Cross-validation of a brief vestibular disorientation test administered by a variety of personnel
Cross validation of brief vestibular disorientation test during pilot training administered by variety of personnel
Ambler, R. K.↗
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Development and Preliminary Testing of a High Precision Long Stroke Slit Change Mechanism for the SPICE Instrument
In the frame of ESA's Solar Orbiter scientific mission, Almatech has been selected to design, develop and test the Slit Change Mechanism of the SPICE (SPectral Imaging of the Coronal Environment) instrument. In order to guaranty optical cleanliness level while fulfilling stringent positioning accuracies and repeatability requirements for slit positioning in the optical path of the instrument, a linear guiding system based on a double flexible blade arrangement has been selected. The four different slits to be used for the SPICE instrument resulted in a total stroke of 16.5 mm in this linear slit changer arrangement. The combination of long stroke and high precision positioning requirements has been identified as the main design challenge to be validated through breadboard models testing. This paper presents the development of SPICE's Slit Change Mechanism (SCM) and the two-step validation tests successfully performed on breadboard models of its flexible blade support system. The validation test results have demonstrated the full adequacy of the flexible blade guiding system implemented in SPICE's Slit Change Mechanism in a stand-alone configuration. Further breadboard test results, studying the influence of the compliant connection to the SCM linear actuator on an enhanced flexible guiding system design have shown significant enhancements in the positioning accuracy and repeatability of the selected flexible guiding system. Preliminary evaluation of the linear actuator design, including a detailed tolerance analyses, has shown the suitability of this satellite roller screw based mechanism for the actuation of the tested flexible guiding system and compliant connection. The presented development and preliminary testing of the high-precision long-stroke Slit Change Mechanism for the SPICE Instrument are considered fully successful such that future tests considering the full Slit Change Mechanism can be performed, with the gained confidence, directly on a Qualification Model. The selected linear Slit Change Mechanism design concept, consisting of a flexible guiding system driven by a hermetically sealed linear drive mechanism, is considered validated for the specific application of the SPICE instrument, with great potential for other special applications where contamination and high precision positioning are dominant design drivers.
Paciotti, Gabriel↗
Modal test and analysis: Multiple tests concept for improved validation of large space structure mathematical models
For the structural dynamic analysis of large space structures, the technology in structural synthesis and the development of structural analysis software have increased the capability to predict the dynamic characteristics of the structural system. The various subsystems which comprise the system are represented by various displacement functions; the displacement functions are then combined to represent the total structure. Experience has indicated that even when subsystem mathematical models are verified by test, the mathematical representations of the total system are often in error because the mathematical model of the structural elements which are significant when loads are applied at the interconnection points are not adequately verified by test. A multiple test concept, based upon the Multiple Boundary Condition Test (MBCT), is presented which will increase the accuracy of the system mathematical model by improving the subsystem test and test/analysis correlation procedure.
