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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,567 records · Page 87

All sources NASA NTRS DOE OSTI

NASA NTRS1981

Ceramic applications in turbine engines

Development testing activities on the 1900 F-configuration ceramic parts were completed, 2070 F-configuration ceramic component rig and engine testing was initiated, and the conceptual design for the 2265 F-configuration engine was identified. Fabrication of the 2070 F-configuration ceramic parts continued, along with burner rig development testing of the 2070 F-configuration metal combustor in preparation for 1132 C (2070 F) qualification test conditions. Shakedown testing of the hot engine simulator (HES) rig was also completed in preparation for testing of a spin rig-qualified ceramic-bladed rotor assembly at 1132 C (2070 F) test conditions. Concurrently, ceramics from new sources and alternate materials continued to be evaluated, and fabrication of 2070 F-configuration ceramic component from these new sources continued. Cold spin testing of the critical 2070 F-configuration blade continued in the spin test rig to qualify a set of ceramic blades at 117% engine speed for the gasifier turbine rotor. Rig testing of the ceramic-bladed gasifier turbine rotor assembly at 108% engine speed was also performed, which resulted in the failure of one blade. The new three-piece hot seal with the nickel oxide/calcium fluoride wearface composition was qualified in the regenerator rig and introduced to engine operation wiwth marginal success.

Byrd, J. A.↗

DOE OSTI2018

FY18 ASC P&EM L2 Milestone 6356: Improve Replication of In-service Mechanical Environments

The overall goal of this work was to improve the modeling of laboratory shock and vibration testing. Laboratory shock and vibration testing is used to qualify Nuclear Weapon components for the environment they will experience in the field. Standard practice is to use rigid test fixtures so that no spurious modes are introduced during laboratory testing. Rigid test fixtures may however in some cases change the dynamics of the component being tested, resulting in laboratory testing being more severe than what would occur in the field.

42 ENGINEERING↗

NASA NTRS1993

Lightning protection technology for small general aviation composite material aircraft

An on going NASA (Small Business Innovative Research) SBIR Phase II design and development program will produce the first lightning protected, fiberglass, General Aviation aircraft that is available as a kit. The results obtained so far in development testing of typical components of the aircraft kit, such as the wing and fuselage panels indicate that the lightning protection design methodology and materials chosen are capable of protecting such small composite airframes from lightning puncture and structural damage associated with severe threat lightning strikes. The primary objective of the program has been to develop a lightening protection design for full scale test airframe and verify its adequacy with full scale laboratory testing, thus enabling production and sale of owner-built, lightning-protected, Stoddard-Hamilton Aircraft, Inc. Glasair II airplanes. A second objective has been to provide lightning protection design guidelines for the General Aviation industry, and to enable these airplanes to meet lightening protection requirements for certification of small airplanes. This paper describes the protection design approaches and development testing results obtained thus far in the program, together with design methodology which can achieve the design goals listed above. The presentation of this paper will also include results of some of the full scale verification tests, which will have been completed by the time of this conference.

Plumer, J. A.↗

NASA NTRS2004

Non-nuclear Testing of Reactor Systems in the Early Flight Fission Test Facilities (EFF-TF)

The Early Flight Fission-Test Facility (EFF-TF) can assist in the &sign and development of systems through highly effective non-nuclear testing of nuclear systems when technical issues associated with near-term space fission systems are "non-nuclear" in nature (e.g. system s nuclear operations are understood). For many systems. thermal simulators can he used to closely mimic fission heat deposition. Axial power profile, radial power profile. and fuel pin thermal conductivity can be matched. In addition to component and subsystem testing, operational and lifetime issues associated with the steady state and transient performance of the integrated reactor module can be investigated. Instrumentation at the EFF-TF allows accurate measurement of temperature, pressure, strain, and bulk core deformation (useful for accurately simulating nuclear behavior). Ongoing research at the EFF-TF is geared towards facilitating research, development, system integration, and system utilization via cooperative efforts with DOE laboratories, industry, universities, and other NASA centers. This paper describes the current efforts for the latter portion of 2003 and beginning of 2004.

VanDyke, Melissa↗

NASA NTRS2014

End-of-test Performance and Wear Characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test

This presentation describes results from the end-of-test performance characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test (LDT). Sub-component performance as well as overall thruster performance is presented and compared to results over the course of the test. Overall wear of critical thruster components is also described, and an update on the first failure mode of the thruster is provided.

