Impact testing of thermoelectric hardware for space power applications
Impact tests on thermoelectric hardware for space power applications
Selwitz, L.↗
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Mercury Conditions for the MESSENGER Mission Simulated in High- Solar-Radiation Vacuum Tests
The MESSENGER (Mercury Surface, Space Environment, Geochemistry, and Ranging) spacecraft, planned for launch in March 2004, will perform two flybys of Mercury before entering a year-long orbit of the planet in September 2009. The mission will provide opportunities for detailed characterization of the surface, interior, atmosphere, and magnetosphere of the closest planet to the Sun. The NASA Glenn Research Center and the MESSENGER spacecraft integrator, the Johns Hopkins University Applied Physics Laboratory, have partnered under a Space Act Agreement to characterize a variety of critical components and materials under simulated conditions expected near Mercury. Glenn's Vacuum Facility 6, which is equipped with a solar simulator, can simulate the vacuum and high solar radiation anticipated in Mercury orbit. The MESSENGER test hardware includes a variety of materials and components that are being characterized during the Tank 6 vacuum tests, where the hardware will be exposed to up to 11 suns insolation, simulating conditions expected in Mercury orbit. In 2002, ten solar vacuum tests were conducted, including beginning of life, end of life, backside exposure, and solar panel thermal shock cycling tests. Components tested include candidate solar array panels, sensors, thermal shielding materials, and communication devices. As an example, for the solar panel thermal shock cycling test, two candidate solar array panels were suspended on a lift mechanism that lowered the panels into a liquid-nitrogen-cooled box. After reaching -140 C, the panels were then lifted out of the box and exposed to the equivalent of 6 suns (8.1 kilowatts per square meters). After five cold soak/heating cycles were completed successfully, there was no apparent degradation in panel performance. An anticipated 100-hr thermal shield life test is planned for autumn, followed by solar panel flight qualification tests in winter. Glenn's ongoing support to the MESSENGER program has been instrumental in identifying design solutions and validating thermal performance models under a very aggressive development schedule. The test data have assisted Johns Hopkins engineers in selecting a flight solar array vendor and a thermal shield design. MESSENGER is one in a series of missions in NASA's Discovery Program. Infrared thermography provides data on the thermal gradients in the MESSENGER components during high solar insolation vacuum testing.
Wong, Wayne A.↗
Pre-Installation Acceptance (PIA) Functional Performance of the Design Verification Test (DVT) Exploration Extra-vehicular Mobility Unit (xEMU)
In an effort that began with technology investment by NASA in a few key components during the Constellation Program and then evolved to demonstrate a packaged Portable Life Support System (PLSS) as part of the Advanced Exploration Systems (AES) Program, the next evolution of the PLSS is now a key component of the Exploration Extra-vehicular Mobility Unit (xEMU) and is assembled as a Design Verification Test (DVT) unit. The xEMU has been detailed with respect to completing a demonstration on the International Space Station (ISS) with support of units for initial lunar capability. The xEMU completed the Preliminary Design Review (PDR) with subsequent Safety Review Panel (SRP) Phase I reviews in 2019-2020. The objectives for DVT are to validate requirements, train the team, learn how to fabricate the hardware with appropriate process controls, assemble the hardware, test the hardware, determine the failure mechanisms/limits of the hardware design and buy down the most risk possible for the qualification and flight phases of the development. With completion of the assembly and initial functional testing of the DVT PLSS in laboratory ambient conditions and vacuum conditions the xEMU has progressed significantly into the DVT objectives. A key part of the test sequences for DVT and all future phases is the Pre-Installation Acceptance (PIA) functional testing which validates the performance of integrated systems including: primary thermal control, auxiliary thermal control, suit ventilation, primary oxygen, secondary oxygen, power distribution, as well as caution and warning all with respect to the applied requirements. This discussion will include an overview of the assembly, summary of the PIA functional testing, lessons learned, and corrective actions implemented moving forward into the remainder of the DVT phase for xEMU.
