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At least 307 records · Page 17

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.↗

Impact of Solar Array Position on ISS Vehicle Charging

The International Space Station (ISS), because of its large structure and high voltage solar arrays, has a complex plasma interaction with the ionosphere in low Earth orbit (LEO). This interaction of the ISS US Segment photovoltaic (PV) power system with the LEO ionospheric plasma produces floating potentials on conducting elements of the ISS structure relative to the local plasma environment. To control the ISS floating potentials, two Plasma Contactor Units (PCUs) are installed on the Z1 truss. Each PCU discharges accumulated electrons from the Space Station structure, thus reducing the potential difference between the ISS structure and the surrounding charged plasma environment. Operations of the PCUs were intended to keep the ISS floating potential to 40 Volts (Reference 1). Exposed dielectric surfaces overlying conducting structure on the Space Station will collect an opposite charge from the ionosphere as the ISS charges. In theory, when an Extravehicular Activity (EVA) crewmember is tethered to structure via the crew safety tether or when metallic surfaces of the Extravehicular Mobility Unit (EMU) come in contact with conducting metallic surfaces of the ISS, the EMU conducting components, including the perspiration-soaked crewmember inside, can become charged to the Space Station floating potential. The concern is the potential dielectric breakdown of anodized aluminum surfaces on the EMU producing an arc from the EMU to the ambient plasma, or nearby ISS structure. If the EMU arcs, an electrical current of an unknown magnitude and duration may conduct through the EVA crewmember, producing an unacceptable condition. This electrical current may be sufficient to startle or fatally shock the EVA crewmember (Reference 2). Hence, as currently defined by the EVA community, the ISS floating potential for all nominal and contingency EVA worksites and translation paths must have a magnitude less than 40 volts relative to the local ionosphere at all times during EVA. Arcing from the EMU is classified as a catastrophic hazard, which requires two-failure tolerant controls, i.e., three hazard controls. Each PCU is capable of maintaining the ISS floating potential below the requirement during EVA. The two PCUs provide a single failure tolerant control of ISS floating potential. In the event of the failure of one or two PCUs, a combination of solar array shunting and turning the solar arrays into their own wakes will be used to supply control of the plasma hazard (Reference 3). The purpose of this paper is to present on-orbit information that shows that ISS solar array placement with respect to the ISS velocity vector can control solar array plasma charging, and hence, provide an operational control for the plasma hazard. Also, this paper will present on-orbit information that shows that shunting of the ISS solar arrays can control solar array plasma charging, and hence, provide an additional operational control for the plasma hazard.

Alred, John↗

Cold Start of a Radiator Equipped with Titanium-Water Heat Pipes

Radiator panels utilizing titanium-water heat pipes are being considered for lunar applications. A traditional sandwich structure is envisioned where heat pipes are embedded between two high thermal conductivity face sheets. The heat pipe evaporators are to be thermally connected to the heat source through one or more manifolds containing coolant. Initial radiator operation on the lunar surface would likely follow a cold soak where the water in the heat pipes is purposely frozen. To achieve heat pipe operation, it will be necessary to thaw the heat pipes. One option is to allow the sunlight impinging on the surface at sunrise to achieve this goal. Testing was conducted in a thermal vacuum chamber to simulate the lunar sunrise and additional modeling was conducted to identify steady-state and transient response. It was found that sunlight impinging on the radiator surface at sunrise was insufficient to solely achieve the goal of thawing the water in the heat pipes. However, starting from a frozen condition was accomplished successfully by applying power to the evaporators. Start up in this fashion was demonstrated without evaporator dryout. Concern is raised over thawing thermosyphons, vertical heat pipes operating in a gravity field, with no wick in the condenser section. This paper presents the results of the simulated cold start study and identifies future work to support radiator panels equipped with titanium-water heat pipes.

Jaworske, Donald A.↗

Extreme High and Low Temperature Operation of the Silicon-On-Insulator Type CHT-OPA Operational Amplifier

