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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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NASA NTRS2019

Astrobee Free Flyers: Integrated and Tested. Ready for Launch!

As of March 2019, four Astrobee free-flying robots have been integrated, tested and shipped to NASA’s Johnson Space Center, Texas, ready to be launched to space. Two of these Astrobee units (Honey and Bumble) will be launched to the International Space Station (ISS) on April 17, 2019, on the Cygnus NG-11 (Northrop Grumman) cargo resupply spacecraft from the Mid-Atlantic Regional Spaceport (MARS) launch facility, at NASA's Wallops Flight Facility, in Virginia, while the third unit (Queen) will be launched in mid-July 2019, with the cargo resupply mission Space-X 18, from Cape Canaveral, at NASA’s Kennedy Space Center. The primary purpose of the Astrobee system is to provide an autonomous and flexible platform for research on zero-g free-flying robotics, with the ability to accommodate guest researchers looking to utilize the unique capabilities of this platform in the microgravity of low earth orbit, and to advance the state of the art of guest science software and research payloads, which range from gecko-inspired adhesives for perching on smooth surfaces, to augmented reality interfaces to help astronauts and robots work together effectively, to RFID reader, performing inventory of RFID tagged items inside the ISS. Astrobee will also serve utility functions, such as free-flying cameras to record video and provide assistance during astronaut activities, and as mobile sensor platforms to conduct surveys of the ISS. In this paper we will give an overview of the status of the Astrobee system, which includes the docking station already launched and mounted in the JAXA JEM module of the ISS, the Astrobee robots, the Astrobee robotic arms, the ground data system (GDS) and the development of the several guest science payloads.

Carlino, Roberto↗
NASA NTRS2005

Space Technology-5 Lithium-Ion Battery Design, Qualification and Integration and Testing

This document is a viewgraph presentation that reviews the Lithium Ion Battery for the Space Technology-5 (ST-5) mission. Included in the document is a review of the ST-5 Mission, a review of the battery requirements, a description of the battery and the battery materials. The testing and the integration and qualification data is reviewed.

Rao, Gopalakishna M.↗
NASA NTRS2024

Mark I Silicon Carbide Integrated Circuit Test Oven Assembly and Programming Guide

This report provides a parts list, with assembly and programming instructions for building firstgeneration (Mark I) compact test ovens; this oven design is customized for prolonged functional electrical testing of prototype silicon carbide (SiC) devices at temperatures up to 500 °C (932 °F). The general approach of using multiple compact ovens to perform long-term, high-temperature electronics testing efficiently is described in a conference paper (Izadnegahdar, Alain, et al.: Alternative Setup for LongDuration Low-Duty-Cycle 600 °C Ambient Testing of SiC Integrated Circuits. International Microelectronics Assembly and Packaging Society (iMAPS) HiTECH 2021 Technology Crossover Extravaganza, 2021), available at https://ntrs.nasa.gov/citations/20210011676. The new Mark I oven design described here offers several significant improvements over the compact oven described in that paper. For example, it is constructed from commercial off-the-shelf (COTS) components and requires minimal assembly. Much of the work involves drilling holes in the two aluminum project boxes, which contain the control electronics and the oven itself. The cost of components is less than $200 (USD) per oven, which makes constructing multiple ovens affordable. In addition, the two-box design separates the high-temperature heater from the electronics, which keeps the electronics cool, prolonging the lifetime of these components.

high temperature↗
NASA NTRS2016

Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.

Garcia, C. P.↗
NASA NTRS2020

Plankton, Aerosol, Cloud, Ocean Ecosystem (PACE) Mission Integration and Testing

This paper describes the plans, flows, key facilities, components and equipment necessary to fully integrate, functionally test and qualify the Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) Observatory. PACE is currently in the design phase of mission implementation. It is scheduled to launch in 2022, extending and improving NASA's twenty-year record of satellite observations of global ocean biology, aerosols and clouds. PACE will advance the assessment of ocean health by measuring the distribution of phytoplankton, which are small plants and algae that sustain the marine food web. It will also continue systematic records of key atmospheric variables associated with air quality and the Earth's climate. The PACE observatory is comprised of the spacecraft and three instruments, an Ocean Color Instrument (OCI) and two polarimeters, the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone). The spacecraft and the OCI, which is the primary instrument, are developed and integrated at the NASA Goddard Space Flight Center (GSFC). The OCI is a hyper-spectral scanning (HSS) radiometer designed to measure spectral radiances from the ultraviolet to shortwave infrared (SWIR) to enable advanced ocean color and heritage cloud and aerosol particle science. The HARP2 and SPEXone are secondary instruments on the PACE observatory, acquired outside of GSFC. The Hyper-Angular Rainbow Polarimeter instrument (HARP2) is a wide swath imaging polarimeter that is capable of characterizing atmospheric aerosols for purposes of sensor atmospheric correction as well as atmospheric science. The SPEXone provides atmospheric aerosol and cloud data at high temporal and spatial resolution. This paper will focus on the Integration and Test (I&T) activities for the PACE mission at NASA GSFC. This I&T phase consists of mechanical, electrical and thermal integration and test of all the spacecraft subsystems and the integration of the instruments with the spacecraft. The PACE observatory environmental tests include electromagnetic interference (EMI)/electromagnetic compatibility (EMC), vibration, acoustics, shock, thermal balance, thermal vacuum, mass properties and center of gravity. This paper will also discuss the observatory shipment to the launch site as well as the launch site processing.