Wear Tests↗

DOE OSTI2024

Building a Simplistic Automatic Extruder: Instrument Development Opportunities for the Laboratory

This work presents an automatic extruder as a research experience for undergraduate students. The system offers a user-friendly approach to preparing vesicles, such as liposomes or polymersomes, with a defined size and polydispersity properties crucial for research in biology and macromolecules. It comprises two syringe pumps connected by a membrane filter. The setup is controlled by software. Compared to manual extrusion, this automated system provides advantages, such as precisely controlled variables. The project describes a tool to enhance undergraduate learning in science and engineering laboratories. Building an automatic extruder serves as a simplified model of a complex industrial process. It offers a clear advantage: automating a well-understood manual extrusion process. To make this project accessible, it is broken down into three manageable tasks: software development, hardware assembly, and testing procedures. This breakdown describes the software created, the hardware components used, and the testing procedures conducted for this project. All project data, including software code, testing data, and procedures, are freely available online. This allows undergraduate students to not only begin their own projects but also contribute to this educational instrument’s ongoing development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1987

Ceramic high pressure gas path seal

Stage 1 ceramic shrouds (high pressure turbine gas path seal) were developed for the GE T700 turbine helicopter engine under the Army/NASA Contract NAS3-23174. This contract successfully proved the viability and benefits of a Stage 1 ceramic shroud for production application. Stage 1 ceramic shrouds were proven by extensive component and engine testing. This Stage 1 ceramic shroud, plasma sprayed ceramic (ZrOs-BY2O3) and bond coating (NiCrAlY) onto a cast metal backing, offers significant engine performance improvement. Due to the ceramic coating, the amount of cooling air required is reduced 20% resulting in a 0.5% increase in horsepower and a 0.3% decrease in specific fuel consumption. This is accomplished with a component which is lower in cost than the current production shroud. Stage 1 ceramic shrouds will be introduced into field service in late 1987.

Liotta, G. C.↗

NASA NTRS1992

Heat transfer in rocket engine combustion chambers and nozzles

The complexities of liquid rocket engine heat transfer which involve the injector faceplate and regeneratively and film cooled walls are being investigated by computational analysis. A conjugate heat transfer analysis will be used to describe localized heating phenomena associated with particular injector configurations and coolant channels and film coolant dumps. These components are being analyzed, and the analysis verified with appropriate test data. Finally, the component analysis will be synthesized into an overall flowfield/heat transfer model. The FDNS code is being used to make the component analyses. Particular attention is being given to the representation of the thermodynamic properties of the fluid streams and to the method of combining the detailed models to represent overall heating. Unit flow models of specific coaxial injector elements have been developed and will be described. Film cooling simulations of film coolant flows typical of the subscale Space Transportation Main Engine (STME) being experimentally studied by Pratt and Whitney have been made, and these results will be presented. Other film coolant experiments have also been simulated to verify the CFD heat transfer model being developed. The status of the study and its relevance as a new design tool are covered. Information is given in viewgraph form.

Anderson, P. G.↗

NASA NTRS1992

Offloading techniques for large deployable space structures

The validation and verification of large deployable space structures are continual challenges which face the integration and test engineer today. Spar Aerospace Limited has worked on various programs in which such structure validation was required and faces similar tasks in the future. This testing is reported and the different offloading and deployment methods which were used, as well as the proposed methods which will be used on future programs, are described. Past programs discussed include the Olympus solar array ambient and thermal vacuum deployments, and the Anik-E array and reflector deployments. The proposed MSAT reflector and boom ambient deployment tests, as well as the proposed RADARSAT Synthetic Aperture Radar (SAR) ambient and thermal vacuum deployment tests will also be presented. A series of tests relating to various component parts of the offloading equipment systems was required. These tests included the characterization and understanding of linear bearings and large (180 in-lbf) constant force spring motors in a thermal vacuum environment, and the results from these tests are presented.

Caravaggio, Levino↗

NASA NTRS2009

Synergistic Development, Test, and Qualification Approaches for the Ares I and V Launch Vehicles

The U.S. National Aeronautics and Space Administration (NASA) initiated plans to develop the Ares I and Ares V launch vehicles in 2005 to meet the mission objectives for future human exploration of space. Ares I is designed to provide the capability to deliver the Orion crew exploration vehicle (CEV) to low-Earth orbit (LEO), either for docking to the International Space Station (ISS) or docking with an Earth departure stage (EDS) and lunar lander for transit to the Moon. Ares V provides the heavy-lift capability to deliver the EDS and lunar lander to orbit. An integrated test plan was developed for Ares I that includes un-crewed flight validation testing and ground testing to qualify structural components and propulsion systems prior to operational deployment. The overall test program also includes a single development test flight conducted prior to the Ares I critical design review (CDR). Since the Ares V concept was formulated to maximize hardware commonality between the Ares V and Ares I launch vehicles, initial test planning for Ares V has considered the extensibility of test approaches and facilities from Ares I. The Ares V test plan was part of a successful mission concept review (MCR) in 2008.

Cockrell, Charles E.↗

NASA NTRS1980

Progress with variable cycle engines

The evaluation of components of an advanced propulsion system for a future supersonic cruise vehicle is discussed. These components, a high performance duct burner for thrust augmentation and a low jet noise coannular exhaust nozzle, are part of the variable stream control engine. An experimental test program involving both isolated component and complete engine tests was conducted for the high performance, low emissions duct burner with excellent results. Nozzle model tests were completed which substantiate the inherent jet noise benefit associated with the unique velocity profile possible of a coannular exhaust nozzle system on a variable stream control engine. Additional nozzle model performance tests have established high thrust efficiency levels at takeoff and supersonic cruise for this nozzle system. Large scale testing of these two critical components is conducted using an F100 engine as the testbed for simulating the variable stream control engine.

