Component and overall performance of an advanced Rankine cycle test rig
Component performance of three loop Rankine cycle test rig using lithium, potassium and NaK-78 as working fluids
Bond, J. A.↗
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The Ares Projects: Building America's Future in Space
NASA's Constellation Program is depending on the Ares Projects to deliver the crew and cargo launch capabilities needed to send human explorers to the Moon and beyond. In 2009, the Ares Projects plan to conduct the first test flight of Ares I, Ares I-X; the first firing of a five-segment development solid rocket motor for the Ares I first stage; building the first integrated Ares I upper stage; continue component testing for the J-2X upper stage engine; and perform more-detailed design studies for the Ares V cargo launch vehicle. Ares I and V will provide the core space launch capabilities needed to continue providing crew and cargo access to the International Space Station (ISS), and to build upon the U.S. history of human spaceflight to the Moon and beyond.
Cook, Stephen A.↗
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↗
Initial wind tunnel tests at Mach 4 and 7 of a hydrogen-burning, airframe-integrated scramjet
A research investigation of a new, fixed-geometry, hydrogen-burning scramjet engine concept, designed for total airframe integration, is currently in progress. Two heavily instrumented engine models incorporate inlet and combustor designs developed previously in component tests. Initial tests of these subscale engine models are being conducted in ground facilities at conditions simulating flight at Mach numbers 4 and 7. The scramjet test results which are presented include inlet performance, ignition/reaction aids, inlet-combustor interactions, and engine performance in terms of thrust balance measurements and internal pressure and heating rate distributions. The relationship of these results to flight engine performance is discussed.
Guy, R. W.↗
Evaluation of a Compression-Loaded-Stitched-Multi-Bay Fuselage Panel With Barely Visible Impact Damage
The experimental results from a stitched VaRTM carbon-epoxy composite panel tested under uni-axial compression loading are presented along with nonlinear finite element analysis prediction of the response. The curved panel is divided by frames and stringers into six bays with a column of three bays along the compressive loading direction. The frames are supported at the frame ends to resist out-of-plane translation. Back-to-back strain gages are used to record the strain and displacement transducers were used to record the out-of-plane displacements. In addition a full-field-displacement measurement technique that utilizes a camera-based-stereo-vision system was used to record the displacements. The panel was loaded to 1.5 times the predicted initial buckling load (1st bay buckling load, P(sub er) from the nonlinear finite element analysis and then was removed from the test machine for impact testing. After impacting with 20 ft-lbs of energy using a spherical impactor to produce barely visible damage the panel was loaded in compression until failure. The buckling load of the first bay to buckle was 97% of the buckling load before impact. The stitching constrained the impact damage from growing during the loading to failure. Impact damage had very little overall effect on panel stiffness. Panel stiffness measured by the full-field-displacement technique indicated a 13% loss in stiffness after impact. The panel failed at 1.64 times the first panel buckling load. The barely visible impact damage did not grow noticeably as the panel failed by global instability due to stringer-web terminations at the frame locations. The predictions from the nonlinear analysis of the finite element modeling of the entire specimen were very effective in the capture of the initial buckling and global behavior of the panel. In addition, the prediction highlighted the weakness of the panel under compression due to stringer web terminations. Both the test results and the nonlinear predictions serve to reinforce the severe penalty in structural integrity caused by the low cost manufacturing technique to terminate the stringer webs, and demonstrates the importance of this type of sub-component testing and high fidelity failure analysis in the design of a composite fuselage.
Baker, Donald J.↗
Develop, demonstrate, and verify large area composite structural bonding with polyimide adhesives
The technology required to produce graphite-polyimide structural components with operational capability at 598 K (600 F) is considered. A series of polyimide adhesives was screened for mechanical and physical properties and processibility in fabricating large midplane bonded panels and honeycomb sandwich panels in an effort to fabricate a structural test component of the space shuttle aft body flap. From 41 formulations, LaRC-13, FM34B-18, and a modified LaRC-13 adhesive were selected for further evaluation. The LaRC-13 adhesive was rated as the best of the three adhesives in terms of availability, cost, processibility, properties, and ability to produce void fee large area (12" x 12") midplane bonds. Surface treatments and primers for the adhesives were evaluated and processes were developed for the fabrication of honeycomb sandwich panels of very good quality which was evidenced by rupture in the honeycomb core rather than in the facesheet bands on flatwise tensile strength testing. The fabrication of the adhesively bonded honeycomb sandwich cover panels, ribs, and leading edge covers of Celion graphite/LARC-160 polyimide laminates is described.
