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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

Structural design methodologies for ceramic-based material systems

One of the primary pacing items for realizing the full potential of ceramic-based structural components is the development of new design methods and protocols. The focus here is on low temperature, fast-fracture analysis of monolithic, whisker-toughened, laminated, and woven ceramic composites. A number of design models and criteria are highlighted. Public domain computer algorithms, which aid engineers in predicting the fast-fracture reliability of structural components, are mentioned. Emphasis is not placed on evaluating the models, but instead is focused on the issues relevant to the current state of the art.

Duffy, Stephen F.↗

Computer Program Re-layers Engineering Drawings

RULCHK computer program aids in structuring layers of information pertaining to part or assembly designed with software described in article "Software for Drawing Design Details Concurrently" (MFS-28444). Checks and optionally updates structure of layers for part. Enables designer to construct model and annotate its documentation without burden of manually layering part to conform to standards at design time.

Crosby, Dewey C., III↗

IPAD project overview

To respond to national needs for improved productivity in engineering design and manufacturing, a NASA supported joint industry/government project is underway denoted Integrated Programs for Aerospace-Vehicle Design (IPAD). The objective is to improve engineering productivity through better use of computer technology. It focuses on development of technology and associated software for integrated company-wide management of engineering information. The project has been underway since 1976 under the guidance of an Industry Technical Advisory Board (ITAB) composed of representatives of major engineering and computer companies and in close collaboration with the Air Force Integrated Computer-Aided Manufacturing (ICAM) program. Results to date on the IPAD project include an in-depth documentation of a representative design process for a large engineering project, the definition and design of computer-aided design software needed to support that process, and the release of prototype software to integrate selected design functions. Ongoing work concentrates on development of prototype software to manage engineering information, and initial software is nearing release.

Fulton, R. E.↗

An automated procedure for developing hybrid computer simulations of turbofan engines

This paper offers a systematic, computer-aided, self-documenting methodology for developing hybrid computer simulations of turbofan engines. The methodology that is presented makes use of a host program that can run on a large digital computer and a machine-dependent target (hybrid) program. The host program performs all of the calculations and data manipulations that are needed to transform user-supplied engine design information to a form suitable for the hybrid computer. The host program also trims the self-contained engine model to match specified design point information. A test case is described and comparisons between hybrid simulation and specified engine performance data are presented.

Szuch, J. R.↗

Design of Object-Oriented Distributed Simulation Classes

Distributed simulation of aircraft engines as part of a computer aided design package being developed by NASA Lewis Research Center for the aircraft industry. The project is called NPSS, an acronym for "Numerical Propulsion Simulation System". NPSS is a flexible object-oriented simulation of aircraft engines requiring high computing speed. It is desirable to run the simulation on a distributed computer system with multiple processors executing portions of the simulation in parallel. The purpose of this research was to investigate object-oriented structures such that individual objects could be distributed. The set of classes used in the simulation must be designed to facilitate parallel computation. Since the portions of the simulation carried out in parallel are not independent of one another, there is the need for communication among the parallel executing processors which in turn implies need for their synchronization. Communication and synchronization can lead to decreased throughput as parallel processors wait for data or synchronization signals from other processors. As a result of this research, the following have been accomplished. The design and implementation of a set of simulation classes which result in a distributed simulation control program have been completed. The design is based upon MIT "Actor" model of a concurrent object and uses "connectors" to structure dynamic connections between simulation components. Connectors may be dynamically created according to the distribution of objects among machines at execution time without any programming changes. Measurements of the basic performance have been carried out with the result that communication overhead of the distributed design is swamped by the computation time of modules unless modules have very short execution times per iteration or time step. An analytical performance model based upon queuing network theory has been designed and implemented. Its application to realistic configurations has not been carried out.

Schoeffler, James D.↗

Design of object-oriented distributed simulation classes

Distributed simulation of aircraft engines as part of a computer aided design package is being developed by NASA Lewis Research Center for the aircraft industry. The project is called NPSS, an acronym for 'Numerical Propulsion Simulation System'. NPSS is a flexible object-oriented simulation of aircraft engines requiring high computing speed. It is desirable to run the simulation on a distributed computer system with multiple processors executing portions of the simulation in parallel. The purpose of this research was to investigate object-oriented structures such that individual objects could be distributed. The set of classes used in the simulation must be designed to facilitate parallel computation. Since the portions of the simulation carried out in parallel are not independent of one another, there is the need for communication among the parallel executing processors which in turn implies need for their synchronization. Communication and synchronization can lead to decreased throughput as parallel processors wait for data or synchronization signals from other processors. As a result of this research, the following have been accomplished. The design and implementation of a set of simulation classes which result in a distributed simulation control program have been completed. The design is based upon MIT 'Actor' model of a concurrent object and uses 'connectors' to structure dynamic connections between simulation components. Connectors may be dynamically created according to the distribution of objects among machines at execution time without any programming changes. Measurements of the basic performance have been carried out with the result that communication overhead of the distributed design is swamped by the computation time of modules unless modules have very short execution times per iteration or time step. An analytical performance model based upon queuing network theory has been designed and implemented. Its application to realistic configurations has not been carried out.