Westmoreland, J. S.↗

DOE OSTI2025

Impact of lead on an axisymmetric, single bead blown powder DED overhung geometry

Metal additive manufacturing can be utilized for the near net-shape manufacture of components in a layer wise technique. Traditionally, the buildup process is conducted in the direction of gravity or bottom to top in the vertical orientation; however, with the availability of commercial systems with additive heads or fixturing that can index from vertical, and the need to manufacture larger parts without modifying available systems, the limitation of manufacturing from bottom to top is removed enabling the buildup of larger components printed at an angle from vertical. The effect of gravity on the melt pool and as-deposited component quality when printing off vertical is unknown in literature, especially for axisymmetric components. This understanding is critical for the advancement of manufacturing components of increased size in 4 and 5-axis additive systems. This investigation utilizes blown powder directed energy deposition to evaluate the change in as-printed geometry when the start point is altered in relation to gravity while the part rotates to manufacture an axisymmetric component. The objectives of this work are to determine the impact of the deposition location on the geometric variability on axisymmetric components. This investigation tests the hypothesis that differences in layer height exist due to a change in catchment efficiency when the deposition location is moved to a tangent of the round geometry due to a change in the melt pool dynamics. It was found the ideal deposition location when printing at 26.6-degrees from vertical was at −90-degrees from the top center point of the component, along the tangent, where gravity was pushing the melt pool down, but the rotation of the part was pulling the deposited material towards the top center of the component. This work provides an understanding of layer height stability and catchment efficiency to guide print orientation strategy for high-aspect ratio components. It was found the −90-degree lead deposition had the best layer height stability at 0.6 % as compared to the top-center at 6.3 % and +90-degree deposition location at 9.2 % for the nominal programmed layer height. The change in layer height also effected the final diameter the greatest for the top center deposition location where the diameter diverged by 2.5 % during the overbuild condition and converged by 0.6 %. In conclusion, this finding will increase the manufacturing efficiency of axisymmetric components by increasing the passive stability of the printing process for the successful manufacture of parts without the need for perfectly calibrated manufacturing parameters.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Aerodynamic instability performance of an advanced high-pressure-ratio compression component

The data acquisition and reduction, test procedures, and results of in-stall and in-surge testing of a NASA high-pressure-ratio compression component are discussed, in addition to the compressor-rig configuration and instrumentation used. Data analysis revealed information about rotating stall hysteresis, rotating stall development and cessation times, and rotating-stall-cell flow blockage. It is found that hysteresis exists in the work coefficient as well as in the pressure coefficient. Airflow rakes were designed to study the in-surge transient response of the compressor. The quasi-steady compressor characteristics underlying the transient-surge data were investigated using a parameter-identification technique.

Hosny, W. M.↗

DOE OSTI2022

Evaluating the Durability of Balance of Systems Components Using C-AST

The testing of branch- and cable-connectors, and fuses in C-AST is introduced. A significant effect was observed when mechanical actuation was introduced to the benchtop prototype testing. Therefore, this presentation emphasizes the mechanical test fixture, data acquisition system, failure analysis of the components used in specimen assemblies, and the validation of the results relative to field failed samples.

components↗

NASA NTRSDate not supplied

Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication techniques. Each of these manufacturing process has unique advantages, applications for use, and challenges. The most common AM processes in use include Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) as well as many solid state processes. While detailed research has been conducted among many of the processes including parameters and material properties, navigating which processes are best to select is difficult as it is based on component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various attributes. These attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hotfire evaluations, and (4) certification approaches. This presentation summarizes these results and meant to introduce various considerations when designing a metal AM component.

Additive Manufacturing↗

NASA NTRS2014

Configuration and Assessment of the GISS ModelE2 Contributions to the CMIP5 Archive

We present a description of the ModelE2 version of the Goddard Institute for Space Studies (GISS) General Circulation Model (GCM) and the configurations used in the simulations performed for the Coupled Model Intercomparison Project Phase 5 (CMIP5). We use six variations related to the treatment of the atmospheric composition, the calculation of aerosol indirect effects, and ocean model component. Specifically, we test the difference between atmospheric models that have noninteractive composition, where radiatively important aerosols and ozone are prescribed from precomputed decadal averages, and interactive versions where atmospheric chemistry and aerosols are calculated given decadally varying emissions. The impact of the first aerosol indirect effect on clouds is either specified using a simple tuning, or parameterized using a cloud microphysics scheme. We also use two dynamic ocean components: the Russell and HYbrid Coordinate Ocean Model (HYCOM) which differ significantly in their basic formulations and grid. Results are presented for the climatological means over the satellite era (1980-2004) taken from transient simulations starting from the preindustrial (1850) driven by estimates of appropriate forcings over the 20th Century. Differences in base climate and variability related to the choice of ocean model are large, indicating an important structural uncertainty. The impact of interactive atmospheric composition on the climatology is relatively small except in regions such as the lower stratosphere, where ozone plays an important role, and the tropics, where aerosol changes affect the hydrological cycle and cloud cover. While key improvements over previous versions of the model are evident, these are not uniform across all metrics.

ocean model↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Additive Manufacturing↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Paul Gradl↗