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ORNL Package Testing Program Overview

When transporting radioactive or hazardous materials, safety and security are top priorities. Packaging and transportation regulations require reliable evidence that containers have passed rigorous performance tests to ensure that the public and the environment are protected from the hazardous nature of the cargo. Because of its long history in energy and security research, Oak Ridge National Laboratory (ORNL) has needed to ship hazardous packages for the past 65 years. Since the 1940s, ORNL has made significant contributions to transportation regulations and has been at the forefront of regulatory testing development. Today, ORNL is a leader in standards development and testing of designs of radioactive material packages. ORNL plays a critical role in ensuring the safe transportation of radioactive materials across the United States by executing rigorous testing campaigns of packages that contain radioactive materials. Early testing activities focused on supporting the development of transportation regulations established by both the International Atomic Energy Agency (IAEA) and the United States. Currently, all package testing activities are performed under the Package Testing Program (PTP) at the Package Evaluation Facility (PEF) located at the National Transportation Research Center (NTRC), which is about 10 miles from the main ORNL campus. The PTP develops and evaluates testing solutions, ensuring that they are safe efficient, and in compliance with regulatory requirements. The vision for the PTP is to be a world-class leader in the evaluation and testing of radioactive and hazardous material packages. The key elements necessary to fulfill this mission are an experienced and professional staff; state-of-the-art facilities, equipment, and instrumentation; and completion of challenging programs and projects important to package transportation. Collaborations with other internal and external organizations play a significant role in building stronger teams and achieving this vision. By adhering to and advancing regulatory standards, ORNL’s PTP supports development of safe and compliant packaging, safeguarding the transportation process from potential risks associated with radioactive material logistics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Results of a wind tunnel/flight test program to compare afterbody/nozzle pressures on a 1/12 scale model and an F-15 aircraft

In 1975 NASA Dryden Flight Research Facility received the No. 2 prototype F-15 aircraft from the USAF to conduct the F-15 Propulsion/Airframe Interactions Program. About the same time, NASA Langley Research Center acquired a 1/12 scale F-15 propulsion model, whose size made it suitable for detailed afterbody/nozzle static pressure distribution studies. Close coordination between Langley and Dryden assured identical orifice locations and nozzle geometries on the model and aircraft. This paper discusses the sequence of the test programs and how retesting the model after completion of the flight tests greatly increased the ability to match hardware and test conditions. The experience gained over the past decade from involvement in the program should prove valuable to any future programs attempting to match wind tunnel and flight test conditions and hardware.

Pendergraft, O. C., Jr.↗

Shuttle antenna radome technology test program. Volume 2: Development of S-band antenna interface design

The effects of the Thermal Protection Subsystem (TPS) contamination on the space shuttle orbiter S band quad antenna due to multiple mission buildup are discussed. A test fixture was designed, fabricated and exposed to ten cycles of simulated ground and flight environments. Radiation pattern and impedance tests were performed to measure the effects of the contaminates. The degradation in antenna performance was attributed to the silicone waterproofing in the TPS tiles rather than exposure to the contaminating sources used in the test program. Validation of the accuracy of an analytical thermal model is discussed. Thermal vacuum tests with a test fixture and a representative S band quad antenna were conducted to evaluate the predictions of the analytical thermal model for two orbital heating conditions and entry from each orbit. The results show that the accuracy of predicting the test fixture thermal responses is largely dependent on the ability to define the boundary and ambient conditions. When the test conditions were accurately included in the analytical model, the predictions were in excellent agreement with measurements.

Kuhlman, E. A.↗

Measurement uncertainty for the Uniform Engine Testing Program conducted at NASA Lewis Research Center

An uncertainty analysis was conducted to determine the bias and precision errors and total uncertainty of measured turbojet engine performance parameters. The engine tests were conducted as part of the Uniform Engine Test Program which was sponsored by the Advisory Group for Aerospace Research and Development (AGARD). With the same engines, support hardware, and instrumentation, performance parameters were measured twice, once during tests conducted in test cell number 3 and again during tests conducted in test cell number 4 of the NASA Lewis Propulsion Systems Laboratory. The analysis covers 15 engine parameters, including engine inlet airflow, engine net thrust, and engine specific fuel consumption measured at high rotor speed of 8875 rpm. Measurements were taken at three flight conditions defined by the following engine inlet pressure, engine inlet total temperature, and engine ram ratio: (1) 82.7 kPa, 288 K, 1.0, (2) 82.7 kPa, 288 K, 1.3, and (3) 20.7 kPa, 288 K, 1.3. In terms of bias, precision, and uncertainty magnitudes, there were no differences between most measurements made in test cells number 3 and 4. The magnitude of the errors increased for both test cells as engine pressure level decreased. Also, the level of the bias error was two to three times larger than that of the precision error.

