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NASA NTRSDate not supplied

Component Level Regression Testing in a Hierarchical Architecture

The Goddard Earth Observing System (GEOS) is an Earth system model consisting of a large suite of individual model components that can be coupled in a flexible manner to investigate a variety of Earth science issues. Specific GEOS model configurations are composed as a hierarchical collection of components based on the Earth System Modeling Framework (ESMF). Regression testing of GEOS is currently limited to (1) full system tests that are poor at isolating specific defects and (2) a suite of unit tests which have very limited coverage. As part of our approach to improve upon the current testing situation, we have prototyped the capability to perform regression tests on individual GEOS components by leveraging and extending existing checkpoint/restart capabilities. In our implementation, each ESMF component has 3 states: Import (what it needs to run), Export (which it needs to provide to other components), and Internal (the component state proper). By capturing, Import, Export and Internal states for a given component during a ull run of GEOS, a generic driver can then rerun the component offline and compare expected exports with those that have been saved. The hierarchical structure of GEOS introduces an interesting wrinkle when trying to test components that in turn drive interacting child components. To fully isolate a parent component, we use the approach of software mocks, in which the exports of children are also saved during the initial capture run of GEOS. Then when testing the parent component, the children components are replaced by a generic mock component that produces exports from the previously saved data and ensures that that all interdependencies among children components are satisfied.

Thomas Clune↗
NASA NTRS2018

Tagging Components in the Test Complex Area

Why tag components differently? - Various methods are in place to tag different components, but not every component is tracked; - Variance in method can make it difficult to obtain component information and identify discrepancies; -Time and resources are spent on component localization and verification. Previous work of RA10 interns: - Researching more efficient asset tracking methods; - Investigating cost effective ways to localize components; - Past interns identified using QR (Quick Response) codes as a potential solution. Link QR codes to Windchill (PLM - Product Lifecycle Management system) DDMS (Design and Data Management System) after QR code is printed/etched and physically tagging it as quickly as possible

Gomez, Sarah↗
NASA NTRS1987

A technology development summary for the AGT101 advanced gas turbine program

A summary is presented of significant technology developments that have been made in the AGT101 advanced gas turbine program. The AGT101 design features are reviewed, and the power section testing and results are addressed in detail. The results of component testing and evaluation are described for the compressor, turbine, regenerator, and foil bearing. Ceramic component development is discussed, including that of the static seal, turbine shroud seal, regenerator shield planar seal, regenerator shield piston ring, stator rig, ceramic combustor, and turbine rotor. Important areas to be addressed by the Advanced Turbine Technology Applications Project now in the planning stage at DOE and NASA are briefly reviewed.

Boyd, Gary L.↗
NASA NTRS2011

Ceramic Matrix Composites for Rotorcraft Engines

Ceramic matrix composite (CMC) components are being developed for turbine engine applications. Compared to metallic components, the CMC components offer benefits of higher temperature capability and less cooling requirements which correlates to improved efficiency and reduced emissions. This presentation discusses a technology develop effort for overcoming challenges in fabricating a CMC vane for the high pressure turbine. The areas of technology development include small component fabrication, ceramic joining and integration, material and component testing and characterization, and design and analysis of concept components.

Halbig, Michael C.↗
NASA NTRS2024

Lessons Learned from Particulate Characterization Laboratory Anomalies

The White Sands Test Facility chemistry laboratory provides quality control for cleanroom operations including cleanliness verification of aerospace hardware by particulate counts and non-volatile residue determinations, particulate counts for liquid hypergolic propellants, gaseous helium and nitrogen propellant pressurizing agents used for ground support equipment and flight test article valve actuation, gaseous oxygen primarily used for component testing, and deionized water for refurbished propellant hardware flushing. Cleanliness verification includes particulate counts and non-volatile residue determinations to industry standard, NASA, and program specifications and levels. Particulate counts are typically to customer-specified specifications and levels including JPR 5322.1H (2016) Levels 50 and 100, Orion (MPCV 70156. Revision H (2018)) Level 100, RPTSTD-8070-0001 Revision 3 (2022), and IEST-STD-CC1246E (2013) Levels 50 and 100. The laboratory issues high pressure filter holders containing membrane filters to test operations personnel, who collect samples by flowing the required volumes of fluid through the filter holder, and the filter holder is returned to the lab for counting. A passing particulate count is required before testing may proceed. Rapid data reduction and issuing of reports indicating a pass or fail of the particulate specification are required. Corrective action and resampling invariably occurs if a sample fails. Consequently, the laboratory must maintain the highest degree of reliability to facilitate quality data used to decide if testing may proceed. Experience and continual improvements have enabled reliability. However, anomalies attributed to lab processes and hardware including filter holders, membranes, and Petri dishes have been encountered. This paper presents a summary of problems, solutions, successes, and lessons learned from particle counting experience for over 35 years.

