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The Structures Flight from 412 Test Wing and the Aerostructures Branch at NASA Armstrong Flight Research Center at Edwards Air Force Base have developed a set of best practices for training a structures flight test engineer. These practices represent the hard-won lessons learned and best practices from training generations of engineers to perform high risk envelope expansion and developmental flight test.
Work was performed to develop and demonstrate vibration diagnostic techniques for the on-line detection of engine rotor disk cracks and other anomalies through a real engine test. An existing single-degree-of-freedom non-resonance-based vibration algorithm was extended to a multi-degree-of-freedom model. In addition, a resonance-based algorithm was also proposed for the case of one or more resonances. The algorithms were integrated into a diagnostic system using state-of-the- art commercial analysis equipment. The system required only non-rotating vibration signals, such as accelerometers and proximity probes, and the rotor shaft 1/rev signal to conduct the health monitoring. Before the engine test, the integrated system was tested in the laboratory by using a small rotor with controlled mass unbalances. The laboratory tests verified the system integration and both the non-resonance and the resonance-based algorithm implementations. In the engine test, the system concluded that after two weeks of cycling, the seeded fan disk flaw did not propagate to a large enough size to be detected by changes in the synchronous vibration. The unbalance induced by mass shifting during the start up and coast down was still the dominant response in the synchronous vibration.
The tests reported in this paper were made to devise simple engine tests which would rate fuels as to their comparative value and their suitability for the operating conditions of the individual engine on which the tests are made. Three commercial fuels were used in two test engines having combustion chambers with and without effective air flow. Strictly comparative performance tests gave almost identical results for the three fuels. Analysis of indicator cards allowed a differentiation between fuels on a basis of rates of combustion. The same comparative ratings were obtained by determining the consistent operating range of injection advance angle for the three fuels. The difference in fuels is more pronounced in a quiescent combustion chamber than in one with high-velocity air flow. A fuel is considered suitable for the operating conditions of an engine with a quiescent combustion chamber if it permits the injection of the fuel to be advanced beyond the optimum without exceeding allowable knock or allowable maximum cylinder pressures.
Review of the current technical and programmatic status of the Integrated System Test of an Airbreathing Rocket (ISTAR) project. November 2002 completed Phase 1 of this project: which worked the conceptual design of the X-43B demonstrator vehicle and Flight Test Engine (FTE) order to develop realistic requirements for the Ground Test Engine (GTE). The latest conceptual FTE and X-43B configuration is briefly reviewed. The project plan is to reduce risk to the GTE and FTE concepts through several tests: thruster, fuel endothermic characterization, engine structure/heat exchanger, injection characterization rig, and full scale direct connect combustion rig. Each of these will be discussed along with the project schedule. This discussion is limited due to ITAR restrictions on open literature papers.
A relocated rocket engine test facility, the Altitude Combustion Stand (ACS), was activated in 2009 at the NASA Glenn Research Center. This facility has the capability to test with a variety of propellants and up to a thrust level of 2000 lbf (8.9 kN) with precise measurement of propellant conditions, propellant flow rates, thrust and altitude conditions. These measurements enable accurate determination of a thruster and/or nozzle s altitude performance for both technology development and flight qualification purposes. In addition the facility was designed to enable efficient test operations to control costs for technology and advanced development projects. A liquid oxygen-liquid methane technology development test program was conducted in the ACS from the fall of 2009 to the fall of 2010. Three test phases were conducted investigating different operational modes and in addition, the project required the complexity of controlling propellant inlet temperatures over an extremely wide range. Despite the challenges of a unique propellant (liquid methane) and wide operating conditions, the facility performed well and delivered up to 24 hot fire tests in a single test day. The resulting data validated the feasibility of utilizing this propellant combination for future deep space applications.
