X-57 Maxwell Operational Flight Envelope
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Ethan Baumann↗
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Cryogenic wind tunnels. II
The application of the cryogenic concept to various types of tunnels including Ludwieg tube tunnel, Evans clean tunnel, blowdown, induced-flow, and continuous-flow fan-driven tunnels is discussed. Benefits related to construction and operating costs are covered, along with benefits related to new testing capabilities. It is noted that cooling the test gas to very low temperatures increases Reynolds number by more than a factor of seven. From the energy standpoint, ambient-temperature fan-driven closed-return tunnels are considered to be the most efficient type of tunnel, while a large reduction in the required tunnel stagnation pressure can be achieved through cryogenic operation. Operating envelopes for three modes of operation for a cryogenic transonic pressure tunnel with a 2.5 by 2.5 test section are outlined. A computer program for calculating flow parameters and power requirements for wind tunnels with operating temperatures from saturation to above ambient is highlighted.
Kilgore, Robert A.↗
Development of the Advance Warning Airborne System(AWAS)
The thermal characteristics of microbursts are utilized by the AWAS IR and OAT features to provide predictive warning of hazardous microbursts ahead of the aircraft during landing or take off. The AWAS was evaluated satisfactorily in 1990 on a Cessna Citation that was intentionally flown into a number of wind shear events. The events were detected, and both the IR and OAT thermal features were shown to be effective. In 1991, AWAS units were flown on three American Airline MD-80's and three Northwest Airlines DC-9's to study and to decrease the nuisance alert response of the system. The AWAS was also flown on the NASA B737 during the summer of 1991. The results of these flights were inconclusive and disappointing. The results were not as promising as before because NASA conducted research flights which were outside of the normal operating envelope for which the AWAS is designed to operate. In an attempt to compensate for these differences in airspeed and mounting location, the automatic features of the system were sometimes overridden by NASA personnel during the flight. Each of these critical factors is discussed in detail. The effect of rain on the OAT signals is presented as a function of the air speed. Use of a 4 pole 1/20 Hertz filter is demonstrated by both the IR and thermal data. Participation in the NASA 1992 program was discussed. FAA direction in the continuing Certification program requires the addition of a reactive feature to the AWAS predictive system. This combined system will not require flight guidance on newer aircraft. The features of AWAS-IV, with the NASA algorithm included, were presented. Expected completion of the FAA Certification plan was also described.
Adamson, H. Patrick↗
The Mars 2020 lander vision system field test
The Mars 2020 Lander Vision System estimates position relative to a map and provides this information to the spacecraft so that large hazards can be avoided during landing. The LVS is a new mission critical sensor and as such requires extensive validation. A field test conducted in May 2019 was the primary means to prove that the LVS will operate as designed. During this test over 600 independent real-time runs on engineering model LVS hardware and software were executed and clearly showed that it could meet a 40m position estimation requirement over a wide operational envelope. This paper will describe the test approach, operations and results. Specific examples as well as aggregate performance will be discussed along with off-nominal testing and fault recovery.
Montgomery, J.↗
The Mars 2020 Lander Vision System Field Test
The Mars 2020 Lander Vision System estimates position relative to a map and provides this information to the spacecraft so that large hazards can be avoided during landing. The LVS is a new mission critical sensor and as such requires extensive validation. A field test conducted in May 2019 was the primary means to prove that the LVS will operate as designed. During this test over 600 independent real-time runs on engineering model LVS hardware and software were executed and clearly showed that it could meet a 40m position estimation requirement over a wide operational envelope. This paper will describe the test approach, operations and results. Specific examples as well as aggregate per-formance will be discussed along with off-nominal testing and fault recovery.
Johnson, A.↗
The characteristics of the planned National Transonic Facility
The National Transonic Facility is a high Reynolds number transonic wind tunnel designed to satisfy the research and development needs of NASA, DOD, and industry. The facility design incorporates the cryogenic approach to achieving high Reynolds numbers with manageable model loads. By using temperature as a test variable, a unique capability to clearly separate aeroelastic, Reynolds number, and Mach number effects will be possible. This capability will open new horizons in transonic aerodynamic research. The tunnel design including unique features and operating envelopes is described. A brief overview of the general operating arrangement and the schedule for facility construction is presented.
