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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

Development and Integration of a Thermal Management Simulation for a Quadrotor Parallel Hybrid Propulsion System

This paper details the development of a propulsion system simulation for a six-passenger parallel hybrid quadrotor and utilizes the Numerical Propulsion System Simulation (NPSS) along with the NPSS Power System Library as the development environment. This simulation integrates an engine power plant with an electrical generation and distribution system and includes the required thermal management system. The thermal management system is comprised of liquid cooling loops that reject the heat load through air to coolant heat exchangers and utilizes a map-based performance estimation method. This method is developed within NPSS and detailed in this paper. The full system model is designed to predict system weight, range, and performance through a proposed mission profile. Results of the paper show an all-engine system maintains the best range, while a mostly electric system that utilizes an engine as a backup or a conditional power contributor offers range benefit.

Vertical lift and take off vehicle↗

Development and Integration of a Thermal Management Simulation for a Quadrotor Parallel Hybrid Propulsion System

This paper details the development of a propulsion system simulation for a six-passenger parallel hybrid quadrotor and utilizes the Numerical Propulsion System Simulation (NPSS) along with the NPSS Power System Library as the development environment. This simulation integrates an engine power plant with an electrical generation and distribution system and includes the required thermal management system. The thermal management system is comprised of liquid cooling loops that reject the heat load through air to coolant heat exchangers and utilizes a map-based performance estimation method. This method is developed within NPSS and detailed in this paper. The full system model is designed to predict system weight, range, and performance through a proposed mission profile. Results of the paper show an all-engine system maintains the best range, while a mostly electric system that utilizes an engine as a backup or a conditional power contributor offers range benefit.

Vertical lift and take off vehicle↗

Advanced Engineering Environments: Implications for Aerospace Manufacturing

There are significant challenges facing today's aerospace industry. Global competition, more complex products, geographically-distributed design teams, demands for lower cost, higher reliability and safer vehicles, and the need to incorporate the latest technologies quicker all face the developer of aerospace systems. New information technologies offer promising opportunities to develop advanced engineering environments (AEEs) to meet these challenges. Significant advances in the state-of-the-art of aerospace engineering practice are envisioned in the areas of engineering design and analytical tools, cost and risk tools, collaborative engineering, and high-fidelity simulations early in the development cycle. These advances will enable modeling and simulation of manufacturing methods, which will in turn allow manufacturing considerations to be included much earlier in the system development cycle. Significant cost savings, increased quality, and decreased manufacturing cycle time are expected to result. This paper will give an overview of the NASA's Intelligent Synthesis Environment, the agency initiative to develop an AEE, with a focus on the anticipated benefits in aerospace manufacturing.

Thomas, D.↗

NASCAP modelling of high-voltage power system interactions with space charged-particle environments

The NASA Charging Analyzer Program (NASCAP), an engineering tool capable of analyzing the impact of the charged particle environment on spacecraft surfaces and systems, is described. NASCAP is a quasi-static computational program which analyzes the charging of a 3-dimensional complex body as a function of time and system-generated voltages for given space environmental conditions. The material properties of the surfaces are taken into account; the surface potentials, low energy sheath, potential distribution in space and particle trajectories are calculated. An application of NASCAP to a simple space solar power station consisting of two 6 m by 18 m solar array wings surrounding a central body is presented. Each solar array wing is considered to be divided into three regions operating at 2000 volts. Results of NASCAP analysis of the system for a normal environment and a moderate geomagnetic substorm environment are discussed.

Stevens, N. J.↗

Design and specification of a centralized manufacturing data management and scheduling system

As was revealed in a previous study, the Materials and Processes Laboratory's Productivity Enhancement Complex (PEC) has a number of automated production areas/cells that are not effectively integrated, limiting the ability of users to readily share data. The recent decision to utilize the PEC for the fabrication of flight hardware has focused new attention on the problem and brought to light the need for an integrated data management and scheduling system. This report addresses this need by developing preliminary designs specifications for a centralized manufacturing data management and scheduling system for managing flight hardware fabrication in the PEC. This prototype system will be developed under the auspices of the Integrated Engineering Environment (IEE) Oversight team and the IEE Committee. At their recommendation the system specifications were based on the fabrication requirements of the AXAF-S Optical Bench.

