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At least 235 records · Page 13

Payload Planning for the International Space Station

A review of the evolution of the International Space Station (ISS) was performed for the purpose of understanding the project objectives. It was requested than an analysis of the current Office of Space Access and Technology (OSAT) Partnership Utilization Plan (PUP) traffic model be completed to monitor the process through which the scientific experiments called payloads are manifested for flight to the ISS. A viewing analysis of the ISS was also proposed to identify the capability to observe the United States Laboratory (US LAB) during the assembly sequence. Observations of the Drop-Tower experiment and nondestructive testing procedures were also performed to maximize the intern's technical experience. Contributions were made to the meeting in which the 1996 OSAT or Code X PUP traffic model was generated using the software tool, Filemaker Pro. The current OSAT traffic model satisfies the requirement for manifesting and delivering the proposed payloads to station. The current viewing capability of station provides the ability to view the US LAB during station assembly sequence. The Drop Tower experiment successfully simulates the effect of microgravity and conveniently documents the results for later use. The non-destructive test proved effective in determining stress in various components tested.

Johnson, Tameka J.↗

Carbon-Carbon Composite Radiator Development for the EO-1 Spacecraft

The Carbon-Carbon Space Radiator Partnership (CSRP), an informal partnership of Government and industrial personnel, was formed to promote the use of Carbon-carbon composites (C-C) as engineering materials for spacecraft thermal management applications . As a part of this effort the partnership has built a structural radiator for the Earth Orbiter - 1 (EO-1) spacecraft. This radiator, using C-C face-sheets with an aluminum honeycomb core, will demonstrate both the thermal and structural properties of C-C under actual service conditions as well as provide performance data from space flight. This paper will present results from the design of the radiator, the thermal/mechanical tests of the facesheet materials, and sub-component test results on the C-C/Al honeycomb sandwich material. The 29- by 28-inch radiator was designed to support two electronics boxes with a combined heat output of 60 watts maximum and a weight of 58 lbs. The analysis of the radiator design shows that the radiator constructed with 20-mil-thick facesheets of a P30-fiber-reinforced C-C from BFGoodrich is able to meet or exceed all the required thermal and mechanical requirements.

Vaughn, Wallace↗

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗

Investigation of Truncated Waveguides

The design, fabrication, and performance of truncated circular and square waveguide cross-sections are presented. An emphasis is placed upon numerical and experimental validation of simple analytical formulae that describe the propagation properties of these structures. A test component, a 90-degree phase shifter, was fabricated and tested at 30 GHz. The concepts explored can be directly applied in the design, synthesis and optimization of components in the microwave to sub-millimeter wavebands.

Lourie, Nathan P.↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

Advanced Gas Turbine (AGT) power-train system development

Technical work on the design and component testing of a 74.5 kW (100 hp) advanced automotive gas turbine is described. Selected component ceramic component design, and procurement were tested. Compressor tests of a modified rotor showed high speed performance improvement over previous rotor designs; efficiency improved by 2.5%, corrected flow by 4.6%, and pressure ratio by 11.6% at 100% speed. The aerodynamic design is completed for both the gasifier and power turbines. Ceramic (silicon carbide) gasifier rotors were spin tested to failure. Improving strengths is indicated by burst speeds and the group of five rotors failed at speeds between 104% and 116% of engine rated speed. The emission results from combustor testing showed NOx levels to be nearly one order of magnitude lower than with previous designs. A one piece ceramic exhaust duct/regenerator seal platform is designed with acceptable low stress levels.

Helms, H. E.↗

Stirling Space Engine Program: Appendixes A, B, C and D - Volume 2

The objective of this program was to develop the technology necessary for operating Stirling power converters in a space environment and to demonstrate this technology in full-scale engine tests. Volume 2 of the report includes the following appendices: Appendix A: Heater Head Development (Starfish Heater Head Program, 1/10th Segment and Full-Scale Heat Pipes, and Sodium Filling and Processing); Appendix B: Component Test Power Converter (CTPC) Component Development (High-temperature Organic Materials, Heat Exchanger Fabrication, Beryllium Issues, Sodium Issues, Wear Couple Tests, Pressure Boundary Penetrations, Heating System Heaters, and Cooler Flow Test); Appendix C: Udimet Testing (Selection of the Reference Material for the Space Stirling Engine Heater Head, Udimet 720LI Creep Test Result Update, Final Summary of Space Stirling Endurance Engine Udimet 720L1 Fatigue Testing Results, Udimet 720l1 Weld Development Summary, and Udimet 720L1 Creep Test Final Results Summary), and Appendix D: CTPC Component Development Photos.

Dhar, Manmohan↗

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↗

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↗

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.↗

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.↗

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↗

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↗

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.↗

Modeling Failure of Electrical Transformers due to Effects of a HEMP Event

Understanding the effect of a high-altitude electromagnetic pulse (HEMP) on the equipment in the United States electrical power grid is important to national security. A present challenge to this understanding is evaluating the vulnerability of transformers to a HEMP. Evaluating vulnerability by direct testing is cost-prohibitive, due to the wide variation in transformers, their high cost, and the large number of tests required to establish vulnerability with confidence. Alternatively, material and component testing can be performed to quantify a model for transformer failure, and the model can be used to assess vulnerability of a wide variety of transformers. This project develops a model of the probability of equipment failure due to effects of a HEMP. Potential failure modes are cataloged, and a model structure is presented which can be quantified by the results of small-scale coupon tests.

24 POWER TRANSMISSION AND DISTRIBUTION↗

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.↗