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NASA NTRS2012

TPSAS-NF1676L-13678-DND

An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is integral stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The goal of the PRSEUS concept is to provide damage-containment capability for composite structures while reducing overall structural weight. The National Aeronautics and Space Administration, the Boeing Company, and the Federal Aviation Administration (FAA) have partnered in an effort to assess the damage-containment features of a full-scale curved PRSEUS panel using the FAA Full-Scale Aircraft Structural Test Evaluation and Research facility. The background, test plan, fixture modifications, pre-test analysis, and planned experimental procedure were presented at the 2011 Aircraft Airworthiness and Sustainment Conference. This follow-on paper and presentation will provide details of the experimental procedure, test results, nondestructive inspection results, and preliminary test analysis comparison. The test program included three phases of loading and inspections: Phase I, as-built; Phase II, with barely visible impact damage (BVID); and Phase III, with a two-bay notch severing the central stiffener. Axial tension, internal pressure, and combined axial tension and internal pressure load conditions were applied during each phase using load levels that demonstrate compliance with the strength, deformation, and damage-tolerance requirements of Title 14 Code of Federal Regulations Part 25. Pressure loads were based on an operating pressure of 9.2 psi, designated as 1P, and the axial loads were based on a design limit load (DLL) of 227 kip. The Phase I test results provided a baseline. First, 50 percent limit-load levels were applied for each of the three load cases to verify proper load introduction and repeatability by examining strain and displacement results. Next, three limit-load cases were applied: limit pressure of 12.2 psi (1.33 P), axial DLL of 227 kip, and combined 1P pressure and axial DLL. Linear strain and displacement results were observed in all load cases. For Phase-II testing, the panel was impacted to introduce BVID with an energy of 40 ft-lb, with the impact located between the central stringer stitch line and flange edge. The impact created non-penetrating visual damage with fiber breaks and delamination between the skin and stringer flange. Limit-load conditions were applied followed by pressure overload of 18.4 psi (2P) and ultimate load conditions, defined as 1.5 times DLL. Inspections were performed after each load case; no damage growth was observed. For Phase-III testing, a two-bay notch was machined severing the central stiffener. The panel was then subjected to limit-load conditions, followed by combined 1P pressure while increasing axial tension load to catastrophic failure. As limit combined loads were approached, damage initiation was observed in the form of 45? splitting at 1P + 79% DLL. Axial loading was increased to 1P + 150 percent DLL causing damage to propagate to the adjacent stringer flanges. Damage was contained within the two-bay region by the stitching rows up to 1P + 176% DLL. Axial load was further increased until catastrophic failure, when a stringer rod failed at 1P + 192% DLL. These test results further verify the damage containment features of the PRSEUS concept and suggest its appropriateness for future flight vehicles.

Andrew Bergan↗

NASA NTRSDate not supplied

NASA Langley Aerothermodynamics Laboratory: Hypersonic Testing Capabilities

A description of the NASA Langley Research Center’s Langley Aerothermodynamics Laboratory (LAL) will be presented in the paper, along with descriptions and details of the facility test techniques and recent upgrades. The LAL consists of three hypersonic blow-down wind tunnels covering Mach numbers of 6 and 10 and unit Reynolds number ranges of 0.5 to 8.3 million per foot as well as a 60-ft Vacuum Sphere Test Chamber. LAL facilities are used to study and define the aerodynamic performance and aeroheating characteristics of flight vehicle concepts. Data collected in the facilities have been used for design and optimization, anchoring computational predictions, generation of aerodynamic databases and design of Thermal Protection Systems. Over the years modifications and enhancements have been made to the facility hardware and instrumentation to increase efficiency, data quality, capabilities and reliability to better meet the programmatic requirements. Recent utilization information illustrates the need for the capabilities associated with these facilities. Recent test programs include the Space Shuttle Program, Crew Exploration Vehicle/Orion/Multi-Purpose Crew Vehicle, Hypersonic International Flight Research Experimentation (HIFiRE), Mars Science Laboratory, Hypersonic Inflatable Aerodynamic Decelerator System (HIADS) and X-51 among others and usage has been split between NASA, Commercial Crew, Department of Defense and private company programs. Plans for future improvements to the facility infrastructure and instrumentation will also be presented.

