Results for “Propulsion Testing” — Page 26

NASA NTRS2014

Current Ground Test Options for Nuclear Thermal Propulsion (NTP)

About 20 different NTP engines/ reactors were tested from 1959 to 1972 as part of the Rover and Nuclear Engine for Rocket Vehicle Application (NERVA) program. Most were tested in open air at test cell A or test cell C, at the Nevada Test Site (NTS). Even after serious engine breakdowns of the reactor (e.g., Phoebus 1A), the test cells were cleaned up for other engine tests. The engine test stand (ETS) was made for high altitude (approximately 1 psia) testing of an NTP engine with a flight configuration, but still had the exhaust released to open air. The Rover/NERVA program became aware of new environmental regulations which would prohibit the release of any significant quantity of radioactive particulates and noble gases into the open air. The nuclear furnace (NF-1) was the last reactor tested before the program was cancelled in 1973, but successfully demonstrated a scrubber concept on how to filter the NTP exhaust. The NF-1 was demonstrated in the summer of 1972. The NF-1 used a 44MW reactor and operated each run for approximately 90 minutes. The system cooled the hot hydrogen exhaust from the engine with a water spray before entering a particle filter. The exhaust then passed through a series of heat exchangers and water separators to help remove water from the exhaust and further reduce the exhaust temperatures. The exhaust was next prepared for the charcoal trap by passing through a dryer and effluent cooler to bring exhaust temperatures close to liquid nitrogen. At those low temperatures, most of the noble gases (e.g., Xe and Kr made from fission products) get captured in the charcoal trap. The filtered hydrogen is finally passed through a flare stack and released to the air. The concept was overall successful but did show a La plating on some surfaces and had multiple recommendations for improvement. The most recent detailed study on the NTP scrubber concept was performed by the ARES Corporation in 2006. The concept is based on a 50,000 lbf thrust engine (approximately 1 GW) with a maximum burn time of 1 hour. The concept utilized lessons learned from NF-1. The strategy breaks down the exhaust into parallel paths to allow flexibility with engine size and mass flow of exhaust. Similar to NF-1, the exhaust is slowed down, cooled, filtered of particulates, filtered of noble gases, and then the clean hydrogen is flared to open air. Another concept proposed by Steve Howe (currently Director of the Center for Space Nuclear Research) to simplify the NTP exhaust filtering is to run the hydrogen exhaust into boreholes underground to filter the exhaust. The two borehole site locations proposed are at the NTS and at the Idaho National Laboratory (INL). At NTS, the boreholes are 8' diameter and 1200' deep. The permeability of hydrogen through the soil and its buoyancy will allow it to rise up through the soil and allow the filtering of noble gases and radioactive particulates. The exhaust needs to be cooled to 600C before entering the borehole to avoid soil glazing. Preliminary analysis shows a small buildup of back pressure with time which depends on permeability. Noble gases entering the borehole walls deep can take a long time before reaching the surface. Other factors affecting permeability include borehole pressure, water saturation, and turbulence. Also, a possible need to pump out contaminated water collected at the bottom of the borehole. At INL, the borehole concept is slightly different. The underground borehole has openings to the soil at special depths which have impermeable interbeds above the water table and below the surface to allow the exhaust to travel horizontal between the impermeable layers. Preliminary results indicate better permeability than at NTS. The last option is total containment of the exhaust during the test run. The concept involves slowing down the flow to subsonic in a water cooled diffuser. The hydrogen is burned off in an oxygen rich afterburner with the only products being steam, oxygen, and some noble gases. A heat exchanger and water spray pulls heat from the steam and lowers the temperature for condensation. The optimum ratio between the two is being investigated, with a goal to minimize the total volume of the water hold tanks. A water tank farm collects the contaminated water. The amount of water produced from burning the hydrogen is approximately 100,000 gallons (not including cooling water) for a 25k lbf engine operating for 50 minutes. Residual gases (e.g., oxygen and some noble gases) can be captured at cryogenic levels with a liquid nitrogen cooled dewar. After a few weeks post-test, the radiation levels can drop to more favorable levels before slowly draining each capture tank and using existing filters. With today's environmental regulations, the NTP exhaust is filtered to meet 10 mrem/year exposure to the general public (at a DOE site) or 100 mrem/year (via NRC when tested elsewhere), when natural background radiation exposure to the general public is 300- 600 mrem per year. The current society feels more comfortable with filtering even lower to as low as reasonably achievable (ALARA).

