SEARCH · Search NASA

Results for “Stack testing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33

All sources NASA NTRS DOE OSTI

NASA NTRS2023

Evaluation of Elements used for Manufacturing of NanoLam Metallized Polymer Film Capacitors

Metallized polymer film capacitors (MPFC) manufactured by NanoLam technology have a better volumetric efficiency and performance that may exceed the reliability of conventional MPFCs typically used in power and high voltage systems that require high insulation resistance and low power losses. These capacitors can be also an effective replacement for electrolytic and stacked ceramic capacitors currently used in space applications looking to save significant volume and mass. This report evaluates the effects of environmental conditions including radiation and storage at room and high temperatures on the characteristics of NanoLam elements used in the production of MPFCs. Assessments of the reliability acceleration factors and predictions for the useful life are made based on highly accelerated life tests (HALT) using distributions of times to parametric failures at different stress conditions. It has been shown that even a relatively small amount of moisture absorbed at room environments in the dielectric layers may substantially change the probability of failure. In the presence of moisture, degradation processes that started after voltage application continue with time during storage.

Metallized polymer film capacitors (MPFC)↗

NASA NTRS2014

Determining the Source of Water Vapor in a Cerium Oxide Electrochemical Oxygen Separator to Achieve Aviator Grade Oxygen

More than a metric ton of water is transported to the International Space Station (ISS) each year to provide breathing oxygen for the astronauts. Water is a safe and compact form of stored oxygen. The water is electrolyzed on ISS and ambient pressure oxygen is delivered to the cabin. A much smaller amount of oxygen is used each year in spacesuits to conduct Extra Vehicular Activities (EVAs). Space suits need high pressure (>1000 psia) high purity oxygen (must meet Aviator Breathing Oxygen "ABO" specifications, >99.5% O2). The water / water electrolysis system cannot directly provide high pressure, high purity oxygen, so oxygen for EVAs is transported to ISS in high pressure gas tanks. The tanks are relatively large and heavy, and the majority of the system launch weight is for the tanks and not the oxygen. Extracting high purity oxygen from cabin air and mechanically compressing the oxygen might enable on-board production of EVA grade oxygen using the existing water / water electrolysis system. This capability might also benefit human spaceflight missions, where oxygen for EVAs could be stored in the form of water, and converted into high pressure oxygen on-demand. Cerium oxide solid electrolyte-based ion transport membranes have been shown to separate oxygen from air, and a supported monolithic wafer form of the CeO2 electrolyte membrane has been shown to deliver oxygen at pressures greater than 300 psia. These supported monolithic wafers can withstand high pressure differentials even though the membrane is very thin, because the ion transport membrane is supported on both sides (Fig 1). The monolithic supported wafers have six distinct layers, each with matched coefficients of thermal expansion. The wafers are assembled into a cell stack which allows easy air flow across the wafers, uniform current distribution, and uniform current density (Fig 2). The oxygen separation is reported to be "infinitely selective" to oxygen [1] with reported purity of 99.99% [2]. Combined with a mechanical compressor, a Solid Electrolyte Oxygen Separator (SEOS) should be capable of producing ABO grade oxygen at pressures >2400 psia, on the space station. Feasibility tests using a SEOS integrated with a mechanical compressor identified an unexpected contaminant in the oxygen: water vapour was found in the oxygen product, sometimes at concentrations higher than 40 ppm (the ABO limit for water vapour is 7 ppm). If solid electrolyte membranes are really "infinitely selective" to oxygen as they are reported to be, where did the water come from? If water is getting into the oxygen, what other contaminants might get into the oxygen? Microscopic analyses of wafers, welds, and oxygen delivery tubes were performed in an attempt to find the source of the water vapour contamination. Hot and cold pressure decay tests were performed. Measurements of water vapour as a function of O2 delivery rate, O2 delivery pressure, and process air humidity levels were the most instructive in finding the source of water contamination (Fig 3). Water contamination was directly affected by oxygen delivery rate (doubling the oxygen production rate cut the water level in half). Water was affected by process air humidity levels and delivery pressure in a way that indicates the water was diffusing into the oxygen delivery system.

