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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 289 records · Page 16
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NASA NTRS2005

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn

A high-efficiency, 110-W(sub e) (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 W(sub e) per kilogram. GRC has performed random vibration testing of a lowerpower version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗
NASA NTRS2005

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn Research Center

A high-efficiency, 110-We (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 We/kg. GRC has performed random vibration testing of a lower-power version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗
NASA NTRS2000

Force limits measured on a space shuttle flight

The random vibration forces between a payload and the sidewall of the space shuttle have been measured in flight and compared with the force specifications used in ground vibration tests. The flight data are in agreement with a semi-empirical method, which is widely used to predict vibration test force limits.

force limiting vibration tests↗
NASA NTRS2007

On the Use of 3dB Qualification Margin for Structural Parts on Expendable Launch Vehicles

The standard random vibration qualification test used for Expendable Launch Vehicle components is Maximum Predicted Environment (MPE) + 6dB for a duration of 4 times the service life of the part. This can be a severe qualification test for these fatigue-sensitive structures. This paper uses flight data from several launch vehicles to establish that reducing the qualification approach to MPE+3dB for the duration of the peak environment (1x life) is valid for fatigue-sensitive structural components. Items that can be classified as fatigue-sensitive are probes, ducts, tubing, bellows, hoses, and any non-functional structure. Non-functional structure may be flight critical or carry fluid, but it cannot include any moving parts or electronics. This reduced qualification approach does not include primary or secondary structure which would be exclusively designed by peak loads, either transient or quasi-static, that are so large and of so few cycles as to make fatigue a moot point.

Yunis, Isam↗
NASA NTRS2008

Environmental Testing of the NEXT PM1 Ion Engine

The NEXT propulsion system is an advanced ion propulsion system presently under development that is oriented towards robotic exploration of the solar system using solar electric power. The Prototype Model engine PM1 was subjected to qualification-level environmental testing to demonstrate compatibility with environments representative of anticipated mission requirements. Random vibration testing, conducted with the thruster mated to the breadboard gimbal, was executed at 10.0 Grms for 2 minutes in each of three axes. Thermal-vacuum testing included a deep cold soak of the engine to temperatures of -168 C and thermal cycling from -120 to 203 C. Although the testing was largely successful, several issues were identified including the fragmentation of potting cement on the discharge and neutralizer cathode heater terminations during vibration which led to abbreviated thermal testing, and generation of particulate contamination from manufacturing processes and engine materials. Thruster performance was nominal throughout the test program, with minor variations in some engine operating parameters likely caused by facility effects. In general, the NEXT PM1 engine and the breadboard gimbal were found to be well-designed against environmental requirements based on the results reported herein. After resolution of the findings from this test program the hardware environmental qualification program can proceed with confidence.

Synder, John S.↗
NASA NTRS2006

A Nonlinear Reduced Order Method for Prediction of Acoustic Fatigue

The goal of this investigation is to assess the quality of high-cycle-fatigue life estimation via a reduced order method, for structures undergoing geometrically nonlinear random vibrations. Modal reduction is performed with several different suites of basis functions. After numerically solving the reduced order system equations of motion, the physical displacement time history is obtained by an inverse transformation and stresses are recovered. Stress ranges obtained through the rainflow counting procedure are used in a linear damage accumulation method to yield fatigue estimates. Fatigue life estimates obtained using various basis functions in the reduced order method are compared with those obtained from numerical simulation in physical degrees-of-freedom.

