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Pressure measurements and gas flow analysis during thermal vacuum tests of manned spacecraft indicating adequate space vacuum simulation
An experimental study was conducted to evaluate different heating methods for thermal structural testing of large scale structures at temperatures up to 350 F as part of the High Speed Research program. The heating techniques evaluated included: radiative/convective, forced convective, and conductive. The radiative/convective heaters included finned strip heaters, and clear and frosted quartz lamps. The forced convective heating was accomplished by closed loop circulation of heated air. The conductive heater consisted of heating blankets. The tests were conducted on an 1/8 inch thick stainless steel plate in a custom-built oven. The criteria used for comparing the different heating methods included test specimen temperature uniformity, heater response time, and consumed power. The parameters investigated included air circulation in the oven, reflectance of oven walls, and the orientation of the test specimen and heaters (vertical and horizontal). It was found that reflectance of oven walls was not an important parameter. Air circulation was necessary to obtain uniform temperatures only for the vertically oriented specimen. Heating blankets provided unacceptably high temperature non-uniformities. Quartz lamps with internal air circulation had the lowest power consumption levels. Using frosted quartz lamps with closed loop circulation of cool air, and closed loop circulation of heated air provided the fastest response time.
Thermal barrier coatings (TBCs) are absolutely critical to the efficient and safe operation of gas turbine engines (GTEs). Manufacturing TBCs is a complex chemical, thermal and mechanical process that requires precise control. And yet, the variation in life of a TBC operated within a GTE is large. This variation ultimately reduces operational performance via a designed reduction to the turbine entry temperature, T4.This paper makes the case for developing advanced THz and sub-millimeter based nondestructive testing (NDT) techniques, capable of estimating when TBC components will fail. Such a technique could identify TBCs with low expected remaining useful lifetimes, directly after production. These TBCs could be re-manufactured, thereby not only improving their own expected useful life, but also the mean lifetime of the entire manufacturing population. A series of calculations demonstrates that TBCs with enhanced life characteristics can withstand higher T4 temperatures. Assuming that a GTE is to operate at a constant thrust, this increased temperature can be traded for a reduction in fuel flow. An analysis comparing fuel savings to manufacturing costs shows that substantial savings are achievable.
Future exploration missions require the development of a new liquid cooling garment (LCG) that offers greater system reliability, is more comfortable, and maximizes thermal performance. To inform the development of a future LCG a thermal performance test was conducted to evaluate three factors: (1) the effect of the thermal comfort undergarment (TCU) on tactile and thermal comfort, (2) the comparable thermal performance of an CSAFE developed engineering evaluation unit (EEU) LCG, which uses a commercial-off-the-shelf (COTS) wicking garment as the base, and (3) the performance of a torso or upper body only LCG configuration to evaluate a proposed auxiliary loop configuration. To evaluate the thermal performance of each configuration a metabolic suit test was conducted, utilizing suited subjects to generate metabolic heat by walking on a treadmill at various speeds. Three (3) test subjects of similar height and weight produced a metabolic load for five tests by either resting (300-600 BTU/hr), walking at a slow pace (1200 BTU/hr), and walking at a brisk pace (2200 BTU/hr). During the test, data was collected that would allow us to track the heat transfer to the LCG and ventilation system to determine the thermal performance of the LCG configurations. Four different test configurations were tested, with one configuration tested twice. The test results show that the CSAFE EEU LCG and EMU LCG had comparable performance. The testing also showed that an auxiliary loop LCG, sized similarly to the shirt-only configuration, should provide adequate cooling for contingency scenarios. Finally, the testing showed the previous analysis that assumed a UA deterioration from the TCU was too conservative and the TCU may prove to be acceptable for future development with additional analysis and testing.
The results are described of a series of current conduction tests with a thermal control blanket to which grounding straps have been attached. The material and the ground strap attachment procedure are described. The current conduction tests consisted of a surge current examination of the ground strap and a dilute flow, energetic electron deposition and transport through the bulk of the insulating film of this thermal blanket material. Both of these test procedures were used previously with thermal control blanket materials.
In June 2011, the multi-university sponsored Cosmic Ray Electron Synchrotron Telescope (CREST) has undergone thermal-vacuum qualification testing at the NASA Glenn Research Center (GRC), Plum Brook Station, Sandusky, Ohio. The testing was performed in the B-2 Space Propulsion Facility vacuum chamber. The CREST was later flown over the Antarctic region as the payload of a stratospheric balloon. Solar simulation was provided by a system of planar infrared lamp arrays specifically designed for CREST. The lamp arrays, in conjunction with a liquid-nitrogen-cooled cold wall, achieved the required thermal conditions for the qualification tests. The following slides accompanied the presentation of the report entitled Solar Simulation for the CREST Preflight Thermal-Vacuum Test at B-2, at the 27th Aerospace Testing Seminar, October 2012. The presentation described the test article, the test facility capability, the solar simulation requirements, the highlights of the engineering approach, and the results achieved. The presentation was intended to generate interest in the report and in the B-2 test facility.