Graf, John↗

NASA NTRS1943

Tests of airfoils designed to delay the compressibility burble

Fundamental investigations of compressibility phenomena for airfoils have shown that serious adverse changes of aerodynamic characteristics occur as the local speed over the surface exceeds the local speed of sound. These adverse changes have been delayed to higher free-stream speeds by development of suitable airfoil shapes. The method of deriving such airfoil shapes is described, and aerodynamic data for a wide range of Mach numbers obtained from tests of these airfoils in the Langley 24-inch high-speed tunnel are presented. These airfoils, designated the NACA 16-series, have increased critical Mach number. The same methods by which these airfoils have been developed are applicable to other airplane components.

Stack, John↗

NASA NTRS1979

Fundamentals of heat measurement

Various methods and devices for obtaining experimental data on heat flux density over wide ranges of temperature and pressure are examined. Laboratory tests and device fabrication details are supplemented by theoretical analyses of heat-conduction and thermoelectric effects, providing design guidelines and information relevant to further research and development. A theory defining the measure of correspondence between transducer signal and the measured heat flux is established for individual (isolated) heat flux transducers subject to space and time-dependent loading. An analysis of the properties of stacked (series-connected) transducers of various types (sandwich-type, plane, and spiral) is used to derive a similarity theory providing general governing relationships. The transducers examined are used in 36 types of derivative devices involving direct heat loss measurements, heat conduction studies, radiation pyrometry, calorimetry in medicine and industry and nuclear reactor dosimetry.

Gerashchenko, O. A.↗

NASA NTRS1989

Ga:Ge array development

Work at the University of Arizona and at Lawrence Berkeley Laboratory on the development of a far infrared array camera for the Multiband Imaging Photometer on the Space Infrared Telescope Facility (SIRTF) is discussed. The camera design uses stacked linear arrays of Ge:Ga photoconductors to make a full two-dimensional array. Initial results from a 1 x 16 array using a thermally isolated J-FET readout are presented. Dark currents below 300 electrons s(exp -1) and readout noises of 60 electrons were attained. Operation of these types of detectors in an ionizing radiation environment are discussed. Results of radiation testing using both low energy gamma rays and protons are given. Work on advanced C-MOS cascode readouts that promise lower temperature operation and higher levels of performance than the current J-FET based devices is described.

Young, Erick T.↗

NASA NTRS2006

A Numerical and Experimental Study of Compression-Loaded Composite Panels With Cutouts

Results from a numerical and experimental study on the effects of laminate orthotropy and circular cutout size on the response of compression-loaded composite curved panels are presented. Several 60-in-radius composite panels with four different laminate configurations were tested with cutout diameters that range from 10% to 60% of the panel width. Finite-element analyses were performed for each panel in order to identify the effects boundary conditions, measured initial geometric imperfections and thickness variations had on the nonlinear and buckling behavior of the panels. The compression-loaded panels considered herein exhibited two separate types of behavior depending on the laminate stacking sequence and cutout size. More specifically, some of the panels exhibited the classical snap-through type buckling response; however, some of the panels exhibited a monotonically increasing stable response and achieved compressive loads in excess of twice the predicted linear bifurcation buckling load. In general, the finite-element analyses were able to predict accurately the nonlinear response and buckling loads of the panels and the prebuckling and postbuckling out-of-plane deformations and strains.

Thornburgh, Robert P.↗

NASA NTRS2006

Systems Integration Processes for NASA Ares I Crew Launch Vehicle

NASA's Exploration Initiative will require development of many new elements to constitute a robust system of systems. New launch vehicles are needed to place cargo and crew in stable Low Earth Orbit (LEO). This paper examines the systems integration processes NASA is utilizing to ensure integration and control of propulsion and nonpropulsion elements within NASA's Crew Launch Vehicle (CLV), now known as the Ares I. The objective of the Ares I is to provide the transportation capabilities to meet the Constellation Program requirements for delivering a Crew Exploration Vehicle (CEV) or other payload to LEO in support of the lunar and Mars missions. The Ares I must successfully provide this capability within cost and schedule, and with an acceptable risk approach. This paper will describe the systems engineering management processes that will be applied to assure Ares I Project success through complete and efficient technical integration. Discussion of technical review and management processes for requirements development and verification, integrated design and analysis, integrated simulation and testing, and the integration of reliability, maintainability and supportability (RMS) into the design will also be included. The Ares I Project is logically divided into elements by the major hardware groupings, and associated management, system engineering, and integration functions. The processes to be described herein are designed to integrate within these Ares I elements and among the other Constellation projects. Also discussed is launch vehicle stack integration (Ares I to CEV, and Ground and Flight Operations integration) throughout the life cycle, including integrated vehicle performance through orbital insertion, recovery of the first stage, and reentry of the upper stage. The processes for decomposing requirements to the elements and ensuring that requirements have been correctly validated, decomposed, and allocated, and that the verification requirements are properly defined to ensure that the system design meets requirements, will be discussed.

