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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.

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At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗
NASA NTRS1992

Environmental qualification testing of the prototype pool boiling experiment

The prototype Pool Boiling Experiment (PBE) flew on the STS-47 mission in September 1992. This report describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the prototype hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave the project team a wider latitude in determining which shuttle thermal altitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the project's laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗
NASA NTRS1993

Air Force Ni-Cd cell qualification program update

The generic qualification of aerospace nickel-cadmium cells is discussed. The test program includes the following: all available manufacturers, all available designs, cells from the previous program, and high and low orbit life cycling. It is the purpose of this program to characterize the beginning of life performance.

Hall, Steve↗
NASA NTRS1992

Transfer of training and simulator qualification or myth and folklore in helicopter simulation

Transfer of training studies at Fort Rucker using the backward-transfer paradigm have shown that existing flight simulators are not entirely adequate for meeting training requirements. Using an ab initio training research simulator, a simulation of the UH-1, training effectiveness ratios were developed. The data demonstrate it to be a cost-effective primary trainer. A simulator qualification method was suggested in which a combination of these transfer-of-training paradigms is used to determine overall simulator fidelity and training effectiveness.

Dohme, Jack↗
NASA NTRS1992

The past as prologue - A look at historical flight qualifications for space nuclear systems

Currently the U.S. is sponsoring production of radioisotope thermoelectric generators (RTGs) for the Cassini mission to Saturn; the SP-100 space nuclear reactor power system for NASA applications; a thermionic space reactor program for DoD applications as well as early work on nuclear propulsion. In an era of heightened public concern about having successful space ventures it is important that a full understanding be developed of what it means to 'flight qualify' a space nuclear system. As a contribution to the ongoing work this paper reviews several qualification programs, including the general-purpose heat source radioisotope thermoelectric generators (GPHS-RTGs) as developed for the Galileo and Ulysses missions, the SNAP-10A space reactor, the Nuclear Engine for Rocket Vehicle Applications (NERVA), the F-1 chemical engine used on the Saturn-V, and the Space Shuttle Main Engines (SSMEs). Similarities and contrasts are noted.

Gary L Bennett↗
NASA NTRS1993

Qualification test of the Ross Double Planetary Mixer

This test report describes the qualification test of the Ross Double Planetary Mixer used to mix room temperature vulcanized (RTV) silicone (Dow Corning 90-006-2) for the redesigned solid rocket motor (RSRM) nozzle joints. Testing was completed 18 June 1993 in the M-113A Nozzle Fabrication Facility at Thiokol Corporation, Space Operations, Brigham City, Utah. The Ross mixer provides better mixing and better control on temperature and humidity, resulting in better quality RTV and a longer usable pot life. The test began on 3 May 1993 and was stopped due to operator error during the tensile strength and elongation testing. Specimens were ruined without gathering any useful data. A 'no test' was declared, the problem was remedied, and the test was re-run with MSFC approval. The test was run and all pass/fail criteria were met, most with a considerable margin. The Ross Double Planetary Mixer met all certification objectives and is recommended for immediate use for mixing RTV silicone for RSRM nozzle joints.

Lueders, Kurt F.↗
NASA NTRS1993

RSRM nozzle actuator bracket/lug fracture mechanics qualification test

This is the final report for the actuator bracket/lug fracture mechanics qualification test. The test plan (CTP-0071) outlined a two-phase test program designed to answer questions about the fracture criticality of the redesigned solid rocket motor (RSRM) nozzle actuator bracket. An analysis conducted using the NASA/FLAGRO fracture mechanics computer program indicated that the actuator bracket might be a fracture critical component. In the NASA/FLAGRO analysis, a simple lug model was used to represent the actuator bracket. It was calculated that the bracket would fracture if subjected to an actuator stall load in the presence of a 0.10 in. corner crack at the actuator attachment hole. The 0.10 in. crack size corresponds to the nondestructive inspection detectability limit for the actuator bracket. The inspection method used is the dye penetrant method. The actuator stall load (103,424 lb) is the maximum load which the actuator bracket is required to withstand during motor operation. This testing was designed to establish the accuracy of the analytical model and to directly determine whether the actuator bracket is capable of meeting fracture mechanics safe-life requirements.

Kelley, Peggy↗
NASA NTRS1994

AF Ni-Cd cell qualification program

The present status of the USAF NiCd cell qualification program, which is underway at the Naval Surface Warfare Center-Crane Division, is summarized. The following topics are discussed: overview; background; purpose; stress tests; results for super Ni-Cd; results for SAFT cells; GPS stress test; GPS simulated orbit; and results for gates cells. The discussion is presented in viewgraph format.