Colin Campbell↗
Solar array Shuttle flight experiment - Hardware development and testing
This paper reports on the fabrication and ground testing of (a) a large area, light-weight, flexible substrate developmental solar array wing that has been built for NASA-MSFC and of (b) the supporting structure and data acquisition system (DAS) which, with the wing, will be flown in the Shuttle as an experiment in 1984. The experiment will verify the dynamics, thermodynamic, and electrical performance predictions of the array wing and will demonstrate the structural capability of the array wing for Orbiter launch and re-entry environments. The experiment hardware verification program was designed to minimize costs and risk of experiment performance degradation while maintaining Shuttle and crew safety. The previous full-scale wing hardware tests included an extension mast water table test and wing testing for random vibration, thermal vacuum, and acoustic environments. The results of these tests were used to define wing design modifications and to scope the test program for the experiment hardware.
Elms, R. V.↗
Assessment of analytical and experimental techniques utilized in conducting plume technology tests 575 and 593
Since exhaust plumes affect vehicle base environment (pressure and heat loads) and the orbiter vehicle aerodynamic control surface effectiveness, an intensive program involving detailed analytical and experimental investigations of the exhaust plume/vehicle interaction was undertaken as a pertinent part of the overall space shuttle development program. The program, called the Plume Technology program, has as its objective the determination of the criteria for simulating rocket engine (in particular, space shuttle propulsion system) plume-induced aerodynamic effects in a wind tunnel environment. The comprehensive experimental program was conducted using test facilities at NASA's Marshall Space Flight Center and Ames Research Center. A post-test examination of some of the experimental results obtained from NASA-MSFC's 14 x 14-inch trisonic wind tunnel is presented. A description is given of the test facility, simulant gas supply system, nozzle hardware, test procedure and test matrix. Analysis of exhaust plume flow fields and comparison of analytical and experimental exhaust plume data are presented.
Baker, L. R.↗
Uprated OMS Engine Status-Sea Level Testing Results
The current Space Shuttle Orbital Maneuvering Engine (OME) is pressure fed, utilizing storable propellants. Performance uprating of this engine, through the use of a gas generator driven turbopump to increase operating pressure, is being pursued by the NASA Johnson Space Center (JSC). Component level design, fabrication, and test activities for this engine system have been on-going since 1984. More recently, a complete engine designated the Integrated Component Test Bed (ICTB), was tested at sea level conditions by Aerojet. A description of the test hardware and results of the sea level test program are presented. These results, which include the test condition operating envelope and projected performance at altitude conditions, confirm the capability of the selected Uprated OME (UOME) configuration to meet or exceed performance and operational requirements. Engine flexibility, demonstrated through testing at two different operational mixture ratios, along with a summary of projected Space Shuttle performance enhancements using the UOME, are discussed. Planned future activities, including ICTB tests at simulated altitude conditions, and recommendations for further engine development, are also discussed.
Bertolino, J. D.↗
Occupant Responses in a Full-Scale Crash Test of the Sikorsky ACAP Helicopter
A full-scale crash test of the Sikorsky Advanced Composite Airframe Program (ACAP) helicopter was performed in 1999 to generate experimental data for correlation with a crash simulation developed using an explicit nonlinear, transient dynamic finite element code. The airframe was the residual flight test hardware from the ACAP program. For the test, the aircraft was outfitted with two crew and two troop seats, and four anthropomorphic test dummies. While the results of the impact test and crash simulation have been documented fairly extensively in the literature, the focus of this paper is to present the detailed occupant response data obtained from the crash test and to correlate the results with injury prediction models. These injury models include the Dynamic Response Index (DRI), the Head Injury Criteria (HIC), the spinal load requirement defined in FAR Part 27.562(c), and a comparison of the duration and magnitude of the occupant vertical acceleration responses with the Eiband whole-body acceleration tolerance curve.
Jackson, Karen E.↗
Occupant Responses in a Full-Scale Crash Test of the Sikorsky ACAP Helicopter
A full-scale crash test of the Sikorsky Advanced Composite Airframe Program (ACAP) helicopter was performed in 1999 to generate experimental data for correlation with a crash simulation developed using an explicit nonlinear, transient dynamic finite element code. The airframe was the residual flight test hardware from the ACAP program. For the test, the aircraft was outfitted with two crew and two troop seats, and four anthropomorphic test dummies. While the results of the impact test and crash simulation have been documented fairly extensively in the literature, the focus of this paper is to present the detailed occupant response data obtained from the crash test and to correlate the results with injury prediction models. These injury models include the Dynamic Response Index (DRI), the Head Injury Criteria (HIC), the spinal load requirement defined in FAR Part 27.562(c), and a comparison of the duration and magnitude of the occupant vertical acceleration responses with the Eiband whole-body acceleration tolerance curve.
