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Current EBC Development and Testing at NASA

SiC SiC Ceramic Matrix Composites (CMCs) are a game changer for advanced power generation equipment because of their high temperature capability, oxidation resistance, and light weight that translate to significant reduction in fuel consumption and emission. Limitations of SiC SiC CMCs include surface recession and component cracking and associated chemical and physical degradation in the CMC. The solution pursued to mitigate surface recession of SiC SiC CMCs is the incorporation of coating systems that provide surface protection, which has become known as an Environmental Barrier Coating (EBC). The development of EBCs for the protection of SiC SiC CMCs was a continuation of coating development work for corrosion protection of silicon-based monolithics. The first and second generation EBCs developed in mid 1990s-early 2000s laid the foundation for current EBCs. Environmental degradation that limits EBC life includes surface recession by steam, oxidation in steam environments, and CMAS-EBC reactions. Many engine tests have been conducted since late 1990s and a first CMC component entered into service in 2016 in a commercial engine. The introduction of CMCs represents significant challenges as failure of the EBC means rapid reduction in component life. A reliable lifing method and engine-relevant testing methods to validate life need to be developed. This paper will current activities on EBC development and testing at NASA.

CMC↗

Application of Background Oriented Schlieren for Altitude Testing of Rocket Engines

A series of experiments was performed to determine the feasibility of using the Background Oriented Schlieren, BOS, flow visualization technique to image a simulated, small, rocket engine, plume under altitude test conditions. Testing was performed at the NASA Glenn Research Centers Altitude Combustion Stand, ACS, using nitrogen as the exhaust gas simulant. Due to limited optical access to the facility test capsule, all of the hardware required to conduct the BOS were located inside the vacuum chamber. During the test series 26 runs were performed using two different nozzle configurations with pressures in the test capsule around 0.3 psia. No problems were encountered during the test series resulting from the optical hardware being located in the test capsule and acceptable resolution images were captured. The test campaign demonstrated the ability of using the BOS technique for small, rocket engine, plume flow visualization during altitude testing.

Background Oriented Schlieren↗

Optimization applications in aircraft engine design and test

Starting with the NASA-sponsored STAEBL program, optimization methods based primarily upon the versatile program COPES/CONMIN were introduced over the past few years to a broad spectrum of engineering problems in structural optimization, engine design, engine test, and more recently, manufacturing processes. By automating design and testing processes, many repetitive and costly trade-off studies have been replaced by optimization procedures. Rather than taking engineers and designers out of the loop, optimization has, in fact, put them more in control by providing sophisticated search techniques. The ultimate decision whether to accept or reject an optimal feasible design still rests with the analyst. Feedback obtained from this decision process has been invaluable since it can be incorporated into the optimization procedure to make it more intelligent. On several occasions, optimization procedures have produced novel designs, such as the nonsymmetric placement of rotor case stiffener rings, not anticipated by engineering designers. In another case, a particularly difficult resonance contraint could not be satisfied using hand iterations for a compressor blade, when the STAEBL program was applied to the problem, a feasible solution was obtained in just two iterations.

Pratt, T. K.↗

Multi-fuel rotary engine for general aviation aircraft

Design studies of advanced multifuel general aviation and commuter aircraft rotary stratified charge engines are summarized. Conceptual design studies were performed at two levels of technology, on advanced general aviation engines sized to provide 186/250 shaft kW/hp under cruise conditions at 7620 (25000 m/ft) altitude. A follow on study extended the results to larger (2500 hp max.) engine sizes suitable for applications such as commuter transports and helicopters. The study engine designs were derived from relevant engine development background including both prior and recent engine test results using direct injected unthrottled rotary engine technology. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 27 to 33 percent fuel economy improvement for the rotary engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed.

