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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Real-Time X-ray Radiography Diagnostics of Components in Solid Rocket Motors

Solid rocket motors (SRMs) typically use nozzle materials which are required to maintain their shape as well as insulate the underlying support structure during the motor operation. In addition, SRMs need internal insulation materials to protect the motor case from the harsh environment resulting from the combustion of solid propellant. In the nozzle, typical materials consist of high density graphite, carbon-carbon composites and carbon phenolic composites. Internal insulation of the motor cases is typically a composite material with carbon, asbestos, Kevlar, or silica fibers in an ablative matrix such as EPDM or NBR. For both nozzle and internal insulation materials, the charring process occurs when the hot combustion products heat the material intensely. The pyrolysis of the matrix material takes away a portion of the thermal energy near the wall surface and leaves behind a char layer. The fiber reinforcement retains the porous char layer which provides continued thermal protection from the hot combustion products. It is of great interest to characterize both the total erosion rates of the material and the char layer thickness. By better understanding of the erosion process for a particular ablative material in a specific flow environment, the required insulation material thickness can be properly selected. The recession rates of internal insulation and nozzle materials of SRMs are typically determined by testing in some sort of simulated environment; either arc-jet testing, flame torch testing, or subscale SRMs of different size. Material recession rates are deduced by comparison of pre- and post-test measurements and then averaging over the duration of the test. However, these averaging techniques cannot be used to determine the instantaneous recession rates of the material. Knowledge of the variation in recession rates in response to the instantaneous flow conditions during the motor operation is of great importance. For example, in many SRM configurations the recession of the solid propellant grain can drastically alter the flow-field and effect the recession of internal insulation and nozzle materials. Simultaneous measurement of the overall erosion rate, the development of the char layer, and the recession of the char-virgin interface during the motor operation can be rather difficult. While invasive techniques have been used with limited success, they have serious drawbacks. Break wires or make wire sensors can be installed into a sufficient number of locations in the charring material from which a time history of the charring surface can be deduced. These sensors fundamentally alter the local structure of the material in which they are imbedded. Also, the location of these sensors within the material is not known precisely without the use of an X-ray. To determine instantaneous recession rates, real-time X-ray radiography (X-ray RTR) has been utilized in several SRM experiments at PSU. The X-ray RTR system discussed in this paper consists of an X-ray source, X-ray image intensifier, and CCD camera connected to a capture computer. The system has been used to examine the ablation process of internal insulation as well as nozzle material erosion in a subscale SRM. The X-ray source is rated to 320 kV at 10 mA and has both a large (5.5 mm) and small (3.0 mm) focal spot. The lead-lined cesium iodide X-ray image intensifier produces an image which is captured by a CCD camera with a 1,000 x 1,000 pixel resolution. To produce accurate imagery of the object of interest, the alignment of the X-ray source to the X-ray image intensifier is crucial. The image sequences captured during the operation of an SRM are then processed to enhance the quality of the images. This procedure allows for computer software to extract data on the total erosion rate and the char layer thickness. Figure 1 Error! Reference source not found.shows a sequence of images captured during the operation the subscale SRM with the X-ray RTR system. The X-rayTR system, alignment procedure, uncertainty determination, and image analysis process will be discussed in detail in the full manuscript.

Cortopassi, A. C.↗
NASA NTRS2012

Oxidation and the Effects of High Temperature Exposures on Notched Fatigue Life of an Advanced Powder Metallurgy Disk Superalloy

