Showing papers by "ASRC Aerospace Corporation published in 2013"

Rate-Based Model Predictive Control of Turbofan Engine Clearance

Abstract: An innovative model predictive control strategy is developed for a rapid-response, closed-loop active clearance control application, in which the objectives are to tightly regulate turbine blade tip clearances and also anticipate and avoid detrimental blade-shroud rub occurrences by optimally maintaining a predefined minimum clearance. At the heart of the controller is a rate-based linear parameter-varying model of a turbofan engine that extends performance to transient regimes in which conventional controllers begin to degrade. Engine-in-the-loop simulations of this rate-critical tip clearance control system with a variety of different actuators and uncertainty modes are presented, demonstrating the efficacy and versatility of this approach. Comparisons are made with a conventional linear quadratic control approach, where it is shown that substantial clearance gap reductions are possible by incorporating the strategy explored in this paper, thereby maximizing the cycle benefits that the tip clearance actuation/sensing hardware is capable of producing. Based on the results, it is concluded that the new strategy has promise for this and other nonlinear aerospace applications that place high importance on attaining strict control objectives during transient regimes.

Design and development of a shape memory alloy activated heat pipe-based thermal switch

Abstract: This work reports on the design, fabrication and testing of a thermal switch wherein the open and closed states were actuated by shape memory alloy (SMA) elements while heat was transferred by a two-phase heat pipe The motivation for such a switch comes from NASA’s need for thermal management in advanced spaceport applications associated with future lunar and Mars missions As the temperature can approximately vary between −233 and 127 ° C during lunar day/night cycles, the switch was designed to reject heat from a cryogen tank into space during the night cycle while providing thermal isolation during the day cycle A Ni471Ti496Fe33 (at%) alloy that exhibited a reversible phase transformation between a trigonal R-phase and a cubic austenite phase was used as the sensing and actuating elements Thermomechanical actuation, accomplished through an antagonistic spring system, resulted in strokes up to 7 mm against bias forces of up to 45 N The actuation system was tested for more than thirty cycles, equivalent to one year of operation The thermal performance, accomplished via a variable length, closed two-phase heat pipe, was evaluated, resulting in heat transfer rates of 13 W using pentane and 10 W using R-134a as working fluids Experimental data were also compared to theoretical predictions where possible Direct comparisons between different design approaches of SMA helical actuators, highlighting the effects of the helix angle, were carried out to give a layout of more accurate design methodologies

Hybrid Kalman Filter: A New Approach for Aircraft Engine In-Flight Diagnostics

Abstract: In this paper, a uniquely structured Kalman filter is developed for its application to in-flight diagnostics of aircraft gas turbine engines. The Kalman filter is a hybrid of a nonlinear on-board engine model (OBEM) and piecewise linear models. The utilization of the nonlinear OBEM allows the reference health baseline of the in-flight diagnostic system to be updated to the degraded health condition of the engines through a relatively simple process. Through this health baseline update, the effectiveness of the in-flight diagnostic algorithm can be maintained as the health of the engine degrades over time. Another significant aspect of the hybrid Kalman filter methodology is its capability to take advantage of conventional linear and nonlinear Kalman filter approaches. Based on the hybrid Kalman filter, an in-flight fault detection system is developed, and its diagnostic capability is evaluated in a simulation environment. Through the evaluation, the suitability of the hybrid Kalman filter technique for aircraft engine in-flight diagnostics is demonstrated.