Farrington, Phillip A.↗

Demonstrated survivability of a high temperature optical fiber cable on a 1500 pound thrust rocket chamber

A demonstration of the ability of an existing optical fiber cable to survive the harsh environment of a rocket engine was performed at the NASA Lewis Research Center. The intent of this demonstration was to prove the feasibility of applying fiber optic technology to rocket engine instrumentation systems. Extreme thermal transient tests were achieved by wrapping a high temperature optical fiber, which was cablized for mechanical robustness, around the combustion chamber outside wall of a 1500 lb Hydrogen-Oxygen rocket engine. Additionally, the fiber was wrapped around coolant inlet pipes which were subject to near liquid hydrogen temperatures. Light from an LED was sent through the multimode fiber, and output power was monitored as a function of time while the engine was fired. The fiber showed no mechanical damage after 419 firings during which it was subject to transients from 30 K to 350 K, and total exposure time to near liquid hydrogen temperatures in excess of 990 seconds. These extreme temperatures did cause attenuation greater than 3 dB, but the signal was fully recovered at room temperature. This experiment demonstrates that commercially available optical fiber cables can survive the environment seen by a typical rocket engine instrumentation system, and disclose a temperature-dependent attenuation observed during exposure to near liquid hydrogen temperatures.

Sovie, Amy L.↗

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

Zhu, Dongming↗

Multiphase Simulations of the SLS Launch Environment

NASA’s Space Launch System (SLS), which will send astronauts back to the Moon in the next few years, is powered by four RS-25 engines and two RSRMV solid rocket boosters (SRBs). During launch the SLS propulsion system generates intense acoustics and other powerful waves, such as ignition overpressure (IOP) which, if unmitigated, have the potential to damage the vehicle and possibly cause loss of mission or crew. To protect the vehicle from these powerful waves, the SLS launch pad design includes an ignition overpressure/sound suppression (IOP/SS) system which sprays 270,000 gallons per minute of water very close to the SRB and RS-25 nozzles. The SRB and RS-25 engine plumes, and the proximity of the IOP/SS water, create a complex multiphase (gas and liquid) environment during the SLS ignition sequence. The interplay among these systems creates challenges related to water spray into/onto engine nozzles, potential debris transport, and additional transient loads due to strong plume-water interactions - all of which the SLS vehicle must be able to withstand. Prior to the Artemis I launch, the SLS multiphase liftoff environment was largely unknown due to differences from the Space Shuttle and other programs. Some data was available from tests of individual systems, but no integrated testing or analysis was available. Even post-launch analysis of Artemis I cannot provide a full understanding of the complex physics involved due to limited (or obstructed) camera views and instrumentation. Computational fluid dynamics (CFD) is being used to investigate the details of the multiphase environment which could not be measured, help comprehend the data gathered from the launch, and ultimately identify phenomena that are a concern for future flights. Project Details Engineers at NASA’s Marshall Space Flight Center (MSFC) have executed simulations using the Loci/STREAM-Volume of Fluid (VoF) multiphase CFD solver to understand this environment. Initial efforts successfully validated the CFD solver on various tests, giving confidence to simulate the SLS multiphase liftoff environment prior to the Artemis I launch. The CFD simulation of the SLS ignition sequence was conducted in three phases. First the IOP/SS water system was simulated for approximately 6 seconds to reach a quasi-steady state. Next, the RS-25 engine plumes were activated and held at full power for 1 second. Lastly, the SRB booster was activated and the simulation was carried out until just prior to vehicle motion. This simulation process mimics the conditions that exist at launch. Results and Impact The SLS ignition sequence simulation results provide deep understanding of the underlying physics occuring during launch. Observations from the simulation include reduction of water splashing into/onto the engine nozzles, change in angling of the dense water sheets, and the origin of the powerful ignition overpressure (IOP) wave. These observations directly inform the SLS program on subjects including plume-water induced side loads, debris transport, and the acoustic launch environment. Additionally, with post launch comparison of CFD observations to flight data, these tools can be applied to launch vehicles and environments other than SLS with confidence. Why HPC Matters The SLS ignition sequence CFD simulations are conducted on meshes up to hundreds of millions of cells on thousands of processors for weeks at a time. These simulations generate terabytes of data that must also be stored and archived for future use on HPC systems. Simply put, the CFD simulations would not be possible without NASA HPC resources. What’s Next Comparisons between the Artemis I flight data and the CFD simulations will be continued to both improve confidence in the CFD results and provide deeper understanding into the SLS multiphase launch environment. This will be used to provide insight for decision making for the first manned SLS flight, Artemis II. Future simulations will target new configurations of the SLS IOP/SS water required to support the more powerful variants of the SLS vehicle, such as Block 1B. Additionally, this capability provides NASA the ability to investigate launch environments for vehicles other than SLS to support other missions.

