Search NASA⌕ Search

SEARCH · Search NASA

Results for “Integration and test”

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.

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

At least 73 records · Page 4

Contact integrity testing of stress-tested silicon terrestrial solar cells

A test procedure was developed and applied to terrestrial silicon solar cells in order to determine the effect of accelerated environmental and time-temperature aging on metal contact integrity. Quantities of cells of four different manufacturers were given the contact integrity test after being subjected to accelerated stress tests that included forward bias-temperature, thermal cycle and thermal shock, power cycle, and bias-temperature humidity tests at two temperature-humidity levels. Significant effects due to certain stress tests were found for some cell types. It is concluded that cells fabricated using plated nickel/solder metallization showed significantly more serious contact integrity degradation than silver-metallized cells.

Prince, J. L.↗

Swing Bed Scrubber Design and Test Integration Results for Carbon Dioxide Removal in the Ventilation Test Loop 2.0

NASA is developing an advanced portable life support system (PLSS) to meet the needs of a new NASA advanced space suit. The PLSS provides the necessary oxygen, ventilation, and thermal protection for an astronaut performing a spacewalk. The PLSS ventilation subsystem is responsible for providing adequate carbon dioxide (CO2) and water vapor removal. To experimentally validate the performance of CO2 removal and advanced CO2 sensing systems, NASA Johnson Space Center developed the Ventilation Test Loop 2.0 (VTL2) and tested the Oceaneering Swing Bed Scrubber (SBS) that was fabricated and delivered under the Constellation Space Suit System Contract in 2015. The SBS was designed to continuously remove CO2 and water vapor from a space suit ventilation loop with a pair of thermally integrated amine beds that alternately adsorb and desorb water vapor and CO2. The SBS hardware was recently resurrected and reassembled to support a full battery of performance testing in the VTL2. This paper describes the design and development of the SBS and the VTL2 along with the performance test results of the SBS.

Ventilation Test Loop↗

Integrated Testing Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I crew launch vehicle is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew and cargo access to the International Space Station (ISS) and, together with the Ares V cargo launch vehicle, serves as a critical component of NASA's future human exploration of the Moon. During the preliminary design phase, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements - including the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine - will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the upper stage Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle ground vibration test (IVGVT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, validate the ability of the upper stage to manage cryogenic propellants to achieve upper stage engine start conditions, and a high-altitude demonstration of the launch abort system (LAS) following stage separation. The Orion 1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Taylor, James L.↗

Computer-aided-engineering system for modeling and analysis of ECLSS integration testing

The accurate modeling and analysis of two-phase fluid networks found in environmental control and life support systems is presently undertaken by computer-aided engineering (CAE) techniques whose generalized fluid dynamics package can solve arbitrary flow networks. The CAE system for integrated test bed modeling and analysis will also furnish interfaces and subsystem/test-article mathematical models. Three-dimensional diagrams of the test bed are generated by the system after performing the requisite simulation and analysis.

Sepahban, Sonbol↗

Flight Systems Integration & Test: Lessons Learned for Future Success

This paper offers a comprehensive view of flight system integration and test (I&T) lessons learned related to mishaps and close calls, focusing on what can be done to improve the I&T process to avoid recurrence. Specific areas within the realm of I&T that are covered in this paper include: I&T team communication and training; design of flight and ground systems for I&T; planning and scheduling; configuration management and process documentation; ground support equipment and tools; cleanrooms and contamination; mechanical integration, handling, and deployments; electrical integration and electrostatic discharge; functional testing and troubleshooting; environmental testing and facilities; and launch site operations. To illustrate "real-world" lessons learned for I&T, examples from throughout the history of the U.S. space program are presented. Also presented are some best practices for I&T that can help mitigate mishaps and close calls on the ground or during flight.

Integration & Test↗

Integrated Testing of a Carbon Dioxide Removal Assembly and a Temperature-Swing Adsorption Compressor for Closed-Loop Air Revitalization

Accumulation and subsequent compression of carbon dioxide that is removed from space cabin are two important processes involved in a closed-loop air revitalization scheme of the International Space Station (ISS). The carbon dioxide removal assembly (CDRA) of ISS currently operates in an open loop mode without a compressor. This paper describes the integrated test results of a flight-like CDRA and a temperature-swing adsorption compressor (TSAC) for carbon dioxide removal and compression. The paper provides details of the TSAC operation at various CO2 loadings and corresponding performance of CDRA.