Mckinney, L. W.↗
Dynamic characteristics of the national full-scale aerodynamic complex drive fan blades
An extensive experimental test program was conducted to define the dynamic characteristics of the newly installed fan blades of the NASA Ames 40- by 80-/80- by 120-Foot Wind Tunnel. The tests were intended to substantiate the blade design and manufacturing process, verify installation integrity, and guarantee safe fan-drive operation. The program included a shake test of each fan blade after installation and before operation as well as the monitoring of blade strain levels during initial operation. Structural characteristics, as determined by the shake test, include the modal frequency and damping values for elastic bending and torsion modes between 5 and 130 Hz. Operational testing defined the maximum and oscillatory blade-bending strains throughout the drive-system operational envelope. Results are presented for the shake test and initial operation of the 40- by 80-Foot Wind Tunnel circuit.
Peterson, Randall L.↗
A Personnel Launch System for safe and efficient manned operations
Several Conceptual designs for a simple, rugged Personnel Launch System (PLS) are presented. This system could transport people to and from Low Earth Orbit (LEO) starting in the late 1990's using a new modular Advanced Launch System (ALS) developed for the Space Exploration Initiative (SEI). The PLS is designed to be one element of a new space transportation architecture including heavy-lift cargo vehicles, lunar transfer vehicles, and multiple-role spcecraft such as the current Space Shuttle. The primary role of the PLS would be to deliver crews embarking on lunar or planetary missions to the Space Station, but it would also be used for earth-orbit sortie missions, space rescue missions, and some satellite servicing missions. The PLS design takes advantage of emerging electronic and structures technologies to offer a robust vehicle with autonomous operating and quick turnaround capabilities. Key features include an intact abort capability anywhere in the operating envelope, and elimination of all toxic propellants to streamline ground operations.
Petro, Andrew J.↗
Experimental Durability Testing of 4H SiC JFET Integrated Circuit Technology at 727 C
We have reported SiC integrated circuits (IC's) with two levels of metal interconnect that have demonstrated prolonged operation for thousands of hours at their intended peak ambient operational temperature of 500 C [1, 2]. However, it is recognized that testing of semiconductor microelectronics at temperatures above their designed operating envelope is vital to qualification. Towards this end, we previously reported operation of a 4H-SiC JFET IC ring oscillator on an initial fast thermal ramp test through 727 C [3]. However, this thermal ramp was not ended until a peak temperature of 880 C (well beyond failure) was attained. Further experiments are necessary to better understand failure mechanisms and upper temperature limit of this extreme-temperature capable 4H-SiC IC technology. Here we report on additional experimental testing of custom-packaged 4H-SiC JFET IC devices at temperatures above 500 C. In one test, the temperature was ramped and then held at 727 C, and the devices were periodically measured until electrical failure was observed. A 4H-SiC JFET on this chip electrically functioned with little change for around 25 hours at 727 C before rapid increases in device resistance caused failure. In a second test, devices from our next generation 4H-SiC JFET ICs were ramped up and then held at 700 C (which is below the maximum deposition temperature of the dielectrics). Three ring oscillators functioned for 8 hours at this temperature before degradation. In a third experiment, an alternative die attach of gold paste and package lid was used, and logic circuit operation was demonstrated for 143.5 hours at 700 C.
JFET↗
Experimental Durability Testing of 4H SiC JFET Integrated Circuit Technology at 727 Degrees Centigrade
We have reported SiC integrated circuits (ICs) with two levels of metal interconnect that have demonstrated prolonged operation for thousands of hours at their intended peak ambient operational temperature of 500 degrees Centigrade. However, it is recognized that testing of semiconductor microelectronics at temperatures above their designed operating envelope is vital to qualification. Towards this end, we previously reported operation of a 4H-SiC JFET IC ring oscillator on an initial fast thermal ramp test through 727 degrees Centigrade. However, this thermal ramp was not ended until a peak temperature of 880 degrees Centigrade (well beyond failure) was attained. Further experiments are necessary to better understand failure mechanisms and upper temperature limit of this extreme-temperature capable 4H-SiC IC technology.Here we report on additional experimental testing of custom-packaged 4H-SiC JFET IC devices at temperatures above 500 degrees Centigrade. In one test, the temperature was ramped and then held at 727 degrees Centigrade, and the devices were periodically measured until electrical failure was observed. A 4H-SiC JFET on this chip electrically functioned with little change for around 25 hours at 727 degrees Centigrade before rapid increases in device resistance caused failure. In a second test, devices from our next generation 4H-SiC JFET ICs were ramped up and then held at 700 degrees Centigrade (which is below the maximum deposition temperature of the dielectrics). Three ring oscillators functioned for 8 hours at this temperature before degradation. In a third experiment, an alternative die attach of gold paste and package lid was used, and logic circuit operation was demonstrated for 143.5 hours at 700 degrees Centigrade.
