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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

Theoretical considerations of some nonlinear aspects of hypersonic panel flutter

A research project to analyze the effects of hypersonic nonlinear aerodynamic loading on panel flutter is reported. The test equipment and procedures for conducting the tests are explained. The effects of aerodynamic linearities on stability were evaluated by determining constant-initial-energy amplitude-sensitive stability boundaries and comparing them with the corresponding linear stability boundaries. An attempt to develop an alternative method of analysis for systems where amplitude-sensitive instability is possible is presented.

Mcintosh, S. C., Jr.↗

On-orbit checkout study

The spaceborne testing equipment carried by the orbiter and the measuring equipment onboard the satellite (telemetry) is tested to verify that each is operating satisfactorily. The satellite command system is also checked. Thermal stabilization with the satellite in the orbiter shadow is achieved in six to eight hours. Satellite subsystem tests are run, and thermal control by heaters is checked. Thermal stabilization with the satellite exposed to the sun (when the orbiter is in sunlight) is again achieved in an estimated six to eight hours. Subsystem tests are again run in the hot condition, and heat rejection tests are made.

Pritchard, E. I.↗

FTS maintenance and calibration at DSS 42/43

An FTS maintenance and calibration task was conducted at DSS 42/43 during August 1978. The objectives of this effort were (1) the routine maintenance and calibration of hydrogen masers, (2) installation and calibration of cesium standards, (3) installation of test equipment for frequency measurement, (4) CRG testing, (5) cabling inspection and repair, (6) check thermal and magnetic environment of H-maser/cesium room, and (7) calibration of frequency and timing subsystem.

Dachel, P. R.↗

Elimination of Potential Electrical Stress During EMC (CS01) Testing

This viewgraph presentation reviews possible ways to eliminate electrical stress during Electromagneticic Compatibility (EMC) testing. The presentation reviews tests that have had problems due to electrical stress. On December 5, 1995 Cassini Radar instrument failed a functional test in preparation for EMC conducted susceptibility (CSO 1 ) testing. The instrument power supply did not turn on as required, and failure occurred prior to injection of CS test stimulus. A investigation of the failure was conducted. A PSPICE simulation of Cassini Radar 30V line using the EMC test setup was performed; the result of the simulation was an oscillation on the 30V input of the power supply. In another case: on December 28, 1999 an oscillation occurred on the input power line of the SlRTF Infrared Array Camera (IRAC) while preparing to perform CSOI testing, Resulted in damage to flight hardware. Subsequent to failure, JPL provided GSFC history and corrective action from Cassini Radar CSOI test failure GSFC implemented the same corrective action as JPL, except that the value of the resistor connected across the isolation transformer primary winding is 2.5 ohms instead of 50 ohms. Three recommendations are made: (1) Make EMC test community aware of the problem and potential solutions by presenting papers at major environmental test conferences (2) Include warnings and safeguards in EMC test requirements and procedures (3) Try to convince EMC test equipment suppliers to design a CSOl test fixture similar to fixture shown in the diagram

Cassini radar↗

Closeout Report for the Refractory Metal Accelerated Heat Pipe Life Test Activity

With the selection of a gas-cooled reactor, this heat pipe accelerated life test activity was closed out and its resources redirected. The scope of this project was to establish the long-term aging effects on Mo-44.5%Re sodium heat pipes when subjected to space reactor temperature and mass fluences. To date, investigators have demonstrated heat pipe life tests of alkali metal systems up to .50,000 hours. Unfortunately, resources have not been available to examine the effect of temperature, mass fluence, or impurity level on corrosion or to conduct post-test forensic examination of heat pipes. The key objective of this effort was to establish a cost/time effective method to systematically test alkali metal heat pipes with both practical and theoretical benefits. During execution of the project, a heat pipe design was established, a majority of the laboratory test equipment systems specified, and operating and test procedures developed. Procurements for the heat pipe units and all major test components were underway at the time the stop work order was issued. An extremely important outcome was the successful fabrication of an annular wick from Mo-5%Re screen (the single, most difficult component to manufacture) using a hot isostatic pressing technique. This Technical Publication (TP) includes specifics regarding the heat pipe calorimeter water-cooling system, vendor design for the radio frequency heating system, possible alternative calorimeter designs, and progress on the vanadium equilibration technique. The methods provided in this TP and preceding project documentation would serve as a good starting point to rapidly implement an accelerated life test. Relevant test data can become available within months, not years, and destructive examination of the first life test heat pipe might begin within 6 months of test initiation. Final conclusions could be drawn in less than a quarter of the mission duration for a long-lived, fission-powered, deep space probe.

