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NASA NTRS2000

ACTS Ka-Band Earth Stations: Technology, Performance, and Lessons Learned

The Advanced Communications Technology Satellite (ACTS) Project invested heavily in prototype Ka-band satellite ground terminals to conduct an experiments program with the ACTS satellite. The ACTS experiment's program proposed to validate Ka-band satellite and ground station technology. demonstrate future telecommunication services. demonstrate commercial viability and market acceptability of these new services, evaluate system networking and processing technology, and characterize Ka-band propagation effects, including development of techniques to mitigate signal fading. This paper will present a summary of the fixed ground terminals developed by the NASA Glenn Research Center and its industry partners, emphasizing the technology and performance of the terminals (Part 1) and the lessons learned throughout their six year operation including the inclined orbit phase of operations (Full Report). An overview of the Ka-band technology and components developed for the ACTS ground stations is presented. Next. the performance of the ground station technology and its evolution during the ACTS campaign are discussed to illustrate the technical tradeoffs made during the program and highlight technical advances by industry to support the ACTS experiments program and terminal operations. Finally. lessons learned during development and operation of the user terminals are discussed for consideration of commercial adoption into future Ka-band systems. The fixed ground stations used for experiments by government, academic, and commercial entities used reflector based offset-fed antenna systems ranging in size from 0.35m to 3.4m antenna diameter. Gateway earth stations included two systems, referred to as the NASA Ground Station (NGS) and the Link Evaluation Terminal (LET). The NGS provides tracking, telemetry, and control (TT&C) and Time Division Multiple Access (TDMA) network control functions. The LET supports technology verification and high data rate experiments. The ground stations successfully demonstrated many services and applications at Ka-band in three different modes of operation: circuit switched TDMA using the satellite on-board processor, satellite switched SS-TDMA applications using the on-board Microwave Switch Matrix (MSM), and conventional transponder (bent-pipe) operation. Data rates ranged from 4.8 kbps up to 622 Mbps. Experiments included: 1) low rate (4.8- 1 00's kbps) remote data acquisition and control using small earth stations, 2) moderate rate (1-45 Mbps) experiments included full duplex voice and video conferencing and both full duplex and asymmetric data rate protocol and network evaluation using mid-size ground stations, and 3) link characterization experiments and high data rate (155-622 Mbps) terrestrial and satellite interoperability application experiments conducted by a consortium of experimenters using the large transportable ground stations.

Reinhart, Richard C.↗

NASA NTRS1994

Integration and test of high-speed transmitter electronics for free-space laser communications

The NASA Lewis Research Center in Cleveland, Ohio, has developed the electronics for a free-space, direct-detection laser communications system demonstration. Under the High-Speed Laser Integrated Terminal Electronics (Hi-LITE) Project, NASA Lewis has built a prototype full-duplex, dual-channel electronics transmitter and receiver operating at 325 megabit S per second (Mbps) per channel and using quaternary pulse-position modulation (QPPM). This paper describes the integration and testing of the transmitter portion for future application in free-space, direct-detection laser communications. A companion paper reviews the receiver portion of the prototype electronics. Minor modifications to the transmitter were made since the initial report on the entire system, and this paper addresses them. The digital electronics are implemented in gallium arsenide integrated circuits mounted on prototype boards. The fabrication and implementation issues related to these high-speed devices are discussed. The transmitter's test results are documented, and its functionality is verified by exercising all modes of operation. Various testing issues pertaining to high-speed circuits are addressed. A description of the transmitter electronics packaging concludes the paper.

