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The engine requirements are emphasized and include: high specific impulse within a restricted installed length constraint, long life, multiple starts, different thrust levels, and man-rated reliability. The engine operating characteristics and the major component analytical design are summarized.
Since 1984 Marshall Space Flight Center was actively engaged in research and development concerning autonomous power systems. Much of the work in this domain has dealt with the development and application of knowledge-based or expert systems to perform tasks previously accomplished only through intensive human involvement. One such task is the health status monitoring of electrical power systems. Such monitoring is a manpower intensive task which is vital to mission success. The Hubble Space Telescope testbed and its associated Nickel Cadmium Battery Expert System (NICBES) were designated as the system on which the initial proof of concept for intelligent power system monitoing will be established. The key function performed by an engineer engaged in system monitoring is to analyze the raw telemetry data and identify from the whole only those elements which can be considered significant. This function requires engineering expertise on the functionality of the system, the mode of operation and the efficient and effective reading of the telemetry data. Application of this expertise to extract the significant components of the data is referred to as data reduction. Such a function possesses characteristics which make it a prime candidate for the application of knowledge-based systems' technologies. Such applications are investigated and recommendations are offered for the development of intelligent data reduction systems.
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.
Sustainable human presence in extreme environments such as lunar and martian bases will require bioregenerative components to human life support systems where plants are used for generation of oxygen, food, and water. Reduced atmospheric pressures will be used to minimize mass and engineering requirements. Few studies have assessed the metabolic and developmental responses of plants to reduced pressure and varied oxygen atmospheres. The first tests of hypobaric pressures on plant gas exchange and biomass production at the Johnson Space Center will be initiated in January 1996 in the Variable Pressure Growth Chamber (VPGC), a large, closed plant growth chamber rated for 10.2 psi. Experiments were designed and protocols detailed for two complete growouts each of lettuce and wheat to generate a general database for human life support requirements and to answer questions about plant growth processes in reduced pressure and varied oxygen environments. The central objective of crop growth studies in the VPGC is to determine the influence of reduced pressure and reduced oxygen on the rates of photosynthesis, dark respiration, evapotranspiration and biomass production of lettuce and wheat. Due to the constraint of one experimental unit, internal controls, called pressure transients, will be used to evaluate rates of CO2 uptake, O2 evolution, and H2O generation. Pressure transients will give interpretive power to the results of repeated growouts at both reduced and ambient pressures. Other experiments involve the generation of response functions to partial pressures of O2 and CO2 and to light intensity. Protocol for determining and calculating rates of gas exchange have been detailed. In order to build these databases and implement the necessary treatment combinations in short time periods, specific requirements for gas injections and removals have been defined. A set of system capability checks will include determination of leakage rates conducted prior to the actual crop growouts. Schedules of experimental events for lettuce and wheat are outlined and include replications in time of diurnal routines, pressure transients, variable pO2, pO2/pCO2 ratio, and light intensity responses.
Using virtual environments to assess complex large scale human tasks provides timely and cost effective results to evaluate designs and to reduce operational risks during assembly and integration of the Space Launch System (SLS). NASA's Marshall Space Flight Center (MSFC) uses a suite of tools to conduct integrated virtual analysis during the design phase of the SLS Program. Siemens Jack is a simulation tool that allows engineers to analyze human interaction with CAD designs by placing a digital human model into the environment to test different scenarios and assess the design's compliance to human factors requirements. Engineers at MSFC are using Jack in conjunction with motion capture and virtual reality systems in MSFC's Virtual Environments Lab (VEL). The VEL provides additional capability beyond standalone Jack to record and analyze a person performing a planned task to assemble the SLS at Kennedy Space Center (KSC). The VEL integrates Vicon Blade motion capture system, Siemens Jack, Oculus Rift, and other virtual tools to perform human factors assessments. By using motion capture and virtual reality, a more accurate breakdown and understanding of how an operator will perform a task can be gained. By virtual analysis, engineers are able to determine if a specific task is capable of being safely performed by both a 5% (approx. 5ft) female and a 95% (approx. 6'1) male. In addition, the analysis will help identify any tools or other accommodations that may to help complete the task. These assessments are critical for the safety of ground support engineers and keeping launch operations on schedule. Motion capture allows engineers to save and examine human movements on a frame by frame basis, while virtual reality gives the actor (person performing a task in the VEL) an immersive view of the task environment. This presentation will discuss the need of human factors for SLS and the benefits of analyzing tasks in NASA MSFC's VEL.
