Results for “component testing” — Page 35

NASA NTRS1988

The effect of compression on individual pressure vessel nickel/hydrogen components

Compression tests were performed on representative Individual Pressure Vessel (IPV) Nickel/Hydrogen cell components in an effort to better understand the effects of force on component compression and the interactions of components under compression. It appears that the separator is the most easily compressed of all of the stack components. It will typically partially compress before any of the other components begin to compress. The compression characteristics of the cell components in assembly differed considerably from what would be predicted based on individual compression characteristics. Component interactions played a significant role in the stack response to compression. The results of the compression tests were factored into the design and selection of Belleville washers added to the cell stack to accommodate nickel electrode expansion while keeping the pressure on the stack within a reasonable range of the original preset.

Manzo, Michelle A.↗

NASA NTRS1988

The effect of compression on Individual Pressure Vessel Nickel/Hydrogen components

Compression tests were performed on representative Individual Pressure Vessel (IPV) Nickel/Hydrogen cell components in an effort to better understand the effects of force on component compression and the interactions of components under compression. It appears that the separator is the most easily compressed of all of the stack components. It will typically partially compress before any of the other components begin to compress. The compression characteristics of the cell components in assembly differed considerably from what would be predicted based on individual compression characteristics. Component interactions played a significant role in the stack response to compression. The results of the compression tests were factored into the design and selection of Belleville washers added to the cell stack to accommodate nickel electrode expansion while keeping the pressure on the stack within a reasonable range of the original preset.

Manzo, Michelle A.↗

NASA NTRS1998

Verification and Quantification of Single Event Effects on High Speed SRAM in Terrestrial Environments

As integrated circuits become more sensitive to charged particles and neutrons, anomalous performance due to single event effects (SEE) is a concern and requires experimental verification and quantification. The Center for Applied Radiation Research (CARR) at Prairie View A&M University has developed experiments as a participant in the NASA ER-2 Flight Program, the APEX balloon flight program and the Student Launch Program. Other high altitude and ground level experiments of interest to DoD and commercial applications are being developed. The experiment characterizes the SEE behavior of high speed and high density SRAM's. The system includes a PC-104 computer unit, an optical drive for storage, a test board with the components under test, and a latchup detection and reset unit. The test program will continuously monitor the stored checkerboard data pattern in the SW and record errors. Since both the computer and the optical drive contain integrated circuits, they are also vulnerable to radiation effects. A latchup detection unit with discrete components will monitor the test program and reset the system when necessary. The first results will be obtained from the NASA ER-2 flights, which are now planned to take place in early 1998 from Dryden Research Center in California. The series of flights, at altitudes up to 70,000 feet, and a variety of flight profiles should yield a distribution of conditions for correlating SEES. SEE measurements will be performed from the time of aircraft power-up on the ground throughout the flight regime until systems power-off after landing.

Huff, H.↗

NASA NTRS2010

Testing of Liquid Metal Components for Nuclear Surface Power Systems

The capability to perform testing at both the module/component level and in near prototypic reactor configurations using a non-nuclear test methodology allowed for evaluation of two components critical to the development of a potential nuclear fission power system for the lunar surface. A pair of 1 kW Stirling power convertors, similar to the type that would be used in a reactor system to convert heat to electricity, were integrated into a reactor simulator system to determine their performance using pumped NaK as the hot side working fluid. The performance in the pumped-NaK system met or exceed the baseline performance measurements where the converters were electrically heated. At the maximum hot-side temperature of 550 C the maximum output power was 2375 watts. A specially-designed test apparatus was fabricated and used to quantify the performance of an annular linear induction pump that is similar to the type that could be used to circulate liquid metal through the core of a space reactor system. The errors on the measurements were generally much smaller than the magnitude of the measurements, permitting accurate performance evaluation over a wide range of operating conditions. The pump produced flow rates spanning roughly 0.16 to 5.7 l/s (2.5 to 90 GPM), and delta p levels from less than 1 kPa to 90 kPa (greater than 0.145 psi to roughly 13 psi). At the nominal FSP system operating temperature of 525 C the maximum efficiency was just over 4%.

