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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Fracture Tests of Etched Components Using a Focused Ion Beam Machine

Many optical MEMS device designs involve large arrays of thin (0.5 to 1 micron components subjected to high stresses due to cyclic loading. These devices are fabricated from a variety of materials, and the properties strongly depend on size and processing. Our objective is to develop standard and convenient test methods that can be used to measure the properties of large numbers of witness samples, for every device we build. In this work we explore a variety of fracture test configurations for 0.5 micron thick silicon nitride membranes machined using the Reactive Ion Etching (RIE) process. Testing was completed using an FEI 620 dual focused ion beam milling machine. Static loads were applied using a probe. and dynamic loads were applied through a piezo-electric stack mounted at the base of the probe. Results from the tests are presented and compared, and application for predicting fracture probability of large arrays of devices are considered.

Kuhn, Jonathan, L.↗
NASA NTRS2003

Software for Testing Electroactive Structural Components

A computer program generates a graphical user interface that, in combination with its other features, facilitates the acquisition and preprocessing of experimental data on the strain response, hysteresis, and power consumption of a multilayer composite-material structural component containing one or more built-in sensor(s) and/or actuator(s) based on piezoelectric materials. This program runs in conjunction with Lab-VIEW software in a computer-controlled instrumentation system. For a test, a specimen is instrumented with appliedvoltage and current sensors and with strain gauges. Once the computational connection to the test setup has been made via the LabVIEW software, this program causes the test instrumentation to step through specified configurations. If the user is satisfied with the test results as displayed by the software, the user activates an icon on a front-panel display, causing the raw current, voltage, and strain data to be digitized and saved. The data are also put into a spreadsheet and can be plotted on a graph. Graphical displays are saved in an image file for future reference. The program also computes and displays the power and the phase angle between voltage and current.

Moses, Robert W.↗
NASA NTRS2017

Design, Manufacture and Test of Cryotank Components

On the composite cryotank technology development (CCTD) project, the Boeing Company built two cryotanks as a means of advancing technology and manufacturing readiness levels (TRL and MRL) and lowering the risk of fabricating full-scale fuel containment vessels.1 CCTD focused on upper stage extended duration applications where long term storage of propellants is required. The project involved the design, analysis, fabrication, and test of manufacturing demonstration units (MDU), a 2.4 m (precursor) and a 5.5 m composite cryotank. Key design features included one-piece wall construction to minimize overall weight (eliminating the need for a bellyband joint), 3-dimensionally (3D) reinforced y-joint material to alleviate stress concentrations at the tank to skirt interface and a purge-able fluted core skirt to carry high axial launch loads. The tanks were made with OoA curing pre-impregnated (prepreg) carbon/epoxy (C/E) slit-tape tow (STT) that contained thin micro-crack resistant plies in the tank wall center to impede permeation. The tanks were fabricated at Boeing's Seattle-based Advanced Development Center (ADC) using RAFP and multipiece break-down tooling. The tooling was designed and built by Janicki Industries (JI) at Sedro Woolley, Washington. Tank assemblage consisted of co-bonded dome covers, one-piece fluted core skirts and mechanical fastened cover/sump. Ultrasonic inspection was performed after every cure or bond and a structural health monitoring system (SHMS) was installed to identify potential impact damage events (in-process and/or during transportation). The tanks were low temperature tested at NASA's George C. Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The testing, which consisted of a sequence of fill/drain pressure and thermal cycles using LH2, was successfully concluded in 2012 on the 2.4 m tank and in 2014 on the 5.5 m tank. Structural, thermal, and permeation performance data was obtained. 2 Critical design features and manufacturing advancements, which helped to validate 25% weight and 30% cost reduction projections, were matured. These advancements will help to guide future composite tank integration activities on next generation long duration aircraft and space launch vehicles. Because CCTD addressed innovative design features, heavy lift size scale-up, multipiece captured tooling, new generation automated material placement (AMP) equipment and OoA materials, this chapter should be of interest to educators, students and manufacturers of composite hardware and flight vehicles.

McCarville, Douglas A.↗
NASA NTRS1977

Shuttle payload vibroacoustic test plan evaluation

Statistical decision theory is used to evaluate seven alternate vibro-acoustic test plans for Space Shuttle payloads; test plans include component, subassembly and payload testing and combinations of component and assembly testing. The optimum test levels and the expected cost are determined for each test plan. By including all of the direct cost associated with each test plan and the probabilistic costs due to ground test and flight failures, the test plans which minimize project cost are determined. The lowest cost approach eliminates component testing and maintains flight vibration reliability by performing subassembly tests at a relatively high acoustic level.

