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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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Reliability growth modeling analysis of the space shuttle main engines based upon the Weibull process
The Weibull process, identified as the inhomogeneous Poisson process with the Weibull intensity function, is used to model the reliability growth assessment of the space shuttle main engine test and flight failure data. Additional tables of percentage-point probabilities for several different values of the confidence coefficient have been generated for setting (1-alpha)100-percent two sided confidence interval estimates on the mean time between failures. The tabled data pertain to two cases: (1) time-terminated testing, and (2) failure-terminated testing. The critical values of the three test statistics, namely Cramer-von Mises, Kolmogorov-Smirnov, and chi-square, were calculated and tabled for use in the goodness of fit tests for the engine reliability data. Numerical results are presented for five different groupings of the engine data that reflect the actual response to the failures.
Advances in Thin Film Thermocouple Durability Under High Temperature and Pressure Testing Conditions
Thin film thermocouples for measuring material surface temperature have been previously demonstrated on several material systems and in various hostile test environments. A well-developed thin film fabrication procedure utilizing shadow masking for patterning the sensors elements had produced thin films with sufficient durability for applications in high temperature and pressure environments that exist in air-breathing and hydrogen-fueled burner rig and engine test facilities. However, while shadow masking had been a reliable method for specimens with flat and gently curved surfaces, it had not been consistently reliable for use on test components with sharp contours. This work reports on the feasibility of utilizing photolithography processing for patterning thin film thermocouples. Because this patterning process required changes in the thin film deposition process from that developed for shadow masking, the effect of these changes on thin film adherence during burner rig testing was evaluated. In addition to the results of changing the patterning method, the effects on thin film adherence of other processes used in the thin film fabrication procedure is also presented.
Certification of damage tolerant composite structure
A reliability based certification testing methodology for impact damage tolerant composite structure was developed. Cocured, adhesively bonded, and impact damaged composite static strength and fatigue life data were statistically analyzed to determine the influence of test parameters on the data scatter. The impact damage resistance and damage tolerance of various structural configurations were characterized through the analysis of an industry wide database of impact test results. Realistic impact damage certification requirements were proposed based on actual fleet aircraft data. The capabilities of available impact damage analysis methods were determined through correlation with experimental data. Probabilistic methods were developed to estimate the reliability of impact damaged composite structures.
Nondestructive testing of microtab welds
Introduction of sinusoidal signal across welded structure to determine reliability of integrated circuit connections is discussed. In-phase frequencies and quadrature frequency functions are used to evaluate weld reliability. Schematic diagram of test equipment and components is provided.
Testing Facility Uncertainty Analyses for RBCC Systems Testing
The Rocket Based Combined Cycle (RBCC) engine is expected to evolve based upon past combined-cycle propulsion test experience/data and new extensive test data. Currently, it is envisioned that a portion of the component and system testing will be pursued at NASA Stennis Space Center (SSC). To realize the greatest benefit of the test data, uncertainty analyses are being performed on the relevant RBCC components and systems to be tested at NASA SSC to ascertain the needed measurement requirements. These studies pertain to the existing E-Complex test stands as well as a new facility, E-4. This paper describes the approach used in the studies and gives examples to demonstrate the approach and the usefulness of the results. Future work will greatly increase the reliability of the test data while minimizing costs by focusing expenditures in the proper areas that are critical to program success and not allowing resources to be wasted in areas that are not significant relative to overall program goals.
