination for each aircraft are assumed provided. Each aircraft's movement is governed by a controlled differential equation (state equation). The problem consists in choosing for each aircraft a path in the route network and a control strategy so as to meet the constraints and reach the destination at the required time. The main contribution of the paper is a model that allows to recast this problem as a decoupled collection of problems in classical optimal control and is easily generalized to the case when inertia cannot be neglected. Some qualitative insight into solution behavior is obtained using the Pontryagin Maximum Principle. Sample numerical solutions are computed using a numerical optimal control solver. The proposed model is first step toward increasing the fidelity of continuous time control models of air traffic in a terminal airspace. The Pontryagin Maximum Principle implies the polygonal shape of those portions of the state trajectories away from those states in which one or more aircraft pair are at minimal separation. The model also confirms the intuition that, the narrower the allowed speed ranges of the aircraft, the smaller the space of optimal solutions, and that an instance of the optimal control problem may not have a solution at all (i.e., no control strategy that meets the separation requirement and other constraints).

transportation network↗
NASA NTRS2016

Space Launch System Booster Separation Aerodynamic Testing in the NASA Langley Unitary Plan Wind Tunnel

A wind-tunnel investigation of a 0.009 scale model of the Space Launch System (SLS) was conducted in the NASA Langley Unitary Plan Wind Tunnel to characterize the aerodynamics of the core and solid rocket boosters (SRBs) during booster separation. High-pressure air was used to simulate plumes from the booster separation motors (BSMs) located on the nose and aft skirt of the SRBs. Force and moment data were acquired on the core and SRBs. These data were used to corroborate computational fluid dynamics (CFD) calculations that were used in developing a booster separation database. The SRBs could be remotely positioned in the x-, y-, and z-direction relative to the core. Data were acquired continuously while the SRBs were moved in the axial direction. The primary parameters varied during the test were: core pitch angle; SRB pitch and yaw angles; SRB nose x-, y-, and z-position relative to the core; and BSM plenum pressure. The test was conducted at a free-stream Mach number of 4.25 and a unit Reynolds number of 1.5 million per foot.

Wilcox, Floyd J., Jr.↗
NASA NTRS2016

Space Launch System Booster Separation Aerodynamic Database Development and Uncertainty Quantification

The development of the aerodynamic database for the Space Launch System (SLS) booster separation environment has presented many challenges because of the complex physics of the ow around three independent bodies due to proximity e ects and jet inter- actions from the booster separation motors and the core stage engines. This aerodynamic environment is dicult to simulate in a wind tunnel experiment and also dicult to simu- late with computational uid dynamics. The database is further complicated by the high dimensionality of the independent variable space, which includes the orientation of the core stage, the relative positions and orientations of the solid rocket boosters, and the thrust lev- els of the various engines. Moreover, the clearance between the core stage and the boosters during the separation event is sensitive to the aerodynamic uncertainties of the database. This paper will present the development process for Version 3 of the SLS booster separa- tion aerodynamic database and the statistics-based uncertainty quanti cation process for the database.

Chan, David T.↗
NASA NTRS2018

Wall-Resolved Large Eddy Simulations of Transonic Shock-Induced Flow Separation

This paper reports the wall-resolved large eddy simulations of shock-induced boundary layer separation over an axisymmetric bump for a flow Mach number of 0.875 and a chord-based Reynolds number of 2.763 million. The incoming boundary layer has a momentum-thickness Reynolds number of 6600 at one and a half chord lengths upstream of the leading edge. The calculations simulate the experiment by Bachalo and Johnson (AIAA Journal, Vol. 24, No. 3, 1986), except that the tunnel walls are ignored and the simulations are performed assuming free air with as many as 24 billion grid points. The effects of domain span, grid resolution and time step on the predictions are examined. The results are found to show some sensitivity to the studied parameters. Owing to the outer boundary conditions, the predicted surface pressure distribution as well as the flow separation and reattachment locations tend to agree better with the experimental results from the larger (6 × 6 ft) tunnel than those from the smaller (2 × 2 ft) tunnel. The predicted Reynolds shear stress profiles in the separated region differ by as much as 31%from the experimental results that were only obtained in the smaller tunnel. The most accurate surface pressure distribution obtained in this study lies within the scatter of the measurements taken in the two facilities.

Uzun, Ali↗
NASA NTRS2018

Active Flow Control for Trailing Edge Flap Separation

Active flow control (AFC) in the form of sweeping jet (SWJ) excitation and discrete steady jet excitation is used to control the flow separation on an NACA 0015 semispan wing with a deflected, simple-hinged, trailing edge flap. This geometry has been the focus of several recent publications that investigated methods to improve the efficiency of sweeping jet actuators. In the current study, the interaction of the AFC excitation with the separated flowfields present at several flap deflection angles was examined. Previous studies with this model have been limited to a maximum flap deflection angle of 40°. The flap deflection range was extended to 60! because systems studies have indicated that a high-lift system with simple-hinged flaps may require larger flap deflections than the Fowler flaps found on most high-lift systems. The results obtained at flap deflection angles of 20°, 40°, and 60° are presented and compared. Force and moment data, Particle Image Velocimetry (PIV) data, and steady and unsteady surface pressure data are used to describe the flowfield with and without AFC. With a flap deflection of 60°, increasing the SWJ actuator momentum at the flap shoulder increased lift due to an increase in circulation but did not completely eliminate the recirculation region above the flap surface. AFC using the discrete steady jet actuators of this study increased lift as well but required more mass flow than the SWJ actuators and had a detrimental effect on lift at the highest mass flow level tested. PIV results showed that the angle between the excitation and the flap surface was not optimal for attaching the separated shear layer.