Abdelwahab, Mahmood↗

Pegasus Air-Launched Space Booster Flight Test Program

Pegasus is a satellite-launching space rocket dropped from a B52 carrier aircraft instead of launching vertically from a ground pad. Its three-year, privately-funded accelerated development was carried out under a demanding design-to-nonrecurring cost methodology, which imposed unique requirements on its flight test program, such as the decision not to drop an inert model from the carrier aircraft; the number and type of captive and free-flight tests; the extent of envelope exploration; and the decision to combine test and operational orbital flights. The authors believe that Pegasus may be the first vehicle where constraints in the number and type of flight tests to be carried out actually influenced the design of the vehicle. During the period November 1989 to February of 1990 a total of three captive flight tests were conducted, starting with a flutter clearing flight and culminating in a complete drop rehearsal. Starting on April 5, 1990, two combination test/operational flights were conducted. A unique aspect of the program was the degree of involvement of flight test personnel in the early design of the vehicle and, conversely, of the design team in flight testing and early flight operations. Various lessons learned as a result of this process are discussed throughout this paper.

Elias, Antonio L.↗

Airframe Noise Results from the QTD II Flight Test Program

With continued growth in air travel, sensitivity to community noise intensifies and materializes in the form of increased monitoring, regulations, and restrictions. Accordingly, realization of quieter aircraft is imperative, albeit only achievable with reduction of both engine and airframe components of total aircraft noise. Model-scale airframe noise testing has aided in this pursuit; however, the results are somewhat limited due to lack of fidelity of model hardware, particularly in simulating full-scale landing gear. Moreover, simulation of true in-flight conditions is non-trivial if not infeasible. This paper reports on an investigation of full-scale landing gear noise measured as part of the 2005 Quiet Technology Demonstrator 2 (QTD2) flight test program. Conventional Boeing 777-300ER main landing gear were tested, along with two noise reduction concepts, namely a toboggan fairing and gear alignment with the local flow, both of which were down-selected from various other noise reduction devices evaluated in model-scale testing at Virginia Tech. The full-scale toboggan fairings were designed by Goodrich Aerostructures as add-on devices allowing for complete retraction of the main gear. The baseline-conventional gear, faired gear, and aligned gear were all evaluated with the high-lift system in the retracted position and deployed at various flap settings, all at engine idle power setting. Measurements were taken with flyover community noise microphones and a large aperture acoustic phased array, yielding far-field spectra, and localized sources (beamform maps). The results were utilized to evaluate qualitatively and quantitatively the merit of each noise reduction concept. Complete similarity between model-scale and full-scale noise reduction levels was not found and requires further investigation. Far-field spectra exhibited no noise reduction for both concepts across all angles and frequencies. Phased array beamform maps show inconclusive evidence of noise reduction at selective frequencies (1500 to 3000 Hz) but are otherwise in general agreement with the far-field spectra results (within measurement uncertainty).

Elkoby, Ronen↗

Deep Space Habitability Design Guidelines Based on the NASA NextSTEP Phase 2 Ground Test Program

This report summarizes habitation design guidelines for deep space habitats, which were derived from the NASA Next Space Technologies for Exploration Partnerships (NextSTEP) Phase 2 Habitat Ground Test Program. All data presented in this document have been contractor-deidentified and approved for public release. The report prioritizes capabilities and recommends allocating those capabilities to either the Habitation and Logistics Outpost (HALO) or the International Habitat (I-Hab). A review of the design guidelines is presented in the main body of the report, along with a list of the 170 specific design guidelines with references to the specific data sources from which they were derived.

Gernhardt, Michael↗

A ground test program to support condition monitoring of a spacecraft attitude control propulsion system

The Comet Rendezvous Asteroid Flyby (CRAF) mission involves seven years of flight from 0.6 to 4.57 Astronomical Units (AU), followed by about 915 days of maneuvering around a comet. Ground testing will characterize the very critical attitude control system thrusters' fuel consumption and performance for all anticipated fuel temperatures over thruster life. The ground test program characterization will support flight condition monitoring. A commercial software application hosted on a commercial microcomputer will control ground test operations and data acquisition using a newly designed thrust stand. The data acquisition and control system uses a graphics-based language and features a visual interface to integrate data acquisition and control.

Clark, Douglas J.↗

Small-scale test program to develop a more efficient swivel nozzle thrust deflector for V/STOL lift/cruise engines

The installed performance degradation of a swivel nozzle thrust deflector system obtained during increased vectoring angles of a large-scale test program was investigated and improved. Small-scale models were used to generate performance data for analyzing selected swivel nozzle configurations. A single-swivel nozzle design model with five different nozzle configurations and a twin-swivel nozzle design model, scaled to 0.15 size of the large-scale test hardware, were statically tested at low exhaust pressure ratios of 1.4, 1.3, 1.2, and 1.1 and vectored at four nozzle positions from 0 deg cruise through 90 deg vertical used for the VTOL mode.

Schlundt, D. W.↗

Intercity rail-passenger car ride quality test program

The Federal Railroad Administration's research and development program relating to intercity rail-passenger ride quality focuses on developing ride quality design criteria and specifications. The FRA ride quality test program and some of the techniques being used to analyze and evaluate the design criteria of the program are discussed.