Travis Rivord↗

PERTS: A Prototyping Environment for Real-Time Systems

We discuss an ongoing project to build a Prototyping Environment for Real-Time Systems, called PERTS. PERTS is a unique prototyping environment in that it has (1) tools and performance models for the analysis and evaluation of real-time prototype systems, (2) building blocks for flexible real-time programs and the support system software, (3) basic building blocks of distributed and intelligent real time applications, and (4) an execution environment. PERTS will make the recent and future theoretical advances in real-time system design and engineering readily usable to practitioners. In particular, it will provide an environment for the use and evaluation of new design approaches, for experimentation with alternative system building blocks and for the analysis and performance profiling of prototype real-time systems.

Liu, Jane W. S.↗

2021 NE-XF Pathways Internship Student Showcase Presentation

Branch of Fluid Mechanics concern with the mechanics and properties of gases and its application to engineering systems. Applications of Pneumatics in the Aerospace systems: (1) Flight Hardware - Reaction Control, Systems, Rocket Pressure Fed Systems (2) Ground Operations – Valve Actuation, Inert Environment (Purge), Tube Drying/Cleaning NE-XFPneumatics Engineering provides design & operation expertise to support EGS. Commodities used at KSC systems: Gaseous Helium (GHe) Gaseous Oxygen (GO2) Gaseous Nitrogen (GN2) Breathing Air (BAIR) Support other subsystems: LH2, LO2, Ground Main Propulsion System (GMPS), etc.

Environmental and Life Support Systems↗

Development of Advanced Environmental Barrier Coatings for SiC/SiC Composites at NASA GRC: Prime-Reliant Design and Durability Perspectives

Environmental barrier coatings (EBCs) are considered technologically important because of the critical needs and their ability to effectively protect the turbine hot-section SiC/SiC ceramic matrix composite (CMC) components in harsh engine combustion environments. The development of NASA's advanced environmental barrier coatings have been aimed at significantly improved the coating system temperature capability, stability, erosion-impact, and CMAS resistance for SiC/SiC turbine airfoil and combustors component applications. The NASA environmental barrier coating developments have also emphasized thermo-mechanical creep and fatigue resistance in simulated engine heat flux and environments. Experimental results and models for advanced EBC systems will be presented to help establishing advanced EBC composition design methodologies, performance modeling and life predictions, for achieving prime-reliant, durable environmental coating systems for 2700-3000 F engine component applications. Major technical barriers in developing environmental barrier coating systems and the coating integration with next generation composites having further improved temperature capability, environmental stability, EBC-CMC fatigue-environment system durability will be discussed.

Environmental barrier coatings (EBCs)↗

ISEE System Technical Report

The Immersive Simulations and Engineering Environment (ISEE) Laboratory at Kennedy Space Center is a tool used to assist with operation simulation, for Human Factors operation activities, assisting future missions. The simulations created are important because they ensure that simulated operations are performed for customers, to assist with requirements. Simultaneously, each simulation will allow stakeholders to determine any and all risk associated with the Human Factors involved in a specific assignment. My internship consists of multiple project elements. The first of which, was to assist the Integrations branch chief in developing a growth rate algorithm proof. The integral part of this project, involved learning to powerup and perform the operational procedures of the ISEE lab, capturing and creating characters used in the CAD model virtual environment. In doing so, this led to use the software to model and 3D print screw cap structures for mock-up. The structures will be used to manipulate weight change out used in mock-up design and construction. These structures will also be used in future mock-up models constructed in the lab.

Darryl A J Minor↗

NASA Glenn Propulsion Systems Lab (PSL) Icing Facility Update

The NASA Glenn Research Center Propulsion Systems Lab (PSL) was recently upgraded to perform engine inlet ice crystal testing in an altitude environment. The system installed 10 spray bars in the inlet plenum for ice crystal generation using 222 spray nozzles. As an altitude test chamber, PSL is capable of simulation of in-flight icing events in a ground test facility. The system was designed to operate at altitudes from 4,000 ft. to 40,000 ft. at Mach numbers up to 0.8M and inlet total temperatures from -60F to +15F.

Calibrating↗

Benchmarking expert system tools

As part of its evaluation of new technologies, the Artificial Intelligence Section of the Mission Planning and Analysis Div. at NASA-Johnson has made timing tests of several expert system building tools. Among the production systems tested were Automated Reasoning Tool, several versions of OPS5, and CLIPS (C Language Integrated Production System), an expert system builder developed by the AI section. Also included in the test were a Zetalisp version of the benchmark along with four versions of the benchmark written in Knowledge Engineering Environment, an object oriented, frame based expert system tool. The benchmarks used for testing are studied.

