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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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NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shock-shock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates a r e highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗

NASA NTRS1997

Reduction of ETS-VI Laser Communication Equipment Optical-Downlink Telemetry Collected During GOLD

Free-space laser communications experiments were conducted between the laser communication equipment (LCE) on board the Japanese Engineering Test Satellite VI (ETS-VI) and the ground station located at the Table Mountain Facility (TMF) during late 1995 and early 1996. This article describes the on-line data reduction process used to decode LCE telemetry (called E2) downlinked on the optical carrier during the Ground/Orbiter Lasercomm Demonstration (GOLD) experiments. The LCE has the capability of transmitting real-time sensor and status information at 128 kbps by modulating the onboard diode laser. The optical downlink was detected on the ground, bit synchronized, and the resulting data stream stored on a data recorder. The recorded data were subsequently decoded by on-line data processing that included cross-correlation of the known telemetry data format and the downlink data stream. Signals obtained from the processing can be useful not only in evaluating the characteristics of the LCE but also in understanding uplink and downlink signal quality.

Toyoshima, M.↗

NASA NTRS1996

Preliminary Results of the Ground/Orbiter Lasercomm Demonstration Experiment between Table Mountain and teh ETS-V1 Satellite

The Ground/Orbiter Lasercomm Demonstration (GOLD) is an optical communications demonstration between the Japanese Engineering Test Satellite (ETS-V1) and an optical ground transmitting and receiving station at the Table Mountain FAcility in Wrightwood California. Laser transmissions to the satellite are performed approximately four hours every third night when the satellite is at apogee above Table Mountain.

optical communications 2-way optical communication↗

NASA NTRS1996

Preliminary Results, Analysis and Overview of Part -1 of the GOLD Experiment

The Ground/Orbiter Lasercomm Demonstration (GOLD) is an optical communications demonstration between Japanese Engineering Test Satellite (ETS-V1) and an optical ground transmitting and receiving station at the Table Mountain Facility in Wrightwood California. Laser transmissions to the satellite were performed approximately four hours every third night when the satellite was at above Table Mountain.

GOLD ETS-V1 Table Mountain Facility optical commun↗

NASA NTRS1996

Preliminary Results, Analysis, and Overview of Part-1 of the GOLD Experiment

The Ground/Orbiter Lasercomm Demonstration (GOLD) is an optical communications demonstraton between the Japanese Engineering Test Satellite (ETS-VI) and an optical ground transmitting and receiving station at the Table Mountain Facility. GOLD was an experiment that demonstrated real-time international collaboration.

optical communications ETS-VI GOLD Table Mountain ↗

NASA NTRS2007

Development of Supersonic Combustion Experiments for CFD Modeling

This paper describes the development of an experiment to acquire data for developing and validating computational fluid dynamics (CFD) models for turbulence in supersonic combusting flows. The intent is that the flow field would be simple yet relevant to flows within hypersonic air-breathing engine combustors undergoing testing in vitiated-air ground-testing facilities. Specifically, it describes development of laboratory-scale hardware to produce a supersonic combusting coaxial jet, discusses design calculations, operability and types of flames observed. These flames are studied using the dual-pump coherent anti- Stokes Raman spectroscopy (CARS) - interferometric Rayleigh scattering (IRS) technique. This technique simultaneously and instantaneously measures temperature, composition, and velocity in the flow, from which many of the important turbulence statistics can be found. Some preliminary CARS data are presented.

Baurle, Robert↗

NASA NTRS2011

Performance Characterization of Loctite (Registered Trademark) 242 and 271 Liquid Locking Compounds (LLCs) as a Secondary Locking Feature for International Space Station (ISS) Fasteners

Several International Space Station (ISS) hardware components use Loctite (and other polymer based liquid locking compounds (LLCs)) as a means of meeting the secondary (redundant) locking feature requirement for fasteners. The primary locking method is the fastener preload, with the application of the Loctite compound which when cured is intended to resist preload reduction. The reliability of these compounds has been questioned due to a number of failures during ground testing. The ISS Program Manager requested the NASA Engineering and Safety Center (NESC) to characterize and quantify sensitivities of Loctite being used as a secondary locking feature. The findings and recommendations provided in this investigation apply to the anaerobic LLCs Loctite 242 and 271. No other anaerobic LLCs were evaluated for this investigation. This document contains the findings and recommendations of the NESC investigation

