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NASA NTRS2015

ME8373 Spring 2015 ICME Proposal ICME Analysis of Fatigue Crack Growth Through a Weld in SA-516 Grade 70 Plate

This paper describes work accomplished to predict the service life of a flexure joint design which is a component of a diffuser duct in the A3 Test Stand, an altitude simulation rocket engine test facility at NASA's Stennis Space Center. The duct has two pressure shells separated by cooling water passages and connected by stiffening ribs and flexure joints. Rocket exhaust flows within the duct and heats the inner pressure shell while the outer pressure shell remains at ambient temperature. The flexure joints allow for differential thermal expansion of the inner and outer pressure shells and are subject to in-service loading by this thermal expansion along with water pressure in the cooling water passage, atmospheric pressure outside the duct, near vacuum conditions within the duct, and vibrational loads from operation of the facility and rocket engine. Figure 1 shows a schematic axisymmetric cross section of the diffuser pressure shells and flexure joints with a zoomed in view of the flexure joint. The flexure joints are expected to eventually fail by fatigue cracking leading to leaks from the cooling water passages to the outside. The zoomed in view in Figure 1 indicates where cracking is expected to occur, namely through a weld bead between two plates of SA-516 Grade 70 steel. This weld bead acts as the fulcrum of the flexure joint and it is clear from inspection of the geometry and loading represented in the zoomed in portion of Figure 1 that inherent in the design there is a severe notch formed between the flexure plate, weld bead, and stiffening ring that will be the site of crack initiation and location from which the crack grows to the outer surface of the weld bead.

Woods, Jody L.↗

NASA NTRS1975

A comparison of measured and predicted sphere shock shapes in hypersonic flows with density ratios from 4 to 19

Measured shock shapes are presented for sphere and hemisphere models in helium, air, CF4, C2F6, and CO2 test gases, corresponding to normal-shock density ratios (primary factor governing shock detachment distance of blunt bodies at hypersonic speeds) from 4 to 19. These shock shapes were obtained in three facilities capable of generating the high density ratios experienced during planetary entry at hypersonic conditions; namely, the 6-inch expansion tube, with hypersonic CF4 tunnel, and pilot CF4 Mach 6 tunnel (with CF4 replaced by C2F6). Measured results are compared with several inviscid perfect-gas shock shape predictions, in which an effective ratio of specific heats is used as input, and with real-gas predictions which include effects of a laminar viscous layer and thermochemical nonequilibrium.

Miller, C. G., III↗

NASA NTRSDate not supplied

Latest Results from NASA Ames’ COSmIC and Optical Constants Facility (OCF): Determining Optical Constants for Titan, Pluto and Protoplanetary Disks Applications

The NASA Ames COsmic SImulation Chamber (COSmIC) is a unique experimental facility that can be used, among many applications, to produce solid particles from gas phase molecular precursors at low temperature (150 K) using a plasma discharge to induce the chemistry in the stream of a free jet expansion. The choice of the initial gas mixture used to produce the solid sample allows the simulation of either cold planetary atmospheres like Titan or Pluto (with N2/CH4-based initial mixtures), or circumstellar environments (with Ar/CxHy-based initial mixtures). The Ames Optical Constants Facility (OCF) allows the determination of optical constants covering a broad wavelength range with high spectral resolution for solid materials, analogs of organic refractory materials formed in planetary and astrophysical environments. The core of the OCF is a Fourier transform infrared (FTIR) spectrometer that allows the continuous characterization of solid samples in the visible to far-infrared (FIR) range (0.59–200 μm, 16,950–50 cm−1). Modeling of the laboratory measurements conducted with the OCF allows the determination of accurate optical constants, n and k, over the full vis-FIR range. Here we present the latest results of two studies that combined (1) experiments performed with COSmIC to produce analogs of aerosols forming in Titan’s atmosphere and analogs of cosmic grains forming in circumstellar envelops, and (2) the characterization of these analogs with the OCF to provide the real and imaginary parts of their refractive indices, n + ik, to the community, from the visible to the FIR. These optical constants can be used as critical input parameters in radiative transfer, atmospheric and reflectance models to interpret observational data of, e.g., Titan’s atmosphere and protoplanetary disks. Providing optical constants for various materials of different compositions allows to explore a broad range of composition by simulating mixtures of materials. We also present a new project to produce analogs of Pluto’s atmospheric aerosols with COSmIC and determine their optical constants with OCF, to be used in reflectance spectra models for the interpretation of New Horizons observations of Lowell Regio, Sputnik Planitia and Cthulhu.

