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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 469 records · Page 26

JPS heater and sensor lightning qualification

Simulated lightning strike testing of the Redesigned Solid Rocket Motor (RSRM) field joint protection system heater assembly was performed at Thiokol Corp., Wendover Lightning Facility. Testing consisted of subjecting the lightning evaluation test article to simulated lightning strikes and evaluating the effects of heater cable transients on cables within the systems tunnel. The maximum short circuit current coupled onto a United Space Boosters, Inc. operational flight cable within the systems tunnel, induced by transients from all cables external to the systems tunnel, was 92 amperes. The maximum open-circuit voltage coupled was 316 volts. The maximum short circuit current coupled onto a United Space Boosters, Inc. operational flight cable within the systems tunnel, induced by heater power cable transients only, was 2.7 amperes; the maximum open-circuit voltage coupled was 39 volts. All heater power cable induced coupling was due to simulated lightning discharges only, no heater operating power was applied during the test. The results showed that, for a worst-case lightning discharge, the heater power cable is responsible for a 3.9 decibel increase in voltage coupling to operational flight cables within the systems tunnel. Testing also showed that current and voltage levels coupled onto cables within the systems tunnel are partially dependant on the relative locations of the cables within the systems tunnel.

Cook, M.↗

Heat pipe fatigue test specimen: Metallurgical evaluation

An innovative creep/fatigue test was run to simulate the temperature, mechanical load, and sodium corrosion conditions expected in a heat pipe designed to supply thermal energy to a Stirling cycle power converter. A sodium-charged Inconel 718 heat pipe with a Nickel 200 screen wick was operated for 1090 hr at temperatures between 950 K (1250 F) and 1050 K (1430 F) while being subjected to creep and fatigue loads in a servo-hydraulic testing machine. After testing, the heat pipe was sectioned and examined using optical microscopy, scanning electron microscopy, and electron microprobe analysis with wavelength dispersive x-ray spectroscopy. The analysis concentrated on evaluating topographic, microstructural, and chemical changes in the sodium exposed surfaces of the heat pipe wall and wick. Surface changes in the evaporator, condenser, and adiabatic sections of the heat pipe were examined in an effort to correlate the changes with the expected sodium environment in the heat pipe. This report describes the setup, operating conditions, and analytical results of the sodium heat pipe fatigue test.

Walak, Steven E.↗

Investigation of noise suppression by sonic inlets for turbofan engines. Volume 1: Program summary

Results of a program for sonic inlet technology development are presented. This program includes configuration and mechanical design selection of concepts, aerodynamic design description of the models, and results of test evaluation. Several sonic inlet concepts were tested and compared for aerodynamic and acoustic performance. Results of these comparative evaluations are presented. Near-field measurements were taken inside several of the inlet models. Results of these tests are discussed with respect to the effect of Mach number gradients on noise attenuation and rotor shock wave attenuation, and boundary layer effects on noise propagation. The test facilities and experimental techniques employed are described briefly.

Klujber, F.↗

Exploration Extravehicular Mobility Unit (xEMU) 11 Foot Vacuum Chamber Upgrades Test Results

The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.

Robert F Marsch↗

Exploration Extravehicular Mobility Unit 11 Foot Vacuum Chamber Upgrades Test Results

The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.

Robert Marsch↗

Study of monopropellants for electrothermal thrusters: Design and fabrication task summary report

The feasibility of operating small thrust level electrothermal thrusters with monopropellants other than MIL-grade hydrazine was studied. Analytical study, design, and fabrication of demonstration thrusters was performed, and an evaluation test program was initiated to evaluate monopropellants with freezing points lower than MIL-grade hydrazine, and to determine their applicability to electrothermal thrusters for spacecraft attitude control. Five demonstration thrusters were fabricated to determine the feasibility of operation with monomethylhydrazine, Aerozine-50, 77 percent hydrazine-23 percent hydrazine azide, and a mixture of hydrazine monopropellants consisting of 35 percent hydrazine-50 percent monomethylhydrazine-15 percent ammonia. The present thruster is designed to produce a steady-state thrust level of 0.344 N at 1.724 x 1 million N/M sq feed pressure. Vacuum specific impulse goals were set at 1961 N-s/kg steady-state and 1716 N-s/kg pulsed-mode.