In separate series of T-700 engine tests, direct comparisons were made between the forward-facing labyrinth and dual-brush compressor discharge seals. Compressor speeds to 43,000 rpm, surface speeds to 160 m/s (530 ft/s), pressures to 1 MPa (145 psi), and temperatures to 680 K (765 F) characterized these tests. The wear estimate for 40 hr of engine operations was less than 0.025 mm (0.001 in.) of the Haynes 25 alloy bristles running against a chromium-oxide-coated rub runner. The pressure drops were higher for the dual-brush than for the forward-facing labyrinth seal, implying better seal characteristics and engine performance for the brush seal. Modification of the secondary flow path requires that changes in cooling air and engine dynamics be accounted for.
In separate series of YT-700 engine tests, direct comparisons were made between the forward-facing labyrinth and dual brush compressor discharge seals. Compressor speeds to 43 000 rpm, surface speeds to 160 m/s (530 ft/s), pressures to 1 MPa (145 psi), and temperatures to 680 K (765 F) characterized these tests. The wear estimate for 46 hr of engine operations was less than 0.025 mm (0.001 in.) of the Haynes 25 alloy bristles running against a chromium-carbide-coated rub runner. The pressure drops were higher for the dual-brush seal than for the forward-facing labyrinth seal and leakage was lower-with the labyrinth seal leakage being 2-1/2 times greater-implying better seal characteristics, better secondary airflow distribution, and better engine performance (3 percent at high pressure to 5 percent at lower pressure) for the brush seal. (However, as brush seals wear down (after 500 to 1000 hr of engine operation), their leakage rates will increase.) Modification of the secondary flow path requires that changes in cooling air and engine dynamics be accounted for.
An uncertainty analysis was conducted to determine the bias and precision errors and total uncertainty of measured turbojet engine performance parameters. The engine tests were conducted as part of the Uniform Engine Test Program which was sponsored by the Advisory Group for Aerospace Research and Development (AGARD). With the same engines, support hardware, and instrumentation, performance parameters were measured twice, once during tests conducted in test cell number 3 and again during tests conducted in test cell number 4 of the NASA Lewis Propulsion Systems Laboratory. The analysis covers 15 engine parameters, including engine inlet airflow, engine net thrust, and engine specific fuel consumption measured at high rotor speed of 8875 rpm. Measurements were taken at three flight conditions defined by the following engine inlet pressure, engine inlet total temperature, and engine ram ratio: (1) 82.7 kPa, 288 K, 1.0, (2) 82.7 kPa, 288 K, 1.3, and (3) 20.7 kPa, 288 K, 1.3. In terms of bias, precision, and uncertainty magnitudes, there were no differences between most measurements made in test cells number 3 and 4. The magnitude of the errors increased for both test cells as engine pressure level decreased. Also, the level of the bias error was two to three times larger than that of the precision error.
The integrity and performance of brush seals have been established. Severe bench and engine tests have shown high initial wear or run-in rates, material smearing at the interface, and bristle and rub-runner wear, but the brush seals did not fail. Short-duration (46 hr) experimental T-700 engine testing of the compressor discharge seal established over 1-percent engine performance gain (brush versus labyrinth). Long-term gains were established only as leakage comparisons, with the brush at least 20 percent better at controlling leakage. Long-term materials issues, such as wear and ultimately seal life, remain to be resolved. Future needs are cited for materials and analysis tools that account for heat generation, thermomechanical behavior, and tribological pairing to enable original equipment manufacturers to design high-temperature, high-surface-speed seals with confidence.
NASA Marshall Space Flight Center (MSFC) has been advancing dynamic optical measurement systems, primarily Digital Image Correlation, for extreme environment rocket engine test applications. The Digital Image Correlation (DIC) technology is used to track local and full field deformations, displacement vectors and local and global strain measurements. This technology has been evaluated at MSFC through lab testing to full scale hotfire engine testing of the J-2X Upper Stage engine at Stennis Space Center. It has been shown to provide reliable measurement data and has replaced many traditional measurement techniques for NASA applications. NASA and AMRDEC have recently signed agreements for NASA to train and transition the technology to applications for missile and helicopter testing. This presentation will provide an overview and progression of the technology, various testing applications at NASA MSFC, overview of Army-NASA test collaborations and application lessons learned about Digital Image Correlation.
