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DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, liquid helium is essential to the testing activities. The test stands used require large amounts of Helium to test the thermal and superconducting cavities and magnets. The liquid helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for user s fees that will provide funding for the replenishment of helium and continual operation at IB1.

Trillo, Angelica↗

NASA NTRS1983

The impact of CFD on development test facilities - A National Research Council projection

The results of a National Research Council study on the effect that advances in computational fluid dynamics (CFD) will have on conventional aeronautical ground testing are reported. Current CFD capabilities include the depiction of linearized inviscid flows and a boundary layer, initial use of Euler coordinates using supercomputers to automatically generate a grid, research and development on Reynolds-averaged Navier-Stokes (N-S) equations, and preliminary research on solutions to the full N-S equations. Improvements in the range of CFD usage is dependent on the development of more powerful supercomputers, exceeding even the projected abilities of the NASA Numerical Aerodynamic Simulator (1 BFLOP/sec). Full representation of the Re-averaged N-S equations will require over one million grid points, a computing level predicted to be available in 15 yr. Present capabilities allow identification of data anomalies, confirmation of data accuracy, and adequateness of model design in wind tunnel trials. Account can be taken of the wall effects and the Re in any flight regime during simulation. CFD can actually be more accurate than instrumented tests, since all points in a flow can be modeled with CFD, while they cannot all be monitored with instrumentation in a wind tunnel.

Korkegi, R. H.↗

NASA NTRS2010

Monitoring System for Storm Readiness and Recovery of Test Facilities: Integrated System Health Management (ISHM) Approach

Severe weather events are likely occurrences on the Mississippi Gulf Coast. It is important to rapidly diagnose and mitigate the effects of storms on Stennis Space Center's rocket engine test complex to avoid delays to critical test article programs, reduce costs, and maintain safety. An Integrated Systems Health Management (ISHM) approach and technologies are employed to integrate environmental (weather) monitoring, structural modeling, and the suite of available facility instrumentation to provide information for readiness before storms, rapid initial damage assessment to guide mitigation planning, and then support on-going assurance as repairs are effected and finally support recertification. The system is denominated Katrina Storm Monitoring System (KStorMS). Integrated Systems Health Management (ISHM) describes a comprehensive set of capabilities that provide insight into the behavior the health of a system. Knowing the status of a system allows decision makers to effectively plan and execute their mission. For example, early insight into component degradation and impending failures provides more time to develop work around strategies and more effectively plan for maintenance. Failures of system elements generally occur over time. Information extracted from sensor data, combined with system-wide knowledge bases and methods for information extraction and fusion, inference, and decision making, can be used to detect incipient failures. If failures do occur, it is critical to detect and isolate them, and suggest an appropriate course of action. ISHM enables determining the condition (health) of every element in a complex system-of-systems or SoS (detect anomalies, diagnose causes, predict future anomalies), and provide data, information, and knowledge (DIaK) to control systems for safe and effective operation. ISHM capability is achieved by using a wide range of technologies that enable anomaly detection, diagnostics, prognostics, and advise for control: (1) anomaly detection algorithms and strategies, (2) fusion of DIaK for anomaly detection (model-based, numerical, statistical, empirical, expert-based, qualitative, etc.), (3) diagnostics/prognostics strategies and methods, (4) user interface, (5) advanced control strategies, (6) integration architectures/frameworks, (7) embedding of intelligence. Many of these technologies are mature, and they are being used in the KStorMS. The paper will describe the design, implementation, and operation of the KStorMS; and discuss further evolution to support other needs such as condition-based maintenance (CBM).

Figueroa, Fernando↗

NASA NTRS2010

Calibration for Thrust and Airflow Measurements in the CE-22 Advanced Nozzle Test Facility

CE-22 facility procedures and measurements for thrust and airflow calibration obtained with choked-flow ASME nozzles are presented. Six calibration nozzles are used at an inlet total pressure from 20 to 48 psia. Throat areas are from 9.9986 to 39.986 sq. in.. Throat Reynolds number varies from 1.8 to 7.9 million. Nozzle gross thrust coefficient (CFG) uncertainty is 0.25 to 0.75 percent, with smaller uncertainly generally for larger nozzles and higher inlet total pressure. Nozzle discharge coefficient (CDN) uncertainty is 0.15 percent or less for all the data. ASME nozzle calibrations need to be done before and after research model testing to achieve these uncertainties. In addition, facility capability in terms of nozzle pressure ratio (NPR) and nozzle airflow are determined. Nozzle pressure ratio of 50 or more is obtainable at 40 psia for throat areas between 20 and 30 sq. in.. Also presented are results for two of the ASME nozzles vectored at 10deg, a dead-weight check of the vertical (perpendicular to the jet axis) force measurement, a calibration of load cell forces for the effects of facility tank deflection with tank pressure, and the calibration of the metric-break labyrinth seal.

