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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 163 records · Page 9

Orbital maneuvering vehicle thermal design and analysis techniques

This paper describes the OMV thermal design that is required to maintain components within temperature limits for all mission phases. A key element in the OMV thermal design is the application of a motorized thermal shade assembly that is a replacement for the more conventional variable conductance heat pipes or louvers. The thermal shade assembly covers equipment module radiator areas, and based upon the radiator temperature input to onboard computer, opens and closes the shade, varying the effective radiator area. Thermal design verification thermal analyses results are presented. Selected thermal analyses methods, including several unique subroutines, are discussed. A representation of enclosure Script F equations, in matrix form, is also included. Personal computer application to the development of the OMV thermal design is summarized.

Chapter, J.↗

Design and development of a prototype wet oxidation system for the reclamation of water and the disposition of waste residues onboard space vehicles

Laboratory investigations to define optimum process conditions for oxidation of fecal/urine slurries were conducted in a one-liter batch reactor. The results of these tests formed the basis for the design, fabrication, and testing of an initial prototype system, including a 100-hour design verification test. Areas of further development were identified during this test. Development of a high pressure slurry pump, materials corrosion studies, oxygen supply trade studies, comparison of salt removal water recovery devices, ammonia removal investigation, development of a solids grinder, reactor design studies and bearing life tests, and development of shutoff valves and a back pressure regulator were undertaken. The development work has progressed to the point where a prototype system suitable for manned chamber testing can be fabricated and tested with a high degree of confidence of success.

Jagow, R. B.↗

Nonlinear Dynamic Modeling and Controls Development for Supersonic Propulsion System Research

This paper covers the propulsion system component modeling and controls development of an integrated nonlinear dynamic simulation for an inlet and engine that can be used for an overall vehicle (APSE) model. The focus here is on developing a methodology for the propulsion model integration, which allows for controls design that prevents inlet instabilities and minimizes the thrust oscillation experienced by the vehicle. Limiting thrust oscillations will be critical to avoid exciting vehicle aeroelastic modes. Model development includes both inlet normal shock position control and engine rotor speed control for a potential supersonic commercial transport. A loop shaping control design process is used that has previously been developed for the engine and verified on linear models, while a simpler approach is used for the inlet control design. Verification of the modeling approach is conducted by simulating a two-dimensional bifurcated inlet and a representative J-85 jet engine previously used in a NASA supersonics project. Preliminary results are presented for the current supersonics project concept variable cycle turbofan engine design.

Connolly, Joseph W.↗

Permutations of the Exploration Extra-vehicular Mobility Unit (xEMU) for Mission Specific Objectives

The Advanced Portable Life Support System began first with NASA investment during the Constellation Program focused on new technologies that were central to the new architecture but with a consideration for development of the most flexible and adaptable design to address the varied future needs for Extra-Vehicular Activity (EVA) capability by the agency as part of the exploration of the moon and beyond. Since that time, the Portable Life Support System (PLSS) architecture has been demonstrated at bread-board level, packaged prototype level with Human In-The Loop (HITL) testing, and has now matured into what has become known as the Exploration Extravehicular Mobility Unit (xEMU) PLSS focused on a demonstration on the International Space Station (ISS) and support for initial lunar missions. The xEMU completed Preliminary Design Review (PDR) and the associated Safety Review Panel (SRP) Phase I reviews in 2019-2020 and is progressing through the Design Verification Test (DVT) phase in 2021. As the agency updates planning for lunar both near term, long term, and beyond, there are many possible permutations of the existing architecture that can be accommodated to enable varied mission objectives. This paper will discuss the current baseline DVT design for xEMU as well as potential permutations of the PLSS architecture to accomplish an Apollo style short-duration down and out mission, a long term lunar ultra-lightweight approach, as well as a potential SuitPort accommodating architecture.

Colin Campbell↗

Test verification of a turbofan partial swirl afterburner

Flamespreading velocities exceeding conventional turbulent flamespreading values were demonstrated in a strong centrifugal flow field. This centrifugal flow field flamespreading concept was integrated into an F100 turbofan engine afterburner by introducing swirling airflow into the afterburner. Successful tests were conducted on F100 Engine P072 at sea level and at altitude conditions in a test chamber. This paper summarizes the design approach, engine design verification tests and performance data. Engine tests showed the swirl afterburner increased fuel-air capability improving combustion stability at adverse conditions for combustion in the engine flight envelope. No engine performance or durability degradation was observed.