Taylor, James L.↗

NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗

NASA NTRS2000

International Space Station United States Oxygen Generator Development Testing

A life test of a liquid anode feed oxygen generator assembly (OGA) using SPE(R) (United Technologies Corporation, Hamilton Sundstrand Division) membrane technology was terminated in June of 1999. In the total 15,658 hours of operation at MSFC since delivery in 1995, the OGA has produced 2,103 kilograms (kg) (4,632 pounds mass (lbm)) of oxygen, and 263 kg (579 lbm) of hydrogen. Evaluation of cell stack characteristics and oxygen and hydrogen hydrophilic/hydrophobic membrane separators will be discussed.

Erickson, Robert J.↗

NASA NTRS2007

Heat Transfer in High Temperature Multilayer Insulation

High temperature multilayer insulations have been investigated as an effective component of thermal-protection systems for atmospheric re-entry of reusable launch vehicles. Heat transfer in multilayer insulations consisting of thin, gold-coated, ceramic reflective foils and Saffil(TradeMark) fibrous insulation spacers was studied both numerically and experimentally. A finite volume numerical thermal model using combined conduction (gaseous and solid) and radiation in porous media was developed. A two-flux model with anisotropic scattering was used for radiation heat transfer in the fibrous insulation spacers between the reflective foils. The thermal model was validated by comparison with effective thermal conductivity measurements in an apparatus based on ASTM standard C201. Measurements were performed at environmental pressures in the range from 1x10(exp -4) to 760 torr over the temperature range from 300 to 1300 K. Four multilayer samples with nominal densities of 48 kg/cu m were tested. The first sample was 13.3 mm thick and had four evenly spaced reflective foils. The other three samples were 26.6 mm thick and utilized either one, two, or four reflective foils, located near the hot boundary with nominal foil spacing of 1.7 mm. The validated thermal model was then used to study relevant design parameters, such as reflective foil spacing and location in the stack-up and coating of one or both sides of foils.

Daryabeigi, Kamran↗

NASA NTRSDate not supplied

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Spacecraft thermal margins depend on the temperature penalty of installed interfaces, yet catalog conductivity omits bondline thickness, mating surfaces, preload, and environment. The Testbed for Advanced Interface Materials in Vacuum (TAIMV) addresses this engineering-data gap by converting ambient/vacuum temperature fields from a four-coupon stack into quantities usable in spacecraft thermal models. Its 17-node steady-state model resolves axial conduction, parasitic fixture paths, grease-filled contact, radiation, and ambient convection. Four monolithic checks gave axial heat-rate ratios of 0.90–1.02, and Braycote calibration self-recovery gave 2.20% casewise mean absolute percentage error (MAPE) and 2.85% maximum difference. With transferable fixture terms frozen, Krytox LVP tested cross-material transfer against a manufacturer-derived external relation. The six Krytox cases gave 2.28% MAPE, 5.10% maximum difference, and full-field residual root-mean-square values of 0.553 °C ambient and 1.306 °C vacuum. Installed-joint resistance spanned 6.39–7.15 × 10⁻⁴ m²·K/W for Braycote and 4.09–4.49 × 10⁻⁴ m²·K/W for Krytox, corresponding to 2.33–6.66 K per modeled interface over the tested heat-flux range. TAIMV therefore supplies directly usable installed-joint resistance and conductance, plus apparent installed conductivity and explicitly model-conditioned grease conductivity/contact terms.