Gerrish, Harold P., Jr.↗

NASA NTRS2018

Particle Size Calibration Testing in the NASA Propulsion Systems Laboratory

The particle size characterization portion of the 2017 Propulsion Systems Laboratory (PSL) Cloud Calibration is described. The work focuses on characterizing the particle size distribution of the icing cloud as a function of simulated atmospheric conditions.These results will aid in upcoming ice crystal and supercooled liquid icing tests in PSL. Measurements acquired with the Phase Doppler Interferometer and High Speed Imaging instruments are presented. Experimental results indicate that the particle size distribution is primarily a function nozzle air and water pressures, and that air speed is not a significant effect for ice crystal clouds in PSL and both thermodynamic conditions and air speed are not significant effects for supercooled liquid water clouds in PSL.

Engine icing↗

NASA NTRS2019

Particle Size Calibration Testing in the NASA Propulsion Systems Laboratory

The particle size characterization portion of the 2017 Propulsion Systems Laboratory (PSL) Cloud Calibration is described. The work focuses on characterizing the particle size distribution of the icing cloud as a function of simulated atmospheric conditions.These results will aid in upcoming ice crystal and supercooled liquid icing tests in PSL. Measurements acquired with the Phase Doppler Interferometer and High Speed Imaging instruments are presented. Experimental results indicate that the particle size distribution is primarily a function nozzle air and water pressures, and that air speed is not a significant effect for ice crystal clouds in PSL and both thermodynamic conditions and air speed are not significant effects for supercooled liquid water clouds in PSL.

Engine Icing↗

NASA NTRS1996

Flight Test of a Propulsion-Based Emergency Control System on the MD-11 Airplane with Emphasis on the Lateral Axis

A large, civilian, multi-engine transport MD-11 airplane control system was recently modified to perform as an emergency backup controller using engine thrust only. The emergency backup system, referred to as the propulsion-controlled aircraft (PCA) system, would be used if a major primary flight control system fails. To allow for longitudinal and lateral-directional control, the PCA system requires at least two engines and is implemented through software modifications. A flight-test program was conducted to evaluate the PCA system high-altitude flying characteristics and to demonstrate its capacity to perform safe landings. The cruise flight conditions, several low approaches and one landing without any aerodynamic flight control surface movement, were demonstrated. This paper presents results that show satisfactory performance of the PCA system in the longitudinal axis. Test results indicate that the lateral-directional axis of the system performed well at high attitude but was sluggish and prone to thermal upsets during landing approaches. Flight-test experiences and test techniques are also discussed with emphasis on the lateral-directional axis because of the difficulties encountered in flight test.

Burken, John J.↗

NASA NTRS2005

A Facility for Testing High-Power Electric Propulsion Systems in Space: A Design Study