Hall, Steve↗
NASA NTRS1994

Qualification test results for blue-red reflecting solar covers

Recent market forces and design innovations have spurred the development of solar cell covers that significantly reduce the solar absorptance for a cell array. GaAs cells, using Ge as the substrate host material, can have a significantly higher output if the solar absorptance of the cell array is reduced. New optical coating design techniques have allowed the construction of covers that reflect the ultraviolet energy (below 350 nm) and the near infrared energy (above 900 nm) resulting in the beneficial reduction in absorptance. Recent modeling suggests three or more present output increase due to the lowered temperature with such a device. Within the last several months we have completed the testing of production samples of these new covers in a qualification series that included the usual environmental effects associated with the routine testing of solar cell covers and the combined effects of protons, electrons and solar UV as would be encountered in space. For the combined effects testing the samples were exposed to 300 sun days equivalent UV, 5 x 10(exp 14)/sq cm of 0.5 MeV protons and 10(exp 15)/sq cm of 1.0 MeV electrons. Measurements of the reflectance, transmission, emittance and other appropriate parameters were made before and after the testing. As measured by the averaged transmission over the cell operating band, the change in transmission for the samples was less than or about equal to 1 percent. The details of the testing and the results in terms of transmission, reflectance and emittance are discussed in the paper.

Beauchamp, W. T.↗
NASA NTRS1995

A manual for pyrotechnic design, development and qualification

Although pyrotechnic devices have been singularly responsible for the success of many of the critical mechanical functions in aerospace programs for over 30 years, ground and in-flight failures continue to occur. Subsequent investigations reveal that little or no quantitative information is available on measuring the effects on performance of system variables or on determining functional margins. Pyrotechnics are considered to be readily available and, therefore, can be managed by any subsystem in which they are applied, such as structure, propulsion, electric power, or life support. The primary purpose of this manual is to alter the concept that the use of pyrotechnics is an art and refute 'justifications' that applications do not need to be understood by providing information on pyrotechnic design, development, and qualification on an engineering basis. Included are approaches to demonstrate functional reliability with less than 10 units, how to manage pyrotechnic-unique requirements, and methods to assure that the system is properly assembled and will perform the required tasks.

Bement, Laurence J.↗
NASA NTRS1995

Space qualification of IR-reflecting coverslides for GaAs solar cells

Improvements to GaAs solar array performance, from the use on solar cell coverslides of several reflecting coatings that reject unusable portions of the solar spectrum, are quantified. Blue-red-rejection (BRR) coverslides provide both infrared reflection (IRR) and ultraviolet rejection (UVR). BRR coverslides were compared to conventional antireflection (AR) and ultraviolet (UV) coated coverslides. A 2% improvement in peak-power output, relative to that from Ar-coated coverslides, is seen for cells utilizing BRR coverslides with the widest bandpass. Coverslide BRR-filter bandpass width and covered-solar-cell short-circuit current is a function of incident light angle and the observed narrower-bandpass filters are more sensitive to change in angle from the normal than are wide-bandpass filters. The first long-term (3000 hours) UV testing of unirradiated and 1 MeV electron-irradiated GaAs solar cells, with multilayer-coated coverslides to reduce solar array operating temperature, has indicated that all multilayer coatings on coverslides and solar cells will experience degradation from the space environment (UV and/or electrons). Five types of coverslide coatings, designed for GaAs solar cells, were tested as part of a NASA-sponsored space-flight qualification for BRR, multi-layer-coated, coverslides. The reponse to the different radiations varied with the coatings. The extent of degradation and its consequences on the solar cell electrical characteristics depend upon the coatings and the radiation. In some cases, an improved optical coupling was observed during long-term UV exposure to the optical stack. The benefits of multi-layered solar cell optics may depend upon both the duration and the radiation environment of a mission.

Meulenberg, Andrew↗
NASA NTRS1993

The Castor 120 (TM) Motor: Development and Qualification Testing Results

This paper discusses Thiokol Corporation's static test results for the development and qualification program of the Castor 120(TM) motor. The demonstration program began with a 25,000-pound motor to demonstrate the new technologies and processes that would be used on the larger Castor 120(TM) motor. The Castor 120(TM) motor was designed to be applicable as a first stage, second stage, or strap-on motor. Static test results from the Castor 25 and two Castor 120(TM) motors are discussed in this paper. The results verified the feasibility of tailoring the propellant grain configuration and nozzle throat diameter to meet various customer requirements. The first and second motors were conditioned successfully at ambient temperature and 28 F, respectively, to demonstrate that the design could handle a wide range of environmental launch conditions. Furthermore, the second Castor 120(TM) motor demonstrated a systems tunnel and forward skirt extension to verify flight-ready stage hardware. It is anticipated that the first flight motor will be ready by the fall of 1994.