Effect of Two Advanced Noise Reduction Technologies on the Aerodynamic Performance of an Ultra High Bypass Ratio Fan

Abstract: A wind tunnel experiment was conducted in the NASA Glenn Research Center anechoic 9- by 15-Foot Low-Speed Wind Tunnel to investigate two new advanced noise reduction technologies in support of the NASA Fundamental Aeronautics Program Subsonic Fixed Wing Project. The goal of the experiment was to demonstrate the noise reduction potential and effect on fan model performance of the two noise reduction technologies in a scale model Ultra-High Bypass turbofan at simulated takeoff and approach aircraft flight speeds. The two novel noise reduction technologies are called Over-the-Rotor acoustic treatment and Soft Vanes. Both technologies were aimed at modifying the local noise source mechanisms of the fan tip vortex/fan case interaction and the rotor wake-stator interaction. For the Over-the-Rotor acoustic treatment, two noise reduction configurations were investigated. The results showed that the two noise reduction technologies, Over-the-Rotor and Soft Vanes, were able to reduce the noise level of the fan model, but the Over-the-Rotor configurations had a significant negative impact on the fan aerodynamic performance; the loss in fan aerodynamic efficiency was between 2.75 to 8.75 percent, depending on configuration, compared to the conventional solid baseline fan case rubstrip also tested. Performance results with the Soft Vanes showed that there was no measurable change in the corrected fan thrust and a 1.8 percent loss in corrected stator vane thrust, which resulted in a total net thrust loss of approximately 0.5 percent compared with the baseline reference stator vane set.

Effects of a Rotating Aerodynamic Probe on the Flow Field of a Compressor Rotor

Abstract: An investigation of distortions of the rotor exit flow field caused by an aerodynamic probe mounted in the rotor is described in this paper. A rotor total pressure Kiel probe, mounted on the rotor hub and extending up to the mid-span radius of a rotor blade channel, generates a wake that forms additional flow blockage. Three types of high-response aerodynamic probes were used to investigate the distorted flow field behind the rotor. These probes were: a split-fiber thermo-anemometric probe to measure velocity and flow direction, a total pressure probe, and a disk probe for in-flow static pressure measurement. The signals acquired from these high-response probes were reduced using an ensemble averaging method based on a once per rotor revolution signal. The rotor ensemble averages were combined to construct contour plots for each rotor channel of the rotor tested. In order to quantify the rotor probe effects, the contour plots for each individual rotor blade passage were averaged into a single value. The distribution of these average values along the rotor circumference is a measure of changes in the rotor exit flow field due to the presence of a probe in the rotor. These distributions were generated for axial flow velocity and for static pressure.

Cfd Modeling of Superheated Fuel Sprays

Abstract: An understanding of fuel atomization and vaporization behavior at superheat conditions is identified to be a topic of importance in the design of modern supersonic engines. As a part of the NASA aeronautics initiative, we have undertaken an assessment study to establish baseline accuracy of existing CFD models used in the evaluation of a ashing jet. In a first attempt towards attaining this goal, we have incorporated an existing superheat vaporization model into our spray solution procedure but made some improvements to combine the existing models valid at superheated conditions with the models valid at stable (non-superheat) evaporating conditions. Also, the paper reports some validation results based on the experimental data obtained from the literature for a superheated spray generated by the sudden release of pressurized R134A from a cylindrical nozzle. The predicted profiles for both gas and droplet velocities show a reasonable agreement with the measured data and exhibit a self-similar pattern similar to the correlation reported in the literature. Because of the uncertainty involved in the specification of the initial conditions, we have investigated the effect of initial droplet size distribution on the validation results. The predicted results were found to be sensitive to the initial conditions used for the droplet size specification. However, it was shown that decent droplet size comparisons could be achieved with properly selected initial conditions, For the case considered, it is reasonable to assume that the present vaporization models are capable of providing a reasonable qualitative description for the two-phase jet characteristics generated by a ashing jet. However, there remains some uncertainty with regard to the specification of certain initial spray conditions and there is a need for experimental data on separate gas and liquid temperatures in order to validate the vaporization models based on the Adachi correlation for a liquid involving R134A.

