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Modal Test and Model Correlation of NASA Plum Brook Station Mechanical Vibration Facility Head Expander –Lessons Learned from the Perspective of an Early-Career Engineer

In preparation for the Sierra Nevada Corporation’s (SNC) Dream Chaser spacecraft vibration test campaign at the Mechanical Vibration Facility (MVF) at NASA Plum Brook Station (PBS) in Sandusky, Ohio, a test-verified model of MVF is needed in order to be able to perform accurate pretest analysis used for determining response limits and abort levels. MVF was designed to vibration test MPCV Orion and was used to perform the system level vibration test of the European Service Module Structural Test Article (E-STA) in 2016. MVF is comprised of an 18 ft diameter annulus table that is driven with sixteen hydraulic vertical actuator assemblies and four hydraulic horizontal actuator assemblies, which allow it to perform single axis vibration testing in the vertical axis and in each of the two orthogonal horizontal axes without the need for reconfiguring the test article. A head expander for the MVF Table has been designed and built that fills in the center opening providing a continuous flat mounting surface with a maximum diameter of 16.25feet that expands the vibration testing capabilities of MVF. The MVF Table with this head expander will be used during the SNC Dream Chaser spacecraft vibration test campaign. Therefore, a critical element in a test-verified model of the MVF will be a test correlated finite element model (FEM) of the head expander. To obtain this, engineers from the Structural Dynamics Lab (SDL) at NASA Glenn Research Center (GRC) in Cleveland, Ohio performed a modal pretest analysis, conducted a modal test in July 2019, and most recently correlated the head expander finite element model to the modal test data up to 300 Hz. From the initial test preparations to the final delivery of a correlated finite element model, all efforts mentioned were led by the same early-career engineers at NASA GRC. From the viewpoint of an early-career engineer, lessons learned about modal pretest analysis, modal testing, and finite element model correlation of the MVF Table expander head will be presented and discussed. This will include the importance of understanding the limitations of using uncorrelated finite element models in the modal pretest analysis and planning, the importance of orthogonality metrics in judging adequacy and accuracy of test mode shapes, and the importance of having the FEM match the as built hardware in the model correlation effort.

Emma L Pierson↗
NASA NTRS2014

Advanced Stirling Convertor (ASC) Development for NASA RPS

Sunpower's Advanced Stirling Convertor (ASC) initiated development under contract to the NASA Glenn Research Center (GRC) and after a series of successful demonstrations, the ASC began transitioning from a technology development project to flight development project. The ASC has very high power conversion efficiency making it attractive for future Radioisotope Power Systems (RPS) in order to make best use of the low plutonium-238 fuel inventory in the U.S. In recent years, the ASC became part of the NASA-Department of Energy Advanced Stirling Radioisotope Generator (ASRG) Integrated Project. Sunpower held two parallel contracts to produce ASC convertors, one with the Department of Energy/Lockheed Martin to produce the ASC-F flight convertors, and one with NASA GRC for the production of ASC-E3 engineering units, the initial units of which served as production pathfinders. The integrated ASC technical team successfully overcame various technical challenges that led to the completion and delivery of the first two pairs of flight-like ASC-E3 by 2013. However, in late Fall 2013, the DOE initiated termination of the Lockheed Martin ASRG flight development contract driven primarily by budget constraints. NASA continues to recognize the importance of high efficiency ASC power conversion for RPS and continues investment in the technology including the continuation of ASC-E3 production at Sunpower and the assembly of the ASRG Engineering Unit #2. This paper provides a summary of ASC technical accomplishments, overview of tests at GRC, plans for continued ASC production at Sunpower, and status of Stirling technology development.