Wada, B. K.↗
Computational Fluid Dynamics Uncertainty Analysis for Payload Fairing Spacecraft Environmental Control Systems
Spacecraft thermal protection systems are at risk of being damaged due to airflow produced from Environmental Control Systems. There are inherent uncertainties and errors associated with using Computational Fluid Dynamics to predict the airflow field around a spacecraft from the Environmental Control System. This proposal describes an approach to validate the uncertainty in using Computational Fluid Dynamics to predict airflow speeds around an encapsulated spacecraft. The research described here is absolutely cutting edge. Quantifying the uncertainty in analytical predictions is imperative to the success of any simulation-based product. The method could provide an alternative to traditional"validation by test only'' mentality. This method could be extended to other disciplines and has potential to provide uncertainty for any numerical simulation, thus lowering the cost of performing these verifications while increasing the confidence in those predictions. Spacecraft requirements can include a maximum airflow speed to protect delicate instruments during ground processing. Computationaf Fluid Dynamics can be used to veritY these requirements; however, the model must be validated by test data. The proposed research project includes the following three objectives and methods. Objective one is develop, model, and perform a Computational Fluid Dynamics analysis of three (3) generic, non-proprietary, environmental control systems and spacecraft configurations. Several commercially available solvers have the capability to model the turbulent, highly three-dimensional, incompressible flow regime. The proposed method uses FLUENT and OPEN FOAM. Objective two is to perform an uncertainty analysis of the Computational Fluid . . . Dynamics model using the methodology found in "Comprehensive Approach to Verification and Validation of Computational Fluid Dynamics Simulations". This method requires three separate grids and solutions, which quantify the error bars around Computational Fluid Dynamics predictions. The method accounts for all uncertainty terms from both numerical and input variables. Objective three is to compile a table of uncertainty parameters that could be used to estimate the error in a Computational Fluid Dynamics model of the Environmental Control System /spacecraft system. Previous studies have looked at the uncertainty in a Computational Fluid Dynamics model for a single output variable at a single point, for example the re-attachment length of a backward facing step. To date, the author is the only person to look at the uncertainty in the entire computational domain. For the flow regime being analyzed (turbulent, threedimensional, incompressible), the error at a single point can propagate into the solution both via flow physics and numerical methods. Calculating the uncertainty in using Computational Fluid Dynamics to accurately predict airflow speeds around encapsulated spacecraft in is imperative to the success of future missions.
Groves, Curtis E.↗
A preliminary correlation of the orbiter stability and control aerodynamics from the first two Space Shuttle flights /STS-1 & 2/ with preflight predictions
A correlation of the stability and control derivatives from flight (STS-1 & 2) with preflight predictions is presented across the Mach range from 0.9 to 25. Flight data obtained from specially designed flight test maneuvers as well as from conventional bank maneuvers generally indicate good agreement with predicted data. However, the vehicle appears to be lateral-directionally more stable than predicted in the transonic regime. Aerodynamic 'reasonableness tests' are employed to test for validity of flight data. The importance of testing multiple models in multiple wind tunnels at the same test conditions is demonstrated.
Underwood, J. M.↗
Design of Experiments for Both Experimental and Analytical Study of Exhaust Plume Effects on Sonic Boom
Computational fluid dynamics (CFD) analysis has been performed to study the plume effects on sonic boom signature for isolated nozzle configurations. The objectives of these analyses were to provide comparison to past work using modern CFD analysis tools, to investigate the differences of high aspect ratio nozzles to circular (axisymmetric) nozzles, and to report the effects of under expanded nozzle operation on boom signature. CFD analysis was used to address the plume effects on sonic boom signature from a baseline exhaust nozzle. Nearfield pressure signatures were collected for nozzle pressure ratios (NPRs) between 6 and 10. A computer code was used to extrapolate these signatures to a ground-observed sonic boom N-wave. Trends show that there is a reduction in sonic boom N-wave signature as NPR is increased from 6 to 10. As low boom designs are developed and improved, there will be a need for understanding the interaction between the aircraft boat tail shocks and the exhaust nozzle plume. These CFD analyses will provide a baseline study for future analysis efforts. For further study, a design of experiments has been conducted to develop a hybrid method where both CFD and small scale wind tunnel testing will validate the observed trends. The CFD and testing will be used to screen a number of factors which are important to low boom propulsion integration, including boat tail angle, nozzle geometry, and the effect of spacing and stagger on nozzle pairs. To design the wind tunnel experiment, CFD was instrumental in developing a model which would provide adequate space to observe the nozzle and boat tail shock structure without interference from the wind tunnel walls.