Karen Berger↗

NASA NTRS2012

Interactive Schematic Integration Within the Propellant System Modeling Environment

Task requirements for rocket propulsion test preparations of the test stand facilities drive the need to model the test facility propellant systems prior to constructing physical modifications. The Propellant System Modeling Environment (PSME) is an initiative designed to enable increased efficiency and expanded capabilities to a broader base of NASA engineers in the use of modeling and simulation (M&S) technologies for rocket propulsion test and launch mission requirements. PSME will enable a wider scope of users to utilize M&S of propulsion test and launch facilities for predictive and post-analysis functionality by offering a clean, easy-to-use, high-performance application environment.

Coote, David↗

NASA NTRSDate not supplied

NASA Small Engine Components Compressor Test Facility: High Efficiency Centrifugal Compressor Vaneless Diffuser and Transition Duct Configurations

The original vaned configuration of the High Efficiency Centrifugal Compressor (HECC) was developed with aggressive design targets to facilitate advancement of state-of-the-art technology in gas turbine compressors. This work documents modifications to the Small Engine Components Compressor Test Facility to support testing of the HECC vaneless diffuser and transition duct configurations, both of which are open geometries. These configurations were developed as follow-up studies to improve understanding of the differences between the predicted and actual performance of the original HECC vaned diffuser stage. Specifically, the vaneless diffuser was designed to provide the impeller with ideal exit conditions such that the impeller performance could be isolated from downstream stationary components, and the additively manufactured transition duct inlet configuration enables investigation into the effects of the inlet flow path on the stage performance. Features of note in the facility are active clearance control, bleed flow regulation, modular inlet configurations, and steady-state and fast-response instrumentation throughout the flow path. Details of the facility and instrumentation are presented as well as the baseline performance of the compressor stage. The geometry, performance, and detailed aerodynamic data have been made available to the public at https://storage.googleapis.com/heccdata/NASA-HECC-Data-Archive.zip.

centrifugal compressor↗

NASA NTRSDate not supplied

NASA Small Engine Components Compressor Test Facility: High Efficiency Centrifugal Compressor Vaneless Diffuser and Transition Duct Configurations

centrifugal compressor↗

NASA NTRS1975

Supersonic CO electric-discharge lasers

Laser modeling activity is described which involved addition of an option allowing N2 as a second diatomic gas. This option is now operational and a few test cases involving N2/CO mixtures were run. Results from these initial test cases are summarized. In the laboratory, a CW double-discharge test facility was constructed and tested. Features include: water-cooled removable electrodes, O-ring construction to facilitate cleaning and design modifications, increased discharge length, and addition of a post-discharge observation section. Preliminary tests with this facility using N2 yielded higher power loadings than obtained in the first-generation facility. Another test-section modification, recently made and as yet untested, will permit injection of secondary gases into the cathode boundary layer. The objective will be to vary and enhance the UV emission spectrum from the auxiliary discharge, thereby influencing the level of photoionization in the main discharge region.

Hason, R. K.↗

NASA NTRS1983

Test results and description of a 1-kW free-piston Stirling engine with a dashpot load

A 1 kW (1.33 hp) single cylinder free piston Stirling engine was installed in the test facilities at the Lewis laboratory. The engine was designed specifically for research of the dynamics of its operation. A more complete description of the engine and its instrumentation is provided in a prior NASA paper TM-82999 by J. G. Schreiber. Initial tests at Lewis showed the power level and efficiency of the engine to be below design level. Tests were performed to help determine the specific problems in the engine causing the below design level performance. Modifications to engine hardware and to the facility where performed in an effort to bring the power output and efficiency to their design values. As finally configured the engine generated more than 1250 watts of output power at an engine efficiency greater than 32 percent. This report presents the tests performed to help determine the specific problems, the results if the problem was eliminated, the fix performed to the hardware, and the test results after the engine was tested. In cases where the fix did not cause the anticipated effects, a possible explanation is given.

