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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Post-test Inspection of NASA’s Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge Chamber

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for the discharge chamber as well as other miscellaneous components such as the high-voltage propellant isolators and electrical cabling. Comparison of magnetic field measurements taken during pretest and post-test inspections indicate that the field strength did not degrade, consistent with performance data obtained during the test. Inspection of discharge chamber mesh samples show a deposition coating primarily composed of grid material that is approximately 15 μm in thickness. This thickness is well within the retention capability of the mesh and is therefore not expected to present any issues. Approximately 3.1 grams of deposition flakes were found at the bottom of the discharge chamber, composed primarily of grid material and carbon. Calculated size histograms of these flakes indicate that 99% have a maximum dimension of 200 μm or smaller, which is significantly less than the ion optics grid gap. Larger flakes that are capable of causing a grid-to-grid short will be analyzed to determine if their formation will occur in flight or is a facility effect. The high-voltage propellant isolators as well as numerous other electrical insulators were inspected and no evidence of arcing or any other issues were found.

Rohit Shastry↗
NASA NTRS1976

Studies of the exhaust products from solid propellant rocket motors

This study was undertaken to determine the feasibility of conducting environmental chamber tests on the physical processes which occur when a solid rocket motor exhaust mixes with the ambient atmosphere. Of particular interest was the interaction between hydrogen chloride, aluminum oxide, and water vapor. The program consisted of three phases: (1) building a small rocket motor and using it to provide the exhaust species in a controlled environment; (2) evaluating instruments used to detect and measure HCl concentrations and if possible determining whether the HCl existed in the gaseous state or as an acid aerosol; (3) monitoring a series of 6.4-percent scale space shuttle motor tests and comparing the results to the environmental chamber studies. Eighteen firings were conducted in an environmental chamber with the initial ambient relative humidity set at values from 29 to 100 percent. Two additional firings were made in a large shed, and four were made on an open concrete apron. Six test firings at MSFC were monitored, and the ground level concentrations are reported. Evidence is presented which shows that the larger Al2O3 (5 to 50 micrometers) particles from the rocket motor can act as condensation nuclei. Under appropriate ambient conditions where there is sufficient water vapor this results in the formation of an acid aerosol. Droplets of this acid were detected both in the environmental chamber and in the scaled shuttle engine tests.

Dawbarn, R.↗
DOE OSTI2025

Novel Technology of Non-Contact Real-Time Radiation Damage Sensor for High Power Targets

High-power proton beams planned for forthcoming long-baseline neutrino experiments will subject solid targets to unprecedented radiation damage, threatening reliability and increasing costs. To address this challenge, we are building a real-time, non-contact sensor that tracks damage by measuring broadband laser reflectivity changes from the target surface. A low-power super-continuum Class 3B laser illuminates the sample inside a vacuum test chamber while a high-resolution fiber-coupled spectrometer captures S- and P-polarized light; spectral shifts reveal defect-driven variations in optical constants. My internship goal is to design, build, and commission this prototype by implementing a laser-safety interlock and light shield, integrating remote-operation cameras, and fabricating modular 3-D-printed mounts that enable tool-free swaps without disturbing alignment. The laser, spectrometer, and vacuum chamber have been delivered; interlock hardware, cameras, and mounts are in final assembly, and leak testing of the chamber is underway. Upcoming work will focus on initial calibration of the sensor and executing first beam-irradiation studies.

Pumarino, Rafael↗
NASA NTRSDate not supplied

Extreme Environment Hot Fire Durability of Post-Processed Additively Manufactured GRCop-Alloy Combustion Chambers in LOX/Hydrogen and LOX/Methane