Jackson, Karen E.↗
Source Identification and Location Techniques
Mr. Weir presented source location results obtained from an engine test as part of the Engine Validation of Noise Reduction Concepts program. Two types of microphone arrays were used in this program to determine the jet noise source distribution for the exhaust from a 4.3 bypass ratio turbofan engine. One was a linear array of 16 microphones located on a 25 ft. sideline and the other was a 103 microphone 3-D "cage" array in the near field of the jet. Data were obtained from a baseline nozzle and from numerous nozzle configuration using chevrons and/or tabs to reduce the jet noise. Mr. Weir presented data from two configurations: the baseline nozzle and a nozzle configuration with chevrons on both the core and bypass nozzles. This chevron configuration had achieved a jet noise reduction of 4 EPNdB in small scale tests conducted at the Glenn Research Center. IR imaging showed that the chevrons produced significant improvements in mixing and greatly reduced the length of the jet potential core. Comparison of source location data from the 1-D phased array showed a shift of the noise sources towards the nozzle and clear reductions of the sources due to the noise reduction devices. Data from the 3-D array showed a single source at a frequency of 125 Hz. located several diameters downstream from the nozzle exit. At 250 and 400 Hz., multiple sources, periodically spaced, appeared to exist downstream of the nozzle. The trend of source location moving toward the nozzle exit with increasing frequency was also observed. The 3-D array data also showed a reduction in source strength with the addition of chevrons. The overall trend of source location with frequency was compared for the two arrays and with classical experience. Similar trends were observed. Although overall trends with frequency and addition of suppression devices were consistent between the data from the 1-D and the 3-D arrays, a comparison of the details of the inferred source locations did show differences. A flight test is planned to determine if the hardware tested statically will achieve similar reductions in flight.
Weir, Donald↗
NASA's Ares I and Ares V Launch Vehicles -- Effective Space Operations Through Efficient Ground Operations
The United States (U.S.) plans to return to the Moon by 2020, with the development of a new human-rated space transportation system to replace the Space Shuttle, which is due for retirement in 2010 after it completes its missions of building the International Space Station and servicing the Hubble Space Telescope. Powering the future of space-based scientific exploration will be the Ares I Crew Launch Vehicle, which will transport the Orion Crew Exploration Vehicle to orbit where it will rendezvous with the Lunar Lander. which will be delivered by the Ares V Cargo Launch Vehicle. This new transportation infrastructure, developed by the National Aeronautics and Space Administration (NASA), will allow astronauts to leave low-Earth orbit for extended lunar exploration and preparation for the first footprint on Mars. All space-based operations begin and are controlled from Earth. NASA's philosophy is to deliver safe, reliable, and cost-effective solutions to sustain a multi-billion-dollar program across several decades. Leveraging 50 years of lessons learned, NASA is partnering with private industry, while building on proven hardware experience. This paper will discuss how the Engineering Directorate at NASA's Marshall Space Flight Center is working with the Ares Projects Office to streamline ground operations concepts and reduce costs. Currently, NASA's budget is around $17 billion, which is less than 1 percent of the U.S. Federal budget. Of this amount, NASA invests approximately $4.5 billion each year in Space Shuttle operations, regardless of whether the spacecraft is flying or not. The affordability requirement is for the Ares I to reduce this expense by 50 percent, in order to allow NASA to invest more in space-based scientific operations. Focusing on this metric, the Engineering Directorate provides several solutions-oriented approaches, including Lean/Six Sigma practices and streamlined hardware testing and integration, such as assembling major hardware elements before shipping to the Kennedy Space Center for launch operations. This paper provides top-level details for several cost saving initiatives, including both process and product improvements that will result in space transportation systems that are designed with operations efficiencies in mind. The Engineering Directorate provides both the intellectual capital embodied in an experienced workforce and unique facilities in which to validate the information technology tools that allow a nationwide team to collaboratively connect across miles that separate them and the engineering disciplines that integrate various piece parts into a whole system. As NASA transforms ground-based operations, it also is transitioning its workforce from an era of intense hands-on labor to a new one of mechanized conveniences and robust hardware with simpler interfaces. Ensuring that space exploration is on sound footing requires that operations efficiencies be designed into the transportation system and implemented in the development stage. Applying experience gained through decades of ground and space op'erations, while using value-added processes and modern business and engineering tools, is the philosophy upon which a new era of exploration will be built to solve some of the most pressing exploration challenges today -- namely, safety, reliability, and affordability.