Dube, Michael J.↗

NASA NTRSDate not supplied

Launching and Deploying the James Webb Space Telescope

On December 25, 2021, at 12:20 UTC, the James Webb Space Telescope lifted off and onward to its destination in orbit at the second Lagrange point. With more than two decades in development, and an international collaboration between NASA, CSA, and ESA, Webb is one of the most anticipated science missions ever launched. After a dramatic and flawless launch, Webb's toughest and riskiest days lie ahead. Unprecedented in its complexity and ambition, over the next two weeks Webb would undergo the most complex on-orbit deployment sequence ever attempted, with any single deployment anomaly carrying the risk of full mission failure. An exquisite design, years of ground testing, a exhaustively trained and rehearsed operations and engineering team, and an unprecedented level of contingency planning, all resulted in a fully and successfully deployed Webb observatory, on its way to L2, and nominally cooling to its cryogenic temperatures. Although Webb still had many more months of commissioning left, there was a collective sigh of relief heard round the world. This incredible achievement was not by chance but was years in the making. We go behind the scenes of Webb's first month on orbit, starting with the unique and challenging launch itself, the time criticality of its mid-course corrections, and a summary of nearly 14 days to undergo nearly 50 major deployments. We discuss what went better than planned and how years of robust and detailed contingency planning were prepared for unanticipated events and on-orbit spacecraft behavior. And finally, we provide a brief overview of the entire commissioning process which successfully completed on July 10th, 2022.

Keith A Parrish↗

NASA NTRS2014

PSL Icing Facility Upgrade Overview

The NASA Glenn Research Center Propulsion Systems Lab (PSL) was recently upgraded to perform engine inlet ice crystal testing in an altitude environment. The system installed 10 spray bars in the inlet plenum for ice crystal generation using 222 spray nozzles. As an altitude test chamber, the PSL is capable of simulating icing events at altitude in a groundtest facility. The system was designed to operate at altitudes from 4,000 to 40,000 ft at Mach numbers up to 0.8M and inlet total temperatures from -60 to +15 degF. This paper and presentation will be part of a series of presentations on PSL Icing and will cover the development of the icing capability through design, developmental testing, installation, initial calibration, and validation engine testing. Information will be presented on the design criteria and process, spray bar developmental testing at Cox and Co., system capabilities, and initial calibration and engine validation test. The PSL icing system was designed to provide NASA and the icing community with a facility that could be used for research studies of engine icing by duplicating in-flight events in a controlled ground-test facility. With the system and the altitude chamber we can produce flight conditions and cloud environments to simulate those encountered in flight. The icing system can be controlled to set various cloud uniformities, droplet median volumetric diameter (MVD), and icing water content (IWC) through a wide variety of conditions. The PSL chamber can set altitudes, Mach numbers, and temperatures of interest to the icing community and also has the instrumentation capability of measuring engine performance during icing testing. PSL last year completed the calibration and initial engine validation of the facility utilizing a Honeywell ALF502-R5 engine and has duplicated in-flight roll back conditions experienced during flight testing. This paper will summarize the modifications and buildup of the facility to accomplish these tests.

Griffin, Thomas A.↗

NASA NTRSDate not supplied

Surface Systems Capability Gaps for Enabling NASA’s Sustainable Lunar Operations

This paper discusses the NASA Ground, Test, and Surface Systems Taxonomy (TX-13) related capability gaps, including details of architecture, technology, engineering, and policy gaps for enabling sustainable lunar surface operations and subsequent Mars missions. Architecture gaps include standardized architectures and interfaces, multi-element systems engineering and integration, design for supportability, and nuclear payload processing and launch approach. Technology gaps, primarily focused on uncrewed surface operations, include automated/autonomous cryogenic loading, transfer, servicing, and storage of commodities; health determination and fault management; automated/autonomous planning and scheduling; automated/autonomous inspection, maintenance and repair; logistics management and reliability; launch and landing site preparation; commodity management; and advanced umbilicals and dust tolerant interfaces. Engineering gaps include high-purity propellant production for ground and surface applications and large-scale xenon servicing capabilities. The policy gap includes nuclear propulsion acceptance testing and qualification approach. Strategically identifying human/automation roles and tasks and infusing automation and autonomy practices early in a system’s lifecycle is essential for achieving the mission objectives for a sustainable human lunar presence, improving performance and mission effectiveness, reducing operations costs and reliance on humans to perform tasks, and accommodating ground communication delays.

Surface Systems↗

NASA NTRS1999

A Synopsis of Ion Propulsion Development Projects in the United States: SERT 1 to Deep Space I

The historical background and characteristics of the experimental flights of ion propulsion systems and the major ground-based technology demonstrations were reviewed. The results of the first successful ion engine flight in 1964, SERT I which demonstrated ion beam neutralization, are discussed along with the extended operation of SERT II starting in 1970. These results together with the technology employed on the early cesium engine flights. the Applications Technology Satellite (ATS) series, and the ground-test demonstrations, have provided the evolutionary path for the development of xenon ion thruster component technologies, control systems, and power circuit implementations. In the 1997-1999 period, the communication satellite flights using ion engine systems and the Deep Space I flight confirmed that these auxiliary and primary propulsion systems have advanced to a high-level of flight-readiness.