Schreiber, J.↗

NASA NTRS1983

Test results and description of a 1 kW free-piston Stirling engine with a dashpot load

Schreiber, J.↗

NASA NTRS1992

A fundamental study of suction for Laminar Flow Control (LFC)

This report covers the period forming the first year of the project. The aim is to experimentally investigate the effects of suction as a technique for Laminar Flow Control. Experiments are to be performed which require substantial modifications to be made to the experimental facility. Considerable effort has been spent developing new high performance constant temperature hot-wire anemometers for general purpose use in the Fluid Mechanics Laboratory. Twenty instruments have been delivered. An important feature of the facility is that it is totally automated under computer control. Unprecedently large quantities of data can be acquired and the results examined using the visualization tools developed specifically for studying the results of numerical simulations on graphics works stations. The experiment must be run for periods of up to a month at a time since the data is collected on a point-by-point basis. Several techniques were implemented to reduce the experimental run-time by a significant factor. Extra probes have been constructed and modifications have been made to the traverse hardware and to the real-time experimental code to enable multiple probes to be used. This will reduce the experimental run-time by the appropriate factor. Hot-wire calibration drift has been a frustrating problem owing to the large range of ambient temperatures experienced in the laboratory. The solution has been to repeat the calibrations at frequent intervals. However the calibration process has consumed up to 40 percent of the run-time. A new method of correcting the drift is very nearly finalized and when implemented it will also lead to a significant reduction in the experimental run-time.

Watmuff, Jonathan H.↗

NASA NTRS2009

Design Evolution and Verification of the A-3 Chemical Steam Generator

Following is an overview of the Chemical Steam Generator system selected to provide vacuum conditions for a new altitude test facility, the A-3 Test Stand at Stennis Space Center (SSC) in Bay St. Louis, MS. A-3 will serve as NASA s primary facility for altitude testing of the J-2X rocket engine, to be used as the primary propulsion device for the upper stages of the Ares launch vehicles. The Chemical Steam Generators (CSGs) will produce vacuum conditions in the test cell through the production and subsequent supersonic ejection of steam into a diffuser downstream of the J-2X engine nozzle exit. The Chemical Steam Generators chosen have a rich heritage of operation at rocket engine altitude test facilities since the days of the Apollo program and are still in use at NASA White Sands Test Facility (WSTF) in New Mexico. The generators at WSTF have been modified to a degree, but are still very close to the heritage design. The intent for the A-3 implementation is to maintain this heritage design as much as possible, making minimal updates only where necessary to substitute for obsolete parts and to increase reliability. Reliability improvements are especially desired because the proposed system will require 27 generators, which is nine times the largest system installed in the 1960s. Improvements were suggested by the original design firm, Reaction Motors, by NASA SSC and NASA WSTF engineers, and by the A-3 test stand design contractor, Jacobs Technology, Inc. (JTI). This paper describes the range of improvements made to the design to date, starting with the heritage generator and the minor modifications made over time at WSTF, to the modernized configuration which will be used at A-3. The paper will discuss NASA s investment in modifications to SSC s E-2 test facility fire a full-scale Chemical Steam Generator in advance of the larger steam system installation at A-3. Risk mitigation testing will be performed in early 2009 at this test facility to verify that the CSGs operate as expected. The generator which will undergo this testing is of the most recent A-3 configuration, and will be instrumented far in excess of what is normally required for operation. The extra data will allow for easier troubleshooting and more complete knowledge of expected generator performance. In addition, the early testing will give SSC personnel experience in operating the CSG systems, which will expedite the process of installation and activation at A-3. Each Chemical Steam Generator is supported by a complement of valves, instruments, and flow control devices, with the entire assembly called a "module." The generators will be installed in groups of three, historically called "units". A module is so called because of its modular ability to be replaced or serviced without disturbing the other two modules installed on the same unit. A module is pictured in Figure 1, shown with its generator secured by white bands in its shipping (vs. installed) configuration. The heritage system at WSTF is composed of a single unit (three generator modules), pictured in Figure 2 as it was installed in 1965. In contrast, A-3 will have nine units operating in parallel to achieve vacuum conditions appropriate for testing the J-2X engine. Each of the combustors operates in two modes and achieves the so-called "full-steam" mode after all three of its stages ignite. Ignition of the first stage is achieved by exciting a spark plug; the second stage and main stage are lit by the flame front of the previous stage. The main stage burns approximately 97% of the total propellant flow and uses the heat energy to vaporize water into superheated steam. While the main stage remains unlit, the combustor is in so-called "idle" mode. In the WSTF system, this idle mode is not optimized for water usage, and does not need to be, as the water is pumped from a large reservoir. The water supply at A-3 will be contained in tanks with finite volume, so water optimization is preferred for the modnized configuration. Multiple solutions for this issue have been proposed, with the leading concept being a change to the operational definition of "idle mode," with the generator running in a lower heat flux condition.