Dumbacher, Daniel L.↗
Environmental Loss Characterization of an Advanced Stirling Convertor (ASC-E2) Insulation Package Using a Mock Heater
Test hardware used as pathfinder for Thermal Standard test materials and methods
Schifer, Nicholas A.↗
The ISRU Field Tests 2010 and 2012 at Mauna Kea, Hawaii: Results from the Miniaturised Mossbauer Spectrometers Mimos II and Mimos IIA
The 2010 and 2012 In-Situ Resource Utilization Analogue Test (ISRU) [1] on the Mauna Kea volcano in Hawai'i was coordinated by the Northern Centre for Advanced Technology (NORCAT) in collaboration with the Canadian Space Agency (CSA), the German Aerospace Center (DLR), and the National Aeronautics and Space Administration (NASA), through the PISCES program. Several instruments were tested as reference candidates for future analogue testing at the new field test site at the Mauna Kea volcano in Hawai'i. The fine-grained, volcanic nature of the material is a suitable lunar and martian analogue, and can be used to test excavation, site preparation, and resource utilization techniques. The 2010 location Pu'u Hiwahine, a cinder cone located below the summit of Mauna Kea (19deg45'39.29" N, 155deg28'14.56" W) at an elevation of ~2800 m, provides a large number of slopes, rock avalanches, etc. to perform mobility tests, site preparation or resource prospecting. Besides hardware testing of technologies and systems related to resource identification, also in situ science measurements played a significant role in integration of ISRU and science instruments. For the advanced Mössbauer instrument MIMOS IIA, the new detector technologies and electronic components increase sensitivity and performance significantly. In combination with the high energy resolution of the SDD it is possible to perform Xray fluorescence analysis simultaneously to Mössbauer spectroscopy. In addition to the Fe-mineralogy, information on the sample's elemental composition will be gathered. The 2010 and 2012 field campaigns demonstrated that in-situ Mössbauer spectroscopy is an effective tool for both science and feedstock exploration and process monitoring. Engineering tests showed that a compact nickel metal hydride battery provided sufficient power for over 12 hr of continuous operation for the MIMOS instruments.
Klingelhoefer, G.↗
Optimization of the Carbon Dioxide Removal Assembly (CDRA-4EU) in Support of the International Space System and Advanced Exploration Systems
The Life Support Systems Project (LSSP) under the Advanced Exploration Systems (AES) program builds upon the work performed under the AES Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project focusing on the numerous technology development areas. The Carbon Dioxide (CO2) removal and associated air drying development efforts are focused on improving the current state-of-the-art system on the International Space Station (ISS) utilizing fixed beds of sorbent pellets by seeking more robust pelletized sorbents, evaluating structured sorbents, and examining alternate bed configurations to improve system efficiency and reliability. A component of the CO2 removal effort utilizes a virtual Carbon Dioxide Removal Assembly, revision 4 (CDRA-4) test bed to test a large number of potential operational configurations with independent variations in flow rate, cycle time, heater ramp rate, and set point. Initial ground testing will provide prerequisite source data and provide baseline data in support of the virtual CDRA. Once the configurations with the highest performance and lowest power requirements are determined by the virtual CDRA, the results will be confirmed by testing these configurations with the CDRA-4EU ground test hardware. This paper describes the initial ground testing of select configurations. The development of the virtual CDRA under the AES-LSS Project will be discussed in a companion paper.
