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This presentation provides the thermal testing panel discussion with an overview of the thermal test facilities at the Dryden Flight Research Center (DFRC) as well as highlights from the thermal test efforts of the past year. This presentation is a little more in-depth than the corresponding material in the center overview presentation.
The development of the Modular High-Temperature Gas-Cooled Reactor is a significant milestone in advanced nuclear reactor technology. One of the concerns for the reactor’s safe operation is the effects of a loss-of-flow accident (LOFA) where the coolant circulators are tripped, and forced coolant flow through the core is lost. Depending on the steam generator placement, loop or intracore natural circulation develops to help transfer heat from the core to the reactor cavity, cooling system. This paper investigates the fundamental physical phenomena associated with intracore coolant natural circulation flow in a one-sixth Computational Fluid Dynamics (CFD) model of the Oregon State University High Temperature Test Facility (OSU HTTF) following a loss-of-flow accident transient. This study employs conjugate heat transfer and steady-state flow along with an SST k-ω turbulence model to characterize the phenomenon of core channel-to-channel natural convection. Previous studies have revealed the importance of complex flow distribution in the inlet and outlet plenums with the potential to generate hot coolant jets. For this reason, complete upper and lower plenum volumes are included in the analyzed computational domain. CFD results also include parametric studies performed for a mesh sensitivity analysis, generated using the STAR-CCM+ software. The resulting channel axial velocities and flow directions support the test facility scaling analysis and similarity group distortions calculation.
The Cosmic Background Explorer Observatory (COBE) underwent a thermal vacuum thermal balance test in the Space Environment Simulator (SES). This was the largest and most complex test ever conducted at this facility. The 4 x 4 m (13 x 13 ft) spacecraft weighed approx. 2223 kg (4900 lbs) for the test. The test set up included simulator panels for the inboard solar array panels, simulator panels for the flight cowlings, Sun and Earth Sensor stimuli, Thermal Radio Frequency Shield heater stimuli and a cryopanel for thermal control in the Attitude Control System Shunt Dissipator area. The fixturing also included a unique 4.3 m (14 ft) diameter Gaseous Helium Cryopanel which provided a 20 K environment for the calibration of one of the spacecraft's instruments, the Differential Microwave Radiometer. This cryogenic panel caused extra contamination concerns and a special method was developed and written into the test procedure to prevent the high buildup of condensibles on the panel which could have led to backstreaming of the thermal vacuum chamber. The test was completed with a high quality simulated space environment provided to the spacecraft. The test requirements, test set up, and special fixturing are described.
The Cosmic Background Explorer Observatory (COBE) underwant a thermal vacuum thermal balance test in the Space Environment Simulator (SES). This was the largest and most complex test ever conducted at this facility. The 4 x 4 m (13 x 13 ft) spacecraft weighed approx. 2223 kg (4900 lbs) for the test. The test set up included simulator panels for the inboard solar array panels, simulator panels for the flight cowlings, Sun and Earth Sensor stimuli, Thermal Radio Frequency Shield heater stimuli and a cryopanel for thermal control in the Attitude Control System Shunt Dissipator area. The fixturing also included a unique 4.3 m (14 ft) diameter Gaseous Helium Cryopanel which provided a 20 K environment for the calibration of one of the spacecraft's instruments, the Differential Microwave Radiometer. This cryogenic panel caused extra contamination concerns and a special method was developed and written into the test procedure to prevent the high buildup of condensibles on the panel which could have led to backstreaming of the thermal vacuum chamber. The test was completed with a high quality simulated space environment provided to the spacecraft. The test requirements, test set up, and special fixturing are described.
A description of the Langley thermal protection system test facility is presented. This facility was designed to provide realistic environments and times for testing thermal protection systems proposed for use on high speed vehicles such as the space shuttle. Products from the combustion of methane-air-oxygen mixtures, having a maximum total enthalpy of 10.3 MJ/kg, are used as a test medium. Test panels with maximum dimensions of 61 cm x 91.4 cm are mounted in the side wall of the test region. Static pressures in the test region can range from .005 to .1 atm and calculated equilibrium temperatures of test panels range from 700 K to 1700 K. Test times can be as long as 1800 sec. Some experimental data obtained while using combustion products of methane-air mixtures are compared with theory, and calibration of the facility is being continued to verify calculated values of parameters which are within the design operating boundaries.
This paper presents an overview of the JPL's efforts to provide its space flight projects with test facilities to meet unique test requirements and to serve the needs of selected outside customers.
