Improvements in structural nondestructive testing
Radiographic and ultrasonic test methods and equipment for improved quality control of welded structures and propellant tanks
ULTRASONIC TESTING↗
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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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Providing the Nation a Significant "High-Test Peroxide" Propulsion Test Capability
Renewed interest in high-test peroxide, as a propellant, required the development of a facility capable of testing rocket propulsion systems. The development of this capability at the NASA Stennis Space Center (SSC), MS, focused on meeting this requirement. The challenges, accomplishments, and lessons learned associated with developing the SSC E3 Test Facility's high-test peroxide capability are presented herein.
Bruce, R.↗
Characterization of a Pressure-Fed LOX/LCH4 Reaction Control System Under Simulated Altitude and Thermal Vacuum Conditions
A liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under simulated altitude and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA) and was initially developed under Project Morpheus. Composed of two 28 lbf-thrust and two 7 lbf-thrust engines, the RCS is fed in parallel with the ICPTA main engine from four propellant tanks. 40 tests consisting of 1,010 individual thruster pulses were performed across 6 different test days. Major test objectives were focused on system dynamics, and included characterization of fluid transients, manifold priming, manifold thermal conditioning, thermodynamic vent system (TVS) performance, and main engine/RCS interaction. Peak surge pressures from valve opening and closing events were examined. It was determined that these events were impacted significantly by vapor cavity formation and collapse. In most cases the valve opening transient was more severe than the valve closing. Under thermal vacuum conditions it was shown that TVS operation is unnecessary to maintain liquid conditions at the thruster inlets. However, under higher heat leak environments the RCS can still be operated in a self-conditioning mode without overboard TVS venting, contingent upon the engines managing a range of potentially severe thermal transients. Lastly, during testing under cold thermal conditions the engines experienced significant ignition problems. Only after warming the thruster bodies with a gaseous nitrogen purge to an intermediate temperature was successful ignition demonstrated.
Atwell, Matthew J.↗
Hot-Fire Testing of 100 LB(sub F) LOX/LCH4 Reaction Control Engine at Altitude Conditions
Liquid oxygen/liquid methane (LO2/LCH4 ) has recently been viewed as a potential green propulsion system for both the Altair ascent main engine (AME) and reaction control system (RCS). The Propulsion and Cryogenic Advanced Development Project (PCAD) has been tasked by NASA to develop these green propellant systems to enable safe and cost effective exploration missions. However, experience with LO2/LCH4 as a propellant combination is limited, so testing of these systems is critical to demonstrating reliable ignition and performance. A test program of a 100 lb f reaction control engine (RCE) is underway at the Altitude Combustion Stand (ACS) of the NASA Glenn Research Center, with a focus on conducting tests at altitude conditions. These tests include a unique propellant conditioning feed system (PCFS) which allows for the inlet conditions of the propellant to be varied to test warm to subcooled liquid propellant temperatures. Engine performance, including thrust, c* and vacuum specific impulse (I(sub sp,vac)) will be presented as a function of propellant temperature conditions. In general, the engine performed as expected, with higher performance at warmer propellant temperatures but better efficiency at lower propellant temperatures. Mixture ratio effects were inconclusive within the uncertainty bands of data, but qualitatively showed higher performance at lower ratios.
Marshall, William M.↗
Examples of Unsteady Combustion in Non-Metallized Propellants
For over thirty years the T-Burner has been the de facto standard for determining the unstable response of solid propellants. This paper reviews some of the different approaches that have been used, and briefly summarizes advantages and disadvantages of the different techniques. Data from a variety of sources have been reviewed and summarized showing the effect of various test conditions and propellant formulation variations. Much of the data taken in the 60's and early 70's were with so-called research propellants, with relatively low solids loading and usually monomodal AP as the oxidizer. Later data were obtained with propellants containing solids loading more typical and practical propellants. Several distinct differences were observed in the data for the different types of propellants. Data varying AP particle size distributions indicate that either additional fine AP or finer AP usually increases the propellant response. A significant reduction in the response can be achieved by reducing the amount of fine AP, while holding burning rate constant either by adding a catalyst or by varying the overall AP size distribution. A significant amount of data has been obtained for reduced smoke propellants containing stability additives. The data indicate that the additives provide significant particle damping, and most often, also reduce the propellant response. Data from double base propellants indicate a much broader response over a wide frequency range. This implies that double base propellants should be more unstable in tangential modes than composite propellants. This trend seems to be consistent with observed motor data. Measuring the response of metallized propellants has been a challenge due to the large damping due to metal oxide particles in the gas. Data from metallized propellants are not presented here, but will be summarized in a future paper.