Knox, J. C.↗

Flight and Integrated Testing: Blazing the Trail for the Ares Launch Vehicles

It has been 30 years since the United States last designed and built a human-rated launch vehicle. The National Aeronautics and Space Administration (NASA) has marshaled unique resources from the government and private sectors that will carry the next generation of astronauts into space safer and more efficiently than ever and send them to the Moon to develop a permanent outpost. NASA's Flight and Integrated Test Office (FITO) located at Marshall Space Flight Center and the Ares I-X Mission Management Office have primary responsibility for developing and conducting critical ground and flight tests for the Ares I and Ares V launch vehicles. These tests will draw upon Saturn and the Space Shuttle experiences, which taught the value of using sound systems engineering practices, while also applying aerospace best practices such as "test as you fly" and other lessons learned. FITO will use a variety of methods to reduce the technical, schedule, and cost risks of flying humans safely aboard a launch vehicle.

Taylor, James L.↗

An Overview of the Concept of Operations for Assembly, Integration, Testing and Ground Servicing Developed for the MPCV-ESM Propulsion System

A concept of operations for the Assembly, Integration and Testing (AIT) and the Ground Systems Development Operations (GSDO) of the European Service Module (ESM) propulsion system has been developed. The AIT concept of operations covers all fabrication, integration and testing activities in both Europe and in the United States. The GSDO Program develops the facilities, equipment, and procedures for the loading of hypergolic propellants, the filling of high-pressure gases, and contingency de-servicing operations for the ESM. NASA and ESA along with the Lockheed Martin and Airbus Space and Defense are currently working together for the EM-1 and EM-2 missions in which the ESM will be flown as part of the Orion Multi-Purpose Crew Vehicle (MPCV). The NASA/ESA SM propulsion team is collaborating with the AIT personnel from ESA/Airbus and NASA/Lockheed Martin to ensure successful integration of the European designed Service Module propulsion system, the Lockheed Martin designed Crew Module Adapter and the heritage Space Shuttle Orbital Maneuvering System Engines (OMS-E) being provided as Government Furnished Equipment (GFE). This paper will provide an overview of the current AIT and GSDO concept of operations for the ESM propulsion system.

Propulsion↗

An Overview of the Concept of Operations for Assembly, Integration, Testing and Ground Servicing Developed for the MPCV-ESM Propulsion System

A concept of operations for the Assembly, Integration and Testing (AIT) and the Ground Systems Development Operations (GSDO) of the European Service Module (ESM) propulsion system has been developed. The AIT concept of operations covers all fabrication, integration and testing activities in both Europe and in the United States. The GSDO Program develops the facilities, equipment, and procedures for the loading of hypergolic propellants, the filling of high-pressure gases, and contingency de-servicing operations for the ESM. NASA and ESA along with the Lockheed Martin and Airbus Space and Defense are currently working together for the EM-1 and EM-2 missions in which the ESM will be flown as part of the Orion Multi-Purpose Crew Vehicle (MPCV). The NASA/ESA SM propulsion team is collaborating with the AIT personnel from ESA/Airbus and NASA/Lockheed Martin to ensure successful integration of the European designed Service Module propulsion system, the Lockheed Martin designed Crew Module Adapter and the heritage Space Shuttle Orbital Maneuvering System Engines (OMS-E) being provided as Government Furnished Equipment (GFE). This paper will provide an overview of the current AIT and GSDO concept of operations for the ESM propulsion system.