A new operational amplifier chip based on silicon-on-insulator technology was evaluated for potential use in extreme temperature environments. The CHT-OPA device is a low power, precision operational amplifier with rail-to-rail output swing capability, and it is rated for operation between -55 C and +225 C. A unity gain inverting circuit was constructed utilizing the CHT-OPA chip and a few passive components. The circuit was evaluated in the temperature range from -190 C to +200 C in terms of signal gain and phase shift, and supply current. The investigations were carried out to determine suitability of this device for use in space exploration missions and aeronautic applications under wide temperature incursion. Re-restart capability at extreme temperatures, i.e. power switched on while the device was soaked at extreme temperatures, was also investigated. In addition, the effects of thermal cycling under a wide temperature range on the operation of this high performance amplifier were determined. The results from this work indicate that this silicon-on-insulator amplifier chip maintained very good operation between +200 C and -190 C. The limited thermal cycling had no effect on the performance of the amplifier, and it was able to re-start at both -190 C and +200 C. In addition, no physical degradation or packaging damage was introduced due to either extreme temperature exposure or thermal cycling. The good performance demonstrated by this silicon-on-insulator operational amplifier renders it a potential candidate for use in space exploration missions or other environments under extreme temperatures. Additional and more comprehensive characterization is, however, required to establish the reliability and suitability of such devices for long term use in extreme temperature applications.

Patterson, Richard↗

Thermal Analysis and Testing of Candidate Materials for PAIDAE Inflatable Aeroshell

The Program to Advance Inflatable-Decelerators for Atmospheric Entry (PAIDAE) is a NASA project tasked with developing and evaluating viable inflatable-decelerator aeroshell geometries and materials. Thermal analysis of material layups supporting an inflatable aeroshell was completed in order to identify expected material response, failure times, and to establish an experimental test matrix to keep barrier layer materials from reaching critical temperature limits during thermal soak. Material layups were then tested in the 8- foot High Temperature Tunnel (8'HTT), where they were subjected to hypersonic aerothermal heating conditions, similar to those expected for a Mars entry. This paper presents a broad overview of the thermal analysis supporting multiple materials, and layup configurations tested in the 8'HTT at flight conditions similar to those that would be experienced during Mars entry trajectories. Direct comparison of TPS samples tested in the 8'HTT verify that the thermal model accurately predicted temperature profiles when there are up to four materials in the test layup. As the number of material layers in each test layup increase (greater than 4), the accuracy of the prediction decreases significantly. The inaccuracy of the model predictions for layups with more than four material layers is believed to be a result of the contact resistance values used throughout the model being inaccurate. In addition, the harsh environment of the 8'HTT, including hot gas penetrating through the material layers, could also be a contributing factor.

DelCorso, Joseph A.↗

Astronaut Thermal Exposure: Re-Entry After Low Earth Orbit Rescue Mission

The STS-125 mission, launched May 11, 2009, is the final servicing mission to the Hubble Space Telescope. The repair mission's EVA tasks are described, including: installing a new wide field camera; installing the Cosmic Origins Spectrograph; repairing the Space Telescope Imaging Spectrograph; installing a new outer blanket layer; adding a Soft Capture and Rendezvous System for eventual controlled deorbit in about 2014; replacing the 'A' side Science Instrument Command and Data Handling module; repairing the Advanced Camera for surveys; and, replacing the rate sensor unit gyroscopes, fine guidance sensors and 3 batteries. Additionally, the Shuttle crew cabin thermal environment is described. A CFD model of per person CO2 demonstrates a discrepancy between crew breathing volume and general mid-deck levels of CO2. A follow-on CFD analysis of the mid-deck temperature distribution is provided. Procedural and engineering mitigation plans are presented to counteract thermal exposure upon reentry to the Earth atmosphere. Some of the procedures include: full cold soak the night prior to deorbit; modifying deck stowage to reduce interference with air flow; and early securing of avionics post-landing to reduce cabin thermal load prior to hatch opening. Engineering mitigation activities include modifying the location of the aft starboard ICUs, eliminating the X3 stack and eliminating ICU exhaust air directed onto astronauts; improved engineering data of ICU performance; and, verifying the adequacy of mid-deck temperature control using CFD models in addition to lumped parameter models. Post-mitigation CFD models of mid-deck temperature profiles and distribution are provided.

Gillis, David B.↗

Analytical Predictions of Thermal Stress in the Stardust PICA Heatshield Under Reentry Flight Conditions

We performed finite element analyses on a model of the Phenolic Impregnated Carbon Ablator (PICA) heatshield from the Stardust sample return capsule (SRC) to predict the thermal stresses in the PICA material during reentry. The heatshield on the Stardust SRC was a 0.83 m sphere cone, fabricated from a single piece of 5.82 cm-thick PICA. The heatshield performed successfully during Earth reentry of the SRC in January 2006. Material response analyses of the full, axisymmetric PICA heatshield were run using the Two-Dimensional Implicit Ablation, Pyrolysis, and Thermal Response Program (TITAN). Peak surface temperatures were predicted to be 3385K, while the temperature at the PICA backface remained at the estimated initial cold-soak temperature of 278K. Surface recession and temperature distribution results from TITAN, at several points in the reentry trajectory, were mapped onto an axisymmetric finite element model of the heatshield. We used the finite element model to predict the thermal stresses in the PICA from differential thermal expansion. The predicted peak compressive stress in the PICA heatshield was 1.38 MPa. Although this level of stress exceeded the chosen design limit for compressive stresses in PICA tiles for the design of the Orion crew exploration vehicle heatshield, the Stardust heatshield exhibited no obvious mechanical failures from thermal stress. The analyses of the Stardust heatshield were used to assess and adjust the level of conservatism in the finite element analyses in support of the Orion heatshield design.