Martian entry test facility for real size entry systems, discussing design, fabrication and operation
This paper describes a general-aviation digital avionics flight-test facility being jointly developed by the Flight Dynamics Laboratory of Princeton University and NASA/Langley Research Center. This facility consists of the Princeton avionics research aircraft (ARA) and NASA/Langley's digital avionics research (DARE) system. The ARA is a fully instrumented five-degree-of-freedom fly-by-wire aircraft. The DARE system contains a state-of-the-art flight computer system and receiving equipment that permits use of the NASA/Wallops Flight Center's position-tracking ground-based display-generation and ground-to-air digital-data-link equipment. The DARE/ARA system will be used for flight evaluation of advanced control, guidance, and display concepts developed as part of NASA/Langley Research Center's general aviation terminal area operations program.
This viewgraph presentation reviews the data compiled by the White Sands Test Facility in reference to toxic offgassing of a film from aluminized Mylar.
Fermi National Accelerator Laboratory (Fermilab) is constructing a new High Field Vertical Magnet Test Facility (HFVMTF) with capabilities comparable to the European facilities EDIPO and FRESCA2. The facility, located at Fermilab, will feature a background magnetic field of 15 T, generated by a magnet provided by Lawrence Berkeley National Laboratory (LBNL). The HFVMTF will support two U.S. national programs under the DOE Office of Science: the U.S. Fusion Energy Science (FES) program and the Magnet Development Program (MDP). It will enable the testing of HTS samples in high magnetic fields across a wide range of temperatures and facilitate the development of hybrid magnets combining LTS and HTS superconductors. This paper presents an overview of the current progress in constructing the facility, including updates on the test cryostat, power supplies, and systems for quench protection and monitoring.
A 1/5 scale model rotor representative of a current technology, high bypass ratio, turbofan engine was installed and tested in the W8 single-stage, high-speed, compressor test facility at NASA Glenn Research Center (GRC). The same fan rotor was tested previously in the GRC 9x15 Low Speed Wind Tunnel as a fan module consisting of the rotor and outlet guide vanes mounted in a flight-like nacelle. The W8 test verified that the aerodynamic performance and detailed flow field of the rotor as installed in W8 were representative of the wind tunnel fan module installation. Modifications to W8 were necessary to ensure that this internal flow facility would have a flow field at the test package that is representative of flow conditions in the wind tunnel installation. Inlet flow conditioning was designed and installed in W8 to lower the fan face turbulence intensity to less than 1.0 percent in order to better match the wind tunnel operating environment. Also, inlet bleed was added to thin the casing boundary layer to be more representative of a flight nacelle boundary layer. On the 100 percent speed operating line the fan pressure rise and mass flow rate agreed with the wind tunnel data to within 1 percent. Detailed hot film surveys of the inlet flow, inlet boundary layer and fan exit flow were compared to results from the wind tunnel. The effect of inlet casing boundary layer thickness on fan performance was quantified. Challenges and lessons learned from testing this high flow, low static pressure rise fan in an internal flow facility are discussed.
This paper describes experiments conducted at the National Research Council (NRC) of Canadas Research Altitiude Test Facility between March 26 and April 11, 2012. The tests, conducted collaboratively between NASA and NRC, focus on three key aspects in preparation for later scaling work to be conducted with a NACA 0012 airfoil model in the NRC Cascade rig: (1) cloud characterization, (2) scaling model development, and (3) ice-shape profile measurements. Regarding cloud characterization, the experiments focus on particle spectra measurements using two shadowgraphy methods, cloud uniformity via particle scattering from a laser sheet, and characterization of the SEA Multi-Element probe. Overviews of each aspect as well as detailed information on the diagnostic method are presented. Select results from the measurements and interpretation are presented which will help guide future work.
The Liquid Transfer Cryogenic Test Facility is a versatile testbed for ground-based cryogenic fluid storage, handling, and transfer experimentation. The test rig contains two well instrumented tanks, and a third interchangeable tank, designed to accommodate liquid nitrogen or liquid hydrogen testing. The internal tank volumes are approx. 18, 5, and 1.2 cu. ft. Tank pressures can be varied from 2 to 30 psia. Preliminary no vent fill tests with nitrogen and hydrogen were successfully completed with the test rig. Initial results indicate that no vent fills of nitrogen above 90 percent full are achievable using this test configuration, in a 1-g environment, and with inlet liquid temperatures as high as 143 R, and an average tank wall temperature of nearly 300 R. This inlet temperature corresponds to a saturation pressure of 19 psia for nitrogen. Hydrogen proved considerably more difficult to transfer between tanks without venting. The highest temperature conditions resulting in a fill level greater than 90 percent were with an inlet liquid temperature of 34 R, and an estimated tank wall temperature of slightly more than 100 R. Saturation pressure for hydrogen at this inlet temperature is 10 psia. All preliminary no vent fill tests were performed with a top mounted full cone nozzle for liquid injection. The nozzle produces a 120 degree conical droplet spray at a differential pressure of 10 psi. Pressure in the receiving tank was held to less than 30 psia for all tests.