Knox, James C.↗
6DOF Testing of the SLS Inertial Navigation Unit
The Navigation System on the NASA Space Launch System (SLS) Block 1 vehicle performs initial alignment of the Inertial Navigation System (INS) navigation frame through gyrocompass alignment (GCA). In lieu of direct testing of GCA accuracy in support of requirement verification, the SLS Navigation Team proposed and conducted an engineering test to, among other things, validate the GCA performance and overall behavior of the SLS INS model through comparison with test data. This paper will detail dynamic hardware testing of the SLS INS, conducted by the SLS Navigation Team at Marshall Space Flight Center's 6DOF Table Facility, in support of GCA performance characterization and INS model validation. A 6-DOF motion platform was used to produce 6DOF pad twist and sway dynamics while a simulated SLS flight computer communicated with the INS. Tests conducted include an evaluation of GCA algorithm robustness to increasingly dynamic pad environments, an examination of GCA algorithm stability and accuracy over long durations, and a long-duration static test to gather enough data for Allan Variance analysis. Test setup, execution, and data analysis will be discussed, including analysis performed in support of SLS INS model validation.
Geohagan, Kevin W.↗
Testing Microgravity Flight Hardware Concepts on the NASA KC-135
This paper provides an overview of utilizing the NASA KC-135 Reduced Gravity Aircraft for the Foam Optics and Mechanics (FOAM) microgravity flight project. The FOAM science requirements are summarized, and the KC-135 test-rig used to test hardware concepts designed to meet the requirements are described. Preliminary results regarding foam dispensing, foam/surface slip tests, and dynamic light scattering data are discussed in support of the flight hardware development for the FOAM experiment.
Motil, Susan M.↗
COFS 1 research overview
The Control of Flexible Structures (COFS) program is divided into three areas of research. These three areas are controls/structures analysis development, ground test experiments, and in-space experiments. The ground test experiments are intended to validate analyses and to confirm through hardware tests our technical readiness to successfully fly the Mast hardware. There is this close relation to the results of ground tests and analytical predictions that must be understood before flight experiments may be attempted. Details relative to each program area are given.
Horner, G. C.↗
NASA's Marshall Space Flight Center Recent Studies and Technology Developments in the Area of SSA/Orbital Debris
NASA/MSFC has been investigating the various aspects of the growing orbital debris problem since early 2009. Data shows that debris ranging in size from 5 mm to 10 cm presents the greatest threat to operational spacecraft today. Therefore, MSFC has focused its efforts on small orbital debris. Using off-the-shelf analysis packages, like the ESA MASTER software, analysts at MSFC have begun to characterize the small debris environment in LEO to support several spacecraft concept studies and hardware test programs addressing the characterization, mitigation, and ultimate removal, if necessary, of small debris. The Small Orbital Debris Active Removal (SODAR) architectural study investigated the overall effectiveness of removing small orbital debris from LEO using a low power, space-based laser. The Small Orbital Debris Detection, Acquisition, and Tracking (SODDAT) conceptual technology demonstration spacecraft was developed to address the challenges of in-situ small orbital debris environment classification including debris observability and instrument requirements for small debris observation. Work is underway at MSFC in the areas of hardware and testing. By combining off the shelf digital video technology, telescope lenses, and advanced video image FPGA processing, MSFC is building a breadboard of a space based, passive orbital tracking camera that can detect and track faint objects (including small debris, satellites, rocket bodies, and NEOs) at ranges of tens to hundreds of kilometers and speeds in excess of 15 km/sec,. MSFC is also sponsoring the development of a one-of-a-kind Dynamic Star Field Simulator with a high resolution large monochrome display and a custom collimator capable of projecting realistic star images with simple orbital debris spots (down to star magnitude 11-12) into a passive orbital detection and tracking system with simulated real-time angular motions of the vehicle mounted sensor. The dynamic star field simulator can be expanded for multiple sensors (including advanced star trackers), real-time vehicle pointing inputs, and more complex orbital debris images. This system is also adaptable to other sensor optics, missions, and installed sensor testing.
Wiegmann, Bruce M.↗
Access flight hardware design and development
Several items were found to be of immense value in the design and development of the Assembly Concept for Construction of Erectable Space Structures (ACCESS) hardware. The early availability of mock-up and engineering test hardware helped to develop the concept and prove the feasibility of the experiment. The extensive neutral buoyancy testing was invaluable in developing the procedures and timelines, proving that the hardware functioned as intended, and effectively trained the astronauts. The early involvement of the crew systems/astronaut personnel was extremely beneficial in shaping the design to meet the EVA compatibility requirements. Also, the early definition of coupled loads and on-orbit dynamic responses can not be overemphasized due to the relative uncertainty in the magnitude of these loads and their impact on the design.
Rogers, John F.↗