Squire, Thomas↗

Wire and Cable Cold Bending Test

One of the factors in assessing the applicability of wire or cable on the lunar surface is its flexibility under extreme cold conditions. Existing wire specifications did not address their mechanical behavior under cold, cryogenic temperature conditions. Therefore tests were performed to provide this information. To assess this characteristic 35 different insulated wire and cable pieces were cold soaked in liquid nitrogen. The segments were then subjected to bending and the force was recorded. Any failure of the insulation or jacketing was also documented for each sample tested. The bending force tests were performed at room temperature to provide a comparison to the change in force needed to bend the samples due to the low temperature conditions. The results from the bending tests were plotted and showed how various types of insulated wire and cable responded to bending under cold conditions. These results were then used to estimate the torque needed to unroll the wire under these low temperature conditions.

Colozza, Anthony↗

Effects of Temperature on the Performance and Stability of Recent COTS Silicon Oscillators

Silicon oscillators have lately emerged to serve as potential replacement for crystal and ceramic resonators to provide timing and clock signals in electronic systems. These semiconductor-based devices, including those that are based on MEMS technology, are reported to be resistant to vibration and shock (an important criteria for systems to be deployed in space), immune to EMI, consume very low current, require few or no external components, and cover a wide range of frequency for analog and digital circuits. In this work, the performance of five recently-developed COTS silicon oscillator chips from different manufacturers was determined within a temperature range that extended beyond the individual specified range of operation. In addition, restart capability at extreme temperatures, i.e. power switched on while the device was soaking at extreme (hot or cold) temperature, and the effects of thermal cycling under a wide temperature range on the operation of these silicon oscillators were also investigated. Performance characterization of each oscillator was obtained in terms of its output frequency, duty cycle, rise and fall times, and supply current at specific test temperatures. The five different oscillators tested operated beyond their specified temperature region, with some displaying excellent stability throughout the whole test temperature range. Others experienced some instability at certain temperature test points as evidenced by fluctuation in the output frequency. Recovery from temperature-induced changes took place when excessive temperatures were removed. It should also be pointed out that all oscillators were able to restart at the extreme test temperatures and to withstand the limited thermal cycling without undergoing any significant changes in their characteristics. In addition, no physical damage was observed in the packaging material of any of these silicon oscillators due to extreme temperature exposure and thermal cycling. It is recommended that additional and more comprehensive testing under long term cycling be carried out to fully establish the reliability of these devices and to determine their suitability for use in space exploration missions under extreme temperature conditions.

Patterson, Richard L.↗

Higher Magnification Imaging of the Polished Aluminum Collector Returned from the Genesis Mission

The polished aluminum collector (previously referred to as the polished aluminum kidney) was intended for noble gas analysis for the Gene-sis mission. The aluminum collector, fabricated from alloy 6061T, was polished for flight with alumina, then diamond paste. Final cleaning was performed by soak-ing and rinsing with hexane, then isopropanol, and last-ly megasonically energized ultrapure water prior to installation. It was mounted inside the collector canister on the thermal shield at JSC in 2000. The polished aluminum collector was not surveyed microscopically prior to flight.