Oxidation and the effects of high temperature exposures on notched fatigue life were considered for a powder metallurgy processed supersolvus heat-treated ME3 disk superalloy. The isothermal static oxidation response at 704 C, 760 C, and 815 C was consistent with other chromia forming nickel-based superalloys: a TiO2-Cr2O3 external oxide formed with a branched Al2O3 internal subscale that extended into a recrystallized - dissolution layer. These surface changes can potentially impact disk durability, making layer growth rates important. Growth of the external scales and dissolution layers followed a cubic rate law, while Al2O3 subscales followed a parabolic rate law. Cr- rich M23C6 carbides at the grain boundaries dissolved to help sustain Cr2O3 growth to depths about 12 times thicker than the scale. The effect of prior exposures was examined through notched low cycle fatigue tests performed to failure in air at 704 C. Prior exposures led to pronounced debits of up to 99 % in fatigue life, where fatigue life decreased inversely with exposure time. Exposures that produced roughly equivalent 1 m thick external scales at the various isotherms showed statistically equivalent fatigue lives, establishing that surface damage drives fatigue debit, not exposure temperature. Fractographic evaluation indicated the failure mode for the pre-exposed specimens involved surface crack initiations that shifted with exposure from predominately single intergranular initiations with transgranular propagation to multi-initiations from the cracked external oxide with intergranular propagation. Weakened grain boundaries at the surface resulting from the M23C6 carbide dissolution are partially responsible for the intergranular cracking. Removing the scale and subscale while leaving a layer where M23C6 carbides were dissolved did not lead to a significant fatigue life improvement, however, also removing the M23C6 carbide dissolution layer led to nearly full recovery of life, with a transgranular initiation typical to that observed in unexposed specimens.

Sudbrack, Chantal K.↗
NASA NTRS2016

Ice Accretions and Full-Scale Iced Aerodynamic Performance Data for a Two-Dimensional NACA 23012 Airfoil

This report documents the data collected during the large wind tunnel campaigns conducted as part of the SUNSET project (StUdies oN Scaling EffecTs due to ice) also known as the Ice-Accretion Aerodynamics Simulation study: a joint effort by NASA, the Office National d'Etudes et Recherches Aérospatiales (ONERA), and the University of Illinois. These data form a benchmark database of full-scale ice accretions and corresponding ice-contaminated aerodynamic performance data for a two-dimensional (2D) NACA 23012 airfoil. The wider research effort also included an analysis of ice-contaminated aerodynamics that categorized ice accretions by aerodynamic effects and an investigation of subscale, low- Reynolds-number ice-contaminated aerodynamics for the NACA 23012 airfoil. The low-Reynolds-number investigation included an analysis of the geometric fidelity needed to reliably assess aerodynamic effects of airfoil icing using artificial ice shapes. Included herein are records of the ice accreted during campaigns in NASA Glenn Research Center's Icing Research Tunnel (IRT). Two different 2D NACA 23012 airfoil models were used during these campaigns; an 18-in. (45.7-cm) chord (subscale) model and a 72-in. (182.9-cm) chord (full-scale) model. The aircraft icing conditions used during these campaigns were selected from the Federal Aviation Administration's (FAA's) Code of Federal Regulations (CFR) Part 25 Appendix C icing envelopes. The records include the test conditions, photographs of the ice accreted, tracings of the ice, and ice depth measurements. Model coordinates and pressure tap locations are also presented. Also included herein are the data recorded during a wind tunnel campaign conducted in the F1 Subsonic Pressurized Wind Tunnel of ONERA. The F1 tunnel is a pressured, high- Reynolds-number facility that could accommodate the full-scale (72-in. (182.9-cm) chord) 2D NACA 23012 model. Molds were made of the ice accreted during selected test runs of the full-scale model in the IRT. From these molds, castings were made that closely replicated the features of the accreted ice. The castings were then mounted on the full-scale model in the F1 tunnel, and aerodynamic performance measurements were made using model surface pressure taps, the facility force balance system, and a large wake rake designed specifically for these tests. Tests were run over a range of Reynolds and Mach numbers. For each run, the model was rotated over a range of angles-of-attack that included airfoil stall. The benchmark data collected during these campaigns were, and continue to be, used for various purposes. The full-scale data form a unique, ice-accretion and associated aerodynamic performance dataset that can be used as a reference when addressing concerns regarding the use of subscale ice-accretion data to assess full-scale icing effects. Further, the data may be used in the development or enhancement of both ice-accretion prediction codes and computational fluid dynamic codes when applied to study the effects of icing. Finally, as was done in the wider study, the data may be used to help determine the level of geometric fidelity needed for artificial ice used to assess aerodynamic degradation due to aircraft icing. The structured, multifaceted approach used in this research effort provides a unique perspective on the aerodynamic effects of aircraft icing. The data presented in this report are available in electronic form upon formal approval by proper NASA and ONERA authorities.

