Icing tests of aircraft-engine induction systems
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The Long Duration Exposure Facility (LDEF) test samples discussed within are part of the Solar Array Materials Passive (SAMPLE) LDEF experiment, which included contributions from NASA and Jet Propulsion Lab (JPL). Only the JPL portion is described in this paper. The JPL test plate contains 30 individual thin silicon solar cell/cover samples. It was the intent of the experiment to evaluate the stability and protective capability of various cover materials such as conventional fused silica and potential alternative materials such as Teflon, silicone RTV's, glass resins, polyimides, and a copolymer encapsulate. Examination of the recovered experiment shows extensive physical changes have occurred. Approximately 150 micrometeoroid/debris impact were noted, some directly on the solar cells. Of particular interest are the results of ultraviolet and atomic oxygen interactions with the various cover materials. Initial results show that the fused silica cover is the most stable and protective, with performance of other materials varying widely. Electrical measurements of the cell/cover samples are presented as part of the evaluation of cover materials to protect cells in low earth orbit environments.
The storing and transfer of cryogenic propellants is an enabling technology for NASA as it moves to expand future missions into low Earth orbit (LEO) and beyond. The transfer of cryogenic propellants is of particular interest because it has never been successfully demonstrated in microgravity. Several ground tests have been conducted in past decades examining various tank chilldown and fill methods. Creating accurate models using these historical datasets is a vital step toward developing appropriate modeling tools to form pre-test predictions for eventual flight and ground tests of various novel injector concepts. The goal of this work was to create a working model in Thermal Desktop using data from the CRYOTE-2 experiments whose purpose was to demonstrate the chill and fill process in a spherical receiver tank parametrically examining the effect of injection method, receiver tank initial wall temperature and initial state, supply pressure, and mass flow rate on the NVF process. These tests were conducting using liquid nitrogen with different injectors with different injection patterns. The focus of the current work is on one particular spray nozzle. The pressure rise inside the tank, the fill level, and the change in the outside wall temperature were all tracked and compared with test data. The Thermal Desktop model was able to accurately predict each of these metrics for this nozzle within 11.0%, 22.0%, and 7.0%, respectively.
Future crewed exploration missions beyond Low Earth Orbit (LEO) will operate farther from Earth and be logistically isolated for longer than any previous human spaceflight mission. Under these conditions, supportability and reliability willbestronger drivers of mission mass and risk than they have been in the past. Items with high failure rates, or uncertain failure rates, can result in high spares mass requirements and/or high risk on deep space missions. Testing is a critical element of system development which provides the opportunity to identify and resolve design issues, defects, or other failure modes before they cause problems during a mission. Reliability growth programs can reduce failure rates by identifying and remove failure modes via design changes, and long-duration life testing can provide valuable data to reduce failure rate estimate uncertainty and verify (to some level of confidence) that components are as reliable as expected. Testing activities take time and resources, however, and must be incorporated into program plans in order to be fully effective. This paper presents an integrated reliability test plan analysis and optimization methodology, which has been used to inform Advanced Exploration Systems (AES) Life Support Systems (LSS) ground test planning for future missions. The methodology determines the optimal number of test units to purchase and allocation of test time –split between reliability growth and uncertainty reduction testing –across a given set of items in order to minimize spares mass for a given mission under constraints on total test cost and schedule. Model outputs also include expected spares mass after testing and the expected number of modifications or refurbishments during testing, both of which can inform program planning. Discussion of the model, conclusions, and future work are also presented.
Future crewed exploration missions beyond Low Earth Orbit (LEO) will operate farther from Earth and be logistically isolated for longer than any previous human spaceflight mission. Under these conditions, supportability and reliability willbestronger drivers of mission mass and risk than they have been in the past. Items with high failure rates, or uncertain failure rates, can result in high spares mass requirements and/or high risk on deep space missions. Testing is a critical element of system development which provides the opportunity to identify and resolve design issues, defects, or other failure modes before they cause problems during a mission. Reliability growth programs can reduce failure rates by identifying and remove failure modes via design changes, and long-duration life testing can provide valuable data to reduce failure rate estimate uncertainty and verify (to some level of confidence) that components are as reliable as expected. Testing activities take time and resources, however, and must be incorporated into program plans in order to be fully effective. This paper presents an integrated reliability test plan analysis and optimization methodology, which has been used to inform Advanced Exploration Systems (AES) Life Support Systems (LSS) ground test planning for future missions. The methodology determines the optimal number of test units to purchase and allocation of test time –split between reliability growth and uncertainty reduction testing –across a given set of items in order to minimize spares mass for a given mission under constraints on total test cost and schedule. Model outputs also include expected spares mass after testing and the expected number of modifications or refurbishments during testing, both of which can inform program planning. Discussion of the model, conclusions, and future work are also presented.