Bhombal, B. D.↗
Quiet Clean Short-haul Experimental Engine (QCSEE) under-the-wing engine composite fan blade: Preliminary design test report
Results of tests conducted on preliminary design polymeric-composite fan blade for the under the wing (UTW) OCSEE engine are presented. During this phase of the program a total of 17preliminary OCSEE UTW composite fan blades were manufactured for various component tests including frequency characteristics, strain distribution, bench fatigue, dovetail pull, whirligig overspeed and whirligig impact. All tests were successfully completed with the exception of whirligig impact tests. Improvements in local impact capability are being evaluated for the OCSEE blade under other NASA and related programs.
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Calculation of Viscous Compressible Flows in Small Gas Turbines
The NASA Lewis Research Center is conducting a program to develop improved technology for the space shuttle main engine (SSmE). This program requires not only a component test program, but also the development of accurate and reliable analyses to support the program. Thus a computer analysis for the prediction of the flow of hot gases, composed of a variety of exhaust products, through rocket and gas turbine components would support this program and also would be suitable for a wide variety of other applications.
Anderson, O. L.↗
Static test of an ultralight airplane
This paper describes all of the work necessary to perform the static test of an ultralight airplane. A steel reaction gantry was designed first, then all of the loading whiffletrees, the hydraulic actuation system, and instrumentation systems were designed. Loads and stress analyses were performed on the airplane and the gantry and whiffletrees. Components tested to date are: tubing samples, cables, and two-by-four whiffletrees. A hydraulic system consisting of a 3000-psi hand pump, 10,000-pound actuator, pressure gage and lines, and a Barksdale valve are described. Load cell calibration and pressure indicator calibration procedures are also described. A description of the strain and deflection measurement system is included. Preliminary data obtained to date are compared to the analytical predictions.
Smith, H. W.↗
Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power
Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but the selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a radioisotope heat source in AMTEC powered planet probes requires the device to be constructed to tolerate operating T greater than 1150K, as well as exposure to Na (g) , and Na (liq) on the high pressure side. The temperatures involved make the characterization of high strength and chemical resistance to Na containing Na 2 O critical. Selection among materials which can be worked should not be driven by ease of fabricablity, as high temperature stability is the critical issue. These concepts drive the selecton of Mo alloys for Na (liq) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable Nb or Ta alloys, are less soluble in Na (liq) containing dissolved Na 2 O, are workable compared with W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.
AMTEC↗
Basic space payload fastener
A new basic space fastener has been developed and tested by the GSFC. The purposes of this fastener are to permit assembly and servicing in space by astronauts and/or robots and to facilitate qualification of payloads on Earth prior to launch by saving time and money during the systems integration and component testing and qualification processes. The space fastener is a rework of the basic machine screw such that crossthreading is impossible; it is self-locking and will not work its way out during launch (vibration proof); it will not wear out despite repeated use; it occupies a small foot print which is comparable to its machine screw equivalent, and it provides force and exhibits strength comparable to its machine screw equivalent. Construction is ultra-simple and cost effective and the principle is applicable across the full range of screw sizes ranging from a #10 screw to 2.5 cm (1 in) or more. In this paper, the fastener principles of operation will be discussed along with test results and construction details. The new fastener also has considerable potential in the commercial sector. A few promising applications will be presented.
Vranish, J. M.↗
5-kWe Free-piston Stirling Engine Convertor
The high reliability, long life, and efficient operation of Free-Piston Stirling Engines (FPSEs) make them an attractive power system to meet future space power requirements with less mass, better efficiency, and less total heat exchanger area than other power convertor options. FPSEs are also flexible in configuration as they can be coupled with many potential heat sources and various heat input systems, heat rejection systems, and power management and distribution systems. Development of a 5-kWe Stirling Convertor Assembly (SCA) is underway to demonstrate the viability of an FPSE for space power. The design is a scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463. The ultimate efficiency target is 25% overall convertor efficiency (electrical power out over heat in). For the single cylinder prototype now in development, cost and time constraints required use of economical and readily available materials (steel versus beryllium) and components (a commercially available linear alternator) and thus lower efficiency. The working gas is helium at 150 bar mean pressure. The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype convertor is done via pumped liquid loops passing through shell and tube heat exchangers. The preliminary and detail designs of the convertor, controller, and support systems (heating loop, cooling loop, and helium supply system) are complete and all hardware is on order. Assembly and test of the prototype at Foster- Miller is planned for early 2008, when work will focus on characterizing convertor dynamics and steady-state operation to determine maximum power output and system efficiency. The device will then be delivered to Auburn University where assessments will include start-up and shutdown characterization and transient response to temperature and load variations. Future activities may include testing at NASA GRC.