Schoeffler, James D.↗

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold rolling material and Ti-6A1-4V and Inconel 718 were selected as typical hot rolling and cold rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape rolling process were developed. These models utilized the upper bound and the slab methods of analysis, and were capable of predicting the lateral spread, roll separating force, roll torque, and local stresses, strains and strain rates. This computer-aided design system was also capable of simulating the actual rolling process, and thereby designing the roll pass schedule in rolling of an airfoil or a similar shape.

Lahoti, G. D.↗

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold-rolling material and Ti-6Al-4V and INCONEL 718 were selected as typical hot-rolling and cold-rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape-rolling process were developed. These models utilize the upper-bound and the slab methods of analysis, and are capable of predicting the lateral spread, roll-separating force, roll torque and local stresses, strains and strain rates. This computer-aided design (CAD) system is also capable of simulating the actual rolling process and thereby designing roll-pass schedule in rolling of an airfoil or similar shape. The predictions from the CAD system were verified with respect to cold rolling of mild steel plates. The system is being applied to cold and hot isothermal rolling of an airfoil shape, and will be verified with respect to laboratory experiments under controlled conditions.

Lahoti, G. D.↗

The Prediction of Nozzle Performance and Heat Transfer in Hydrogen/Oxygen Rocket Engines with Transpiration Cooling, Film Cooling, and High Area Ratios

An advanced engineering computational model has been developed to aid in the analysis of chemical rocket engines. The complete multispecies, chemically reacting and diffusing Navier-Stokes equations are modelled, including the Soret thermal diffusion and Dufour energy transfer terms. Demonstration cases are presented for a 1030:1 area ratio nozzle, a 25 lbf film-cooled nozzle, and a transpiration-cooled plug-and-spool rocket engine. The results indicate that the thrust coefficient predictions of the 1030:1 nozzle and the film-cooled nozzle are within 0.2 to 0.5 percent, respectively, of experimental measurements. Further, the model's predictions agree very well with the heat transfer measurements made in all of the nozzle test cases. It is demonstrated that thermal diffusion has a significant effect on the predicted mass fraction of hydrogen along the wall of the nozzle and was shown to represent a significant fraction of the diffusion fluxes occurring in the transpiration-cooled rocket engine.

Kacynski, Kenneth J.↗

Feasibility of Actively Cooled Silicon Nitride Airfoil for Turbine Applications Demonstrated

Nickel-base superalloys currently limit gas turbine engine performance. Active cooling has extended the temperature range of service of nickel-base superalloys in current gas turbine engines, but the margin for further improvement appears modest. Therefore, significant advancements in materials technology are needed to raise turbine inlet temperatures above 2400 F to increase engine specific thrust and operating efficiency. Because of their low density and high-temperature strength and thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, the high processing costs and low impact resistance of silicon nitride ceramics have proven to be major obstacles for widespread applications. Advanced rapid prototyping technology in combination with conventional gel casting and sintering can reduce high processing costs and may offer an affordable manufacturing approach. Researchers at the NASA Glenn Research Center, in cooperation with a local university and an aerospace company, are developing actively cooled and functionally graded ceramic structures. The objective of this program is to develop cost-effective manufacturing technology and experimental and analytical capabilities for environmentally stable, aerodynamically efficient, foreign-object-damage-resistant, in situ toughened silicon nitride turbine nozzle vanes, and to test these vanes under simulated engine conditions. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. With cooling, the surface temperature decreased to approximately 1910 F--a drop of approximately 440 F. This preliminary study demonstrates that a near-net-shape silicon nitride airfoil can be fabricated and that silicon nitride can sustain severe thermal shock and the thermal gradients induced by cooling and, thus, is a viable candidate for cooled components.