Ground Servicing↗

Lost in Translation: the Case for Integrated Testing

The building of a spacecraft is complex and often involves multiple suppliers and companies that have their own designs and processes. Standards have been developed across the industries to reduce the chances for critical flight errors at the system level, but the spacecraft is still vulnerable to the introduction of critical errors during integration of these systems. Critical errors can occur at any time during the process and in many cases, human reliability analysis (HRA) identifies human error as a risk driver. Most programs have a test plan in place that is intended to catch these errors, but it is not uncommon for schedule and cost stress to result in less testing than initially planned. Therefore, integrated testing, or "testing as you fly," is essential as a final check on the design and assembly to catch any errors prior to the mission. This presentation will outline the unique benefits of integrated testing by catching critical flight errors that can otherwise go undetected, discuss HRA methods that are used to identify opportunities for human error, lessons learned and challenges over ownership of testing will be discussed.

Young, Aaron↗

Integration Testing of a Modular Discharge Supply for NASA's High Voltage Hall Accelerator Thruster

NASA s In-Space Propulsion Technology Program is developing a high performance Hall thruster that can fulfill the needs of future Discovery-class missions. The result of this effort is the High Voltage Hall Accelerator thruster that can operate over a power range from 0.3 to 3.5 kW and a specific impulse from 1,000 to 2,800 sec, and process 300 kg of xenon propellant. Simultaneously, a 4.0 kW discharge power supply comprised of two parallel modules was developed. These power modules use an innovative three-phase resonant topology that can efficiently supply full power to the thruster at an output voltage range of 200 to 700 V at an input voltage range of 80 to 160 V. Efficiencies as high as 95.9 percent were measured during an integration test with the NASA103M.XL thruster. The accuracy of the master/slave current sharing circuit and various thruster ignition techniques were evaluated.

Pinero, Luis R.↗

Beam Commissioning and Integrated Test of the PIP-II Injector Test Facility

The PIP-II Injector Test (PIP2IT) facility is a near-complete low energy portion of the Superconducting PIP-II linac driver. PIP2IT comprises the warm front end and the first two PIP-II superconducting cryomodules. PIP2IT is designed to accelerate a 2 mA H⁻ beam to an energy of 20 MeV. The facility serves as a testbed for a number of advanced technologies required to operate PIP-II and provides an opportunity to gain experience with commissioning of the superconducting linac, significantly reducing project technical risks. Some PIP2IT components are contributions from international partners, who also lend their expertise to the accelerator project. The project has been successfully commissioned with the beam in 2021, demonstrating the performance required for the LBNF/DUNE. In this paper, we describe the facility and its critical systems. We discuss our experience with the integrated testing and beam commissioning of PIP2IT, and present commissioning results. This important milestone ushers in a new era at Fermilab of proton beam delivery using superconducting radio-frequency accelerators.

43 PARTICLE ACCELERATORS↗

James Webb Space Telescope Primary Mirror Integration: Testing the Multiwavelength Interferometer on the Test Bed Telescope

The James Webb Space Telescope (JWST) integration includes a center of curvature test on its 18 primary mirror segment assemblies (PMSAs). This important test is the only ground test that will demonstrate the ability to align all 18 PMSAs. Using a multi-wavelength interferometer (MWIF) integrated to the test bed telescope (TBT), a one-sixth scale model of the JWST, we verify our ability to align and phase the 18 PMSAs. In this paper we will discuss data analysis and test results when using the MWIF to align the segments of the TBT in preparation for alignment of the JWST.

Olczak, Gene↗

CVT/GPL phase 3 integrated testing

The hardware for 20 candidate shuttle program life sciences experiments was installed in the GPL and experiments were conducted during a 5-day simulated mission. The experiments involved humans, primates, rats, chickens, and marigold plants. All experiments were completed to the satisfaction of the experimenters. In addition to the scientific data gathered for each experiment, information was obtained concerning experiment hardware design and integration, experiment procedures, GPL support systems, and test operations. The results of the integrated tests are presented.