Castner, Raymond S.↗
NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster
I. Motivation and Background Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall Current Thruster in support of the NASA mission to establish a permanent human presence in lunar orbit and to land the next American astronauts on the South Pole of the Moon. The project is led by the NASA Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by L3 Harris Aerojet Rocketdyne (AR).The AEPS project has completed the development testing of a high power, solar electric propulsion Hall Current thruster that will be used on the NASA Power & Propulsion Element (PPE) of the Gateway space station. NASA initially built three Technology Development Units to understand key characteristics of the hall-effect rocket with magnetic shielding. The design led to development testing on two Engineering Test Unit Thrusters and multiple critical components. The project has begun production of the three flight thrusters and entered qualification testing at the component and thruster levels. II. Approach NASA and AR teams completed all development phases of the project, including full development and integration testing of the Engineering Model hardware, Critical Design Review, and ground test equipment validation, as well as fabrication and acceptance testing of the initial qualification thruster. Qualification and verification of the environmental and life requirements of the AEPS design was initiated in the Fall of 2023 and will be accomplished on two thruster units and using a series of component-level tests during 2024 and 2025. Environmental testing will incorporate functional reference firings, shock, vibration, and Thermal Vacuum (TVAC) testing. Life verification will assess the thruster wear and performance over the lifetime of the Gateway spacecraft. Critical component qualification tests include cathode heater, magnet coils, magnet heaters, temperature sensors, and a cathode assembly that will undergo life cycle testing on multiple units. Flight thrusters will complete assembly and acceptance testing and be delivered to the PPE program in early 2025. III. Preliminary and Anticipated Results The program has completed the acceptance testing, including dynamic testing and hot fire characterization, of the first qualification thruster. In the Fall of 2023, the program entered the environmental qualification phase for thruster testing. This paper will present an overview of the AEPS thruster project, thruster capabilities and flight design, preliminary results from the thruster acceptance and qualification testing, component life cycle testing and flight hardware status.
Clayton Kachele↗
Kepler Data Validation I: Architecture, Diagnostic Tests, and Data Products for Vetting Transiting Planet Candidates
The Kepler Mission was designed to identify and characterize transiting planets in the Kepler Field of View and to determine their occurrence rates. Emphasis was placed on identification of Earth-size planets orbiting in the Habitable Zone of their host stars. Science data were acquired for a period of four years. Long-cadence data with 29.4 min sampling were obtained for approx. 200,000 individual stellar targets in at least one observing quarter in the primary Kepler Mission. Light curves for target stars are extracted in the Kepler Science Data Processing Pipeline, and are searched for transiting planet signatures. A Threshold Crossing Event is generated in the transit search for targets where the transit detection threshold is exceeded and transit consistency checks are satisfied. These targets are subjected to further scrutiny in the Data Validation (DV) component of the Pipeline. Transiting planet candidates are characterized in DV, and light curves are searched for additional planets after transit signatures are modeled and removed. A suite of diagnostic tests is performed on all candidates to aid in discrimination between genuine transiting planets and instrumental or astrophysical false positives. Data products are generated per target and planet candidate to document and display transiting planet model fit and diagnostic test results. These products are exported to the Exoplanet Archive at the NASA Exoplanet Science Institute, and are available to the community. We describe the DV architecture and diagnostic tests, and provide a brief overview of the data products. Transiting planet modeling and the search for multiple planets on individual targets are described in a companion paper. The final revision of the Kepler Pipeline code base is available to the general public through GitHub. The Kepler Pipeline has also been modified to support the Transiting Exoplanet Survey Satellite (TESS) Mission which is expected to commence in 2018.
data analysis↗
Development and Testing of a Sorbent-Based Atmosphere Revitalization System 2010/2011
Spacecraft being developed for future exploration missions incorporate Environmental Control and Life Support Systems (ECLSS) that limit weight, power, and volume thus requiring systems with higher levels of efficiency while maintaining high dependability and robustness. For air revitalization, an approach that meets those goals utilizes a regenerative Vacuum-Swing Adsorption (VSA) system that removes 100% of the CO2 from the cabin atmosphere as well as 100% of the water. A Sorbent Based Atmosphere Revitalization (SBAR) system is a VSA system that utilizes standard commercial adsorbents that have been proven effective and safe in spacecraft including Skylab and the International Space Station. The SBAR system is the subject of a development, test, and evaluation program that is being conducted at NASA s Marshall Space Flight Center. While previous testing had validated that the technology is a viable option, potential improvements to system design and operation were identified. Modifications of the full-scale SBAR test articles and adsorption cycles have been implemented and have shown significant performance gains resulting in a decrease in the consumables required for a mission as well as improved mission safety. Previous testing had utilized single bed test articles, during this period the test facility was enhanced to allow testing on the full 2-bed SBAR system. The test facility simulates a spacecraft ECLSS and allows testing of the SBAR system over the full range of operational conditions using mission simulations that assess the real-time performance of the SBAR system during scenarios that include the metabolic transients associated with extravehicular activity. Although future manned missions are currently being redefined, the atmosphere revitalization requirements for the spacecraft are expected to be quite similar to the Orion and the Altair vehicles and the SBAR test program addressed validation to the defined mission requirements as well as operation in other potential vehicle architectures. The development program, including test articles, the test facility, and tests and results through early 2011 is discussed.