Hanloser, K. J.↗

Development of a static feed water electrolysis system

A one person level oxygen generation subsystem was developed and production of the one person oxygen metabolic requirements, 0.82 kg, per day was demonstrated without the need for condenser/separators or electrolyte pumps. During 650 hours of shakedown, design verification, and endurance testing, cell voltages averaged 1.62 V at 206 mA/sq cm and at average operating temperature as low as 326 K, virtually corresponding to the state of the art performance previously established for single cells. This high efficiency and low waste heat generation prevented maintenance of the 339 K design temperature without supplemental heating. Improved water electrolysis cell frames were designed, new injection molds were fabricated, and a series of frames was molded. A modified three fluid pressure controller was developed and a static feed water electrolysis that requires no electrolyte in the static feed compartment was developed and successfully evaluated.

Schubert, F. H.↗

The role of failure/problems in engineering: A commentary of failures experienced - lessons learned

The written version of a series of seminars given to several aerospace companies and three NASA centers are presented. The results are lessons learned through a study of the problems experienced in 35 years of engineering. The basic conclusion is that the primary cause of problems has not been mission technologies, as important as technology is, but the neglect of basic principles. Undergirding this is the lack of a systems focus from determining requirements through design, verification, and operations phases. Many of the concepts discussed are fundamental to total quality management (TQM) and can be used to augment this product enhanced philosophy. Fourteen principles are addressed with problems experienced and are used as examples. Included is a discussion of the implication of constraints, poorly defined requirements, and schedules. Design guidelines, lessons learned, and future tasks are listed. Two additional sections are included that deal with personal lessons learned and thoughts on future thrusts (TQM).

Ryan, R. S.↗

Development of Lightweight Material Composites to Insulate Cryogenic Tanks for 30-Day Storage in Outer Space

A conceptual design was developed for an MLI system which will meet the design constraints of an ILRV used for 7- to 30-day missions. The ten tasks are briefly described: (1) material survey and procurement, material property tests, and selection of composites to be considered; (2) definition of environmental parameters and tooling requirements, and thermal and structural design verification test definition; (3) definition of tanks and associated hardware to be used, and definition of MLI concepts to be considered; (4) thermal analyses, including purge, evacuation, and reentry repressurization analyses; (5) structural analyses (6) thermal degradation tests of composite and structural tests of fastener; (7) selection of MLI materials and system; (8) definition of a conceptual MLI system design; (9) evaluation of nondestructive inspection techniques and definition of procedures for repair of damaged areas; and (10) preparation of preliminary specifications.

Krause, D. R.↗

Development Status of the NASA 30-cm Ion Thruster and Power Processor

Xenon ion propulsion systems are being developed by NASA Lewis Research Center and the Jet Propulsion Laboratory to provide flight qualification and validation for planetary and earth-orbital missions. In the ground-test element of this program, light-weight (less than 7 kg), 30 cm diameter ion thrusters have been fabricated, and preliminary design verification tests have been conducted. At 2.3 kW, the thrust, specific impulse, and efficiency were 91 mN, 3300 s, and 0.65, respectively. An engineering model thruster is now undergoing a 2000 h wear-test. A breadboard power processor is being developed to operate from an 80 V to 120 V power bus with inverter switching frequencies of 50 kHz. The power processor design is a pathfinder and uses only three power supplies. The projected specific mass of a flight unit is about 5 kg/kW with an efficiency of 0.92 at the full-power of 2.5 kW. Preliminary integration tests of the neutralizer power supply and the ion thruster have been completed. Fabrication and test of the discharge and beam/accelerator power stages are underway.

