Ground test facilities for aircraft airbreathing propulsion system development.
Ground test facilities for aircraft air breathing propulsion system development
TEST FACILITY↗
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Acoustically treated ground test nacelle for the General Electric TF34 turbofan
A description is given of the ground test quiet nacelle for the TF34 engine. The suppression treatment consists of cylindrical splitters in the inlet and fan exhaust ducts plus duct wall treatment and core exhaust wall treatment. Aerodynamic design analysis of the inlet and exhaust ducts and overall engine performance with pressure losses from the acoustic treatment is included. The objectives of the test program are to obtain noise data for a heavily suppressed high bypass turbofan with various arrangements of exhaust systems and acoustic treatment, and to provide a basis for the power plants of the Quiet Experimental STOL Aircraft (Questol).
Edkins, D. P.↗
Effects of the air breathing engine plumes on SSV orbiter subsonic wing pressure distributions (OA57A)
Experimental aerodynamic pressure investigations were conducted on a 0.0405 scale representation of the -89 space shuttle orbiter ferry configuration in the Rockwell International 7.75 x 11.00 foot Low Speed Wind Tunnel. The primary test objective was to investigate the orbiter wing pressure distribution resulting from five under-wing engine nacelle plumes. Two five engine nacelle configurations were tested at 3 ground plane heights with pressure bug measurements being made on the left upper and lower wing panel. In addition, base and balance cavity pressure measurements were made, with elevon normal and hinge moment measurements on the right panel.
Cameron, B. W., Jr.↗
Payload specialist station study. Volume 3: Program study cost estimates. Part 1: Work breakdown structure
The work breakdown structure (WBS) for the Payload Specialist Station (PSS) is presented. The WBS is divided into two elements--PSS contractor and mission unique requirements. In accordance with the study ground rules, it is assumed that a single contractor, hereafter referred to as PSS Contractor will perform the following: (1) provide C and D hardware (MFDS and elements of MMSE), except for GFE; (2) identify software requirements; (3) provide GSE and ground test software; and (4) perform systems engineering and integration in support of the Aft Flight Deck (AFD) C and D concept. The PSS Contractor WBS element encompasses a core or standardized PSS concept. Payload peculiar C and D requirements identified by users will originate as a part of the WBS element mission unique requirements; these requirements will be provided to the PSS Contractor for implementation.
Source record↗
SSME failure detection
During ground testing of the Space Shuttle Main Engine (SSME), there have been twenty-six major incidents resulting in substantial hardware damage and loss. Historical characteristics, advances in detection technology, and advances in computing technology led to plans for study of an advanced real time SSME test stand failure detection system which would reduce damage and preserve evidence when a failure with major incident potential occurs. This detection system will speed recognition of dangerous engine operation, and quicken the shutdown decision. The scope of this study, SSME characteristics, SSME test history, the problem definition, and some technical issues will be addressed herein.
Cikanek, H. A., III↗
Failure Control Techniques for the SSME
Since ground testing of the Space Shuttle Main Engine (SSME) began in 1975, the detection of engine anomalies and the prevention of major damage have been achieved by a multi-faceted detection/shutdown system. The system continues the monitoring task today and consists of the following: sensors, automatic redline and other limit logic, redundant sensors and controller voting logic, conditional decision logic, and human monitoring. Typically, on the order of 300 to 500 measurements are sensed and recorded for each test, while on the order of 100 are used for control and monitoring. Despite extensive monitoring by the current detection system, twenty-seven (27) major incidents have occurred. This number would appear insignificant compared with over 1200 hot-fire tests which have taken place since 1976. However, the number suggests the requirement for and future benefits of a more advanced failure detection system.