Miller, Lee A.↗
Existing and Required Modeling Capabilities for Evaluating ATM Systems and Concepts
ATM systems throughout the world are entering a period of major transition and change. The combination of important technological developments and of the globalization of the air transportation industry has necessitated a reexamination of some of the fundamental premises of existing Air Traffic Management (ATM) concepts. New ATM concepts have to be examined, concepts that may place more emphasis on: strategic traffic management; planning and control; partial decentralization of decision-making; and added reliance on the aircraft to carry out strategic ATM plans, with ground controllers confined primarily to a monitoring and supervisory role. 'Free Flight' is a case in point. In order to study, evaluate and validate such new concepts, the ATM community will have to rely heavily on models and computer-based tools/utilities, covering a wide range of issues and metrics related to safety, capacity and efficiency. The state of the art in such modeling support is adequate in some respects, but clearly deficient in others. It is the objective of this study to assist in: (1) assessing the strengths and weaknesses of existing fast-time models and tools for the study of ATM systems and concepts and (2) identifying and prioritizing the requirements for the development of additional modeling capabilities in the near future. A three-stage process has been followed to this purpose: 1. Through the analysis of two case studies involving future ATM system scenarios, as well as through expert assessment, modeling capabilities and supporting tools needed for testing and validating future ATM systems and concepts were identified and described. 2. Existing fast-time ATM models and support tools were reviewed and assessed with regard to the degree to which they offer the capabilities identified under Step 1. 3 . The findings of 1 and 2 were combined to draw conclusions about (1) the best capabilities currently existing, (2) the types of concept testing and validation that can be carried out reliably with such existing capabilities and (3) the currently unavailable modeling capabilities that should receive high priority for near-term research and development. It should be emphasized that the study is concerned only with the class of 'fast time' analytical and simulation models. 'Real time' models, that typically involve humans-in-the-loop, comprise another extensive class which is not addressed in this report. However, the relationship between some of the fast-time models reviewed and a few well-known real-time models is identified in several parts of this report and the potential benefits from the combined use of these two classes of models-a very important subject-are discussed in chapters 4 and 7.
Odoni, Amedeo R.↗
LS-DYNA Analysis of a Full-Scale Helicopter Crash Test
A full-scale crash test of an MD-500 helicopter was conducted in December 2009 at NASA Langley's Landing and Impact Research facility (LandIR). The MD-500 helicopter was fitted with a composite honeycomb Deployable Energy Absorber (DEA) and tested under vertical and horizontal impact velocities of 26 ft/sec and 40 ft/sec, respectively. The objectives of the test were to evaluate the performance of the DEA concept under realistic crash conditions and to generate test data for validation of a system integrated LS-DYNA finite element model. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests was conducted to evaluate the impact performances of various components, including a new crush tube and the DEA blocks. Parameters defined within the system integrated finite element model were determined from these tests. The objective of this paper is to summarize the finite element models developed and analyses performed, beginning with pre-test and continuing through post test validation.