Unusual requirements for the Pressure Distribution/Air Data System (PD/ADS) transducer thermal vacuum testing led to the development of a conductively heated and cooled, fully automated, bell-jar test system. The system has proven to be easily adaptable for other tests and offers the advantages of quick turn-around and low operational cost.
The research testing and demonstration of new bulk-fill materials for cryogenic thermal insulation systems was performed by the Cryogenics Test Laboratory at NASA Kennedy Space Center. Thermal conductivity testing under actual-use cryogenic conditions is a key to understanding the total system performance encompassing engineering, economics, and materials factors. A number of bulk fill insulation materials, including aerogel beads, glass bubbles, and perlite powder, were tested using a new cylindrical cryostat. Boundary temperatures for the liquid nitrogen boil-off method were 293 K and 78 K. Tests were performed as a function of cold vacuum pressure from high vacuum to no vacuum conditions. Results are compared with other complementary test methods in the range of 300 K to 20 K. Various testing techniques are shown to be required to obtain a complete understanding of the operating performance of a material and to provide data for answers to design engineering questions.
Outline: Background of ISS (International Space Station) Material Science Research Rack; NASA SCA (Sample Cartridge Assembly) Design; GEDS (Gravitational Effects in Distortion in Sintering) Experiment Ampoule Design; Development Testing Summary; Thermal Modeling and Analysis. Summary: GEDS design development challenging (GEDS Ampoule design developed through MUGS (Microgravity) testing; Short duration transient sample processing; Unable to measure sample temperatures); MUGS Development testing used to gather data (Actual LGF (Low Gradient Furnace)-like furnace response; Provided sample for sintering evaluation); Transient thermal model integral to successful GEDS experiment (Development testing provided furnace response; PI (Performance Indicator) evaluation of sintering anchored model evaluation of processing durations; Thermal transient model used to determine flight SCA sample processing profiles).
The primary objective of this study was to simulate lunar thermal environments to qualify a modified Commercial-Off-The-Shelf (COTS) camera for potential flight applications. A comprehensive testing regimen was developed, including both vacuum and thermal vacuum testing. The tests subjected the camera to temperatures corresponding to expected extrema, and thermal performance was recorded throughout the process. The testing demonstrated that both the camera and its thermal protection systems were able to maintain operational functionality under most of the simulated conditions. The results of the testing indicate that the implemented thermal protection system is effective for the expected lunar environments. Despite the decrease in operational time in comparison with terrestrial usage, the camera's overall performance supports its suitability for use in both flight and lunar missions.
A contact heat exchanger concept is being developed for use onboard Space Station as an interface device between external thermal bus and pressurized modules. The concept relies on mechanical contact activated by the fluid pressure inside thin-walled tubes. Structural testings were carried out to confirm the technology feasibility of using such thin-walled tubes. The test results also verified the linear elastic stress analysis which was used to predict the tube mechanical behaviors. A preliminary thermal testing was also performed with liquid Freon-11 flowing inside tubes and heat being supplied by electrical heating from the bottom of the contact heat exchanger baseplate. The test results showed excellent agreement of test data with analytical prediction for all thermal resistances except for the two-phase flow characteristics. Testing with two-phase flow inside tubes will, however, be performed on the NASA-JSC test bed.
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In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.
In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.
The test procedure used and the results obtained from an evaluation test program conducted to obtain thermal performance data on a Sunworks single glazed air solar collector under simulated conditions are described. A time constant test and incident angle modifier test were conducted to determine the transient effect and the incident angle effect on the collector. These results and the results of the collector load test are also discussed.
The test procedure used and the results obtained from an evaluation test program, conducted to obtain thermal performance data on a Solaron double glazed air solar collector under simulated conditions in a solar simulator are described. A time constant test and incident angle modifier test were also conducted to determine the transient effect and the incident angle effect on the collector. These results and the results of the collector load test are also discussed. The Solaron collector absorber plate is made of 24-gage steel, the coating is baked-on black paint, the cover consists of two sheets of 1/8-inch low-iron tempered glass, and the insulation is one thickness of 3 5/8-inch fiberglass batting.
The PATCOOL is a NASA sponsored, University of Florida developed 3U Cu-beSat meant to investigate the feasibility of using a cryogenic selective surface coating as a new, more efficient way of passively cooling components in space. Initial tests on the ground demonstrate that this coating should provide a much higher reflectance of the Sun’s irradiant power than any existing coating, while still providing far-infrared power emission. The ultimate validation of this tech-nology requires on-orbit testing. PATCOOL hosts a 4-sample housing, with the samples shaped as thin cylinders (coin-like). Two samples are coated with state-of-the-art material, while the other pair uses the new coating to be evaluated. The temperatures of all samples during the mission (minimum 72 hours of data col-lection) are measured via thermistors. The samples are connected via thin Kevlar strings to the housing, to minimize heat transfer. The housing is designed to shield the samples from Earth’s thermal radiation, and the CubeSat is attitude stabilized and controlled via a gravity gradient boom, magnetorquers and a reaction wheel set. Thermal Desktop simulations show PATCOOL’s ability to thermally isolate the samples from heat exchanges other than with Sun and deep space, thanks to its thermal design and the chosen attitude profile.