Extreme environment survivability of metal additive manufactured (AM) GRCop-alloy thrust chambers has been demonstrated in different bi-propellants at near stoichiometric and even oxygen rich combustion. GRCop-alloy chambers tested at NASA Marshall Space Flight Center (MSFC) have accumulated over 26,000 seconds of hot fire duration and over 500 starts. These chambers are produced using an AM process called laser powder bed fusion (L-PBF). A major feature of this process is high wall surface roughness which can be customized in post processing to leverage various performance advantages. Post-processing can include heat treatment, final machining, polishing, and welding and is key to hardware survivability in extreme environments. Surface finish enhancement techniques were applied to the hot wall and coolant channels to reduce the overall total heat load to the chamber walls. Performance optimization of various thrust class TCA’s is a strategic technology goal of NASA MSFC. Three different chamber geometries using cryogenic methane and de-ionized water as coolants were hot fire tested to obtain their life cycle, pressure drop, and heat load performances. Several 1.2K lbf LOX/H2 chambers, 1K lbf LOX/CH4 chambers, and 7K lbf LOX/CH4 chambers were tested. All post-processed configurations performed remarkably well when subjected to extreme hot fire test conditions. Streaking and blanching due to localized oxygen rich conditions were observed on some test articles in their as-built surface finish state. However, this is actually a function of the injector mixing and only serves to further establish the durability of L-PBF GRCop-alloy thrust chambers. Several different polishing techniques were applied to the hot wall and integrated coolant channels prior to hot fire testing and their performances assessed. Overall, AM produced GRCop chambers are extremely reliable, durable, and customizable to the desired performance metrics.

grcop↗
NASA NTRS1996

Surface Tension Driven Convection Experiment-2 (STDCE-2

The surface tension driven convection experiment-2 (STDCE-2) was conducted onboard the U.S. Microgravity Laboratory (USML)-2 Spacelab which was launched on October 20, 1995. The main objectives of the experiment was to study oscillatory thermocapillary flows in microgravity. Thermocapillary flows were generated in cylindrical test chambers filled with 2 centistokes silicone oil. Six modules were used to study three different chamber diameters and two different heating modes. Tests with both flat and curved free surfaces were conducted. The flow field was studied by flow visualization and an infrared imaging system recorded the oil free-surface temperature. An optical (Ronchi) system was used to measure the oil free-surface deformation and motions. A total of 55 tests were conducted and oscillations were found in most of them. The data are being analyzed.

Ostrach, Simon↗
NASA NTRS2004

NASA Glenn's Acoustical Testing Laboratory Awarded Accreditation by the National Voluntary Laboratory Accreditation Program

NASA Glenn Research Center's Acoustical Testing Laboratory (ATL) provides a comprehensive array of acoustical testing services, including sound pressure level, sound intensity level, and sound-power-level testing per International Standards Organization (ISO)1 3744. Since its establishment in September 2000, the ATL has provided acoustic emission testing and noise control services for a variety of customers, particularly microgravity space flight hardware that must meet International Space Station acoustic emission requirements. The ATL consists of a 23- by 27- by 20-ft (height) convertible hemi/anechoic test chamber and a separate sound-attenuating test support enclosure. The ATL employs a personal-computer-based data acquisition system that provides up to 26 channels of simultaneous data acquisition with real-time analysis (ref. 4). Specialized diagnostic tools, including a scanning sound-intensity system, allow the ATL's technical staff to support its clients' aggressive low-noise design efforts to meet the space station's acoustic emission requirement. From its inception, the ATL has pursued the goal of developing a comprehensive ISO 17025-compliant quality program that would incorporate Glenn's existing ISO 9000 quality system policies as well as ATL-specific technical policies and procedures. In March 2003, the ATL quality program was awarded accreditation by the National Voluntary Laboratory Accreditation Program (NVLAP) for sound-power-level testing in accordance with ISO 3744. The NVLAP program is administered by the National Institutes of Standards and Technology (NIST) of the U.S. Department of Commerce and provides third-party accreditation for testing and calibration laboratories. There are currently 24 NVLAP-accredited acoustical testing laboratories in the United States. NVLAP accreditation covering one or more specific testing procedures conducted in accordance with established test standards is awarded upon successful completion of an intensive onsite assessment that includes proficiency testing and documentation review. The ATL NVLAP accreditation currently applies specifically to its ISO 3744 soundpower- level determination procedure (see the photograph) and supporting ISO 17025 quality system, although all ATL operations are conducted in accordance with its quality system. The ATL staff is currently developing additional procedures to adapt this quality system to the testing of space flight hardware in accordance with International Space Station acoustic emission requirements.<

Akers, James C.↗
NASA NTRS1992

A new approach for data acquisition at the JPL space simulators

In 1990, a personal computer based data acquisition system was put into service for the Space Simulators and Environmental Test Laboratory at the Jet Propulsion Laboratory (JPL) in Pasadena, California. The new system replaced an outdated minicomputer system which had been in use since 1980. This new data acquisition system was designed and built by JPL for the specific task of acquiring thermal test data in support of space simulation and thermal vacuum testing at JPL. The data acquisition system was designed using powerful personal computers and local-area-network (LAN) technology. Reliability, expandability, and maintainability were some of the most important criteria in the design of the data system and in the selection of hardware and software components. The data acquisition system is used to record both test chamber operational data and thermal data from the unit under test. Tests are conducted in numerous small thermal vacuum chambers and in the large solar simulator and range in size from individual components using only 2 or 3 thermocouples to entire planetary spacecraft requiring in excess of 1200 channels of test data. The system supports several of these tests running concurrently. The previous data system is described along with reasons for its replacement, the types of data acquired, the new data system, and the benefits obtained from the new system including information on tests performed to date.