Airframe-integrated scramjet engine tests have 8 completed at Mach 7 in the NASA Langley 8-Foot High Temperature Tunnel under the Hyper-X program. These tests provided critical engine data as well as design and database verification for the Mach 7 flight tests of the Hyper-X research vehicle (X-43), which will provide the first-ever airframe- integrated scramjet flight data. The first model tested was the Hyper-X Engine Model (HXEM), and the second was the Hyper-X Flight Engine (HXFE). The HXEM, a partial-width, full-height engine that is mounted on an airframe structure to simulate the forebody features of the X-43, was tested to provide data linking flowpath development databases to the complete airframe-integrated three-dimensional flight configuration and to isolate effects of ground testing conditions and techniques. The HXFE, an exact geometric representation of the X-43 scramjet engine mounted on an airframe structure that duplicates the entire three-dimensional propulsion flowpath from the vehicle leading edge to the vehicle base, was tested to verify the complete design as it will be flight tested. This paper presents an overview of these two tests, their importance to the Hyper-X program, and the significance of their contribution to scramjet database development.
Airframe-integrated scramjet engine tests have been completed at Mach 7 in the NASA Langley 8-Foot High Temperature Tunnel under the Hyper-X program. These tests provided critical engine data as well as design and database verification for the Mach 7 flight tests of the Hyper-X research vehicle (X-43), which will provide the first-ever airframe-integrated scramjet flight data. The first model tested was the Hyper-X Engine Model (HXEM), and the second was the Hyper-X Flight Engine (HXFE). The HXEM, a partial-width, full-height engine that is mounted on an airframe structure to simulate the forebody features of the X-43, was tested to provide data linking flowpath development databases to the complete airframe-integrated three-dimensional flight configuration, and to isolate effects of ground testing conditions and techniques. The HXFE, an exact geometric representation of the X-43 scramjet engine mounted on an airframe structure that duplicates the entire three-dimensional propulsion flowpath from the vehicle leading edge to the vehicle base, was tested to verify the complete design as it will be flight tested. This paper presents an overview of these two tests, their importance to the Hyper-X program, and the significance of their contribution to scramjet database development.
The mixed-fuels program examined included two major phases: the development of a reformer that would provide an onboard source of hydrogen, and the testing of induction systems and mixed fuels on a conventional V8 engine to verify the concept and define the system's potential. The discussion is limited to the engine testing phase. The testing program is reviewed and the effectiveness of an IDAC data acquisition system in supporting the engine testing program is demonstrated. The data system's application is illustrated by examples.
The development of a test engineer oriented language has been under way at the Kennedy Space Center for several years. The result of this effort is the Ground Operations Aerospace Language, GOAL, a self-documenting, high-order language suitable for coding automatic test, checkout and launch procedures. GOAL is a highly readable, writable, retainable language that is easily learned by nonprogramming oriented engineers. It is sufficiently powerful for use at all levels of Space Shuttle ground processing, from line replaceable unit checkout to integrated launch day operations. This paper will relate the language development, and describe GOAL and its applications.
A two-stage vorbix (vortex burning and mixing) combustor and associated fuel system components were successfully tested in an experimental JT9D engine at steady-state and transient operating conditions, using ASTM Jet-A fuel. Full-scale JT9D experimental engine tests were conducted in a phase three aircraft experimental clean combustor program. The low-pollution combustor, fuel system, and fuel control concepts were derived from phase one and phase two programs in which several combustor concepts were evaluated, refined, and optimized in a component test rig. Significant pollution reductions were achieved with the combustor which meets the performance, operating, and installation requirements of the engine.