Silicon Carbide↗
A new airfoil research capability
The design and construction of a self streamlining wall test section for the Langley 0.3 meter transonic cryogenic tunnel was included in the fiscal year 1978 construction of facilities budget for Langley Research Center. The design is based on the research being carried out by M. J. Goodyer at the University of Southampton, Southampton, England, and is supported by Langley Research Center. This paper presents a brief description of the project. Included are some of the design considerations, anticipated operational envelope, and sketches showing the detail design concepts. Some details of the proposed operational mode, safety aspects, and preliminary schedule are presented.
Ladson, C. L.↗
Materials and construction techniques for cryogenic wind tunnel facilities for instruction/research use
The results of the cryogenic wind tunnel program conducted at NASA Langley Research Center are presented to provide a starting point for the design of an instructional/research wind tunnel facility. The advantages of the cryogenic concept are discussed, and operating envelopes for a representative facility are presented to indicate the range and mode of operation. Special attention is given to the design, construction and materials problems peculiar to cryogenic wind tunnels. The control system for operation of a cryogenic tunnel is considered, and a portion of a linearized mathematical model is developed for determining the tunnel dynamic characteristics.
Morse, S. F.↗
Derated ion thruster design issues
Preliminary activities to develop and refine a lightweight 30 cm engineering model ion thruster are discussed. The approach is to develop a 'derated' ion thruster capable of performing both auxiliary and primary propulsion roles over an input power range of at least 0.5 to 5.0 kilo-W. Design modifications to a baseline thruster to reduce mass and volume are discussed. Performance data over an order of magnitude input power range are presented, with emphasis on the performance impact of engine throttling. Thruster design modifications to optimize performance over specific power envelopes are discussed. Additionally, lifetime estimates based on wear test measurements are made for the operation envelope of the engine.
Patterson, Michael J.↗
Optical Characterization of Component Wear and Near-Field Plasma of the Hermes Thruster
Optical emission spectral (OES) data are presented which correlate trends in sputtered species and the near-field plasma with the Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster operating condition. The relative density of singly-ionized xenon (Xe II) is estimated using a collisional-radiative model. OES data were collected at three radial and several axial locations downstream of the thruster's exit plane. These data were deconvolved to show the structure for the near-field plasma as a function of thruster operating condition. The magnetic field is shown to have a much greater affect on plasma structure than the discharge voltage with the primary ionization/acceleration zone boundary being similar for all nominal operating voltages at constant power. OES measurement of sputtered boron shows that the HERMeS thruster is magnetically shielded across its operating envelope. Preliminary assessment of carbon sputtered from the keeper face suggest it increases significantly with operating voltage, but the uncertainty associated with these measurements is very high.
Electric Propulsion↗
Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Unsteady Analyses and Risk Assessment - Part 2
Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Design Support of the feasibility of operating conditions and procedures is critical in such cases due to the possibility of startup/shutdown transients, moving shock structures, unsteady shock-boundary layer interactions and engine and diffuser unstart modes that can result in catastrophic failure. Analyses of such systems is difficult due to resolution requirements needed to accurately capture moving shock structures, shock-boundary layer interactions, two-phase flow regimes and engine unstart modes. In a companion paper, we will demonstrate with the use of CFD, steady analyses advanced capability to evaluate supersonic diffuser and steam ejector performance in the sub-scale A-3 facility. In this paper we will address transient issues with the operation of the facility especially at startup and shutdown, and assess risks related to afterburning due to the interaction of a fuel rich plume with oxygen that is a by-product of the steam ejectors. The primary areas that will be addressed in this paper are: (1) analyses of unstart modes due to flow transients especially during startup/ignition, (2) engine safety during the shutdown process (3) interaction of steam ejectors with the primary plume i.e. flow transients as well as probability of afterburning. In this abstract we discuss unsteady analyses of the engine shutdown process. However, the final paper will include analyses of a staged startup, drawdown of the engine test cell pressure, and risk assessment of potential afterburning in the facility. Unsteady simulations have been carried out to study the engine shutdown process in the facility and understand the physics behind the interactions between the steam ejectors, the test cell and the supersonic diffuser. As a first approximation, to understand the dominant unsteady mechanisms in the engine test cell and the supersonic diffuser, the turning duct in the facility was removed. As the engine loses power a rarefaction wave travels downstream that disrupts the shock cell structure in the supersonic diffuser. Flow from the test cell is seen to expand into the supersonic diffuser section and re-pressurizes the area around the nozzle along with a upstream traveling compression wave that emanates from near the first stage ejectors. Flow from the first stage ejector expands to the center of the duct and a new shock train is formed between the first and second stage ejectors. Both stage ejectors keep the facility pressurized and prevent any large amplitude pressure fluctuations from affecting the engine nozzle. The resultant pressure loads the nozzle experiences in the shutdown process are small.