Stahle, C. V.↗
NASA NTRS1991

System and component design and test of a 10 hp, 18,000 rpm AC dynamometer utilizing a high frequency AC voltage link, part 1

Hard and soft switching test results conducted with one of the samples of first generation MOS-controlled thyristor (MCTs) and similar test results with several different samples of second generation MCT's are reported. A simple chopper circuit is used to investigate the basic switching characteristics of MCT under hard switching and various types of resonant circuits are used to determine soft switching characteristics of MCT under both zero voltage and zero current switching. Next, operation principles of a pulse density modulated converter (PDMC) for three phase (3F) to 3F two-step power conversion via parallel resonant high frequency (HF) AC link are reviewed. The details for the selection of power switches and other power components required for the construction of the power circuit for the second generation 3F to 3F converter system are discussed. The problems encountered in the first generation system are considered. Design and performance of the first generation 3F to 3F power converter system and field oriented induction moter drive based upon a 3 kVA, 20 kHz parallel resonant HF AC link are described. Low harmonic current at the input and output, unity power factor operation of input, and bidirectional flow capability of the system are shown via both computer and experimental results. The work completed on the construction and testing of the second generation converter and field oriented induction motor drive based upon specifications for a 10 hp squirrel cage dynamometer and a 20 kHz parallel resonant HF AC link is discussed. The induction machine is designed to deliver 10 hp or 7.46 kW when operated as an AC-dynamo with power fed back to the source through the converter. Results presented reveal that the proposed power level requires additional energy storage elements to overcome difficulties with a peak link voltage variation problem that limits reaching to the desired power level. The power level test of the second generation converter after the addition of extra energy storage elements to the HF link are described. The importance of the source voltage level to achieve a better current regulation for the source side PDMC is also briefly discussed. The power levels achieved in the motoring mode of operation show that the proposed power levels achieved in the generating mode of operation can also be easily achieved provided that no mechanical speed limitation were present to drive the induction machine at the proposed power level.

Lipo, Thomas A.↗
NASA NTRS1990

Advanced Turbine Technology Applications Project (ATTAP)

Advanced Turbine Technology Application Project (ATTAP) activities during the past year were highlighted by test-bed engine design and development activities; ceramic component design; materials and component characterization; ceramic component process development and fabrication; component rig testing; and test-bed engine fabrication and testing. Although substantial technical challenges remain, all areas exhibited progress. Test-bed engine design and development activity included engine mechanical design, power turbine flow-path design and mechanical layout, and engine system integration aimed at upgrading the AGT-5 from a 1038 C metal engine to a durable 1371 C structural ceramic component test-bed engine. ATTAP-defined ceramic and associated ceramic/metal component design activities include: the ceramic combustor body, the ceramic gasifier turbine static structure, the ceramic gasifier turbine rotor, the ceramic/metal power turbine static structure, and the ceramic power turbine rotors. The materials and component characterization efforts included the testing and evaluation of several candidate ceramic materials and components being developed for use in the ATTAP. Ceramic component process development and fabrication activities are being conducted for the gasifier turbine rotor, gasifier turbine vanes, gasifier turbine scroll, extruded regenerator disks, and thermal insulation. Component rig testing activities include the development of the necessary test procedures and conduction of rig testing of the ceramic components and assemblies. Four-hundred hours of hot gasifier rig test time were accumulated with turbine inlet temperatures exceeding 1204 C at 100 percent design gasifier speed. A total of 348.6 test hours were achieved on a single ceramic rotor without failure and a second ceramic rotor was retired in engine-ready condition at 364.9 test hours. Test-bed engine fabrication, testing, and development supported improvements in ceramic component technology that will permit the achievement of program performance and durability goals. The designated durability engine accumulated 359.3 hour of test time, 226.9 of which were on the General Motors gas turbine durability schedule.

Source record↗
NASA NTRS1992

Advanced Turbine Technology Applications Project (ATTAP)