Addy, Harold E., Jr.↗
NASA NTRS2016

An Overview of Active Flow Control Enhanced Vertical Tail Technology Development

This paper summarizes a joint NASA/Boeing research effort to advance Active Flow Control (AFC) technology to enhance aerodynamic efficiency of a vertical tail. Sweeping jet AFC technology was successfully tested on subscale and full-scale models as well as in flight. The subscale test was performed at Caltech on a ~14% scale model. More than 50% side force enhancement was achieved by the sweeping jet actuation when the momentum coefficient was 1.7%. AFC caused significant increases in suction pressure on the actuator side and associated side force enhancement. Subsequently, a full-scale Boeing 757 vertical tail model equipped with sweeping jets was tested at the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel at NASA Ames Research Center. There, flow separation control optimization was performed at near flight conditions. Greater than 20% increase in side force were achieved for the maximum rudder deflection of 30deg at the key sideslip angles (0deg and -7.5deg) with a 31-actuator AFC configuration. Based on these tests, the momentum coefficient is shown to be a necessary, but not sufficient parameter to use for design and scaling of sweeping jet AFC from subscale tests to full-scale applications. Leveraging the knowledge gained from the wind tunnel tests, the AFC-enhanced vertical tail technology was successfully flown on the Boeing 757 ecoDemonstrator in the spring of 2015.

Lin, John C.↗
NASA NTRS2017

Estimates for the Aerodynamic Coefficients of Ringsail and Disk-Gap-Band Parachutes Operating on Mars

Models are presented for the aerodynamic coefficients of Supersonic Ringsail and Disk-Gap-Band parachutes as functions of total porosity, Lambda(sub t), Mach number, M, and total angle of attack, Alpha(sub t) (when necessary). The source aerodynamic coefficients data used for creating these models were obtained from a wind tunnel test of subscale parachutes. In this wind tunnel test, subscale parachutes of both parachute types were fabricated from two different fabrics with very different permeabilities. By varying the fabric permeability, while maintaining the parachute geometry constant, it was possible to vary Alpha(sub t). The fabric permeability test data necessary for the calculation of Alpha(sub t) were obtained from samples of the same fabrics used to fabricate the subscale parachutes. Although the models for the aerodynamic coefficients are simple polynomial functions of Alpha(sub t) and M, they are capable of producing good reproductions of the source data. The (Alpha(sub t), M) domains over which these models are applicable are clearly defined. The models are applicable to flight operations on Mars.

Cruz, Juan R.↗
NASA NTRS2017

Carbon-Carbon Nozzle Extension Development in Support of In-Space and Upper-Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. Due to the large size of such nozzles, and the related engine performance requirements, carbon-carbon (C-C) composite nozzle extensions are being considered to reduce weight impacts. Currently, the state-of-the-art is represented by the metallic and foreign composite nozzle extensions limited to approximately 2000 degrees F. used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles. NASA and industry partners are working towards advancing the domestic supply chain for C-C composite nozzle extensions. These development efforts are primarily being conducted through the NASA Small Business Innovation Research (SBIR) program in addition to other low level internal research efforts. This has allowed for the initial material development and characterization, subscale hardware fabrication, and completion of hot-fire testing in relevant environments. NASA and industry partners have designed, fabricated and hot-fire tested several subscale domestically produced C-C extensions to advance the material and coatings fabrication technology for use with a variety of liquid rocket and scramjet engines. Testing at NASA's Marshall Space Flight Center (MSFC) evaluated heritage and state-of-the-art C-C materials and coatings, demonstrating the initial capabilities of the high temperature materials and their fabrication methods. This paper discusses the initial material development, design and fabrication of the subscale carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work. The follow on work includes the fabrication of ultra-high temperature materials, larger C-C nozzle extensions, material characterization, sub-element testing and hot-fire testing at larger scale.

