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DOE OSTI2023

A Fast Reactor Irradiation Experiment Design in the ATR

Modern modeling techniques were used to investigate a proposed method for fast neutron irradiations in an existing thermal-spectrum reactor, the Advanced Test Reactor (ATR). This method builds upon pre-existing ideas, where fast flux is increased by surrounding the specimens with fissionable “booster fuel” but diverges from historical approaches by using an already developed fuel element design used in the Belgian Reactor 2 (BR2) as the booster fuel while leveraging modern 3-D modeling and simulation techniques. Design evaluations and neutronics simulations were performed to evaluate the performance of a BR2 fuel element irradiated in an ATR flux trap with test pins in the central channel of the BR2 fuel element. These efforts have yielded promising results. Adding a BR2 fuel element in the northeast (NE) flux trap of ATR was predicted to result in a 150% increase to the incident fast neutron flux with a fast (>0.1 MeV) to thermal (<0.625 eV) neutron flux ratio ranging from approximately 50 to 150, dependent on the material used for thermal neutron filtering and volume of moderator within the central channel of the BR2 element. The predicted annual fast neutron fluence (>0.1 MeV) ranges from 7.9 × 1021 to 9.1 × 1021 n/cm2. Given the relatively large fast to thermal neutron flux ratio, the calculated radial power profiles within 4.3 mm outer diameter U10Zr fueled specimens irradiated within the BR2 booster fuel element are adequate representations of those within fast neutron reactors. The predicted radial power profiles are not flat, but they are more prototypic than those seen in advanced fuels tests which began in ATR in 2003. Another distinct advantage of this experiment design is that full-scale test pins can be irradiated to augment the ongoing series of reduced scale advanced fuels tests. The proposed experiment design irradiated within a BR2 fuel element in a flux trap of ATR offers an improved alternative to the current testing of advanced reactor fuels in ATR. Selected results from this design evaluation are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Terry Turbopump Expanded Operating Band Modeling and Simulation Efforts in Fiscal Year 2020 - Progress Report

The Terry Turbine Expanded Operating Band Project is currently conducting testing at Texas A&M University as part of a revised experimental program meant to supplant previous full-scale testing plans under the headings of Milestone 5 and Milestone 6. In consultation with Sandia National Laboratories technical staff and with modeling and simulation support from the same, the hybrid Milestone 5&6 plan is moving forward with experiments aimed at addressing knowledge gaps regarding scale, working fluid, and turbopump self-regulation. Modeling and simulation efforts at Sandia National Laboratories in FY20 fell under the broad umbrella of Milestone 7 and consisted exclusively of MELCOR-related tasks aimed at: 1) Constructing/improving input models of Texas A&M University experiments, 2) Constructing a generic boiling water reactor input model according to best practices with systems-level Teny turbine capabilities, and 3) Adding code capability in order to leverage experimental data/findings, address bugs, and improve general code robustness Project impacts of the Covid-19 pandemic have fortunately been minimal thus far but are mentioned as necessary when discussing the hybrid Milestone 5&6 progress as well as the corresponding Milestone 7 modeling and simulation progress.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1991

Aging aircraft NDI Development and Demonstration Center (AANC): An overview

A major center with emphasis on validation of nondestructive inspection (NDI) techniques for aging aircraft, the Aging Aircraft NDI Development and Demonstration Center (AANC), has been funded by the FAA at Sandia National Laboratories. The Center has been assigned specific tasks in developing techniques for the nondestructive inspection of static engine parts, assessing inspection reliability (POD experiments), developing testbeds for NDI validation, maintaining a FAA library of characterized aircraft structural test specimens, and leasing a hangar to house a high flight cycle transport aircraft for use as a full scale test bed.

Aging Aircraft↗

NASA NTRS1980

Analysis of wear-debris from full-scale bearing fatigue tests using the ferrograph

The ferrograph was used to determine the types and quantities of wear particles generated during full-scale bearing fatigue tests. Deep-groove ball bearings made from AISI 52100 steel were used. A MIL-L-23699 tetraester lubricant was used in a recirculating lubrication system containing a 49 mm absolute filter. Test conditions included a maximum Hertz stress of 2.4 GPa, a shaft speed of 15,000 rpm, and a lubricant supply temperature of 74 C (165 F). Four fatigue failures were detected by accelerometers in this test set. In general, the ferrograph was more sensitive (up to 23 hr) in detecting spall initiation than either accelerometers or the normal spectrographic oil analysis. Four particle types were observed: normal rubbing wear particles, spheres, nonferrous particles, and severe wear (spall) fragments.