Shurney, R. E.↗

Model Preparation Areas for Propulsion Airframe Integration Testing at the NASA Langley Research Center

Currently, there are three major NASA Langley facilities that perform Propulsion Airframe Integration (PAI) testing. These include the National Transonic Facility (NTF), the 14- by 22-Foot Subsonic Tunnel, and the 4-Foot Supersonic Unitary Plan Wind Tunnel. While each of these facilities have their respective model preparation areas, one model preparation area, located at the NTF complex, focuses on high mass flow blowing systems in support of other Langley Research Center facilities. The application of PAI requires special attention to the air delivery system interaction with the model. These interactions focus on the tares across the force and moment balance. The interactions are a result of the mass flow and pressure of the air through the system and the efficiency of the inlet and nozzle geometries. While this paper does not characterize any specific propulsion system, it does focus on the mass flow and pressure requirements for risk-reduction planning of such systems prior to installation in a designated wind tunnel. An example of model and nozzle sizing will be presented for the Tail Cone Thruster (TCT) variant of the Common Research Model (CRM).

PAI↗

Zero-Boiloff Cryogenic Storage Cryocooler Integration Test

Developments in NASA Glenn Research Center's Centaur work have led to an exciting new cryogenic storage concept being considered for future NASA space missions. With long-duration cryogenic storage, propellants will boil off because of the environmental heating of the tank. To accommodate these losses, extra propellant is required along with larger propellant tanks. Analyses of space transportation concepts show that spacetransfer cryogenic stages with the zero boiloff (ZBO) cryogenic storage concept reduce the stage mass for missions longer than approximately 45 days in low Earth orbit. The ZBO system consists of an active cryocooling system using a cryocooler in addition to traditional passive thermal insulation. Engineers at Glenn analyzed, designed, built, and bench tested a heat exchanger and integration hardware for a large-scale ZBO demonstration for the NASA Marshall Space Flight Center. The heat exchanger, which transfers the heat that enters the tank from the fluid to the cryocooler, must limit the temperature difference across it to limit the cryocooler size and power requirements. With a low temperature difference, the system efficiency is improved. For that temperature difference to be reduced, the thermal conductivity must be as high as possible at liquid hydrogen temperatures, around 25 K (-248 C). In addition, it is important for the heat exchanger to be welded to a stainless steel flange and have enough strength to accommodate piping stress. High-conductivity copper was selected and fabricated, then integrated with the stainless steel piping tee as shown in the cutaway representation. Literature showed that this conductivity might range from 2 to 100 W/cm/K but that is was likely to be around 13 W/cm/K. Unexpectedly, this conductivity was measured to be 23 W/cm/K, which limited the temperature increase along the heat exchanger to just 2 K. This limited temperature increase, compared with the predicted difference of 3.5 K, improves the overall system efficiency by 7.4 percent and limits the expected integration losses to a projected 4 percent with a flight design for liquid hydrogen storage. These results improve the cryocooler integration concept by allowing the cryocooler to operate at a lower input power, or by potentially permitting a smaller cryocooler to be selected.

Plachta, David W.↗

Integration, Testing and Performance of the Infrared Multi-Object Spectrometer

The Infrared Multi-Object Spectrometer (IRMOS) is a principle investigator-class instrument for the Kitt Peak National Observatory 2.1 m and Mayall 3.8 m telescopes. IRMOS is a near-IR (0.8 - 2.5 micron) spectrometer with low-to mid-resolving power (R = lambda/delta lambda = 300 - 3000). On the 3.8 m telescope, IRMOS produces simultaneous spectra of approximately 100 objects in its approximately 3 x 2 arcmin field of view using a commercial micro electro-mechanical systems (MEMS) digital micro-mirror device (DMD) from Texas Instruments. The multi-mirror array DMD operates as a real-time programmable slit mask. The all-reflective optical design consists of two imaging subsystems. The focal reducer images the focal plane of the telescope onto the DMD field stop, and the spectrograph images the DMD onto a large-format detector. The instrument operates at approximately 80 K, cooled by a single electro-mechanical cryocooler. The bench and all components are made from aluminum 6061-T651. There are three cryogenic mechanisms. We describe laboratory integration and test of IRMOS before shipment to Kitt Peak. We give an overview of the optical alignment technique and integration of optical, mechanical, electrical and cryogenic subsystems. We compare optical test results to model predictions of point spread function size and morphology, contrast, and stray light. We discuss some lessons learned and conclude with a prediction for performance on the telescope.

Ohl, Raymond G.↗

Integrated Test Stand

Explore the source record for details and available documents.

43 PARTICLE ACCELERATORS↗