Soni, Nitin J.↗

NASA NTRS2011

External-Compression Supersonic Inlet Design Code

A computer code named SUPIN has been developed to perform aerodynamic design and analysis of external-compression, supersonic inlets. The baseline set of inlets include axisymmetric pitot, two-dimensional single-duct, axisymmetric outward-turning, and two-dimensional bifurcated-duct inlets. The aerodynamic methods are based on low-fidelity analytical and numerical procedures. The geometric methods are based on planar geometry elements. SUPIN has three modes of operation: 1) generate the inlet geometry from a explicit set of geometry information, 2) size and design the inlet geometry and analyze the aerodynamic performance, and 3) compute the aerodynamic performance of a specified inlet geometry. The aerodynamic performance quantities includes inlet flow rates, total pressure recovery, and drag. The geometry output from SUPIN includes inlet dimensions, cross-sectional areas, coordinates of planar profiles, and surface grids suitable for input to grid generators for analysis by computational fluid dynamics (CFD) methods. The input data file for SUPIN and the output file from SUPIN are text (ASCII) files. The surface grid files are output as formatted Plot3D or stereolithography (STL) files. SUPIN executes in batch mode and is available as a Microsoft Windows executable and Fortran95 source code with a makefile for Linux.

Slater, John W.↗

DOE OSTI2024

Design of Zone-Based Hierarchical Protection System for 100% Renewable Microgrids

Design of a reliable and secure protection system for a 100% renewable microgrid with only inverter-based resources (IBRs), is quite challenging. Most of the existing protection schemes in the state-of-the-art are suitable for microgrids with mixed-type of distributed energy resources (DERs) that covers both rotating machine-based DERs as well as IBR-based DERs, where the fault current level is moderately high. Due to drastic reduction in fault current level based on mode of operation and the variation of the low fault current level based on the operating level of the IBRs, the existing protection schemes face critical challenges, in case of a 100% renewable microgrid. This article proposes a zone-based hierarchical protection scheme that partitions a microgrid into various zones-of-protection and assigns speed-based hierarchical protection schemes in order to address the fundamental challenges of such microgrids. The performance of the proposed scheme is evaluated using time-domain simulation study on a microgrid test system. The results corroborates that the proposed hierarchical zone-based protection scheme exhibits enhanced reliability, security and dependability while tested with various fault cases (fault types, locations, and impedances), and non-fault cases during both grid-tied and islanded mode.

grid-forming inverter↗

DOE OSTI2024

Design of Zone-Based Hierarchical Protection System for 100% Renewable Microgrids: Preprint

grid-forming inverter↗

NASA NTRS2015

Control and Non-Payload Communications (CNPC) Prototype Radio - Generation 2 Security Architecture Lab Test Report

NASA Glenn Research Center, in cooperation with Rockwell Collins, is working to develop a prototype Control and Non-Payload Communications (CNPC) radio platform as part of NASA Integrated Systems Research Program's (ISRP) Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) project. A primary focus of the project is to work with the FAA and industry standards bodies to build and demonstrate a safe, secure, and efficient CNPC architecture that can be used by industry to evaluate the feasibility of deploying a system using these technologies in an operational capacity. GRC has been working in conjunction with these groups to assess threats, identify security requirements, and to develop a system of standards-based security controls that can be applied to the current GRC prototype CNPC architecture as a demonstration platform. The security controls were integrated into a lab test bed mock-up of the Mobile IPv6 architecture currently being used for NASA flight testing, and a series of network tests were conducted to evaluate the security overhead of the controls compared to the baseline CNPC link without any security. The aim of testing was to evaluate the performance impact of the additional security control overhead when added to the Mobile IPv6 architecture in various modes of operation. The statistics collected included packet captures at points along the path to gauge packet size as the sample data traversed the CNPC network, round trip latency, jitter, and throughput. The effort involved a series of tests of the baseline link, a link with Robust Header Compression (ROHC) and without security controls, a link with security controls and without ROHC, and finally a link with both ROHC and security controls enabled. The effort demonstrated that ROHC is both desirable and necessary to offset the additional expected overhead of applying security controls to the CNPC link.