Solid rocket motor (SRM) slag has been identified as a potential source of man-made orbital debris. The possibility that SRMs (in addition to generating dust particles in the sub-millimeter range) may generate particles up to centimeters in size has caused concern regarding their contribution to the debris environment. Returned surfaces from space do not have sufficient area or exposure time to provide a clear picture of the SRM millimeter and centimeter debris population. Currently, radar observation is probably the only way to collect data showing the debris contribution from SRMs. Such observation is used to sample the debris environment, but it is difficult to obtain accurate orbital elements for the detected debris objects. NASA has developed several models to describe the different orbital debris populations, based on assumed debris production mechanisms to create clouds of debris objects that can be propagated in time. The NASA model, LEGEND (LEO-to-GEO Environment Debris), functions as a time-tested debris model for most debris sources. However, the current LEGEND model does not include contributions from the SRM population. An SRM model has recently been developed by NASA, based on purely theoretical details of SRM production and known SRM launches, but verification with hard data is needed. Because the detections of individual SRM objects cannot be deterministically separated from the total debris observed by radar, the validation of the SRM model can only be done by combining it with the LEGEND breakup model and comparing it with data. By applying observational constraints, the degree of SRM slag contribution to the environment may be estimated. This serves as an observationally sound method from which to calibrate a purely theoretical model into something more realistic. For this study, we use the populations observed by the Haystack radar from 1996 to present. For the SRM debris, we use a historical database of SRM launches, propellant masses, and estimated locations and times of tailoff to produce and propagate the SRM debris clouds. Comparisons with radar data from the ensuing years were made, and the SRM model was altered with respect to size and mass production of slag particles to reflect the populations estimated from the data. The result is a model SRM population that fits within the bounds of the observed environment and estimates of the production and contribution of SRM debris to the environment.
NASA is planning a series of short and long duration human and robotic missions to explore the Moon and then Mars. The series of missions will begin with a new crew exploration vehicle (called Orion) that will initially provide crew exchange and cargo supply support to the International Space Station (ISS) and then become a human conveyance for travel to the Moon. The Orion vehicle will be mounted atop the Ares I launch vehicle for a series of pre-launch tests and then launched and inserted into low Earth orbit (LEO) for crew exchange missions to the ISS. The Orion and Ares I comprise the initial vehicles in the Constellation system of systems that later includes Ares V, Earth departure stage, lunar lander, and other lunar surface systems for the lunar exploration missions. These key systems will enable the lunar surface exploration missions to be initiated in 2018. The complexity of the Constellation system of systems and missions will require a communication and navigation infrastructure to provide low and high rate forward and return communication services, tracking services, and ground network services. The infrastructure must provide robust, reliable, safe, sustainable, and autonomous operations at minimum cost while maximizing the exploration capabilities and science return. The infrastructure will be based on a network of networks architecture that will integrate NASA legacy communication, modified elements, and navigation systems. New networks will be added to extend communication, navigation, and timing services for the Moon missions. Internet protocol (IP) and network management systems within the networks will enable interoperability throughout the Constellation system of systems. An integrated network architecture has developed based on the emerging Constellation requirements for Orion missions. The architecture, as presented in this paper, addresses the early Orion missions to the ISS with communication, navigation, and network services over five phases of a mission: pre-launch, launch from T0 to T+6.5 min, launch from T+6.5 min to 12 min, in LEO for rendezvous and docking with ISS, and return to Earth. The network of networks that supports the mission during each of these phases and the concepts of operations during those phases are developed as a high level operational concepts graphic called OV-1, an architecture diagram type described in the Department of Defense Architecture Framework (DoDAF). Additional operational views on organizational relationships (OV-4), operational activities (OV-5), and operational node connectivity (OV-2) are also discussed. The system interfaces view (SV-1) that provides the communication and navigation services to Orion is also included and described. The challenges of architecting integrated network architecture for the NASA Orion missions are highlighted.
The Space Communications and Navigation program, at the National Aeronautics and Space Administration, is developing free-space optical communications technology to facilitate the next generation of space missions in near-Earth, Lunar, and planetary space. A discussion of optimetric observation performance and hardware-in-the-loop test results are presented. Simulation of orbit-determination for LEO and Lunar spacecraft relying on optimetric tracking extends raw observation accuracy to realizable orbit-determination performance. Potential science and operational applications are reviewed, along with NASA's approach for developing optimetric technology. Current investments in developing optimetric hardware and plans for NASA's future optical communications network define the path for a future operational optimetric capability in the 2020's and beyond.