Jack G Hilden↗
NASA NTRS1996

The design, development and qualification of a lightweight antenna pointing mechanism

This paper describes the design, development, and qualification of a new lightweight and compact Antenna Pointing Mechanism (APM). The APM was specially designed to meet the stringent mass, envelope, and environmental requirements of OFFEQ experimental satellite. During the development phase, some problems were encountered with the brushless DC motors, slip ring contact resistance, and bearing drag torque. All of these problems were resolved, and two APM units have been operating successfully in orbit since April, 1995.

Shmulevitz, M.↗
NASA NTRS1996

Space qualification of UV and IR reflecting coverslides for GaAs solar cells

As part of the space qualification effort for blue-red reflecting coverslides designed for use with GaAs solar cells, the first long-term (3000 hours) UV testing of unirradiated and 1 MeV electron-irradiated GaAs solar cells, with 4 types of multilayer-coated coverslides to reduce operating temperature, has produced some unexpected results. Important conclusions from this study, which includes two parallel tests, are as follows: (1) All of the GaAs solar cells with multilayer-coated coverslides display UV degradation. The laboratory data, extrapolated to 10 years in orbit, point to a significant loss mechanism from a combination of absorption and a reduction in optical match in such coatings from this portion of the space environment; (2) The effects of contamination in a vacuum system, on the measured degradation in solar-cell short-circuit current during a UV test, depend upon the type of coverslide coatings present on the coverslide surfaces. This has implications for both coated coverslides and optical solar reflectors (OSR's) in space; and (3) Because of the observed trends in this test and uncertainties in the extrapolation of data for multilayer coated coverslides, the use of any multilayer-coated coverslides for extended missions (greater than 1 year) cannot be recommended without prior flight testing.

Meulenberg, Andrew↗
NASA NTRS1994

Development and Qualification of Alternate Blowing Agents for Space Shuttle External Tank Thermal Protection System

The Aerospace industry has a long history of using low density polyurethane and polyurethane-modified isocyanurate foam systems as lightweight, low cost, easily processed cryogenic Thermal Protection Systems (TPS) for ascent vehicles. The Thermal Protection System of the Space Shuttle External Tank (ET) is required so that quality liquid cryogenic propellant can be supplied to the Orbiter main engines and to protect the metal structure of the tanks from becoming too hot from aerodynamic heating, hence preventing premature break-up of the tank. These foams are all blown with CFC-1 I blowing agent which has been identified by the Environmental Protection Agency (EPA) as an ozone depleting substance. CFCs will not be manufactured after 1995, Consequently, alternate blowing agent substances must be identified and implemented to assure continued ET manufacture and delivery. This paper describes the various testing performed to select and qualify HCFC-1 41 b as a near term drop-in replacement for CFC-11. Although originally intended to be a one for one substitution in the formulation, several technical issues were identified regarding material performance and processability which required both formulation changes and special processing considerations to overcome. In order to evaluate these material changes, each material was subjected to various tests to qualify them to meet the various loads imposed on them during long term storage, pre-launch operations, launch, separation and re-entry. Each material was tested for structural, thermal, aeroshear, and stress/strain loads for the various flight environments each encounters. Details of the development and qualification program and the resolution of specific problems are discussed in this paper.

Williams, Charles W.↗
NASA NTRS1997

High-Flux, High-Temperature Thermal Vacuum Qualification Testing of a Solar Receiver Aperture Shield

As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.

Kerslake, Thomas W.↗
NASA NTRS2000

LH2 Tank Composite Coverplate Development and Flight Qualification for the X-33

In this paper, the development history for the first cryogenic pressurized fuel tank coverplates is presented along with a synopsis of the development strategy and technologies which led to success on this program. Coverplates are the large access panels used to access launch vehicle fuel tanks. These structures incorporate all of the requirements for a pressure vessel as well as the added requirement to mount all of the miscellaneous access points required for a fuel management system. The first composite coverplates to meet the requirements for flight qualification were developed on the X-33 program. The X-33 composite coverplates went from an open requirement to successful finished flight hardware with multiple unique configurations, complete with verification testing, in less than eighteen months. Besides the rapid development schedule, these components introduced several new technologies previously unseen in cryogenic composites including solutions to cryogenic shrinkage, self-supporting sealing surfaces, and highly loaded composite bosses with precision sealing interfaces. These components were proven to seal liquid hydrogen at cryogenic temperatures under maximum loading and pressure conditions.

Wright, Richard J.↗