Mars Atmospheric Capture and Gas Separation

Abstract: The Mars atmospheric capture and gas separation project is selecting, developing, and demonstrating techniques to capture and purify Martian atmospheric gases for their utilization for the production of hydrocarbons, oxygen, and water in ISRU systems. Trace gases will be required to be separated from Martian atmospheric gases to provide pure C02 to processing elements. In addition, other Martian gases, such as nitrogen and argon, occur in concentrations high enough to be useful as buffer gas and should be captured as welL To achieve these goals, highly efficient gas separation processes will be required. These gas separation techniques are also required across various areas within the ISRU project to support various consumable production processes. The development of innovative gas separation techniques will evaluate the current state-of-the-art for the gas separation required, with the objective to demonstrate and develop light-weight, low-power methods for gas separation. Gas separation requirements include, but are not limited to the selective separation of: (1) methane and water from un-reacted carbon oxides (C02- CO) and hydrogen typical of a Sabatier-type process, (2) carbon oxides and water from unreacted hydrogen from a Reverse Water-Gas Shift process, (3) carbon oxides from oxygen from a trash/waste processing reaction, and (4) helium from hydrogen or oxygen from a propellant scavenging process. Potential technologies for the separations include freezers, selective membranes, selective solvents, polymeric sorbents, zeolites, and new technologies. This paper and presentation will summarize the results of an extensive literature review and laboratory evaluations of candidate technologies for the capture and separation of C02 and other relevant gases.

Temperature and Species Measurements of Combustion Produced by a 9-point Lean Direct Injector

Abstract: This paper presents measurements of temperature and relative species concentrations in the combustion flowfield of a 9-point swirl venturi lean direct injector fueled with JP-8. The temperature and relative species concentrations of the flame produced by the injector were measured using spontaneous Raman scattering (SRS). Results of measurements taken at four flame conditions are presented. The species concentrations reported are measured relative to nitrogen and include oxygen, carbon dioxide, and water.

Limitations of Phased Array Beamforming in Open Rotor Noise Source Imaging

Abstract: Phased array beamforming results of the F31/A31 historical baseline counter-rotating open rotor blade set were investigated for measurement data taken on the NASA Counter-Rotating Open Rotor Propulsion Rig in the 9- by 15-Foot Low-Speed Wind Tunnel of NASA Glenn Research Center as well as data produced using the LINPROP open rotor tone noise code. The planar microphone array was positioned broadside and parallel to the axis of the open rotor, roughly 2.3 rotor diameters away. The results provide insight as to why the apparent noise sources of the blade passing frequency tones and interaction tones appear at their nominal Mach radii instead of at the actual noise sources, even if those locations are not on the blades. Contour maps corresponding to the sound fields produced by the radiating sound waves, taken from the simulations, are used to illustrate how the interaction patterns of circumferential spinning modes of rotating coherent noise sources interact with the phased array, often giving misleading results, as the apparent sources do not always show where the actual noise sources are located. This suggests that a more sophisticated source model would be required to accurately locate the sources of each tone. The results of this study also have implications with regard to the shielding of open rotor sources by airframe empennages.

Resolve 2010 Field Test

Abstract: This slide presentation reviews the field tests conducted in 2010 of the Regolith Environment Science & Oxygen & Lunar Volatile Extraction (RESOLVE). The Resolve program consist of several mechanism: (1) Excavation and Bulk Regolith Characterization (EBRC) which is designed to act as a drill and crusher, (2) Regolith Volatiles Characterization (RVC) which is a reactor and does gas analysis,(3) Lunar Water Resources Demonstration (LWRD) which is a fluid system, water and hydrogen capture device and (4) the Rover. The scientific goal of this test is to demonstrate evolution of low levels of hydrogen and water as a function of temperature. The Engineering goals of this test are to demonstrate:(1) Integration onto new rover (2) Miniaturization of electronics rack (3) Operation from battery packs (elimination of generator) (4) Remote command/control and (5) Operation while roving. Views of the 2008 and the 2010 mechanisms, a overhead view of the mission path, a view of the terrain, the two drill sites, and a graphic of the Master Events Controller Graphical User Interface (MEC GUI) are shown. There are descriptions of the Gas chromatography (GC), the operational procedure, water and hydrogen doping of tephra. There is also a review of some of the results, and future direction for research and tests.

