ALBERT

Description: This task is to hot-fire test an existing Space Launch Mission (SLM) injector that is applicable for all expander cycle engines being considered for the exploration upper stage. The work leverages investment made in FY 2013 that was used to additively manufacture three injectors (fig. 1) all by different vendors..

Description: This task is to design, fabricate, and spin test to failure a Ti6-4 hydrogen turbopump impeller that was built using the selective laser melting (SLM) fabrication process (fig. 1). The impeller is sized around upper stage engine requirements. In addition to the spin burst test, material testing will be performed on coupons that are built with the impeller.

Description: NASA is currently working on the Evolvabe Mars Campaign (EMC) study to outline transportation and mission options for human exploration of Mars. One of the key aspects of the EMC is leveraging current and planned near-term technology investments to build an affordable and evolvable approach to Mars exploration. This leveraging of investments includes the use of high-power Solar Electric Propulsion (SEP) systems, evolved from those currently under development in support of the Asteroid Redirect Mission (ARM), to deliver payloads to Mars. The EMC is considering several transportation options that combine solar electric and chemical propulsion technologies to deliver crew and cargo to Mars. In one primary architecture option, the SEP propulsion system is used to pre-deploy mission elements to Mars while a high-thrust chemical propulsion system is used to send crew on faster ballistic transfers between Earth and Mars. This high-thrust chemical system uses liquid oxygen - liquid methane main propulsion and reaction control systems integrated into the Methane Cryogenic Propulsion Stage (MCPS). Over the past year, there have been several studies completed to provide critical design and development information related to the MCPS. This paper is intended to provide a summary of these efforts. A summary of the current point of departure design for the MCPS is provided as well as an overview of the mission architecture and concept of operations that the MCPS is intended to support. To leverage the capabilities of solar electric propulsion to the greatest extent possible, the EMC architecture pre-deploys to Mars orbit the stages required for returning crew from Mars. While this changes the risk posture of the architecture, it can provide some mass savings by using higher-efficiency systems for interplanetary transfer. However, this does introduce significantly longer flight times to Mars which, in turn, increases the overall lifetime of the stages to as long as 2500 days. This unique aspect to the concept of operations introduces several challenges, specifically related to propellant storage and engine reliability. These challenges and some potential solutions are discussed. Specific focus is provided on two key technology areas; propulsion and cryogenic fluid management. In the area of propulsion development, the development of an integrated methane propulsion system that combines both main propulsion and reaction control is discussed. This includes an overview of potential development paths, areas where development for Mars applications are complementary to development efforts underway in other parts of the aerospace industry, and commonality between the MCPS methane propulsion applications and other Mars elements, including the Mars lander systems. This commonality is a key affordability aspect of the Evolvable Mars Campaign. A similar discussion is provided for cryogenic fluid management technologies including a discussion of how using cryo propulsion in the Mars transportation application not only provides performance benefits but also leverages decades of technology development investments made by NASA and its aerospace contractor community.

Description: No abstract available

Description: No abstract available

Description: One-dimensional water-hammer modeling involves the solution of two coupled non-linear hyperbolic partial differential equations (PDEs). These equations result from applying the principles of conservation of mass and momentum to flow through a pipe, and usually the assumption that the speed at which pressure waves propagate through the pipe is constant. In order to solve these equations for the interested quantities (i.e. pressures and flow rates), they must first be converted to a system of ordinary differential equations (ODEs) by either approximating the spatial derivative terms with numerical techniques or using the Method of Characteristics (MOC). The MOC approach is ideal in that no numerical approximation errors are introduced in converting the original system of PDEs into an equivalent system of ODEs. Unfortunately this resulting system of ODEs is bound by a time step constraint so that when integrating the equations the solution can only be obtained at fixed time intervals. If the fluid system to be modeled also contains dynamic components (i.e. components that are best modeled by a system of ODEs), it may be necessary to take extremely small time steps during certain points of the model simulation in order to achieve stability and/or accuracy in the solution. Coupled together, the fixed time step constraint invoked by the MOC, and the occasional need for extremely small time steps in order to obtain stability and/or accuracy, can greatly increase simulation run times. As one solution to this problem, a method for combining variable step integration (VSI) algorithms with the MOC was developed for modeling water-hammer in systems with highly dynamic components. A case study is presented in which reverse flow through a dual-flapper check valve introduces a water-hammer event. The predicted pressure responses upstream of the check-valve are compared with test data.