COsmic SImulation Chamber (COSmIC)↗

NASA NTRS2002

Flight Evaluation of the Army/NASA Variable Stability Fly-by-Wire Rotorcraft Aircrew Systems Concept Airborne Laboratory (RASCAL) JUH-60A

NASA Ames Research Center and the U.S. Army Aeroflight dynamics Directorate (AFDD) have performed initial flight evaluations of the Research Flight Control System (RFCS) integrated into the Army/NASA Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) JUH-GOA. The highly modified JUH-GOA Black Hawk helicopter is a full authority, high bandwidth, variable stability, in-flight simulator designed to support development of advanced flight control, sensor, and integrated display and control technologies in a fail safe environment. Preparation for flight test required an extensive hazard analysis and ground testing to ensure proper system operation. A hardware in the loop development facility was utilized to evaluate control law stability following software changes, assess servo hardover upset conditions during manual and monitor disengagements and provide pilot familiarization of test techniques and software changes prior to flight. First engagement of the RFCS was conducted on 31 Aug 2001. RFCS transfer system operation, envelope expansion and a limited rate monitor evaluation have been completed with low bandwidth and model following control laws. The presentation will discuss the following - System overview including aircraft modifications and integrated development facilities used with the RASCAL facility. - Preliminary hazard identification and mitigation prior to flight test. - Ground testing used to qualify the RFCS transfer system and verify fault monitor operation. - Flight test results of low-bandwidth and model following control law evaluations including maneuver agility, control limitations, fault monitor reliability, and recovery from manual and monitor disengagement. - Lessons learned including test techniques using a passive three-axis sidearm controller, the value of the development facility in reducing risk and crew coordination issues related to the operation of a full authority, variable stability platform. - Future research and modifications planned for the RASCAL aircraft.

Dave Arterburn↗

NASA NTRS2026

Investigation of Bipropellant Plume-Induced Contamination Effects on Coverglass Materials

Contamination and degradation of external spacecraft materials by unburned and partially combusted species from bipropellant thruster plumes has long been observed as a key component of the induced space environment. Space shuttle flight experiments and returned flight hardware from the International Space Station (ISS) have both experienced microscopic impact features induced by high-velocity thruster plume droplets. Analytical results have shown that droplet impingement angle relative to a receiving surface plays a key role in the surface damage. Although impacts with normal impingement angles contribute more severely to surface degradation than highly oblique angles, surface effects at higher impingement angles should not be dismissed. Thruster plume-induced materials degradation is a complex phenomenon that depends on a variety of parameters, including but not limited to material type, system temperature and pressure, plume composition, and thruster firing specifications such as number of pulses, pulse duration, and sample distance from the thruster. For space applications, attaining the vacuum pressure and temperature conditions necessary for flight-like plume expansion and exposure conditions is not a trivial task. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) is a facility uniquely capable of simulating such conditions. Test coupons were exposed to bipropellant thruster firings under high vacuum at the DLR facility. Percent area coverage (PAC) and droplet size distributions were evaluated for the uncoated and coated solar array coverglass materials over a range of impingement angles (0̊ to 75̊). A post-test imaging workflow was developed that aimed to quantify changes in sample surface morphology obtained from scanning electron microscopy (SEM) images using the Image Processing and Analysis in Java (ImageJ) tool; an opensource image processing software. The goal was to create a framework through which to evaluate the effect of bipropellant-induced PAC and droplet size distribution on solar array coverglass optical transmission losses. Understanding this relationship is important because optical transmission losses are known to lead to current reduction in solar power generation systems. In addition to the development of surface characterization workflows, valuable lessons learned as they pertain to future investigations and experiments will be discussed. The authors hope that sharing these lessons will facilitate more utilization of DLR’s unique capabilities as well as open the conversation for how best to address experimental characterization of flight-like plume expansion and its impacts on materials surface degradation effects.