Performance Evaluation of an Actuator Dust Seal for Lunar Operation

Abstract: Exploration of extraterrestrial surfaces (e.g. moon, Mars, asteroid) will require durable space mechanisms that will survive potentially dusty surface conditions in addition to the hard vacuum and extreme temperatures of space. Baseline tests with lunar simulant were recently completed at NASA GRC on a new Low-Temperature Mechanism (LTM) dust seal for space actuator application. Following are top-level findings of the tests completed to date in vacuum using NU-LHT-2M lunar-highlands simulant. A complete set of findings are found in the conclusions section.Tests were run at approximately 10-7 torr with unidirectional rotational speed of 39 RPM.Initial break-in runs were performed at atmospheric conditions with no simulant. During the break-in runs, the maximum torque observed was 16.7 lbf-in. while the maximum seal outer diameter temperature was 103F. Only 0.4 milligrams of NU-LHT-2M simulant passed through the sealshaft interface in the first 511,000 cycles while under vacuum despite a chip on the secondary sealing surface.Approximately 650,000 of a planned 1,000,000 cycles were completed in vacuum with NU-LHT-2M simulant.Upon test disassembly NU-LHT-2M was found on the secondary sealing surface.

Multi-Dimensional Damage Detection for Surfaces and Structures

Abstract: Current designs for inflatable or semi-rigidized structures for habitats and space applications use a multiple-layer construction, alternating thin layers with thicker, stronger layers, which produces a layered composite structure that is much better at resisting damage. Even though such composite structures or layered systems are robust, they can still be susceptible to penetration damage. The ability to detect damage to surfaces of inflatable or semi-rigid habitat structures is of great interest to NASA. Damage caused by impacts of foreign objects such as micrometeorites can rupture the shell of these structures, causing loss of critical hardware and/or the life of the crew. While not all impacts will have a catastrophic result, it will be very important to identify and locate areas of the exterior shell that have been damaged by impacts so that repairs (or other provisions) can be made to reduce the probability of shell wall rupture. This disclosure describes a system that will provide real-time data regarding the health of the inflatable shell or rigidized structures, and information related to the location and depth of impact damage. The innovation described here is a method of determining the size, location, and direction of damage in a multilayered structure. In the multi-dimensional damage detection system, layers of two-dimensional thin film detection layers are used to form a layered composite, with non-detection layers separating the detection layers. The non-detection layers may be either thicker or thinner than the detection layers. The thin-film damage detection layers are thin films of materials with a conductive grid or striped pattern. The conductive pattern may be applied by several methods, including printing, plating, sputtering, photolithography, and etching, and can include as many detection layers that are necessary for the structure construction or to afford the detection detail level required. The damage is detected using a detector or sensory system, which may include a time domain reflectometer, resistivity monitoring hardware, or other resistance-based systems. To begin, a layered composite consisting of thin-film damage detection layers separated by non-damage detection layers is fabricated. The damage detection layers are attached to a detector that provides details regarding the physical health of each detection layer individually. If damage occurs to any of the detection layers, a change in the electrical properties of the detection layers damaged occurs, and a response is generated. Real-time analysis of these responses will provide details regarding the depth, location, and size estimation of the damage. Multiple damages can be detected, and the extent (depth) of the damage can be used to generate prognostic information related to the expected lifetime of the layered composite system. The detection system can be fabricated very easily using off-the-shelf equipment, and the detection algorithms can be written and updated (as needed) to provide the level of detail needed based on the system being monitored. Connecting to the thin film detection layers is very easy as well. The truly unique feature of the system is its flexibility; the system can be designed to gather as much (or as little) information as the end user feels necessary. Individual detection layers can be turned on or off as necessary, and algorithms can be used to optimize performance. The system can be used to generate both diagnostic and prognostic information related to the health of layer composite structures, which will be essential if such systems are utilized for space exploration. The technology is also applicable to other in-situ health monitoring systems for structure integrity.

