Analysis of Spacecraft Failures During Thermal-Vacuum Testing
Environmental testing - analysis of spacecraft failures during thermal vacuum testing - quality assurance and spacecraft reliability
SPACECRAFT RELIABILITY↗
SEARCH · Search NASA
Results for “Test and analysis”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Pre-Launch Analysis and Test of the Ocean Color Instrument Modulation Transfer Function
Launched in February 2024, the Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. The Ocean Color Instrument (OCI) is the primary instrument supporting PACE by collecting accurate radiometric data of the Earth by observing the top of atmosphere reflectance and is a combination hyperspectral (ultra-violet to near infrared) / multiband imager (shortwave infrared). An important aspect of the radiometry is the ability of OCI to resolve contrast from scene to scene to achieve data accuracy requirements. This paper reviews the analysis that was performed to verify the modulation transfer function requirement levied against the instrument and presents the supportive test data collected during pre-launch instrument testing to supplement the analysis. The requirements levied against OCI drove to a 1.2 km2 ground resolution leading to a Nyquist period of 2.4 km (0.417 cycles / km). The analysis is comprehensive with incorporation of as many contributors as practical to provide the clearest possible picture of the margin against requirements. The analysis provided input for additional design trade studies and insight into the aspects of the design that required the most attention during the implementation phase. We describe four separate MTF contributor networks based on the instrument design and mutual exclusivity of contributing factors. The various networks represent the hyperspectral and multiband detection systems separately as well as the along track and cross track imaging dimensions. Ground-test was performed against the MTF primary contributors and the results were used to validate the analysis as will be presented here.
OCI↗
Pre-Launch Analysis and Test of the Ocean Color Instrument Modulation Transfer Function
Launched in February 2024, the Plankton, Aerosol, Cloud, and ocean Ecosystem (PACE) mission represents NASA’s next investment in ocean biology, clouds, and aerosol data records. The Ocean Color Instrument (OCI) is the primary instrument supporting PACE by collecting accurate radiometric data of the Earth by observing the top of atmosphere reflectance and is a combination hyperspectral (ultra-violet to near infrared) / multiband imager (shortwave infrared). An important aspect of the radiometry is the ability of OCI to resolve contrast from scene to scene to achieve data accuracy requirements. This paper reviews the analysis that was performed to verify the modulation transfer function requirement levied against the instrument and presents the supportive test data collected during pre-launch instrument testing to supplement the analysis. The requirements levied against OCI drove to a 1.2 km2 ground resolution leading to a Nyquist period of 2.4 km (0.417 cycles / km). The analysis is comprehensive with incorporation of as many contributors as practical to provide the clearest possible picture of the margin against requirements. The analysis provided input for additional design trade studies and insight into the aspects of the design that required the most attention during the implementation phase. We describe four separate MTF contributor networks based on the instrument design and mutual exclusivity of contributing factors. The various networks represent the hyperspectral and multiband detection systems separately as well as the along track and cross track imaging dimensions. Ground-test was performed against the MTF primary contributors and the results were used to validate the analysis as will be presented here.
OCI↗
Thermal Analysis and Testing of Fastrac Gas Generator Design
The Fastrac Engine is being developed by the Marshall Space Flight Center (MSFC) to help meet the goal of substantially reducing the cost of access to space. This engine relies on a simple gas-generator cycle, which burns a small amount of RP-1 and oxygen to provide gas to drive the turbine and then exhausts the spent fuel. The Fastrac program envisions a combination of analysis, design and hot-fire evaluation testing. This paper provides the supporting thermal analysis of the gas generator design. In order to ensure that the design objectives were met, the evaluation tests have started on a component level and a total of 15 tests of different durations were completed to date at MSFC. The correlated thermal model results will also be compared against hot-fire thermocouple data gathered.