Jones, W. R.↗

NASA NTRS1980

Analysis of wear debris from full-scale bearing fatigue tests using the Ferrograph

The Ferrograph was used to determine the types of quantities of wear particles generated during full-scale bearing fatigue tests. Deep-groove ball bearings made from AISI 52100 steel were used. A MIL-L-23699 tetraester lubricant was used in a recirculating lubrication system containing a 49-micron absolute filter. Test conditions included a maximum Hertz stress of 2.4 GPa, a shaft speed of 15,000 rpm and a lubricant supply temperature of 74 C (165 F). Four fatigue failures were detected by accelerometers in this test set. In general, the Ferrograph was more sensitive (up to 23 h) in detecting spall initiation than either accelerometers or the normal spectrographic oil analysis (SOAP). Four particle types were observed: normal rubbing wear particles, spheres, nonferrous particles, and severe wear (spall) fragments.

Jones, W. R., Jr.↗

NASA NTRS1979

Icing testing in the large Modane wind-tunnel on full-scale and reduced scale models

Icing tests on full scale models of parts of aircraft (wings, tailplanes, radome) equipped with actual de-icing systems were carried out in the large Modane wind tunnel of ONERA. For studying icing on the Concorde, it was necessary to use a 1/6 scale half model. The equations governing the relevant parameter ratios to obtain reasonably good similitude water catching and ice accretion are recalled. Despite the inherent limitations of this particular kind of testing, i.e., the impossibility of duplicating both the Mach and Reynolds conditions for the main flow pattern, it is possible to obtain on a reduced scale model a reasonably good representation of icing cloud catching and of the shape of resulting ice accretion.

Charpin, F.↗

NASA NTRS1950

Data from Tests of a 1/5-Scale Model of a Proposed High-Speed Submarine in the Langley Full-Scale Tunnel

Tests of a 1/5 scale model of a proposed 153-foot high-speed submarine have been conducted in the Langley full-scale tunnel at the request of the Bureau of Ships, Department of the Navy. The test program included: (1) force tests to determine the drag, control effectiveness, and static stability characteristics for a number of model configurations, both in pitch and in yaw, (2) pressure measurements to determine the boundary-layer conditions and flow characteristics in the region of the propeller, and (3) an investigation of the effects of propeller operation on the model aerodynamic characteristics. In response to oral requests from the Bureau of Ships representatives t hat the basic data obtained in these tests be made available to them as rapidly as possible, this data report has been prepared to present some of the more pertinent results. All test results given in the present paper are for the propeller-removed condition and were obtained at a Reynolds number of approximately 22,300,000 based on model length.

Cocke, Bennie W.↗

NASA NTRS2009

Flight Validation of a Handling Qualities Metric for a Damaged Aircraft

Objectives: a) Develop an asymmetric handling qualities metric to predict cross coupling effects of a damaged aircraft: 1) Initial use of U.S Army Aeronautical Design Specification ADS-33; 2) Modification as required based on flight test results. b) Simulation and Flight Validation of proposed metric: 1) F-16 VISTA (March 2010); 2) F-18 Full Scale Test bed (Potential Early Experiment); and 3) Flight Simulators (GTM, ACFS, F-18 HILS). c) Provide flight validated metric and tool box to control law designers.

Cogan, Bruce R.↗

DOE OSTI2022

Flow Sensor Test Article (F-STAr) (Design and Fabrication Status Report)

The Flow Sensor Test Article (F-STAr) is a test article currently under construction for the Mechanisms Engineering Test Loop (METL). F-STAr was designed to provide high sodium flowrate capabilities for sensor calibration, component testing, and fluid studies. Figure 1 shows two solid model views of the new test article. F-STAr includes a high-capacity pump that can provide a nominal flowrate of 120 GPM; a test section support structure that can accommodate a wide array of sub-test articles and their instrumentation; and finally, a heating and cooling system to aid in controlling the testing environment. Initially, F-STAr will be configured to test liquid metal flow sensors, specifically field shift sensors like the Eddy Current Flow Sensors (ECFS) based on the RDT C4-7T standard. To test these sensors, two test sections were designed that attempt to model Sodium Fast Reactor (SFR) outlet conditions. Figure 2 shows models of the “Full-Scaled Test Section” (FSTS) that represents a generic SFR fuel handling socket and a “Pseudo-Scaled Test Section” (PSTS) that represents a generic array of scaled fuel handling sockets. While F-STAr will be configured to test ECFS’s, it can also be outfitted to meet other experimental needs. For example, F-STAr could be setup with a test section that includes a fluidic diode or a component test investigating the performance of hydrodynamic bearings. Other test sections include studies of sodium thermal hydraulics like thermal striping. Overall, F-STAr is a flexible test article designed to accommodate many needs. This report will provide a status update on the design and construction of F-STAr. Manufacturing of all components has commenced, and several components have already been completed. These components include the pump and test section assembly stand. Other components, such as the heater, have been completed but were rejected due to the vendor not meeting the requirements of the purchase order. Lastly, the submersible flowmeter and main flange components are under construction, and their status will be reviewed in this report. Overall, most of the F-STAr components and parts will be completed by the end of September 2022.

