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NASA NTRS2010

Ares I-X Flight Test Vehicle Modal Test

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, was launched on October 28, 2009. Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle was not practical within project constraints, modal tests for several configurations during vehicle stacking were defined to calibrate the FEM. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report describes the test requirements, constraints, pre-test analysis, test execution and results for the Ares I-X flight test vehicle modal test on the Mobile Launcher Platform. Initial comparisons between pre-test predictions and test data are also presented.

Buehrle, Ralph D.↗

NASA NTRS2024

NESC Ceramic Oxygen Generator (COG) Technology Development

The NASA Engineering and Safety Center (NESC) sponsored a project to accelerate the pace of technology development of a ceramic oxygen generator (COG), for NASA and COVID related medical use. NASA applications for this technology include spacesuit oxygen tank recharge, medical applications include providing medical oxygen in remote and low resource settings. During this project, five full-scale (i.e., 30 wafer) cell stacks were built and tested in prototype systems capable of producing pressurized oxygen. System testing measured oxygen product purity, delivery pressure, production rate, and energy use. This report describes ion transport membrane mechanisms, cell stack configuration, and test results.

Oxygen↗

NASA NTRS2010

Hollow Fiber Spacesuit Water Membrane Evaporator Development and Testing for Advanced Spacesuits

The spacesuit water membrane evaporator (SWME) is being developed to perform the thermal control function for advanced spacesuits to take advantage of recent advances in micropore membrane technology in providing a robust heat-rejection device that is potentially less sensitive to contamination than is the sublimator. Principles of a sheet membrane SWME design were demonstrated using a prototypic test article that was tested in a vacuum chamber at JSC in July 1999. The Membrana Celgard X50-215 microporous hollow fiber (HoFi) membrane was selected after recent contamination tests as the most suitable candidate among commercial alternatives for HoFi SWME prototype development. A design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape, was developed into a full-scale prototype consisting 14,300 tube bundled into 30 stacks, each of which are formed into a chevron shape and separated by spacers and organized into three sectors of ten nested stacks. Vacuum chamber testing has been performed characterize heat rejection as a function of inlet water temperature and water vapor backpressure and to show contamination resistance to the constituents expected to be found in potable water produced by the distillation processes. Other tests showed the tolerance to freezing and suitability to reject heat in a Mars pressure environment.

Bue, Grant C.↗

NASA NTRS2014

Advanced Mirror & Modelling Technology Development

The 2020 Decadal technology survey is starting in 2018. Technology on the shelf at that time will help guide selection to future low risk and low cost missions. The Advanced Mirror Technology Development (AMTD) team has identified development priorities based on science goals and engineering requirements for Ultraviolet Optical near‐Infrared (UVOIR) missions in order to contribute to the selection process. One key development identified was lightweight mirror fabrication and testing. A monolithic, stacked, deep core mirror was fused and replicated twice to achieve the desired radius of curvature. It was subsequently successfully polished and tested. A recently awarded second phase to the AMTD project will develop larger mirrors to demonstrate the lateral scaling of the deep core mirror technology. Another key development was rapid modeling for the mirror. One model focused on generating optical and structural model results in minutes instead of months. Many variables could be accounted for regarding the core, face plate and back structure details. A portion of a spacecraft model was also developed. The spacecraft model incorporated direct integration to transform optical path difference to Point Spread Function (PSF) and between PSF to modulation transfer function. The second phase to the project will take the results of the rapid mirror modeler and integrate them into the rapid spacecraft modeler.

Effinger, Michael↗

NASA NTRS1988

Assembly Test Article (ATA)

The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.

Ricks, Glen A.↗

NASA NTRS1988

Improvements in magnetic bearing performance for flywheel energy storage

The paper considers the development of a 500-Watt-hour magnetically suspended flywheel stack energy storage system. The work includes hardware testing results from a stack flywheel energy storage system, improvements in the area of noncontacting displacement transducers, and performance enhancements of magnetic bearings. Experimental results show that a stack flywheel energy storage system is feasible technology.