Kirchner, Casey K.↗

NASA NTRS1990

Research at NASA's NFAC wind tunnels

The National Full-Scale Aerodynamics Complex (NFAC) is a unique combination of wind tunnels that allow the testing of aerodynamic and dynamic models at full or large scale. It can even accommodate actual aircraft with their engines running. Maintaining full-scale Reynolds numbers and testing with surface irregularities, protuberances, and control surface gaps that either closely match the full-scale or indeed are those of the full-scale aircraft help produce test data that accurately predict what can be expected from future flight investigations. This complex has grown from the venerable 40- by 80-ft wind tunnel that has served for over 40 years helping researchers obtain data to better understand the aerodynamics of a wide range of aircraft from helicopters to the space shuttle. A recent modification to the tunnel expanded its maximum speed capabilities, added a new 80- by 120-ft test section and provided extensive acoustic treatment. The modification is certain to make the NFAC an even more useful facility for NASA's ongoing research activities. A brief background is presented on the original facility and the kind of testing that has been accomplished using it through the years. A summary of the modification project and the measured capabilities of the two test sections is followed by a review of recent testing activities and of research projected for the future.

Edenborough, H. Kipling↗

NASA NTRS1972

Space radiation studies at the White Sands Missile Range Fast Burst Reactor

The operation of the White Sands Missile Range Fast Burst Reactor is discussed. Space radiation studies in radiobiology, dosimetry, and transient radiation effects on electronic systems and components are described. Proposed modifications to increase the capability of the facility are discussed.

Delapaz, A.↗

NASA NTRS1974

Cost effectiveness as applied to the Viking Lander systems-level thermal development test program

The economic aspects of thermal testing at the systems-level as applied to the Viking Lander Capsule thermal development program are reviewed. The unique mission profile and pioneering scientific goals of Viking imposed novel requirements on testing, including the development of a simulation technique for the Martian thermal environment. The selected approach included modifications of an existing conventional thermal vacuum facility, and improved test-operational techniques that are applicable to the simulation of the other mission phases as well, thereby contributing significantly to the cost effectiveness of the overall thermal test program.

Buna, T.↗

NASA NTRS1976

DSN research and technology support

Continuing remote controlled pulsar observations are noted, along with routine observations of 22 pulsars. Preliminary installation of equipment for planned unattended operation of the Venus Station is reported, along with extensive measurements and performance evaluation of the 26-m antenna. Support of the X-band radar at the Mars Station (DSS 14), and stability and reliability testing of the DSS 13 receiving system is reported. Klystron testing and other DSN support activities of the DSN High-Power Transmitter Maintenance Facility are noted, along with energy conservation modifications to two buildings at DSS 13. Radio Science experiment support included Planetary Radio Astronomy, Pulsar Rotation Constancy, Interstellar Microwave Spectroscopy, and Very Long Baseline Interferometry observations. An increased schedule of clock synchronization transmissions, planned on five-day centers, is noted, as 39 transmissions were made to Australia, DSS 43, and Spain, DSS 63.

