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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.

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NASA NTRS2017

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishingverifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

Qualification↗
NASA NTRS2024

Test and Analysis of the 8-foot Diameter Cylindrical Sandwich Composite Test Article CTA8.2B: As part of the NASA Engineering and Safety Center Shell Buckling Knockdown Factor Project

The buckling response of thin-walled cylindrical structures have long been shown to be sensitive to various imperfections. That is, imperfections related to load introduction, boundary conditions, material property variation, and geometric deviations can all contribute to experimentally obtained buckling loads being lower than the buckling loads predicted for perfect representations of the same thin-walled cylindrical structure. To account for the influence of geometry-based imperfections of a thin-walled cylindrical structure on buckling response, a design factor (also known as a buckling knockdown factor) is used during the design phase. Guidelines for buckling knockdown factors are readily available in NASA SP-8007, Buckling of Thin Walled Circular Cylinders, which was updated in 2020. Prior to this recent update, NASA SP-8007 had not been updated since 1969, and since that time, computational analysis, experimental testing, and manufacturing methods have significantly improved. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF, NESC Assessment 07-010-E) had the goal of developing buckling design recommendations for select classes of metallic and composite launch-vehicle structures [3]. Specifically, the test and analysis results from the fourth SBKF composite test article SBKF-P3-CYL-CTA8.2B, which is referred to as CTA8.2B, are described in this paper. This test was the fourth in a series of four tests on sandwich composite cylinders that will be used to experimentally validate analysis methods, which in turn can be used to develop new analysis-based shell buckling design guidelines for typical sandwich composite launch vehicle cylindrical structures. Publications describing previous test validation with analysis are available in Refs. CTA8.2B was designed to occupy one corner of the design space with approximately equal bending stiffnesses in the axial and transverse directions and have a larger ratio of radius to effective shell thickness. Each test article had a unique design and was designed to occupy a specific region of the design space. CTA8.2B was an 8-foot diameter honeycomb-core sandwich cylinder that was fabricated and tested at the NASA Marshall Space Flight Center (MSFC). The primary objectives of this test were to interrogate the structural capability of a composite test article, and to verify the test article design and analysis approach for cylinders subjected to axial compression and combined axial and bending loads. First, descriptions of the test article design and test are given in Section 2.0, and modeling and analysis methods used in support of the test article design and testing activities are described briefly in Section 3.0. Then, select test results are presented and compared to predicted results in Section 4.0, and concluding remarks are presented in Section 5.0. Finally, drawings of CTA8.2B and references used to support the test and analysis are provided in the Appendix.

Nonlinear analysis↗
NASA NTRS2026

A Summary of Test and Analysis Results from a Second Lift+Cruise Full-Scale Drop Test

The realization of advanced air mobility markets is enabling new forms of transportation to take shape in the United States and around the world. Though currently in development, as these markets mature, new types of vertical take-off and landing (VTOL) vehicles have been undergoing development for use. There are many factors which must be addressed prior to these types of vehicles becoming viable alternative forms of transportation in these markets. These factors include incorporation into the existing airspaces, the logistics of operating in urban environments, along with numerous factors associated with safety and reliability. To address some of the safety aspects associated with the development of these new types of vehicles, NASA has been conducting research into the performance of an example electric VTOL (eVTOL) aircraft as a part of the Revolutionary Vertical Lift Technology (RVLT) project. Over the course of this research, many aspects including the development of energy absorbing components, the evaluation of seating systems, the development of advanced finite element material model systems and the acquisition of full-scale vehicle impact data were investigated. The report will discuss aspects related to the acquisition of full-scale vehicle data which occurred in the form of a full-scale impact test conducted in the Summer of 2025. This test was on a NASA designed Lift+Cruise composite cabin test article and represented a partial capstone in the entirety of previous eVTOL research conducted for the project. In this test, a variety of experiments were included in order to investigate the effect of a full-scale environment on the experiment results. In parallel, the development of a computational impact model to simulate the full-scale test will be discussed in this report. A model of the Lift+Cruise test article was developed utilizing data collected from previous sub- and full-scale test data and then simulated in the current test environment. The model development, its use in pre-test predictions, and its use in post-test correlation will all be presented. This report will present the test data acquired from the Lift+Cruise test and document several of the results obtained. One intended result is to determine the effect of a complex full-scale crash impact on the identification of occupant injury risk within seat and vehicle designs. A second intended result is to determine whether high-fidelity models can be used with some confidence in the prediction of test events and can allow for additional test cases to be simulated without the need of having to conduct additional tests. The overall goal of the test is to provide the community with data that can be used for design, development or certification efforts, along with providing data on what an example eVTOL crash incident could entail.