Nguyen, H.↗
Application of Molecular Adsorber Coatings in Chamber A for the James Webb Space Telescope
As a coating made of highly porous zeolite materials, the Molecular Adsorber Coating (MAC) was developed to capture outgassed molecular contaminants, such as hydrocarbons and silicones. For spaceflight applications, the adsorptive capabilities of the coating can alleviate on-orbit outgassing concerns on or near sensitive surfaces and instruments within the spacecraft. Similarly, this sprayable paint technology has proven to be significantly beneficial for ground-based space applications, in particular, for vacuum chamber environments. This presentation describes the application of the MAC technology for the James Webb Space Telescope (JWST) at NASA Johnson Space Center (JSC). The coating was used as a mitigation tool to entrap outgassed contaminants, specifically silicone-based diffusion pump oil, from within JSCs cryogenic optical vacuum chamber test facility called Chamber A. This presentation summarizes the background, fabrication, installation, chemical analysis test results, and future plans for the MAC technology, which was effectively used to protect the JWST test equipment from vacuum chamber contamination. As a coating made of highly porous zeolite materials, the Molecular Adsorber Coating (MAC) was developed to capture outgassed molecular contaminants, such as hydrocarbons and silicones. For spaceflight applications, the adsorptive capabilities of the coating can alleviate on-orbit outgassing concerns on or near sensitive surfaces and instruments within the spacecraft. Similarly, this sprayable paint technology has proven to be significantly beneficial for ground-based space applications, in particular, for vacuum chamber environments. This presentation describes the application of the MAC technology for the James Webb Space Telescope (JWST) at NASA Johnson Space Center (JSC). The coating was used as a mitigation tool to entrap outgassed contaminants, specifically silicone-based diffusion pump oil, from within JSCs cryogenic optical vacuum chamber test facility called Chamber A. This presentation summarizes the background, fabrication, installation, chemical analysis test results, and future plans for the MAC technology, which was effectively used to protect the JWST test equipment from vacuum chamber contamination.
molecular contamination↗
Post-test navigation data analysis techniques for the shuttle ALT
Postflight test analysis data processing techniques for shuttle approach and landing tests (ALT) navigation data are defined. Postfight test processor requirements are described along with operational and design requirements, data input requirements, and software test requirements. The postflight test data processing is described based on the natural test sequence: quick-look analysis, postflight navigation processing, and error isolation processing. Emphasis is placed on the tradeoffs that must remain open and subject to analysis until final definition is achieved in the shuttle data processing system and the overall ALT plan. A development plan for the implementation of the ALT postflight test navigation data processing system is presented. Conclusions are presented.
Source record↗
A Frequency-Domain Substructure System Identification Algorithm
A new frequency-domain system identification algorithm is presented for system identification of substructures, such as payloads to be flown aboard the Space Shuttle. In the vibration test, all interface degrees of freedom where the substructure is connected to the carrier structure are either subjected to active excitation or are supported by a test stand with the reaction forces measured. The measured frequency-response data is used to obtain a linear, viscous-damped model with all interface-degree of freedom entries included. This model can then be used to validate analytical substructure models. This procedure makes it possible to obtain not only the fixed-interface modal data associated with a Craig-Bampton substructure model, but also the data associated with constraint modes. With this proposed algorithm, multiple-boundary-condition tests are not required, and test-stand dynamics is accounted for without requiring a separate modal test or finite element modeling of the test stand. Numerical simulations are used in examining the algorithm's ability to estimate valid reduced-order structural models. The algorithm's performance when frequency-response data covering narrow and broad frequency bandwidths is used as input is explored. Its performance when noise is added to the frequency-response data and the use of different least squares solution techniques are also examined. The identified reduced-order models are also compared for accuracy with other test-analysis models and a formulation for a Craig-Bampton test-analysis model is also presented.
Blades, Eric L.↗
Design, analysis, and testing of high frequency passively damped struts
Objectives of the research are: (1) to develop design requirements for damped struts to stabilize control system in the high frequency cross-over and spill-over range; (2) to design, fabricate and test viscously damped strut and viscoelastically damped strut; (3) to verify accuracy of design and analysis methodology of damped struts; and (4) to design and build test apparatus, and develop data reduction algorithm to measure strut complex stiffness. In order to meet the stringent performance requirements of the SPICE experiment, the active control system is used to suppress the dynamic responses of the low order structural modes. However, the control system also inadvertently drives some of the higher order modes unstable in the cross-over and spill-over frequency range. Passive damping is a reliable and effective way to provide damping to stabilize the control system. It also improves the robustness of the control system. Damping is designed into the SPICE testbed as an integral part of the control-structure technology.
