Vacuum chamber heat-transmission analysis
Effect of test chamber pressure level on accuracy of deep space heat transfer simulation
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Apollo experience report: Manned thermal-vacuum testing of spacecraft
Manned thermal-vacuum tests of the Apollo spacecraft presented many first-time problems in the areas of test philosophy, operational concepts, and program implementation. The rationale used to resolve these problems is explained and examined critically in view of actual experience. The series of 12 tests involving 1517 hours of chamber operating time resulted in the disclosure of numerous equipment and procedural deficiencies of significance to the flight mission. Test experience and results in view of subsequent flight experience confirmed that thermal-vacuum testing of integrated manned spacecraft provides a feasible, cost-effective, and safe technique with which to obtain maximum confidence in spacecraft flight worthiness early in the program.
Mclane, J. C., Jr.↗
Optothermal Stability of Large ULE and Zerodur Mirrors
Marshall Space Flight Center's (MSFC) X-ray and Cryogenic Test Facility (XRCF) has tested the optothermal stability of two low-CTE, large-aperture mirrors in a thermal vacuum chamber. The mirrors deformed from several causes such as: thermal gradients, thermal soaks, coefficient of thermal expansion (CTE) gradients, CTE mismatch, and stiction. This paper focuses on how the aforementioned conditions affected the surface figure of the large optics while in vacuum at temperatures ranging from 230 to 310 K (-43 to 37 ˚C). The presented data, conclusions, and taxonomy are useful for designing mirrors and support structures for telescopes. The data is particularly useful for telescopes that require extreme dimensional stability or telescopes that operate at a temperature far from ambient.
Brooks, Thomas E.↗
Modeling the TPF interferometer
The Terrestrial Planet Finder interferometer design concepts are large and complex systems that must operate in environments that are impractical to reproduce in preflight testing. The structurally-connected design is 36 meters long - longer than all but one thermal vacuum chamber in existence. The formation flying design will be comprised of up to five separate spacecraft, each with a sunshield over 15 meters on a side, and is designed to operate with formation sizes spanning over 100 meters to very close formations. System-level verification of the performance of the designs will need to rely on analytical modeling. The effort to model the many physical aspects of the designs under study is under way*. This paper describes the program of modeling for the TPF-I concepts. The program includes a number of types of models, such as the standard stand-alone optics, thermal, and structural models, as well as an end-to-end performance model of the project system called the Observatory Simulation. Aspects of each model are discussed including the purpose, methods of implementation (software applications), and approaches to validation. Program-level considerations (such as model-to-model integration and configuration management) are also discussed. Given that there are at least seven different organizations contributing to model developments and more than twenty separate models, these are special challenges.
Henry, Curt↗
Mass spectrometer use in a large chamber
The early satellites were somewhat insensitive to contamination produced during the construction and testing phases. The On-Orbit lifetime was such that contamination effects went either unnoticed or unrecognized. With today's On-Orbit lifetimes approaching 10+ years, contamination has become a paramount concern. The scientific payloads have increased in complexity and sensitivity. The ability to clean a contaminated sensor has greatly diminished. This requires better pumping systems and methods for improved monitoring. The conversion from diffusion pumped thermal vacuum chambers to cryo pumped chambers with the use of Misner traps and selective cold traps has reduced contamination. Witness samples supply a record of the condensates that remain after a testing cycle, but impart no knowledge of the contaminant migration during the cycle that may be a month in duration. Due to a customer's request that mass spectrometry be used during the testing of their spacecraft, a consultant was contracted to install a mass spectrometer to determine the feasibility of the instrument. The equipment and methodology described will start with the original system and its evolution to GE's present system.