Power Efficiency↗
NASA NTRS2005

Modeling and Analysis of Space Based Transceivers

This paper presents the tool chain, methodology, and results of an on-going study being performed jointly by Space Communication Experts at NASA Glenn Research Center (GRC), General Dynamics C4 Systems (GD), and Southwest Research Institute (SwRI). The team is evaluating the applicability and tradeoffs concerning the use of Software Defined Radio (SDR) technologies for Space missions. The Space Telecommunications Radio Systems (STRS) project is developing an approach toward building SDR-based transceivers for space communications applications based on an accompanying software architecture that can be used to implement transceivers for NASA space missions. The study is assessing the overall cost and benefit of employing SDR technologies in general, and of developing a software architecture standard for its space SDR transceivers. The study is considering the cost and benefit of existing architectures, such as the Joint Tactical Radio Systems (JTRS) Software Communications Architecture (SCA), as well as potential new space-specific architectures.

Moore, Michael S.↗
NASA NTRS2016

Alternative Bio-Derived JP-8 Class Fuel and JP-8 Fuel: Flame Tube Combustor Test Results Compared using a GE TAPS Injector Configuration

This paper presents results from tests in a NASA Glenn Research Center (GRC) flame tube facility, where a bio-derived alternate fuel was compared with JP-8 for emissions and general combustion performance. A research version of General Electric Aviation (GE) TAPS injector was used for the tests. Results include 2D, planar laser-based imaging as well as basic flow visualization of the flame. Four conditions were selected that simulate various engine power conditions relevant to NASA Fundamental Aeronautics Supersonics and Environmentally Responsible Aviation Projects were tested.

optical diagnostics↗
NASA NTRS2005

Development, Implementation and Application of Micromechanical Analysis Tools for Advanced High Temperature Composites

This document contains the final report to the NASA Glenn Research Center (GRC) for the research project entitled Development, Implementation, and Application of Micromechanical Analysis Tools for Advanced High-Temperature Composites. The research supporting this initiative has been conducted by Dr. Brett A. Bednarcyk, a Senior Scientist at OM in Brookpark, Ohio from the period of August 1998 to March 2005. Most of the work summarized herein involved development, implementation, and application of enhancements and new capabilities for NASA GRC's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) software package. When the project began, this software was at a low TRL (3-4) and at release version 2.0. Due to this project, the TRL of MAC/GMC has been raised to 7 and two new versions (3.0 and 4.0) have been released. The most important accomplishments with respect to MAC/GMC are: (1) A multi-scale framework has been built around the software, enabling coupled design and analysis from the global structure scale down to the micro fiber-matrix scale; (2) The software has been expanded to analyze smart materials; (3) State-of-the-art micromechanics theories have been implemented and validated within the code; (4) The damage, failure, and lifing capabilities of the code have been expanded from a very limited state to a vast degree of functionality and utility; and (5) The user flexibility of the code has been significantly enhanced. MAC/GMC is now the premier code for design and analysis of advanced composite and smart materials. It is a candidate for the 2005 NASA Software of the Year Award. The work completed over the course of the project is summarized below on a year by year basis. All publications resulting from the project are listed at the end of this report.

Source record↗
NASA NTRS2004

Development of a Multi-bus, Multi-source Reconfigurable Stirling Radioisotope Power System Test Bed

The National Aeronautics and Space Administration (NASA) has typically used Radioisotope Thermoelectric Generators (RTG) as their source of electric power for deep space missions. A more efficient and potentially more cost effective alternative to the RTG, the high efficiency 110 watt Stirling Radioisotope Generator 110 (SRG110) is being developed by the Department of Energy (DOE), Lockheed Martin (LM), Stirling Technology Company (STC) and NASA Glenn Research Center (GRC). The SRG110 consists of two Stirling convertors (Stirling Engine and Linear Alternator) in a dual-opposed configuration, and two General Purpose Heat Source (GPHS) modules. Although Stirling convertors have been successfully operated as a power source for the utility grid and as a stand-alone portable generator, demonstration of the technology required to interconnect two Stirling convertors for a spacecraft power system has not been attempted. NASA GRC is developing a Power System Test Bed (PSTB) to evaluate the performance of a Stirling convertor in an integrated electrical power system application. This paper will describe the status of the PSTB and on-going activities pertaining to the PSTB in the NASA Thermal-Energy Conversion Branch of the Power and On-Board Propulsion Technology Division.