Kuenzly, J. D.↗

Performance of the Lester battery charger in electric vehicles

Tests are performed on an improved battery charger. The primary purpose of the testing is to develop test methodologies for battery charger evaluation. Tests are developed to characterize the charger in terms of its charge algorithm and to assess the effects of battery initial state of charge and temperature on charger and battery efficiency. Tests show this charger to be a considerable improvement in the state of the art for electric vehicle chargers.

Vivian, H. C.↗

High temperature metal matrix composites for future aerospace systems

Research was conducted on metal matrix composites and intermetallic matrix composites to understand their behavior under anticipated future operating conditions envisioned for aerospace power and propulsion systems of the 21st century. Extremes in environmental conditions, high temperature, long operating lives, and cyclic conditions dictate that the test evaluations not only include laboratory testing, but simulated flight conditions. The various processing techniques employed to fabricate composites are discussed along with the basic research underway to understand the behavior of high temperature composites, and the relationship of this research to future aerospace systems.

Stephens, Joseph R.↗

High temperature metal matrix composites for future aerospace systems

Research was conducted on metal matrix composites and intermetallic matrix composites to understand their behavior under anticipated future operating conditions envisioned for aerospace power and propulsion systems of the 21st century. Extremes in environmental conditions, high temperature, long operating lives, and cyclic conditions dictate that the test evaluations not only include laboratory testing, but simulated flight conditions. The various processing techniques employed to fabricate composites are discussed along with the basic research underway to understand the behavior of high temperature composites, and the relationship of this research to future aerospace systems.

Stephens, Joseph R.↗

Nonlinear Analysis and Post-Test Correlation for a Curved PRSEUS Panel

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, developed by The Boeing Company, has been extensively studied as part of the National Aeronautics and Space Administration's (NASA s) Environmentally Responsible Aviation (ERA) Program. The PRSEUS concept provides a light-weight alternative to aluminum or traditional composite design concepts and is applicable to traditional-shaped fuselage barrels and wings, as well as advanced configurations such as a hybrid wing body or truss braced wings. Therefore, NASA, the Federal Aviation Administration (FAA) and The Boeing Company partnered in an effort to assess the performance and damage arrestments capabilities of a PRSEUS concept panel using a full-scale curved panel in the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. Testing was conducted in the FASTER facility by subjecting the panel to axial tension loads applied to the ends of the panel, internal pressure, and combined axial tension and internal pressure loadings. Additionally, reactive hoop loads were applied to the skin and frames of the panel along its edges. The panel successfully supported the required design loads in the pristine condition and with a severed stiffener. The panel also demonstrated that the PRSEUS concept could arrest the progression of damage including crack arrestment and crack turning. This paper presents the nonlinear post-test analysis and correlation with test results for the curved PRSEUS panel. It is shown that nonlinear analysis can accurately calculate the behavior of a PRSEUS panel under tension, pressure and combined loading conditions.

Gould, Kevin↗

NASA-STD-6001B Test 1 Upward Flame Propagation; Sample Length Impact on MOC Investigation

Understanding the combustion behavior of materials in the elevated oxygen environments of habitable spacecraft is of utmost importance to crew safety and mission success. Currently, certification for unrestricted flight usage of a material with respect to flammability involves passing the Upward Flame Propagation Test of NASA-STD-6001B (Test 1). This test evaluates materials in a standardized test configuration for two failure criteria: self-extinguishment within 15 cm (6 in.) and the propensity of flame propagation by means of flaming material transfer. By the NASA standard, full-length samples are 30 cm (12 in.) in length; however, factors independent of the test method such as limited material availability or various nonstandard test configurations limit the full pretest sample lengths available for test. This paper characterizes the dependence, if any, of pretest sample length on NASA-STD-6001B Test 1 results. Testing was performed using the Maximum Oxygen Concentration (MOC) Threshold Method to obtain a data set for each sample length tested. In addition, various material types, including cloth (Nomex), foam (TA-301) and solids (Ultem), were tested to investigate potential effects of test specimen types. Though additional data needs to be generated to provide statistical confidence, preliminary findings are that use of variable sample lengths has minimal impact on NASA-STD-6001B flammability performance and MOC determination.