Gradl, Paul R.↗
NASA NTRS2017

Estimates for the Aerodynamic Coefficients of Ringsail and Disk-Gap-Band Parachutes Operating on Mars

The creation of flight dynamics simulations is often part of the design, development, and flight operations of missions that include entry, descent, and landing (EDL) in their concept of operation. Such flight dynamics simulations include models for many of the EDL sub-systems. For EDL systems that include a parachute, models of the parachute’s aerodynamic characteristics must be created for inclusion in the flight dynamics simulations. Models are presented for the aerodynamic coefficients (i.e., C(D),C(Tot),C(T),C(N), and C(m,SLCP)) of Supersonic Ringsail (SSRS) and Disk-Gap-Band (DGB) parachutes as functions of total porosity, λ(T), Mach number, M, and total angle of attack, λ(T) (when necessary). The source aerodynamic coefficients data used for creating these models were obtained from a wind tunnel test of subscale parachutes. In this wind tunnel test, subscale parachutes of both parachute types were fabricated from two different fabrics with very different permeabilities. By varying the fabric permeability, while maintaining the parachute geometry constant, it was possible to vary λ(T). The fabric permeability test data necessary for the calculation of λ(T) were obtained from samples of the same fabrics used to fabricate the subscale parachutes. Although the models for the aerodynamic coefficients are simple polynomial functions of λ(T) and M, they are capable of producing good reproductions of the source data. The (λ(T), M) domains over which these models are applicable are clearly defined. The models and their domains are applicable to flight operations on Mars. The models presented in this report are not unique – other models could be created from the source data. To make the creation of alternative numerical models, the aerodynamic coefficients source data are included in this report.

Cruz, Juan R.↗
NASA NTRS1966

Thermal stress-relief treatments for 2219 aluminum alloy are evaluated

Evaluation of three thermal stress relief treatments for 2219 aluminum alloy in terms of their effect on residual stress, mechanical properties, and stress corrosion resistance. The treatments are post aging and stress relieving fullscale and subscale parts formed in the aged T81 condition, and aging subscale parts formed in the unaged T31 condition.

Source record↗
NASA NTRS1972

Space storable propellant performance program coaxial injector characterization

An experimental program was conducted to characterize the circular coaxial injector concept for application with the space-storable gas/liquid propellant combination FLOX(82.6% F2)/CH4(g) at high pressure. The primary goal of the program was to obtain high characteristic velocity efficiency in conjunction with acceptable injector/chamber compatibility. A series of subscale (single element) cold flow and hot fire experiments was employed to establish design criteria for a 3000-lbf (sea level) engine operating at 500 psia. The subscale experiments characterized both high performance core elements and peripheral elements with enhanced injector/chamber compatibility. The full-scale injector which evolved from the study demonstrated a performance level of 99 percent of the theoretical shifting characteristic exhaust velocity with low chamber heat flux levels. A 44-second-duration firing demonstrated the durability of the injector. Parametric data are presented that are applicable for the design of circular, coaxial injectors that operate with injection dynamics (fuel and oxidizer velocity, etc.) similar to those employed in the work reported.

Burick, R. J.↗
NASA NTRS1972

Design fabrication and nondestructive testing of six experimental AGCarb/Intermold 3 cylinder assemblies

Six subscale Intermold cylinder assemblies with a total of twelve different concepts for transition to AGCarb were fabricated. Three of the cylinder assemblies were made by helically winding the hoop fibers and three were of orthogonal configuration. The fabrication process is summarized and details of each manufacturing method are given. The objectives of the test program were to: (1) demonstrate the fabricability of the Intermold 3 subscale flanges, (2) produce an integral transition from Intermold 3 to AGCarb material, (3) define a workable manufacturing process, and (4) identify a best suited inspection method. The objectives were met and the results are described.