Annett, Martin S.↗
Grappling Spacecraft
This article provides a survey overview of the techniques, mechanisms, algorithms, and test and validation strategies required for the design of roboticgrappling vehicles intended to approach and grapple free-flying client satellites. We concentrate on using a robotic arm to grapple a free-floating spacecraft, as distinct from spacecraft docking and berthing, where two spacecraft directly mate with each other. Robotic grappling of client spacecraft is a deceptively complex problem: It entails designing a robotic system that functions robustly in the visually stark, thermally extreme orbital environment,operating near massive and extremely expensive yet fragile client hardware,using relatively slow flight computers with limited and laggy communica-tions. Spaceflight robotic systems are challenging to test and validate priorto deployment and extremely expensive to launch, which significantly limitsopportunities to experiment with new techniques. These factors make thedesign and operation of orbital robotic systems significantly different fromthose of their terrestrial counterparts, and as a result, only a relative handfulof systems have been demonstrated on orbit. Nevertheless, there is increas-ing interest in on-orbit robotic servicing and assembly missions, and grap-pling is the core requirement for these systems. Although existing systemssuch as the Space Station Remote Manipulator System have demonstratedextremely reliable operation, upcoming missions will attempt to expand thetypes of spacecraft that can be safely and dependably grappled and berthed.
Carl Glen Henshaw↗
Evaluating Meteorological Dust Events and Machine-Learning Based Dust Identification in Geostationary Satellite Imagery
NASA scientists in the Short-term Prediction Research and Transition Center (SPoRT) developed a physically-based machine learning approach to identify dust in satellite imagery with a focus on night-time dust detection (Berndt et al. 201; DustTracker-AI). NASA/NOAA Geostationary Environmental Operational Satellite-16 (GOES-16) imagery was used for training and model inputs. The training, testing and validation data set consists of 28 events in the Southwest United States, capturing dust and null events in the region from 2018-2020.With 83 distinct images and millions of pixels a random forest model was trained and validated, correctly labeling 85% of dust pixels.For the first time, the model was run in near-real time production during the spring of 2022 and dust probability visualizations were made available to NOAA National Weather Service (NWS) forecasters to assess its utility for dust forecasting. Results indicated the model helped increase the confidence in the presence of dust and enabled dust tracking for a longer period of time into the night-time hours. Forecaster assessment and running the model in near real-time allowed for the team to determine the types of events missed, captured, and false alarms. To gain additional context on model performance,the SPoRT team sought to gather more detailed information on the training database(e.g., meteorological characteristics and drivers). The goal of this project was to identify the meteorological drivers for the dust events and create a database which synthesized information from observations, forecaster discussions, and analyses pertaining to the dust events to understand the types of events currently used to train the model. A more detailed meteorological synopsis was created for each dust event in the training, testing, and validation datasets. Following the completion of the database and documentation, the classification details revealed that 88% of the dust events were synoptically driven while mesoscale events were less prevalent in model datasets. Meteorological conditions found such as mixing layer depth and wind velocity had mean values of 645mb and 21kt respectively.With conditions of deep mixed layers and moderate to strong surface winds a mesoscale thunderstorm outflow event was considered and subsequently added to the model training data set to test the impact of additional mesoscale training data. The model was retrained and then qualitatively tested on a sample thunderstorm outflow case that the original model was unable to identify. Preliminary results showed potential that the addition of more mesoscale events included in the training data could help to better identify indistinct and localized dust events.
Connor Welch↗
Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.
Richard K. Moore↗
Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.