Communication Networks↗

NASA NTRS1989

Prototype part task trainer: A remote manipulator system simulator

The Part Task Trainer program (PTT) is a kinematic simulation of the Remote Manipulator System (RMS) for the orbiter. The purpose of the PTT is to supply a low cost man-in-the-loop simulator, allowing the student to learn operational procedures which then can be used in the more expensive full scale simulators. PTT will allow the crew members to work on their arm operation skills without the need for other people running the simulation. The controlling algorithms for the arm were coded out of the Functional Subsystem Requirements Document to ensure realistic operation of the simulation. Relying on the hardware of the workstation to provide fast refresh rates for full shaded images allows the simulation to be run on small low cost stand alone work stations, removing the need to be tied into a multi-million dollar computer for the simulation. PTT will allow the student to make errors which in full scale mock up simulators might cause failures or damage hardware. On the screen the user is shown a graphical representation of the RMS control panel in the aft cockpit of the orbiter, along with a main view window and up to six trunion and guide windows. The dials drawn on the panel may be turned to select the desired mode of operation. The inputs controlling the arm are read from a chair with a Translational Hand Controller (THC) and a Rotational Hand Controller (RHC) attached to it.

Shores, David↗

NASA NTRS1991

Goodard Space Flight Center/Wallops Flight Facility airborne geoscience support capability

Goddard Space Flight Center's Wallops Facility (GSFC/WFF), operates six aircraft which are used as airborne geoscience platforms. The aircraft complement consists of two UH-1B helicopters, one twin engine Skyvan, one twin jet T-39, and two four engine turboprop aircraft (P-3 and Electra) offering the research community a wide range of payload, altitude, speed, and range capabilities. WFF's support to a principal investigator include mission planning of all supporting elements, installation of equipment on the aircraft, fabrication of brackets, and adapters as required to adapt payloads to the aircraft, and planning of mission profiles to meet science objectives. The flight regime includes local, regional, and global missions. The WFF aircraft serve scientists at GSFC, other NASA centers, other government agencies, and universities. The WFF mode of operation features the walk on method of conducting research projects. The principal investigator requests aircraft support by letter to WFF and after approval is granted, works with the assigned mission manager to plan all phases of project support. The instrumentation is installed in WFF electronics racks, mounted on the aircraft, the missions are flown, and the equipment is removed when the scientific objectives are met. The principal investigator reimburses WFF for each flight hours, any overtime and travel expenses generated by the project, and for other mission-related expenses such as aircraft support services required at deployment bases.

Navarro, Roger L.↗

NASA NTRS2020

Improvements of On-orbit Characterization of Terra MODIS Short-wave Infrared Spectral Bands Out-of-Band Responses

The short-wave infrared (SWIR) bands (5-7, 26) of Terra MODIS, which are co-located with the mid-wav e infrared (MWIR) bands (20-25) on the short and mid-wave infrared (SMIR) Focal Plane Assembly (FPA),have a known issue related to 5.3 μm out-of-band (OOB) thermal leak and electronic crosstalk that was identified prelaunch. As a result, a crosstalk correction algorithm was designed and implemented in the MODIS Level 1B (L1B) calibration. Shortly after the Terra launch, extensive efforts were under taken to help characterize and mitigate the impact due to the OOB response and crosstalk on the SWIR on-orbit calibration and, consequently, the associated L1Bdata products. In addition, special night time day mode (NTDM) operations have been regularly scheduled to derive the crosstalk correction coefficients. Since MODIS does not have a spectral band centered at 5.3 μm, its band 28 (7.325 μm) was chosen as the surrogate sending band to simulate the OOB radiances at 5.3 μm. This was largely based on the measurements from the MODIS Airborne Simulator (MAS) spectrometer field campaigns in the early months after the Terra launch. In the case of Aqua MODIS, the magnitude of the SWIR crosstalk was much smaller and band 25 (4.52 μm) was found to be more effective as the sending band for the crosstalk correction. In recent years, the Terra MODIS photovoltaic (PV) long-wave infrared (LWIR) bands (27-30)electronic crosstalk has increased considerably, especially after the spacecraft safe-mode event occurred in February2016. This accentuated degradation in the PV LWIR performance has also impacted the performance of the SWIR crosstalk correction and thus its calibration and data quality. In this paper, we examine the use of band 25 as the sending band for the Terra MODIS SWIR crosstalk correction and compare its performance with that based on band 28 as the sending band. Results indicate an improvement of on-orbit gain stability for the SWIR calibration and reduced detector to detector and sub-frame to sub-frame striping in the calibrated L1B imagery, especially during the period when the PV LWIR electronic crosstalk has become more severe. This approach has been implemented in the forward production of Terra MODIS Collection 6 and Collection 6.1,starting from July 2019, and is planned to be used for the future reprocessing of MODIS L1B and to help improve the mission-long reflectance calibration and trending stability of the SWIR bands.