energy storage systems↗
DOE OSTI2025

Mechanisms Engineering Test Loop (METL) Operations, Maintenance, and Testing - FY2025

This report documents the operations, maintenance, and improvements that were performed at the Mechanisms Engineering Test Loop (METL) and its supporting infrastructure during FY2024. The METL facility had a very successful seventh year of operations while supporting the testing of multiple test article experiments in the facility. The METL facility continued supporting the Gear Test Assembly (GTA) testing and the Thermal Hydraulic Experimental Test Article (THETA) with the full testing with both the primary and secondary systems. Work to accommodate two additional experiments, a flow sensor test article (F-STAr) gripper test and a fuel handling gripper test article (GrTA) continued as they are expected to undergo testing in METL in FY2025. In addition, a new 18” test article, the Sample Testing Basket (STB) was used a few times to provide screening tests for sodium service materials. A fifth test vessel was installed in the location of Test Vessel 6, and a wet vapor nitrogen sodium processing system was developed and initially tested.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2016

Pilot Field Test: Use of a Compression Garment During a Stand Test After Long-Duration Space Flight

Orthostatic intolerance (OI) is a concern for astronauts returning from long-duration space flight. One countermeasure that has been used to protect against OI after short-duration bed rest and space flight is the use of lower body and abdominal compression garments. However, since the end of the Space Shuttle era we have not been able to test crewmembers during the first 24 hours after landing on Earth. NASA's Pilot Field Test provided us the opportunity to test cardiovascular responses of crewmembers wearing the Russian Kentavr compression garment during a stand test at multiple time points throughout the first 24 hours after landing. HYPOTHESIS We hypothesized that the Kentavr compression garment would prevent an increase in heart rate (HR) >15 bpm during a 3.5-min stand test. METHODS: The Pilot Field Test was conducted up to 3 times during the first 24 hours after crewmembers returned to Earth: (1) either in a tent adjacent to the Soyuz landing site in Kazakhstan (approx.1 hr) or after transportation to the Karaganda airport (approx. 4 hr); (2) during a refueling stop in Scotland (approx.12 hr); and (3) upon return to NASA Johnson Space Center (JSC) (approx.24 hr). We measured HR and arterial pressure (finger photoplethysmography) for 2 min while the crewmember was prone and throughout 3.5 min of quiet standing. Eleven crewmembers consented to participate; however, 2 felt too ill to start the test and 1 stopped 30 sec into the stand portion of the test. Of the remaining 8 crewmembers, 2 did not wear the Russian Kentavr compression garment. Because of inclement weather at the landing site, 5 crewmembers were flown by helicopter to the Karaganda airport before initial testing and received intravenous saline before completing the stand test. One of these crewmembers wore only the portion of the Russian Kentavr compression garment that covered the lower leg and thus lacked thigh and abdominal compression. All crewmembers continued wearing the Russian Kentavr compression garment during the second testing session in Scotland, but none wore it during testing at JSC. RESULTS: The mean Delta HR from the supine to standing position in the 8 crewmembers measured pre-flight or 60 days after return from long-duration space flight was 9.8 bpm. During the first few hours after landing from long-duration space flight, the mean Delta HR of the 6 crewmembers who wore the Russian Kentavr compression garment in Kazakhstan or Karaganda was +14 bpm and the change in mean arterial pressure (Delta MAP) was +0.8 mmHg, while the 2 crewmembers who did not wear the Russian Kentavr compression garment had a Delta HR of +38 bpm and a Delta MAP of +1.1 mmHg. In Scotland, 4 crewmembers wore the Russian Kentavr compression garment and had a Delta HR of +7.4 bpm while the 3 crewmembers who did not wear it had a Delta HR of +25.0 bpm. Seven crewmembers were tested upon return to JSC approx. 24 hr after landing, but none wore the Russian Kentavr compression garment and their Delta HR was 16.0 bpm. CONCLUSIONS: These are the first stand-test data to be collected from long-duration crewmembers during the first 24 hr of re-adaptation to gravity on Earth. The Delta HR measured in crewmembers who completed the stand-test while wearing Kentavr within the first approx.4 hours after returning to Earth was only slightly elevated from pre-flight Delta HR, while the few subjects who did not wear the Russian Kentavr compression garment had a much larger increase in HR in order to maintain arterial pressure throughout 3.5-min of standing. These data demonstrate the effectiveness of a compression garment in preventing large increases in HR during a 3.5 min stand test after long-duration space flight. However, the fact that three crewmembers were too ill to complete the test or was not able to complete 3.5 min of standing despite wearing the Russian Kentavr compression garment indicates that wearing a compression garment does not resolve all problems crewmembers face during the period of re-adaptation immediately after return to Earth's gravity.