Martin, J.↗

Static Torsion Testing and Modeling of a Variable Thickness Hybrid Composite Bull Gear

Torsional strength of a variable thickness hybrid gear web was measured by performing static testing on the part in a large torsion test frame. The outer rim of the hybrid gear web was fixed to the bottom of the test frame and loading was applied to the web through a shaft. The test setup included the installation of digital image correlation (DIC) systems to obtain deformation and strain measurements from the surfaces of the hybrid gear web and the mechanical test equipment to ensure reliability of the test. The results indicated that the variable thickness hybrid gear web achieved approximately twice the torsional strength compared to that of previous hybrid gear designs. The DIC analysis showed significantly more straining of the loading shaft than the actual test article. Additionally, the results demonstrated the importance and affect that the metallic, lobed interlock features had on the principal strain and out-of-plane displacement fields. The analysis revealed that the fixed outer rim was in fact rotating and a rigid body motion compensation (RBMC) function was computed to determine the actual rotation of the hub and composite web relative to the outer rim. Modeling simulations were performed for the variable thickness hybrid gear web and correlated well with the RBMC rotational deformation seen in the DIC analysis. In addition to benchmarking the load capacity of the hybrid gear web, measuring its strength is useful information to define the parameters needed for dynamic, endurance, and other testing of the part.

Johnston, Joel P.↗

Capturing, Analyzing, Maintaining, and Disseminating Shape Memory Material Data Between Information Management Systems

With an increased demand on reducing the time, cost, and effort to develop new materials, Integrated Computational Materials Engineering (ICME) has received widespread attention in various engineering disciplines as a catalyst for significantly reducing experimental testing during the material design process. An ICME approach to design can enable ‘fit-for-purpose’ materials to be realized in engineering applications by incorporating well-understood process-property-performance relationships between the various length and time scales in a material’s structure, enabling material optimization. However, such an approach requires validated multiscale models at the various length scales for a material, which in turn requires a large amount of data, a robust means of storing the data, and the ability to link data to developed material models. The NASA Vision 2040 [1] has identified nine key elements to enabling ICME approaches in system level design, with one being “Data, Information, and Visualization”, thus outlining the importance of a robust information management system for ICME. As the relationship between microstructure, properties, and material performance become better understood and incorporated into multiscale models that can be leveraged in application design, the emergence of new materials with application-driven properties can be realized. One such new material class that has seen growing attention are shape memory materials (SMM), in which a material can transition between a deformed and undeformed state via a reversible phase transformation when subject to a thermal, mechanical, or magnetic load [2]. SMMs have been used widely in aerospace and biomedical industries, including applications such as actuators, low-shock mechanisms, medical staples, braces, and stents [3, 4]. These materials exhibit unique behavior due to their ability to transition between phases, and thus the mechanisms that enable this transition must be captured in a data information management system and incorporated into SMM material models. At NASA Glenn Research Center, the Shape Memory Materials Database (SMMD) Tool has been developed to capture the necessary information that governs SMM material behavior and provide users the ability to select and visualize various SMMs for a specific application [5]. The database contains point-wise data for published SMM materials, along with the pedigree metadata for traceability necessary for a robust information management system. The database is also capable of storing in-house test data performed at NASA GRC by interacting with the developed Shape Memory Alloy (SMA) Analytics tool to extract the necessary point-wise values and populate the database. Although the SMMD Tool offers its users a single, authoritative source for SMM material data that is critical for model development and material design, the full material pedigree of the in-house test data for SMMs is not currently captured and is out of the scope for the SMMD tool. In this work, the schema for capturing SMM test data within the larger NASA GRC ICME Schema [6, 7, 8, 9] will be developed and implemented for thermomechanical tests conducted at NASA GRC. The developed schema will not only store the relevant data needed for the SMMD tool, but also the material pedigree (i.e., production of the bulk material, bulk material analysis, sample cut-out diagrams, sample fabrication procedure, etc.), test pedigree (i.e., test equipment used, measurement systems used, raw test data), and analysis pedigree (i.e., how the data in the SMMD tool is calculated). Furthermore, a Python-based framework will be developed to seamlessly interact between the SMA Analytics and SMMD tools, which will write the full dataset and associated metadata to the GRC Information Management System before passing the required point-wise data to the SMMD tool. Data informatics is a key element of the NASA Vision 2040, which requires not only that data is stored and maintained throughout the material lifecycle, but that the data is also accessible and reusable such that material development efforts can be minimized. Therefore, for an ICME design approach to be realized, a centralized information management system that drives the ICME process must be able to communicate with other databases. The work that will be presented in this presentation will therefore not only demonstrate the ability of NASA GRC’s information management system to capture SMM data, but also its ability to interact with pre-existing tools specialized for such materials.

