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The article presents a summary of the propulsion system tests conducted on a number of aircraft at the NASA Dryden Flight Research Center. The tests included digital engine control systems, engine-inlet compatibility, inlet-airframe interactions, nozzle-boattail drag and advanced turboprop acoustics. Among the aircraft evaluated were the F-15, HiMAT, F-14, and the JetStar.
The optimum facility to complement existing high Reynolds number transonic wind tunnels is discussed. It is proposed that the facility be cryogenic, have a total pressure of five atmospheres or less, and have a test section on the order of 4- to 5-meters square. The large size is to accommodate complicated models such as those used in propulsion testing. It is suggested that magnetic suspension and wall interference minimization and correction procedures be used. Simplicity of initial design is stressed as a means of providing for future growth opportunities.
For the past year, NASA Marshall Space Flight Center and Johnson Space Center have been working on a government version of a lunar lander design for the Resource Prospector Mission. A propulsion cold flow test system, representing an early flight design of the propulsion system, has been fabricated. The primary objective of the cold flow test is to simulate the Resource Prospector propulsion system operation through water flow testing and obtain data for anchoring analytical models. This effort will also provide an opportunity to develop a propulsion system mockup to examine hardware integration to a flight structure. This paper will report the work progress of the propulsion cold flow test system development and test preparation. At the time this paper is written, the initial waterhammer testing is underway. The initial assessment of the test data suggests that the results are as expected and have a similar trend with the pretest prediction. The test results will be reported in a future conference.
Over the past 50 years, the National Aeronautics and Space Administration (NASA) has delivered space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides the United States' (U.S.) capability for both crew and heavy cargo to low-Earth orbit to' construct the International Space Station, before the Shuttle is retired in 2010. In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle (Figure 1). The goals for this new system include increased safety and reliability coupled with lower operations costs that promote sustainable space exploration for decades to come. The Ares I will loft the Orion Crew Exploration Vehicle, while the heavy-lift Ares V will carry the Altair Lunar Lander and the equipment and supplies needed to construct a lunar outpost for a new generation of human and robotic space pioneers. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level test activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity and to validate computer modeling and simulation (Figure 2), as well as the main propulsion test article analysis to be conducted in the Static Test Stand. These activities also will help prove and refine mission concepts of operation, while supporting the spectrum of design and development work being performed by Marshall's Engineering Directorate, ranging from launch vehicles and lunar rovers to scientific spacecraft and associated experiments. Ultimately, fielding a robust space transportation solution that will carry international explorers and essential payloads will pave the way for a new century of scientific discovery beyond planet Earth.
Arnold Engineering Development Center (AEDC) was conceived at the close of World War II, when major new developments in flight technology were presaged by new aerodynamic and propulsion concepts. During the past 40 years, AEDC has played a significant part in the development of many aerospace systems. The original plans were extended through the years by some additional facilities, particularly in the area of propulsion testing. AEDC now has undertaken development of a master plan in an attempt to project requirements and to plan for ground test and computational facilities over the coming 20 to 30 years. This report was prepared in response to an AEDC request that the National Research Council (NRC) assemble a committee to prepare guidance for planning and modernizing AEDC facilities for the development and testing of future classes of aerospace systems as envisaged by the U.S. Air Force.
Since the 1990's, when the Class I Ozone Depleting Substance (ODS) chlorofluorocarbon‐113 (CFC‐113) was banned, NASA's propulsion test facilities at Marshall Space Flight Center (MSFC) and Stennis Space Center (SSC) have relied upon hydrochlorofluorocarbon‐225 (HCFC‐225) to safely clean and verify the cleanliness of large scale propulsion oxygen systems. Effective January 1, 2015, the production, import, export, and new use of HCFC‐225, a Class II ODS, was prohibited by the Clean Air Act. In 2012 through 2014, leveraging resources from both NASA and the Defense Logistics Agency ‐ Aviation Hazardous Minimization and Green Products Branch, test labs at MSFC, SSC, and Johnson Space Center's White Sands Test Facility (WSTF) collaborated to seek out, test, and qualify a replacement for HCFC‐225 that is both an effective cleaner and safe for use with oxygen systems. This presentation summarizes the tests performed, results, and lessons learned. It also demonstrates the benefits of cross‐agency collaboration in a time of limited resources.
The design, testing, fabrication, and problems associated with the development of the Mariner 9 propulsion system are described. Also covered are the design and operation of the associated ground support equipment used to test and service the propulsion system.