Gateway↗

NASA NTRSDate not supplied

First Optical Constants from 0.4 to 1.6 µm of Titan Aerosol Analogs Produced in the NASA Ames COSmIC Facility and Their Use in a New Analysis of Cassini VIMS Observations

We have determined the real and imaginary refractive indices (n and k, respectively), from the visible to the near infrared (0.4 to 1.6 μm), of five laboratory-generated organic refractory materials produced from gas-phase chemistry with the NASA Ames COSmIC facility. The solid samples were produced using a plasma discharge in the stream of a 200-K supersonic jet-cooled expansion of different gas mixtures to study the impact of the molecular precursors on the solid sample optical properties. Three samples were produced from N2:CH4 (95:5) gas mixtures using three different high voltages (700V, 800V and 1000V) to vary the energy in the plasma discharge. One sample was produced from a N2:CH4:C2H2 (94:5:5:0.5) gas mixture, with a high voltage of 1000 V. The fifth sample was produced in an Ar:CH4 (95:5) gas mixture with a high voltage of 1000 V to produce a nitrogen-free hydrocarbon sample. The optical constants, n and k, of these five samples were determined using spectral reflectance measurements. They appear to be positively correlated with the nitrogen content in the solid sample, i.e., a sample with larger nitrogen content exhibits higher n and k values. We have used these refractive indices as input parameters in a radiative transfer model to analyze Cassini Visible Infrared Mapping Spectrometer (VIMS) observations of Titan’s atmosphere. The results show that using the tholin samples with higher n and k values (higher nitrogen content) provides a better fit to the observational data than using the samples with lower n and k values (lower nitrogen content). The Titan tholins with higher nitrogen content therefore appear to be more representative of the Titan aerosols observed by VIMS.

Titan Aerosol Analogs↗

NASA NTRS1970

The Lunar Communications Relay Unit system design

Lunar Surface Exploration by Early Apollo Astronauts was limited by the range capabilities and configuration of the surface communications. To permit greater scientific yield from manned lunar exploration, it was necessary to provide improvements in crew mobility plus communications compatible with extended extravehicular activity. Expansion of EVA** and video communications capability was constrained by the requirement of interfacing with existing earth and lunar surface facilities, vehicle payload requirements, and crew operational considerations. Various trade-off s were conducted to permit rapid development of a feasible communication’s system which are described herein. The revision of the EVA mission profile necessitated establishment of new signal design parameters compatible with mobile and fixed site relay configurations. The design approach selected required strict discipline to enable integration of the electrical, mechanical, thermal and human factor fields. The resultant design of the Lunar Communications Relay Unit is a portable communications package to provide relay-to-earth of voice, data and color television from lunar surface locations far beyond the LM landing site and relay of ground voice to the EVA crew.

B. Trachtenberg↗

NASA NTRS1974

Shock shapes of blunt bodies in hypersonic helium, air, and CO2 flows

A primary factor governing hypersonic flowfield characteristics of blunt vehicles entering planetary atmospheres is the normal shock density ratio. Hence, a means of duplicating or simulating the high density ratios experienced during planetary entry is needed. One facility having the capability of generating a range of hypersonic-hypervelocity flow conditions in arbitrary test gases is the expansion tube. Preliminary shock shape results obtained in the Langley 6-in. expansion tube at hypersonic conditions are presented. Normal shock density ratios from approximately 4 to 19 were generated using helium, air, and CO2 test gases at freestream velocities from 5 to 7 km/sec. Test models were a flat-faced cylinder and the Viking aeroshell.

Miller, C. G.↗

NASA NTRS2009

Recovering Aerodynamic Side Loads on Rocket Nozzles using Quasi-Static Strain-Gage Measurements

During over-expanded operation of rocket nozzles, which is defined to be when the exit pressure is greater than internal pressure over some part of the nozzle, the nozzle will experience a transverse forcing function due to the pressure differential across the nozzle wall. Over-expansion occurs during the nozzle start-up and shutdown transient, even in high-altitude engines, because most test facilities cannot completely reproduce the near-vacuum pressures at those altitudes. During this transient, the pressure differential moves axially down the nozzle as it becomes pressurized, but this differential is never perfectly symmetric circumferentially. The character of the forcing function is highly complex and defined by a series of restricted and free shock separations. The subject of this paper is the determination of the magnitude of this loading during sub-scale testing via measurement of the structural dynamic response of the nozzle and its support structure. An initial attempt at back-calculating this load using the inverse of the transfer function was performed, but this attempt was shown to be highly susceptible to numerical error. The final method chosen was to use statically calibrated strain data and to filter out the system fundamental frequency such that the measured response yields close to the correct dynamic loading function. This method was shown to capture 93% of the pressure spectral energy using controlled load shaker testing. This method is one of the only practical ways for the inverse determination of the forcing function for non-stationary excitations, and, to the authors' knowledge, has not been described in the literature to date.