Melton, LaTunia Pack↗
NASA NTRS2018

Simulation Evaluations of an Autonomous Urban Air Mobility Network Management and Separation Service

This presents an initial implementation of an autonomous Urban Air Mobility network management and aircraft separation service for urban airspace that does 1) departure and arrival scheduling across the network, 2) continuous trajectory management to ensure safe separation between aircraft, and 3) seamless integration with traditional operations. The highly-autonomous AutoResolver algorithm developed for traditional aviation was extended to provide these capabilities. An evaluation of this initial implementation was conducted in fast-time simulations using a dense, two-hour traffic scenario with Urban Air Mobility aircraft flying between a network of 20 vertiports in the Dallas-Fort Worth metroplex. When the spatial separation was reduced from 0:3 nmi (nautical miles) to 0:1nmi, the total delay decreased by 7:3 percent...

Bosson, Christabelle S.↗
NASA NTRS2015

CFD Simulations of the Space Launch System Ascent Aerodynamics and Booster Separation

This paper presents details of Computational Fluid Dynamic modeling of the Space Launch System during ascent. The primary focus of the paper is the flow simulation of the vehicle during ascent using the Overflow Navier-Stokes code. Computations of 739 first-stage flight conditions covering a range of Mach numbers, angles of attack, and roll angles were computed. The overset grid system contained 375 million grid points, and over 28 mil- lion CPU hours were used in the simulations. The simulations were run on the Pleiades supercomputer at the NASA Advanced Supercomputer Center at Ames Research Center. The data products from this work include integrated line-loads, surface pressure coefficients, venting pressures, and protuberance air-loads. Detailed comparisons were made of the aerodynamic performance predicted by Overflow and the wind-tunnel derived aero- dynamic database. A small number of the cases were run with two different turbulence models and with two differencing schemes. These results were used to quantify the sensitivity to the choice of the turbulence model and to the differencing scheme. The paper also introduces an effort to use the inviscid, unstructured Cartesian solver Cart3D to compute the aerodynamics during booster separation. Adaptive mesh refinement is being used to enable accurate simulations of sixteen booster-separation-motor plumes. The use of this tool is explored in preparation for building a booster-separation aerodynamic database.

Ascent Aerodynamics↗
NASA NTRS2019

Effect of Spatial Filtering in Implicit Large-Eddy Simulations of Separated Flows

The relatively high Reynolds number of turbulent flows encountered in various applications puts these problems well beyond the reach of direct numerical simulation (DNS) at present. Meanwhile, lower-fidelity Reynolds-averaged Navier-Stokes (RANS) calculations are known to be not accurate enough in complex problems, such as smooth-body flow separation and other flows involving highly-unsteady phenomena. Hence, given the current infeasibility of DNS and the unsatisfactory performance of RANS, intermediate techniques such as large-eddy simulation (LES) and hybrid RANS-LES, whose fidelity lie between RANS and DNS, have received much attention for application to various problems of practical importance. Modeling of the effect of missing scales on resolved scales, also known as subgrid-scale (SGS) modeling, is an important subject for LES. SGS models can be broadly categorized as explicit or implicit approaches. The explicit approach is based on an SGS model that explicitly appears in the governing equations expressed in the form of so-called “filtered Navier-Stokes equations”, which describe the evolution of the turbulence scales resolved by the LES grid. The effect of the scales unresolved by the grid is represented by the SGS model. The implicit modeling approach, on the other hand, does not employ an explicit model but instead treats the intrinsic dissipation of the numerical discretization scheme as an implicit SGS model. An LES without an explicit SGS model is commonly termed as an implicit LES (ILES). The relative merits of one SGS modeling approach over another is a subject of ongoing debate. We have opted to employ an ILES methodology, based on high-order compact finite-difference and spatial filtering schemes, in our recent investigations of separated flow problems [1, 2]. Further discussion of our preference of ILES over explicit LES is provided in Uzun and Malik [2]. The spatial filtering operation, described in the next section, is treated as an implicit SGS model for the ILES. Some observations made during the course of our recent investigations, which pointed out to excessive numerical dissipation in certain parts of the flowfield, prompted us to take a closer look at the potential effect of the spatial filter on ILES predictions. This technical note is therefore devoted to spatial filter effects in the context of a high Reynolds number, transonic shock-induced separated flow.