Chapman, Peter A.↗
Energy Efficient Engine combustor test hardware detailed design report
The Energy Efficient Engine (E3) Combustor Development effort was conducted as part of the overall NASA/GE E3 Program. This effort included the selection of an advanced double-annular combustion system design. The primary intent was to evolve a design which meets the stringent emissions and life goals of the E3 as well as all of the usual performance requirements of combustion systems for modern turbofan engines. Numerous detailed design studies were conducted to define the features of the combustion system design. Development test hardware was fabricated, and an extensive testing effort was undertaken to evaluate the combustion system subcomponents in order to verify and refine the design. Technology derived from this development effort will be incorporated into the engine combustion system hardware design. This advanced engine combustion system will then be evaluated in component testing to verify the design intent. What is evolving from this development effort is an advanced combustion system capable of satisfying all of the combustion system design objectives and requirements of the E3. Fuel nozzle, diffuser, starting, and emissions design studies are discussed.
Burrus, D. L.↗
Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power (abstract)
Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a GPHS in AMTEC powered outer planet probes requires the device to be constructed to tolerate T greater than 1150K, as well as exposure to Na(sub (g)), and Na(sub (liq)) on the high pressure side. The temperatures involved make critical high strength and chemical resistance to Na containing Na(sub 2)O. Selection among materials which can be worked should not be driven by ease of fabricability, as high temperature stability is the critical issue. These concepts drive the selection of Mo alloys for Na(sub (liq)) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable NB or Ta alloys, are less soluble in Na(sub (liq)) containing dissolved Na(sub 2)O, are workable compared to W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.
AMTEC thermal to electric conversion↗
Programmatic status of NASA's CSTI high capacity power Stirling space power converter program
An overview is presented of the NASA Lewis Research Center Free-Piston Stirling Space Power Converter Technology Development Program. This work is being conducted under NASA's Civil Space Technology Initiative (CSTI). The goal of the CSTI High Capacity Power element is to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA space initiatives. Efforts are focused upon increasing system thermal and electric energy conversion efficiency at least fivefold over current SP-100 technology, and on achieving systems that are compatible with space nuclear reactors. The status of test activities with the Space Power Research Engine (SPRE) is discussed. Design deficiencies are gradually being corrected and the power converter is now outputting 11.5 kWe at a temperature ratio of 2 (design output is 12.5 kWe). Detail designs were completed for the 1050 K Component Test Power Converter (CTPC). The success of these and future designs is dependent upon supporting research and technology efforts including heat pipes, gas bearings, superalloy joining technologies and high efficiency alternators. An update of progress in these technologies is provided.
Dudenhoefer, James E.↗
Programmatic status of NASA's CSTI High Capacity Power Stirling Space Power Converter Program
An overview is presented of the NASA Lewis Research Center Free-Piston Stirling Space Power Converter Technology Department Program. This work is being conducted under NASA's Civil Space Technology Initiative (CSTI). The goal of the CSTI High Capacity Power element is to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA space initiatives. Efforts are focused upon increasing system thermal and electric energy conversion efficiency at least fivefold over current SP-100 technology, and on achieving systems that are compatible with space nuclear reactors. The status of test activities with the Space Power Research Engine (SPRE) is discussed. Design deficiencies are gradually being corrected and the power converter is now outputting 11.5 kWe at a temperature ratio of 2 (design output is 12.5 kWe). Detail designs were completed for the 1050 K Component Test Power Converter (CTPC). The success of these and future designs is dependent upon supporting research and technology efforts including heat pipes, gas bearings, superalloy joining technologies and high efficiency alternators. An update of progress in these technologies is provided.
Dudenhoefer, James E.↗
Nuclear electric propulsion development and qualification facilities
This paper summarizes the findings of a Tri-Agency panel consisting of members from the National Aeronautics and Space Administration (NASA), U.S. Department of Energy (DOE), and U.S. Department of Defense (DOD) that were charged with reviewing the status and availability of facilities to test components and subsystems for megawatt-class nuclear electric propulsion (NEP) systems. The facilities required to support development of NEP are available in NASA centers, DOE laboratories, and industry. However, several key facilities require significant and near-term modification in order to perform the testing required to meet a 2014 launch date. For the higher powered Mars cargo and piloted missions, the priority established for facility preparation is: (1) a thruster developmental testing facility, (2) a thruster lifetime testing facility, (3) a dynamic energy conversion development and demonstration facility, and (4) an advanced reactor testing facility (if required to demonstrate an advanced multiwatt power system). Facilities to support development of the power conditioning and heat rejection subsystems are available in industry, federal laboratories, and universities. In addition to the development facilities, a new preflight qualifications and acceptance testing facility will be required to support the deployment of NEP systems for precursor, cargo, or piloted Mars missions. Because the deployment strategy for NEP involves early demonstration missions, the demonstration of the SP-100 power system is needed by the early 2000's.
Dutt, D. S.↗
Mechanical Components Branch Overview
Mr. James Zakrajsek, chief of the Mechanical Components Branch, presented an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. In space mechanisms, we conduct fundamental research on lubricants, materials, components and mechanisms subjected to deep space and planetary environments.
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