Bhatt, Ramakrishna T.↗

Computing Q-D Relationships for Storage of Rocket Fuels

The Quantity Distance Measurement Tool is a GIS BASEP computer program that aids safety engineers by calculating quantity-distance (Q-D) relationships for vessels that contain explosive chemicals used in testing rocket engines. (Q-D relationships are standard relationships between specified quantities of specified explosive materials and minimum distances by which they must be separated from persons, objects, and other explosives to obtain specified types and degrees of protection.) The program uses customized geographic-information-system (GIS) software and calculates Q-D relationships in accordance with NASA's Safety Standard For Explosives, Propellants, and Pyrotechnics. Displays generated by the program enable the identification of hazards, showing the relationships of propellant-storage-vessel safety buffers to inhabited facilities and public roads. Current Q-D information is calculated and maintained in graphical form for all vessels that contain propellants or other chemicals, the explosiveness of which is expressed in TNT equivalents [amounts of trinitrotoluene (TNT) having equivalent explosive effects]. The program is useful in the acquisition, siting, construction, and/or modification of storage vessels and other facilities in the development of an improved test-facility safety program.

Jester, Keith↗

Automated procedure for developing hybrid computer simulations of turbofan engines. Part 1: General description

A systematic, computer-aided, self-documenting methodology for developing hybrid computer simulations of turbofan engines is presented. The methodology that is pesented makes use of a host program that can run on a large digital computer and a machine-dependent target (hybrid) program. The host program performs all the calculations and data manipulations that are needed to transform user-supplied engine design information to a form suitable for the hybrid computer. The host program also trims the self-contained engine model to match specified design-point information. Part I contains a general discussion of the methodology, describes a test case, and presents comparisons between hybrid simulation and specified engine performance data. Part II, a companion document, contains documentation, in the form of computer printouts, for the test case.

Szuch, J. R.↗

The prediction of nozzle performance and heat transfer in hydrogen/oxygen rocket engines with transpiration cooling, film cooling, and high area ratios

An advanced engineering computational model has been developed to aid in the analysis and design of hydrogen/oxygen chemical rocket engines. The complete multi-species, chemically reacting and diffusing Navier-Stokes equations are modelled, finite difference approach that is tailored to be conservative in an axisymmetric coordinate system for both the inviscid and viscous terms. Demonstration cases are presented for a 1030:1 area ratio nozzle, a 25 lbf film cooled nozzle, and transpiration cooled plug-and-spool rocket engine. The results indicate that the thrust coefficient predictions of the 1030:1 nozzle and the film cooled nozzle are within 0.2 to 0.5 percent, respectively, of experimental measurements when all of the chemical reaction and diffusion terms are considered. Further, the model's predictions agree very well with the heat transfer measurements made in all of the nozzle test cases. The Soret thermal diffusion term is demonstrated to have a significant effect on the predicted mass fraction of hydrogen along the wall of the nozzle in both the laminar flow 1030:1 nozzle and the turbulent plug-and-spool rocket engine analysis cases performed. Further, the Soret term was shown to represent a significant fraction of the diffusion fluxes occurring in the transpiration cooled rocket engine.

Kacynski, Kenneth J.↗

True Concurrent Thermal Engineering Integrating CAD Model Building with Finite Element and Finite Difference Methods

Thermal engineering has long been left out of the concurrent engineering environment dominated by CAD (computer aided design) and FEM (finite element method) software. Current tools attempt to force the thermal design process into an environment primarily created to support structural analysis, which results in inappropriate thermal models. As a result, many thermal engineers either build models "by hand" or use geometric user interfaces that are separate from and have little useful connection, if any, to CAD and FEM systems. This paper describes the development of a new thermal design environment called the Thermal Desktop. This system, while fully integrated into a neutral, low cost CAD system, and which utilizes both FEM and FD methods, does not compromise the needs of the thermal engineer. Rather, the features needed for concurrent thermal analysis are specifically addressed by combining traditional parametric surface based radiation and FD based conduction modeling with CAD and FEM methods. The use of flexible and familiar temperature solvers such as SINDA/FLUINT (Systems Improved Numerical Differencing Analyzer/Fluid Integrator) is retained.