Beckstead, M. W.↗
High-Propellant Throughput Sub-kW Electric Propulsion System for Deep Space Science and Exploration
The National Aeronautics and Space Administration (NASA) is maturing high-propellant throughput sub-kilowatt electric propulsion technologies to enable small spacecraft deep space science and exploration missions with high delta-v requirements. The pathfinder model (PM) propulsion system consists of the H71M-PM Hall-effect thruster, a breadboard 1-kW power processing unit (PPU), and a propellant flow control system. The propulsion system requirements balance the needs of various high delta-v NASA and commercial industry mission concepts to achieve a design that both enables a variety of NASA small spacecraft deep space missions, while remaining viable for select commercial applications. The H71M-PM thruster has completed performance characterization and three 500-h short duration wear tests (SDWT). The propulsion system provides stable thrust generation over a wide range of operating conditions from 200 W to 1 kW, and 200 V to 400 V. The thruster has demonstrated a thrust as high as 68 mN at 300 V and 1 kW. The thruster has similarly demonstrated a specific impulse of 1850 s at 400 V and 1 kW. Key surfaces were machined between each SDWT to simulate accelerated discharge channel and pole cover erosion. Profilometry scans across masked pole cover surfaces were conducted to determine erosion rates. SDWT results support that a target thruster lifetime of 14 kh with 50% margin is achievable. Component testing has demonstrated propellant azimuthal flow uniformity better than ± 2 percent of the nominal value, azimuthal magnetic field uniformity better than ± 0.5 percent of the nominal value, and cathode heater cycle testing to greater than 30,000 cycles. Propulsion system integrated system testing is planned to use the H71M-PM and a breadboard 1-kW PPU. Pathfinder model test results are now supporting the design of the H71M-EM engineering model thruster. A second-generation breadboard PPU has been fabricated and is currently under test. NASA has made these technologies available to U.S. industry through a no cost, nonexclusive license agreement.
Hall↗
Modal survey of the space shuttle solid rocket motor using multiple input methods
The ability to accurately characterize propellant in a finite element model is a concern of engineers tasked with studying the dynamic response of the Space Shuttle Solid Rocket Motor (SRM). THe uncertainties arising from propellant characterization through specimem testing led to the decision to perform a model survey and model correlation of a single segment of the Shuttle SRM. Multiple input methods were used to excite and define case/propellant modes of both an inert segment and, later, a live propellant segment. These tests were successful at defining highly damped, flexible modes, several pairs of which occured with frequency spacing of less than two percent.
Brillhart, Ralph↗
The 260: The Largest Solid Rocket Motor Ever Tested
Aerojet in the mid 1960s, under contract to NASA, built and static hot fire tested the largest solid rocket motor (SRM) in history for the purpose of demonstrating the feasibility of utilizing large SRMs for space exploration. This program successfully fabricated two high strength steel chambers, loaded each with approximately 1,68 million pounds of propellant, and static test fired these giants with their nozzles up from an underground silo located adjacent to the Florida everglades. Maximum thrust and total impulse in excess of 5,000,000 lbf and 3,470,000,000 lbf-sec were achieved. Flames from the second firing, conducted at night, were seen over eighty miles away. For comparative purposes: the thrust developed was nearly 100 times that of a Minuteman III second stage and the 260 in.-dia cross-section was over 3 times that of the Space Shuttle SRM.
Crimmins, P.↗
Slosh testing of a prototype electric propulsion Mercury propellant tank with positive expulsion diaphragm
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Ross, R. G., Jr.↗
Heat sterilizable solid-propellant development
The binders tested were polyurethanes made from two hydroxy-terminated polybutadienes, R-45 and Butarez HT, one hydroxy-terminated butadiene-acrylonitrile copolymer, Hycar 1300X 17, and a hydroxy-terminated prepolymer, Esterdiol 560, made from the dimerized fatty acid Empol 1010. The isocyanates used most extensively were isophorone diisocyanate (IPDI) and a polymeric diisocyanate, DDI. Stress relaxation was used to examine the chemical changes that took place in the binder when subjected to the sterilization temperatures. The thermal stability of the oxidizer, ammonium perchlorate (AP), was tested by thermogravimetry in the isothermal and nonisothermal modes. The effect of particle size, recrystallization, moisture content, and doping on the heat stability of AP could be evaluated by this method. The volatile degradation products, obtained when AP samples were aged at 135 C for prolonged periods, were analyzed by mass spectroscopy.
Kalfayan, S. H.↗
Low-speed wind-tunnel tests of single- and counter-rotation propellers
A low-speed (Mach 0 to 0.3) wind-tunnel investigation was conducted to determine the basic performance, force and moment characteristics, and flow-field velocities of single- and counter-rotation propellers. Compared with the eight-blade single-rotation propeller, a four- by four- (4 x 4) blade counter-rotation propeller with the same blade design produced substantially higher thrust coefficients for the same blade angles and advance ratios. The results further indicated that ingestion of the wake from a supporting pylon for a pusher configuration produced no significant change in the propeller thrust performance for either the single- or counter-rotation propellers. A two-component laser velocimeter (LV) system was used to make detailed measurements of the propeller flow fields. Results show increasing slipstream velocities with increasing blade angle and decreasing advance ratio. Flow-field measurements for the counter-rotation propeller show that the rear propeller turned the flow in the opposite direction from the front propeller and, therefore, could eliminate the swirl component of velocity, as would be expected.
