Activation and Initial Test Operations, Large Rocket Engine - Thrust Chamber Test Facilities Technology Report
Activation and initial test operations of thrust chamber facility for NASA M-1 rocket engine
ROCKET TEST STATION↗
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Acoustic-Structure Interaction in Rocket Engines: Validation Testing
While analyzing a rocket engine component, it is often necessary to account for any effects that adjacent fluids (e.g., liquid fuels or oxidizers) might have on the structural dynamics of the component. To better characterize the fully coupled fluid-structure system responses, an analytical approach that models the system as a coupled expansion of rigid wall acoustic modes and in vacuo structural modes has been proposed. The present work seeks to experimentally validate this approach. To experimentally observe well-coupled system modes, the test article and fluid cavities are designed such that the uncoupled structural frequencies are comparable to the uncoupled acoustic frequencies. The test measures the natural frequencies, mode shapes, and forced response of cylindrical test articles in contact with fluid-filled cylindrical and/or annular cavities. The test article is excited with a stinger and the fluid-loaded response is acquired using a laser-doppler vibrometer. The experimentally determined fluid-loaded natural frequencies are compared directly to the results of the analytical model. Due to the geometric configuration of the test article, the analytical model is found to be valid for natural modes with circumferential wave numbers greater than four. In the case of these modes, the natural frequencies predicted by the analytical model demonstrate excellent agreement with the experimentally determined natural frequencies.
Davis, R. Benjamin↗
The use of programmable logic controllers (PLC) for rocket engine component testing
Application of PLCs to the rocket engine component testing at a new Stennis Space Center Component Test Facility is suggested as an alternative to dedicated specialized computers. The PLC systems are characterized by rugged design, intuitive software, fault tolerance, flexibility, multiple end device options, networking capability, and built-in diagnostics. A distributed PLC-based system is projected to be used for testing LH2/LOx turbopumps required for the ALS/NLS rocket engines.
Nail, William↗
An experimental evaluation of 100-lb-thrust ablatively cooled rocket engines
Test firing of 100-lb thrust ablatively cooled rocket chambers
ROCKET CHAMBER↗
Experimental evaluation of six ablative-material thrust chambers as components of storable-propellant rocket engines
Test firing evaluation of six ablative-material thrust chambers as components of storable propellant rocket engines
COMBUSTION CHAMBER↗
Rehabilitation of the Rocket Vehicle Integration Test Stand at Edwards Air Force Base
Since initial use in 1958 for the X-15 rocket-powered research airplane, the Rocket Engine Test Facility has proven essential for testing and servicing rocket-powered vehicles at Edwards Air Force Base. For almost two decades, several successful flight-test programs utilized the capability of this facility. The Department of Defense has recently demonstrated a renewed interest in propulsion technology development with the establishment of the National Aerospace Initiative. More recently, the National Aeronautics and Space Administration is undergoing a transformation to realign the organization, focusing on the Vision for Space Exploration. These initiatives provide a clear indication that a very capable ground-test stand at Edwards Air Force Base will be beneficial to support the testing of future access-to-space vehicles. To meet the demand of full integration testing of rocket-powered vehicles, the NASA Dryden Flight Research Center, the Air Force Flight Test Center, and the Air Force Research Laboratory have combined their resources in an effort to restore and upgrade the original X-15 Rocket Engine Test Facility to become the new Rocket Vehicle Integration Test Stand. This report describes the history of the X-15 Rocket Engine Test Facility, discusses the current status of the facility, and summarizes recent efforts to rehabilitate the facility to support potential access-to-space flight-test programs. A summary of the capabilities of the facility is presented and other important issues are discussed.
Jones, Daniel S.↗
Development of a digital control system for a spacecraft propulsion test facility
A digital computer control and abort system which is used at NASA-Lewis research center is described. The system was designed to control test operations such as rocket engine testing, structure testing, and wind tunnel tests. Because of the nature of spacecraft system testing, particularly rocket engine testing, the unique features of the system are, control function updating at a 20 millisecond rate, continuous abort monitoring and a software system designed for short duration tests rather than continuous on-line control. To accomplish these system requirements, special hardware was designed. The presentation includes a description of the computer system and special interface hardware as well as a general description of the software used.
Smalley, R. R.↗
Development of a digital control system for a spacecraft propulsion test facility.