Plant, David P.↗

NASA NTRS1984

Develop and test fuel cell powered on-site integrated total energy systems

On-going testing of an 11 cell, 10.7 in. x 14 in. stack (about 1 kW) reached 2600 hours on steady load. Nonmetallic cooling plates and an automated electrolyte replenishment system continued to perform well. A 10 cell, 10.7 in. x 14 in. stack was constructed with a modified electrolyte matrix configuration for the purpose of reducing cell IR loss. The desired effect was achieved, but the general cell performance level was irregular. Evaluation is continuing. Preparations for a long term 25 cell, 13 in. x 23 in. test stack (about 4 kW) approached completion. Start up in early May 1984 is expected.

Kaufman, A.↗

NASA NTRS2007

Solar Airplanes and Regenerative Fuel Cells

A solar electric aircraft with the potential to "fly forever" has captured NASA's interest, and the concept for such an aircraft was pursued under Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project. Feasibility of this aircraft happens to depend on the successful development of solar power technologies critical to NASA's Exploration Initiatives; hence, there was widespread interest throughout NASA to bring these technologies to a flight demonstration. The most critical is an energy storage system to sustain mission power during night periods. For the solar airplane, whose flight capability is already limited by the diffuse nature of solar flux and subject to latitude and time of year constraints, the feasibility of long endurance flight depends on a storage density figure of merit better than 400-600 watt-hr per kilogram. This figure of merit is beyond the capability of present day storage technologies (other than nuclear) but may be achievable in the hydrogen-oxygen regenerative fuel cell (RFC). This potential has led NASA to undertake the practical development of a hydrogen-oxygen regenerative fuel cell, initially as solar energy storage for a high altitude UAV science platform but eventually to serve as the primary power source for NASAs lunar base and other planet surface installations. Potentially the highest storage capacity and lowest weight of any non-nuclear device, a flight-weight RFC aboard a solar-electric aircraft that is flown continuously through several successive day-night cycles will provide the most convincing demonstration that this technology's widespread potential has been realized. In 1998 NASA began development of a closed cycle hydrogen oxygen PEM RFC under the Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project and continued its development, originally for a solar electric airplane flight, through FY2005 under the Low Emissions Alternative Power (LEAP) project. Construction of the closed loop system began in 2002 at the NASA Glenn Research Center in Cleveland, Ohio. System checkout was completed, and testing began, in July of 2003. The initial test sequences were done with only a fuel cell or electrolyzer in the test rig. Those tests were used to verify the test apparatus, procedures, and software. The first complete cycles of the fully closed loop, regenerative fuel cell system were successfully completed in the following September. Following some hardware upgrades to increase reactant recirculation flow, the test rig was operated at full power in December 2003 and again in January 2004. In March 2004 a newer generation of fuel cell and electrolyzer stacks was substituted for the original hardware and these stacks were successfully tested at full power under cyclic operation in June of 2004.

Bents, David J.↗

NASA NTRS2011

NASA PEMFC Development Background and History

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. Four vendors have designed and fabricated non-flow-through fuel cell stacks under NASA funding. One of these vendors is considered the "baseline" vendor, and the remaining three vendors are competing for the "alternate" role. Each has undergone testing of their stack hardware integrated with a NASA balance-of-plant. Future Exploration applications for this hardware include primary fuel cells for a Lunar Lander and regenerative fuel cells for Surface Systems.