Dunham, D. M.↗
Static tests of four two-blade NACA propellers differing in camber and solidity
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Platt, Robert J , Jr↗
Static Tests of a Shrouded and an Unshrouded Propeller
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Platt, Robert J , Jr↗
Liquefied Natural Gas (LNG) as Propellant Fuels; Storage and Transfer Effects: Background, Testing, Data, & Analysis
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Adam Swanger↗
Noise of a model counterrotation propeller with reduced aft rotor diameter at simulated takeoff/approach conditions (F7/A3)
A model high-speed advanced counterrotation propeller, F7/A3, was tested in the NASA Lewis Research Center 9 by 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish propeller operating conditions. The propeller was run at two setting angles (front angle/rear angle) of 36.4/43.5 and 41.1/46.4 degrees, forward rotor tip speeds from 165 to 259 m/sec, rotor spacings from 8.48 to 14.99 cm based on pitch change axis separation, and angles of attack to 16 degrees. The aft rotor diameter was 85 percent of the forward rotor diameter to reduce tip vortex-aft rotor interaction as a major interaction noise source. Results are compared with equal diameter F7/A7 data which was previously obtained under similar operating conditions. The aft rotor-alone tone was 7 dB lower for the reduced diameter aft rotor, due to reduced tip speed at constant rpm. Interaction tone levels for the F7/A3 propeller were higher at minimum row spacing and lower at maximum spacing.
Woodward, Richard P.↗
Noise of a model counterrotation propeller with reduced aft rotor diameter at simulated takeoff/approach conditions (F7/A3)
A model high-speed advanced counterrotation propeller, F7/A3, was tested in the NASA Lewis Research Center 9 by 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish propeller operating conditions. The propeller was run at two setting angles (front angle/rear angle) of 36.4/43.5 and 41.1/46.4 degrees, forward rotor tip speeds from 165 to 259 m/sec, rotor spacings from 8.48 to 14.99 cm based on pitch change axis separation, and angles of attack to 16 degrees. The aft rotor diameter was 85 percent of the forward rotor diameter to reduce tip vortex-aft rotor interaction as a major interaction noise source. Results are compared with equal diameter F7/A7 data which was previously obtained under similar operating conditions. The aft rotor-alone tone was 7 dB lower for the reduced diameter aft rotor, due to reduced tip speed at constant rpm. Interaction tone levels for the F7/A3 propeller were higher at minimum row spacing and lower at maximum spacing.
Woodward, Richard P.↗
Microanalysis of extended-test xenon hollow cathodes
Four hollow cathode electron sources were analyzed via boroscopy, scanning electron microscopy, energy dispersive x ray analysis, and x ray diffraction analysis. These techniques were used to develop a preliminary understanding of the chemistry of the devices that arise from contamination due to inadequate feed-system integrity and improper insert activation. Two hollow cathodes were operated in an ion thruster simulator at an emission current of 23.0 A for approximately 500 hrs. The two tests differed in propellant-feed systems, discharge power supplies, and activation procedures. Tungsten deposition and barium tungstate formation on the internal cathode surfaces occurred during the first test, which were believed to result from oxygen contamination of the propellant feed-system. Consequently, the test facility was upgraded to reduce contamination, and the test was repeated. The second hollow cathode was found to have experienced significantly less tungsten deposition. A second pair of cathodes examined were the discharge and the neutralizer hollow cathodes used in a life-test of a 30-cm ring-cusp ion thruster at a 5.5 kW power level. The cathodes' test history was documented and the post-test microanalyses are described. The most significant change resulting from the life-test was substantial tungsten deposition on the internal cathode surfaces, as well as removal of material from the insert surface. In addition, barium tungstate and molybdate were found on insert surfaces. As a result of the cathode examinations, procedures and approaches were proposed for improved discharge ignition and cathode longevity.
Verhey, Timothy R.↗
Aerodynamic characteristics of two general aviation canard configurations at high angles of attack
The results of wind tunnel tests of two propeller driven canard general aviation aircraft models at high angles of attack are reported. Both tractor and pusher prop configurations were examined. Angles of attack of -6 to 40 deg were used with the pusher model at Re of 1,600,000, and from -30 to 90 deg and Re of 550,000 for the tractor model. The tests showed that the canard would stall long before the wing and produce a nose-down tendency, thus effectively keeping the aircraft out of the stall regime. However, a sequence of pilot actions or design factors such as the airfoils, relative geometry of the canard and wing, the propeller location and the center of gravity location could introduce a wide variance in stall characteristics from one aircraft to another.
Chambers, J. R.↗