Flight tests of the propulsion system of a YF-12 airplane were made which included off-schedule inlet operation and deliberately induced unstarts and compressor stalls. The tests showed inlet/engine compatibility to be good through most of the flight envelope. The position of the terminal shock wave could be determined from throat static pressure profiles or from root-mean-square levels of throat static pressure fluctuations. A digital simulation of the control system showed an oscillation of the forward bypass doors to be caused by hysteresis in the bypass door actuator linkages.
The objective of the presented work was to develop validated computational fluid dynamics (CFD) based methodologies for predicting propellant detonations and their associated blast environments. Applications of interest were scenarios relevant to rocket propulsion test and launch facilities. All model development was conducted within the framework of the Loci/CHEM CFD tool due to its reliability and robustness in predicting high-speed combusting flow-fields associated with rocket engines and plumes. During the course of the project, verification and validation studies were completed for hydrogen-fueled detonation phenomena such as shock-induced combustion, confined detonation waves, vapor cloud explosions, and deflagration-to-detonation transition (DDT) processes. The DDT validation cases included predicting flame acceleration mechanisms associated with turbulent flame-jets and flow-obstacles. Excellent comparison between test data and model predictions were observed. The proposed CFD methodology was then successfully applied to model a detonation event that occurred during liquid oxygen/gaseous hydrogen rocket diffuser testing at NASA Stennis Space Center.
This work presents a summary of the performance test campaign of the 12.5 kW Advanced Electric Propulsion System (AEPS) Engineering Test Unit 2 (ETU-2) thruster produced by Aerojet Rocketdyne. This test campaign had three major goals: to assess design compliance with thruster requirements, provide a comparison to the previously-tested NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Units (TDUs) from which the AEPS ETU design was derived, and support AEPS application on the Power and Propulsion Element (PPE). Assessments of ETU-2 performance were conducted at discharge powers of 2.6 to 13.1 kW, which encompasses the original AEPS throttle conditions as well as those most relevant for AEPS application on PPE. The results from the test campaign indicate that ETU-2 performance meets or exceeds all AEPS thruster performance requirements and matches the values and trends previously measured with the HERMeS TDUs. In addition, similar to the HERMeS TDUs, ETU-2 performance showed minimal variation over approximately 1636 h of operating time due to the incorporation of magnetic shielding. Taken together, these results show that the AEPS design is successfully replicating the performance of the HERMeS TDUs to within the empirical uncertainty and meeting its performance requirements as the design progresses to its Critical Design Review.
This work presents a summary of the performance test campaign of the 12.5 kW Advanced Electric Propulsion System (AEPS) Engineering Test Unit 2 (ETU-2) thruster produced by Aerojet Rocketdyne. This test campaign had three major goals: to assess design compliance with thruster requirements, provide a comparison to the previously-tested NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Units (TDUs) from which the AEPS ETU design was derived, and support AEPS application on the Power and Propulsion Element (PPE). Assessments of ETU-2 performance were conducted at discharge powers of 2.6 to 13.1 kW, which encompasses the original AEPS throttle conditions as well as those most relevant for AEPS application on PPE. The results from the test campaign indicate that ETU-2 performance meets or exceeds all AEPS thruster performance requirements and matches the values and trends previously measured with the HERMeS TDUs. In addition, similar to the HERMeS TDUs, ETU-2 performance showed minimal variation over approximately 1636 h of operating time due to the incorporation of magnetic shielding. Taken together, these results show that the AEPS design is successfully replicating the performance of the HERMeS TDUs to within the empirical uncertainty and meeting its performance requirements as the design progresses to its Critical Design Review.
The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42 inch exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accommodate models approximately 10 feet long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation, the facility status, the operating capabilities, and specific applications of the HTF.
The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42-in. exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accomodate models approximately 10 ft long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation activities, the facility status, the operating capabilities, and specific applications of the HTF.
As more space operators implement large constellations of spacecraft, automating orbit maintenance maneuvers becomes a key feature of their operations concept to ensure that the workload is manageable. However the practice of performing a maneuver without sharing the plan with other nearby spacecraft causes a risk that two spacecraft will collide, not only destroying the spacecraft involved, but creating debris that will affect all other spacecraft using that orbit regime. In order to share the maneuver plan, a predicted ephemeris file containing the maneuver must be sent to a central authority to screen against predicted trajectories of all other on-orbit objects to determine where and when close approaches may occur that need to be mitigated. Currently the screening authority used by US operators is the 19th Space Defense Squadron. However the conjunction screening process in use by the 19th was developed over 30 years ago and was not designed with automation in mind, so screenings are performed once every 8 hours, meaning that spacecraft using automated maneuvering need to allow 16 hours to share their maneuver plan via the screening process. Many operators assume that automated maneuver planning must be real-time; however this time between planning and execution to allow for screening is possible if planned for during system design. In an effort to speed up the screening process, NASA has developed a prototype system for performing near-real-time screenings. This prototype system was necessitated to support the NASA Starling mission, a constellation of 4 cubesats that planned to fly at the same altitude as the SpaceX Starlink constellation, both performing automated maneuvering. Without screening of the planned maneuvers, the two constellations risked a collision. Once converted from a prototype to an operational system, this capability will greatly help smallsats, for example those that are planning to test propulsive capabilities, by allowing fast turnaround feedback to ensure safety form collision with other objects. This paper describes the existing CA process, the prototype real-time capability, and results from the experiment that tested the prototype.