MODIS, Terra, Aqua, MODIS, SWIR, calibration, out-↗

NASA NTRS1975

Computer simulation of thermal and fluid systems for MIUS integration and subsystems test /MIST/ laboratory

This paper describes the application of the SINDA (systems improved numerical differencing analyzer) computer program to simulate the operation of the NASA/JSC MIUS integration and subsystems test (MIST) laboratory. The MIST laboratory is designed to test the integration capability of the following subsystems of a modular integrated utility system (MIUS): (1) electric power generation, (2) space heating and cooling, (3) solid waste disposal, (4) potable water supply, and (5) waste water treatment. The SINDA/MIST computer model is designed to simulate the response of these subsystems to externally impressed loads. The computer model determines the amount of recovered waste heat from the prime mover exhaust, water jacket and oil/aftercooler and from the incinerator. This recovered waste heat is used in the model to heat potable water, for space heating, absorption air conditioning, waste water sterilization, and to provide for thermal storage. The details of the thermal and fluid simulation of MIST including the system configuration, modes of operation modeled, SINDA model characteristics and the results of several analyses are described.

Rochelle, W. C.↗

NASA NTRS1993

Reconfigurable fuzzy cell

This invention relates to a reconfigurable fuzzy cell comprising a digital control programmable gain operation amplifier, an analog-to-digital converter, an electrically erasable PROM, and 8-bit counter and comparator, and supporting logic configured to achieve in real-time fuzzy systems high throughput, grade-of-membership or membership-value conversion of multi-input sensor data. The invention provides a flexible multiplexing-capable configuration, implemented entirely in hardware, for effectuating S-, Z-, and PI-membership functions or combinations thereof, based upon fuzzy logic level-set theory. A membership value table storing 'knowledge data' for each of S-, Z-, and PI-functions is contained within a nonvolatile memory for storing bits of membership and parametric information in a plurality of address spaces. Based upon parametric and control signals, analog sensor data is digitized and converted into grade-of-membership data. In situ learn and recognition modes of operation are also provided.

Salazar, George A.↗

NASA NTRS1989

Spectral calibration analysis of the airborne oceanographic lidar

Efforts were concentrated on the spectral resolution of the Airborne Oceanographic Lidar (AOL). This year's work was targeted towards the analysis of calibration techniques to enable the AOL to measure absolute radiances of both passive and active modes of operation. Absolute spectral calibration of the AOL is necessary in order to fully understand and monitor the sensitivity and stability of the total system. Calibration is also needed to obtain valid surface truth data, with which to improve the accuracy of satellite-borne oceanic color scanners. In particular, accurate measurements of oceanic chlorophyll concentrations rests upon reliable irradiance calibrations of both laser induced and solar induced chlorophyll fluoresence. An analysis was performed on the spectral calibration methods used by the AOL. The optical path of the instrumentation was examined to study how the radiance from a calibration sphere was influenced. Ray tracing analysis was performed, including the Cassegrain-telescope optics. It was determined that the calibration radiance was significantly effected by optical-defocusing, due to close positioning of the calibration sphere with respect to the telescope. Since the multi-mode usages of the AOL require varying altitudes and trajectories, a computational algorithm was developed to compensate for image distortions of the telescope optics. Secondary mirror blockage, secondary vignetting, and beam divergence was determined, in order to account for the actual amount of calibrated flux received at the spectral sensors.