Przekop, Adam↗
NASA NTRS2008

Initial Assessment of the Ares I-X Launch Vehicle Upper Stage to Vibroacoustic Flight Environments

The Ares I launch vehicle will be NASA s first new launch vehicle since 1981. Currently in design, it will replace the Space Shuttle in taking astronauts to the International Space Station, and will eventually play a major role in humankind s return to the Moon and eventually to Mars. Prior to any manned flight of this vehicle, unmanned test readiness flights will be flown. The first of these readiness flights, named Ares I-X, is scheduled to be launched in April 2009. The NASA Glenn Research Center is responsible for the design, manufacture, test and analysis of the Ares I-X upper stage simulator (USS) element. As part of the design effort, the structural dynamic response of the Ares I-X launch vehicle to its vibroacoustic flight environments must be analyzed. The launch vehicle will be exposed to extremely high acoustic pressures during its lift-off and aerodynamic stages of flight. This in turn will cause high levels of random vibration on the vehicle's outer surface that will be transmitted to its interior. Critical flight equipment, such as its avionics and flight guidance components are susceptible to damage from this excitation. This study addresses the modelling, analysis and predictions from examining the structural dynamic response of the Ares I-X upper stage to its vibroacoustic excitations. A statistical energy analysis (SEA) model was used to predict the high frequency response of the vehicle at locations of interest. Key to this study was the definition of the excitation fields corresponding to lift off acoustics and the unsteady aerodynamic pressure fluctuations during flight. The predicted results will be used by the Ares I-X Project to verify the flight qualification status of the Ares I-X upper stage components.

Larko, Jeffrey M.↗
NASA NTRS2010

Ares I-X Launch Abort System, Crew Module, and Upper Stage Simulator Vibroacoustic Flight Data Evaluation, Comparison to Predictions, and Recommendations for Adjustments to Prediction Methodology and Assumptions

The National Aeronautics and Space Administration (NASA) Constellation Program (CxP) has identified a series of tests to provide insight into the design and development of the Crew Launch Vehicle (CLV) and Crew Exploration Vehicle (CEV). Ares I-X was selected as the first suborbital development flight test to help meet CxP objectives. The Ares I-X flight test vehicle (FTV) is an early operational model of CLV, with specific emphasis on CLV and ground operation characteristics necessary to meet Ares I-X flight test objectives. The in-flight part of the test includes a trajectory to simulate maximum dynamic pressure during flight and perform a stage separation of the Upper Stage Simulator (USS) from the First Stage (FS). The in-flight test also includes recovery of the FS. The random vibration response from the ARES 1-X flight will be reconstructed for a few specific locations that were instrumented with accelerometers. This recorded data will be helpful in validating and refining vibration prediction tools and methodology. Measured vibroacoustic environments associated with lift off and ascent phases of the Ares I-X mission will be compared with pre-flight vibration predictions. The measured flight data was given as time histories which will be converted into power spectral density plots for comparison with the maximum predicted environments. The maximum predicted environments are documented in the Vibroacoustics and Shock Environment Data Book, AI1-SYS-ACOv4.10 Vibration predictions made using statistical energy analysis (SEA) VAOne computer program will also be incorporated in the comparisons. Ascent and lift off measured acoustics will also be compared to predictions to assess whether any discrepancies between the predicted vibration levels and measured vibration levels are attributable to inaccurate acoustic predictions. These comparisons will also be helpful in assessing whether adjustments to prediction methodologies are needed to improve agreement between the predicted and measured flight data. Future assessment will incorporate hybrid methods in VAOne analysis (i.e., boundary element methods, BEM and finite element methods, FEM). These hybrid methods will enable the ability to import NASTRAN models providing much more detailed modeling of the underlying beams and support structure of the ARES 1-X test vehicle. Measured acoustic data will be incorporated into these analyses to improve correlation for additional post flight analysis.

Smith, Andrew↗
NASA NTRS2009

Advanced Development Program for a 625 lbf thrust engine for Ares First Stage Roll Control System

NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;

Dawson, Matt↗
NASA NTRS2012

Static Gas-Charging Plug

A gas-charging plug can be easily analyzed for random vibration. The design features two steeped O-rings in a radial configuration at two different diameters, with a 0.050-in. (.1.3-mm) diameter through-hole between the two O-rings. In the charging state, the top O-ring is engaged and sealing. The bottom O-ring outer diameter is not squeezed, and allows air to flow by it into the tank. The inner diameter is stretched to plug the gland diameter, and is restrained by the O-ring groove. The charging port bushing provides mechanical stop to restrain the plug during gas charge removal. It also prevents the plug from becoming a projectile when removing gas charge from the accumulator. The plug can easily be verified after installation to ensure leakage requirements are met.