Taniguchi, M. H.↗
Development of an advanced failure detection algorithm for the SSME
Since ground testing of the Space Shuttle Main Engine began in 1975, a multifaceted detection/shutdown system has been used to detect engine anomalies and initiate shutdown. In spite of this system, 27 major incidents have occurred since testing began. Although a small percentage of over 1200 successful hot fire tests, such incidents can result in significant cost and schedule impacts. Therefore, an advanced failure detection algorithm has been developed which consists of three detection approaches designed for a failure characteristic that has been previously documented. Simulations using sensor data from five incident tests show the algorithm detecting an anomally and signalling shutdown prior to the redline cutoff time. The foundation elements of the algorithm and its functioning are described.
Norman, A.↗
The NASA Langley Scramjet Test Complex
The NASA Langley Scramjet Test Complex consists of five propulsion facilities which cover a wide spectrum of supersonic combustion ramjet (scramjet) test capabilities. These facilities permit observation of the effects on scramjet performance of speed and dynamic pressure from Mach 3.5 to near-orbital speeds, engine size from Mach 4 to 7, and test gas composition from Mach 4 to 7. In the Mach 3.5 to 8 speed range, the complex includes a direct-connect combustor test facility, two small-scale complete engine test facilities, and a large-scale complete engine test facility. In the hypervelocity speed range, a shock-expansion tube is used for combustor tests from Mach 12 to Mach 17+. This facility has recently been operated in a tunnel mode, to explore the possibility of semi-free-jet testing of complete engine modules at hypervelocity conditions. This paper presents a description of the current configurations and capabilities of the facilities of the NASA Langley Scramjet Test Complex, reviews the most recent scramjet tests in the facilities, and discusses comparative engine tests designed to gain information about ground facility effects on scramjet performance.
R.W. Guy↗
Lessons Learned on Operating and Preparing Operations for a Technology Mission from the Perspective of the Earth Observing-1 Mission
The New Millennium Program's first Earth-observing mission (EO-1) is a technology validation mission. It is managed by the NASA Goddard Space Flight Center in Greenbelt, Maryland and is scheduled for launch in the summer of 2000. The purpose of this mission is to flight-validate revolutionary technologies that will contribute to the reduction of cost and increase of capabilities for future land imaging missions. In the EO-1 mission, there are five instrument, five spacecraft, and three supporting technologies to flight-validate during a year of operations. EO-1 operations and the accompanying ground system were intended to be simple in order to maintain low operational costs. For purposes of formulating operations, it was initially modeled as a small science mission. However, it quickly evolved into a more complex mission due to the difficulties in effectively integrating all of the validation plans of the individual technologies. As a consequence, more operational support was required to confidently complete the on-orbit validation of the new technologies. This paper will outline the issues and lessons learned applicable to future technology validation missions. Examples of some of these include the following: (1) operational complexity encountered in integrating all of the validation plans into a coherent operational plan, (2) initial desire to run single shift operations subsequently growing to 6 "around-the-clock" operations, (3) managing changes in the technologies that ultimately affected operations, (4) necessity for better team communications within the project to offset the effects of change on the Ground System Developers, Operations Engineers, Integration and Test Engineers, S/C Subsystem Engineers, and Scientists, and (5) the need for a more experienced Flight Operations Team to achieve the necessary operational flexibility. The discussion will conclude by providing several cost comparisons for developing operations from previous missions to EO-1 and discuss some details that might be done differently for future technology validation missions.
Mandl, Dan↗
Lessons in the Design and Characterization Testing of the Semi-Span Super-Sonic Transport (S4T) Wind-Tunnel Model
This paper focuses on some of the more challenging design processes and characterization tests of the Semi-Span Super-Sonic Transport (S4T)-Active Controls Testbed (ACT). The model was successfully tested in four entries in the National Aeronautics and Space Administration Langley Transonic Dynamics Tunnel to satisfy the goals and objectives of the Fundamental Aeronautics Program Supersonic Project Aero-Propulso-Servo-Elastic effort. Due to the complexity of the S4T-ACT, only a small sample of the technical challenges for designing and characterizing the model will be presented. Specifically, the challenges encountered in designing the model include scaling the Technology Concept Airplane to model scale, designing the model fuselage, aileron actuator, and engine pylons. Characterization tests included full model ground vibration tests, wing stiffness measurements, geometry measurements, proof load testing, and measurement of fuselage static and dynamic properties.