Brown, Andrew↗

NASA NTRS2010

Early Scientific Results and Future Prospects for the Rejuvenated Hubble Space Telescope

Following the extraordinarily successful Servicing Mission 4 (SM4) of Hubble Space Telescope (HST) in May of 2009, the Observatory is now fully equipped with a broad array of powerful science instruments that put it at the pinnacle of its scientific power. Relevant to the subject matter of the Beyond 2010 Conference, HST will be well-placed over the next five-plus years to advance our knowledge of the formation of high-redshift galaxies and their growth with cosmic time; the emergence of structure in the early universe via Dark Matter-driven gravitational instability; and the universe's expansion history and any resulting implications for the temporal character of Dark Energy. These are fitting projects for the iconic facility now celebrating its 20th anniversary in orbit.

Niedner, Malcolm B.↗

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 NTRSDate not supplied

STABLE Study for the Habitable Worlds Observatory

We report on progress on the STABLE study, which was awarded on the NASA 2023 ROSES D.19 opportunity. In the study, we are developing technologies for the Habitable Worlds Observatory (HWO) in four areas: Micrometeoroid Impact Mitigation, Telescope Temperature Control, Ultra-Stable Telescope Structure Materials and Modeling, and Improvement of Thermal Expansion Test Capability. This study is a collaboration between Northrop Grumman, Kratos, NeXolve, JPL, STScI, NASA’s White Sands Test Facility, and NASA Goddard’s Ultra-Stable Test Facility. We will also discuss our plans for our follow-on study as part of NASA’s 2024 ROSES D.19. In this study, we will address additional technologies as well as perform analysis of HWO architecture options.

Habitable Worlds Observatory↗

NASA NTRS1999

Experimental and Computational Investigation of a Translating-Throat Single-Expansion-Ramp Nozzle

An experimental and computational study was conducted on a high-speed, single-expansion-ramp nozzle (SERN) concept designed for efficient off-design performance. The translating-throat SERN concept adjusts the axial location of the throat to provide a variable expansion ratio and allow a more optimum jet exhaust expansion at various flight conditions in an effort to maximize nozzle performance. Three design points (throat locations) were investigated to simulate the operation of this concept at subsonic-transonic, low supersonic, and high supersonic flight conditions. The experimental study was conducted in the jet exit test facility at the Langley Research Center. Internal nozzle performance was obtained at nozzle pressure ratios (NPR's) up to 13 for six nozzles with design nozzle pressure ratios near 9, 42, and 102. Two expansion-ramp surfaces, one concave and one convex, were tested for each design point. Paint-oil flow and focusing schlieren flow visualization techniques were utilized to acquire additional flow data at selected NPR'S. The Navier-Stokes code, PAB3D, was used with a two-equation k-e turbulence model for the computational study. Nozzle performance characteristics were predicted at nozzle pressure ratios of 5, 9, and 13 for the concave ramp, low Mach number nozzle and at 10, 13, and 102 for the concave ramp, high Mach number nozzle.

Deere, Karen A.↗

NASA NTRS1996

Shock Tunnel Studies of Scramjet Phenomena

Work focussed on a large number of preliminary studies of supersonic combustion in a simple combustion duct - thrust nozzle combination, investigating effects of Mach number, equivalence ratio, combustor divergence, fuel injecting angle and other parameters with an influence on the combustion process. This phase lasted for some three or four years, during which strongest emphasis was placed on responding to the request for preliminary experimental information on high enthalpy effects, to support the technology maturation activities of the NASP program. As the need for preliminary data became less urgent, it was possible to conduct more systematic studies of high enthalpy combustion phenomena, and to initiate other projects aimed at improving the facilities and instrumentation used for studying scramjet phenomena at high enthalpies. The combustion studies were particularly directed towards hypersonic combustion, and to the effects of injecting fuel along the combustion chamber wall. A substantial effort was directed towards a study of the effect of scale on the supersonic combustion process. The influence of wave phenomena (both compression waves and expansion waves) on the realization of thrust from a supersonic combustion process was also investigated. The effect of chemical kinetics was looked into, particularly as it affected the composition of the test flow provided by a ground facility. The effect of injection of the fuel through wall orifices was compared with injection from a strut spanning the stream, and the effect of heating the fuel prior to injection was investigated. Studies of fuel-air mixing by shock impingement were also done, as well as mass spectrometer surveys of a combustion wake. The use of hypersonic nozzles with an expansion tube was investigated. A new method was developed for measuring the forces acting of a model in less than one millisecond. Also included in this report are listings of published journal papers and conference presentations.