This paper will describe the results of the preliminary phase of a NASA design study for a facility to test high-power electric propulsion systems in space. The results of this design study are intended to provide a firm foundation for a subsequent detailed design and development activities leading to the deployment of a valuable space facility supporting the new vision of space exploration. The objectives for human and robotic exploration of space can be accomplished affordably, safely and effectively with high-power electric propulsion systems. But, as thruster power levels rise to the hundreds of kilowatts and up to megawatts, their testing will pose stringent and expensive demands on existing Earth-based vacuum facilities. These considerations and the access to near-Earth space provided by the International Space Station (ISS) have led to a renewed interest in space testing. The ISS could provide an excellent platform for a space-based test facility with the continuous vacuum conditions of the natural space environment and no chamber walls to modify the open boundary conditions of the propulsion system exhaust. The platform would be designed to accommodate the side-by-side testing of multiple types of electric thrusters currently under development and thus provide a strong basis for comparing their relative performance. The utility of testing on the station is further enhanced by the human presence, enabling close interaction with and modification of the test hardware in a true laboratory environment. These conditions facilitate rapid development and flight certification at potentially lower cost than with conventional Earth-bound facilities. As an added benefit, the propulsive effect of these tests could provide some drag compensation for the station, reducing the re-boost cost for the orbital facility. While it is expected that the ISS will not be capable of generating continuous levels of high power, the utilization of state-of-the-art energy storage media would be sufficient to achieve very high power levels over intervals short enough to be feasible and long enough to provide ample demonstration of steady-state operation. This paper will outline the results of the preliminary phase of the design study with emphasis on the requirements that will dictate the system design.

Petro, Andrew J.↗

NASA NTRS2017

Nuclear Cryogenic Propulsion Stage (NCPS) Fuel Element Testing in the Nuclear Thermal Rocket Element Environmental Simulator (NTREES)

To support the on-going nuclear thermal propulsion effort, a state-of-the-art non nuclear experimental test setup has been constructed to evaluate the performance characteristics of candidate fuel element materials and geometries in representative environments. The facility to perform this testing is referred to as the Nuclear Thermal Rocket Element Environment Simulator (NTREES). Last year NTREES was successfully used to satisfy a testing milestone for the Nuclear Cryogenic Propulsion Stage (NCPS) project and met or exceeded all required objectives.

Emrich, William J., Jr.↗

NASA NTRS1973

Aspects of large-scale, subsonic, wind-tunnel design for propulsion noise research

The case for full-scale acoustic testing of propulsion systems at flight conditions and the use of wind tunnels for this work are discussed. The problems associated with measuring noise in wind tunnels are discussed, and wind-tunnel design requirements to provide a useful facility for noise research are established. Full-scale subsonic wind-tunnel designs that meet the requirements are described, and it is shown that state-of-art acoustics technology must be used in the drive-fan design to minimize background noise. If this is successfully done, acoustic treatment in the drive system area may be avoided.

Hickey, D. H.↗

NASA NTRS1976

The development and flight test of an electronic integrated propulsion control system

Advanced technical features of the electronic integrated propulsion control system (IPCS) and flight evaluation tests of IPCS (F-111E with TF30-P-9 engines as test vehicle) are described. Nine baseline flight tests and 15 IPCS flight tests were conducted. Instrumentation, data acquisition and data processing systems, software maintenance procedures, flight test procedures, flight safety criteria, flight test results, and ground and flight testing of the aircraft system are described. Advantages conferred by IPCS include: faster accelerations (both gas generator and afterburner performance), better thrust and flight control, reduced flight idle thrust, reduced engine ground trim, extended service ceiling, automatic stall detection, and stall recovery detection.

Johnson, H. J.↗

NASA NTRS1994

NASA Activities in Support of the ASTOVL/CTOL CALF Project

A review of the NASA activities in support of the ARPA ASTOVL/CTOL CALF Project will be presented. These supporting activities include large-scale model tests on the Outdoor Aerodynamics Research Facility (OARF) and in the 40-ft by 80-ft wind tunnel at NASA Ames; manned simulations of the candidate concepts on the Ames Vertical Motion Simulator; scale model and component tests at NASA Langley Research Center; and propulsion component tests at NASA Lewis Research Center.