Unsteady Velocity Measurements in the NASA Research Low Speed Axial Compressor: Smooth Wall Configuration

Abstract: The report is a collection of experimental unsteady data acquired in the first stage of the NASA Low Speed Axial Compressor in configuration with smooth (solid) wall treatment over the first rotor. The aim of the report is to present a reliable experimental data base that can be used for analysis of the compressor flow behavior, and hopefully help with further improvements of compressor CFD codes. All data analysis is strictly restricted to verification of reliability of the experimental data reported. The report is divided into six main sections. First two sections cover the low speed axial compressor, the basic instrumentation, and the in-house developed methodology of unsteady velocity measurements using a thermo-anemometric split-fiber probe. The next two sections contain experimental data presented as averaged radial distributions for three compressor operation conditions, including the distribution of the total temperature rise over the first rotor, and ensemble averages of unsteady flow data based on a rotor blade passage period. Ensemble averages based on the rotor revolution period, and spectral analysis of unsteady flow parameters are presented in the last two sections. The report is completed with two appendices where performance and dynamic response of thermo-anemometric probes is discussed.

Dust Tolerant Eva-Compatible Connectors

Abstract: The objectives of this project are to develop connectors (quick disconnects and umbilical systems) that can be repetitively and reliably mated and de-mated during Lunar surface extra-vehicular activities. These standardized interfaces will be required for structural integrity and commodities transfer between linked surface elements. QD's fittings are needed for EVA spacesuit Primary Life Support Systems as well as liquid cooled garment circulation and suit heat rejection. Umbilical electro-mechanical systems (connectors) are needed between discrete surface systems for transfer of air, power, fluid (water), and data must be capable of being operated by extra vehicular astronaut crew members and/or robotic assistants. There exists an urgent need to prevent electro-statically charged dust and debris from clogging and degrading the interface seals and causing leakage and spills of hazardous commodities, contaminating the flowstream, and degrading the mechanisms needed for umbilical connection. Other challenges include modularity, standardization, autonomous operation, and lifetime sealing issues.

Investigation of Flow Instabilities in the Inlet Ducts of DP-1C VTOL Aircraft

Abstract: An investigation of flow instabilities in the inlet ducts of a two-engine vertical takeoff and landing aircraft DP-1C is described in this report. Recent tests revealed that the engines stall during run ups while the aircraft is operating on the ground. These pop stalls occurred at relatively low power levels, sometimes as low as 60 percent of the engine full speed. Inability to run the engines up to the full speed level is attributed to in-ground effects associated with hot gas ingestion. Such pop stalls were never experienced when the aircraft was tested on a elevated grid platform, which ensured that the aircraft was operating in out-of-the-ground-effect conditions. Based on available information on problems experienced with other vertical takeoff and landing aircraft designs, it was assumed that the engine stalls were caused by partial ingestion of hot gases streaming forward from the main exit nozzle under the aircraft inlets, which are very close to the ground. It was also suggested that the nose wheel undercarriage, located between the inlets, may generate vortices or an unstable wake causing intense mixing of hot exit gases with incoming inlet flow, which would enhance the hot gas ingestion. After running a short three-day series of tests with fully instrumented engine inlets, it is now believed the most probable reason for engine pop stalls are random ingestions of a vortex generated between the two streams moving in opposite directions: outbound hot gas stream from the main nozzle close to the ground and inbound inlet flow above. Originally, the vortex is in a horizontal plane. However, at a certain velocity ratio of these two streams, the vortex attaches either to the ground or the aircraft surface at one end and the other end is swallowed by one of the aircraft inlets. Once the vortex enters the inlet duct, a puff of hot air can be sucked through the vortex core into the engine, which causes a serious inlet flow field distortion followed by an engine stall. Once the engine stalls, the outflow from the inlet pushes the vortex away and the engine resumes normal operation. This hypothesis needs to be verified experimentally; e.g., by extensive smoke flow visualization ahead of the aircraft inlets.