Jones, C.↗

Baseline performance and emissions data for a single-cylinder, direct-injected diesel engine

Comprehensive fuel consumption, mean effective cylinder pressure, and emission test results for a supercharged, single-cylinder, direct-injected, four-stroke-cycle, diesel test engine are documented. Inlet air-to-exhaust pressure ratios were varied from 1.25 to 3.35 in order to establish the potential effects of turbocharging techniques on engine performance. Inlet air temperatures and pressures were adjusted from 34 to 107 C and from 193 to 414 kPa to determine the effects on engine performance and emissions. Engine output ranged from 300 to 2100 kPa (brake mean effective pressure) in the speed range of 1000 to 3000 rpm. Gaseous and particulate emission rates were measured. Real-time values of engine friction and pumping loop losses were measured independently and compared with motored engine values.

Dezelick, R. A.↗

Multi-fuel rotary engine for general aviation aircraft

Design studies of advanced multifuel general aviation and commuter aircraft rotary stratified charge engines are summarized. Conceptual design studies were performed at two levels of technology, an advanced general aviation engines sized to provide 186/250 shaft kW/hp under cruise conditions at 7620 (25,000 m/ft) altitude. A follow on study extended the results to larger (2500 hp max.) engine sizes suitable for applications such as commuter transports and helicopters. The study engine designs were derived from relevant engine development background including both prior and recent engine test results using direct injected unthrottled rotary engine technology. Aircraft studies, using these resultant growth engines, define anticipated system effects of the performance and power density improvements for both single engine and twin engine airplanes. The calculated results indicate superior system performance and 27 to 33 percent fuel economy improvement for the rotary engine airplanes as compared to equivalent airframe concept designs with current baseline engines. The research and technology activities required to attain the projected engine performance levels are also discussed. Previously announced in STAR as N83-18910

Jones, C.↗

Thermal barrier coating life-prediction model development

Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.

Strangman, T. E.↗

Flight Tests of an Airplane Showing Dependence of the Maximum Lift Coefficient on the Test Conditions

Data are presented to show the extent to which the maximum lift coefficient and consequently the minimum speed of an airplane, determined by flight tests, may vary with test conditions. The data show that cl-max may vary as much as 14 percent, depending on the altitude and wing loading at which the tests were made, the position or motion of the propeller, and the rate at which the angle of attack is changing when the maximum lift coefficient is obtained. The variation of the maximum lift coefficient with these factors, which are under the control of the test engineer, shows the need of standardizing the test procedure. A further variation is shown with wing conditions as affected by weathering and vibration, factors that cannot be completely controlled.

Soule, H A↗

Dual-Actuator Active Vibration-Control System

Dual-actuator active vibration-control (DAAVC) system is developmental system of type described in "Active Vibration Dampers for Rotating Machinery" (LEW-15427). System features sensors and actuators positioned and oriented at bearings to measure and counteract vibrations of shaft along either of two axes perpendicular to axis of rotation. Effective in damping vibrations of helicopter-engine test stand, making it safer to operate engine at speeds near and above first resonance of engine/test-stand system. Opens new opportunities for engine designers to draw more power from engine, and concept applicable to other rotating machines.

Kascak, Albert F.↗

Research and development of high thermal stability fuels

Increases in aircraft performance are leading to increases in the thermal stress on the primary aircraft coolant--the fuel. Fuel thermal stability limitations may offset future aircraft performance gains. The Air Force's Wright Laboratory is sponsoring several research programs to address this problem. The development of an additive package for JP-8 to improve its thermal stability is the primary focus of this paper. This program involves extensive testing of fuels and additives in a variety of test devices, culminating in tests in a fuel system simulator and engine tests. These tests involve Air Force personnel, on-site contractors (University of Dayton Research Institute, Systems Research Laboratories), Pratt and Whitney Aircraft Co., additive manufacturers, and Sandia National Laboratory. The test devices include several flowing and static tests, where the behavior of a fuel is investigated in a wide variety of environments. The study of several baseline fuels in these devices has led to some new insights into the mechanisms of fuel thermal (in)stability. It is becoming clear that a fuel's tendency to oxidize (to form peroxides, for example) is often inversely proportional to its tendency to form insoluble deposits.