Riley, Gary↗

Ares I-X: First Step in a New Era of Exploration

Since 2005, NASA's Constellation Program has been designing, building, and testing the next generation of launch and space vehicles to carry humans beyond low-Earth orbit (LEO). On October 28, 2009, the Ares Projects successfully launched the first suborbital development flight test of the Ares I crew launch vehicle, Ares I-X, from Kennedy Space Center (KSC). Although the final Constellation Program architecture is under review, data and lessons obtained from Ares I-X can be applied to any launch vehicle. This presentation will discuss the mission background and future impacts of the flight. Ares I is designed to carry up to four astronauts to the International Space Station (ISS). It also can be used with the Ares V cargo launch vehicle for a variety of missions beyond LEO. The Ares I-X development flight test was conceived in 2006 to acquire early engineering, operations, and environment data during liftoff, ascent, and first stage recovery. Engineers are using the test flight data to improve the Ares I design before its critical design review the final review before manufacturing of the flight vehicle begins. The Ares I-X flight test vehicle incorporated a mix of flight and mockup hardware, reflecting a similar length and mass to the operational vehicle. It was powered by a four-segment SRB from the Space Shuttle inventory, and was modified to include a fifth, spacer segment that made the booster approximately the same size as the five-segment SRB. The Ares I-X flight closely approximated flight conditions the Ares I will experience through Mach 4.5, performing a first stage separation at an altitude of 125,000 feet and reaching a maximum dynamic pressure ("Max Q") of approximately 850 pounds per square foot. The Ares I-X Mission Management Office (MMO) was organized functionally to address all the major test elements, including: first stage, avionics, and roll control (Marshall Space Flight Center); upper stage simulator (Glenn Research Center); crew module/launch abort system simulator (Langley Research Center); and ground systems and operations (KSC). Interfaces between vehicle elements and vehicle-ground elements, as well as environment analyses were performed by a systems engineering and integration team at Langley. Experience and lessons learned from these integrated product teams area are already being integrated into the Ares Projects to support the next generation of exploration launch vehicles.

Davis, Stephan R.↗

Advanced transportation system studies technical area 3: Alternate propulsion system concepts. SSME upper stage use

The main objective was to determine viable methods for starting the Space Shuttle Main Engine (SSME) in an altitude environment and restarting it in an orbit environment with minimum changes in utilization of the engine system or hardware. The study concluded that the use of the SSME in an upper stage is feasible with minimal changes to the engine systems. The altitude start case requires only a change in the valve sequencing during start and reorificing of the ASI lines. Inlet pressures can be moderately low at 40 psia for the LOX and 32 psia for the H2. The orbital restart case adds the need to recirculate propellant and thermal control paint (to keep the turbomachinery inlets cold to minimize the tank pressures needed), and the need to heat two small components (to maintain acceptable mixture ratios during the early part of the start). These actions allow start anytime after approximately 120 minutes. Earlier starts (approximately one hour) are also possible but would require additional component heating for mixture ratio control during the early portion of the start sequence.

Strangeland, Eric↗

Utilization fo the Satellite Test Assistant Robot (STAR) for Visual and Thermal Analysis for Articles in the Thermal Vacuum Test Environment

An innovative new telerobotic inspection system called STAR has been developed to asist engineers in the visual and thermal analysis fo flight hardware being tested in a simulated space environment. This paper describes the architecture of the STAR mechanical and control systems and discusses some uses of STAR to date.

STAR satellite test assistant robot space simulati↗

Development of Supersonic Retro-Propulsion for Future Mars Entry, Descent, and Landing Systems

Recent studies have concluded that Viking-era entry system technologies are reaching their practical limits and must be succeeded by new methods capable of delivering large payloads (greater than 10 metric tons) required for human exploration of Mars. One such technology, termed Supersonic Retro-Propulsion, has been proposed as an enabling deceleration technique. However, in order to be considered for future NASA flight projects, this technology will require significant maturation beyond its current state. This paper proposes a roadmap for advancing the component technologies to a point where Supersonic Retro-Propulsion can be reliably used on future Mars missions to land much larger payloads than are currently possible using Viking-based systems. The development roadmap includes technology gates that are achieved through testing and/or analysis, culminating with subscale flight tests in Earth atmosphere that demonstrate stable and controlled flight. The component technologies requiring advancement include large engines capable of throttling, computational models for entry vehicle aerodynamic/propulsive force and moment interactions, aerothermodynamic environments modeling, entry vehicle stability and control methods, integrated systems engineering and analyses, and high-fidelity six degree-of-freedom trajectory simulations. Quantifiable metrics are also proposed as a means to gage the technical progress of Supersonic Retro-Propulsion. Finally, an aggressive schedule is proposed for advancing the technology through sub-scale flight tests at Earth by 2016.

Edquist, Karl T.↗