Coleman, Anthony S.↗
NASA NTRS2014

Enhanced Fan Noise Modeling for Turbofan Engines

This report describes work by consultants to Diversitech Inc. for the NASA Glenn Research Center (GRC) to revise the fan noise prediction procedure based on fan noise data obtained in the 9- by 15 Foot Low-Speed Wind Tunnel at GRC. The purpose of this task is to begin development of an enhanced, analytical, more physics-based, fan noise prediction method applicable to commercial turbofan propulsion systems. The method is to be suitable for programming into a computational model for eventual incorporation into NASA's current aircraft system noise prediction computer codes. The scope of this task is in alignment with the mission of the Propulsion 21 research effort conducted by the coalition of NASA, state government, industry, and academia to develop aeropropulsion technologies. A model for fan noise prediction was developed based on measured noise levels for the R4 rotor with several outlet guide vane variations and three fan exhaust areas. The model predicts the complete fan noise spectrum, including broadband noise, tones, and for supersonic tip speeds, combination tones. Both spectra and directivity are predicted. Good agreement with data was achieved for all fan geometries. Comparisons with data from a second fan, the ADP fan, also showed good agreement.

aircraft↗
NASA NTRS2014

The Green Propellant Infusion Mission Thruster Performance Testing for Plume Diagnostics

The Green Propellant Infusion Mission (GPIM) is sponsored by NASA's Space Technology Mission Directorate (STMD) Technology Demonstration Mission (TDM) office. The goal of GPIM is to advance the technology readiness level of a green propulsion system, specifically, one using the monopropellant, AF-M315E, by demonstrating ground handling, spacecraft processing, and on-orbit operations. One of the risks identified for GPIM is potential contamination of sensitive spacecraft surfaces from the effluents in the plumes of AF-M315E thrusters. NASA Glenn Research Center (GRC) is conducting activities to characterize the effects of AF-M315E plume impingement and deposition. GRC has established individual plume models of the 22-N and 1-N thrusters that will be used on the GPIM spacecraft. The model simulations will be correlated with plume measurement data from Laboratory and Engineering Model 22-N, AF-M315E thrusters. The thrusters are currently being tested in a small rocket, altitude facility at NASA GRC. A suite of diagnostics, including Raman spectroscopy, Rayleigh spectroscopy, and Schlieren imaging are being used to acquire plume measurements of AF-M315E thrusters. Plume data will include temperature, velocity, relative density, and species concentration. The plume measurement data will be compared to the corresponding simulations of the plume model. The GRC effort will establish a data set of AF-M315E plume measurements and a plume model that can be used for future AF-M315E applications.

Green Propellants↗
NASA NTRS2000

Partnering to Change the Way NASA and the Nation Communicate Through Space

For at least 20 years, the Space Communications Program at NASA Glenn Research Center (GRC) has focused on enhancing the capability and competitiveness of the U.S. commercial communications satellite industry. GRC has partnered with the industry on the development of enabling technologies to help maintain U.S. preeminence in the worldwide communications satellite marketplace. The Advanced Communications Technology Satellite (ACTS) has been the most significant space communications technology endeavor ever performed at GRC, and the centerpiece of GRC's communication technology program for the last decade. Under new sponsorship from NASA's Human Exploration and Development of Space Enterprise, GRC has transitioned the focus and direction of its program, from commercial relevance to NASA mission relevance. Instead of one major experimental spacecraft and one headquarters sponsor, GRC is now exploring opportunities for all of NASA's Enterprises to benefit from advances in space communications technologies, and accomplish their missions through the use of existing and emerging commercially provided services. A growing vision within NASA is to leverage the best commercial standards, technologies, and services as a starting point to satisfy NASA's unique needs. GRC's heritage of industry partnerships is closely aligned with this vision. NASA intends to leverage the explosive growth of the telecommunications industry through its impressive technology advancements and potential new commercial satellite systems. GRC's partnerships with the industry, academia, and other government agencies will directly support all four NASA's future mission needs, while advancing the state of the art of commercial practice. GRC now conducts applied research and develops and demonstrates advanced communications and network technologies in support of all four NASA Enterprises (Human Exploration and Development of Space, Space Science, Earth Science, and Aero-Space Technologies).