Stalker, R. J.↗

NASA NTRS1994

Development and application of computational aerothermodynamics flowfield computer codes

Research was performed in the area of computational modeling and application of hypersonic, high-enthalpy, thermo-chemical nonequilibrium flow (Aerothermodynamics) problems. A number of computational fluid dynamic (CFD) codes were developed and applied to simulate high altitude rocket-plume, the Aeroassist Flight Experiment (AFE), hypersonic base flow for planetary probes, the single expansion ramp model (SERN) connected with the National Aerospace Plane, hypersonic drag devices, hypersonic ramp flows, ballistic range models, shock tunnel facility nozzles, transient and steady flows in the shock tunnel facility, arc-jet flows, thermochemical nonequilibrium flows around simple and complex bodies, axisymmetric ionized flows of interest to re-entry, unsteady shock induced combustion phenomena, high enthalpy pulsed facility simulations, and unsteady shock boundary layer interactions in shock tunnels. Computational modeling involved developing appropriate numerical schemes for the flows on interest and developing, applying, and validating appropriate thermochemical processes. As part of improving the accuracy of the numerical predictions, adaptive grid algorithms were explored, and a user-friendly, self-adaptive code (SAGE) was developed. Aerothermodynamic flows of interest included energy transfer due to strong radiation, and a significant level of effort was spent in developing computational codes for calculating radiation and radiation modeling. In addition, computational tools were developed and applied to predict the radiative heat flux and spectra that reach the model surface.

Venkatapathy, Ethiraj↗

NASA NTRS2001

A New Kind of Curing

A new curing method using automated tape placement (ATP) with electron beam (EB), or e-beam, produces a combination known as in situ e-beam curing. Through a Small Business Innovation Research (SBIR) contract from NASA's Marshall Space Flight Center, Science Research Laboratory, Inc., created the in situ e-beam curing technique, which uses a low-energy electron beam gun to cure various composite materials. One important benefit is the technique's utilization of room temperature curing, which lessens the chance of mismatching the thermal expansion coefficients of different materials. For instance, metals and composites will expand at different rates when heated, but the low-energy e-beam gun reduces the expansion differential. Using a low-energy gun also results in less x-ray shielding, significantly reduced capital costs, reduced facility space, and increased processing capabilities for larger parts. However, using a low-energy gun also means that each tape layer is treated individually because the gun can penetrate only one layer at a time. The e-beam gun emits lower energy x-rays, which are more easily shielded than those emitted by previous guns. The low-energy system is relatively portable due to its light weight and small size. The gun weighs about 70 pounds and can be easily mounted on a robotic arm or an ATP head.

Source record↗

NASA NTRS1987

Expansion of space station diagnostic capability to include serological identification of viral and bacterial infections

It is necessary that an adequate microbiology capability be provided as part of the Health Maintenance Facility (HMF) to support expected microbial disease events during long periods of space flight. The applications of morphological and biochemical studies to confirm the presence of certain bacterial and fungal disease agents are currently available and under consideration. This confirmation would be greatly facilitated through employment of serological methods to aid in the identification for not only bacterial and fungal agents, but viruses as well. A number of serological approached were considered, particularly the use of Enzyme Linked Immunosorbent Assays (ELISAs), which could be utilized during space flight conditions. A solid phase, membrane supported ELISA for the detection of Bordetella pertussis was developed to show a potential model system that would meet the HMF requirements and specifications for the future space station. A second model system for the detection of Legionella pneumophilia, an expected bacterial disease agent, is currently under investigation.

Hejtmancik, Kelly E.↗

NASA NTRS1977

Cryogenic wind-tunnel technology

The cryogenic concept and the advantages it offers with respect to achieving full scale Reynolds number in a moderate size tunnel at reasonable levels of dynamic pressure are described. Aspects which must be considered during the development of a facility that uses gaseous nitrogen as the test gas are examined. These include the properties of nitrogen, particularly at high pressure; isentropic expansion and normal shock flows in nitrogen; real gas ratios; and the problem of condensation. Sources of information on cryogenic technology are cited.

Kilgore, R. A.↗