Ahuja, Vineet↗
Final analysis and design of a thermal protection system for 8-foot HTST combustor
The cylindrical shell combustor with T-bar supports in the 8-foot HTST at the NASA-Langley Research Center encountered vibratory fatigue cracking over a period of 50-250 tunnel tests within a limited range of the required operating envelope. A preliminary design study provided several suitable thermal protection system designs for the combustor, one of which was a two-pass regenerative type air-cooled omega-shaped segment liner. A final design layout of the omega segment liner was prepared and analyzed for steady-state and transient conditions. The design of a support system for the fuel spray bar assembly was also included. Detail drawings suitable for fabrication purposes were also prepared. Liner design problems defined during the preliminary study included (1) the ingress of gas into the attachment bulb section of the omega segment, (2) the large thermal gradient along the leg of the omega bulb attachment section and, (3) the local peak metal temperature at the radius between the liner ID and the leg of the bulb attachment. These were resolved during the final design task. Analyses of the final design of the omega segment liner indicated that all design goals were met and the design provided the capability of operating over the required test envelope with a life expectancy substantially above the goal of 1500 cycles.
Moskowitz, S.↗
Indirect Magnetic Measurements on the Aerodynamic Heating Facility (AHF)
The arc jet complex at NASA Ames Research Center (ARC) investigates various thermal protection systems (TPS) and their performance in high enthalpy flow environments to improve heat shields used in atmospheric entry. The arc jet operates by inducing an arc between two electrodes and passing the heated gas through a supersonic nozzle. The arc plasma is typically a partially ionized air mixture at low temperature (< 2 eV) but operates for long periods of time (up to 30 min) at high power (< 60 MW). However, simulations using the in-house ARC Heater Simulator (ARCHeS) code predict that the arc is still unstable to MHD instabilities, primarily the kink instability, which limit the operational envelope of the facility [1]. Consequently, it is important to better characterize these instabilities to improve facility stability and extend operational ranges. Due to the high enthalpy and long timescales (i.e., minutes) arc diagnostics must be non-invasive (i.e., optical or magnetic). This work will cover the development of tri-axial magnetic hall sensors for arc jet instabilities and subsequent 3D characterization of arc motion. The latest results describing the kink instability amplitude, frequency and wavelength will be presented and represent the first measurements of this instability in a NASA arc jet facility. References: [1] Meurisse, J. (2018). 3D Unsteady Model of Arc Heater Plasma Flow Using the ARC Heater Simulator (ARCHeS), APS Gaseous Electronics Conference, 2018: APS.
Sebastian Vicente Colom↗
Uprated OMS Engine Status-Sea Level Testing Results
The current Space Shuttle Orbital Maneuvering Engine (OME) is pressure fed, utilizing storable propellants. Performance uprating of this engine, through the use of a gas generator driven turbopump to increase operating pressure, is being pursued by the NASA Johnson Space Center (JSC). Component level design, fabrication, and test activities for this engine system have been on-going since 1984. More recently, a complete engine designated the Integrated Component Test Bed (ICTB), was tested at sea level conditions by Aerojet. A description of the test hardware and results of the sea level test program are presented. These results, which include the test condition operating envelope and projected performance at altitude conditions, confirm the capability of the selected Uprated OME (UOME) configuration to meet or exceed performance and operational requirements. Engine flexibility, demonstrated through testing at two different operational mixture ratios, along with a summary of projected Space Shuttle performance enhancements using the UOME, are discussed. Planned future activities, including ICTB tests at simulated altitude conditions, and recommendations for further engine development, are also discussed.
Bertolino, J. D.↗