42 ENGINEERING↗

NASA NTRS1996

Aspirating Seal Development: Analytical Modeling and Seal Test Rig

This effort is to develop large diameter (22 - 36 inch) Aspirating Seals for application in aircraft engines. Stein Seal Co. will be fabricating the 36-inch seal(s) for testing. GE's task is to establish a thorough understanding of the operation of Aspirating Seals through analytical modeling and full-scale testing. The two primary objectives of this project are to develop the analytical models of the aspirating seal system, to upgrade using GE's funds, GE's 50-inch seal test rig for testing the Aspirating Seal (back-to-back with a corresponding brush seal), test the aspirating seal(s) for seal closure, tracking and maneuver transients (tilt) at operating pressures and temperatures, and validate the analytical model. The objective of the analytical model development is to evaluate the transient and steady-state dynamic performance characteristics of the seal designed by Stein. The transient dynamic model uses a multi-body system approach: the Stator, Seal face and the rotor are treated as individual bodies with relative degrees of freedom. Initially, the thirty-six springs are represented as a single one trying to keep open the aspirating face. Stops (Contact elements) are provided between the stator and the seal (to compensate the preload in the fully-open position) and between the rotor face and Seal face (to detect rub). The secondary seal is considered as part of the stator. The film's load, damping and stiffness characteristics as functions of pressure and clearance are evaluated using a separate (NASA) code GFACE. Initially, a laminar flow theory is used. Special two-dimensional interpolation routines are written to establish exact film load and damping values at each integration time step. Additionally, other user-routines are written to read-in actual pressure, rpm, stator-growth and rotor growth data and, later, to transfer these as appropriate loads/motions in the system-dynamic model. The transient dynamic model evaluates the various motions, clearances and forces as the seals are subjected to different aircraft maneuvers: Windmilling restart; start-ground idle; ground idle-takeoff; takeoff-burst chop, etc. Results of this model show that the seal closes appropriately and does not ram into the rotor for all of the conditions analyzed. The rig upgrade design for testing Aspirating Seals has been completed. Long lead-time items (forgings, etc.) have been ordered.

Bharat Bagepalli↗

NASA NTRS2009

The E-3 Test Facility at Stennis Space Center: Research and Development Testing for Cryogenic and Storable Propellant Combustion Systems

This paper will provide the reader a broad overview of the current upgraded capabilities of NASA's John C. Stennis Space Center E-3 Test Facility to perform testing for rocket engine combustion systems and components using liquid and gaseous oxygen, gaseous and liquid methane, gaseous hydrogen, hydrocarbon based fuels, hydrogen peroxide, high pressure water and various inert fluids. Details of propellant system capabilities will be highlighted as well as their application to recent test programs and accomplishments. Data acquisition and control, test monitoring, systems engineering and test processes will be discussed as part of the total capability of E-3 to provide affordable alternatives for subscale to full scale testing for many different requirements in the propulsion community.

Pazos, John T.↗

NASA NTRS1948

Free-Spinning-Tunnel Tests of a 0.057-Scale Model of the Chance Vought XF7U-1 Airplane

An investigation of the spin and recovery characteristics of a 0.057-scale model of the Chance Vought XF7U-1 airplane has been conducted in the Langley 20-foot free-spinning tunnel. The effects of control settings and movements on the erect and inverted spin and recovery characteristics were determined, as were also the effects of extending the wing slats, of center-of-gravity movement, and-of variation in the mass distribution. The investigation also included wing-tip spin-recovery-parachute tests, pilot-escape tests, and rudder-control-force tests. The investigation indicated that the spin and recovery characteristics of the airplane will be satisfactory for all conditions. It was found that a single 4.24-foot (full-scale) parachute when opened alone from the outboard wing tip or two 8.77-foot (full-scale) parachutes when opened simultaneously, one from each wing tip, would effect satisfactory emergency recoveries (the drag coefficients of the parachutes, based on the surface area of the parachute, were 0.83 and 0.70 for the 4.24- and 8.77-foot parachutes, respectively). The towline length in both cases was 25 feet (full scale). Tests results showed that, if the pilot should have to leave the airplane during a spin, he should jump from the outboard side (left side in a right spin) of the cockpit. The rudder-control force necessary for recovery from a spin was found to be rather high but appeared to be within the upper limits of a pilot's capabilities.