Wilson, Samuel B., III↗

NASA NTRSDate not supplied

Solar Array System Combined Environmental Effects Tests: Gateway Power and Propulsion Element

The NASA Lunar Orbital Platform-Gateway (LOP-G), a vital component of NASA’s Artemis program, will serve as a multi-purpose outpost orbiting the Moon. A foundational component of LOP-G is the Power and Propulsion Element (PPE). The PPE is a high-power, +60-kilowatt solar electric propulsion spacecraft that will provide power, high-rate communications, attitude control, and orbital transfer capabilities for the Gateway. The solar array system will utilize 4-junction photovoltaic cell technology on a flexible substrate (roll-out solar array or ROSA) in combination with multiple diode assemblies to combine the power of the solar array strings. NASA’s Marshall Space Flight Center, together with the PPE developer, Maxar, are in the midst of completing a rigorous combined environments test campaign of 3 solar array coupons and 1 array blocking diode board coupon. The campaign includes Ultra-Violet Radiation, Charged Particle Radiation, Ion Erosion, Thermal Cycles, and Electrostatic Discharge tests. The environments are applied in 3 separate incremental stages reflecting the various mission phases: 460 days of Earth-to-Lunar Transit, with much of that time through the Van Allen Belts, 5-years in Lunar Near-Rectilinear Halo Orbit (NRHO) at the Moon, and finally 15-years in Lunar NRHO, which represents the end of the design life. This paper will report on the state of the testing for each coupon, and brief look at the array performance, including some unexpected sensitivities of array blocking diodes.

Gateway↗

NASA NTRS2002

An End-To-End Test of A Simulated Nuclear Electric Propulsion System

The Safe Affordable Fission Engine (SAFE) test series addresses Phase I Space Fission Systems issues in it particular non-nuclear testing and system integration issues leading to the testing and non-nuclear demonstration of a 400-kW fully integrated flight unit. The first part of the SAFE 30 test series demonstrated operation of the simulated nuclear core and heat pipe system. Experimental data acquired in a number of different test scenarios will validate existing computational models, demonstrated system flexibility (fast start-ups, multiple start-ups/shut downs), simulate predictable failure modes and operating environments. The objective of the second part is to demonstrate an integrated propulsion system consisting of a core, conversion system and a thruster where the system converts thermal heat into jet power. This end-to-end system demonstration sets a precedent for ground testing of nuclear electric propulsion systems. The paper describes the SAFE 30 end-to-end system demonstration and its subsystems.

VanDyke, Melissa↗

NASA NTRS2005

Large Liquid Rocket Testing: Strategies and Challenges

Rocket propulsion development is enabled by rigorous ground testing in order to mitigate the propulsion systems risks that are inherent in space flight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth. In particular, large liquid rocket propulsion development and testing over the past five decades of human and robotic space flight has involved a combination of component-level testing and engine-level testing to first demonstrate that the propulsion devices were designed to meet the specified requirements for the Earth to Orbit launchers that they powered. This was followed by a vigorous test campaign to demonstrate the designed propulsion articles over the required operational envelope, and over robust margins, such that a sufficiently reliable propulsion system is delivered prior to first flight. It is possible that hundreds of tests, and on the order of a hundred thousand test seconds, are needed to achieve a high-reliability, flight-ready, liquid rocket engine system. This paper overviews aspects of earlier and recent experience of liquid rocket propulsion testing at NASA Stennis Space Center, where full scale flight engines and flight stages, as well as a significant amount of development testing has taken place in the past decade. The liquid rocket testing experience discussed includes testing of engine components (gas generators, preburners, thrust chambers, pumps, powerheads), as well as engine systems and complete stages. The number of tests, accumulated test seconds, and years of test stand occupancy needed to meet varying test objectives, will be selectively discussed and compared for the wide variety of ground test work that has been conducted at Stennis for subscale and full scale liquid rocket devices. Since rocket propulsion is a crucial long-lead element of any space system acquisition or development, the appropriate plan and strategy must be put in place at the outset of the development effort. A deferment of this test planning, or inattention to strategy, will compromise the ability of the development program to achieve its systems reliability requirements and/or its development milestones. It is important for the government leadership and support team, as well as the vehicle and propulsion development team, to give early consideration to this aspect of space propulsion and space transportation work.