Fisher, Terry C.↗
NASA NTRS1952

Effect of design changes and operating conditions on combustion and operational performance of a 28-inch diameter Ram-jet engine / T. B. Shillito and Shigeo Nakanishi

The results of an altitude test-chamber investigation of the effects of a number of design changes and operating conditions on altitude peformance of a 28-inch diameter ram jet engine are presented. Most of the investigation was for a simulated flight Mach number of 2.0 above the tropopause. Fuel-air distribution, gutter width, the presence of a pilot flame, cimbustion-chamber-inlet temperature, and exhaust-nozzle throat area were found to have significant effects on limits of combustion. Combustion efficiency increased with increasing combustion-chamber-inlet temperature and was adversely affected by an increase in the exhaust-nozzld area. Similiar lean limits of combustion were obtained for both Diesel fuel and normal heptane, but combustion efficiences obtained with Diesel fuel were lower than those obtained with normal heptane.

NOZZLES, EXHAUST - ENGINES, JET↗
DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1974

The use of large cylindrical enclosures as a cost effective approach to reverberant acoustic testing

The feasibility of using existing cylindrical enclosures as cost effective substitutes for reverberant acoustic test chambers is investigated. In particular the performance of two large cylindrical environmental chambers, 1400 and 14,000 cu m in volume, is evaluated in detail. Reverberant acoustic chamber characteristics are predicted using classical acoustic theory and are compared to results obtained from actual chamber measurements. A method of scaling low level test results to predict the performance of a particular driver/horn/chamber configuration is also discussed. This prediction technique is confirmed by actual test data using a 200 kilowatt acoustic generator.

On, F. J.↗
NASA NTRS1988

Computer code for the prediction of nozzle admittance

A procedure which can accurately characterize injector designs for large thrust (0.5 to 1.5 million pounds), high pressure (500 to 3000 psia) LOX/hydrocarbon engines is currently under development. In this procedure, a rectangular cross-sectional combustion chamber is to be used to simulate the lower traverse frequency modes of the large scale chamber. The chamber will be sized so that the first width mode of the rectangular chamber corresponds to the first tangential mode of the full-scale chamber. Test data to be obtained from the rectangular chamber will be used to assess the full scale engine stability. This requires the development of combustion stability models for rectangular chambers. As part of the combustion stability model development, a computer code, NOAD based on existing theory was developed to calculate the nozzle admittances for both rectangular and axisymmetric nozzles. This code is detailed.

Nguyen, Thong V.↗
NASA NTRS1991

A new technique for oil backstreaming contamination measurements

Due to the large size and the number of diffusion pumps, space simulation chambers cannot be easily calibrated by the usual test dome method for measuring backstreaming from oil diffusion pumps. In addition, location dependent contamination may be an important parameter of the test. The backstreaming contamination was measured in the Space Power Facility (SPF) near Sandusky, OH, the largest space simulation vacuum test chamber in the U.S.. Small clean silicon wafers placed at all desired measurement sites were used as contamination sensors. The facility used diffusion pumps with DC 705 oil. The thickness of the contamination oil film was measured using ellipsometry. Since the oil did not wet the silicon substrate uniformly, two analysis models were developed to measure the oil film: (1) continuous, homogeneous film; and (2) islands of oil with the islands varying in coverage fraction and height. In both cases, the contamination film refractive index was assumed to be that of DC 705. The second model improved the ellipsometric analysis quality parameter by up to two orders of magnitude, especially for the low coverage cases. Comparison of the two models shows that the continuous film model overestimates the oil volume by less than 50 percent. Absolute numbers for backstreaming are in good agreement with published results for diffusion pumps. Good agreement was also found between the ellipsometric results and measurements done by x-ray photoelectron spectroscopy (XPS) and by scanning electron microscopy (SEM) on examples exposed to the same vacuum runs.