Petro, Susanna↗
NASA NTRSDate not supplied

SLS Integrated Modal Test Uncertainty Quantification using the Hybrid Parametric Variation Method

Uncertainty in structural loading during launch is a significant concern in the development of spacecraft and launch vehicles. Small variations in launch vehicle and payload mode shapes and their interaction can result in significant variation in system loads. In many cases involving large aerospace systems it is difficult, not economical, or impossible to perform a system modal test. However, it is still vital to obtain test results that can be compared with analytical predictions to validate models. Instead, the “Building Block Approach” is used in which system components are tested individually. Component models are correlated and updated to agree as best they can with test results. The Space Launch System consists of a number of components that are assembled into a launch vehicle. Finite element models of the components are developed, reduced to Hurty/Craig-Bampton models and assembled to represent different phases of flight. The only opportunity to obtain modal test data from an assembled Space Launch System will be during the Integrated Modal Test. There is always uncertainty in every model, which flows into uncertainty in predicted system results. Uncertainty Quantification is used to determine statistical bounds on prediction accuracy based on model uncertainty. For the Space Launch System, model uncertainty is at the Hurty/Craig-Bampton component level. Uncertainty in the Hurty/Craig-Bampton components is quantified using the hybrid parametric variation approach that combines parametric and nonparametric uncertainty. Uncertainty in model form is one of the biggest contributors to uncertainty in complex built-up structures. This type of uncertainty cannot be represented by variations infinite element model input parameters and thus cannot be included in a parametric approach. However, model-form uncertainty can be modeled using a nonparametric approach based on random matrix theory. The hybrid parametric variation method requires the selection of dispersion values for the Hurty/Craig-Bampton fixed-interface eigenvalues, and the Hurty/Craig-Bampton stiffness matrices. Component test/analysis frequency error is used to identify the fixed-interface eigenvalue dispersions, while test/analysis cross-orthogonality is used to identify stiffness dispersion values. The hybrid parametric variation uncertainty quantification approach is applied to the Space Launch System Integrated Modal Test configuration. Monte Carlo analysis is performed, and statistics are determined for modal correlation metrics, frequency response from Integrated Modal Test shakers to selected accelerometers, as well as other metrics for determining how well target modes are excited and identified. If the predicted uncertainty envelopes future Integrated Modal Test results, then there will be increased confidence in the utility of the component-based hybrid parametric variation uncertainty quantification approach.

Uncertainty Quantification↗
NASA NTRS2008

Integrated Suit Test 1 - A Study to Evaluate Effects of Suit Weight, Pressure, and Kinematics on Human Performance during Lunar Ambulation

In an effort to design the next generation Lunar suit, NASA has initiated a series of tests aimed at understanding the human physiological and biomechanical affects of space suits under a variety of conditions. The first of these tests was the EVA Walkback Test (ICES 2007-01-3133). NASA-JSC assembled a multi-disciplinary team to conduct the second test of the series, titled Integrated Suit Test 1 (IST-1), from March 6 through July 24, 2007. Similar to the Walkback Test, this study was performed with the Mark III (MKIII) EVA Technology Demonstrator suit, a treadmill, and the Partial Gravity Simulator in the Space Vehicle Mock-Up Facility at Johnson Space Center. The data collected for IST-1 included metabolic rates, ground reaction forces, biomechanics, and subjective workload and controllability feedback on both suited and unsuited (shirt-sleeve) astronaut subjects. For IST-1 the center of gravity was controlled to a nearly perfect position while the weight, pressure and biomechanics (waist locked vs. unlocked) were varied individually to evaluate the effects of each on the ability to perform level (0 degree incline) ambulation in simulated Lunar gravity. The detailed test methodology and preliminary key findings of IST-1 are summarized in this report.