Laurie, S. S.↗
NASA NTRS1986

Pretest Report for the Full Span Propulsive Wing/Canard Model Test in the NASA Langley 4 x 7 Meter Low Speed Wind Tunnel Second Series Test

A full span propulsive wing/canard model is to be tested in the NASA Langley Research Center (LaRC) 4 x 7 meter low speed wind tunnel. These tests are a continuation of the tests conducted in Feb. 1984, NASA test No.290, and are being conducted under NASA Contract NAS1-17171. The purpose of these tests is to obtain extensive lateral-directional data with a revised fuselage concept. The wings, canards, and vertical tail of this second test series model are the same as tested in the previous test period. The fuselage and internal flow path have been modified to better reflect an external configuration suitable for a fighter airplane. Internal ducting and structure were changed as required to provide test efficiency and blowing control. The model fuselage tested during the 1984 tests was fabricated with flat sides to provide multiple wing and canard placement variations. The locations of the wing and canard are important variables in configuration development. With the establishment of the desired relative placement of the lifting surfaces, a typically shaped fuselage has been fabricated for these tests. This report provides the information necessary for the second series tests of the propulsive wing/canard model. The discussion in this report is limited to that affected by the model changes and to the second series test program. The pretest report information for test 290 which is valid for the second series test was published in Rockwell report NR 83H-79. This report is presented as Appendix 1 and the modified fuselage stress report is presented as Appendix 2 to this pretest report.

Stewart, V. R.↗
NASA NTRS2015

Buckling Test Results from the 8-Foot-Diameter Orthogrid-Stiffened Cylinder Test Article TA01

Results from the testing of cylinder test article SBKF-P2-CYLTA01 (referred to herein as TA01) are presented. The testing was conducted at the Marshall Space Flight Center (MSFC), November 19‒21, 2008, in support of the Shell Buckling Knockdown Factor (SBKF) Project.i The test was used to verify the performance of a newly constructed buckling test facility at MSFC and to verify the test article design and analysis approach used by the SBKF project researchers. TA01 is an 8-foot-diameter (96-inches), 78.0-inch long, aluminum-lithium (Al-Li), orthogrid-stiffened cylindrical shell similar to those used in current state-of-the-art launch vehicle structures and was designed to exhibit global buckling when subjected to compression loads. Five different load sequences were applied to TA01 during testing and included four sub-critical load sequences, i.e., loading conditions that did not cause buckling or material failure, and one final load sequence to buckling and collapse. The sub-critical load sequences consisted of either uniform axial compression loading or combined axial compression and bending and the final load sequence subjected TA01 to uniform axial compression. Traditional displacement transducers and strain gages were used to monitor the test article response at nearly 300 locations and an advanced digital image correlation system was used to obtain low-speed and high-speed full-field displacement measurements of the outer surface of the test article. Overall, the test facility and test article performed as designed. In particular, the test facility successfully applied all desired load combinations to the test article and was able to test safely into the postbuckling range of loading, and the test article failed by global buckling. In addition, the test results correlated well with initial pretest predictions.