Hoberecht, Mark↗

NASA NTRS2006

Excitations for Rapidly Estimating Flight-Control Parameters

A flight test on an F-15 airplane was performed to evaluate the utility of prescribed simultaneous independent surface excitations (PreSISE) for real-time estimation of flight-control parameters, including stability and control derivatives. The ability to extract these derivatives in nearly real time is needed to support flight demonstration of intelligent flight-control system (IFCS) concepts under development at NASA, in academia, and in industry. Traditionally, flight maneuvers have been designed and executed to obtain estimates of stability and control derivatives by use of a post-flight analysis technique. For an IFCS, it is required to be able to modify control laws in real time for an aircraft that has been damaged in flight (because of combat, weather, or a system failure). The flight test included PreSISE maneuvers, during which all desired control surfaces are excited simultaneously, but at different frequencies, resulting in aircraft motions about all coordinate axes. The objectives of the test were to obtain data for post-flight analysis and to perform the analysis to determine: 1) The accuracy of derivatives estimated by use of PreSISE, 2) The required durations of PreSISE inputs, and 3) The minimum required magnitudes of PreSISE inputs. The PreSISE inputs in the flight test consisted of stacked sine-wave excitations at various frequencies, including symmetric and differential excitations of canard and stabilator control surfaces and excitations of aileron and rudder control surfaces of a highly modified F-15 airplane. Small, medium, and large excitations were tested in 15-second maneuvers at subsonic, transonic, and supersonic speeds. Typical excitations are shown in Figure 1. Flight-test data were analyzed by use of pEst, which is an industry-standard output-error technique developed by Dryden Flight Research Center. Data were also analyzed by use of Fourier-transform regression (FTR), which was developed for onboard, real-time estimation of the derivatives.

Moes, Tim↗

NASA NTRS1981

Cell module and fuel conditioner development

The test results of and post test analysis of Stack 559 are reported. The design features and construction status of Stacks 560, 561, 562 and 563 are described. The measurements of cell materials compressibility are rationalized and summarized and an explanation of their uses is given. Preliminary results of a manifold material/coating survey are given. The results of shift converter catalyst performance tests and reforming catalyst aging tests are reported. State points for full load and part load operation of the fuel conditioning subsystem tabulated. Work on the data base for the fuel conditioner ancillary subsystems is summarized.

Hoover, D. Q., Jr.↗

NASA NTRS1981

Evaluation of distributed gas cooling of pressurized PAFC for utility power generation

Two short stacks were pressure tested at 446 kPa (4.4 atm.) and the pressure gains were more than the theoretically predicted gains. Temperature profiles were observed to be independent of operating pressure. The pressure drop was found to be inversely proportional to operating pressure as expected. Continuous pressurized operation of a stack for 1000 hours verified the compatability of the fuel cell component design. A simple pressurization procedure was also developed. Six separate designs, covering two gas cooling schemes (DIGAS and separated) and two cooling channel geometries (straight through and treed), were analysed on the net voltage output basis. Separated cooling with 5 cells per cooler was recognized to be the best among the designs considered.

Farooque, M.↗

NASA NTRS1984

Advanced Gas Turbine (AGT) powertrain system development for automotive applications

Rotor dynamic instability investigations were conducted. Forward ball bearing hydraulic mount configurations were tested with little effect. Trial assembly of S/N 002 ceramic engine was initiated. Impeller design activities were completed on the straight line element (SLE) blade definition to address near-net-shape powder metal die forging. Performance characteristics of the Baseline Test 2A impeller were closely preserved. The modified blading design has been released for tooling procurement. Developmental testing of the diffusion flame combustor (DFC) for initial use in the S/N 002 2100 F ceramic structures engine was completed. A natural gas slave preheater was designed and fabricated. Preliminary regenerator static seal rig testing showed a significant reduction in leakage and sensitivity to stack height. Ceramic screening tests were completed and two complete sets of ceramic static structures were qualified for engine testing. Efforts on rotor dynamics development to resolve subsynchronous motion were continued.

Source record↗

NASA NTRS1988

System characterization of a magnetically suspended flywheel

The purpose of flywheel energy storage is to provide a means to save energy during times when the satellite is in sunlight, and then return the energy during the time when the satellite is in darkness. Typically, an energy storage device operates cyclically, where for satellites in Low Earth Orbit (LEO) the typical period is 60 minutes of sunlight followed by 30 minutes of darkness. If a lifetime of 17 years is required the energy storage system must be capable of sustaining approximately 100,000 cycles. The recent developments at the University of Maryland and how these progressions apply to a 500 Watt-hour magnetically suspended flywheel stack energy storage system are covered. The work includes hardware testing results from a stack flywheel energy storage system, improvements in the area of non-contacting displacement transducers, and performance enhancements of magnetic bearings. The experimental results show that a stack flywheel energy storage system is a feasible technology.