Rodriquez, Melissa C.↗

Assessment of CFD Hypersonic Turbulent Heating Rates for Space Shuttle Orbiter

Turbulent CFD codes are assessed for the prediction of convective heat transfer rates at turbulent, hypersonic conditions. Algebraic turbulence models are used within the DPLR and LAURA CFD codes. The benchmark heat transfer rates are derived from thermocouple measurements of the Space Shuttle orbiter Discovery windward tiles during the STS-119 and STS-128 entries. The thermocouples were located underneath the reaction-cured glass coating on the thermal protection tiles. Boundary layer transition flight experiments conducted during both of those entries promoted turbulent flow at unusually high Mach numbers, with the present analysis considering Mach 10{15. Similar prior comparisons of CFD predictions directly to the flight temperature measurements were unsatisfactory, showing diverging trends between prediction and measurement for Mach numbers greater than 11. In the prior work, surface temperatures and convective heat transfer rates had been assumed to be in radiative equilibrium. The present work employs a one-dimensional time-accurate conduction analysis to relate measured temperatures to surface heat transfer rates, removing heat soak lag from the flight data, in order to better assess the predictive accuracy of the numerical models. The turbulent CFD shows good agreement for turbulent fuselage flow up to Mach 13. But on the wing in the wake of the boundary layer trip, the inclusion of tile conduction effects does not explain the prior observed discrepancy in trends between simulation and experiment; the flight heat transfer measurements are roughly constant over Mach 11-15, versus an increasing trend with Mach number from the CFD.

Wood, William A.↗

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗

Semiautomated, Reproducible Batch Processing of Soy

A computer-controlled apparatus processes batches of soybeans into one or more of a variety of food products, under conditions that can be chosen by the user and reproduced from batch to batch. Examples of products include soy milk, tofu, okara (an insoluble protein and fiber byproduct of soy milk), and whey. Most processing steps take place without intervention by the user. This apparatus was developed for use in research on processing of soy. It is also a prototype of other soy-processing apparatuses for research, industrial, and home use. Prior soy-processing equipment includes household devices that automatically produce soy milk but do not automatically produce tofu. The designs of prior soy-processing equipment require users to manually transfer intermediate solid soy products and to press them manually and, hence, under conditions that are not consistent from batch to batch. Prior designs do not afford choices of processing conditions: Users cannot use previously developed soy-processing equipment to investigate the effects of variations of techniques used to produce soy milk (e.g., cold grinding, hot grinding, and pre-cook blanching) and of such process parameters as cooking times and temperatures, grinding times, soaking times and temperatures, rinsing conditions, and sizes of particles generated by grinding. In contrast, the present apparatus is amenable to such investigations. The apparatus (see figure) includes a processing tank and a jacketed holding or coagulation tank. The processing tank can be capped by either of two different heads and can contain either of two different insertable mesh baskets. The first head includes a grinding blade and heating elements. The second head includes an automated press piston. One mesh basket, designated the okara basket, has oblong holes with a size equivalent to about 40 mesh [40 openings per inch (.16 openings per centimeter)]. The second mesh basket, designated the tofu basket, has holes of 70 mesh [70 openings per inch (.28 openings per centimeter)] and is used in conjunction with the press-piston head. Supporting equipment includes a soy-milk heat exchanger for maintaining selected coagulation temperatures, a filter system for separating okara from other particulate matter and from soy milk, two pumps, and various thermocouples, flowmeters, level indicators, pressure sensors, valves, tubes, and sample ports

Thoerne, Mary↗

A Novel Tungsten-Nickel Alloy Ohmic Contact to SiC at 900 C

A novel tungsten-nickel ohmic contact metallization on 4H-SiC and 6H-SiC capable of surviving temperatures as high as 900 C is reported. Preliminary results revealed the following: 1) ohmic contact on n-type 4H-SiC having net doping levels (Nd's) of 1.4 and 2 x 10(exp 19) per cubic centimeter, with specific contact resistances rhosNd's of 7.69 x 10(exp -4) and 5.81 x 10(exp -4) OMEGA (raised dot) square centimeters, respectively, after rapid thermal annealing (RTA), and 5.9 x 10(exp -3) and 2.51 x 10(exp -4) OMEGA (raised dot) square centimeters, respectively, after subsequent soak at 900 C for 1 h in argon, and 2) ohmic contact on n- and p-type 6H-SiC having Nd > 2 x 10(exp 19) and Na > 1 x 10(exp 20) per cubic centimeter, with rhosNd = 5 x 10(exp -5) and rhosNa = 2 X 10(exp -4) OMEGA (raised dot) square centimeter, respectively, after RTA, and rhosNd = 2.5 x 10 (exp -5) and rhosNa = 1.5 x 10(exp -4) OMEGA (raised dot) square centimeter after subsequent treatment at 900 C for 1 h in argon, respectively.