Hilburger, Mark W.↗
NASA NTRS2022

Assessment of the NASA Glenn 8- by 6-Foot Supersonic Wind Tunnel Supersonic Test Section for Sonic Boom and Supersonic Testing

The NASA Glenn Research Center performed a Sonic Boom Exploratory test with Boeing as an industry partner. The test was performed in the transonic test section of the 8-by 6-foot supersonic wind tunnel (8x6 SWT) in 2012. Since that test, research has been performed to validate the suitability of the supersonic test section, located upstream of the 8x6 transonic test section. This little used upstream supersonic test section can be better for certain objectives in supersonic testing and sonic boom validation. Background pressure profiles were collected in a Mach number stability test (in 2014) with a sonic boom pressure measurement rail installed in the ceiling of the smooth supersonic test section. Results from this test demonstrated favorable background pressure profiles for future sonic boom validation tests. A preliminary supersonic test section calibration was performed in 2016, followed by a detailed calibration in 2020; which also demonstrated the stable and uniform flow characteristics in the supersonic test section. The calibration test utilized the transonic array and the cone-cylinder calibration model in the smooth supersonic test section of the 8x6 SWT. Completion of the calibration prepared the facility for sonic boom assessments of the Low Boom Flight Demonstrator.

Sonic Boom↗
NASA NTRS2019

Combined Qualification Vibration Testing and Fixed Base Modal Testing Utilizing a Fixed Based Correction Method

Vibration testing spaceflight hardware is a vital, but time consuming and expensive endeavor. Traditionally modal tests are performed at the component, subassembly, or system level, preferably free-free with mass loaded interfaces or fixed base on a seismic mass to identify the fundamental structural dynamic (modal) characteristics. Vibration tests are then traditionally performed on single-axis slip tables at qualification levels that envelope the maximum predicted flight environment and workmanship in order to verify the spaceflight hardware can survive its flight environment. These two tests currently require two significantly different test setups, facilities, and ultimately reconfiguration of the spaceflight hardware. The vision of this research is to show how traditional fixed-base modal testing can be accomplished using vibration qualification testing facilities, which not only streamlines testing and reduces test costs, but also opens up the possibility of performing modal testing to untraditionally high excitation levels that provide for test-correlated finite element models to be more representative of the spaceflight hardware's response in a flight environment. This paper documents the first steps towards this vision, which is the comparison of modal parameters identified from a traditional fixed-based modal test performed on a modal floor and those obtained by utilizing a fixed based correction method with a large single-axis electrodynamic shaker driving a slip table supplemented with additional small portable shakers driving on the slip table and test article. To show robustness of this approach, the test article chosen is a simple linear weldment, whose mass, size, and modal parameters couple well with the dynamics of the shaker/slip table. This paper will show that all dynamics due to the shaker/slip table were successfully removed resulting in true fixed-base modal parameters, including modal damping, being successfully extracted from a traditional style base-shake vibration test setup.

Base-Shake↗
NASA NTRS1947

High-Speed Wind-Tunnel Tests of a Model of the Lockheed YP-80A Airplane Including Correlation with Flight Tests and Tests of Dive-Recovery Flaps

This report contains the results of tests of a 1/3-scale model of the Lockheed YP-90A "Shooting Star" airplane and a comparison of drag, maximum lift coefficient, and elevator angle required for level flight as measured in the wind tunnel and in flight. Included in the report are the general aerodynamic characteristics of the model and of two types of dive-recovery flaps, one at several positions along the chord on the lower surface of the wing and the other on the lower surface of the fuselage. The results show good agreement between the flight and wind-tunnel measurements at all Mach numbers. The results indicate that the YP-80A is controllable in pitch by the elevators to a Mach number of at least 0.85. The fuselage dive-recovery flaps are effective for producing a climbing moment and increasing the drag at Mach numbers up to at least 0.8. The wing dive-recovery flaps are most effective for producing a climbing moment at 0.75 Mach number. At 0.85 Mach number, their effectiveness is approximately 50 percent of the maximum. The optimum position for the wing dive-recovery flaps to produce a climbing moment is at approximately 35 percent of the chord.