Lessons Learned↗
NASA NTRS1993

Test stand 116 at the Marshall Space Flight Center

A discussion of propulsion component testing in general and the capabilities of Test Stand 116 at the Marshall Space Flight Center (MSFC) in particular will serve to educate the aerospace community concerning this national resource. Historical significance, facility systems and capabilities, and day-to-day test operations are the focus of this discussion.

Best, Philip↗
NASA NTRS2004

Test Planning Approach and Lessons

As NASA began technology risk reduction activities and planning for the next generation launch vehicle under the Space Launch Initiative (SLI), now the Next Generation Launch Technology (NGLT) Program, a review of past large liquid rocket engine development programs was performed. The intent of the review was to identify any significant lessons from the development testing programs that could be applied to current and future engine development programs. Because the primary prototype engine in design at the time of this study was the Boeing-Rocketdyne RS-84, the study was slightly biased towards LOX/RP-1 liquid propellant engines. However, the significant lessons identified are universal. It is anticipated that these lessons will serve as a reference for test planning in the Engine Systems Group at Marshall Space Flight Center (MSFC). Towards the end of F-1 and J-2 engine development testing, NASA/MSFC asked Rocketdyne to review those test programs. The result was a document titled, Study to Accelerate Development by Test of a Rocket Engine (R-8099). The "intent (of this study) is to apply this thinking and learning to more efficiently develop rocket engines to high reliability with improved cost effectivenes" Additionally, several other engine programs were reviewed - such as SSME, NSTS, STME, MC-1, and RS-83- to support or refute the R-8099. R-8099 revealed two primary lessons for test planning, which were supported by the other engine development programs. First, engine development programs can benefit from arranging the test program for engine system testing as early as feasible. The best test for determining environments is at the system level, the closest to the operational flight environment. Secondly, the component testing, which tends to be elaborate, should instead be geared towards reducing risk to enable system test. Technical risk can be reduced at the component level, but the design can only be truly verified and validated after engine system testing.

Parkinson, Douglas A.↗
NASA NTRS1972

Spacecraft thermal vacuum testing

An approach for developing a general thermal vacuum test program philosophy is discussed. Guidelines are established that will assist the project engineer in relating the risk associated with flying any spacecraft to its test program. Computerized techniques can be used to help ascertain these guidelines, which relate the risk to the level of test (component, subsystem, etc), as well as to the type of test (development, qualification, etc). The interrelationship between the test program and the analytical effort is also discussed. The Skylab Apollo telescope mount general thermal vacuum test program, including test schedules, instrumentation, and test results is also discussed.

Elam, B. F.↗
NASA NTRS1988

Initial test results for the mini-mast

The objectives of the 20-meter Mini-Mast were: (1) to learn how to efficiently test this type of large truss structure, (2) to relate component testing to the overall behavior of the structure, and (3) to update the associated analytical model based upon the experimental data. The Mini-Mast represents structural characteristics similar to the COFS beam which is planned to be flown on Shuttle to perform on-orbit structures and controls experiments. The information is of interest to LDR because it represents analysis and test information on a truss-type structure which may be similar to the Large Deployable Reflector (LDR) backup structure. The structure has a total of 111 titanium joints; the joint in the center of the truss element is a near-center latch joint. The results of this research indicate that linear deployable-type structures can be built, but difficulties do exist in extracting modes with identical frequencies; gravitational loading does affect the ground test results; and prediction of truss-type-structure dynamic characteristics is not trivial.