In FY11, NASA formulated a plan for Nuclear Thermal Propulsion (NTP) development that included Foundational Technology Development followed by system-level Technology Demonstrations The ongoing NTP project, funded by NASAs Advanced Exploration Systems (AES) program, is focused on Foundational Technology Development and includes 5 key task activities:(1) Fuel element fabrication and non-nuclear validation testing of heritage fuel options;(2) Engine conceptual design;(3) Mission analysis and engine requirements definition;(4) Identification of affordable options for ground testing; and(5) Formulation of an affordable and sustainable NTP development program Performance parameters for Point of Departure designs for a small criticality-limited and full size 25 klbf-class engine were developed during FYs 13-14 using heritage fuel element designs for both RoverNERVA Graphite Composite (GC) and Ceramic Metal (Cermet) fuel forms To focus the fuel development effort and maximize use of its resources, the AES program decided, in FY14, that a leader-follower down selection between GC and cermet fuel was required An Independent Review Panel (IRP) was convened by NASA and tasked with reviewing the available fuel data and making a recommendation to NASA. In February 2015, the IRP recommended and the AES program endorsed GC as the leader fuel In FY14, a preliminary development schedule DDTE plan was produced by GRC, DOE industry for the AES program. Assumptions, considerations and key task activities are presented here Two small (7.5 and 16.5 klbf) engine sizes were considered for ground and flight technology demonstration within a 10-year timeframe; their ability to support future human exploration missions was also examined and a recommendation on a preferred size is provided.
Health management (HM) technologies have been employed for safety critical system for decades, but a coherent systematic process to integrate HM into the system design is not yet clear. Consequently, in most cases, health management resorts to be an after-thought or 'band-aid' solution. Moreover, limited guidance exists for carrying out systems engineering (SE) on the subject of writing requirements for designs with integrated vehicle health management (IVHM). It is well accepted that requirements are key to developing a successful IVHM system right from the concept stage to development, verification, utilization, and support. However, writing requirements for systems with IVHM capability have unique challenges that require the designers to look beyond their own domains and consider the constraints and specifications of other interlinked systems. In this paper we look at various stages in the SE process and identify activities specific to IVHM design and development. More importantly, several relevant questions are posed that system engineers must address at various design and development stages. Addressing these questions should provide some guidance to systems engineers towards writing IVHM related requirements to ensure that appropriate IVHM functions are built into the system design.
This paper proposes an evolutionary approach for inspection planning which introduces various reliability engineering tools into the process and assess system trade-offs among reliability, engineering requirement, manufacturing capability and inspection cost to establish an optimal inspection plan. The examples presented in the paper illustrate some advantages and benefits of the new approach. Through the analysis, reliability and engineering impacts due to manufacturing process capability and inspection uncertainty are clearly understood; the most cost effective and efficient inspection plan can be established and associated risks are well controlled; some inspection reductions and relaxations are well justified; and design feedbacks and changes may be initiated from the analysis conclusion to further enhance reliability and reduce cost. The approach is particularly promising as global competitions and customer quality improvement expectations are rapidly increasing.