Effect of Solar Exposure on the Atomic Oxygen Erosion of Hubble Space Telescope Aluminized-Teflon Thermal Shields

Abstract: When exposed to low Earth orbit (LEO) environment, external spacecraft materials degrade due to radiation, thermal cycling, micrometeoroid and debris impacts, and interaction with atomic oxygen (AO). Collisions between AO and spacecraft can result in oxidation of external spacecraft surface materials, which can lead to erosion and severe structural and/or optical properties deterioration. It is therefore essential to understand the AO erosion yield (Ey), the volume loss per incident oxygen atom (cm3/atom) of polymers to assure durability of spacecraft materials. The objective of this study was to determine whether solar radiation exposure can increase the rate of AO erosion of polymers in LEO. The material studied was a section of aluminized-Teflon® fluorinated ethylene propylene (Al-FEP) thermal shield exposed to space on the Hubble Space Telescope (HST) for 8.25 years. Retrieved samples were sectioned from the circular thermal shield and exposed to ground laboratory thermal energy AO. The results indicate that the average Ey of the solar facing HST Al-FEP was 1.9 × 10−24 cm3/atom, while the average Ey of the anti-solar HST Al-FEP was 1.5 × 10−24 cm3/atom. The Ey of the pristine samples was 1.6 to 1.7 × 10−24 cm3/atom. These results indicate that solar exposure affects the post-flight erosion rate of FEP in a plasma asher. Therefore, it likely affects the erosion rate while in LEO.

Polymer Strain Experiment on MISSE 6

Abstract: Experiments have been conducted in low Earth orbit (LEO) on the Long Duration Exposure Facility (LDEF) and the Materials International Space Station Experiment 2 (MISSE 2) that involved slightly stretched polymers held at their perimeters. In several instances, tearing occurred at the polymers’ perimeters. A possible cause for such material failure may be polymer shrinkage as a result of LEO exposure, causing the stress level to gradually increase until the polymers tear. The potential for tearing may be increased by radiation induced surface embrittlement of the polymer. An active experiment, called the Polymer Strain Experiment (PSE), was designed and installed on MISSE 6B to measure the strain in 6 one-end free standing polymers as a function of time. It was thought that radiation or other environmental factors may possibly induce shrinkage in some polymers developing a tensile stress when held in place. Post-flight testing was conducted on the six flight samples including dehydration shrinkage, thermal vacuum strain, scanning electron microscopy and mandrel bend testing.

Electronics for Low Temperature Space Exploration Missions

Abstract: Exploration missions to outer planets and deep space require spacecraft, probes, and on-board data and communication systems to operate reliably and efficiently under severe harsh conditions. On-board electronics, in particular those in direct exposures to the space environment without any shielding or protection, will encounter extreme low temperature and thermal cycling in their service cycle in most of NASA s upcoming exploration missions. For example, Venus atmosphere, Jupiter atmosphere, Moon surface, Pluto orbiter, Mars, comets, Titan, Europa, and James Webb Space Telescope all involve low-temperature surroundings. Therefore, electronics for space exploration missions need to be designed for operation under such environmental conditions. There are ongoing efforts at the NASA Glenn Research Center (GRC) to establish a database on the operation and reliability of electronic devices and circuits under extreme temperature operation for space applications. This work is being performed under the Extreme Temperature Electronics Program with collaboration and support of the NASA Electronic Parts and Packaging (NEPP) Program. The results of these investigations will be used to establish safe operating areas and to identify degradation and failure modes, and the information will be disseminated to mission planners and system designers for use as tools for proper part selection and in risk mitigation. An overview of this program along with experimental data will be presented.