T Edwards↗

Developments in Test Facility and Data Networking for the Altitude Test Stand at the John C. Stennis Space Center, MS - A General Overview

May 2007, NASA's Constellation Program selected John C Stennis Space Center (SSC) near Waveland Mississippi as the site to construct an altitude test facility for the developmental and qualification testing of the Ares1 upper stage (US) engine. Test requirements born out of the Ares1 US propulsion system design necessitate exceptional Data Acquisition System (DAS) design solutions that support facility and propellant systems conditioning, test operations control and test data analysis. This paper reviews the new A3 Altitude Test Facility's DAS design requirements for real-time deterministic digital data, DAS technology enhancements, system trades, technology validation activities, and the current status of this system's new architecture. Also to be discussed will be current network technologies to improve data transfer.

Hebert, Phillip W., Sr.↗

Combinatorial Generation of Test Suites

Testgen is a computer program that generates suites of input and configuration vectors for testing other software or software/hardware systems. As systems become ever more complex, often, there is not enough time to test systems against all possible combinations of inputs and configurations, so test engineers need to be selective in formulating test plans. Testgen helps to satisfy this need: In response to a test-suite-requirement-specification model, it generates a minimal set of test vectors that satisfies all the requirements.

Dvorak, Daniel L.↗

Shooting the Moon

This story is about an unlikely NASA mission to the Moon. It was unlikely because it was started with far too little time and too-little money to complete. It was unlikely because it was able to take chances to accept risk of failure. It was unlikely because it was searching for the unthinkable: water-ice on the moon... Figure 1-1: LCROSS Mission. The mission of the Lunar CRater Observation and Sensing Satellite (LCROSS) was to investigate the possibility of water ice in craters on the Moon s poles. This is certainly an interesting scientific topic in itself, but I intend to focus on the compelling experience of managing the LCROSS Project in the context of this storied Agency. Perhaps most interesting are the implications this story has for managing any development effort, lunar or not, and working a balance to achieve success. NASA is by design a risk-taking agency within the US Government. It could be argued that NASA s purpose in the aerospace community is to take on the really big challenges that either the corporate world can t afford, are not yet profitable endeavors, or are just too risky for private corporations to entertain. However, expectations of the Agency have evolved. A combination of grim human tragedies and some very public cost and schedule overruns have challenged the public s and Congress s tolerance for risk-taking within the Agency. NASA, which is supposed to be in the business of taking risks to do bold, difficult things, has become less and less able to do so within its cost framework. Yet effectively replacing prudent risk management with attempts to "risk-eliminate" is completely unaffordable. So where does risk-taking fit within the Agency, or within private/corporate organizations for that matter? Where astronauts play there is clearly concern about risk. When an organization puts humans in harm s way, it is understandably going to take extra effort to assure nobody gets hurt. Doing so, of course, costs money - a lot of money to pay for labor and hardware which is attempting to assure nothing will go wrong. Sophisticated designs, with doubly- or triply-redundant systems, extensive testing to verify those systems, and numerous engineering test units built to learn and evolve a hardware design, all drive the cost and time required to implement. Human spaceflight is an expensive business because of the exceptional system complexity and levels of assurance required for human space travel. What about missions that do not involve human spaceflight? What about missions whose potential failure will not take a human life, whose costs are small and whose urgency and importance are limited by design? A portfolio consisting of this type of mission can be designed to be risk tolerant, not requiring large expenditures to guarantee against failure. With the money saved, the number of missions that can be executed within the portfolio grows, or the total cost of the portfolio can be reduced. The NASA LCROSS mission is a pathfinder example of a low-cost, quick turn-around mission which struck a balance on mission risk, while accomplishing big objectives, like defining how we understand the Moon.