Source record↗
Launch Processing System - A system to support the Space Shuttle
Kennedy Space Center (KSC) is designing and acquiring a Launch Processing System (LPS), an important part of Ground Support Equipment (GSE), to Support launch site operations in a more efficient way than was done on previous programs. LPS will provide (1) automatic control of GSE and Shuttle systems for test and operations, (2) real time data analysis and information display, and (3) efficient recall of test data and engineering files to support Shuttle ground operations. Modern automation techniques, off-the-shelf components, and modular design are being employed to the maximum to achieve these goals. The cost of acquisition, operations, and maintenance of LPS is of great importance and is considered with each engineering trade.
Paul, H. C.↗
Flight Testing the Linear Aerospike SR-71 Experiment (LASRE)
The design of the next generation of space access vehicles has led to a unique flight test that blends the space and flight research worlds. The new space vehicle designs, such as the X-33 vehicle and Reusable Launch Vehicle (RLV), are powered by linear aerospike rocket engines. Conceived of in the 1960's, these aerospike engines have yet to be flown, and many questions remain regarding aerospike engine performance and efficiency in flight. To provide some of these data before flying on the X-33 vehicle and the RLV, a spacecraft rocket engine has been flight-tested atop the NASA SR-71 aircraft as the Linear Aerospike SR-71 Experiment (LASRE). A 20 percent-scale, semispan model of the X-33 vehicle, the aerospike engine, and all the required fuel and oxidizer tanks and propellant feed systems have been mounted atop the SR-71 airplane for this experiment. A major technical objective of the LASRE flight test is to obtain installed-engine performance flight data for comparison to wind-tunnel results and for the development of computational fluid dynamics-based design methodologies. The ultimate goal of firing the aerospike rocket engine in flight is still forthcoming. An extensive design and development phase of the experiment hardware has been completed, including approximately 40 ground tests. Five flights of the LASRE and firing the rocket engine using inert liquid nitrogen and helium in place of liquid oxygen and hydrogen have been successfully completed.
Stephen Corda↗
Low Emissions Alternative Power (LEAP) Project Office Business Team of the Aeropropulsion Research Program Office (ARPO) Org. 0140
The program for which I am working at this summer is Propulsion and Power/Low Emissions Alternative Power (P&P/LEAP). It invests in a fundamental TRL 1-6 research and technology portfolio that will enable the future of: Alternative fuels and/or alternative propulsion systems, non-combustion (electric) propulsion systems. P&P/LEAP will identify and capitalize on the highest potential concepts generated both internal and external to the Agency. During my 2004 summer at NASA Glenn Research Center, I worked with my mentor Barbara Mader, in the Project Office with the Business Team completing various tasks for the project and personnel. The LEAP project is a highly matrixed organization. The Project Office is responsible for the goals advocacy and dollar (budget) of the LEAP project. The objectives of the LEAP Project are to discover new energy sources and develop unconventional engines and power systems directed towards greatly reduced emissions, enable new vehicle concepts for public mobility, new science missions and national security. The Propulsion and PowerLow Emissions Alternative Power directly supports the environmental, mobility, national security objectives of the Vehicle Systems Program and the Aeronautics Technology Theme. Technology deliverables include the demonstration through integrated ground tests, a constant volume combustor in an engine system, and UAV/small transport aircraft all electric power system. My mentor serves as a key member of the management team for the Aeropropulsion Research Program Office (ARPO). She has represented the office on numerous occasions, and is a member of a number of center-wide panels/teams, such as the Space management Committee and is chair to the Business Process Consolidation Team. She is responsible for the overall coordination of resources for the Propulsion and Power Project - from advocacy to implementation. The goal for my summer at NASA was to document processes and archive program documents from the past years. I used the computer and office machines, and also worked with personnel in setting up a Cost Estimation Plan. I gained office experience in Word, Excel, and Power Point, with the completion of a variety of tasks. I made spreadsheets that pertained to the budget plan for Journey to Tomorrow, to name a few I have supported the office by tracking resource information: including programmatic travel, project budget at the center level to budgets for individual research sub-projects and grants. I also assisted the Program Support Office in their duties including, representing the office on numerous occasions on center-wide team/panels, such as the Space management committee, IFMP Budget Formulation, Journey to Tomorrow Committee, and the Vehicle Systems Program Business Process Team.