Chuvala, Tom↗
Experimental Data for Two Different Alternator Configurations in a Solar Brayton Power System
A solar dynamic (SD) space power system has been under test at the NASA Lewis Research Center since 1994. The SD Ground Test Demonstration (GTD) system includes a solar concentrator, heat receiver with thermal energy storage, Brayton power conversion unit, and radiator installed in a thermal-vacuum chamber with a solar simulator. The Brayton unit has been operated with two different turboalternator compressor (TAC) assemblies, one which included a Rice Lundell alternator and another which incorporated a permanent magnet (PM) alternator. The Rice alternator was part of the mini-Brayton rotating unit, designed and built during the 1970's and refurbished for the GTD. The PM TAC was a development unit from the Joint US/Russian SD Flight Project. This paper highlights the operational differences (and similarities) between the Rice and PM TAC configurations including a comparative evaluation of startup characteristics and operating performance. The two alternator configurations were tested under similar thermal conditions, as an interchangeable component within the SD system. The electrical characteristics of the two units, however, dictated the use of significantly different power conditioning and control strategies. The electrical control architectures are described and compared. Test data are presented on TAC startup and system operating performance for both configurations.
Mason, Lee S.↗
Thermal Management of JWST Cryo-Vacuum Test Support Equipment
In 2017, the James Webb Space Telescope (JWST) underwent functional testing and optical metrology verification of the combined Optical Telescope Element and Integrated Science Instrument Module (OTIS) under cryogenic vacuum conditions in Chamber A at the Johnson Space Center. The ground support and test equipment developed and tested over the previous decade to facilitate this test event were crucial elements of its success. Ground systems required for this test fall into several groups, including thermal simulators, mechanical support hardware, telemetry systems, and metrology systems. This paper will provide a summary of these systems, their development challenges, key features, and highlight thermal performance in the cryovac test.
Havey, Keith A., Jr.↗
EVA Training and Development Facilities
Overview: Vast majority of US EVA (ExtraVehicular Activity) training and EVA hardware development occurs at JSC; EVA training facilities used to develop and refine procedures and improve skills; EVA hardware development facilities test hardware to evaluate performance and certify requirement compliance; Environmental chambers enable testing of hardware from as large as suits to as small as individual components in thermal vacuum conditions.
Cupples, Scott↗
The Micro-Arcsecond Metrology Testbed
The Micro-Arcsecond Metrology (MAM) testbed is a ground-based system of optical and electronic equipment for testing components, systems, and engineering concepts for the Space Interferometer Mission (SIM) and similar future missions, in which optical interferometers will be operated in outer space. In addition, the MAM testbed is of interest in its own right as a highly precise metrological system. The designs of the SIM interferometer and the MAM testbed reflect a requirement to measure both the position of the starlight central fringe and the change in the internal optical path of the interferometer with sufficient spatial resolution to generate astrometric data with angular resolution at the microarcsecond level. The internal path is to be measured by use of a small metrological laser beam of 1,319-nm wavelength, whereas the position of the starlight fringe is to be estimated by use of a charge-coupled-device (CCD) image detector sampling a large concentric annular beam. For the SIM to succeed, the optical path length determined from the interferometer fringes must be tracked by the metrological subsystem to within tens of picometers, through all operational motions of an interferometer delay line and siderostats. The purpose of the experiments performed on the MAM testbed is to demonstrate this agreement in a large-scale simulation that includes a substantial portion of the system in the planned configuration for operation in outer space. A major challenge in this endeavor is to align the metrological beam with the starlight beam in order to maintain consistency between the metrological and starlight subsystems at the system level. The MAM testbed includes an optical interferometer with a white light source, all major optical components of a stellar interferometer, and heterodyne metrological sensors. The aforementioned subsystems are installed in a large vacuum chamber in order to suppress atmospheric and thermal disturbances. The MAM is divided into two distinct subsystems: the test article (TA), which is the interferometer proper, and the inverse interferometer pseudo-star (IIPS), which synthesizes the light coming from a distant target star by providing spatially coherent wavefronts out of two mirrors, separated by the MAM baseline, that feed directly into two siderostats that are parts of the TA. The two feed mirrors of the IIPS are articulated (in translation and tilt) in order to simulate stars located at different orientations in space, while still illuminating the TA siderostats. The spectrum of the simulated starlight of the IIPS corresponds to that of a blackbody at a temperature of about 3,100 K.