ATTAP activities during the past year included test-bed engine design and development, ceramic component design, materials and component characterization, ceramic component process development and fabrication, ceramic component rig testing, and test-bed engine fabrication and testing. Significant technical challenges remain, but all areas exhibited progress. Test-bed engine design and development included engine mechanical design, combustion system design, alternate aerodynamic designs of gasifier scrolls, and engine system integration aimed at upgrading the AGT-5 from a 1038 C (1900 F) metal engine to a durable 1372 C (2500 F) structural ceramic component test-bed engine. ATTAP-defined ceramic and associated ceramic/metal component design activities completed include the ceramic gasifier turbine static structure, the ceramic gasifier turbine rotor, ceramic combustors, the ceramic regenerator disk, the ceramic power turbine rotors, and the ceramic/metal power turbine static structure. The material and component characterization efforts included the testing and evaluation of seven candidate materials and three development components. Ceramic component process development and fabrication proceeded for the gasifier turbine rotor, gasifier turbine scroll, gasifier turbine vanes and vane platform, extruded regenerator disks, and thermal insulation. Component rig activities included the development of both rigs and the necessary test procedures, and conduct of rig testing of the ceramic components and assemblies. Test-bed engine fabrication, testing, and development supported improvements in ceramic component technology that permit the achievement of both program performance and durability goals. Total test time in 1991 amounted to 847 hours, of which 128 hours were engine testing, and 719 were hot rig testing.

Source record↗
NASA NTRS2004

Fabrication and Testing of Habitat Components Using In-Situ Materials for Martian Exploration

The development of Mars for human activity will require the utilization of Martian materials in building habitats and working structures. One approach is to use polymer binders with regolith to form structural elements. Not only can useful composite materials be produced in this way but the radiation protection properties are also increased. This is important since only modest protection from space radiation is provided by the Martian atmosphere. We have studied composites fabricated using Martian regolith simulant and polymers which can be synthesized from local Martian materials for their potential use as radiation shields for manned Mars missions. To validate shielding effectiveness, composites are irradiated with a 55 MeV proton beam and neutron beams up to 800 MeV. Shielding effects on microelectronic devices are measured by placing them behind samples of the composites during irradiation. To measure structural properties of the composites, preliminary characterization and mechanical testing are made for the composites.

Kim, M.-H. Y.↗
NASA NTRS2008

The J-2X Upper Stage Engine: From Heritage to Hardware

NASA's Global Exploration Strategy requires safe, reliable, robust, efficient transportation to support sustainable operations from Earth to orbit and into the far reaches of the solar system. NASA selected the Ares I crew launch vehicle and the Ares V cargo launch vehicle to provide that transportation. Guiding principles in creating the architecture represented by the Ares vehicles were the maximum use of heritage hardware and legacy knowledge, particularly Space Shuttle assets, and commonality between the Ares vehicles where possible to streamline the hardware development approach and reduce programmatic, technical, and budget risks. The J-2X exemplifies those goals. It was selected by the Exploration Systems Architecture Study (ESAS) as the upper stage propulsion for the Ares I Upper Stage and the Ares V Earth Departure Stage (EDS). The J-2X is an evolved version ofthe historic J-2 engine that successfully powered the second stage of the Saturn I launch vehicle and the second and third stages of the Saturn V launch vehicle. The Constellation architecture, however, requires performance greater than its predecessor. The new architecture calls for larger payloads delivered to the Moon and demands greater loss of mission reliability and numerous other requirements associated with human rating that were not applied to the original J-2. As a result, the J-2X must operate at much higher temperatures, pressures, and flow rates than the heritage J-2, making it one of the highest performing gas generator cycle engines ever built, approaching the efficiency of more complex stage combustion engines. Development is focused on early risk mitigation, component and subassembly test, and engine system test. The development plans include testing engine components, including the subscale injector, main igniter, powerpack assembly (turbopumps, gas generator and associated ducting and structural mounts), full-scale gas generator, valves, and control software with hardware-in-the-loop. Testing expanded in 2007, accompanied by the refinement of the design through several key milestones. This paper discusses those 2007 tests and milestones, as well as updates key developments in 2008.

Byrd, THomas↗
NASA NTRS1973

The Viking surface sampler

A surface sampler subsystem for the Viking Lander has been designed, fabricated, cleaned, and successfully tested. Testing has included component level tests to qualification environment and subsystem level tests. This development hardware has also been integrated into a System Test Bed (STB) for the lander system. In addition to the normal dynamic and thermal environments the surface sampler hardware has been tested in an aircraft to simulate the effects of the reduced Martian gravity. Although problems have been encountered with the first-build and integration, the basic design appears to be sound and hardware qualification is scheduled for late 1973.