Gernhardt, Michael L.↗
NASA NTRS1994

The role of mission operations in spacecraft integration and test

The participation of mission operations personnel in the spacecraft integration and test process offers significant benefits to spacecraft programs in terms of test efficiency, staffing and training efficiency, test completeness, and subsequent cost containment. Operations personnel who have had real-time contact experience and have been responsible for the assessment of on orbit spacecraft operations bring a unique view of spacecraft operations to pre-launch spacecraft test activities. Because of the unique view of the spacecraft/ground interface that experienced operations personnel have, they can propose optimum test approaches and optimum test data analysis techniques. Additionally, the testing that is typically required to validate operations methodologies can be integrated into spacecraft performance testing scenarios.

Harvey, Raymond J.↗
NASA NTRS1989

Chain Of Test Contacts For Integrated Circuits

Test structure forms chain of "cross" contacts fabricated together with large-scale integrated circuits. If necessary, number of such chains incorporated at suitable locations in integrated-circuit wafer for determination of fabrication yield of contacts. In new structure, resistances of individual contacts determined: In addition to making it possible to identify local defects, enables generation of statistical distributions of contact resistances for prediction of "parametric" contact yield of fabrication process.

Lieneweg, Udo↗
NASA NTRS2020

The Origins Space Telescope Integration and Testing

This paper describes the plans, flows, key facilities, test beds, pathfinders, simulators and ground support equipment that could be used to fully integrate, functionally test and qualify the Origins Space Telescope (Origins). The Origins Observatory consists of the Spacecraft Bus Module (SBM) and the Cryogenic Payload Module (CPM), which comprises the telescope and three science instruments. The telescope is a Three Mirror Anastigmat (TMA) and is composed of four mirrors: three with optical power (the elliptical primary, hyperbolic secondary, and elliptical tertiary mirrors) and a flat field-steering mirror (FSM). The three science instruments spanning the wavelength range 2.8 to 588 μm provide the powerful new spectroscopic and imaging capabilities required to achieve the scientific objectives. The Origins Survey Spectrometer (OSS) uses six gratings in parallel to take multi-beam spectra simultaneously across the 25 to 588 μm window through long slits enabling deep 3D extra-galactic surveys. The Far-IR Imager/Polarimeter (FIP) provides imaging and polarimetric measurement capabilities at 50 and 250 μm. Its fast mapping enables rapid follow-up of transient or variable sources and efficient monitoring campaigns. The Mid-Infrared Spectrometer (MISC-T) provides spectroscopy simultaneously over 2.8 to 20 μm with exquisite stability and precision (<5 ppm between 2.8 to 10 μm, <20 ppm between 11 to 20 μm). All the instruments are delivered for Integration and Test fully qualified and calibrated. The Integration and Test program implemented at each level of assembly is discussed as well as the separation of thermal vacuum testing between the hot and cold zones of the Observatory. Portions of this manuscript appear in the Origins Study Final Report.

Origins↗
NASA NTRS1992

Computer integrated laboratory testing

The objective is the integration of computers into the Engineering Materials Science Laboratory course, where existing test equipment is not computerized. The first lab procedure is to demonstrate and produce a material phase change curve. The second procedure is a demonstration of the modulus of elasticity and related stress-strain curve, plastic performance, maximum and failure strength. The process of recording data by sensors that are connected to a data logger which adds a time base, and the data logger in turn connected to a computer, places the materials labs into a computer integrated mode with minimum expense and maximum flexibility. The sensor signals are input into a spread sheet for tabular records, curve generation, and graph printing.

Dahl, Charles C.↗
NASA NTRS2007

Integration and Testing Challenges of Small Satellite Missions: Experiences from the Space Technology 5 Project