Sovey, James S.↗

Rapid Cycle Amine 4.0 System Development

Carbon dioxide (CO2) and humidity control is a key function of the spacesuit Portable Life Support Subsystem (PLSS). The latest spacesuit design utilizes a pressure swing bed containing a solid amine sorbent to scrub CO2 and humidity produced by the crewmember from the ventilation loop. The solid amine sorbent removes CO2 and humidity from the ventilation loop through a chemisorption mechanism. Simultaneously, CO2 and humidity are desorbed to vacuum via the two-bed pressure swing system during operation. This continuous regeneration allows for longer Extravehicular Activity (EVA) times while minimizing maintenance, consumables, and power usage. This concept has been in development for over 20 years, during which many prototypes and design iterations have been fabricated and evaluated. This paper discusses the recent Rapid Cycle Amine (RCA) design, development, and testing that has been done to advance the technology. The most recent fabrication is the RCA 3.0. It was delivered to NASA Johnson Space Center in 2015 and has since been tested at the component level and at the integrated PLSS level. The purpose of the component level testing was to understand CO2 removal capacity, end-of-life performance, and establish a baseline performance prior to integrated testing. The RCA 3.0 was integrated into the Exploration Extravehicular Mobility Unit (xEMU) PLSS for a comprehensive Design Verification Test (DVT) series. The integrated testing provided the benefit of characterizing the impact performance degradation has on the system. Many of the RCA requirements were developed through analysis, based on the limitations of the PLSS and, in some cases, assumptions about the system and flow behavior. Integrated testing was an opportunity to validate those requirements and assumptions. While the RCA 3.0 was being tested, the next design iteration, RCA 4.0, was under development. The RCA 4.0 preliminary design phase began in late-2019 and shortly after the Preliminary Design Review, the critical design phase began in 2021. The design work has concluded with the completion of a Pre-Manufacturing Review in 2022. This paper provides an overview of the RCA 4.0 system design, summarizes the results of integrated RCA 3.0 testing, and discusses the pertinence of driving requirements such as mass, volume, and power consumption.

Kelsey Bloom↗

Extended-MHD simulations of disruption mitigation via massive gas injection in SPARC

Recent developments to the M3D-C1 code enable higher fidelity modeling of disruptions, and can be applied in the design verification of reactor-scale tokamaks. Among these new capabilities is a method to mesh conducting vessel structures such as coils and passive plates, packing of the toroidal mesh around gas injectors, as well as anisotropic resistivity inside the vessel structures. We present extended-magnetohydrodynamic (MHD) simulations of disruption mitigation via massive gas injection (MGI) in SPARC. The goal of this study is to inform the disruption mitigation layout of SPARC and aid in the design of an effective gas injector configuration. Fully three-dimensional simulations with M3D-C1 are carried out for various injector configurations with the primary goal of determining the effect of different MGI parameters on heat loads and vessel forces. The simulations include a model for impurity ionization, recombination, advection and radiation, as well as spatially resolved conducting structures around the plasma. A localized mixture of deuterium and neon with a small toroidal and poloidal width is injected in up to six locations. We demonstrate that M3D-C1 can model a rapid shutdown via MGI using narrow and more realistic gas plumes than in previous simulations. As a result of the q = 1 surface in the SPARC baseline case a sawtooth is observed early in the simulations. Despite the sawtooth and the onset of edge MHD instabilities, the impurity distribution remains localized around the injector locations, but enables a radiative shutdown of the plasma. We find that using the maximum of six gas injectors results in a lower peaking factor and leads to a more even distribution of radiation toroidally than using two injectors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Shuttle Radar Topography Mission (SRTM) Flight System Design and Operations Overview

This paper provides an overview of the Shuttle Radar Topography Mission (SRTM), with emphasis on flight system implementation and mission operations from systems engineering perspective. Successfully flown in February, 2000, the SRTM's primary payload consists of several subsystems to form the first spaceborne dual-frequency (C-band and X-band) fixed baseline interferometric synthetic aperture radar (InSAR) system, with the mission objective to acquire data sets over 80% of Earth's landmass for height reconstruction. The paper provides system architecture, unique design features, engineering budgets, design verification, in-flight checkout and data acquisition of the SRTM payload, in particular for the C-band system. Mission operation and post-mission data processing activities are also presented. The complexity of the SRTM as a system, the ambitious mission objective, the demanding requirements and the high interdependency between multi-disciplined subsystems posed many challenges. The engineering experience and the insight thus gained have important implications for future spaceborne interferometric SAR mission design and implementation.