Rousey, Carlton E.↗

NASA NTRS1963

LATERAL-RANGE AND HYPERSONIC LIFT-DRAG-RATIO REQUIREMENTS FOR EFFICIENT FERRY SERVICE FROM A NEAR-EARTH MANNED SPACE STATION

The operation of any long-term manned space station will require some type of ferry vehicle to transport men and equipment to and from the station with regularity and reliability. Such a vehicle, designed for entry at near-orbital speeds, could also be useful in the return from any deeper space mission if either an earth-orbit rendezvous terminal maneuver or a maneuver combining atmospheric braking and a near-earth parking orbit is used. This study was undertaken to determine the class of vehicle which could be most efficiently used as a ferry vehicle between a near-earth space station and the earth. One measure of this efficiency is the ability of the vehicle to reach pre-chosen landing sites with some prescribed frequency. In considering this frequency of return it is necessary to consider not only the normal mode of operation in which only infrequent returns are scheduled at desirable times, but also operation under various degrees of emergency, which dictate quick or even immediate return to earth. In extreme emergencies, when immediate return to earth is necessary, choice of landing site becomes impractical. In most cases, however, although it might be required to abandon the station quickly, the ferry vehicle could remain in orbit for some time before initiating reentry in order to land at a prechosen site. The allowable delay time in orbit would be determined primarily by the capabilities of the ferry life-support system. This paper will examine the geometry of the ferry ranging problem, that is, the lateral ranges required to reach chosen landing sites from various near-earth orbits, and will investigate and compare several means of achieving these ranges. The particular case considered is that of returning from a space station which is in a circular orbit at an altitude of 200 statute miles, but the results obtained are not sensitive to orbit altitude for orbits within a few hundred miles of the surface. From this orbit, the vehicle will retro and reenter at very close to satellite velocity. The downrange problem can be handled by proper timing of the retrofiring , and the desired lateral range can be achieved by aerodynamics, space propulsion to change orbit plane, atmospheric propulsion, or combinations of these methods. The relative cost in terms of weight of using these different methods to achieve lateral range will be discussed.

Hypersonic vehicle↗

NASA NTRS2011

Planetary Education and Outreach Using the NOAA Science on a Sphere

Science On a Sphere (SOS) is a large visualization system, developed by the National Oceanic and Atmospheric Administration (NOAH), that uses computers running Redhat Linux and four video projectors to display animated data onto the outside of a sphere. Said another way, SOS is a stationary globe that can show dynamic, animated images in spherical form. Visualization of cylindrical data maps show planets, their atmosphere, oceans, and land, in very realistic form. The SOS system uses 4 video projectors to display images onto the sphere. Each projector is driven by a separate computer, and a fifth computer is used to control the operation of the display computers. Each computer is a relatively powerful PC with a high-end graphics card. The video projectors have native XGA resolution. The projectors are placed at the corners of a 30' x 30' square with a 68" carbon fiber sphere suspended in the center of the square. The equator of the sphere is typically located 86" off the floor. SOS uses common image formats such as JPEG, or TIFF in a very specific, but simple form; the images are plotted on an equatorial cylindrical equidistant projection, or as it is commonly known, a latitude/longitude grid, where the image is twice as wide as it is high (rectangular). 2048x] 024 is the minimum usable spatial resolution without some noticeable pixelation. Labels and text can be applied within the image, or using a timestamp-like feature within the SOS system software. There are two basic modes of operation for SOS: displaying a single image or an animated sequence of frames. The frame or frames can be setup to rotate or tilt, as in a planetary rotation. Sequences of images that animate through time produce a movie visualization, with or without an overlain soundtrack. After the images are processed, SOS will display the images in sequence and play them like a movie across the entire sphere surface. Movies can be of any arbitrary length, limited mainly by disk space and can be animated at frame rates up to 30 frames per second. Transitions, special effects, and other computer graphics techniques can be added to a sequence through the use of off-the-shelf software, like Final Cut Pro. However, one drawback is that the Sphere cannot be used in the same manner as a flat movie screen; images cannot be pushed to a "side", a highlighted area must be viewable to all sides of the room simultaneously, and some transitions do not work as well as others. We discuss these issues and workarounds in our poster.