New antenna technologies have unlocked a new class of missions using CubeSats for Earth Science or Deep Space operations. This class of small satellites have historically been mostly used as teaching tools allowing students to design and test small satellites and develop space experiments. With the rise of new game-changing antenna technologies, overcoming their small size and need for high gain, they can now be used beyond Low Earth Orbit (LEO). Over the past 5 years, technologists at the Jet Propulsion Laboratory have designed, tested and successfully flown these innovative Smallsat antennas, enabling new telecommunication and science achievements.
Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as MSL and Mars 2020. Continued development of a more mass efficient and compliant versions of PICA that use a carbon felt as the substrate will be presented. The felt based versions of PICA known as Conformal PICA (C-PICA) and Soft PICA (S-PICA), are very comparable in terms of peak heat-flux capabilities compared to standard PICA. The lower density and of C-PICA and S-PICA further show a much higher thermal protection efficiency and hence more mass savings. The compliant nature of these materials allows for use on a wide variety of substrates and therefore makes it very attractive for commercial low earth orbit missions as well as NASA’s aerocapture missions to Ice Giants. NASA is currently working with several commercial partners (Varda and Inversion Space) to Technology Transfer C/S-PICA variants for commercial LEO missions. Thermal, mechanical, and representative environment arc-jet tests have been conducted comparing the performance of Conformal and Soft-PICA materials.
Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.
Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.
The main obstacle to the implementation of a high-voltage solar array in space is arcing on the conductor-dielectric junctions exposed to the surrounding plasma. One obvious solution to this problem would be the installation of fully encapsulated solar arrays which were not having exposed conductors at all. However, there are many technological difficulties that must be overcome before the employment of fully encapsulated arrays will turn into reality. An alternative solution to raise arc threshold by modifications of conventionally designed solar arrays looks more appealing, at least in the nearest future. A comprehensive study of arc inception mechanism suggests that such modifications can be done in the following directions: 1) To insulate conductor-dielectric junction from a plasma environment (wrapthrough interconnects); 2) To change a coverglass geometry (overhang); 3) To increase a coverglass thickness; 4) To outgas areas of conductor-dielectric junctions. The operation of high-voltage array in LEO produces also the parasitic current power drain on the electrical system. Moreover, the current collected from space plasma by solar arrays determines the spacecraft floating potential that is very important for the design of spacecraft and its scientific apparatus. In order to verify the validity of suggested modifications and to measure current collection five different solar array samples have been tested in a large vacuum chamber. Each sample (36 silicon based cells) consists of three strings containing 12 cells connected in series. Thus, arc rate and current collection can be measured on every string independently, or on a whole sample when strings are connected in parallel. The heater installed in the chamber provides the possibility to test samples under temperature as high as 80 C that stimulates the LEO operational temperature. The experimental setup is described below.
The main obstacle to the implementation of a high-voltage solar array in space is arcing on the conductor-dielectric junctions exposed to the surrounding plasma. One obvious solution to this problem would be the installation of fully encapsulated solar arrays which were not having exposed conductors at all. However, there are many technological difficulties that must be overcome before the employment of fully encapsulated arrays will turn into reality. An alternative solution to raise arc threshold by modifications of conventionally designed solar arrays looks more appealing, at least in the nearest future. A comprehensive study of arc inception mechanism [1-4] suggests that such modifications can be done in the following directions: i) to insulate conductor-dielectric junction from a plasma environment (wrapthrough interconnects); ii) to change a coverglass geometry (overhang); iii) to increase a coverglass thickness; iiii) to outgas areas of conductor-dielectric junctions. The operation of high-voltage array in LEO produces also the parasitic current power drain on the electrical system. Moreover, the current collected from space plasma by solar arrays determines the spacecraft floating potential that is very important for the design of spacecraft and its scientific apparatus. In order to verify the validity of suggested modifications and to measure current collection five different solar array samples have been tested in large vacuum chamber. Each sample (36 silicon based cells) consists of three strings containing 12 cells connected in series. Thus, arc rate and current collection can be measured on every string independently, or on a whole sample when strings are connected in parallel. The heater installed in the chamber provides the possibility to test samples under temperature as high as 80 C that simulates the LEO operational temperature. The experimental setup is described below.