A full-scale field application of glass bubbles insulation has been demonstrated in a 218,000 L liquid hydrogen storage tank. This work is the evolution of extensive materials testing, laboratory scale testing, and system studies leading to the use of glass bubbles insulation as a cost efficient and high performance alternative in cryogenic storage tanks of any size. The tank utilized is part of a rocket propulsion test complex at the NASA Stennis Space Center and is a 1960's vintage spherical double wall tank with an evacuated annulus. The original perlite that was removed from the annulus was in pristine condition and showed no signs of deterioration or compaction. Test results show a significant reduction in liquid hydrogen boiloff when compared to recent baseline data prior to removal of the perlite insulation. The data also validates the previous laboratory scale testing (1000 L) and full-scale numerical modeling (3,200,000 L) of boiloff in spherical cryogenic storage tanks. The performance of the tank will continue to be monitored during operation of the tank over the coming years.
Since early 2005, NASA's Robotic Lunar Lander Development (RLLD) office at NASA MSFC, in partnership with the Applied Physics Laboratory (APL), has developed mission concepts and preformed risk-reduction activities to address planetary science and exploration objectives uniquely met with landed missions. The RLLD team developed several concepts for lunar human-exploration precursor missions to demonstrate precision landing and in-situ resource utilization, a multi-node lunar geophysical network mission, either as a stand-alone mission, or as part of the International Lunar Network (ILN), a Lunar Polar Volatiles Explorer and a Mercury lander mission for the Planetary Science decadal survey, and an asteroid rendezvous and landing mission for the Exploration Precursor Robotics Mission (xPRM) office. The RLLD team has conducted an extensive number of risk-reduction activities in areas common to all lander concepts, including thruster testing, propulsion thermal control demonstration, composite deck design and fabrication, and landing leg stability and vibration. In parallel, the team has developed two robotic lander testbeds providing closed-loop, autonomous hover and descent activities for integration and testing of flight-like components and algorithms. A compressed-air test article had its first flight in September 2009 and completed over 150 successful flights. This small test article (107 kg dry/146 kg wet) uses a central throttleable thruster to offset gravity, plus 3 descent thrusters (~37lbf ea) and 6 attitude-control thrusters (~12lbf ea) to emulate the flight system with pulsed operation over approximately 10s of flight time. The test article uses carbon composite honeycomb decks, custom avionics (COTS components assembled in-house), and custom flight and ground software. A larger (206 kg dry/322 kg wet), hydrogen peroxide-propelled vehicle began flight tests in spring 2011 and fly over 30 successful flights to a maximum altitude of 30m. The monoprop testbed also uses a central gravity-canceling thruster and 3 descent thrusters, but has 12 attitude-control thrusters and a maximum flight time of over a minute. The testbed uses aluminum ortho-grid decks, an LN200-1 IMU, Roke Manor Radar Altimeter, Illunis optical cameras, Novatel Pro-Pak GPS truth data system, Pressure transducers & thermocouples for housekeeping, "In-Control" ground system software, and the core Flight Executive (cFE) modular software environment. The peroxide lander testbed is able to accept other sensors and algorithms for testing, both from within NASA and from other customers. Through these activities, the RLLD team has significantly reduced technical risks for all small and medium class robotic landers for the Moon and other airless planetary bodies.
Research into hypersonic propulsion; i.e., supersonic combustion, was seriously initiated at the Langley Research Center in the 1960's with the Hypersonic Research Engine (HRE) project. This project was designed to demonstrate supersonic combustion within the context of an engine module consisting of an inlet, combustor, and nozzle. In addition, the HRE utilized both subsonic and supersonic combustion (dual-mode) to demonstrate smooth operation over a Mach 4 to 7 speed range. The propulsion program thus concentrated on fundamental supersonic combustion studies and free jet propulsion tests for the three dimensional fixed geometry engine design to demonstrate inlet and combustor integration and installed performance potential. The developmental history of the program is presented. Additionally, the HRE program's effect on the current state of hypersonic propulsion is discussed.