heat transfer↗

NASA NTRS1995

Space qualification of IR-reflecting coverslides for GaAs solar cells

Improvements to GaAs solar array performance, from the use on solar cell coverslides of several reflecting coatings that reject unusable portions of the solar spectrum, are quantified. Blue-red-rejection (BRR) coverslides provide both infrared reflection (IRR) and ultraviolet rejection (UVR). BRR coverslides were compared to conventional antireflection (AR) and ultraviolet (UV) coated coverslides. A 2% improvement in peak-power output, relative to that from Ar-coated coverslides, is seen for cells utilizing BRR coverslides with the widest bandpass. Coverslide BRR-filter bandpass width and covered-solar-cell short-circuit current is a function of incident light angle and the observed narrower-bandpass filters are more sensitive to change in angle from the normal than are wide-bandpass filters. The first long-term (3000 hours) UV testing of unirradiated and 1 MeV electron-irradiated GaAs solar cells, with multilayer-coated coverslides to reduce solar array operating temperature, has indicated that all multilayer coatings on coverslides and solar cells will experience degradation from the space environment (UV and/or electrons). Five types of coverslide coatings, designed for GaAs solar cells, were tested as part of a NASA-sponsored space-flight qualification for BRR, multi-layer-coated, coverslides. The reponse to the different radiations varied with the coatings. The extent of degradation and its consequences on the solar cell electrical characteristics depend upon the coatings and the radiation. In some cases, an improved optical coupling was observed during long-term UV exposure to the optical stack. The benefits of multi-layered solar cell optics may depend upon both the duration and the radiation environment of a mission.

Meulenberg, Andrew↗

NASA NTRS2010

Fuel-Cell Water Separator

The main product of a typical fuel cell is water, and many fuel-cell configurations use the flow of excess gases (i.e., gases not consumed by the reaction) to drive the resultant water out of the cell. This two-phase mixture then exits through an exhaust port where the two fluids must again be separated to prevent the fuel cell from flooding and to facilitate the reutilization of both fluids. The Glenn Research Center (GRC) has designed, built, and tested an innovative fuel-cell water separator that not only removes liquid water from a fuel cell s exhaust ports, but does so with no moving parts or other power-consuming components. Instead it employs the potential and kinetic energies already present in the moving exhaust flow. In addition, the geometry of the separator is explicitly intended to be integrated into a fuel-cell stack, providing a direct mate with the fuel cell s existing flow ports. The separator is also fully scalable, allowing it to accommodate a wide range of water removal requirements. Multiple separators can simply be "stacked" in series or parallel to adapt to the water production/removal rate. GRC s separator accomplishes the task of water removal by coupling a high aspect- ratio flow chamber with a highly hydrophilic, polyethersulfone membrane. The hydrophilic membrane readily absorbs and transports the liquid water away from the mixture while simultaneously resisting gas penetration. The expansive flow path maximizes the interaction of the water particles with the membrane while minimizing the overall gas flow restriction. In essence, each fluid takes its corresponding path of least resistance, and the two fluids are effectively separated. The GRC fuel-cell water separator has a broad range of applications, including commercial hydrogen-air fuel cells currently being considered for power generation in automobiles.

Burke, Kenneth Alan↗

NASA NTRS1934

The NACA High-Speed Wind Tunnel and Tests of Six Propeller Sections

This report gives a description of the high-speed wind tunnel of the National Advisory Committee for Aeronautics. The operation of the tunnel is also described and the method of presenting the data is given. An account of an investigation of the aerodynamic properties of six propeller sections is included.

Stack, John↗

NASA NTRS1993

Response of automated tow placed laminates to stress concentrations

In this study, the response of laminates with stress concentrations is explored. Automated Tow Placed (ATP, also known as Fiber Placement) laminates are compared to conventional tape layup manufacturing. Previous tensile fracture tests on fiber placed laminates show an improvement in tensile fracture of large notches over 20 percent compared to tape layup laminates. A hierarchial modeling scheme is presented. In this scheme, a global model is developed for laminates with notches. A local model is developed to study the influence of inhomogeneities at the notch tip, which are a consequence of the fiber placement manufacturing technique. In addition, a stacked membrane model was developed to study delaminations and splitting on a ply-by-ply basis. The results indicate that some benefit with respect to tensile fracture (up to 11 percent) can be gained from inhomogeneity alone, but that the most improvement may be obtained with splitting and delaminations which are more severe in the case of fiber placement compared to tape layup. Improvements up to 36 percent were found from the model for fiber placed laminates with damage at the notch tip compared to conventional tape layup.