Seger, R. B.↗
NASA NTRS1976

Laboratory-scale uranium RF plasma confinement experiments

An experimental investigation was conducted using 80 kW and 1.2 MW RF induction heater facilities to aid in developing the technology necessary for designing a self-critical fissioning uranium plasma core reactor. Pure uranium hexafluoride (UF6) was injected into argon-confined, steady-state, RF-heated plasmas in different uranium plasma confinement tests to investigate the characteristics of plamas core nuclear reactors. The objectives were: (1) to confine as high a density of uranium vapor as possible within the plasma while simultaneously minimizing the uranium compound wall deposition; (2) to develop and test materials and handling techniques suitable for use with high-temperature, high-pressure gaseous UF6; and (3) to develop complementary diagnostic instrumentation and measurement techniques to characterize the uranium plasma and residue deposited on the test chamber components. In all tests, the plasma was a fluid-mechanically-confined vortex-type contained within a fused-silica cylindrical test chamber. The test chamber peripheral wall was 5.7 cm ID by 10 cm long.

Roman, W. C.↗
NASA NTRS1979

High temperature UF6 and plasma research

Research currently under way on technology for uranium plasma core reactors is reviewed. A feeder system to provide a controlled and steady flow of UF6 at rates up to 5 g/sec and temperatures up to 500 K into rf plasma test chambers operating at pressures of up to 20 atm has been developed. Plasma emission and dye laser absorption measurements have been used to estimate the radial distribution of uranium atom number density within the plasma. X-ray absorption equipment and techniques have also been employed to measure the amount of uranium in the plasma, and dc plasma torch experiments have shown variations in plasma VUV emission with temperature. Analysis of residues deposited on various test-chamber components after plasma tests reveals traces of several uranium oxides, including UO2F2, and various exhaust duct configurations with flow augmentation are under investigation as means of preventing uranium deposition. Other areas of research include off- and on-line exhaust gas diagnostics, and a UF6/Ar injection, separation and recirculation system.

Roman, W. C.↗
NASA NTRS1999

Thermographic Testing Using on the X-33 Space Launch Vehicle Program by BFGoodrich Aerospace

The X-33 program is a team effort sponsored by NASA, under Cooperative Agreement NCC8-115, and led by the Lockheed Martin Corporation. Team member BFGoodrich Aerospace Aerostructures Group (formerly Rohr) is responsible for design, manufacture, and integration of the Thermal Protection System (TPS) of the X-33 launch vehicle. The X-33 is a half-scale, experimental prototype of a vehicle called RLV (Reusable Launch Vehicle) or VentureStar(Trademark), an SSTO (single stage to orbit) vehicle, which is a proposed successor to the aging Space Shuttle. Thermographic testing has been employed by BFGoodrich Aerospace Aerostructures Group for a wide variety of uses in the testing of components of the X-33. Thermographic NDT (TNDT) has been used for inspecting large graphite-epoxy/aluminum honeycomb sandwich panels used on the Leeward Aeroshell structure of the X-33. And TNDT is being evaluated for use in inspecting carbon-carbon composite parts such as the nosecap and wing leading edge components. Pulsed Infrared Testing (PIRT), a special form of TNDT, is used for the routine inspection of sandwich panels made of brazed inconel honeycomb and facesheets. In the developmental and qualification testing of sub-elements of the X-33, thermography has been used to monitor 1) Arc Jet tests at NASA Ames Research Center in Mountainview, CA and NASA Johnson Space Center in Houston, TX, 2) High Temperature (wind) Tunnel Tests (HTT) at NASA Langley Research Center in Langley, VA, and 3) Hot Gas Tests at NASA Marshall Space Flight Center in Huntsville, AL.

Burleigh, Douglas↗
NASA NTRS2008

Estimation of the Unsteady Aerodynamic Load on Space Shuttle External Tank Protuberances from a Component Wind Tunnel Test

At the wake of the Columbia (STS-107) accident it was decided to remove the Protuberance Aerodynamic Load (PAL) Ramp that was originally intended to protect various protuberances outside of the Space Shuttle External Tank from high buffet load induced by cross-flows at transonic speed. In order to establish the buffet load without the PAL ramp, a wind tunnel test was conducted where segments of the protuberances were instrumented with dynamic pressure transducers; and power-spectra of sectional lift and drag forces at various span-wise locations between two adjacent support brackets were measured under different cross flow angles, Mach number and other conditions. Additionally, frequency-dependent spatial correlations between the sectional forces were also established. The sectional forces were then adjusted by the correlation length to establish span-averaged spectra of normal and lateral forces that can be suitably "added" to various other unsteady forces encountered by the protuberance. This paper describes the methodology used for calculating the correlation-adjusted power spectrum of the buffet load. A second part of the paper describes wind-tunnel results on the difference in the buffet load on the protuberances with and without the PAL ramp. In general when the ramp height is the same as that of the protuberance height, such as that found on the liquid Oxygen part of the tank, the ramp is found to cause significant reduction of the unsteady aerodynamic load. However, on the liquid Hydrogen part of the tank, where the Oxygen feed-line is far larger in diameter than the height of the PAL ramp, little protection is found to be available to all but the Cable Tray.