Horta, L.↗
NASA NTRS1992

Activities of the NASA/Marshall Space Flight Center pump stage technology team

In order to advance rocket propulsion technology, the Consortium for Computational Fluid Dynamics (CFD) Application in Propulsion Technology has been formed at Marshall Space Flight Center (MSFC). The Consortium consists of three Teams: the turbine stage team, the pump stage team (PST), and the combustion devices team. The PST has formulated and is implementing a plan for pump technology development whose end product will be validated CFD codes suitable for application to pump components, test data suitable for validating CFD codes, and advanced pump components optimized using CFD codes. The PST's work during the fall of 1991 and the winter and spring of 1992 is discussed in this paper. This work is highlighted by CFD analyses of an advanced impeller design and collection of laser two-focus velocimeter data for the Space Shuttle Main Engine High Pressure Fuel Pump impeller.

Garcia, R.↗
NASA NTRS2000

Packaging Technology Developed for High-Temperature SiC Sensors and Electronics

A ceramic- and thick-film-materials-based prototype electronic package designed for silicon carbide (SiC) high-temperature sensors and electronics has been successfully tested at 500 C in an oxygen-containing air environment for 500 hours. This package was designed, fabricated, assembled, and electronically evaluated at the NASA Glenn Research Center at Lewis Field with an in-house-fabricated SiC semiconductor test chip. High-temperature electronics and sensors are necessary for harsh-environment space and aeronautical applications, such as space missions to the inner solar system or the emission control electronics and sensors in aeronautical engines. Single-crystal SiC has such excellent physical and chemical material properties that SiC-based semiconductor electronics can operate at temperatures over 600 C, which is significantly higher than the limit for Si-based semiconductor devices. SiC semiconductor chips were recently demonstrated to be operable at temperatures as high as 600 C, but only in the probe station environment because suitable packaging technology for sensors and electronics at temperatures of 500 C and beyond did not exist. Thus, packaging technology for SiC-based sensors and electronics is immediately needed for both application and commercialization of high-temperature SiC sensors and electronics. In response to this need, researchers at Glenn designed, fabricated, and assembled a prototype electronic package for high-temperature electronics, sensors, and microelectromechanical systems (MEMS) using aluminum nitride (AlN) substrate and gold (Au) thick-film materials. This prototype package successfully survived a soak test at 500 C in air for 500 hours. Packaging components tested included thick-film high-temperature metallization, internal wire bonds, external lead bonds, and a SiC diode chip die-attachment. Each test loop, which was composed of thick-film printed wire, wire bond, and lead bond was subjected to a 50-mA direct current for 250 hours at 500 C.

Chen, Liang-Yu↗
NASA NTRS2017

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Torus Mechanical Testing

The Armstrong Flight Research Center has performed loads testing of a series of developmental atmospheric entry decelerator structural components. Test setup hardware were designed and fabricated. In addition, test plan and checklist were developed for the consistent and efficient execution of the tests. Eight test articles were successfully tested in over one hundred test runs as test objectives were met. Test article buckling shapes and buckling loads were observed. Displacements and strains were also recorded as various load cases were applied. The test data was sent to Langley Research Center to help with the construction of the finite element model of the decelerator assembly.

buckling↗
NASA NTRS1989

Dynamic Torque Calibration Unit

Proposed dynamic torque calibration unit (DTCU) measures torque in rotary actuator components such as motors, bearings, gear trains, and flex couplings. Unique because designed specifically for testing components under low rates. Measures torque in device under test during controlled steady rotation or oscillation. Rotor oriented vertically, supported by upper angular-contact bearing and lower radial-contact bearing that floats axially to prevent thermal expansion from loading bearings. High-load capacity air bearing available to replace ball bearings when higher load capacity or reduction in rate noise required.

Agronin, Michael L.↗
NASA NTRS2003

Thermally Simulated Testing of a Direct-Drive Gas-Cooled Nuclear Reactor

This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet-sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrical thermal simulation of reactor components and concepts.

Godfroy, Thomas↗
NASA NTRS1974

Miniature probes for use in gas turbine testing

Several examples of miniature probes (null type as well as fixed position) are presented which have proved useful in aircraft and space power systems component testing and are applicable to automotive gas turbine testing. These probes are used to determine component or system performance from the measurement of gas temperature as well as total and static pressure, and flow direction. Detailed drawings of the sensors are presented along with experimental data covering the flow characteristics over the range of intended use.

Glawe, G. E.↗