Goullioud, Renaud↗
Managing Risk for Thermal Vacuum Testing of the International Space Station Radiators
The International Space Station (ISS) is designed with large deployable radiator panels that are used to reject waste heat from the habitation modules. Qualification testing of the Heat Rejection System (HRS) radiators was performed using qualification hardware only. As a result of those tests, over 30 design changes were made to the actual flight hardware. Consequently, a system level test of the flight hardware was needed to validate its performance in the final configuration. A full thermal vacuum test was performed on the flight hardware in order to demonstrate its ability to deploy on-orbit. Since there is an increased level of risk associated with testing flight hardware, because of cost and schedule limitations, special risk mitigation procedures were developed and implemented for the test program, This paper introduces the Continuous Risk Management process that was utilized for the ISS HRS test program. Testing was performed in the Space Power Facility at the NASA Glenn Research Center, Plum Brook Station located in Sandusky, Ohio. The radiator system was installed in the 100-foot diameter by 122-foot tall vacuum chamber on a special deployment track. Radiator deployments were performed at several thermal conditions similar to those expected on-orbit using both the primary deployment mechanism and the back-up deployment mechanism. The tests were highly successful and were completed without incident.
Carek, Jerry A.↗
MISSE-11 Ground Experiment Control
Back during the Apollo missions, when astronauts were being sent to the moon to explore and further scientific knowledge by conducting experiments and collecting samples for scientists back on Earth, they were faced with a surprising problem. It was discovered that the moon’s surface is covered with dust that has electrostatic properties, which would stick to suit and equipment. This hindered the functionality of the astronauts’ space suits, solar panels, optical instruments, among other exposed surfaces due to the jagged geometry of the dust which would damage said equipment. To resolve this issue, the Electrostatics and Surface Physics Laboratory (ESPL) came up with the solution of using an Electrodynamic Dust Shield (EDS)1 that uses electrostatic forces to move particles across a surface. Varieties of this dust shield have been developed for different applications. The purpose of the Materials International Space Station Experiments 11 (MISSE-11) is to experiment a payload that contains the dust mitigation technology to be flown to space for one year and an identical payload will be on earth, under vacuum, in the Electrostatics and Surface Physics Laboratory. The space payload was prepared prior to our arrival and shipped to fly on the International Space Station (ISS). The payload staying on the ground is going to act as a control for the experiment so that we may compare it to the payload that was flown in space. During our time at Kennedy Space Center, we were tasked with building and start testing the ground control unit of the MISSE-11 payload. To complete our task for the ground control unit, we constructed a new vacuum chamber setup and added automated aspects, procured the necessary flight electronics, designed and communicated for the machining of the payload frame, and performed functional and thermal testing on the electronics to the same original operational standards. Some modifications were made where possible, without affecting the performance of the samples, to be efficient with the production of the control unit while keeping important aspects identical. The experiment is now nearly complete, and testing will be starting within the next few weeks.
MISSE↗
The design and operation of a planet emitted and albedo radiation simulator
A simulator is described, which provides a dynamic simulation of planetary albedo and planet-emitted thermal radiation. The simulator was designed for model tests of advanced thermal control concepts, the development of space hardware, and flight qualification of small payloads. The simulator was designed to be used in a vacuum chamber equipped with liquid nitrogen cold walls and a solar simulator. The simulator consists of two major components: a gimbaled model support system and an array of quartz infrared lamps. Tests indicate that the apparatus will satisfactorily simulate the secondary radiation on a 0.92-meter spherical body in near-earth orbits. Calculations indicate that other shapes can be accommodated without structural modifications.