The Orion (CEV) thermal protection system (TPS) advanced development project (ADP) was initiated in late 2006 to reduce developmental risk by significant investment in multiple heat shield architectural solutions that can meet the needs both the Low Earth orbit (LEO) and Lunar return missions. At the same time, the CEV TPS ADP was also charged with developing a preliminary design for the heat shield to meet the PDR requirement and at the time of the PDR, transfer the design to Lockheed- Martin, the prime contractor. We reported on the developmental activities of the first 18 months at the IPPW5 in Bordeaux, France, last summer. In June 08, at the time of the IPPW6, the CEV TPS ADP would have nearly completed the preparation for the Orion PDR and would be close to the original three-year mark. We plan to report on the progress at the Atlanta workshop. In the past year, Orion TPS ADP investment in TPS Technology, especially in PICA ablative Heat-shield design, development, testing and engineering (DDTE) has paid off in enabling MSL mission to switch from SLA 561 V heat shield to PICA heat shield. CEV TPS ADP considered SLA 561 V as a candidate for LEO missions and our testing identified failure modes in SLA and as a result, we dropped SLA for further evaluation. This close synergy between two projects is a highly visible example of how investment in technology areas can and does benefit multiple missions. In addition, CEV TPS ADP has been able to revive the Apollo ablative system namely AVCOAT honeycomb architecture as an alternate to the baseline PICA architecture and we plan to report the progress we have made in AVCOAT. CEV TPS ADP has invested considerable resources in developing analytical models for PICA and AVCOAT, material property measurements that is essential to the design of the heat-shield, in arcjet testing, in understanding the differences between different arc jet facilities, namely NASA Ames, NASA JSC and Air Force's AEDC, and in Non-Destructive Evaluation (NDE), and in integration of and manufacturing heat shield as a system. The capabilities of the two heat shield systems including failure modes via testing and analysis, once established, can serve the Probe Community and future mission designers to inner and outer planetary exploration very well. For example, missions to Venus, Mars and Titan can use either one of the system by selecting the mission design parameters that utilizes the full characteristics of these system to make use of system efficiency that will result in reduced heat shield mass, system robustness that will enhance mission success and cost. We plan to present significant progresses of the past three years and highlight the significant contributions CEV TPS ADP Project has made to advance the state of the art in Thermal Protection System technology that has and will continue to benefit future entry probe missions.
Results from three NASA SBIR solar array technology programs are presented. The programs discussed are: 1) Thin Film Photovoltaic UltraFlex Solar Array; 2) Low Cost/Mass Electrostatically Clean Solar Array (ESCA); and 3) Stretched Lens Array SquareRigger (SLASR). The purpose of the Thin Film UltraFlex (TFUF) Program is to mature and validate the use of advanced flexible thin film photovoltaics blankets as the electrical subsystem element within an UltraFlex solar array structural system. In this program operational prototype flexible array segments, using United Solar amorphous silicon cells, are being manufactured and tested for the flight qualified UltraFlex structure. In addition, large size (e.g. 10 kW GEO) TFUF wing systems are being designed and analyzed. Thermal cycle and electrical test and analysis results from the TFUF program are presented. The purpose of the second program entitled, Low Cost/Mass Electrostatically Clean Solar Array (ESCA) System, is to develop an Electrostatically Clean Solar Array meeting NASA s design requirements and ready this technology for commercialization and use on the NASA MMS and GED missions. The ESCA designs developed use flight proven materials and processes to create a ESCA system that yields low cost, low mass, high reliability, high power density, and is adaptable to any cell type and coverglass thickness. All program objectives, which included developing specifications, creating ESCA concepts, concept analysis and trade studies, producing detailed designs of the most promising ESCA treatments, manufacturing ESCA demonstration panels, and LEO (2,000 cycles) and GEO (1,350 cycles) thermal cycling testing of the down-selected designs were successfully achieved. The purpose of the third program entitled, "High Power Platform for the Stretched Lens Array," is to develop an extremely lightweight, high efficiency, high power, high voltage, and low stowed volume solar array suitable for very high power (multi-kW to MW) applications. These objectives are achieved by combining two cutting edge technologies, the SquareRigger solar array structure and the Stretched Lens Array (SLA). The SLA SquareRigger solar array is termed SLASR. All program objectives, which included developing specifications, creating preliminary designs for a near-term SLASR, detailed structural, mass, power, and sizing analyses, fabrication and power testing of a functional flight-like SLASR solar blanket, were successfully achieved.
The Lightning Imaging Sensor (LIS) wide field-of-view solid-state camera can measure the global distribution of lightning from LEO, through the use of a narrowband interference filter to detect the neutral O band at 777.4 nm. Prelaunch testing and calibration of the LIS has required three separate laboratory systems; absolute radiometric calibration of the sensor will be furnished over the whole spectral range by a high resolution monochromator and motorized gimbals.
A wide variety of materials and experiment support hardware were flown on the Long Duration Exposure Facility (LDEF). Postflight testing has determined the effects of the almost 6 years of low-earth orbit (LEO) exposure on this hardware. An overview of the results are presented. Hardware discussed includes adhesives, fasteners, lubricants, data storage systems, solar cells, seals, and the LDEF structure. Lessons learned from the testing and analysis of LDEF hardware is also presented.