Panczak, Tim↗

Genesis Solar Wind – Capture, Return, Curate and Analyze: Looking Backward and Creating a Timeline

Introduction: In 1997 NASA’S Discovery Program selected the Genesis mission proposal to return solar wind samples to Earth for laboratory analyses. Principal Investigator Donald S. Burnett and the science team defined the purity of collector materials and ability to analyze solar wind composition to the precision required for planetary science. As a small mission, focused on a well-defined science goal, yet needing careful attention to engineering details, the communication among scientists and engineers, nurtured by Don Burnett, was exceptional. Genesis Mission and Curation Legacy: Genesis, as the first U. S. spacecraft to return astromaterial samples since Apollo, not only integrated the mission planning and flight teams, but also the science and sample curation teams during the mission development period. Since Genesis is a sample return mission, the Science Team was essential in certifying the collectors (sample containers for solar atoms). From inception, Genesis established mission funding for returned sample curation. JSC was lead in contamination control during mission preparation, including establishment of an ISO 4 cleanroom facility and use of ultrapure water (UPW) for cleaning flight hardware (and, as it turned out, for cleaning collectors after the mishap). Reliable, fast communication among scientists, engineers and curators at the hands-on level established deep respect among team members and efficient decision-making. JSC’s 50-years of astromaterial sample curation provided experienced sample processors onsite during recovery in Utah (a deep bench for emergency response). Post-recovery curation included iterative collaboration with science sample users to clean or verify cleanliness of samples. The science legacy from Genesis is addressed by Burnett and Jurewicz, this volume. In The Beginning: After Apollo sample return, Burnett and Marcia Neugebauer at JPL began discussing a solar wind sample return, with Neugebauer arguing that separate collection of solar wind regimes was essential science. By 1992 a solar wind sample return mission was presented at a workshop, and by 1994 a mission was proposed named Suess-Urey. The mission was re-proposed under a new name GENESIS and selected in 1997. Susan Niebur captured the Genesis mission history and stories, from high level management documents and from many interviews with participants [2]. Her account lets readers glimpse personality of participants in quotations from interviews. Need and Scope for Detailed Technical Timeline: A timeline constructed from lower level task documents has been initiated to document the resources and skills actually used, as well as task sequence or concurrency. Timelines for high level mission events are captured in two documents [1] [2] and for detailed re-entry events in [3]. A detailed technical timeline for Genesis mission and curation activities will provide data points for lower level tasks, such as ISO 4 curation facility construction time, preparation for nominal sample field recovery, mishap recovery, and UPW expansion. Changes in technology context 1990-2024: Semiconductor technologies were easily accessible in the U.S.A. (1990-1999), and the Genesis team used those resources for cleanroom design and UPW system expansion. Image documentation was changing from film to digital during cleanroom construction and payload cleaning (1997-2001). Engineering design was done using computer aided design proprietary software, making more difficult the archiving of payload configuration and materials. Email of documents, tracked delivery service and virtual meeting capability greatly improved communication efficiency. Information sources – Pre-launch mission preparation: Examples of mission science, engineering and contamination control are collector purity testing, payload design/fabrication and ISO 4 cleanroom construction. Information on timing of these activities comes from facility readiness reviews, management reviews, shipping documents, procurement documents, test reports, travel documents, laboratory logs, Quality Assurance documents, dates on images, participant notebooks and emails. Information sources – Sample return re-entry and field recovery activities: Information comes from event timelines produced by Mid-Air Recovery team, Lockheed team lead notes and from chase video, JPL Quality Assurance. Information also comes from images and logbooks from UTTR cleanroom operations and from curatorial documents. Information sources – Resulting science and sample cleaning processes: Agendas from the annual gatherings of the science team initially trace testing for collector purity/cleanliness, and after sample recovery, include collector cleaning and cleanliness assessment. Post-recovery documents include curatorial orders and procedures, sample allocation documents and LPSC abstracts. Timeline Objectives: A simple spreadsheet timeline with headers DATE, EVENT, PEOPLE, COMMENT, INFORMATION SOURCE has been initiated and currently has over 90 entries. While this is not definitive historical research, it is a quick look at the evolution of Genesis curation with pointers to documents or people with information. Engineers for future missions may find useful points of comparison for development of facilities. References:[1] Genesis Mission Reference Document, (2011) JPL D-62382.[2] Niebur S. M., edited by Brown D. W. (2023) NASA’s Discovery Program: The First 20 Years of Competitive Planetary Exploration, NASA-SP-2023-4238.[3] Genesis Mishap Investigation Board Report, Vol. 1 (July 2005).

solar wind↗

Computer Code Aids Design Of Wings

AERO2S computer code developed to aid design engineers in selection and evaluation of aerodynamically efficient wing/canard and wing/horizontal-tail configurations that includes simple hinged-flap systems. Code rapidly estimates longitudinal aerodynamic characteristics of conceptual airplane lifting-surface arrangements. Developed in FORTRAN V on CDC 6000 computer system, and ported to MS-DOS environment.

Carlson, Harry W.↗