A solar-thermal engine serves as a high-temperature solar-radiation absorber, heat exchanger, and rocket nozzle. collecting concentrated solar radiation into an absorber cavity and transferring this energy to a propellant as heat. Propellant gas can be heated to temperatures approaching 4,500 F and expanded in a rocket nozzle, creating low thrust with a high specific impulse (I(sub sp)). The Shooting Star Experiment (SSE) solar-thermal engine is made of 100 percent chemical vapor deposited (CVD) rhenium. The engine 'module' consists of an engine assembly, propellant feedline, engine support structure, thermal insulation, and instrumentation. Engine thermal performance tests consist of a series of high-temperature thermal cycles intended to characterize the propulsive performance of the engines and the thermal effectiveness of the engine support structure and insulation system. A silicone-carbide electrical resistance heater, placed inside the inner shell, substitutes for solar radiation and heats the engine. Although the preferred propellant is hydrogen, the propellant used in these tests is gaseous nitrogen. Because rhenium oxidizes at elevated temperatures, the tests are performed in a vacuum chamber. Test data will include transient and steady state temperatures on selected engine surfaces, propellant pressures and flow rates, and engine thrust levels. The engine propellant-feed system is designed to Supply GN2 to the engine at a constant inlet pressure of 60 psia, producing a near-constant thrust of 1.0 lb. Gaseous hydrogen will be used in subsequent tests. The propellant flow rate decreases with increasing propellant temperature, while maintaining constant thrust, increasing engine I(sub sp). In conjunction with analytical models of the heat exchanger, the temperature data will provide insight into the effectiveness of the insulation system, the structural support system, and the overall engine performance. These tests also provide experience on operational aspects of the engine and associated subsystems, and will include independent variation of both steady slate heat-exchanger temperature prior to thrust operation and nitrogen inlet pressure (flow rate) during thrust operation. Although the Shooting Star engines were designed as thermal-storage engines to accommodate mission parameters, they are fully capable of operating as scalable, direct-gain engines. Tests are conducted in both operational modes. Engine thrust and propellant flow rate will be measured and thereby I(sub sp). The objective of these tests is to investigate the effectiveness of the solar engine as a heat exchanger and a rocket. Of particular interest is the effectiveness of the support structure as a thermal insulator, the integrity of both the insulation system and the insulation containment system, the overall temperature distribution throughout the engine module, and the thermal power required to sustain steady state fluid temperatures at various flow rates.
The Simulation Software, KATE (Knowledgebase Autonomous Test Engineer), is used to demonstrate the automatic identification of faults in a system. The ACLO (Autonomous Cryogenics Loading Operation) project uses KATE to monitor and find faults in the loading of the cryogenics int o a vehicle fuel tank. The KATE software interfaces with the IHM (Integrated Health Management) systems bus to communicate with other systems that are part of ACLO. One system that KATE uses the IHM bus to communicate with is AIS (Advanced Inspection System). KATE will send messages to AIS when there is a detected anomaly. These messages include visual inspection of specific valves, pressure gauges and control messages to have AIS open or close manual valves. My goals include implementing the connection to the IHM bus within KATE and for the AIS project. I will also be working on implementing changes to KATE's Ul and implementing the physics objects in KATE that will model portions of the cryogenics loading operation.
Although the importance of aerosols and their precursors are 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. 1997 NASA LaRC engine test, as well as the parallel 1997 NASA LaRC flight measurement, attempts to address both issues by expanding measurements of aerosols and aerosol precursors with fuels containing different levels of fuel sulfur content. The specific objective of the 1997 engine test is to obtain a database of sulfur oxides emissions as well as the non-volatile particulate emission properties as a function of fuel sulfur and engine operating conditions. Four diagnostic systems, extractive and non-intrusive (optical), will be assembled for the gaseous and particulate emissions characterization measurements study. NASA is responsible for the extractive gaseous emissions measurement system which contains an array of analyzers dedicated to examining the concentrations of specific gases (NO, NO(x), CO, CO2, O2, THC, SO2) and the smoke number. University of Missouri-Rolla uses the Mobile Aerosol Sampling System to measure aerosol/particulate total concentration, size distribution, volatility and hydration property. Air Force Research Laboratory uses the Chemical Ionization Mass Spectrometer to measure SO2, SO3/H2SO4, and HN03 Aerodyne Research, Inc. uses Infrared Tunable Diode Laser system to measure SO2, SO3, NO, H2O, and CO2.