The Space Technology 5(ST5) payload was successfully carried into orbit on an OSC Pegasus XL launch vehicle, which was carried aloft and dropped from the OSC Lockheed L-1011 from Vandenberg Air Force Base March 22,2006, at 9:03 am Eastern time, 6:03 am Pacific time. In order to reach the completion of the development and successful launch of ST 5, the systems integration and test(I&T) team determined that a different approach was required to meet the project requirements rather than the standard I&T approach used for single, room-sized satellites. The ST5 payload, part of NASA's New Millennium Program headquartered at JPL, consisted of three micro satellites (approximately 30 kg each) and the Pegasus Support Structure (PSS), the system that connected the spacecrafts to the launch vehicle and deployed the spacecrafts into orbit from the Pegasus XL launch vehicle. ST5 was a technology demonstration payload, intended to test six (6) new technologies for potential use for future space flights along with demonstrating the ability of small satellites to perform quality science. The main technology was a science grade magnetometer designed to take measurements of the earth's magnetic field. The three spacecraft were designed, integrated, and tested at NASA Goddard Space Flight Center with integration and environmental testing occurring in the Bldg. 7-1 0-15-29. The three spacecraft were integrated and tested by the same I&T team. The I&T Manager determined that there was insufficient time in the schedule to perform the three I&T spacecraft activities in series used standard approaches. The solution was for spacecraft #1 to undergo integration and test first, followed by spacecraft #2 and #3 simultaneously. This simultaneous integration was successful for several reasons. Each spacecraft had a Lead Test Conductor who planned and coordinated their spacecraft through its integration and test activities. One team of engineers and technicians executed the integration of all three spacecraft, learning and gaining knowledge and efficiency as spacecraft #1 integration and testing progressed. They became acutely familiar with the hardware, operation and processes for I&T, thus each team member had the experience and knowledge to safely execute I&T for spacecraft #2 and #3 together. The integration team was very versatile and each member could perform many different activities or work any spacecraft, when needed. Daily meetings between the three Lead TCs and technician team allowed the team to plan and implement activities efficiently. The three (3) spacecraft and PSS were successfully integrated and tested, shipped to the launch site, and ready for launch per the I&T schedule that was planned three years previously.

Sauerwein, Timothy A.↗
NASA NTRS1984

Guidelines for testing and release procedures

Guidelines and procedures are recommended for the testing and release of the types of computer software efforts commonly performed at NASA/Ames Research Center. All recommendations are based on the premise that testing and release activities must be specifically selected for the environment, size, and purpose of each individual software project. Guidelines are presented for building a Test Plan and using formal Test Plan and Test Care Inspections on it. Frequent references are made to NASA/Ames Guidelines for Software Inspections. Guidelines are presented for selecting an Overall Test Approach and for each of the four main phases of testing: (1) Unit Testing of Components, (2) Integration Testing of Components, (3) System Integration Testing, and (4) Acceptance Testing. Tools used for testing are listed, including those available from operating systems used at Ames, specialized tools which can be developed, unit test drivers, stub module generators, and the use of format test reporting schemes.

Molari, R.↗
NASA NTRSDate not supplied

RST Optical Telescope Integration and Test Preparation

The OTA for the Nancy Grace Roman Space Telescope includes the primary mirror, secondary mirror, and aft optics for guiding light into the Wide Field Instrument and the Coronagraph Instrument. The telescope is taking shape as the tested optical mirror assemblies are integrated. The assemblies have been thermal cycled to the cold temperatures for infrared operation, load tested to launch loads, vibration tested, and optically tested. Testing included launch-level vibration testing of the 2.4-meter light-weighted primary mirror assembly. In addition, the telescope control electronics (TCE) box has been fully assembled and the environmental testing of the TCE is progressing. Pictures and descriptions of the integration and test progress are provided, along with performance results measured at these levels of assemblies. Planning and test equipment preparation for the telescope thermal vacuum testing continues including plans to take advantage of the large dynamic range available with focus diversity phase retrieval and a Shack-Hartmann wavefront sensor for the gravity-sagged primary mirror.

Tony L Whitman↗
NASA NTRS2001

Integration and Test for Small Shuttle Payloads

Recommended approaches for shuttle small payload integration and test (I&T) are presented. The paper is intended for consideration by developers of small shuttle payloads, including I&T managers, project managers, and system engineers. Examples and lessons learned are presented based on the extensive history of the NASA's Hitchhiker project. All aspects of I&T are presented, including: (1) I&T team responsibilities, coordination, and communication; (2) Flight hardware handling practices; (3) Documentation and configuration management; (4) I&T considerations for payload development; (5) I&T at the development facility; (6) Prelaunch operations, transfer, orbiter integration, and interface testing; and (7) Postflight operations. This paper is of special interest to those payload projects which have small budgets and few resources: That is, the truly 'faster, cheaper, better' projects. All shuttle small payload developers are strongly encouraged to apply these guidelines during I&T planning and ground operations to take full advantage of today's limited resources and to help ensure mission success.

Wright, Michael R.↗
NASA NTRS2007

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew access to the International Space Station (ISS) and, together with the Ares V Cargo Launch Vehicle (CaLV), serves as one component of a future launch capability for human exploration of the Moon. During the system requirements definition process and early design cycles, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements: the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine, will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle dynamic test (IVDT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, and a highaltitude actuation of the launch abort system (LAS) following separation. The Orion-1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Cockrell, Charles E., Jr.↗