Ali Uzun↗
NASA NTRS2019

Laser Light Sheet Flow Visualization of the Space Launch System Booster Separation Test

Planar flow visualizations were obtained in a wind tunnel test in the NASA Langley Research Center’s Unitary Plan Wind Tunnel using the laser-light-sheet method. This method uses a laser to illuminate fine particles generated in the wind tunnel to visualize flow structures. The test article was designed to simulate the separation of the two solid rocket boosters (SRBs) from the core stage of the NASA Space Launch System (SLS) at Mach 4 using a scale model. The test was run on of the SLS Block 1B Cargo (27005) configuration and the SLS Block 1B Crew (28005) configuration. Planar flow visualization was obtained only on the crew configuration. Air at pressures up to 1500 psi was used to simulate plumes from the booster separation motors (BSMs) located at the nose, and aft skirt of the two boosters. The facility free stream was seeded with water vapor, which condensed and froze into small ice crystals in the tunnel nozzle expansion. A continuous wave green (532 nm) laser sheet was used to illuminate the ice crystals, and the resulting Mie-scattered light was collected with a camera. The resulting images clearly identify shock waves and other flow features including BSM plume shapes. Measurements were acquired for different BSM pressures and booster separation locations.

Danehy, Paul M.↗
NASA NTRS2019

Experimental and Numerical Analysis of Skin-Stiffener Separation Using a Seven-Point Bend Configuration

Skin-stiffener separation in stiffened composite panels consists of a complex interaction between multiple scales of progressive damage and failure mechanisms. This work used a superposed cohesive element method of modeling resistance curve effects that represents the structural interface of a unidirectional tape skin and a fabric stiffener. Finite element models using cohesive elements with input properties obtained from tape-to-fabric interface characterization tests were compared to experimental results of a stable skin-stiffener separation characterization test using a seven-point bend fixture. This fixture deformed the stiffened panel specimens into a buckled configuration which induced mixed-mode interlaminar stress states at the skin-stiffener interface. The advantage of this fixture was the potential for more stable damage initiation and delamination growth compared to a stringer-stiffened panel under axial compression. Use of the superposed cohesive elements showed promise, but the characterization of interface material properties as input to the cohesive elements remains a crucial component to be investigated to ensure accurate prediction of skin-stiffener separation.

Kosztowny, Cyrus J. R.↗
NASA NTRS2020

Dual Anion-Cation Crosslinked Poly(ionic liquid) Composite Membranes for Enhanced CO2 Separation

Herein, we propose a strategy of developing novel dual anionic-cationic crosslinked poly(IL)-IL composite membranes via a photopolymerization method for enhanced CO2 separations. These are the first examples of dually photopolymerized anionic-cationic poly(IL)-IL composite systems, in which the backbones of poly(IL)s feature both pendant anions and cations without any mobile counterions unlike poly(IL) reported so far in the literature. A new type of dual photopolymerizable anionic-cationic IL (DIL) monomer having methacrylate functional group tethered with highly delocalized sulfonimide anion (–SO2–N(-)–SO2–C7H7) and a vinylimidazolium counterion ([C4(vim)](+)) was successfully synthesized and photopolymerized with four distinct amounts of free IL with a structurally analogous cation ([C4(mim)][Tf2N]) and 20 wt% PEGDA crosslinker, offering novel composite matrices. Further, the structure-property relationships as well as gas separation behaviors of the four newly developed dual anioniccationic poly(IL)-IL composite membranes were extensively characterized by FT-IR, DSC, and XRD. All of the newly developed dual anionic-cationic poly(IL)-IL composite membranes displayed outstanding permselectivites for CO2/CH4, CO2/N2, and CO2/H2 gas pairs together with reasonable CO2 permeabilities. As a result, all the dual anionic-cationic poly(IL)-IL composite membranes outperformed the common poly(IL)-IL systems in the upper bound limit plots with best CO2 permeability of 40 barrer and CO2/CH4 permselectivity of 85. This study may pave a new platform to explore countless potential poly(IL)-IL composites for selective separation of CO2 from flue gas, natural gas, and syngas streams.

Irshad Kammakakam↗
NASA NTRSDate not supplied

Initiation and Propagation of Skin/Stiffener Separation in Postbuckled Structures Subjected to Cyclic Loads

A methodology is proposed to evaluate experimentally and numerically the initiation and propagation of skin/stiffener separation in postbuckled panels subjected to cyclic loads. The response mechanisms that characterize skin/stiffener separation were investigated using a three point bend (3PB) test specimen, which is a simple specimen consisting of a laminate representing the skin and a doubler representing the stiffener flange. The 3PB tests were performed under quasi-static and cyclic loads. A fatigue cohesive model was used to analyze the initiation and propagation of skin/stiffener separation in the 3PB. The results indicate that the fatigue cohesive model with model parameters obtained from quasi-static fracture tests can provide accurate predictions of initiation from a pristine state, and the rate of fatigue crack propagation for a variety of mode mixities, load levels, and stress ratios.

Carlos G Davila↗