Jackson, E. B.↗

NASA NTRS1984

Microgravity containerless processing in long drop tubes

Extensive experience in utilizing long drop tubes for studying effects of microgravity on the solidification of alloys was obtained. While some modifications are necessary to improve versatility, the facility proved to be most useful. Both an electron beam furnace and an electromagnetic levitation furnace can be used. The electron beam furnace is used with vacuum environments (0.00001 torr), whereas the levitation furnace is presently used only in inert gas environments (above 100 torr). Experiments are best applied to refractory alloys because of the sensitivity of the detectors now being used to observe solidification. Processing of lower melting point metals and alloys simply cannot be recorded. On the other hand, expected improvements in detector sensitivity will allow experimentation with relatively low melting alloys. In such cases, solidification will occur in flight only if higher inert gas pressure is used (100 to 760 torr) to increase heat loss by convection. Under these conditions microgravity conditions no longer apply. However, as shown by results to date, it is not microgravity as such that is important in drop tube solidification. Instead it is the containerless nature of the process that is significant, leading to large degrees of undercooling before solidification and therefore to unique alloys.

Bayuzick, R. J.↗

NASA NTRS1989

Real-time application of knowledge-based systems

The Rapid Prototyping Facility (RPF) was developed to meet a need for a facility which allows flight systems concepts to be prototyped in a manner which allows for real-time flight test experience with a prototype system. This need was focused during the development and demonstration of the expert system flight status monitor (ESFSM). The ESFSM was a prototype system developed on a LISP machine, but lack of a method for progressive testing and problem identification led to an impractical system. The RPF concept was developed, and the ATMS designed to exercise its capabilities. The ATMS Phase 1 demonstration provided a practical vehicle for testing the RPF, as well as a useful tool. ATMS Phase 2 development continues. A dedicated F-18 is expected to be assigned for facility use in late 1988, with RAV modifications. A knowledge-based autopilot is being developed using the RPF. This is a system which provides elementary autopilot functions and is intended as a vehicle for testing expert system verification and validation methods. An expert system propulsion monitor is being prototyped. This system provides real-time assistance to an engineer monitoring a propulsion system during a flight.

Brumbaugh, Randal W.↗

NASA NTRS1990

Detailed modal testing of a solid rocket motor using a portable test system

Modern analytical techniques have expended the ability to evaluate solid rocket motors used in launch vehicles. As more detailed models of solid rocket motors were developed, testing methods were required to verify the models. Experimental modal analysis (modal testing) of space structures and launch vehicles has been a requirement for model validation for many years. However, previous testing of solid rocket motors has not typically involved dynamic modal testing of full scale motors for verification of solid propellant or system assembly properties. Innovative approaches to the testing of solid rocket motors were developed and modal testing of a full scale, two segment Titan 34D Solid Rocket Motor (SRM) was performed to validate detailed computer modeling. Special modifications were made to convert an existing facility into a temporary modal test facility which would accommodate the test article. The assembly of conventional data acquisition equipment into a multiple channel count portable system has made modal testing in the field feasible. Special purpose hydraulic exciters were configured to apply the dynamic driving forces required. All instrumentation and data collection equipment were installed at the test site for the duration of the test program and removed upon completion. Conversion of an existing test facility into a temporary modal test facility, and use of a multiple channel count portable test data acquisition system allowed all test objectives to be met and resulted in validation of the computer model in a minimum time.

Glozman, Vladimir↗

NASA NTRS1995

Acoustic Modifications of the Ames 40x80 Foot Wind Tunnel and Test Techniques for High-Speed Research Model Testing

The NFAC 40- by 80- Foot Wind Tunnel at Ames is being refurbished with a new, deep acoustic lining in the test section which will make the facility nearly anechoic over a large frequency range. The modification history, key elements, and schedule will be discussed. Design features and expected performance gains will be described. Background noise reductions will be summarized. Improvements in aeroacoustic research techniques have been developed and used recently at NFAC on several wind tunnel tests of High Speed Research models. Research on quiet inflow microphones and struts will be described. The Acoustic Survey Apparatus in the 40x80 will be illustrated. A special intensity probe was tested for source localization. Multi-channel, high speed digital data acquisition is now used for acoustics. And most important, phased microphone arrays have been developed and tested which have proven to be very powerful for source identification and increased signal-to-noise ratio. Use of these tools for the HEAT model will be illustrated. In addition, an acoustically absorbent symmetry plane was built to satisfy the HEAT semispan aerodynamic and acoustic requirements. Acoustic performance of that symmetry plane will be shown.

Soderman, Paul T.↗