Sweet, G. E.↗
Molecular Accumulation during JWST’s Optical Telescope Cryogenic Thermal Vacuum Testing
Maintaining molecular cleanliness during the JWST’s Optical Telescope/Instrument Module (OTIS) Cryogenic Thermal Vacuum (TV) test campaign was critical to the success of its optical mission on orbit. In the thermal vacuum tests leading up to the final cryogenic test to validate the OTIS flight hardware, NASA Johnson Space Center’s (JSC’s) TV Chamber A was fully characterized for molecular contamination. It was found to contain common volatile condensable materials (VCM), including hydrocarbons, plasticizers, and silicones, all of which absorb in JWST’s infrared wavelength region. Due to the risks involved, cleaning molecular contamination from the OTIS mirrors was not an option and heating the Primary Mirror (PM) segments would have also been a risky and expensive endeavor. As a result, a monitoring process was developed and implemented during four different Pathfinder or risk reduction tests that were scheduled to occur prior to the flight hardware test. The goal was to quantify and assess the risk of molecular contamination depositing on the PM resulting from relatively warm chamber shrouds “leading” colder PM mirrors during warmup, by a margin of 10-50 Kelvin (K). This was accomplished using Cryogenic Quartz Crystal Microbalances (CQCMs), held at temperatures slightly cooler than the segments to signal the onset of contamination events. Per the JWST Contamination Control Plan (CCP)1, the total Primary Mirror molecular allocation requirement was 50 angstroms. In all tests, the results showed an average accumulated molecular contamination of <10 angstroms.
molecular, contamination, thermal vacuum, cryogeni↗
Space station common module thermal management: Design and construction of a test bed
In this project, a thermal test bed was designed, simulated, and planned for construction. The thermal system features interior and exterior thermal loads and interfacing with the central-radiator thermal bus. Components of the test bed include body mounted radiator loop with interface heat exchangers (600 Btu/hr); an internal loop with cabin air-conditioning and cold plates (3400 Btu/hr); interface heat exchangers to the central bus (13,000 Btu/hr); and provisions for new technology including advanced radiators, thermal storage, and refrigeration. The apparatus will be mounted in a chamber, heated with lamps, and tested in a vacuum chamber with LN2-cooled walls. Simulation of the test bed was accomplished using a DEC PRO 350 computer and the software package TK! olver. Key input variables were absorbed solar radiation and cold plate loads. The results indicate temperatures on the two loops will be nominal when the radiation and cold plate loads are in the range of 25% to 75% of peak loads. If all loads fall to zero, except the cabin air system which was fixed, the radiator fluid will drop below -100 F and may cause excessive pressure drop. If all loads reach 100%, the cabin air temperature could rise to 96 F.
Barile, R. G.↗
Environmental qualification testing of payload G-534, the Pool Boiling Experiment
Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.
Sexton, J. Andrew↗
Environmental qualification testing of the prototype pool boiling experiment
The prototype Pool Boiling Experiment (PBE) flew on the STS-47 mission in September 1992. This report describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the prototype hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave the project team a wider latitude in determining which shuttle thermal altitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the project's laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.
Sexton, J. Andrew↗
H2 arcjet performance mapping program
Work performed during the period of Mar. 1991 to Jan. 1992 is reviewed. High power H2 arcjets are being considered for electric powered orbit transfer vehicles (EOTV). Mission analyses indicate that the overall arcjet thrust efficiency is very important since increasing the efficiency increases the thrust, and thereby reduces the total trip time for the same power. For example, increasing the thrust efficiency at the same specific impulse from 30 to 40 percent will reduce the trip time by 25 percent. For a 200 day mission, this equates to 50 days, which results in lower ground costs and less time during which the payload is dormant. Arcjet performance levels of 1200 seconds specific impulse (lsp) at 35 to 40 percent efficiency with lifetimes over 1000 hours are needed to support EOTV missions. Because of the potential very high efficiency levels, the objective of this program was to evaluate the ability of a scaled Giannini-style thruster to achieve the performance levels while operating at a reduced nominal power of 10 kW. To meet this objective, a review of past literature was conducted; scaling relationships were developed and applied to establish critical dimensions; a development thruster was designed with the aid of the plasma analysis model KARNAC and finite element thermal modeling; test hardware was fabricated; and a series of performance tests were conducted in RRC's Cell 11 vacuum chamber with its null-balance thrust stand.
Source record↗
The space simulation facilities at IAL SPACE
The thermal vacuum facilities of IAL SPACE were tailored for testing of the ESA payloads. They were progressively upgraded for cryogenic payloads including 4 K (liquid helium temperature) experiments. A detailed review of the three vacuum chambers, ranging from 1.5 to 5 m diameter, is presented including the corresponding capabilities in the vacuum, thermal, and optical fields. The various aspects of cleanliness, product assurance, and quality control are also presented.
Henrist, M.↗