Simon-Miller, A. A.↗

NASA NTRS1989

Hydrocarbon-fueled scramjet combustor component development tests

Technology is being developed for a hydrocarbon-fueled engine operating as a scramjet over the flight Mach number range from 5.6 to 7. A series of connected-pipe tests were performed to define scramjet combustor design criteria applicable to the United Technologies Research Center (UTRC) engine concept which comprises a pair of modular axisymmetric combustor underslung on a supersonic/hypersonic missile. The development of key pilot and fuel injector components of the combustor is pursued in a variable-geometry two-dimensional test section over a range of combustor entrance conditions simulating the intended flight regime. The applicability of the two-dimensional test results to the axisymmetric engine is ensured by maintaining a proper simulation of combustor entrance conditions and preserving the actual length scale in the two-dimensional test configuration. An air-breathing pilot was developed and tested to evaluate flame stabilization and flame propagation characteristics. A pilot configuration was developed that operated stably, with minimal flow spillage, at exhaust stagnation temperatures as high as 4500 R with ethylene fuel. It was demonstrated that the pilot promotes efficient combustion of either gaseous ethylene or preheated liquid Jet-A (JP-5) when they are injected into the supersonic mainstream flow as primary fuels. For the tests with Jet-A fuel, the fuel was heated in an array of internal cooling passages within the pilot walls to a thermodynamic condition such that it would flash-vaporize upon injection into the mainstream flow. The idea of using the air-breathing pilot and distributed primary and secondary fuel injectors to achieve efficient supersonic combustion over a wide range of equivalence ratios was also experimentally demonstrated during the program. During staged fuel injection tests with gaseous ethylene fuel, high secondary fuel combustion efficiencies were achieved and smooth transitions from fully supersonic to dual mode (supersonic/subsonic) operation were demonstrated at high overall equivalence ratios.

Kay, Ira W.↗

NASA NTRS1994

Galileo mission planning for Low Gain Antenna based operations

The Galileo mission operations concept is undergoing substantial redesign, necessitated by the deployment failure of the High Gain Antenna, while the spacecraft is on its way to Jupiter. The new design applies state-of-the-art technology and processes to increase the telemetry rate available through the Low Gain Antenna and to increase the information density of the telemetry. This paper describes the mission planning process being developed as part of this redesign. Principal topics include a brief description of the new mission concept and anticipated science return (these have been covered more extensively in earlier papers), identification of key drivers on the mission planning process, a description of the process and its implementation schedule, a discussion of the application of automated mission planning tool to the process, and a status report on mission planning work to date. Galileo enhancements include extensive reprogramming of on-board computers and substantial hard ware and software upgrades for the Deep Space Network (DSN). The principal mode of operation will be onboard recording of science data followed by extended playback periods. A variety of techniques will be used to compress and edit the data both before recording and during playback. A highly-compressed real-time science data stream will also be important. The telemetry rate will be increased using advanced coding techniques and advanced receivers. Galileo mission planning for orbital operations now involves partitioning of several scarce resources. Particularly difficult are division of the telemetry among the many users (eleven instruments, radio science, engineering monitoring, and navigation) and allocation of space on the tape recorder at each of the ten satellite encounters. The planning process is complicated by uncertainty in forecast performance of the DSN modifications and the non-deterministic nature of the new data compression schemes. Key mission planning steps include quantifying resource or capabilities to be allocated, prioritizing science observations and estimating resource needs for each, working inter-and intra-orbit trades of these resources among the Project elements, and planning real-time science activity. The first major mission planning activity, a high level, orbit-by-orbit allocation of resources among science objectives, has already been completed; and results are illustrated in the paper. To make efficient use of limited resources, Galileo mission planning will rely on automated mission planning tools capable of dealing with interactions among time-varying downlink capability, real-time science and engineering data transmission, and playback of recorded data. A new generic mission planning tool is being adapted for this purpose.