Sovey, James S.↗

NASA NTRS2016

Application of High Speed Digital Image Correlation in Rocket Engine Hot Fire Testing

Hot fire testing of rocket engine components and rocket engine systems is a critical aspect of the development process to understand performance, reliability and system interactions. Ground testing provides the opportunity for highly instrumented development testing to validate analytical model predictions and determine necessary design changes and process improvements. To properly obtain discrete measurements for model validation, instrumentation must survive in the highly dynamic and extreme temperature application of hot fire testing. Digital Image Correlation has been investigated and being evaluated as a technique to augment traditional instrumentation during component and engine testing providing further data for additional performance improvements and cost savings. The feasibility of digital image correlation techniques were demonstrated in subscale and full scale hotfire testing. This incorporated a pair of high speed cameras to measure three-dimensional, real-time displacements and strains installed and operated under the extreme environments present on the test stand. The development process, setup and calibrations, data collection, hotfire test data collection and post-test analysis and results are presented in this paper.

Gradl, Paul R.↗

NASA NTRS1983

A study of interior noise levels, noise sources and transmission paths in light aircraft

The interior noise levels and spectral characteristics of 18 single-and twin-engine propeller-driven light aircraft, and source-path diagnosis of a single-engine aircraft which was considered representative of a large part of the fleet were studied. The purpose of the flight surveys was to measure internal noise levels and identify principal noise sources and paths under a carefully controlled and standardized set of flight procedures. The diagnostic tests consisted of flights and ground tests in which various parts of the aircraft, such as engine mounts, the engine compartment, exhaust pipe, individual panels, and the wing strut were instrumented to determine source levels and transmission path strengths using the transfer function technique. Predominant source and path combinations are identified. Experimental techniques are described. Data, transfer function calculations to derive source-path contributions to the cabin acoustic environment, and implications of the findings for noise control design are analyzed.

Hayden, R. E.↗

NASA NTRS2016

Post-Flight Assessment of Avcoat Thermal Protection System for the Exploration Flight Test-1

On December 5, 2014 NASA conducted the first flight test of its next generation human-class Orion spacecraft. The flight was called the Exploration Flight Test -1 (EFT-1) which lasted for 4 hours and culminated into a re-entry trajectory at 9 km/s. This flight test of the 5-meter Orion Crew Module demonstrated various sub-systems including the Avcoat ablative thermal protection system (TPS) on the heat shield. The Avcoat TPS had been developed from the Apollo-era recipe with a few key modifications. The engineering for thermal sizing was supported by modeling, analysis, and ground tests in arc jet facilities. This paper will describe a postlfight analysis plan and present results from post-recovery inspections, data analysis from embedded sensors, TPS sample extraction and characterization in the laboratory. After the recovery of the vehicle, a full photographic survey and surface scans of the TPS were performed. The recovered vehicle showed physical evidence of flow disturbances, varying degrees of surface roughness, and excessive recession downstream of compression pads. The TPS recession was measured at more than 200 locations of interest on the Avcoat surface. The heat shield was then processed for sample extraction prior to TPS removal using the 7-Axis Milling machine at Marshall Space Flight Center. Around 182 rectangular TPS samples were extracted for subsequent analysis and investigation. The final paper will also present results of sample analysis. The planned investigation includes sidewall imaging, followed by image analysis to characterize TPS response by quantifying different layers in the char and pyrolysis zones. A full postmortem of the instrumentation and sensor ports will also be performed to confirm no adverse effects due to the sensors themselves. A subset of the samples will undergo structural testing and perform detailed characterization of any cracks and integrity of gore seams. Finally, the material will be characterized with layer-by-layer density measurements and SEM investigations to evaluate material morphology at microstructural level including identification of elements and compounds.