Vrotsos, Pete A.↗
NASA NTRS2005

Materials on the International Space Station - Forward Technology Solar Cell Experiment

This paper describes a space solar cell experiment currently being built by the Naval Research Laboratory (NRL) in collaboration with NASA Glenn Research Center (GRC), and the US Naval Academy (USNA). The experiment has been named the Forward Technology Solar Cell Experiment (FTSCE), and the purpose is to rapidly put current and future generation space solar cells on orbit and provide validation data for these technologies. The FTSCE is being fielded in response to recent on-orbit and ground test anomalies associated with space solar arrays that have raised concern over the survivability of new solar technologies in the space environment and the validity of present ground test protocols. The FTSCE is being built as part of the Fifth Materials on the International Space Station (MISSE) Experiment (MISSE-5), which is a NASA program to characterize the performance of new prospective spacecraft materials when subjected to the synergistic effects of the space environment. Telemetry, command, control, and communication (TNC) for the FTSCE will be achieved through the Amateur Satellite Service using the PCSat2 system, which is an Amateur Radio system designed and built by the USNA. In addition to providing an off-the-shelf solution for FTSCE TNC, PCSat2 will provide a communications node for the Amateur Radio satellite system. The FTSCE and PCSat2 will be housed within the passive experiment container (PEC), which is an approximately 2ft x2ft x 4in metal container built by NASA Langley Research Center (NASA LaRC) as part of the MISSE-5 program. NASA LaRC has also supplied a thin film materials experiment that will fly on the exterior of the thermal blanket covering the PCSat2. The PEC is planned to be transported to the ISS on a Shuttle flight. The PEC will be mounted on the exterior of the ISS by an astronaut during an extravehicular activity (EVA). After nominally one year, the PEC will be retrieved and returned to Earth. At the time of writing this paper, the subsystems of the experiment are being integrated at NRL, and we are preparing to commence environmental testing.

Walters, R. J.↗
NASA NTRS2004

Computational Modeling of NEXT 2000-Hour Wear Test Results

Ion optics computational models are invaluable tools for the design of ion optics systems. In this study, a new computational model developed by an outside vendor for NASA Glenn Research Center (GRC) is presented. This model is a gun code which has been modified to model the plasma sheaths both upstream and downstream of the ion optics. The model handles multiple species (e.g. singly and doubly-charged ions) and includes a charge-exchange model for erosion estimates. The model uses commercially available solid design and meshing software, allowing high flexibility in ion optics geometric configurations. This computational model is compared to experimental results from the NASA Evolutionary Xenon Thruster (NEXT) 2000-hour wear test, including over-focusing along the edge apertures, pit-and-groove erosion due to charge exchange, and beamlet distortion at the edge of the hole pattern.

Malone, Shane P.↗
NASA NTRS2007

Hydrogen Generation Through Renewable Energy Sources at the NASA Glenn Research Center

An evaluation of the potential for generating high pressure, high purity hydrogen at the NASA Glenn Research Center (GRC) was performed. This evaluation was based on producing hydrogen utilizing a prototype Hamilton Standard electrolyzer that is capable of producing hydrogen at 3000 psi. The present state of the electrolyzer system was determined to identify the refurbishment requirements. The power for operating the electrolyzer would be produced through renewable power sources. Both wind and solar were considered in the analysis. The solar power production capability was based on the existing solar array field located at NASA GRC. The refurbishment and upgrade potential of the array field was determined and the array output was analyzed with various levels of upgrades throughout the year. The total available monthly and yearly energy from the array was determined. A wind turbine was also sized for operation. This sizing evaluated the wind potential at the site and produced an operational design point for the wind turbine. Commercially available wind turbines were evaluated to determine their applicability to this site. The system installation and power integration were also addressed. This included items such as housing the electrolyzer, power management, water supply, gas storage, cooling and hydrogen dispensing.