Pharmacokinetics of Intranasal Scopolamine Gel Formulation (Inscop)
Space Motion Sickness (SMS) is commonly experienced by astronauts and often requires treatment with medications during early flight days of space missions. Orally administered scopolamine is commonly used by astronauts to prevent SMS. Bioavailability of oral (PO) SMS medications is often low and highly variable. Intranasal (IN) administration of medications achieves higher and more reliable bioavailability than from an equivalent PO dose. Methods: To test the safety and reliability of INSCOP, two clinical studies were performed, a dose escalation study and a comparison study administering INSCOP during normal ambulation and head down tilt bedrest. Efficacy was evaluated by testing INSCOP with two, different motion sickness inducing paradigms. Results: Preliminary results indicate that INSCOP demonstrates linear pharmacokinetics and a low side effect profile. In head down tilt bedrest, relative bioavailability of INSCOP was increased for females at both doses (0.2 and 0.4 mg) and for males at the higher dose (0.4 mg) but is reduced at the lower dose (0.2 mg) compared to normal ambulation. INSCOP displays gender specific differences during ABR. One of the treatment efficacy trials conducted at Dartmouth Hitchcock Medical Center demonstrated that INSCOP is efficacious at both doses (0.2 and 0.4 mg) in suppressing motion sickness symptoms as indicated by longer chair ride times with INSCOP administration than with placebo, and efficacy increases with dose. Similar results were seen using another motion sickness simulator, the motion simulator dome, at the Naval Aerospace Medical Research Laboratory, with significantly increased time in the dome in motion-susceptible subjects when using INSCOP compared to untreated controls. Conclusion: Higher bioavailability, linear pharmacokinetics, a low incidence of side effects, and a favorable efficacy profile make INSCOP a desirable formulation for prophylactic and rescue treatment of astronauts in space and military personnel on duty.
Development of A Non-Explosive Release Device for Aerospace Applications
A simple, non-explosive, high load-capacity release mechanism using shape memory alloy is currently being developed for space flight. This device, the Frangibolt, could replace most pyrotechnic devices in applications where the need for safety, reliability, non-destructive testing, and minimal mechanical shock is more crucial than the need for rapid actuation. Prototype hardware has been designed, tested, and proven in laboratory conditions. Operation and demonstration of these devices evidenced reliable and repeatable performance, clearly indicating that extensive testing for flight qualification is warranted. Here, the Frangibolt design is discussed, recent test results of laboratory units are described, and the work that must be performed in the upcoming months to qualify the device for aerospace applications is addressed.
Support to quality and reliability assurance laboratory
Acceptance test plan for Apollo telescope seismic pad and pointing system
A Novel Method for Quantifying Helmeted Field of View of a Space Suit - And What it Means for Constellation
Field of view has always been a design feature paramount to helmet design, and in particular spacesuit design, where the helmet must provide an adequate field of view for a large range of activities, environments, and body positions. Historically, suited field of view has been evaluated either qualitatively in parallel with design or quantitatively using various test methods and protocols. As such, oftentimes legacy suit field of view information is either ambiguous for lack of supporting data or contradictory to other field of view tests performed with different subjects and test methods. This paper serves to document a new field of view testing method that is more reliable and repeatable than its predecessors. It borrows heavily from standard field of vision tests such as the Goldmann kinetic perimetry test, but is designed specifically for evaluating field of view of a spacesuit helmet. In this test, three suits utilizing three different helmet designs were tested for field of view. Not only do these tests provide more reliable field of view data for legacy and prototype helmet designs, they also provide insight into how helmet design impacts field of view and what this means for the Constellation Project spacesuit helmet, which must meet stringent field of view requirements that are more generous to the crewmember than legacy designs.
Upgrades to the ISS Water Recovery System
The International Space Station Water Recovery System (WRS) is comprised of the Water Processor Assembly (WPA) and the Urine Processor Assembly (UPA). The WRS produces potable water from a combination of crew urine (first processed through the UPA), crew latent, and Sabatier product water. Though the WRS has performed well since operations began in November 2008, several modifications have been identified to improve the overall system performance. These modifications can reduce resupply and improve overall system reliability, which is beneficial for the ongoing ISS mission as well as for future NASA manned missions. The following paper details efforts to reduce the resupply mass of the WPA Multifiltration Bed, develop improved catalyst for the WPA Catalytic Reactor, evaluate optimum operation of UPA through parametric testing, and improve reliability of the UPA fluids pump and Distillation Assembly.