Thacher, E. F.↗
NASA NTRS1975

Space shuttle orbit maneuvering engine reusable thrust chamber program

Analyses and preliminary designs of candidate OME propellant combinations and corresponding engine designs were conducted and evaluated in terms of performance, operating limits, program cost, risk, inherent life and maintainability. For the Rocketdyne recommended and NASA approved propellant combination and cooling concept (NTO/MMH regeneratively cooled engine), a demonstration thrust chamber was designed, fabricated, and experimentally evaluated to define operating characteristics and limits. Alternate fuel (50-50) operating characteristics were also investigated with the demonstration chamber. Adverse operating effects on regenerative cooled operation were evaluated using subscale electrically heated tubes and channels. An investigation of like doublet element characteristics using subscale tests was performed. Full scale 8- and 10-inch diameter like-doublet injectors for the OME were designed, fabricated, and tested. Injector stability was evaluated analytically and experimentally.

Pauckert, R. P.↗
NASA NTRS1975

Evaluation of powder metallurgy superalloy disk materials

A program was conducted to develop nickel-base superalloy disk material using prealloyed powder metallurgy techniques. The program included fabrication of test specimens and subscale turbine disks from four different prealloyed powders (NASA-TRW-VIA, AF2-1DA, Mar-M-432 and MERL 80). Based on evaluation of these specimens and disks, two alloys (AF2-1DA and Mar-M-432) were selected for scale-up evaluation. Using fabricating experience gained in the subscale turbine disk effort, test specimens and full scale turbine disks were formed from the selected alloys. These specimens and disks were then subjected to a rigorous test program to evaluate their physical properties and determine their suitability for use in advanced performance turbine engines. A major objective of the program was to develop processes which would yield alloy properties that would be repeatable in producing jet engine disks from the same powder metallurgy alloys. The feasibility of manufacturing full scale gas turbine engine disks by thermomechanical processing of pre-alloyed metal powders was demonstrated. AF2-1DA was shown to possess tensile and creep-rupture properties in excess of those of Astroloy, one of the highest temperature capability disk alloys now in production. It was determined that metallographic evaluation after post-HIP elevated temperature exposure should be used to verify the effectiveness of consolidation of hot isostatically pressed billets.

Evans, D. J.↗
NASA NTRS1976

Surface tension propellant control for Viking 75 Orbiter

The paper describes the selection, development and qualification of the surface tension system and includes results of low-g drop tower tests of scale models, 1-g simulation tests of low-g large ullage settling and liquid withdrawal, structural qualification tests, and propellant surface tension/contact angle studies. Subscale testing and analyses were used to evaluate the ability of the system to maintain or recover the desired propellant orientation following possible disturbances during the Viking mission. This effort included drop tower tests to demonstrate that valid wick paths exist for moving any displaced propellant back over the tank outlet. Variations in surface tension resulting from aging, temperature, and lubricant contamination were studied and the effects of surface finish, referee fluid exposure, aging, and lubricant contamination on contact angle were assessed. Results of movies of typical subscale drop tower tests and full scale slosh tests are discussed.

Dowdy, M. W.↗
NASA NTRS1976

Acceleration effects on the performance of solid-propellant rocket motors

Some acceleration effects on rocket performance have been well publicized. The dynamic process, characterized by marked increases in 'localized' burning rate, produces excessive case heating, slag retention, pressure buildup, and/or internal flow alterations. Data are presented illustrating drastic effects at low accelerations for sustainer type propellants and its relevance to several recent failures. Normalized orientation dependence of rate augmentation appears coupled to acceleration level and base burning rate. Effects appear influenced by propellant composition. Predictions using subscale motor data show good agreement with observed performance for ground spin and flight tests. Subscale test methods and results are also discussed.