Cleary, Joseph W.↗
NASA NTRS1990

Detailed modal testing of a solid rocket motor using a portable test system

Modern analytical techniques have expended the ability to evaluate solid rocket motors used in launch vehicles. As more detailed models of solid rocket motors were developed, testing methods were required to verify the models. Experimental modal analysis (modal testing) of space structures and launch vehicles has been a requirement for model validation for many years. However, previous testing of solid rocket motors has not typically involved dynamic modal testing of full scale motors for verification of solid propellant or system assembly properties. Innovative approaches to the testing of solid rocket motors were developed and modal testing of a full scale, two segment Titan 34D Solid Rocket Motor (SRM) was performed to validate detailed computer modeling. Special modifications were made to convert an existing facility into a temporary modal test facility which would accommodate the test article. The assembly of conventional data acquisition equipment into a multiple channel count portable system has made modal testing in the field feasible. Special purpose hydraulic exciters were configured to apply the dynamic driving forces required. All instrumentation and data collection equipment were installed at the test site for the duration of the test program and removed upon completion. Conversion of an existing test facility into a temporary modal test facility, and use of a multiple channel count portable test data acquisition system allowed all test objectives to be met and resulted in validation of the computer model in a minimum time.

Glozman, Vladimir↗
NASA NTRS2006

Error response test system and method using test mask variable

An error response test system and method with increased functionality and improved performance is provided. The error response test system provides the ability to inject errors into the application under test to test the error response of the application under test in an automated and efficient manner. The error response system injects errors into the application through a test mask variable. The test mask variable is added to the application under test. During normal operation, the test mask variable is set to allow the application under test to operate normally. During testing, the error response test system can change the test mask variable to introduce an error into the application under test. The error response system can then monitor the application under test to determine whether the application has the correct response to the error.

Gender, Thomas K.↗
NASA NTRS2019

Combined Qualification Vibration Testing and Fixed Base Modal Testing Utilizing a Fixed Based Correction Method

Vibration testing spaceflight hardware is a vital, but time consuming and expensive endeavor. Traditionally modal tests are performed at the component, subassembly, or system level, preferably free-free with mass loaded interfaces or fixed base on a seismic mass to identify the fundamental structural dynamic (modal) characteristics. Vibration tests are then traditionally performed on single-axis slip tables at qualification levels that envelope the maximum predicted flight environment plus 3 dB and workmanship in order to verify the spaceflight hardware can survive its flight environment. These two tests currently require two significantly different test setups, facilities, and ultimately reconfiguration of the spaceflight hardware. The vision of this research is to show how traditional fixed-base modal testing can be accomplished using vibration qualification testing facilities, which not only streamlines testing and reduces test costs, but also opens up the possibility of performing modal testing to untraditionally high excitation levels that provide for test-correlated finite element models to be more representative of the spaceflight hardware's response in a flight environment. This paper documents the first steps towards this vision, which is the comparison of modal parameters identified from a traditional fixed-based modal test performed on a modal floor and those obtained by utilizing a fixed based correction method with a large single-axis electrodynamic shaker driving a slip table supplemented with additional small portable shakers driving on the slip table and test article. To show robustness of this approach, the test article chosen is a simple linear weldment, whose mass, size, and modal parameters couple well with the dynamics of the shaker/slip table. This paper will show that all dynamics due to the shaker/slip table were successfully removed resulting in true fixed-base modal parameters, including modal damping, being successfully extracted from a traditional style base-shake vibration test setup.

Winkel, James P.↗