A digital computer control and abort system which is used at NASA-Lewis Research Center's Plum Brook Test Facilities is described. The system was designed by NASA personnel to control test operations such as rocket engine testing, structure testing, and wind tunnel tests. Because of the nature of spacecraft system testing, particularly rocket engine testing, the unique features of the system are, control function updating at a 20 millisecond rate, continuous abort monitoring and a software system designed for short duration tests rather than continuous on-line control. To accomplish these system requirements, special hardware was designed. The presentation will include a description of the computer system including special interface hardware as well as a general description of the software used.
Smalley, R. R.↗
Development of a digital control system for a spacecraft propulsion test facility.
Description of a digital computer control and abort system designed by NASA personnel to control test operations such as rocket engine testing, structure testing, and wind tunnel tests. Because of the nature of spacecraft system testing, particularly rocket engine testing, the unique features of the system are, control function updating at a 20 millisecond rate, continuous abort monitoring, and a software system designed for short duration tests rather than continuous on-line control. The presentation includes a description of the computer system and special interface hardware as well as a general description of the software used.
Smalley, R. R.↗
Prediction of Acoustic Loads Generated by Propulsion Systems
NASA Stennis Space Center is one of the nation's premier facilities for conducting large-scale rocket engine testing. As liquid rocket engines vary in size, so do the acoustic loads that they produce. When these acoustic loads reach very high levels they may cause damages both to humans and to actual structures surrounding the testing area. To prevent these damages, prediction tools are used to estimate the spectral content and levels of the acoustics being generated by the rocket engine plumes and model their propagation through the surrounding atmosphere. Prior to the current work, two different acoustic prediction tools were being implemented at Stennis Space Center, each having their own advantages and disadvantages depending on the application. Therefore, a new prediction tool was created, using NASA SP-8072 handbook as a guide, which would replicate the same prediction methods as the previous codes, but eliminate any of the drawbacks the individual codes had. Aside from replicating the previous modeling capability in a single framework, additional modeling functions were added thereby expanding the current modeling capability. To verify that the new code could reproduce the same predictions as the previous codes, two verification test cases were defined. These verification test cases also served as validation cases as the predicted results were compared to actual test data.
Perez, Linamaria↗
Structural damage claims resulting from acoustic environments developed during static test firing of rocket engines
During static testing of multi-million pound thrust rocket engines areas adjacent to the test site have been subjected to the noise generated by rocket engines. Structural damage claims and subjective complaints were filed by those who alleged that the noise levels were excessive. The statistical analysis of these claims and complaints which were filed during these rocket engine development programs led to the determination of a relationship between claims and overall sound pressure level. Community exposure criteria are then assessed based on what can be considered allowable acoustic environments from large rocket engines.
Guest, S. H.↗
Rocket Propulsion Test Design and Analysis
As the small satellite launch vehicle (SSLV) market grows and NASA continues to prepare for upcoming missions in the Artemis program, John C. Stennis Space Center’s (SSC) testing facilities must adapt to the increasing demand in liquid rocket engine testing. The Rocket Propulsion Test Design and Analysis Project for this rotation focused in both of this areas through two separate subprojects, the creation of a Private Rocket Engine Database and the automatization of the A1-Set Point Prediction Model. To identify the testing requirements of future Stennis Space Center (SSC) costumers, an excel spread sheet was commissioned as a database to collect technical and non-technical features of over one hundred privately developed liquid and hybrid rocket engine. Similarly, The A-1 Set Point Sheet Model is used to satisfy Aerojet Rocketdyne’s testing requirements of Net Positive Suction Pressure (NPSP) for the RS-25 staged combustion cycle engine. To expand the capabilities of this prediction model, a feed back loop was programmed to automate the search of setpoints using Excel Visual Basic for Applications (VBA).