Kirk, James A.↗

NASA NTRS2005

Operating Deflection Shapes for the Space Shuttle Partial Stack Rollout

In November of 2003 a rollout test was performed to gain a better understanding of the dynamic environment for the Space Shuttle during transportation from the Vehicle Assembly Building to the launch pad. This was part of a study evaluating the methodology for including the rollout dynamic loads in the Space Shuttle fatigue life predictions. The rollout test was conducted with a partial stack consisting of the Crawler Transporter, Mobile Launch Platform, and the Solid Rocket Boosters with an interconnecting crossbeam. Instrumentation included over 100 accelerometers. Data was recorded for steady state speeds, start-ups and stops, and ambient wind excitations with the vehicle at idle. This paper will describe the operating deflection shape analysis performed using the measured acceleration response data. The response data for the steady state speed runs were dominated by harmonics of the forcing frequencies, which were proportional to the vehicle speed. Assuming a broadband excitation for the wind, analyses of the data sets with the vehicle at idle were used to estimate the natural frequencies and corresponding mode shapes. Comparisons of the measured modal properties with numerical predictions are presented.

Buehrle, Ralph D.↗

NASA NTRSDate not supplied

Space Launch System (SLS) Human Factors Engineering Modeling & Analysis

The Human Systems Integration & Engineering (HSI&E) team at NASA’s Marshall Space Flight Center (MSFC) strives to advocate for the humans in the loop of Space Launch System’s (SLS) ground operations. Using assessment methods like human simulation, virtual reality, and physical mockups, both flight hardware and ground support equipment (GSE) are evaluated for human integration. Those ranging from 5th percentile female (approximately 5’2” tall) to 95th percentile male (approximately 6’2” tall) should be able to perform all SLS stacking operations. Operations include element physical mates, element electrical mates, and testing activities. The primary human simulation software used is Process Simulate Human (PSH) made by Siemens. This software supplies highly accurate human manikins that can interact with CAD models. PSH was used to evaluate the Transportation and Integration Platform’s (TIP) side opening that was designed for access to the Payload Adapter (PLA) cables. Technicians will need to access these cables for testing purposes before element stacking at Kennedy Space Center (KSC). After performing an analysis in PSH using the TIP side opening, it was found that neither a 5th percentile female or a 95th percentile male could perform the task as the designers had intended. There is a C-beam that blocks access to the cables (both physically and visually). An alternative analysis was performed using PSH to look at another access point to the PLA cables. Although this method would disrupt already established procedures and produce more work, the designers confirmed it was an option. Instead of technicians accessing the cables through the side opening in the TIP, a human simulation was performed for going through a panel opening in the bottom of the TIP. This method requires removal of a TIP panel and a stepladder of at least 36 inches for a 5th percentile female to access the cables.

human factors↗

NASA NTRS1981

Simultaneous measurement of three atmospheric pollutants

Method enables simultaneous concentration monitoring of atmospheric SO2, NO, and NO2. Fluorescing pollutant gases in sample are excited by visible output of dye laser and its second-harmonic ultraviolet frequencies. Three photomultipliers, each with suitable optical filters, view fluorescence. Method tests ambient air, stack emissions, and highway automotive exhausts.

Sinha, M. P.↗

NASA NTRS1987

Thermal properties and effects for Li/BCX (thionyl chloride) cells

New NASA requirements for the screening of lithium cells for space applications involve thermal soaks at elevated temperatures (149 C). The currently qualified Li/BCX cells and three design modifications have been evaluated showing that a design incorporating a shortened electrode stack met this test condition while continuing to satisfy the performance and safety requirements for cells used on NASA manned space vehicles. Information was also developed to show that measured heat capacities for the BCX D size cells correlated well with the heat generated from cells discharged in an insulated environment. Calculated heat capacities based on the amounts and types of materials in a cell were low compared to these values. This information provides the basis for the design of battery packs in the highly insulating environment of outer space.

Takeuchi, E. S.↗