Aerothermodynamics↗

NASA NTRS2018

Leveraging Commercial Software Defined Radio for Low Cost Deep Space Testing

In a typical space mission development life cycle, there is a stage where the spacecraft needs to test against the ground station for interface compatibility to ensure that the spacecraft will be properly tracked after launch. This testing normally requires the spacecraft team to bring their flight equipment to the ground station facility. While recognizing that testing with actual flight or engineering module is the most preferred option because of maximum fidelity, there are occasion when the use of actual flight hardware is a logistically challenge because of spacecraft development. Having another test tool that can emulate the spacecraft signal – by recording the signal transmitted by the spacecraft and regenerate an RF signal for ground system testing - would be very useful. It is even more an attractive option if such spacecraft emulator is inexpensive and highly portable. In this paper, we describe a low-cost, light-weight recorder/playback assembly (RPA) that supports deep space missions testing. The equipment leverages on commercially available software defined radios (SDR) and public-domain software. The RPA has been used to support two missions. One effort is to validate that the Uchinoura 34-m tracking station of the Japanese Aerospace Exploration Agency (JAXA) would be able to track the upcoming NASA Exploration Mission 1 (EM-1) spacecraft, scheduled for launch in 2019. The second effort is to help with the testing and certification of the 21-m antenna ground station at the Morehead State University (MSU) in Kentucky, United States, prior to the time when the Lunar IceCube spacecraft is ready for actual compatibility testing. The RPA also enables students/staff training of the new ground station, using the RPA signal as test input into the system. This low-cost test signal allows the MSU team to save money on not having to develop a full-scale self-generated telemetry test signal source.

White, Leslie↗

NASA NTRS1991

Charge control experiments on a CH-53E helicopter in a dusty environment

Charge control tests were carried out on a ground based, Marine Corps helicopter to determine if control of the electric fields acting on the engine exhaust gases could be used to reduce the electrification of the helicopter when it operated in a dusty atmosphere. The test aircraft was flown to a dusty, unpaved area and was then isolated electrically from the earth. When the helicopter engines were operated at ground idle with the rotor locked, the isolated aircraft charged positively, as had been observed previously. However, when the rotor brake was released and the turning rotor created a downdraft that raised dust clouds, the aircraft always became charged more positively, to potentials ranging form +30 to +45 kV. The dust clouds raised by the rotor downwash invariably carried negative space charges with concentrations of up to -100 nC/cu m and caused surface electric fields with strengths of up to 10 kV/m immediately down wind of the aircraft. The natural charging of the helicopter operating in these dust clouds was successfully opposed by control of the electric fields acting on the hot, electrically conductive exhaust gases. The control was achieved by placing electrostatic shield around the exhausts.

Moore, C. B.↗

NASA NTRSDate not supplied

Particle and Trace Gas Emissions Indices Measured During the 2021 Boeing ecoDemonstrator Emissions Ground Test

We present particle and trace gas emissions indices sampled on the ground at 30 meters behind the CFM LEAP-1B engines of the Boeing ecoDemonstrator 737-9 aircraft. Testing was carried out at Boeing Field in Seattle, WA, USA in Fall of 2021. Four different fuels were investigated including a 100% sustainable aviation fuel (SAF), a petroleum-based Jet A fuel, and two SAF blends. Total and non-volatile particle number concentrations were measured with a pair of condensation particle counters with one operating behind a custom-built thermal denuder heated to 350 degrees Celsius. Similarly, total and non-volatile particle number size distributions were measured with a pair of Scanning Mobility Particle Sizers (SMPSs). Non-volatile particle mass was estimated from particle light absorption techniques using an assumed mass absorption coefficient, while particle chemical speciation was measured by an Soot Particle Aerosol Mass Spectrometer (SP-AMS). A detailed list of instruments is given on the project website [1]. Overall, the results are consistent with expectations based on ICAO Emissions Databank certification data for the LEAP-1B with a stark reduction in non-volatile particle number and mass observed for the higher thrust conditions when the combustor was staged. The production of volatile particles under these conditions as well as experimental considerations related to background subtraction methods will be discussed.

Benjamin A. Nault↗

NASA NTRS2014

NASA Rocket Propulsion Test Replacement Effort for Oxygen System Cleaner - Hydrochlorofluorocarbon (HCFC) 225

Gaseous and liquid oxygen are extremely reactive materials used in bipropellant propulsion systems. Both flight and ground oxygen systems require a high level of cleanliness to support engine performance, testing, and prevent mishaps. Solvents used to clean and verify the cleanliness of oxygen systems and supporting test hardware must be compatible with the system's materials of construction and effective at removing or reducing expected contaminants to an acceptable level. This paper will define the philosophy and test approach used for evaluating replacement solvents for the current Marshall Space Flight Center/Stennis Space Center baseline HCFC‐225 material that will no longer be available for purchase after 2014. MSFC/SSC applications in cleaning / sampling oxygen propulsion components, support equipment, and test system were reviewed then candidate replacement cleaners and test methods selected. All of these factors as well as testing results will be discussed.

DeWitt Burns, H.↗