Project Managers often face challenging technical, schedule and budget issues. This presentation will explore how the Ares I-X Roll Control System Integrated Product Team (IPT) mitigated challenges such as concurrent engineering requirements and environments and evolving program processes, while successfully managing an aggressive project schedule and tight budget. IPT challenges also included communications and negotiations among inter- and intra-government agencies, including the US Air Force, NASA/MSFC Propulsion Engineering, LaRC, GRC, KSC, WSTF, and the Constellation Program. In order to successfully meet these challenges it was essential that the IPT define those items that most affected the schedule critical path, define early mitigation strategies to reduce technical, schedule, and budget risks, and maintain the end-product focus of an "unmanned test flight" context for the flight hardware. The makeup of the IPT and how it would function were also important considerations. The IPT consisted of NASA/MSFC (project management, engineering, and safety/quality) and contractors (Teledyne Brown Engineering and Pratt and Whitney Rocketdyne, who supplied heritage hardware experience). The early decision to have a small focused IPT working "badgelessly" across functional lines to eliminate functional stove-piping allowed for many more tasks to be done by fewer people. It also enhanced a sense of ownership of the products, while still being able to revert back to traditional roles in order to provide the required technical independence in design reviews and verification closures. This presentation will highlight several prominent issues and discuss how they were mitigated and the resulting Lessons Learned that might benefit other projects.
In FY11, NASA formulated a plan for Nuclear Thermal Propulsion (NTP) development that included Foundational Technology Development followed by system-level Technology Demonstrations. The ongoing NTP project, funded by NASA's Advanced Exploration Systems (AES) program, is focused on Foundational Technology Development and includes 5 key task activities: (1) Fuel element fabrication and non-nuclear validation testing of heritage fuel options; (2) Engine conceptual design; (3) Mission analysis and engine requirements definition; (4) Identification of affordable options for ground testing; and (5) Formulation of an affordable and sustainable NTP development program. Performance parameters for Point of Departure designs for a small criticality-limited and full size 25 klb (sub f) (kip, or 1000 pound-force)-class engine were developed during FYs 13-14 using heritage fuel element designs for both Rover NERVA (Nuclear Engine for Rocket Vehicle Applications) Graphite Composite (GC) and Ceramic Metal (Cermet) fuel forms. To focus the fuel development effort and maximize use of its resources, the AES program decided, in FY14, that a leader-follower down-selection between GC and cermet fuel was required. An Independent Review Panel (IRP) was convened by NASA and tasked with reviewing the available fuel data and making a recommendation to NASA. In February 2015, the IRP recommended and the AES program endorsed GC as the leader fuel In FY14, a preliminary development schedule DDTE (Design Development Test and Evaluation) plan was produced by GRC (Glenn Research Center), DOE (Department of Energy) and industry for the AES program. Assumptions, considerations and key task activities are presented here. At the direction of NASA HQ (32515), NASA and DOE are to work together to formulate a detailed development plan and schedule allowing the affordable development of a small (7.5-16.5 klbf) GC engine for possible flight technology demonstration (FTD) mission within a 10-year timeframe.
Spectral characterizations were made of the Ocean Color Instrument (OCI) short-wave infrared (SWIR) Detection Subassembly (SDS) responses (940–2260 nm) prior to their integration. Using modulated output light from a Fourier transform spectrometer, the in-band relative spectral responses of the nine different configurations of SDSs were found along with out-of-band (OOB) sensitivity. From these spectral responses, the center wavelengths (λ0), full widths at half of the maximum, full widths at 1% of the maximum, and OOB rejection ratios were determined. All spectral parameters are within requirements. There are 2–8 repeats of each configuration, and the 1 σ spread among repeats is largest for the 1250 nm and 1615 nm high-gain configurations and is greater than 1 nm. The engineering requirement is for these values to be within ±4 nm and ±10 nm, respectively, of 19 the nominal λ0. There is also a λ0 temperature dependence, which is expected. This temperature dependence is nearly a linear function of wavelength with a 9.5 × 10−3 nm K−1 relationship on average.
Prototype expert systems developed for a variety of NASA projects in the business/management and engineering domains are discussed. Business-related problems addressed include an assistant for simulating launch vehicle processing, a plan advisor for the acquisition of automated data processing equipment, and an expert system for the identification of customer requirements. Engineering problems treated include an expert system for detecting potential ignition sources in LOX and gaseous-oxygen transportation systems and an expert system for hazardous-gas detection.