Richard Moore↗
Gear Crack Propagation Investigation
Reduced weight is a major design goal in aircraft power transmissions. Some gear designs incorporate thin rims to help meet this goal. Thin rims, however, may lead to bending fatigue cracks. These cracks may propagate through a gear tooth or into the gear rim. A crack that propagates through a tooth would probably not be catastrophic, and ample warning of a failure could be possible. On the other hand, a crack that propagates through the rim would be catastrophic. Such cracks could lead to disengagement of a rotor or propeller from an engine, loss of an aircraft, and fatalities. To help create and validate tools for the gear designer, the NASA Lewis Research Center performed in-house analytical and experimental studies to investigate the effect of rim thickness on gear-tooth crack propagation. Our goal was to determine whether cracks grew through gear teeth (benign failure mode) or through gear rims (catastrophic failure mode) for various rim thicknesses. In addition, we investigated the effect of rim thickness on crack propagation life. A finite-element-based computer program simulated gear-tooth crack propagation. The analysis used principles of linear elastic fracture mechanics, and quarter-point, triangular elements were used at the crack tip to represent the stress singularity. The program had an automated crack propagation option in which cracks were grown numerically via an automated remeshing scheme. Crack-tip stress-intensity factors were estimated to determine crack-propagation direction. Also, various fatigue crack growth models were used to estimate crack-propagation life. Experiments were performed in Lewis' Spur Gear Fatigue Rig to validate predicted crack propagation results. Gears with various backup ratios were tested to validate crack-path predictions. Also, test gears were installed with special crack-propagation gages in the tooth fillet region to measure bending-fatigue crack growth. From both predictions and tests, gears with backup ratios (rim thickness divided by tooth height) of 3.3 and 1.0 produced tooth fractures, whereas a backup ratio of 0.3 produced rim fractures. For a backup ratio of 0.5, the experiments produced rim fractures and the predictions produced both rim and tooth fractures, depending on the initial geometry of the crack. Good correlation between predicted and measured crack growth was achieved when the fatigue crack-closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear-tooth fillet region increased. This retarded crack growth and increased the number of crack-propagation cycles to failure.
Source record↗
NASA Lewis advanced IPV nickel-hydrogen technology
Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts. Some of the advancements are as follows: to use 26 percent potassium hydroxide electrolyte to improve cycle life and performance, to modify the state of the art cell design to eliminate identified failure modes and further improve cycle life, and to develop a lightweight nickel electrode to reduce battery mass, hence reduce launch and/or increase satellite payload. A breakthrough in the LEO cycle life of individual pressure vessel nickel-hydrogen battery cells was reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 accelerated LEO cycles at 80 percent DOD compared to 3,500 cycles for cells containing 31 percent KOH. Results of the boiler plate cell tests have been validated at NWSC, Crane, Indiana. Forty-eight ampere-hour flight cells containing 26 and 31 percent KOH have undergone real time LEO cycle life testing at an 80 percent DOD, 10 C. The three cells containing 26 percent KOH failed on the average at cycle 19,500. The three cells containing 31 percent KOH failed on the average at cycle 6,400. Validation testing of NASA Lewis 125 Ah advanced design IPV nickel-hydrogen flight cells is also being conducted at NWSC, Crane, Indiana under a NASA Lewis contract. This consists of characterization, storage, and cycle life testing. There was no capacity degradation after 52 days of storage with the cells in the discharged state, on open circuit, 0 C, and a hydrogen pressure of 14.5 psia. The catalyzed wall wick cells have been cycled for over 22,694 cycles with no cell failures in the continuing test. All three of the non-catalyzed wall wick cells failed (cycles 9,588; 13,900; and 20,575). Cycle life test results of the Fibrex nickel electrode has demonstrated the feasibility of an improved nickel electrode giving a higher specific energy nickel-hydrogen cell. A nickel-hydrogen boiler plate cell using an 80 mil thick, 90 percent porous Fibrex nickel electrode has been cycled for 10,000 cycles at 40 percent DOD.
Smithrick, John J.↗
Validation of Finite Element Crash Test Dummy Models for Predicting Orion Crew Member Injuries During a Simulated Vehicle Landing
A series of crash tests were conducted with dummies during simulated Orion crew module landings at the Wright-Patterson Air Force Base. These tests consisted of several crew configurations with and without astronaut suits. Some test results were collected and are presented. In addition, finite element models of the tests were developed and are presented. The finite element models were validated using the experimental data, and the test responses were compared with the computed results. Occupant crash data, such as forces, moments, and accelerations, were collected from the simulations and compared with injury criteria to assess occupant survivability and injury. Some of the injury criteria published in the literature is summarized for completeness. These criteria were used to determine potential injury during crew impact events.
Tabiei, Al↗