Buttler, Jennifer A.↗
Scramjet Development Tests Supporting the Mach 10 Flight of the X-43
The Hyper-X Project s successful third flight of the X-43 at near Mach 10 in 2004 proved the potential for airbreathing propulsion at hypersonic speeds. The engine flowpath used in the X-43 research vehicle was developed and evaluated in a systematic series of ground tests in the NASA HyPulse Shock Tunnel at conditions duplicating Mach 10 flight using a full scale height, partial width engine model of the flight engine. Tests were conducted over a range of equivalence ratios from 0.8 to 1.6 using hydrogen and a mixture of two-percent silane in hydrogen fuels. Silane gas was used as an ignition aid during the short duration of the pulse facility tests. Variation of the engine inflow conditions, pressure, temperature, and Mach number, were parametrically varied during the test entries to broaden the database over the expected uncertainty in the flight conditions. A review of the ground test technique and comparisons of the ground test pressures along with selected flight data are presented.
Rogers, R. C.↗
Characterizing Electrical Arc Behavior in Ion Engines
Test results using an engineering model Advanced NEXT thruster are presented to identify different arc types utilizing ground test hardware. Three distinct arc types were observed: grid-to-grid arcs, high voltage-to-chassis arcs, and a combination of both. The frequency of high voltage-to-chassis arcs ranged from 4-30%, depending on operating conditions and hardware configuration. Higher beam currents were typically associated with more frequent high voltage-to-chassis arcs. During these arcs, the measured chassis current levels ranged from 20-70 A, however a significant portion of the output beam current returned to the beam supply via the neutralizer cathode plasma, which may be a ground test facility effect. The paper also discusses conducted susceptibility tests that can be performed at the spacecraft level to address the transients associated with arcing events.
electric propulsion↗
Solar Thermal Propulsion Improvements at Marshall Space Flight Center
Solar Thermal Propulsion (STP) is a concept which operates by transferring solar energy to a propellant, which thermally expands through a nozzle. The specific impulse performance is about twice that of chemical combustions engines, since there is no need for an oxidizer. In orbit, an inflatable concentrator mirror captures sunlight and focuses it inside an engine absorber cavity/heat exchanger, which then heats the propellant. The primary application of STP is with upperstages taking payloads from low earth orbit to geosynchronous earth orbit or earth escape velocities. STP engines are made of high temperature materials since heat exchanger operation requires temperatures greater than 2500K. Refractory metals such as tungsten and rhenium have been examined. The materials must also be compatible with hot hydrogen propellant. MSFC has three different engine designs, made of different refractory metal materials ready to test. Future engines will be made of high temperature carbide materials, which can withstand temperatures greater than 3000K, hot hydrogen, and provide higher performance. A specific impulse greater than 1000 seconds greatly reduces the amount of required propellant. A special 1 OkW solar ground test facility was made at MSFC to test various STP engine designs. The heliostat mirror, with dual-axis gear drive, tracks and reflects sunlight to the 18 ft. diameter concentrator mirror. The concentrator then focuses sunlight through a vacuum chamber window to a small focal point inside the STP engine. The facility closely simulates how the STP engine would function in orbit. The flux intensity at the focal point is equivalent to the intensity at a distance of 7 solar radii from the sun.