In order to optimize systems, systems engineers require some sort of measure with which to compare vastly different system components. One such measure is system exergy, or the usable system work. Exergy balance analysis models provide a comparison of different system configurations, allowing systems engineers to compare different systems configuration options. This paper presents the exergy efficiency of several Mars transportation system configurations, using data on the interplanetary trajectory, engine performance, and vehicle mass. The importance of the starting and final parking orbits is addressed in the analysis, as well as intermediate hyperbolic escape and entry orbits within Earth and Mars' spheres of influence (SOIs). Propulsion systems analyzed include low-enriched uranium (LEU) nuclear thermal propulsion (NTP), high-enriched uranium (HEU) NTP, LEU methane (CH4) NTP, and liquid oxygen (LOX)/liquid hydrogen (LH2) chemical propulsion.
In order to optimize systems, systems engineers require some sort of measure with which to compare vastly different system components. One such measure is system exergy, or the usable system work. Exergy balance analysis models provide a comparison of different system configurations, allowing systems engineers to compare different systems configuration options. This paper presents the exergy efficiency of several Mars transportation system configurations, using data on the interplanetary trajectory, engine performance, and vehicle mass. The importance of the starting and final parking orbits is addressed in the analysis, as well as intermediate hyperbolic escape and entry orbits within Earth and Mars' spheres of influence (SOIs). Propulsion systems analyzed include low-enriched uranium (LEU) nuclear thermal propulsion (NTP), high-enriched uranium (HEU) NTP, LEU methane (CH4) NTP, and liquid oxygen (LOX)/liquid hydrogen (LH2) chemical propulsion.
In order to optimize systems, systems engineers require some sort of measure with which to compare vastly different system components. One such measure is system exergy, or the usable system work. Exergy balance analysis models provide a comparison of different system configurations, allowing systems engineers to compare different systems configuration options. This paper presents the exergy efficiency of several Mars transportation system configurations, using data on the interplanetary trajectory, engine performance, and vehicle mass. The importance of the starting and final parking orbits is addressed in the analysis, as well as intermediate hyperbolic escape and entry orbits within Earth and Mars' spheres of influence (SOIs). Propulsion systems analyzed include low-enriched uranium (LEU) nuclear thermal propulsion (NTP), high-enriched uranium (HEU) NTP, LEU methane (CH4) NTP, and liquid oxygen (LOX)/liquid hydrogen (LH2) chemical propulsion.
Steady-state testing of advanced, multimegawatt MPD engines requires vacuum facilities with pumping speeds which are not presently available. Gas dynamic diffusers have been proposed as a possible solution to this problem. An analytical investigation into the feasibility of using a diffuser for pumping the MPD engine exhaust is presented here. This analysis uses a detailed equation of state based on the partition function for the high temperature argon exhaust. On the basis of the electron-ion momentum exchange collision frequency in the exhaust plasma, it was concluded that the diffuser gas dynamics could be modeled to a first approximation with ordinary continuum equations. Calculations of the stagnation pressure in the diffuser, downstream of a strong normal shock, yielded pressures on the order of 10 torr suggesting that the diffuser is feasible for pumping the MPD engine exhaust.
Space Station program office planning and requirements activity has accelerated during the past year to bring the Space Station Freedom Program (SSF) through the program requirements review phase during 1988. The preliminary design review cycle began in Jan. 89, and is now planned for completion, with formal preliminary design reviews between Apr. and Sept., 1990. This paper briefly describes the PROGRAMMATIC aspects of the engineering and integration management of the SSF crew systems. Emphasis is given to the Crew Health Care System, which includes the Health Maintenance Facility, the Exercise Countermeasure Facility, and the Environmental Health System; all managed within the Man-Systems, one of the twelve 'distributed systems.' Medical and engineering requirements to meet the needs of the mature Space Station operations environment and highlights of critical technologies and equipment in development will be reviewed.
The use of ceramic materials in the hot section of the fuel turbopump of advanced reusable rocket engines promises increased performance and payload capability, improved component life and economics, and greater design flexibility. Severe thermal transients present during operation of the Space Shuttle Main Engine (SSME), push metallic components to the limit of their capabilities. Future engine requirements might be even more severe. In phase one of this two-phase program, performance benefits were quantified and continuous fiber reinforced ceramic matrix composite components demonstrated a potential to survive the hostile environment of an advanced rocket engine turbopump.