Rahman, Shamim A.↗

NASA NTRS1998

F100 Engine Emissions Tested in NASA Lewis' Propulsion Systems Laboratory

Recent advances in atmospheric sciences have shown that the chemical composition of the entire atmosphere of the planet (gases and airborne particles) has been changed due to human activity and that these changes have changed the heat balance of the planet. National Research Council findings indicate that anthropogenic aerosols1 reduce the amount of solar radiation reaching the Earth's surface. Atmospheric global models suggest that sulfate aerosols change the energy balance of the Northern Hemisphere as much as anthropogenic greenhouse gases have. In response to these findings, NASA initiated the Atmospheric Effects of Aviation Project (AEAP) to advance the research needed to define present and future aircraft emissions and their effects on the Earth's atmosphere. Although the importance of aerosols and their precursors is now well recognized, the characterization of current subsonic engines for these emissions is far from complete. Furthermore, since the relationship of engine operating parameters to aerosol emissions is not known, extrapolation to untested and unbuilt engines necessarily remains highly uncertain. Tests in 1997-an engine test at the NASA Lewis Research Center and the corresponding flight measurement test at the NASA Langley Research Center-attempted to address both issues by measuring emissions when fuels containing different levels of sulfur were burned. Measurement systems from four research groups were involved in the Lewis engine test: A Lewis gas analyzer suite to measure the concentration of gaseous species 1. including NO, NOx, CO, CO2, O2, THC, and SO2 as well as the smoke number; 2. A University of Missouri-Rolla Mobile Aerosol Sampling System to measure aerosol and particulate properties including the total concentration, size distribution, volatility, and hydration property; 3. An Air Force Research Laboratory Chemical Ionization Mass Spectrometer to measure the concentration of SO2 and SO3/H2SO4; and 4. An Aerodyne Research Inc. Tunable Diode Laser System to measure the concentrations of SO2, SO3, NO, NO2, CO2, and H2O. By September 1997, an F100 engine operating at several power levels at sea level and up to six simulated altitudes had been tested with commercial jet fuels with three levels of sulfur content and one military jet fuel. The data are being vigorously analyzed. A complete report is anticipated for the 1998 Atmospheric Effects of Aviation Project Annual Conference.

Wey, Chowen C.↗

NASA NTRS1965

Analysis of potential secondary experiments for a solar-thermionis flight test vehicle. Volume I - Summary Final report, 14 May - 15 Oct. 1965

Experiments and payloads for solar thermionic flight test vehicle - mission planning flight test vehicle

MISSION PLANNING↗

NASA NTRS2018

Preparation for Hollow Cathode Testing for the Advanced Electric Propulsion System at NASA Glenn Research Center

NASA Glenn Research Center is performing activities to support the unique needs of hollow cathode development and testing for the Advanced Electric Propulsion System (AEPS). Three existing vacuum facilities have been outfitted as cathode test facilities, and each will serve a different role in upcoming testing. Vacuum Facility 67 is being developed to serve as a long-duration test facility for the Engineering Development Unit cathode, which is to be delivered by the AEPS contractor. It will feature a thruster-like magnetic field simulator and cold-cycle capability via a liquid nitrogen-cooled cold plate. Vacuum Facility 17 is being developed as a test facility for short- to medium-duration experiments in order to provide auxiliary support for the long-duration testing. It will feature a magnetic field simulator but not cold-cycling. Finally, Vacuum Facility 1 will be a high-pumping speed cathode development environment, and will feature an array of plasma and temperature diagnostics. In addition to the facility preparation work, a new cathode, referred to as the Mark II, has been designed. The Mark II is an evolution of the Technology Demonstration Unit cathodes that better evokes the geometry, fabrication, and construction of the forthcoming Engineering Development Unit. This cathode serves as a transition between the Technology Demonstration Unit cathodes used during early thruster development and the forthcoming Engineering Development Unit cathodes. It will be used as a means of verifying the new test facilities prior to arrival of Engineering Development Unit hardware. Details of the Mark II design and key features are presented, as well as details of future work to be performed.