John Paul Ortiz↗
Subscale Validation of the Subsurface Active Filtration of Exhaust (SAFE) Approach to NTP Ground Testing
Brief History of NTP: Project Rover Began in 1950s by Los Alamos Scientific Labs (now Los Alamos National Labs) and ran until 1970s Tested a series of nuclear reactor engines of varying size at Nevada Test Site (now Nevada National Security Site) Ranged in scale from 111 kN (25 klbf) to 1.1 MN (250 klbf) Included Nuclear Furnace-1 tests Demonstrated the viability and capability of a nuclear rocket engine test program One of Kennedys 4 goals during famous moon speech to Congress Nuclear Engines for Rocket Vehicle Applications (NERVA) Atomic Energy Commission and NASA joint venture started in 1964 Parallel effort to Project Rover was focused on technology demonstration Tested XE engine, a 245-kN (55-klbf) engine to demonstrate startup shutdown sequencing. Hot-hydrogen stream is passed directly through fuel elements potential for radioactive material to be eroded into gaseous fuel flow as identified in previous programs NERVA and Project Rover (1950s-70s) were able to test in open atmosphere similar to conventional rocket engine test stands today Nuclear Furance-1 tests employed a full scrubber system Increased government and environmental regulations prohibit the modern testing in open atmosphere. Since the 1960s, there has been an increasing cessation on open air testing of nuclear material Political and national security concerns further compound the regulatory environment
Test Facilities↗
Application of Background Oriented Schlieren for Altitude Testing of Rocket Engines
A series of experiments was performed to determine the feasibility of using the Background Oriented Schlieren, BOS, flow visualization technique to image a simulated, small, rocket engine, plume under altitude test conditions. Testing was performed at the NASA Glenn Research Centers Altitude Combustion Stand, ACS, using nitrogen as the exhaust gas simulant. Due to limited optical access to the facility test capsule, all of the hardware required to conduct the BOS were located inside the vacuum chamber. During the test series 26 runs were performed using two different nozzle configurations with pressures in the test capsule around 0.3 psia. No problems were encountered during the test series resulting from the optical hardware being located in the test capsule and acceptable resolution images were captured. The test campaign demonstrated the ability of using the BOS technique for small, rocket engine, plume flow visualization during altitude testing.
Background Oriented Schlieren↗
Application of High Speed Digital Image Correlation in Rocket Engine Hot Fire Testing
Hot fire testing of rocket engine components and rocket engine systems is a critical aspect of the development process to understand performance, reliability and system interactions. Ground testing provides the opportunity for highly instrumented development testing to validate analytical model predictions and determine necessary design changes and process improvements. To properly obtain discrete measurements for model validation, instrumentation must survive in the highly dynamic and extreme temperature application of hot fire testing. Digital Image Correlation has been investigated and being evaluated as a technique to augment traditional instrumentation during component and engine testing providing further data for additional performance improvements and cost savings. The feasibility of digital image correlation techniques were demonstrated in subscale and full scale hotfire testing. This incorporated a pair of high speed cameras to measure three-dimensional, real-time displacements and strains installed and operated under the extreme environments present on the test stand. The development process, setup and calibrations, data collection, hotfire test data collection and post-test analysis and results are presented in this paper.
Gradl, Paul R.↗
Space chemical propulsion test facilities at NASA Lewis Research Center
The NASA Lewis Research Center, located in Cleveland, Ohio has a number of space chemical propulsion test facilities which constitute a significant national space testing resource. The purpose of this paper is to make more users aware of these test facilities and to encourage their use through cooperative agreements between the government, industry, and universities. Research which is of interest to the government is especiallly encouraged and often can be done in a cooperative manner that best uses the resources of all parties. This paper presents an overview of the Lewis test facilities. These facilities are clustered into three test areas: the Rocket Engine Test Facilities (RETF), the Rocket Laboratory (RL), and the Cryogenic Components Laboratory (CCL).
Urasek, Donald C.↗
Smart Sensor Demonstration Payload
Sensors are a critical element to any monitoring, control, and evaluation processes such as those needed to support ground based testing for rocket engine test. Sensor applications involve tens to thousands of sensors; their reliable performance is critical to achieving overall system goals. Many figures of merit are used to describe and evaluate sensor characteristics; for example, sensitivity and linearity. In addition, sensor selection must satisfy many trade-offs among system engineering (SE) requirements to best integrate sensors into complex systems [1]. These SE trades include the familiar constraints of power, signal conditioning, cabling, reliability, and mass, and now include considerations such as spectrum allocation and interference for wireless sensors. Our group at NASA s John C. Stennis Space Center (SSC) works in the broad area of integrated systems health management (ISHM). Core ISHM technologies include smart and intelligent sensors, anomaly detection, root cause analysis, prognosis, and interfaces to operators and other system elements [2]. Sensor technologies are the base fabric that feed data and health information to higher layers. Cost-effective operation of the complement of test stands benefits from technologies and methodologies that contribute to reductions in labor costs, improvements in efficiency, reductions in turn-around times, improved reliability, and other measures. ISHM is an active area of development at SSC because it offers the potential to achieve many of those operational goals [3-5].
Schmalzel, John↗
Activation and initial test operations of large rocket engine - Thrust chamber test facilities.
M-1 Engine Thrust Chamber Assembly test facilities and analog computor simulation during checkout
TEST FACILITY↗