Indoe, William↗
NASA NTRS2012

Orion MPCV Service Module Avionics Ring Pallet Testing, Correlation, and Analysis

The NASA Orion Multi-Purpose Crew Vehicle (MPCV) is being designed to replace the Space Shuttle as the main manned spacecraft for the agency. Based on the predicted environments in the Service Module avionics ring, an isolation system was deemed necessary to protect the avionics packages carried by the spacecraft. Impact, sinusoidal, and random vibration testing were conducted on a prototype Orion Service Module avionics pallet in March 2010 at the NASA Glenn Research Center Structural Dynamics Laboratory (SDL). The pallet design utilized wire rope isolators to reduce the vibration levels seen by the avionics packages. The current pallet design utilizes the same wire rope isolators (M6-120-10) that were tested in March 2010. In an effort to save cost and schedule, the Finite Element Models of the prototype pallet tested in March 2010 were correlated. Frequency Response Function (FRF) comparisons, mode shape and frequency were all part of the correlation process. The non-linear behavior and the modeling the wire rope isolators proved to be the most difficult part of the correlation process. The correlated models of the wire rope isolators were taken from the prototype design and integrated into the current design for future frequency response analysis and component environment specification.

Staab, Lucas↗
NASA NTRS2012

Advanced Stirling Convertor Durability Testing: Plans and Interim Results

The U.S. Department of Energy (DOE), Lockheed Martin Corporation (LM), and NASA Glenn Research Center (GRC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. In support of this program, GRC has been involved in testing Stirling convertors, including the Advanced Stirling Convertor (ASC), for use in the ASRG. This testing includes electromagnetic interference/compatibility (EMI/EMC), structural dynamics, advanced materials, organics, and unattended extended operation. The purpose of the durability tests is to experimentally demonstrate the margins in the ASC design. Due to the high value of the hardware, previous ASC tests focused on establishing baseline performance of the convertors within the nominal operating conditions. The durability tests present the first planned extension of the operating conditions into regions beyond those intended to meet the product spec, where the possibility exists of lateral contact, overstroke, or over-temperature events. These tests are not intended to cause damage that would shorten the life of the convertors, so they can transition into extended operation at the conclusion of the tests. This paper describes the four tests included in the durability test sequence: 1) start/stop cycling, 2) exposure to constant acceleration in the lateral and axial directions, 3) random vibration at increased piston amplitude to induce contact events, and 4) overstroke testing to simulate potential failures during processing or during the mission life where contact events could occur. The paper also summarizes the analysis and simulation used to predict the results of each of these tests.

Meer, David W.↗
NASA NTRS2012

Advanced Stirling Convertor Durability Testing: Plans and Interim Results

The U.S. Department of Energy (DOE), Lockheed Martin Corporation (LM), and NASA Glenn Research Center (GRC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. In support of this program, NASA?s Glenn Research Center (GRC) has been involved in testing Stirling convertors, including the Advanced Stirling Convertor (ASC), for use in the ASRG. This testing includes electromagnetic interference/compatibility (EMI/EMC), structural dynamics, advanced materials, organics, and unattended extended operation. The purpose of the durability tests is to experimentally demonstrate the margins in the ASC design. Due to the high value of the hardware, previous ASC tests focused on establishing baseline performance of the convertors within the nominal operating conditions. The durability tests present the first planned extension of the operating conditions into regions beyond those intended to meet the product spec, where the possibility exists of lateral contact, overstroke, or over-temperature events. These tests are not intended to cause damage that would shorten the life of the convertors, so they can transition into extended operation at the conclusion of the tests. This paper describes the four tests included in the durability test sequence: 1) start/stop cycling, 2) exposure to constant acceleration in the lateral and axial directions, 3) random vibration at increased piston amplitude to induce contact events, and 4) overstroke testing to simulate potential failures during processing or during the mission life where contact events could occur. The paper also summarizes the analysis and simulation used to predict the results of each of these tests.