Data management↗

A 7.6m /25-ft/ extreme environments simulator

Stainless steel cylindrical simulation chamber permits testing equipment under extreme cold, high partial vacuums, and intense solar radiation. Applications include heat balance and temperature distribution studies, investigations of subsystem interactions, tests of attitude control equipment and sensors, and acceptance tests of complete systems.

Argoud, M. J.↗

Influence of gaseous hydrogen on the mechanical properties of incoloy 903

Solid specimens of the alloy Inconel 903 (iron based alloy) were exposed to four gaseous environments and high temperatures. Air, pure helium, pure hydrogen, and hydrogen and water vapor combined were the gaseous environments employed, and the temperature was 1400 F. Various mechanical property tests (low cycle fatigue, creep-rupture, tensile properties) were performed on the alloy. Results indicate that the hydrogen and water vapor environment cause a sharp reduction in the mechanical properties of the alloy. Photographs of the test equipment used and the microstructure of the tested alloy are included.

Source record↗

Pressure scaled water impact test of a 12.5 inch diameter model of the Space Shuttle solid rocket booster

A total of 59 tail first drops were made. Model entry conditions simulated full scale vertical velocities of approximately 75 to 110 ft/sec with horizontal velocities up to 45 ft/sec and impact angles to + or - 10 deg. These tests were conducted at scaled atmospheric pressures (1.26 psia or 65 mm.Hg). The model, test program, test facility, test equipment, instrumentation system, data reduction procedures, and test results are described.

Source record↗

High frequency, high power capacitor development

A program to develop a special high energy density, high power transfer capacitor to operate at frequency of 40 kHz, 600 V rms at 125 A rms plus 600 V dc bias for space operation. The program included material evaluation and selection, a capacitor design was prepared, a thermal analysis performed on the design. Fifty capacitors were manufactured for testing at 10 kHz and 40 kHz for 50 hours at Industrial Electric Heating Co. of Columbus, Ohio. The vacuum endurance test used on environmental chamber and temperature plate furnished by Maxwell. The capacitors were energized with a special power conditioning apparatus developed by Industrial Electric Heating Co. Temperature conditions of the capacitors were monitored by IEHCo test equipment. Successful completion of the vacuum endurance test series confirmed achievement of the main goal of producing a capacitor or reliable operation at high frequency in an environment normally not hospitable to electrical and electronic components. The capacitor developed compared to a typical commercial capacitor at the 40 kHz level represents a decrease in size and weight by a factor of seven.

White, C. W.↗

Qualification Motor no. 8 (QM-8), volume 1

All inspection and instrumentation data indicate that the QM-8 static test firing conducted 20 January 1989 was successful. Ambient temperature at T-0 was 28 F. With two flights successfully accomplished, this final test in the redesigned solid rocket motor (RSRM) program certified that the design meets motor performance requirements under extreme cold conditions. This test was a prerequisite to the third flight. The entire test article was cold conditioned at 20 to 25 F for approximately 31 days to assure a maximum propellant mean bulk temperature (PMBT) of 40 F, making it the lowest PMBT in the history of the program. This extreme condition also presented the opportunity to certify critical components at low temperatures. Certification of field joint and igniter heaters, adhesive bondline integrity, flex bearing performance, flight instrumentation performance, RSRM seal performance, and LSC and nozzle plug performance was accomplished. Prior to motor ignition, the field joints were maintained between 75 to 130 F, the igniter-to-case joint was maintained between 75 to 123 F, and the case-to-nozzle joint was maintained between 75 to 120 F. QM-8 was tested with induced side loads to simulate the strut loads experienced during ignition and maximum aerodynamic loading conditions. The ability of the safe and arm device to change position from safe-to-arm and arm-to-safe was certified. Ballistics performance was certified at the lower limits. Values were within specification requirements. Nozzle performance was nominal with typical erosion. The use of Fiberite carbon-cloth phenolic was certified. The water deluge system, CO2 quench, and other test equipment performed as planned during all required test operations.