Polzin, K. A.↗

DOE OSTI2023

Rapid, Approximate Multi-Axis Vibration Testing [Thesis]

The aerospace industry uses vibration shaker tables to perform component durability testing. In these tests a component, piece of equipment, or entire system is attached to a shaker table where it is subjected to dynamic excitation. The goal is to understand how the article under test will perform in its service environment without having to run it through its entire service life via field testing. In a vibration test, an aerospace system or component is qualified if it is shown to survive a test meant to replicate its lifetime service conditions. The test is designed based on recorded field data. To develop a test, a system is taken through all of its intended environments, e.g., transportation, launch, and reentry. Acceleration data measured from these environments is then brought back to the lab and imported into a shaker table controller. The controller then drives a vibration test intended to mimic the acceleration conditions experienced by the system or specific components of the system in the field. However, it is often difficult to match the measured field response in a lab test. This is largely due to the test’s boundary conditions and excitation methods. In a lab test, a shaker table is the excitation source. The two most common shaker table types, differentiated by their number of independent degrees of freedom, are single-axis and multi-axis shaker tables. Multi-axis shakers have the ability to reproduce service environments more realistically, as real accelerations inevitably produce multiple degrees of freedom of excitation simultaneously. Figure 1 depicts a generic multi-axis testing setup on a three-axis shaker table. Often multi-axis tests use six-degree-of-freedom (6DOF) shaker tables. Yet multi-axis shakers are not yet common in the aerospace industry due in part to their high cost and the difficulty for shaker controllers to handle the added complexity. Single-axis shaker tables are much more common. They are not as expensive to purchase and have a wide range of control software options.

42 ENGINEERING↗

NASA NTRS2022

Metal Additive Manufacturing for Spaceflight

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, hot-fire testing, and infusion into development and flight applications. This presentation will discuss some of the various AM processes, components, testing and development efforts for spaceflight applications at NASA used on launch vehicles and propulsion systems. - AM process comparisons and selection for spaceflight applications. - Novel alloy development, characterization, and maturation for extreme environments. - Infusion and maturation of AM components into development and flight applications.

Additive manufacturing↗

NASA NTRS1991

A simulated lightning effects test facility for testing live and inert missiles and components

Details of a simulated lightning effects test facility for testing live and inert missiles, motors, and explosive components are described. The test facility is designed to simulate the high current, continuing current, and high rate-of-rise current components of an idealized direct strike lightning waveform. The Lightning Test Facility was in operation since May, 1988, and consists of: 3 separate capacitor banks used to produce the lightning test components; a permanently fixed large steel safety cage for retaining the item under test (should it be ignited during testing); an earth covered bunker housing the control/equipment room; a charge/discharge building containing the charging/discharging switching; a remotely located blockhouse from which the test personnel control hazardous testing; and interconnecting cables.

Craven, Jeffery D.↗

NASA NTRS1983

Energy efficient engine. Fan and quarter-stage component performance report

The fan configuration for the general Electric/NASA Energy Efficient Engine was selected following an extensive preliminary design study. The fan has an inlet radius ratio of 0.342 and a specific flowrate of 208.9 Kg/sec/sq. m (42.8 1bm/sec/sq. ft). The design corrected tip speed is 411.5 m/sec (1350 ft/sec) producing a bypass flow total-pressure ratio of 1.65 and a core flow total-pressure ratio of 1.6. The design bypass ratio is 6.8. The aerodynamic design point corresponds to the maximum climb power setting at Mach 0.8 and 10.67 Km (35,000 ft) altitude. The fully-instrumented fan component was tested in the Lynn Large Fan Test Facility in 1981. The overall performance results, reported herein, showed excellent fan performance with the fan meeting all of its component test goals of flow, efficiency and stall margin.

Cline, S. J.↗

NASA NTRS1986

On testing of functionally equivalent components of fault-tolerant software

Six functionally equivalent programs were tested with specification based random and extremal/special value (ESV) test cases. Statement and branch coverage were used to measure and compare the attained testing effectiveness. It was observed that both measures reached a nearly steady state value after 25 to 75 random test cases. Coverage saturation curves appear to follow an exponential growth model. However, the steady state values for branch coverage of different components, but the same input cases, differed by as much as 22 percent. The effect is the result of the differences in the detailed structure of the components. Improvement in coverage provided by the random test data, after the ESV cases were executed, was only about 1 percent. Results indicate that extensive random testing can be a process of diminishing returns, and that in the FTS context functional ('black box') testing can provide a very uneven execution coverage of the functionally equivalent software, and therefore should be supplemented by structure based testing.