Gerrish, Harold P.↗
Assessment of Near-Term Fuel Screening and Qualification Needs for Nuclear Thermal Propulsion Systems
Nuclear thermal propulsion (NTP) is an in-space propulsion technology capable of both high specific impulse (850–1000 s) and thrust (44–1112 kN), which can help reduce trip times for crewed missions beyond low Earth orbit. NTP technology has been demonstrated during historic programs. Over 20 ground test reactor experiments were performed, which demonstrated the prototypic reactor operations, during the Nuclear Engine for Rocket Vehicle Application (NERVA)/Rover program (1955–1972). Although historical programs have shown that NTP is a viable in-space propulsion technology, developing NTP in modern programs is contingent on the development and qualification of ultrahigh-temperature nuclear fuel technologies that can withstand engine operating conditions. In historical NTP development programs such as NERVA/Rover, prototypic reactor/engine schemes were ground tested to assess the overall system feasibility and to qualify the reactor fuel forms for eventual flight systems. Although this approach is effective to verify fuel performance under prototypic conditions, relying solely on full-scale NTP reactor tests as the pathway for verifying or qualifying fuel is inefficient and cost prohibitive today. Additionally, modern nuclear licensing requirements state that before test reactor approval, reactor components and fuel elements should be qualified via non-nuclear (out-of-pile) and nuclear (in-pile) testing under representative operating conditions. Using this methodology, fuel matures as production scale fabrication methods are established, and as produced fuel performance is demonstrated. Here, this paper provides an overview of historical approaches to NTP fuel performance maturation, including fuel screening and qualification needs, and provides insight for establishing an efficient testing paradigm that can be implemented to rapidly and affordably develop NTP fuel forms for eventual qualification.
42 ENGINEERING↗
Semi-Automated Diagnosis, Repair, and Rework of Spacecraft Electronics
NASA's Constellation Program for Exploration of the Moon and Mars places human crews in extreme isolation in resource scarce environments. Near Earth, the discontinuation of Space Shuttle flights after 2010 will alter the up- and down-mass capacity for the International Space Station (ISS). NASA is considering new options for logistics support strategies for future missions. Aerospace systems are often composed of replaceable modular blocks that minimize the need for complex service operations in the field. Such a strategy however, implies a robust and responsive logistics infrastructure with relatively low transportation costs. The modular Orbital Replacement Units (ORU) used for ISS requires relatively large blocks of replacement hardware even though the actual failed component may really be three orders of magnitude smaller. The ability to perform in-situ repair of electronics circuits at the component level can dramatically reduce the scale of spares and related logistics cost. This ability also reduces mission risk, increases crew independence and improves the overall supportability of the program. The Component-Level Electronics Assembly Repair (CLEAR) task under the NASA Supportability program was established to demonstrate the practicality of repair by first investigating widely used soldering materials and processes (M&P) performed by modest manual means. The work will result in program guidelines for performing manual repairs along with design guidance for circuit reparability. The next phase of CLEAR recognizes that manual repair has its limitations and some highly integrated devices are extremely difficult to handle and demand semi-automated equipment. Further, electronics repairs require a broad range of diagnostic capability to isolate the faulty components. Finally repairs must pass functional tests to determine that the repairs are successful and the circuit can be returned to service. To prevent equipment demands from exceeding spacecraft volume capacity and skill demands from exceeding crew time and training limits, the CLEAR project is examining options provided by non-real time tele-operations, robotics, and a new generation of diagnostic equipment. This paper outlines a strategy to create an effective repair environment where, with the support of ground based engineers, crewmembers can diagnose, repair and test flight electronics in-situ. This paper also discusses the implications of successful tele-robotic repairs when expanded to rework and reconfiguration of used flight assets for building Constellation infrastructure elements.
Struk, Peter M.↗