Scharr, R. L.↗

Spacelab baseline ECS trace contaminant removal test program

An estimate of the Spacelab Baseline Environmental Control System's contaminated removal capability was required to allow determination of the need for a supplemental trace contaminant removal system. Results from a test program to determine this removal capability are presented.

Ray, C. D.↗

X-24B flight test program

The X-24B is an air launched, rocket powered research aircraft. A number of its design features constitute a tradeoff between aerodynamics and heating considerations. A vehicle description is given and test program objectives are discussed along with operational procedures and aspects of energy management. Attention is also given to X-24B handling qualities, approach and landing, wind tunnel data and simulation, and proposed X-24C vehicle requirements.

Manke, J. A.↗

Resonant AC power system proof-of-concept test program

Proof-of-concept testing was performed on a 20-kHz, resonant power system breadboard from 1981 through 1985. The testing began with the evaluation of a single, 1.0-kW resonant inverter and progressed to the testing of breadboard systems with higher power levels and more capability. The final breadboard configuration tested was a 25.0-kW breadboard with six inverters providing power to three user-interface modules over a 50-meter, 20-kHz bus. The breadboard demonstrated the ability to synchronize multiple resonant inverters to power a common bus. Single-phase and three-phase 20-kHz power distribution was demonstrated. Simple conversion of 20-kHz to dc and variable-frequency ac was demonstrated as was bidirectional power flow between 20-kHz and dc. Steady state measurements of efficiency, power-factor tolerance, and conducted emissions and conducted susceptibility were made. In addition, transient responses were recorded for such conditions as start up, shut down, load changes. The results showed the 20-kHz resonant system to be a desirable technology for a spacecraft power management and distribution system with multiple users and a utility-type bus.

Wappes, Loran J.↗

ORNL Package Testing Program Overview

Radioactive materials are widespread in our everyday activities which are used in many different types of industries: Consumer products, Medicine, Industry, Energy, and Defense. In the United States there is about 3 million shipments of radioactive materials per year. With radioactive material being very widespread the number of new applications to ship these quantities increases daily. As such, ensuring the safe and secure transport of these materials is paramount, necessitating stringent packaging, transportation, and certification requirements. Shipments of radioactive materials have been made from Oak Ridge National Laboratory (ORNL) for the past 65 years. Since the 1940s ORNL has been at the forefront of the early development of regulations pertaining to the transport of radioactive shipments and associated regulatory testing. The early involvement resulted in ORNL being one of the leaders in the development of regulations and testing standards pertaining to the testing and design of packages. Today all package testing activities are conducted under the Package Testing Program (PTP) at ORNL at the Package Evaluation Facility (PEF). The PTP develops and evaluates testing solutions – ensuring that they are safe, efficient, and meet regulatory requirements ORNL PTP has extensive experience in the regulatory testing of radioactive material packages, supporting certification of Type A, Type, B, Type AF, and special form packages. The PEF serves as a one-stop-shop for design, testing, and certification of a wide variety of packages needed for shipment of radioactive materials. The facility provides the space, expertise, and equipment necessary to conduct rigorous performance testing under both normal and accident conditions or transport environments including free drop, dynamic crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal test. The PTP remains a key contributor to the safety and compliance of radioactive material transportation. This presentation will provide an overview of the program’s history, capabilities, and its ongoing role in advancing regulatory standards and transportation safety.

Martinez, Oscar [ORNL] (ORCID:0000000181814046)↗

Space Shuttle Orbiter nose cap and wing leading edge certification test program

A reinforced carbon-carbon thermal protection system is used on the space shuttle orbiter vehicle's nose cap and wing leading edge regions where temperatures reach 1538 C (2800 F). To verify the analyses used to certify reinforced carbon-carbon for the first flight and operational missions, a multi-environment incremental test program was developed and implemented through the combined efforts of Rockwell International and the National Aeronautics and Space Administration. Three separate facilities at the Johnson Space Center were used to subject full-scale nose cap and wing leading edge test articles to simulated critical launch, on-orbit, and atmospheric entry environments.

Suppanz, M. J.↗

Variable area radial turbine fabrication and test program

A variable area radial turbine with a moveable nozzle sidewall was experimentally evaluated. The turbine was designed for an advanced variable capacity gas turbine rotorcraft engine. The turbine has a mass flow rate of 2.27 kg/sec (5.0 lbs/sec), and a rotor inlet temperature of 1477K (2200 F). Testing was conducted at a reduced inlet temperature, but the aerodynamic parameters and Reynolds numbers were duplicated. Overall performance was obtained for a range of nozzle areas from 50% to 100% of the maximum area. The test program determined the effect on performance of: (1) Moving the hub or shroud sidewall; (2) Sidewall-vane clearance leakage; (3) Vaneless space geometry change; and (4) Nozzle cooling flows. Data were obtained for a range of pressure ratios and speeds and are presented in a number of performance maps.

Rogo, C.↗