Garecht, D. M.↗

Space shuttle Production Verification Motor 1 (PV-1) static fire

All inspection and instrumentation data indicate that the PV-1 static test firing conducted 18 Aug. 1988 was successful. With the exception of the intentionally flawed joints and static test modifications, PV-1 was flight configuration. Fail-safe flaws guaranteeing pressure to test the sealing capability of primary O-rings were included in the aft field joint, case-to-nozzle joint, and nozzle internal Joint 5. The test was conducted at ambient conditions, with the exception of the field joints and case/nozzle joints which were maintained at a minimum of 75 F. Ballistics performance values were within specification requirements. The PV-1 motor exhibited chamber pressure oscillations similar to previously tested Space Shuttle redesigned solid rocket motors, particularly QM-7. The first longitudinal mode oscillations experienced by PV-1 were the strongest ever measured in a Space Shuttle motor. Investigation into this observation is being conducted. Joint insulation performed as designed with no evidence of gas flow within unflawed forward field joints. The intentionally flawed center and aft case field joint insulation performance was excellent. There was no evidence of hot gas past the center field joint capture feature O-ring, the case-to-nozzle joint primary O-ring, or the aft field joint primary O-ring. O-ring seals and barriers with assured pressure at the flaws showed erosion and heat effect, but all sealed against passage of hot gases with the exception of the aft field joint capture feature O-ring. There was no evidence of erosion, heat effect, or blowby on any O-ring seals or barriers at the unflawed joints. Nozzle performance was nominal with typical erosion. Post-test examination revealed that the forward nose ring was of the old high performance motor design configuration with the 150-deg ply angle. All nozzle components remained intact for post-test evaluation. The thrust vector control system operated correctly. The water deluge system, CO2 quench, and other test equipment performed as planned during all required test operations.

Source record↗

Hydrazine Catalyst Production: Sustaining S-405 Technology

The development of the iridium-based Shell 405 catalyst for spontaneous decomposition of hydrazine was one of the key enabling technologies for today's spacecraft and launch vehicles. To ensure that this crucial technology was not lost when Shell elected to exit the business, Aerojet, supported by NASA, has developed a dedicated catalyst production facility that will supply catalyst for future spacecraft and launch vehicle requirements. We have undertaken a program to transfer catalyst production from Shell Chemical USA (Houston, TX) to Aerojet's Redmond, WA location. This technology transition was aided by Aerojet's 30 years of catalyst manufacturing experience and NASA diligence and support in sustaining essential technologies. The facility has produced and tested S-405 catalyst to existing Shell 405 specifications and standards. Our presentation will describe the technology transition effort including development of the manufacturing facility, capture of the manufacturing process, test equipment validation, initial batch build and final testing.

Wucherer, E. J.↗

Programs for Testing an SSME-Monitoring System

A suite of computer programs has been developed for special test equipment (STE) that is used in verification testing of the Health Management Computer Integrated Rack Assembly (HMCIRA), a ground-based system of analog and digital electronic hardware and software for "flight-like" testing for development of components of an advanced health-management system for the space shuttle main engine (SSME). The STE software enables the STE to simulate the analog input and the data flow of an SSME test firing from start to finish.

Lang, Andre↗

Hardware and Software Integration to Support Real-Time Space Link Emulation

Prior to operational use, communications hardware and software must be thoroughly tested and verified. In space-link communications, field testing equipment can be prohibitively expensive and cannot test to non-ideal situations. In this paper, we show how software and hardware emulation tools can be used to accurately model the characteristics of a satellite communication channel in a lab environment. We describe some of the challenges associated with developing an emulation lab and present results to demonstrate the channel modeling. We then show how network emulation software can be used to extend a hardware emulation model without requiring additional network and channel simulation hardware.

Murawski, Robert↗