Description: The structural performance of two advanced composite tow-steered shells with cutouts, manufactured using an automated fiber placement system, is assessed using both experimental and analytical methods. The shells' fiber orientation angles vary continuously around their circumference from +/-10 degrees on the crown and keel, to +/-45 degrees on the sides. The raised surface features on one shell result from application of all 24 tows during each fiber placement system pass, while the second shell uses the system's tow drop/add capability to achieve a more uniform wall thickness. These unstiffened shells were previously tested in axial compression and buckled elastically. A single cutout, scaled to represent a passenger door on a commercial aircraft, is then machined into one side of each shell. The prebuckling axial stiffnesses and bifurcation buckling loads of the shells with cutouts are also computed using linear finite element structural analyses for initial comparisons with test data. When retested, large deflections were observed around the cutouts, but the shells carried an average of 92 percent of the axial stiffness, and 86 percent of the buckling loads, of the shells without cutouts. These relatively small reductions in performance demonstrate the potential for using tow steering to mitigate the adverse effects of typical design features on the overall structural performance.

Description: The structural performance of two advanced composite tow-steered shells with large cutouts, manufactured using an automated fiber placement system, is assessed using both experimental and analytical methods. The fiber orientation angles of the shells vary continuously around their circumference from +/- 10 degrees on the crown and keel, to +/- 45 degrees on the sides. The raised surface features on one shell result from application of all 24 tows during each fiber placement system pass, while the second shell uses the tow drop/add capability of the system to achieve a more uniform wall thickness. These unstiffened shells, both without and with small cutouts, were previously tested in axial compression and buckled elastically. In this study, a single unreinforced cutout, scaled to represent a cargo door on a commercial aircraft, is machined into one side of each shell. The prebuckling axial stiffnesses and bifurcation buckling loads of these shells with large cutouts are also computed using linear finite element structural analyses for preliminary comparisons with test data. During testing, large displacements are observed around the large cutouts, but the shells maintain an average of 91 percent of the axial stiffness, and also carry 85 percent of the buckling loads, when compared to the pristine shells without cutouts. These relatively small reductions indicate that there is great potential for using tow steering to mitigate the adverse effects of large cutouts on the overall structural performance.

Description: No abstract available

Description: NASA is currently working on the Evolvabe Mars Campaign (EMC) study to outline transportation and mission options for human exploration of Mars. One of the key aspects of the EMC is leveraging current and planned near-term technology investments to build an affordable and evolvable approach to Mars exploration. This leveraging of investments includes the use of high-power Solar Electric Propulsion (SEP) systems evolved from those currently under development in support of the Asteroid Redirect Mission to deliver payloads to Mars. The EMC is considering several transportation options that combine solar electric and chemical propulsion technologies to deliver crew and cargo to Mars. In one primary architecture option, the SEP propulsion system is used to pre-deploy mission elements to Mars while a high-thrust chemical propulsion system is used to send crew on faster ballistic transfers between Earth and Mars. This high-thrust chemical system uses liquid oxygen - liquid methane main propulsion and reaction control systems integrated into the Methane Cryogenic Propulsion Stage (MCPS). Over the past year, there have been several studies completed to provide critical design and development information related to the MCPS. This paper is intended to provide a summary of these efforts. A summary of the current point of departure design for the MCPS is provided as well as an overview of the mission architecture and concept of operations that the MCPS is intended to support. To leverage the capabilities of solar electric propulsion to the greatest extent possible, the EMC architecture pre-deploys the required stages for returning crew from Mars. While this changes the risk posture of the architecture, it provides mass savings by using higher-efficiency systems for interplanetary transfer. However, this does introduce significantly longer flight times to Mars which, in turn, increases the overall lifetime of the stages to as long as 3000 days. This unique aspect to the concept of operations introduces several challenges, specifically related to propellant storage and engine reliability. These challenges and some potential solutions are discussed. Specific focus is provided on two key technology areas; propulsion and cryogenic fluid management. In the area of propulsion development, the development of an integrated methane propulsion system that combines both main propulsion and reaction control is discussed. This includes an overview of potential development paths, areas where development for Mars applications are complementary to development efforts underway in other parts of the aerospace industry, and commonality between the MCPS methane propulsion applications and other Mars elements, including the Mars lander systems. This commonality is a key affordability aspect of the Evolvable Mars Campaign. A similar discussion is provided for cryogenic fluid management technologies including a discussion of how using cryo-propulsion in the Mars transportation application not only provides performance benefits but also leverages decades of technology development investments made by NASA and its aerospace contractor community.