Gershman, R.↗

NASA NTRS2010

Lifetime Assessment of the NEXT Ion Thruster

Ion thrusters are low thrust, high specific impulse devices with required operational lifetimes on the order of 10,000 to 100,000 hr. The NEXT ion thruster is the latest generation of ion thrusters under development. The NEXT ion thruster currently has a qualification level propellant throughput requirement of 450 kg of xenon, which corresponds to roughly 22,000 hr of operation at the highest throttling point. Currently, a NEXT engineering model ion thruster with prototype model ion optics is undergoing a long duration test to determine wear characteristics and establish propellant throughput capability. The NEXT thruster includes many improvements over previous generations of ion thrusters, but two of its component improvements have a larger effect on thruster lifetime. These include the ion optics with tighter tolerances, a masked region and better gap control, and the discharge cathode keeper material change to graphite. Data from the NEXT 2000 hr wear test, the NEXT long duration test, and further analysis is used to determine the expected lifetime of the NEXT ion thruster. This paper will review the predictions for all of the anticipated failure mechanisms. The mechanisms will include wear of the ion optics and cathode s orifice plate and keeper from the plasma, depletion of low work function material in each cathode s insert, and spalling of material in the discharge chamber leading to arcing. Based on the analysis of the NEXT ion thruster, the first failure mode for operation above a specific impulse of 2000 sec is expected to be the structural failure of the ion optics at 750 kg of propellant throughput, 1.7 times the qualification requirement. An assessment based on mission analyses for operation below a specific impulse of 2000 sec indicates that the NEXT thruster is capable of double the propellant throughput required by these missions.

VanNoord, Jonathan L.↗

NASA NTRS1999

Turbomachinery Design Quality Checks to Avoid Friction Induced Structural Failure

A unique configuration of the P&W SSME Alternate Fuel Turbopump turbine disk/blade assembly, combined with a severe thermal environment, resulted in several structural anomalies that were driven by frictional contact forces. Understanding the mechanics of these problems provides new quality checks for future turbo machinery designs. During development testing in 1997 of the SSME alternate fuel turbopump at Stennis Space Center, several potentially serious problems surfaced with the turbine disk/blade assembly that had not been experienced in extensive earlier testing. Changes to the operational thermal environment were noted based on analytical prediction of modifications that affected performance and on stationary thermal measurements adjacent to the rotor assembly. A detailed structural investigation was required to reveal the mechanism of distress induced by the change. The turbine disk experienced cracking in several locations due to increased thermal gradient induced stress during start and shutdown transients. This was easily predictable using standard analysis procedures and expected once the thermal environment was characterized. What was not expected was the curling of a piston ring used for blade axial retention in the disk, indentation of the axial face of the blade attachment by a spacer separating the first and second stage blades, and most significantly, galling and cracking of the blade root attachment that could have resulted in blade release. Past experience, in gas turbine environments, set a precedent of never relying on friction for help and to evaluate it only in specific instances where it was obvious that it would degrade capability. In each of the three cases above, friction proved to be a determining factor that pushed the components into an unsatisfactory mode of operation. The higher than expected temperatures and rapid thermal transients combined with friction to move beyond past experience. The turbine disk/blade assembly configuration contributed to the potential for these problems to occur by limiting the radial deflection from thermals and centrifugal loading. The cooled solid bore configuration was chosen to improve rotordynamic stability by limiting the length of rotor overhang while still protecting the roller bearing by maintaining zero slope under the inner race. During a start transient, the rim area of the disk heats rapidly and expands axially and circumferentially and requires corresponding radial and axial growth of the disk to maintain relative positioning of the disk, blades, spacers and retainer rings. The stiffness, large thermal mass, and bore cooling flow combine to severely limit the disk rim radial growth which results in the potential for relative movement between these parts. Friction then becomes a player in the determination of component stress.

Moore, Jerry H.↗