Lucy, M. H.↗
NASA NTRS1976

Mach 4 free-jet tunnel starting experiments for a hypersonic research engine model causing high blockage

Tests of a full scale hypersonic research engine (HRE) were conducted in the hypersonic tunnel facility at Mach numbers of 5, 6, and 7. Since the HRE would cause a rather high blockage (48.83 percent of the nozzle area), subscale tests were conducted in various available small wind tunnels prior to the full scale tests to study the effects of model blockage on tunnel starting. The results of the Mach 4 subscale tests which utilized a model system at 0.0952 scale which simulated the HRE in the test section of the tunnel are presented. A satisfactory tunnel starting could not be achieved by varying the free jet length or diffuser size nor by inserting the model into the test stream after tunnel starting. However, the installation of a shroud around the HRE model allowed the tunnel to start with the model preset in the tunnel at a tunnel stagnation pressure to atmospheric exit pressure ratio of 13.4. The simulation of the discharge of instrumentation cooling water and the addition of test hardware at the aft end of the HRE model did not have a significant effect on the tunnel starting.

Carson, G. T., Jr.↗
NASA NTRS1975

Space shuttle orbital maneuvering engine platelet injector program

A platelet face injector for the Orbit Maneuvering Engine (OME) on the space shuttle was evaluated as a means of obtaining additional design margin and lower cost. The program was conducted in three phases. The first phase evaluated single injection elements, or unielements; it involved visual flow studies, mixing experiments using propellant simulants, and hot firings to assess combustion efficiency, chamber wall compatibility, and injector face temperatures. In the second phase, subscale units producing 600 lbf thrust were used to further evaluate the orifice patterns chosen on the basis of unielement testing. In addition to combustion efficiency, chamber and injector heat transfer, the subscale testing provided a preliminary indication of injector stability. Full scale testing of the selected patterns at 6,000 lbf thrust was performed in the third phase. Performance, heat transfer, and combustion stability were evaluated over the anticipated range of OMS operating conditions. The effects on combustion stability of acoustic cavity configuration, including cavity depth, open area, inlet contour, and other parameters, were investigated.

Source record↗
NASA NTRS1979

Preliminary results of penetrator field test program, Tonopah, Nevada, 16-28 April 1979

Subscale (0.63 scale) penetrators impacted various sizes of volcanic rocks resting on and within compacted plays sediments. All penetrators were identical in size, shape, weight, and impact velocity. Although minor variations in impact angle were documented, the final orientation of the buried penetrators was primarily a consequence of the size, shape, and depth of the rocks encountered during impact. In situ measurements of impacted penetrators revealed that surface and buried layers of rocks having diameters up to 3 times the penetrator diameter caused only small ( 10 deg) angles of deflection. Only large single rocks greater than 10 times the penetrator diameter caused deflections appreciably greater than 10 deg. The large deflection angles followed by the penetrator were strongly influenced by fracture planes that developed in the rock as it broke apart. No catastrophic failure of the penetrator occurred during these tests. A cross section of the path of each penetrator through the ground is shown together with details on orientation before, during, and after the tests. Comparisons are made with results of previous subscale penetrator tests, and conclusions are drawn with respect to full-scale Mars penetrator performance.

Blanchard, M. B.↗
NASA NTRS1981

High-pressure LOX/hydrocarbon preburners and gas generators

The objective of the program was to conduct a small scale hardware test program to establish the technology base required for LOX/hydrocarbon preburners and gas generators. The program consisted of six major tasks; Task I reviewed and assessed the performance prediction models and defined a subscale test program. Task II designed and fabricated this subscale hardware. Task III tested and analyzed the data from this hardware. Task IV analyzed the hot fire results and formulated a preliminary design for 40K preburner assemblies. Task V took the preliminary design and detailed and fabricated three 40K size preburner assemblies, one each fuel-rich LOX/CH, and LOX/RP-1 and one oxidizer rich LOX/CH4. Task VI delivered these preburner assemblies to MSFC for subsequent evaluation.

Huebner, A. W.↗