Shen, Yuhsyen↗

Applying Monte Carlo Simulation to Launch Vehicle Design and Requirements Verification

- This presentation applies statistics to launch vehicle design, but the methods may be used for other engineering applications - Vehicle Models: What do we know when? How to separate parameters for making Monte Carlo runs - Known when assembling the vehicle but not during design - Known prior to committing to flight - Unknown at lift off - How do we correctly model the vehicle during the design phases? - Number of Monte Carlo samples - Requirements success - Design parameter values

Monte Carlo↗

Rocket Sled Propelled Testing of a Supersonic Inflatable Aerodynamic Decelerator

Decelerators (IADs) have traditionally been tested in wind tunnels. As the limitations of these test facilities are reached, other avenues must be pursued. The IAD being tested is a Supersonic IAD (SIAD), which attaches just aft of the heatshield around the perimeter of an entry body. This 'attached torus' SIAD is meant to improve the accuracy of landing for robotic class missions to Mars and allow for potentially increased payloads. The SIAD Design Verification (SDV) test aims to qualify the SIAD by applying a targeted aerodynamic load to the vehicle. While many test architectures were researched, a rocket sled track was ultimately chosen to be the most cost effective way to achieve the desired dynamic pressures. The Supersonic Naval Ordnance Research Track (SNORT) at the Naval Air Warfare Center Weapons Division (NAWCWD) China Lake is a four mile test track, traditionally used for warhead and ejection seat testing. Prior to SDV, inflatable drag bodies have been tested on this particular track. Teams at Jet Propulsion Laboratory (JPL) and NAWCWD collaborate together to design and fabricate one of the largest sleds ever built. The SDV sled is comprised of three individual sleds: a Pusher Sled which holds the solid booster rockets, an Item Sled which supports the test vehicle, and a Camera Sled that is pushed in front for in-situ footage and measurements. The JPL-designed Test Vehicle has a full-scale heatshield shape and contains all instrumentation and inflation systems necessary to inflate and test a SIAD. The first campaign that is run at SNORT tested all hardware and instrumentation before the SIAD was ready to be tested. For each of the three tests in this campaign, the number of rockets and top speed was increased and the data analyzed to ensure the hardware is safe at the necessary accelerations and aerodynamic loads.

Supersonic Inflatable Aerodynamic Decelerators (SI↗

Ground Based Microgravity Emissions Testing Of Flight Hardware

To control microgravity environment on the International Space Station (ISS), NASA developed payloads have to meet the payload integration requirements of the Space Station Program, specifically a microgravity allocation plan. The Microgravity Emissions Laboratory (MEL) was developed at NASA Glenn Research Center (GRC) for verification of the payloads compliance with payload integration requirements. MEL is a 6 degree of freedom inertial measurement system capable of characterizing the microgravity emissions, generated by a disturber, down to a micro g. Microgravity Emissions tests provide a payload developer with a tool to assess payload's compliance with the requirements, i.e. forces and moments, generated by the payload at its center of gravity. Forces and moments are presented in time domain for both stationary and transient signals, and in frequency domain for the stationary signals. To date, MEL conducted over thirty tests of ISS hardware. The test results are being successfully used by the payload developers for design verification and improvement.

Samorezov, Sergey↗

Work Practice Simulation of Complex Human-Automation Systems in Safety Critical Situations: The Brahms Generalized berlingen Model

The transition from the current air traffic system to the next generation air traffic system will require the introduction of new automated systems, including transferring some functions from air traffic controllers to on­-board automation. This report describes a new design verification and validation (V&V) methodology for assessing aviation safety. The approach involves a detailed computer simulation of work practices that includes people interacting with flight-critical systems. The research is part of an effort to develop new modeling and verification methodologies that can assess the safety of flight-critical systems, system configurations, and operational concepts. The 2002 Ueberlingen mid-air collision was chosen for analysis and modeling because one of the main causes of the accident was one crew's response to a conflict between the instructions of the air traffic controller and the instructions of TCAS, an automated Traffic Alert and Collision Avoidance System on-board warning system. It thus furnishes an example of the problem of authority versus autonomy. It provides a starting point for exploring authority/autonomy conflict in the larger system of organization, tools, and practices in which the participants' moment-by-moment actions take place. We have developed a general air traffic system model (not a specific simulation of Überlingen events), called the Brahms Generalized Ueberlingen Model (Brahms-GUeM). Brahms is a multi-agent simulation system that models people, tools, facilities/vehicles, and geography to simulate the current air transportation system as a collection of distributed, interactive subsystems (e.g., airports, air-traffic control towers and personnel, aircraft, automated flight systems and air-traffic tools, instruments, crew). Brahms-GUeM can be configured in different ways, called scenarios, such that anomalous events that contributed to the Überlingen accident can be modeled as functioning according to requirements or in an anomalous condition, as occurred during the accident. Brahms-GUeM thus implicitly defines a class of scenarios, which include as an instance what occurred at Überlingen. Brahms-GUeM is a modeling framework enabling "what if" analysis of alternative work system configurations and thus facilitating design of alternative operations concepts. It enables subsequent adaption (reusing simulation components) for modeling and simulating NextGen scenarios. This project demonstrates that BRAHMS provides the capacity to model the complexity of air transportation systems, going beyond idealized and simple flights to include for example the interaction of pilots and ATCOs. The research shows clearly that verification and validation must include the entire work system, on the one hand to check that mechanisms exist to handle failures of communication and alerting subsystems and/or failures of people to notice, comprehend, or communicate problematic (unsafe) situations; but also to understand how people must use their own judgment in relating fallible systems like TCAS to other sources of information and thus to evaluate how the unreliability of automation affects system safety. The simulation shows in particular that distributed agents (people and automated systems) acting without knowledge of each others' actions can create a complex, dynamic system whose interactive behavior is unexpected and is changing too quickly to comprehend and control.