Harper, Susana Tapia↗

Task 4 supporting technology. Part 2: Detailed test plan for thermal seals. Thermal seals evaluation, improvement and test. CAN8-1, Reusable Launch Vehicle (RLV), advanced technology demonstrator: X-33. Leading edge and seals thermal protection system technology demonstration

The objective is to develop the advanced thermal seals to a technology readiness level (TRL) of 6 to support the rapid turnaround time and low maintenance requirements of the X-33 and the future reusable launch vehicle (RLV). This program is divided into three subtasks: (1) orbiter thermal seals operation history review; (2) material, process, and design improvement; and (3) fabrication and evaluation of the advanced thermal seals.

Hogenson, P. A.↗

Demonstration of a Non-Toxic Reaction Control Engine

Three non-toxic demonstration reaction control engines (RCE) were successfully tested at the Aerojet Sacramento facility under a technology contract sponsored by the National Aeronautics and Space Administration s (NASA) Marshall Space Flight Center (MSFC). The goals of the NASA MSFC contract (NAS8-01109) were to develop and expand the technical maturity of a non-toxic, on-orbit auxiliary propulsion system (APS) thruster under the auspices of the Exploration Systems Mission Directorate. The demonstration engine utilized Liquid Oxygen (LOX) and Ethanol as propellants to produce 870 lbf thrust. The Aerojet RCE s were successfully acceptance tested over a broad range of operating conditions. Steady state tests evaluated engine response to varying chamber pressures and mixture ratios. In addition to the steady state tests, a variety of pulsing tests were conducted over a wide range of electrical pulse widths (EPW). Each EPW condition was also tested over a range of percent duty cycles (DC), and bit impulse and pulsing specific impulse were determined for each of these conditions. White Sands Test Facility (WSTF) in April 2005 for incorporation into a cryogenic Auxiliary Propulsion System Test Bed (APSTB). The APSTB is a test article that will be utilized in an altitude test cell to simulate anticipated mission applications. The objectives of this APSTB testing included evaluation of engine performance over an extended duty cycle map of propellant pressure and temperature, as well as engine and system performance at typical mission duty cycles over extended periods of time. This paper provides acceptance test results and a status of the engine performance as part of the system level testing. Subsequent to acceptance testing at Aerojet, these three engines were delivered to the NASA

Robinson, Philip J.↗

Demonstration of a Non-Toxic Reaction Control Engine

T:hree non-toxic demonstration reaction control engines (RCE) were successfully tested at the Aerojet Sacramento facility under a technology contract sponsored by the National Aeronautics and Space Administration's (NASA) Marshall Space Flight Center (MSFC). The goals of the NASA MSFC contract (NAS8-01109) were to develop and expand the technical maturity of a non-toxic, on-orbit auxiliary propulsion system (APS) thruster under the auspices of the Exploration Systems Mission Directorate. The demonstration engine utilized Liquid Oxygen (LOX) and Ethanol as propellants to produce 870 lbf thrust. The Aerojet RCE's were successfully acceptance tested over a broad range of operating conditions. Steady state tests evaluated engine response to varying chamber pressures and mixture ratios. In addition to the steady state tests, a variety of pulsing tests were conducted over a wide range of electrical pulse widths (EPW). Each EPW condition was also tested over a range of percent duty cycles (DC), and bit impulse and pulsing specific impulse were determined for each of these conditions. Subsequent to acceptance testing at Aerojet, these three engines were delivered to the NASA White Sands Test Facility (WSTF) in April 2005 for incorporation into a cryogenic Auxiliary Propulsion System Test Bed (APSTB). The APSTB is a test article that will be utilized in an altitude test cell to simulate anticipated mission applications. The objectives of this APSTB testing included evaluation of engine performance over an extended duty cycle map of propellant pressure and temperature, as well as engine and system performance at typical mission duty cycles over extended periods of time. This paper provides acceptance test results and a status of the engine performance as part of the system level testing.