Vouk, Mladen A.↗

NASA NTRS2015

Impact Testing and Simulation of a Sinusoid Foam Sandwich Energy Absorber

A sinusoidal-shaped foam sandwich energy absorber was developed and evaluated at NASA Langley Research Center through multi-level testing and simulation performed under the Transport Rotorcraft Airframe Crash Testbed (TRACT) research project. The energy absorber, designated the "sinusoid," consisted of hybrid carbon- Kevlar® plain weave fabric face sheets, two layers for each face sheet oriented at +/-45deg with respect to the vertical or crush direction, and a closed-cell ELFOAM(TradeMark) P200 polyisocyanurate (2.0-lb/ft3) foam core. The design goal for the energy absorber was to achieve an average floor-level acceleration of between 25- and 40-g during the full-scale crash test of a retrofitted CH-46E helicopter airframe, designated TRACT 2. Variations in the design were assessed through quasi-static and dynamic crush testing of component specimens. Once the design was finalized, a 5-ft-long subfloor beam was fabricated and retrofitted into a barrel section of a CH-46E helicopter. A vertical drop test of the barrel section was conducted onto concrete to evaluate the performance of the energy absorber prior to retrofit into TRACT 2. Finite element models were developed of all test articles and simulations were performed using LSDYNA ®, a commercial nonlinear explicit transient dynamic finite element code. Test analysis results are presented for the sinusoid foam sandwich energy absorber as comparisons of load-displacement and acceleration-time-history responses, as well as predicted and experimental structural deformations and progressive damage for each evaluation level (component testing through barrel section drop testing).

Jackson, Karen E.↗

NASA NTRS1990

The mini-dome Fresnel lens photovoltaic concentrator array - Current status of component and prototype panel testing

NASA Lewis and ENTECH have been developing a high-efficiency, lightweight space photovoltaic concentrator array. The emphasis of the program has shifted to fabrication and testing of the minidome Fresnel lens and other array components. Protototype lenses have been tested for optical efficiency, with results around 90 percent, and tracking error performance. The results of these tests have been very consistent with the predicted analytical performance. Work has also progressed in the fabrication of the array support structure. Recent advances in 30 percent efficient stacked cell technology will have a significant effect on the array performance. It is concluded that near-term array performance goals of 300 W/sq m and 100 W/kg are feasible.

Piszczor, M. F.↗

NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗

NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗

DOE OSTI2020

AGR-5/6/7 Post-Irradiation Examination Plan

This plan describes the PIE activities to be carried out on AGR-5/6/7 fuel and the non-fuel components of the AGR-5/6/7 irradiation test train. PIE of AGR-5/6/7 fuel and test train components will provide data on fuel performance over a range of irradiation conditions (e.g., burnup, neutron fluence, and temperature), test fuel under postulated accident conditions, and support development of fuel performance and fission product transport models. Examination of the non-fuel test train components will give information on TRISO fuel and compact performance and information on releases of radioactive fission products from the fuel compacts. PIE of the fuel compacts is used for many purposes including, but not limited to: updating the irradiation thermal calculations, measuring burnup, determining retention/release of fission products from the compacts and the TRISO particles, determining TRISO layer failure rates, determining fuel performance at elevated accident temperatures, determining fuel performance under oxidizing atmospheres, determining the distribution of fission products within the compact and fuel particles, and observing compact and particle morphology to explain mechanisms of TRISO layer failure and/or fission product release/retention.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1972

Development of a container for handling, testing, and storing discrete microelectronic components

A container has been developed for handling, testing, burning-in, and storing discrete microelectronic components without removal from the protective package. The package was designed to accommodate the leadless inverted device and other carrier-mounted active devices and chip-type discrete resistors and capacitors. Before the indicated development, components were handled and tested in various ways, some of which resulted in damage or contamination. The basic design of the container utilizes precision machined printed circuit boards and chemically milled (photoetched) contact springs. Included in this design for protection is an O-ring-sealed cover. Methods of fabrication and limitations of the current hardware are presented. Current applications of and possible extensions to the technology are discussed.

Filip, G. L.↗

NASA NTRS1969

Nondestructive testing of brazed rocket engine components.

Radiographic, ultrasonic, thermographic and leak test quality control for brazed liquid propellant rocket engine components

Adams, C.↗

NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗

NASA NTRS1980

Estimation procedures to measure and monitor failure rates of components during thermal-vacuum testing

Estimation procedures are described for measuring component failure rates, for comparing the failure rates of two different groups of components, and for formulating confidence intervals for testing hypotheses (based on failure rates) that the two groups perform similarly or differently. Appendix A contains an example of an analysis in which these methods are applied to investigate the characteristics of two groups of spacecraft components. The estimation procedures are adaptable to system level testing and to monitoring failure characteristics in orbit.

Williams, R. E.↗