complex systems↗

Comparison of Exploration Portable Life Support Subsystem (xPLSS) Thermal Modeling to Thermal Vacuum Testing

To support NASA’s goal to return to the Moon through the Artemis mission, the development of an exploration portable life support system (xPLSS) has been conducted at Johnson Space Center (JSC). As part of this development process, a large system level thermal/fluid model of the xPLSS was developed using Thermal Desktop and an in-house human model (METMAN). The xPLSS model was used throughout the design process to predict the performance and temperature of nearly all components within the xPLSS. In the fall of 2023, the design, verification, and testing (DVT) unit of the xPLSS was tested in a thermal vacuum (TVAC) chamber at JSC. This testing consisted of combining the xPLSS with an upper torso of the exploration pressure garment system (xPGS) and simulating five extravehicular activities (EVAs) in extreme thermal conditions (two cold EVAs and three hot EVAs). The data generated in this test series provided system level data of the xPLSS operating in vacuum and at flight-like environmental temperatures for the first time. This data was compared to results output by the xPLSS system model to assess the accuracy of previous analyses and improve the fidelity and accuracy of the xPLSS system model. The comparison between model and test hardware provides valuable insight that will help improve the design and fidelity of next generation space suits. In general, comparison between test data and model data generally showed slightly un-conservative values (model predicting colder temperatures than test in hot environments, and hotter temperatures than test in cold environments). Model assumptions and test assumptions were assessed to understand potential causes of some of these sources in error. Recommendations to improve the fidelity of the xPLSS model were also made based on the results presented in this paper.

xPLSS↗

Comparison of Exploration Portable Life Support Subsystem (xPLSS) Thermal Modeling to Thermal Vacuum Testing

To support NASA’s goal to return to the Moon through the Artemis Mission, the development of an Exploration Portable Life Support Subsystem (xPLSS) has been conducted at Johnson Space Center (JSC). As part of this development process, a large system level thermal/fluid model of the xPLSS was developed using Thermal Desktop and an in-house human model (METMAN). The xPLSS model was used throughout the design process to predict the performance and temperature of nearly all components within the xPLSS. In the fall of 2023, the Design, Verification, and Testing (DVT) unit of the xPLSS was tested in a thermal vacuum (TVAC) chamber at JSC. This testing consisted of combining the xPLSS with an upper torso of the Exploration Pressure Garment System (xPGS) and simulating five Extravehicular Activities (EVAs) in extreme thermal conditions (two cold EVAs and three hot EVAs). The data generated in this test series provided system level data of the xPLSS operating in vacuum and at flight-like environmental temperatures for the first time. These data were compared to results output by the xPLSS system model to assess the accuracy of previous analyses and improve the fidelity and accuracy of the xPLSS system model. The comparison between model and test hardware provides valuable insight that will help improve the design and fidelity of next generation space suits. In general, comparison between test data and model data generally showed slightly un-conservative values (model predicting colder temperatures than test in hot environments, and hotter temperatures than test in cold environments). Model assumptions and test assumptions were assessed to understand potential causes of some of these sources in error. Recommendations to improve the fidelity of the xPLSS model were also made based on the results presented in this paper.

xPLSS↗