Yiu, Y. C.↗
Drop testing and analysis of six-foot diameter graphite-epoxy frames
Graphite-epoxy frames were drop tested onto a concrete floor to simulate crash loadings. The frames have Z-shaped cross-sections typical of designs often proposed for fuselage structure of advanced composite transports. The 6-foot diameter of the frames was chosen to reduce specimen fabrication costs and to facilitate testing. Response of the frames from accelerometer, strain gage, and photographic measurements are presented which characterize the behavior under 25-30 fps vertical impact velocity onto concrete. Failure of the graphite-epoxy frames involved a complete separation through the cross section near the impact point. All damage to the composite frame was confined to an area close to the impact point. Failure of aluminum frames tested for comparison were different from the composite specimens. The aluminum frames yielded (plastic hinges formed) at several locations around the lower portion of the frame without failing completely across the section.
Boitnott, R. L.↗
Stability test and analysis of the Space Shuttle Primary Reaction Control Subsystem thruster
The results are reported of a test program conducted on the Space Shuttle Primary Reaction Control Subsystem thruster in order to investigate the effects of trapped helium bubbles and saturated propellants on stability, determine if thruster-to-thruster stability variations are significant, and determine stability under STS-representative conditions. It is concluded that the thruster design is highly reliable in flight and that burn-through has not occurred. Significantly unstable thrusters are screened out, and wire wrap is found to protect against chamber burn-throughs and to provide a fail-safe thruster for this situation.
Applewhite, John↗
An accurate nonlinear finite element analysis and test correlation of a stiffened composite wing panel
State-of-the-art nonlinear finite element analysis techniques are evaluated by applying them to a realistic aircraft structural component. A wing panel from the V-22 tiltrotor aircraft is chosen because it is a typical modern aircraft structural component for which there is experimental data for comparison of results. From blueprints and drawings, a very detailed finite element model containing 2284 9-node Assumed Natural-Coordinate Strain elements was generated. A novel solution strategy which accounts for geometric nonlinearity through the use of corotating element reference frames and nonlinear strain-displacement relations is used to analyze this detailed model. Results from linear analyses using the same finite element model are presented in order to illustrate the advantages and costs of the nonlinear analysis as compared with the more traditional linear analysis.
Davis, D. D., Jr.↗
Multilayer Pressure Vessel Materials Testing and Analysis
To provide NASA a comprehensive suite of materials strength, fracture toughness and crack growth rate test results for use in remaining life calculations for aging multilayer pressure vessels, Southwest Research Institute (R) (SwRI) was contracted in two phases to obtain relevant material property data from a representative vessel. This report describes Phase 1 of this effort which includes a preliminary material property assessment as well as a fractographic, fracture mechanics and fatigue crack growth analyses of an induced flaw in the outer shell of a representative multilayer vessel that was subjected to cyclic pressure test. SwRI performed this Phase 1 effort under contract to the Digital Wave Corporation in support of their contract to Jacobs ATOM for the NASA Ames Research Center.
Cardinal, Joseph W.↗
Development Testing and Analysis of the Integrated Gateway-ESPRIT Bipropellant Refuelling System
The Gateway will be humanity’s first space station orbiting the Moon completed by NASA in partnership with ESA and other US and international partners. The Gateway will provide critical support to sustainable human exploration on the moon through the Artemis program. To enable the Lunar Gateway to complete its mission, on orbit refuelling is essential. The ESPRIT Refuelling Module (ERM) will provide the capability to transfer propellants, MMH and MON-3, through the Habitation and Logistics Outpost (HALO) to the Power and Propulsion Element (PPE). The transfer of these propellants carries known risks and hazards. These hazards include overpressure of the propellant lines during priming sequences between modules and during refuelling pause operations. To support the early system development and to mitigate these risks, a collaborative test program between NASA, ESA and Thales Alenia Space was completed at the Thales Alenia Space test facility in Harwell, UK. This test program integrated fluidic breadboards of the ERM, HALO and PPE modules. The objectives of the test program were to demonstrate and characterise critical performance and transient operations, inform refuelling concept of operations and to calibrate and validate numerical models of the refuelling subsystem in EcosimPro. To support the completion of this final objective a detailed model of the integrated breadboard was developed in EcosimPro and key steady-state and transient test cases were simulated. As an industry first, a National Institute of Standards and Technology (NIST) database correlation for Hydrofluoroether (HFE-7000) was used as a mixed oxides of nitrogen (MON-3) simulant with EcosimPro and European Space Propulsion System Simulation (ESPSS) libraries to result in a more accurate analysis for transient phenomenon such as priming. The test and simulation data showed good agreement validating the model for further system analysis as the ERM design progresses.