Improving Sanitation and Health in Rural Alaska
In rural Alaskan communities personal health is threatened by energy costs and limited access to clean water, wastewater management, and adequate nutrition. Fuel-‐based energy systems are significant factors in determining local accessibility to clean water, sanitation and food. Increasing fuel costs induce a scarcity of access and impact residents' health. The University of Alaska Fairbanks (UAF) School of Natural Resources and Agricultural Sciences (SNRAS), NASA's Ames Research Center, and USDA Agricultural Research Service (ARS) have joined forces to develop high‐efficiency, low‐energy consuming techniques for water treatment and food production in rural circumpolar communities. Methods intended for exploration of space and establishment of settlements on the Moon or Mars will ultimately benefit Earth's communities in the circumpolar north. The initial phase of collaboration is completed. Researchers from NASA Ames Research Center and SNRAS, funded by the USDA‐ARS, tested a simple, reliable, low-energy sewage treatment system to recycle wastewater for use in food production and other reuse options in communities. The system extracted up to 70% of the water from sewage and rejected up to 92% of ions in the sewage with no carryover of toxic effects. Biological testing showed that plant growth using recovered water in the nutrient solution was equivalent to that using high‐purity distilled water. With successful demonstration that the low energy consuming wastewater treatment system can provide safe water for communities and food production, the team is ready to move forward to a full‐scale production testbed. The SNRAS/NASA team (including Alaska students) will design a prototype to match water processing rates and food production to meet rural community sanitation needs and nutritional preferences. This system would be operated in Fairbanks at the University of Alaska through SNRAS. Long‐term performance will be validated and operational needs of the system determined. The testbed will be a part of the university education and operator training program. The "Forgotten Alaska" has long awaited this technology to augment the traditional
Development and Reliability of Screen-Printable Fire-Through Cu Paste for Passivated Contact Solar Cells
We present the development of copper (Cu) paste which has been screen printed on Selective Emitter-Passivated Emitter Rear Contact (SE-PERC) solar cells. This paste can also be applied to Tunnel Oxide Passivated Contact (TOPCON) solar cells due to its fire-through nature. Champion PERC cells have achieved ....efficiency with ...parameters . Accelerated testing to investigate reliability performance of the SE- PERC mini-modules were carried out in damp heat chamber with 85oC and 85% humidity. The devices were found to be operational even after 1,500 hours. Devices with screen printed Ag contacts on the front side have been studied in parallel to the Cu contacts for comparison.
Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module
Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.
Free-jet Tests of a 1.1-inch-diameter Supersonic Ram-jet Engine
Results are presented of free-jet tests of a 1.1-inch-diameter hydrogen-burning ram-jet engine over a Mach number range from 1.42 to 2.28 and a Reynolds number range from 6.01 times 10 to the 6th power to 15.78 times 10 to the 6th power. Tests demonstrated the reliability and wide operating range of the engine and showed its suitability for installation on wind-tunnel models of airplane and missile configurations. A comparison of engine operation with combustion-chamber lengths of 3.33 and 1.51 engine diameters was made at a Mach number of 2.06. A maximum test thrust coefficient of 0.905 was obtained at fuel-air ratio of 0.034 and a Mach number of 2.06 for the engine with the 3.33-diameter combustion chamber.
Validation of Cryogenic Propellant Tank Self-Pressurization
NASA’s near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center’s (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC’s Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA’s CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.
Validation of Cryogenic Propellant Tank Self-Pressurization
NASA's near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center's (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC's Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA's CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.
A Novel Method for Quantifying Helmeted Field of View of a Spacesuit - And What It Means for Constellation
Field of view has always been a design feature paramount to helmet design, and in particular spacesuit design, where the helmet must provide an adequate field of view for a large range of activities, environments, and body positions. Historically, suited field of view has been evaluated either qualitatively in parallel with design or quantitatively using various test methods and protocols. As such, oftentimes legacy suit field of view information is either ambiguous for lack of supporting data or contradictory to other field of view tests performed with different subjects and test methods. This paper serves to document a new field of view testing method that is more reliable and repeatable than its predecessors. It borrows heavily from standard ophthalmologic field of vision tests such as the Goldmann kinetic perimetry test, but is designed specifically for evaluating field of view of a spacesuit helmet. In this test, four suits utilizing three different helmet designs were tested for field of view. Not only do these tests provide more reliable field of view data for legacy and prototype helmet designs, they also provide insight into how helmet design impacts field of view and what this means for the Constellation Project spacesuit helmet, which must meet stringent field of view requirements that are more generous to the crewmember than legacy designs.