Colozza, Anthony↗
NASA NTRS2011

Enhanced Core Noise Modeling for Turbofan Engines

This report describes work performed by MTC Technologies (MTCT) for NASA Glenn Research Center (GRC) under Contract NAS3-00178, Task Order No. 15. MTCT previously developed a first-generation empirical model that correlates the core/combustion noise of four GE engines, the CF6, CF34, CFM56, and GE90 for General Electric (GE) under Contract No. 200-1X-14W53048, in support of GRC Contract NAS3-01135. MTCT has demonstrated in earlier noise modeling efforts that the improvement of predictive modeling is greatly enhanced by an iterative approach, so in support of NASA's Quiet Aircraft Technology Project, GRC sponsored this effort to improve the model. Since the noise data available for correlation are total engine noise spectra, it is total engine noise that must be predicted. Since the scope of this effort was not sufficient to explore fan and turbine noise, the most meaningful comparisons must be restricted to frequencies below the blade passage frequency. Below the blade passage frequency and at relatively high power settings jet noise is expected to be the dominant source, and comparisons are shown that demonstrate the accuracy of the jet noise model recently developed by MTCT for NASA under Contract NAS3-00178, Task Order No. 10. At lower power settings the core noise became most apparent, and these data corrected for the contribution of jet noise were then used to establish the characteristics of core noise. There is clearly more than one spectral range where core noise is evident, so the spectral approach developed by von Glahn and Krejsa in 1982 wherein four spectral regions overlap, was used in the GE effort. Further analysis indicates that the two higher frequency components, which are often somewhat masked by turbomachinery noise, can be treated as one component, and it is on that basis that the current model is formulated. The frequency scaling relationships are improved and are now based on combustor and core nozzle geometries. In conjunction with the Task Order No. 10 jet noise model, this core noise model is shown to provide statistical accuracy comparable to the jet noise model for frequencies below blade passage. This model is incorporated in the NASA FOOTPR code and a user s guide is provided.

Stone, James R.↗
NASA NTRS2017

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASA's RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit #2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗
NASA NTRS2018

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASAs RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit 2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗
NASA NTRS2001

Duplex Direct Data Distribution System

The NASA Glenn Research Center (GRC) is developing and demonstrating communications and network technologies that are helping to enable the near-Earth space Internet. GRC envisions several service categories. The first of these categories is direct data distribution or D3 (pronounced "D-cubed"). Commercially provided D3 will make it possible to download a data set from a spacecraft, like the International Space Station. as easily as one can extract a file from a remote server today, using a file transfer protocol. In a second category, NASA spacecraft will make use of commercial satellite communication (SATCOM) systems. Some of those services will come from purchasing time on unused transponders that cover landmasses. While it is likely there will be gaps in service coverage, Internet services should be available using these systems. This report addresses alternative methods of implementing a full duplex enhancement of the GRC developed experimental Ka-Band Direct Data Distribution (D3) space-to-ground communication link. The resulting duplex version is called the Duplex Direct Data Distribution (D4) system. The D4 system is intended to provide high-data-rate commercial direct or internet-based communications service between the NASA spacecraft in low earth orbit (LEO) and the respective principal investigators associated with these spacecraft. Candidate commercial services were assessed regarding their near-term potential to meet NASA requirements. Candidates included Ka-band and V-band geostationary orbit and non-geostationary orbit satellite relay services and direct downlink ("LEO teleport") services. End-to-end systems concepts were examined and characterized in terms of alternative link layer architectures. Alternatives included a Direct Link, a Relay Link, a Hybrid Link, and a Dual Mode Link. The direct link assessment examined sample ground terminal placements and antenna angle issues. The SATCOM-based alternatives examined existing or proposed commercial SATCOM services that could be available in the 2005 time frame. The alternatives were evaluated and compared in terms of average daily system throughput and cost per bit. Throughput was estimated based on hypothetical scenarios supporting the International Space Station and polar orbiting missions. The feasibility of using standard TCP and a modified TCP was evaluated and risks were identified. An estimate of the TCP acknowledgment data rate required to support a return channel rate of 622 Mbps was developed using OPNET.