Andrews, Daniel R.↗

CAIDA CUI Confirmation for OMRS & LCC SOCRRATES Emulator and iSEE Upgrade, Operations, & Analysis

This internship has focused on providing solutions for the Customer Avionics Interface Development and Analysis (CAIDA) subsystem. The main emulator that has been used during this internship is the Software-Only CEV (Crew Exploration Vehicle) Risk Reduction Analysis and Test Engineering Simulator (SOCRRATES). This emulator uses advanced math and physics methods to simulate specific points in a mission, such as ascent, entry, and orbit. Exploration Ground Systems (EGS) must ensure that all KSC based ground systems can be properly integrated with the flight vehicle software, therefore, the Modeling and Simulation Branch (NE-XM) of the KSC (Kennedy Space Center) Engineering Directorate supports a virtual environment that simulates the interface between ground systems and the flight vehicle. A primary component in assuring that is knowing whether the emulators have incorporated the correct CUIs (Compact Unique Identifiers) into their system, as well as understanding both the static and dynamic responses of the individual CUIs. Also, an effort for verification of Operational Maintenance Requirements Specifications (OMRS) and Launch Commit Criteria (LCC) that are supported by SOCRRATES for the Orion Crew Module were part of the project tasks this semester. This internship also focused on comparing two different simulation Commercial-off-the-shelf (COTS) products and to determine whether or not a COTS package was a viable replacement for the current software that the iSEE (Immersive Simulations and Engineering Environment) lab uses. Upon research and testing, I found that this software was not feasible for the lab. It could not easily load CAD (Computer-Aided Design) or CREO models, give live feedback while the user is in the environment, and was not compatible with a virtual reality headset, all of which are necessary for the lab.

Bundy, Caleb↗

Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS)

Starting in 2013 and completing in 2019, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations with extreme entry environments such as Venus, Saturn, Uranus, Neptune and high-speed sample return missions to Earth. A key aspect of the project has been the building and testing of a 1-meter base diameter Engineering Test Unit (ETU) representative of what could be used for a Saturn probe. This paper provides a high-level overview of the HEEET project including manufacturing and testing of the ETU for structural model verification, establish system capability and verify manufacturing workmanship.

Extreme Entry Environment↗

Heatshield for Extreme Entry Environment Technology (HEEET) Thermal Protection System (TPS)

Over the last 5 years, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations with extreme entry environments such as Venus, Saturn, Uranus, Neptune and high speed sample return missions to Earth. A key aspect of the project has been the building and testing of a 1-meter base diameter Engineering Test Unit (ETU) representative of what could be used for a Saturn probe. This paper provides a high level overview of the HEEET project including manufacturing and testing of the ETU which has been subjected to mission relevant thermal and mechanical loads, to verify structural models, establish system capability and verify manufacturing workmanship.

TPS↗

An Update on Ice Crystal Icing Research at NASA Glenn Research Center

This presentation is an update on the Ice Crystal Icing Research that has been conducted at the NASA Glenn Research Center in recent years. This presentation highlights key findings from fundamental ice crystal icing tests and from a fully instrumented research engine test. All material in the presentation is publicly available information.

Bartkus, Tadas↗

Characterization of Nancy Grace Roman Space Telescope Slitless Spectrometer (grism)

We have published the optical design and early test results of the Roman Space Telescope grism spectrometer in previous SPIE proceedings. We report the follow-on activity of the spectral and radiometric calibrations, including the calibration methods, experiment designs, and test equipment calibration, such as the light source and detectors used in the test. The grism calibration includes the throughput versus wavelength, which is largely determined by the diffraction efficiency of the two diffractive surfaces. It also includes spectral resolution, point spread function, and relative radiometric measurements. The measured results are presented. The comparisons between the test data and the theoretical simulations are also presented. The tests and results presented are from the engineering test unit in ambient room temperature environment. The thermal/vacuum tests are planned to verify the results when the flight unit is ready.

Qian Gong↗