Daughtridge, Lee T., Jr.↗

NASA NTRS1985

Frequency response of a jet engine test facility air supply system

The frequency response of a laboratory scale model of a portion of the air supply system of an engine test facility is obtained both experimentally and using one-dimensional, small-signal, distributed parameter theory. The effects of line terminations and mean flow are considered. Good agreement between experiment and theory is obtained. Predictions are extended to a full scale test facility air supply system operating under several possible test conditions.

Franke, M. E.↗

NASA NTRS2020

Loads Correlation of a Full-Scale Proprotor on the Tiltrotor Test Rig

In 2018, a full-scale isolated proprotor test was conducted in the USAF National Full-Scale Aerodynamics Complex (NFAC) at NASA Ames. The test article was the 3-bladed Bell 699 research rotor derived from the AW609 rotor. For this test, the NASA Tiltrotor Test Rig (TTR) and rotor were installed in the 40- by 80-foot test section. Correlations between the 2018 test data and predictions from the comprehensive analysis CAMRAD II for blade and yoke (flexbeam) loads and rotor torque are presented. The full range of conversion to helicopter modes is covered: conversion 30-, 45-, and 60-deg TTR yaw, and helicopter 75- and 90-deg TTR yaw. The flap moment correlation is reasonable to good; the pitch link load and torsion moment are uniformly underpredicted. The measured 2P lag moment and 2P torque are not captured by the analysis. The inability to predict the 2P component is currently attributed to the analytical assumption of a perfect gimbal, whereas the actual test gimbal may be operating imperfectly and thus introducing the 2P harmonic. A new analytical model that accounts for non-ideal gimbal operation is needed.

Kottapalli, Sesi↗

NASA NTRS1974

Propulsion system tests on a full scale Centaur vehicle to investigate 3-burn mission capability of the D-lT configuration

Propulsion system tests were conducted on a full scale Centaur vehicle to investigate system capability of the proposed D-lT configuration for a three-burn mission. This particular mission profile requires that the engines be capable of restarting and firing for a final maneuver after a 5-1/2-hour coast to synchronous orbit. The thermal conditioning requirements of the engine and propellant feed system components for engine start under these conditions were investigated. Performance data were also obtained on the D-lT type computer controlled propellant tank pressurization system. The test results demonstrated that the RL-10 engines on the Centaur vehicle could be started and run reliably after being thermally conditioned to predicted engine start conditions for a one, two and three burn mission. Investigation of the thermal margins also indicated that engine starts could be accomplished at the maximum predicted component temperature conditions with prestart durations less than planned for flight.

Groesbeck, W. A.↗

NASA NTRS2015

Tests of Full-Scale Helicopter Rotors at High Advancing Tip Mach Numbers and Advance Ratios

As a continuation of the studies of reference 1, three full-scale helicopter rotors have been tested in the Ames Research Center 40- by SO-foot wind tunnel. All three of them were two-bladed, teetering rotors. One of the rotors incorporated the NACA 0012 airfoil section over the entire length of the blade. This rotor was tested at advance ratios up to 1.05. Both of the other rotors were tapered in thickness and incorporated leading-edge camber over the outer 20 percent of the blade radius. The larger of these rotors was tested at advancing tip Mach numbers up to 1.02. Data were obtained for a wide range of lift and propulsive force, and are presented without discussion.

High Advancing Tip Mach Numbers↗

NASA NTRS1978

An investigation of drag reduction for tractor trailer vehicles

Force and moment data were obtained from a one-twenty-fifth scale wind tunnel model of a cab-over-engine tractor trailer combination. The tests define the aerodynamic characteristics of the baseline (unmodified) vehicle and several modified configurations. The primary modifications consist of: (1) greatly increased forebody corner radii, (2) a smooth fairing over the cab-to-trailer gap, (3) a smoothed underbody, and (4) rear streamlining (boattailing)of the trailer. Tests were conducted for yaw angles from 0 deg to 30 deg. The reduction in drag, relative to the baseline, obtained by combining the modifications are compared for the zero yaw condition with full scale coast down drag results for similar configurations. The drag reductions obtained from the model and full scale tests are in good agreement.

Muirhead, V. U.↗

NASA NTRS1973

Results of Full-Scale Wind Tunnel Tests on the H.126 Jet Flap Aircraft

The aerodynamic characteristics of the full-scale H.126 jet flap aircraft were studied in a 40- by 80 foot wind tunnel. The H.126 aircraft is designed for research on flight characteristics of an aircraft using the jet flap principle. Static longitudinal, lateral, and directional characteristics were measured at a Reynolds number of 2.5 to 2.7 million. The jet control power as well as the aerodynamic characteristics were measured and are presented herein with limited discussion. The primary configuration variables were flap and aileron deflection.

Aiken, T. N.↗