Robinson, Philip J.↗

Development of a full-scale transmission testing procedure to evaluate advanced lubricants

Experimental tests were performed on the OH-58A helicopter main rotor transmission in the NASA Lewis 500-hp Helicopter Transmission Test Stand. The testing was part of a joint Navy/NASA/Army lubrication program. The objective of the program was to develop a separate lubricant for gearboxes and demonstrate an improved performance in life and load-carrying capacity. The goal of the experiments was to develop a testing procedure to fail certain transmission components using a MIL-L-23699 base reference oil, then run identical tests with improved lubricants and demonstrate performance. The tests were directed at failing components that the Navy has had problems with due to marginal lubrication. These failures included mast shaft bearing micropitting, sun gear and planet bearing fatigue, and spiral bevel gear scoring. A variety of tests were performed and over 900 hours of total run time accumulated for these tests. Some success was achieved in developing a testing procedure to produce sun gear and planet bearing fatigue failures. Only marginal success was achieved in producing mast shaft bearing micropitting and spiral bevel gear scoring.

Lewicki, David G.↗

Final Report Document: Microgravity Medical Eyewash B

Senior Capstone Design Team 15 has been commissioned by the National Aeronautics and Space Administration (NASA) to redesign the current microgravity eye wash station. The current design exhibits four primary limitations: single-use operation, excessive mass and volume, operational complexity requiring coordination with external systems, and dependence on frequent Earth resupply missions. Our updated eyewash design will be deployed on long-range space missions that could last multiple years. Based on these and other requirements from our customer, we have developed our updated eyewash design. Our compact, single-eye system uses capillary-driven flow and a free-floating water ball. This design allows us to eliminate pumps and bulky tubing, decreasing the mass and volume of the overall system. The containment eyecup is held to the astronaut's face with a strap, and a silicone seal prevents leakage while improving user comfort. Contaminated water is contained within a disposal bag containing wicking material to pull it back out of the eyecup after washing the eye. This system is reusable, efficient, and easy to activate quickly. We evaluated our design through calculations, microfluidic testing, and user try-on testing to verify our requirements. Our work demonstrated that steady-state flow was capable with our capillary framework, achieving 1.31 L/min. The prototype construction confirmed mass and volume reductions, and try-on-testing evaluated the ability to put on the system quickly. Almost all major design requirements were achieved, and water loss could be validated by testing in microgravity. Our design went through a number of iterations to reach the final solution presented in this report. These changes were driven by our testing and collaboration from each member of the team. Updated models optimized tube placement and geometry of the eyecup to better direct flow as it pools across the eye. Changes to our tubing bends improved capillary efficiency and increased the flow rate we were capable of achieving. And improved bracket placements adjusted the fit, comfort, and seal of the eyecup to the astronaut's face. Our capillary-based eyewash system is technically feasible and has been theoretically validated to operate effectively in microgravity conditions. Testing and analysis indicate that it can meet or exceed the required performance metrics, including flow rate and safety constraints. Overall, the design represents a viable alternative to current ISS-dependent eyewash systems for future space missions.

Jeffrey Allen↗

Thermal performance of honeywell double covered liquid solar collector

The test procedures and results obtained during an evaluation test program to determine the outdoor performance characteristics of the Honeywell liquid solar collector are presented. The program was based on the thermal evaluation of a Honeywell double covered liquid solar collection. Initial plans included the simultaneous testing of a single covered Honeywell collector. During the initial testing, the single covered collector failed due to leakage; thus, testing continued on the double covered collector only. To better define the operating characteristics of the collector, several additional data points were obtained beyond those requested.

Losey, R.↗