Werner, Roger A.↗

NASA NTRS2009

Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG) is being considered to power deep space missions. An engineering unit, the ASRG-EU, was designed and fabricated by Lockheed Martin under contract to the Department of Energy. This unit is currently on an extended operation test at NASA Glenn Research Center to generate performance data and validate the life and reliability predictions for the generator and the Stirling convertors. A special test facility was designed and built for testing the ASRG-EU. Details of the test facility design are discussed. The facility can operate the convertors under AC bus control or with the ASRG-EU controller. It can regulate input thermal power in either a fixed temperature or fixed power mode. An enclosure circulates cooled air around the ASRG-EU to remove heat rejected from the ASRG-EU by convection. A custom monitoring and data acquisition system supports the test. Various safety features, which allow 2417 unattended operation, are discussed.

Lewandowski, Edward J.↗

NASA NTRS1988

Payload bay atmospheric vent airflow testing at the Vibration and Acoustic Test Facility

Several concerns related to venting the Space Shuttle Orbiter payload bay during launch led to laboratory experiments with a flight-type vent box installed in the wall of a subsonic wind tunnel. This report describes the test setups and procedures used to acquire data for characterization of airflow through the vent box and acoustic tones radiated from the vent-box cavity. A flexible boundary-layer spoiler which reduced the vent-tone amplitude is described.

Johnston, James D., Jr.↗

NASA NTRS1986

Meeting today's requirements for large thermal vacuum test facilities

The Lockheed Thermal Vacuum Facility at Sunnyvale, California, completed in late 1986, one of the largest multi-program facilities constructed to date is described. The horizontal 12.2 m diameter by 24.4 m long chamber has removable heads at each end and houses a thermal shroud providing a test volume 10.4 m diameter by 24.4 m long. The chamber and thermal shroud are configured to permit the insertion of a 6.1 m wide by 24.4 m long vibration isolated optical bench. The pumpimg system incorporates an internal cryopumping array, turbomolecular pumps and cryopumps to handle multi-program needs and ranges of gas loads. The high vacuum system is capable of achieving clean, dry and empty pressures below 1.3 times 10 to the minus 6 power Pa (10 to the minus 8 power torr.)

Corinth, R. L.↗

NASA NTRS1975

Method of predicting radiation heat transfer in turbine cooling test facilities

A method is presented for calculating the average net radiation heat flux to turbine vanes and blades. The net radiation heat flux at a vane leading edge calculated by this method was compared with heat flux values independently determined from experimental tests on a vane in a cascade. The spectral emissivities of the turbine vane and the cascade wall were also measured.

Gladden, H. J.↗

NASA NTRS1977

Baseline performance of solar collectors for NASA Langley solar building test facility

The solar collector field contains seven collector designs. Before operation in the field, the experimental performances (thermal efficiencies) of the seven collector designs were measured in an indoor solar simulator. The resulting data provided a baseline for later comparison with actual field test data. The simulator test results are presented for the collectors as received, and after several weeks of outdoor exposure with no coolant (dry operation). Six of the seven collector designs tested showed substantial reductions in thermal efficiency after dry operation.

Knoll, R. H.↗

NASA NTRS1992

Slush hydrogen transfer studies at the NASA K-Site Test Facility

An experimental study was performed as part of the National Aerospace Plane (NASP) effort to determine slush hydrogen production and transfer characteristics. Flow rate and pressure drop characteristics were determined for slush hydrogen flow through a vacuum-jacketed transfer system. These characteristics were compared to similar tests using normal boiling point and triple point hydrogen. In addition, experimental flow characteristic data was compared with predictions from the FLUSH analytical model. Slush hydrogen density loss during the transfer process was also examined.

Hardy, Terry L.↗

NASA NTRS1992

Slush hydrogen transfer studies at the NASA K-Site Test Facility

Hardy, Terry L.↗

NASA NTRS2001

Investigation of the Flow-Induced Vibration in the E2 Test Facility

An investigation of flow induced vibration due to coupling between the fluid flow and the propellants lines (LOX and RP-1) was performed. Various flow rate conditions were studied to check whether flow induced vibration was possible due to vortex shedding in both valves and pipe lines. Resonance test was conducted for all segments of the LOX-feedline for the preburner under test. In addition, critical values of frequency and velocity are calculated using a mass damping model. A simple chart characterizing the relation between frequency and velocity is developed for each component; i.e. propellant lines, valves and flow meters. It was found that flow induced vibration occurs for various segments with flow rates of 113 lb/s, 275 lb/s and 40 lb/s. Even more interesting using critical conditions for buckling, it was found that the valve or pipe may collapse for a flow rate of 275 lb/s and valve height of 10% of pipe diameter. Furthermore, two models for the acoustic pressure acting on the segments particularly for the valve are proposed.