Greenfield, Israel↗
NASA NTRS2013

Small Radioisotope Power System Testing at NASA Glenn Research Center

In April 2009, NASA Glenn Research Center (GRC) formed an integrated product team (IPT) to develop a Small Radioisotope Power System (SRPS) utilizing a single Advanced Stirling Convertor (ASC) with passive balancer. A single ASC produces approximately 80 We making this system advantageous for small distributed lunar science stations. The IPT consists of Sunpower, Inc., to provide the single ASC with a passive balancer, The Johns Hopkins University Applied Physics Laboratory (JHUAPL) to design an engineering model Single Convertor Controller (SCC) for an ASC with a passive balancer, and NASA GRC to provide technical support to these tasks and to develop a simulated lunar lander test stand. The single ASC with a passive balancer, simulated lunar lander test stand, and SCC were delivered to GRC and were tested as a system. The testing sequence at GRC included SCC fault tolerance, integration, electromagnetic interference (EMI), vibration, and extended operation testing. The SCC fault tolerance test characterized the SCCs ability to handle various fault conditions, including high or low bus power consumption, total open load or short circuit, and replacing a failed SCC card while the backup maintains control of the ASC. The integrated test characterized the behavior of the system across a range of operating conditions, including variations in cold-end temperature and piston amplitude, including the emitted vibration to both the sensors on the lunar lander and the lunar surface. The EMI test characterized the AC and DC magnetic and electric fields emitted by the SCC and single ASC. The vibration test confirms the SCCs ability to control the single ASC during launch. The extended operation test allows data to be collected over a period of thousands of hours to obtain long term performance data of the ASC with a passive balancer and the SCC. This paper will discuss the results of each of these tests.

Vibration↗
NASA NTRS2004

Advanced SiC/SiC Ceramic Composites For Gas-Turbine Engine Components

NASA Glenn Research Center (GRC) is developing a variety of advanced SiC/SiC ceramic composite (ASC) systems that allow these materials to operate for hundreds of hours under stress in air at temperatures approaching 2700 F. These SiC/SiC composite systems are lightweight (approximately 30% metal density) and, in comparison to monolithic ceramics and carbon fiber-reinforced ceramic composites, are able to reliably retain their structural properties for long times under aggressive gas-turbine engine environments. The key for the ASC systems is related first to the NASA development of the Sylramic-iBN Sic fiber, which displays higher thermal stability than any other SiC- based ceramic fibers and possesses an in-situ grown BN surface layer for higher environmental durability. This fiber is simply derived from Sylramic Sic fiber type that is currently produced at ATK COI Ceramics (COIC). Further capability is then derived by using chemical vapor infiltration (CVI) and/or polymer infiltration and pyrolysis (PIP) to form a Sic-based matrix with high creep and rupture resistance as well as high thermal conductivity. The objectives of this study were (1) to optimize the constituents and processing parameters for a Sylramic-iBN fiber reinforced ceramic composite system in which the Sic-based matrix is formed at COIC almost entirely by PIP (full PIP approach), (2) to evaluate the properties of this system in comparison to other 2700 F Sylramic-iBN systems in which the matrix is formed by full CVI and CVI + PIP, and (3) to examine the pros and cons of the full PIP approach for fabricating hot-section engine components. A key goal is the development of a composite system with low porosity, thereby providing high modulus, high matrix cracking strength, high interlaminar strength, and high thermal conductivity, a major property requirement for engine components that will experience high thermal gradients during service. Other key composite property goals are demonstration at high temperatures of high environmental resistance and high creep resistance, which in turn will result in long component life. Data are presented from a variety of laboratory tests on simple two-dimensional panels that examine these properties and compare the performance of the optimized full PIP system with those of the full CVI and CVI + PIP hybrid systems. Underlying mechanisms for performance differences in the various systems are discussed. Remaining issues for further property enhancement and for application of the full PIP approach for engine components are also discussed, as well as on-going approaches at NASA to solve these issues.

H. M. Yun↗