Refuelling↗
Analysis and Test Correlation of Proof of Concept Box for Blended Wing Body-Low Speed Vehicle
The Low Speed Vehicle (LSV) is a 14.2% scale remotely piloted vehicle of the revolutionary Blended Wing Body concept. The design of the LSV includes an all composite airframe. Due to internal manufacturing capability restrictions, room temperature layups were necessary. An extensive materials testing and manufacturing process development effort was underwent to establish a process that would achieve the high modulus/low weight properties required to meet the design requirements. The analysis process involved a loads development effort that incorporated aero loads to determine internal forces that could be applied to a traditional FEM of the vehicle and to conduct detailed component analyses. A new tool, Hypersizer, was added to the design process to address various composite failure modes and to optimize the skin panel thickness of the upper and lower skins for the vehicle. The analysis required an iterative approach as material properties were continually changing. As a part of the material characterization effort, test articles, including a proof of concept wing box and a full-scale wing, were fabricated. The proof of concept box was fabricated based on very preliminary material studies and tested in bending, torsion, and shear. The box was then tested to failure under shear. The proof of concept box was also analyzed using Nastran and Hypersizer. The results of both analyses were scaled to determine the predicted failure load. The test results were compared to both the Nastran and Hypersizer analytical predictions. The actual failure occurred at 899 lbs. The failure was predicted at 1167 lbs based on the Nastran analysis. The Hypersizer analysis predicted a lower failure load of 960 lbs. The Nastran analysis alone was not sufficient to predict the failure load because it does not identify local composite failure modes. This analysis has traditionally been done using closed form solutions. Although Hypersizer is typically used as an optimizer for the design process, the failure prediction was used to help gain acceptance and confidence in this new tool. The correlated models and process were to be used to analyze the full BWB-LSV airframe design. The analysis and correlation with test results of the proof of concept box is presented here, including the comparison of the Nastran and Hypersizer results.
Spellman, Regina L.↗
Analysis and test of a space truss foldable hinge
The Mini-Mast is a 20-meter long deployable, three-longeron, truss-beam being used to develop analytical and experimental methods for predicting the physical behavior of large space structures. With 57 corner-body hinges and 54 mid-body hinges, the Mini-Mast is highly joint-dominated, necessitating inclusion of the compliance of the joints in analytical models. This study demonstrates an approach for calculating the stiffness properties of a complicated hinge called the mid-body hinge. The process includes detailed modeling with solid-body modeling software and the use of finite element analysis. Load-deflection tests were conducted to determine the axial stiffness of the mid-body hinge. This is compared to the axial stiffness value determined from a finite element analysis.
Nimmo, N. A.↗
Cube corner retroreflector test and analysis
Cube corner retroreflectors with nominal dihedral angles of 90 deg 0 min 1.5 sec were fabricated, tested, and analyzed to determine the return energy in the annular ring of the far field diffraction pattern required by the Laser Geodynamic Satellite. Performance was assessed for variations in the dihedral angles, optical surfaces, and thermal environment. Despite relatively high independent axial and radial sensitivities, the changes caused by the anticipated thermal environment were found to be negligible; however, there were substantial variations between the analytical predictions and measured performance.-
Zurasky, J. L.↗
Shuttle environmental and thermal control/life support system computer program
Computer programs developed to simulate the RSECS (representative shuttle environmental control system) are described. These programs were prepared to provide pretest predictions, post-test analysis and real-time problem analysis for RSECS test planning and evaluation. These programs are on a magnetic tape cassette and on a disc device that is part of the WANG-2200 series computer system.
Elfers, F. A.↗
Failure analysis of electronic parts: Laboratory methods
Failure analysis test methods are presented for use in analyzing candidate electronic parts and in improving future design reliability. Each test is classified as nondestructive, semidestructive, or destructive. The effects upon applicable part types (i.e. integrated circuit, transitor) are discussed. Methodology is given for performing the following: immersion tests, radio graphic tests, dewpoint tests, gas ambient analysis, cross sectioning, and ultraviolet examination.
Anstead, R. J.↗