Meer, Dave↗
NASA NTRS2005

Design and Qualification of the AMS-02 Flight Cryocoolers

Four commercial Sunpower M87N Stirling-cycle cryocoolers will be used to extend the lifetime of the Alpha Magnetic Spectrometer-02 (AMS-02) experiment. The cryocoolers will be mounted to the AMS-02 vacuum case using a structure that will thermally and mechanically decouple the cryocooler from the vacuum case. This paper discusses modifications of the Sunpower M87N cryocooler to make it acceptable for space flight applications and suitable for use on AMS-02. Details of the flight model qualification test program are presented. AMS-02 is a state-of-the-art particle physics detector containing a large superfluid helium-cooled superconducting magnet. Highly sensitive detector plates inside the magnet measure a particle's speed, mass, charge, and direction. The AMS-02 experiment, which will be flown as an attached payload on the International Space Station, will study the properties and origin of cosmic particles and nuclei including antimatter and dark matter. Two engineering model cryocoolers have been under test at NASA Goddard since November 2001. Qualification testing of the engineering model cryocooler bracket assembly including random vibration and thermal vacuum testing was completed at the end of April 2005. The flight cryocoolers were received in December 2003. Acceptance testing of the flight cryocooler bracket assemblies began in May 2005 .

Shirey, Kimberly↗
NASA NTRS2014

The Effect of Drive Signal Limiting on High Cycle Fatigue Life Analysis

It is common practice to assume a Gaussian distribution of both the input acceleration and the response when modeling random vibration tests. In the laboratory, however, shaker controllers often limit the drive signal to prevent high amplitude peaks. The high amplitudes may either be truncated at a given level (socalled brick wall limiting or abrupt clipping), or compressed (soft limiting), resulting in drive signals which are no longer Gaussian. The paper first introduces several methods for limiting a drive signal, including brick wall limiting and compression. The limited signal is then passed through a linear time-invariant system representing a device under test. High cycle fatigue life predictions are subsequently made using spectral fatigue and rainflow cycle counting schemes. The life predictions are compared with those obtained from unclipped input signals. Some guidelines are provided to help the test engineer decide how clipping should be applied under different test scenarios.

Kihm, Frederic↗
NASA NTRS2014

Evaluation of Polymer Hermetically Sealed Tantalum Capacitors

Polymer cathode tantalum capacitors have lower ESR (equivalent series resistance) compared to other types of tantalum capacitors and for this reason have gained popularity in the electronics design community. Their use allows improved performance of power supply systems along with substantial reduction of size and weight of the components used. However, these parts have poor thermal stability and can degrade in humid environments. Polymer hermetically sealed (PHS) capacitors avoid problems related to environmental degradation of molded case parts and can potentially replace current wet and solid hermetically sealed capacitors. In this work, PHS capacitors manufactured per DLA LAM DWG#13030 are evaluated for space applications. Several lots of capacitors manufactured over period from 2010 to 2014 were tested for the consistency of performance, electrical and thermal characteristics, highly accelerated life testing, and robustness under reverse bias and random vibration conditions. Special attention was given to analysis of leakage currents and the effect of long-term high temperature storage on capacitors in as is condition and after hermeticity loss. The results show that PHS capacitors might be especially effective for low-temperature applications or for system requiring a cold start-up. Additional screening and qualification testing have been recommended to assure the necessary quality of capacitors for space projects.

ferrite beads↗