Advanced Electric Propulsion System (AEPS)↗

NASA NTRS2018

Preparation for Hollow Cathode Testing for the Advanced Electric Propulsion System at NASA Glenn Research Center

NASA Glenn Research Center is performing activities to support the unique needs of hollow cathode development and testing for the Advanced Electric Propulsion System (AEPS). Three existing vacuum facilities have been outfitted as cathode test facilities, and each will serve a different role in upcoming testing. Vacuum Facility 67 is being developed to serve as a long-duration test facility for the Engineering Development Unit cathode, which is to be delivered by the AEPS contractor. It will feature a thruster-like magnetic field simulator and cold-cycle capability via a liquid nitrogen-cooled cold plate. Vacuum Facility 17 is being developed as a test facility for short- to medium-duration experiments in order to provide auxiliary support for the long-duration testing. It will feature a magnetic field simulator but not cold-cycling. Finally, Vacuum Facility 1 will be a high-pumping speed cathode development environment, and will feature an array of plasma and temperature diagnostics. In addition to the facility preparation work, a new cathode, referred to as the Mark II, has been designed. The Mark II is an evolution of the Technology Demonstration Unit cathodes that better evokes the geometry, fabrication, and construction of the forthcoming Engineering Development Unit. This cathode serves as a transition between the Technology Demonstration Unit cathodes used during early thruster development and the forthcoming Engineering Development Unit cathodes. It will be used as a means of verifying the new test facilities prior to arrival of Engineering Development Unit hardware. Details of the Mark II design and key features are presented, as well as details of future work to be performed.

Hall, Scott J.↗

NASA NTRS2018

Preparation for Hollow Cathode Testing for the Advanced Electric Propulsion System at NASA Glenn Research Center

NASA Glenn Research Center is performing activities to support the unique needs of hollow cathode development and testing for the Advanced Electric Propulsion System (AEPS). Three existing vacuum facilities have been outfitted as cathode test facilities, and each will serve a different role in upcoming testing. Vacuum Facility 67 is being developed to serve as a long-duration test facility for the Engineering Development Unit cathode, which is to be delivered by the AEPS contractor. It will feature a thruster-like magnetic field simulator and cold-cycle capability via a liquid nitrogen-cooled cold plate. Vacuum Facility 17 is being developed as a test facility for short- to medium-duration experiments in order to provide auxiliary support for the long-duration testing. It will feature a magnetic field simulator but not cold-cycling. Finally, Vacuum Facility 1 will be a high-pumping speed cathode development environment, and will feature an array of plasma and temperature diagnostics. In addition to the facility preparation work, a new cathode, referred to as the Mark II, has been designed. The Mark II is an evolution of the Technology Demonstration Unit cathodes that better evokes the geometry, fabrication, and construction of the forthcoming Engineering Development Unit. This cathode serves as a transition between the Technology Demonstration Unit cathodes used during early thruster development and the forthcoming Engineering Development Unit cathodes. It will be used as a means of verifying the new test facilities prior to arrival of Engineering Development Unit hardware. Details of the Mark II design and key features are presented, as well as details of future work to be performed.

Hall, Scott J.↗

NASA NTRS1963

Introduction to Nuclear Propulsion: Lecture 15 - Nuclear Test Operations

The test operation of nuclear power plants, specifically nuclear rockets, bears some interesting similarities to the operation of chemical rocket tests as well as, of course, many differences. A significant feature common to both nuclear and chemical rocket tests is that all the fuel for the entire operation is loaded at the start of the test. As a direct consequence of this fact, the operation of nuclear power plants must be surrounded with adequate safety precautions, as is indeed the case in the operation of chemical rockets, A second direct consequence is that in both types of testing a very thorough and complete checkout is made before starting the test.

TEST METHOD↗