Cairns, Douglas S.↗

NASA NTRS1983

Wall-temperature effects on the aerodynamics of a hydrogen-fueled transport concept in Mach 8 blowdown and shock tunnels

Results are presented from two separate tests on the same blended wing-body hydrogen fueled transport model at a Mach number of about 8 and a range of Reynolds numbers (based on theoretical body length) of 0.597 x 10 to the 6th power to about 156.22 x 10 to the 6th power. Tests were made in conventional hypersonic blowdown tunnel and a hypersonic shock tunnel at angles of attack of -2 deg to about 8 deg, with an extensive study made at a constant angle of attack of 3 deg. The model boundary-layer flow varied from laminar at the lower Reynolds numbers to predominantly turbulent at the higher Reynolds numbers. Model wall temperatures and stream static temperatures varied widely between the two tests, particularly at the lower Reynolds numbers. These temperature differences resulted in marked variations of the axial-force coefficients between the two tests, due in part to the effects of induced pressure and viscous interaction variations. The normal-force coefficient was essentially independent of Reynolds number. Analysis of results utilized current theoretical computer programs and basic boundary-layer theory.

Penland, J. A.↗

NASA NTRS1994

A shadowgraph study of Space Transportation System (STS): The Space Shuttle Launch Vehicle (SSLV)

A shadowgraph study of the space transportation system (STS), the space shuttle launch vehicle, is presented. The shadowgraphs presented in this study were obtained over the past 10 years from wind tunnel tests performed in the NASA Marshall Space Flight Center's 14-Inch Trisonic Wind Tunnel during the space shuttle development program. Shadowgraphs of the STS at various angles-of-attack and roll angles are shown for the Mach range of 0.6 to 4.96. The major flow field phenomena over the mated vehicle configuration are shown in these shadowgraphs. Shadowgraphs are also presented for the orbiter without the lower stack (reentry configuration) and the lower stack without the orbiter. A short study of external tank nose geometry effects on the mated vehicles flow field is presented. These shadowgraphs are used in the aerothermodynamic analysis of the external flow conditions the launch vehicle encounters during the ascent stage of flight.

Springer, A. M.↗

NASA NTRSDate not supplied

Fiber Optics Sensing System (FOSS) deployment on Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID)

Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) is a technology demonstration of an inflatable aeroshell to slow down and protect heavy and valuable payloads when entering atmospheres such as those of the Earth and Mars. The ultimate project goal is to enable future payload deliveries to Mars. The LOFTID is based on more than a decade of development of the hypersonic inflatable aerodynamic decelerator (HIAD) technology, which consists of a stack of the inflatable concentric rings that make up the inflatable structure that is covered with a Flexible Thermal Protection System (FTPS) and, when combined, form the inflatable aeroshell. The goal of the LOFTID demonstration was to verify that a flexible heat shield, packed into a small-volume payload, can be inflated exoatmospherically to sizes much larger than that of the launch vehicle fairing and survive re-entry into the Earth atmosphere while withstanding a temperature excess of 1,600 °C. The LOFTID is part of Technology Demonstration Missions (TDM) under the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD). The NASA Armstrong Flight Research Center (AFRC) (Edwards, California) is part of the LOFTID program, where a space-launch version of the fiber optic sensing system (FOSS) is integrated into the avionics bay of the re-entry vehicle to provide high-spatial-density temperature measurements in three strategic locations of the vehicle. The program is part of a partnership agreement between the NASA Launch Service Program (LSP) at Kennedy Space Center (KSC) (Merritt Island, Florida) and the main Center of the LOFTID program at NASA Langley Research Center (LaRC) (Hampton, Virginia). This paper will first give a brief introduction of the FOSS, then discuss how the FOSS was integrated into LOFTID, in terms of fiber sensor integration into various sections of the vehicle, as well as integration of the FOSS interrogator into the avionics bay. Finally, data analysis during the LOFTID re-entry will be discussed.

Allen R Parker↗