Castillo, Luciano↗

NASA NTRS2001

Investigation of the Flow-Induced Vibration in the E2 Test Facility

An investigation of flow induced vibration due to coupling between the fluid flow and the propellants lines (LOX and RP-1) was performed. Various flow rate conditions were studied to check whether flow induced vibration was possible due to vortex shedding in both valves and pipe lines. Resonances test was conducted for all segments of the LOX-feedline for the preburner under test. In addition, critical values of frequency and velocity are calculated using a mass damping model. A simple chart characterizing the relation between frequency and velocity is developed for each component; i.e. propellant lines, valves and flow meters. It was found that flow induced vibration occurs for various segments with flow rates of 113 1b/s, 275 lb/s and 40 lb/s. Even more interesting using critical conditions for buckling, it was found that the valve or pipe may collapse for a flow rate of 275 lb/s and valve height of 10% of pipe diameter. Furthermore, two models for the acoustic pressure acting on the segments particularly for the valve are proposed.

Castillo, Luciano↗

NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗

NASA NTRS2016

Performance Evaluation of the International Space Station Flow Boiling and Condensation Experiment (FBCE) Test Facility

A ground-based experimental facility to perform flow boiling and condensation experiments is built in support of the development of the long duration Flow Boiling and Condensation Experiment (FBCE) destined for operation on board of the International Space Station (ISS) Fluid Integrated Rack (FIR). We performed tests with the condensation test module oriented horizontally and vertically. Using FC-72 as the test fluid and water as the cooling fluid, we evaluated the operational characteristics of the condensation module and generated ground based data encompassing the range of parameters of interest to the condensation experiment to be performed on the ISS. During this testing, we also evaluated the pressure drop profile across different components of the fluid subsystem, heater performance, on-orbit degassing subsystem, and the heat loss from different components. In this presentation, we discuss representative results of performance testing of the FBCE flow loop. These results will be used in the refinement of the flight system design and build-up of the FBCE which is scheduled for flight in 2019.

microgravity↗

NASA NTRS1980

Automatic control of NASA Langley's 0.3-meter cryogenic test facility

Experience during the past 6 years of operation of the 0.3-meter transonic cryogenic tunnel at the NASA Langley Research Center has shown that there are problems associated with efficient operation and control of cryogenic tunnels using manual control schemes. This is due to the high degree of process crosscoupling between the independent control variables (temperature, pressure, and fan drive speed) and the desired test condition (Mach number and Reynolds number). One problem has been the inability to maintain long-term accurate control of the test parameters. Additionally, the time required to change from one test condition to another has proven to be excessively long and much less efficient than desirable in terms of liquid nitrogen and electrical power usage. For these reasons, studies have been undertaken to: (1) develop and validate a mathematical model of the 0.3-meter cryogenic tunnel process, (2) utilize this model in a hybrid computer simulation to design temperature and pressure feedback control laws, and (3) evaluate the adequacy of these control schemes by analysis of closed-loop experimental data. This paper will present the results of these studies.

Thibodeaux, J. J.↗

NASA NTRS1994

Hypervelocity Impact Test Facility: A gun for hire

An affordable technique has been developed to duplicate the types of impacts observed on spacecraft, including the Shuttle, by use of a certified Hypervelocity Impact Facility (HIF) which propels particulates using capacitor driven electric gun techniques. The fully operational facility provides a flux of particles in the 10-100 micron diameter range with a velocity distribution covering the space debris and interplanetary dust particle environment. HIF measurements of particle size, composition, impact angle and velocity distribution indicate that such parameters can be controlled in a specified, tailored test designed for or by the user. Unique diagnostics enable researchers to fully describe the impact for evaluating the 'targets' under full power or load. Users regularly evaluate space hardware, including solar cells, coatings, and materials, exposing selected portions of space-qualified items to a wide range of impact events and environmental conditions. Benefits include corroboration of data obtained from impact events, flight simulation of designs, accelerated aging of systems, and development of manufacturing techniques.

Johnson, Calvin R.↗

NASA NTRS2012

A Study in a New Test Facility on Indoor Annoyance Caused by Sonic Booms

A sonic-boom simulator at NASA Langley Research Center has been constructed to research the indoor human response to low-amplitude sonic booms. The research goal is the development of a psychoacoustic model for individual sonic booms to be validated by future community studies. The study in this report assessed the suitability of existing noise metrics for predicting indoor human annoyance. The test signals included a wide range of synthesized and recorded sonic-boom waveforms. Results indicated that no noise metric predicts indoor annoyance to sonic-boom sounds better than Perceived Level, PL. During the study it became apparent that structural vibrations induced by the test signals were contributing to annoyance, so the relationship between sound and vibration at levels of equivalent annoyance has been quantified.

Rathsam, Jonathan↗