Hybrid propulsion could be a potential game changing technology for several Mars applications, such as Mars Sample Return (MSR) and human exploration. A flexible hybrid test facility has been built at the Jet Propulsion Laboratory to provide data relevant to the design of such systems. This paper presents the motivations for such a system and its design. The facility is capable of testing 5 cm diameter fuel grains with gaseous oxygen and Mars in situ propellant production simulating oxidizer (varying mixtures of GO2, CO2 and CO). All currently planned tests utilize paraffin based fuels; however, alternative hybrid fuels may be used in the future. Variable length to outer diameter (L/D) ratios may also be tested to give insight on potential packaging constraints. The goal of this research is to enable the inclusion of hybrid propulsion systems in future mission design studies by determining the empirical constants in the regression rate equation for paraffin-based fuels with space storable and/or in situ oxidizers and to investigate the effect of L/D on combustion efficiency. Test results will be reported separately.
Future NASA missions to explore the solar system will be long-duration missions, requiring human life support systems which must operate with very high reliability over long periods of time. Such systems must be highly regenerative, requiring minimum resupply, to enable the crews to be largely self-sufficient. These regenerative life support systems will use a combination of higher plants, microorganisms, and physicochemical processes to recycle air and water, produce food, and process wastes. A key step in the development of these systems is establishment of a human-rated test facility specifically tailored to evaluation of closed, regenerative life supports systems--one in which long-duration, large-scale testing involving human test crews can be performed. Construction of such a facility, the Advanced Life Support Program's (ALS) Human-Rated Test Facility (HRTF), has begun at NASA's Johnson Space Center, and definition of systems and development of initial outfitting concepts for the facility are underway. This paper will provide an overview of the HRTF project plan, an explanation of baseline configurations, and descriptive illustrations of facility outfitting concepts.
The original vaned configuration of the High Efficiency Centrifugal Compressor (HECC) was developed with aggressive design targets to facilitate advancement of state-of-the-art technology in gas turbine compressors. This work documents modifications to the Small Engine Components Compressor Test Facility to support testing of the HECC vaneless diffuser and transition duct configurations, both of which are open geometries. These configurations were developed as follow-up studies to improve understanding of the differences between the predicted and actual performance of the original HECC vaned diffuser stage. Specifically, the vaneless diffuser was designed to provide the impeller with ideal exit conditions such that the impeller performance could be isolated from downstream stationary components, and the additively manufactured transition duct inlet configuration enables investigation into the effects of the inlet flow path on the stage performance. Features of note in the facility are active clearance control, bleed flow regulation, modular inlet configurations, and steady-state and fast-response instrumentation throughout the flow path. Details of the facility and instrumentation are presented as well as the baseline performance of the compressor stage. The geometry, performance, and detailed aerodynamic data have been made available to the public at https://storage.googleapis.com/heccdata/NASA-HECC-Data-Archive.zip.
The original vaned configuration of the High Efficiency Centrifugal Compressor (HECC) was developed with aggressive design targets to facilitate advancement of state-of-the-art technology in gas turbine compressors. This work documents modifications to the Small Engine Components Compressor Test Facility to support testing of the HECC vaneless diffuser and transition duct configurations, both of which are open geometries. These configurations were developed as follow-up studies to improve understanding of the differences between the predicted and actual performance of the original HECC vaned diffuser stage. Specifically, the vaneless diffuser was designed to provide the impeller with ideal exit conditions such that the impeller performance could be isolated from downstream stationary components, and the additively manufactured transition duct inlet configuration enables investigation into the effects of the inlet flow path on the stage performance. Features of note in the facility are active clearance control, bleed flow regulation, modular inlet configurations, and steady-state and fast-response instrumentation throughout the flow path. Details of the facility and instrumentation are presented as well as the baseline performance of the compressor stage. The geometry, performance, and detailed aerodynamic data have been made available to the public at https://storage.googleapis.com/hecc-data/NASA-HECC-Data-Archive.zip.
Cost optimization for 260-inch diameter solid rocket engine test facility