Okojie, Robert S.↗

Detecting Conductive Liquid Leaking from Nonconductive Pipe

A method that can be implemented with relatively simple electronic circuitry provides a capability for detecting leakage of an electrically conductive liquid from an electrically nonconductive underground pipe. Alternatively or in addition, the method can be applied to locate the pipe, whether or not there is a leak. Although the method is subject to limitations (some of which are described below), it is still attractive as an additional option for detecting leaks and locating pipes without need for extensive digging. The method is based on capacitive coupling of an alternating electrical signal from the liquid to a portable electronic unit that resembles a metal detector. A signal voltage is applied to the liquid at some convenient point along the pipe: for example, the signal could be coupled into the liquid via an aboveground metal pipe fitting, the interior surface of which is in contact with the liquid. The signal is conducted through the liquid in the pipe; in the case of diffusive leak of liquid into the surrounding ground, the signal is conducted through the leak, into the portion of the adjacent ground that has become soaked with the liquid. (A drip leak cannot be detected by this method because there is no conductive path between the liquid inside and the liquid outside the pipe.) The portable unit includes an electrically conductive plate connected to the input terminal of an amplifier. When the plate is brought near the pipe or the leaked liquid, a small portion of the signal power is coupled capacitively from the liquid to the plate. The user scans the plate near the ground surface to find the locus of maximum signal strength. The leak can be identified as a relatively wide area, contiguous with the location of the pipe, over which the signal is detectable.

Youngquist, Robert C.↗

Impact Foam Testing for Multi-Mission Earth Entry Vehicle Applications

Multi-Mission Earth Entry Vehicles (MMEEVs) are blunt-body vehicles designed with the purpose of transporting payloads from outer space to the surface of the Earth. To achieve high-reliability and minimum weight, MMEEVs avoid use of limited-reliability systems, such as parachutes and retro-rockets, instead using built-in impact attenuators to absorb energy remaining at impact to meet landing loads requirements. The Multi-Mission Systems Analysis for Planetary Entry (M-SAPE) parametric design tool is used to facilitate the design of MMEEVs and develop the trade space. Testing was conducted to characterize the material properties of several candidate impact foam attenuators to enhance M-SAPE analysis. In the current effort, two different Rohacell foams were tested to determine their thermal conductivity in support of MMEEV design applications. These applications include thermal insulation during atmospheric entry, impact attenuation, and post-impact thermal insulation in support of thermal soak analysis. Results indicate that for these closed-cell foams, the effect of impact is limited on thermal conductivity due to the venting of the virgin material gas and subsequent ambient air replacement. Results also indicate that the effect of foam temperature is significant compared to data suggested by manufacturer's specifications.

Glaab, Louis J.↗

Arcjet Testing of Micro-Meteoroid Impacted Thermal Protection Materials

There are several harsh space environments that could affect thermal protection systems and in turn pose risks to the atmospheric entry vehicles. These environments include micrometeoroid impact, extreme cold temperatures, and ionizing radiation during deep space cruise, all followed by atmospheric entry heating. To mitigate these risks, different thermal protection material samples were subjected to multiple tests, including hyper velocity impact, cold soak, irradiation, and arcjet testing, at various NASA facilities that simulated these environments. The materials included a variety of honeycomb packed ablative materials as well as carbon-based non-ablative thermal protection systems. The present paper describes the results of the multiple test campaign with a focus on arcjet testing of thermal protection materials. The tests showed promising results for ablative materials. However, the carbon-based non-ablative system presented some concerns regarding the potential risks to an entry vehicle. This study provides valuable information regarding the capability of various thermal protection materials to withstand harsh space environments, which is critical to sample return and planetary entry missions.

Agrawal, Parul↗

Assessment of Ice Shape Roughness Using a Self-Orgainizing Map Approach

Self-organizing maps are neural-network techniques for representing noisy, multidimensional data aligned along a lower-dimensional and nonlinear manifold. For a large set of noisy data, each element of a finite set of codebook vectors is iteratively moved in the direction of the data closest to the winner codebook vector. Through successive iterations, the codebook vectors begin to align with the trends of the higher-dimensional data. Prior investigations of ice shapes have focused on using self-organizing maps to characterize mean ice forms. The Icing Research Branch has recently acquired a high resolution three dimensional scanner system capable of resolving ice shape surface roughness. A method is presented for the evaluation of surface roughness variations using high-resolution surface scans based on a self-organizing map representation of the mean ice shape. The new method is demonstrated for 1) an 18-in. NACA 23012 airfoil 2 AOA just after the initial ice coverage of the leading 5 of the suction surface of the airfoil, 2) a 21-in. NACA 0012 at 0AOA following coverage of the leading 10 of the airfoil surface, and 3) a cold-soaked 21-in.NACA 0012 airfoil without ice. The SOM method resulted in descriptions of the statistical coverage limits and a quantitative representation of early stages of ice roughness formation on the airfoils. Limitations of the SOM method are explored, and the uncertainty limits of the method are investigated using the non-iced NACA 0012 airfoil measurements.

Icing↗