Alterovitz, S. A.↗
NASA NTRS1993

New technique for oil backstreaming contamination measurements

Due to the large size and the number of diffusion pumps, space simulation chambers cannot be easily calibrated by the usual test dome method for measuring backstreaming from oil diffusion pumps. In addition, location dependent contamination may be an important parameter of the test. The backstreaming contamination in the Space Power Facility (SPF) near Sandusky, Ohio, the largest space simulation vacuum test chamber in the U.S.A. was measured. Small size clean silicon wafers as contamination sensors placed at all desired measurement sites were used. The facility used diffusion pumps with DC 705 oil. The thickness of the contamination oil film was measured using ellipsometry. Since the oil did not wet uniformly the silicon substrate, two analysis models were developed to measure the oil film: continuous, homogeneous film and islands of oil with the islands varying in coverage fraction and height. In both cases, the contamination film refractive index was assumed to be that of DC 705. The second model improved the ellipsometric analysis quality parameter by up to two orders of magnitude, especially for the low coverage cases. Comparison of the two models for our case shows that the continuous film model overestimates the oil volume by less than 50 percent. Absolute numbers for backstreaming are in good agreement with published results for diffusion pumps. Good agreement was also found between the ellipsometric results and measurements done by x ray photoelectron spectroscopy (XPS) and by scanning electron microscopy (SEM) on samples exposed to the same vacuum runs.

Alterovitz, S. A.↗
NASA NTRS2000

Investigation of Acoustic Fields for the Cassini Spacecraft: Reverberant Versus Launch Environments

The characterization and understanding of the acoustic field within a launch vehicle's payload fairing (PLF) is critical to the qualification of a spacecraft and ultimately to the success of its mission. Acoustic measurements taken recently for the Cassini mission have allowed unique opportunities to advance the aerospace industry's knowledge in this field. Prior to its launch, the expected liftoff acoustic environment of the spacecraft was investigated in a full-scale acoustic test of a Titan IV PLF and Cassini simulator in a reverberant test chamber. A major goal of this acoustic ground test was to quantify and verify the noise reduction performance of special barrier blankets that were designed especially to reduce the Cassirii acoustic environment. This paper will describe both the ground test and flight measurements, and compare the Cassini acoustic environment measured during launch with that measured earlier in the ground test. Special emphasis will be given to the noise reduction performance of the barrier blankets and to the acoustic coherence measured within the PLF.

Hughes, William O.↗
NASA NTRS2004

Cryogenic testing of Planck sorption cooler test facility

A test facility has been upgraded in preparation for testing of two hydrogen sorption cryocoolers operating at 18/20 K. these sorption coolers are currently under development at the Jet Propulsion Laboratory. This work summarizes the scope of the test facility upgrade, including design for cryogenic cooling power delivery, system thermal management, insulation schemes, and data acquisition techniques. Ground support equipment for the sorption coolers, structural features of the test chamber, and the vacuum system involved for system testing will also be described in detail.

Planck sorption cooler↗
NASA NTRS2008

Analysis of the Effects of Vitiates on Surface Heat Flux in Ground Tests of Hypersonic Vehicles

To achieve the high enthalpy conditions associated with hypersonic flight, many ground test facilities burn fuel in the air upstream of the test chamber. Unfortunately, the products of combustion contaminate the test gas and alter gas properties and the heat fluxes associated with aerodynamic heating. The difference in the heating rates between clean air and a vitiated test medium needs to be understood so that the thermal management system for hypersonic vehicles can be properly designed. This is particularly important for advanced hypersonic vehicle concepts powered by air-breathing propulsion systems that couple cooling requirements, fuel flow rates, and combustor performance by flowing fuel through sub-surface cooling passages to cool engine components and preheat the fuel prior to combustion. An analytical investigation was performed comparing clean air to a gas vitiated with methane/oxygen combustion products to determine if variations in gas properties contributed to changes in predicted heat flux. This investigation started with simple relationships, evolved into writing an engineering-level code, and ended with running a series of CFD cases. It was noted that it is not possible to simultaneously match all of the gas properties between clean and vitiated test gases. A study was then conducted selecting various combinations of freestream properties for a vitiated test gas that matched clean air values to determine which combination of parameters affected the computed heat transfer the least. The best combination of properties to match was the free-stream total sensible enthalpy, dynamic pressure, and either the velocity or Mach number. This combination yielded only a 2% difference in heating. Other combinations showed departures of up to 10% in the heat flux estimate.

Cuda, Vincent↗