Panda, J.↗
NASA NTRS2008

Estimation of the Unsteady Aerodynamic Load on Space Shuttle External Tank Protuberances from a Component Wind Tunnel Test

At the wake of the Columbia (STS-107) accident it was decided to remove the Protuberance Aerodynamic Load (PAL) Ramp that was originally intended to protect various protuberances outside of the Space Shuttle External Tank from high buffet load induced by cross-flows at transonic speed. In order to establish the buffet load without the PAL ramp, a wind tunnel test was conducted where segments of the protuberances were instrumented with dynamic pressure transducers; and power-spectra of sectional lift and drag forces at various span-wise locations between two adjacent support brackets were measured under different cross flow angles, Mach number and other conditions. Additionally, frequency-dependent spatial correlations between the sectional forces were also established. The sectional forces were then adjusted by the correlation length to establish span-averaged spectra of normal and lateral forces that can be suitably "added" to various other unsteady forces encountered by the protuberance. This paper describes the methodology used for calculating the correlation-adjusted power spectrum of the buffet load. A second part of the paper describes wind-tunnel results on the difference in the buffet load on the protuberances with and without the PAL ramp. In general when the ramp height is the same as that of the protuberance height, such as that found on the liquid Oxygen part of the tank, the ramp is found to cause significant reduction of the unsteady aerodynamic load. However, on the liquid Hydrogen part of the tank, where the Oxygen feed-line is far larger in diameter than the height of the PAL ramp, little protection is found to be available to all but the Cable Tray.

Panda, Jayatana↗
NASA NTRS2008

High Velocity Linear Induction Launcher with Exit-Edge Compensation for Testing of Aerospace Components

Advances in ultra high speed linear induction electromagnetic launchers over the past decade have focused on magnetic compensation of the exit and entry-edge transient flux wave to produce efficient and compact linear electric machinery. The paper discusses two approaches to edge compensation in long-stator induction catapults with typical end speeds of 150 to 1,500 m/s. In classical linear induction machines, the exit-edge effect is manifest as two auxiliary traveling waves that produce a magnetic drag on the projectile and a loss of magnetic flux over the main surface of the machine. In the new design for the Stator Compensated Induction Machine (SCIM) high velocity launcher, the exit-edge effect is nulled by a dual wavelength machine or alternately the airgap flux is peaked at a location prior to the exit edge. A four (4) stage LIM catapult is presently being constructed for 180 m/s end speed operation using double-sided longitudinal flux machines. Advanced exit and entry edge compensation is being used to maximize system efficiency, and minimize stray heating of the reaction armature. Each stage will output approximately 60 kN of force and produce over 500 G s of acceleration on the armature. The advantage of this design is there is no ablation to the projectile and no sliding contacts, allowing repeated firing of the launcher without maintenance of any sort. The paper shows results of a parametric study for 500 m/s and 1,500 m/s linear induction launchers incorporating two of the latest compensation techniques for an air-core stator primary and an iron-core primary winding. Typical thrust densities for these machines are in the range of 150 kN/sq.m. to 225 kN/sq.m. and these compete favorably with permanent magnet linear synchronous machines. The operational advantages of the high speed SCIM launcher are shown by eliminating the need for pole-angle position sensors as would be required by synchronous systems. The stator power factor is also improved.

Kuznetsov, Stephen↗
NASA NTRS2010

Testing of Laser Components Subjected to Exposure in Space

Materials International Space Station Experiment (MISSE) missions provide an opportunity for developing space qualifiable materials by studying the response of novel materials when subjected to the synergistic effects of the harsh space environment. MISSE 6 was transported to the international Space Station (ISS) via STS 123 on March 11. 2008. The astronauts successfully attached the passive experiment containers (PEC) to external handrails of the international space station (ISS) and opened up for long term exposure. After more than a year of exposure attached to the station's exterior, the PEC with several hundred material samples returned to the earth with the STS-128 space shuttle crew that was launched on shuttle Discovery from the Kennedy Space Center, Fla., on Aug. 28. Meanwhile, MISSE 7 launch is scheduled to be launched on STS 129 mission. MISSE-7 was launched on Space Shuttle mission STS-129 on Atlantis was launched on November 16, 2009. This paper will briefly review recent efforts on MISSE 6 and MISSE 7 missions at NASA Langley Research Center (LaRC).

Prasad, Narasimha S.↗