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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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At least 775 records · Page 43

NASA's Space Launch System Takes Shape

Major hardware and software for NASA's Space Launch System (SLS) began rolling off assembly lines in 2016, setting the stage for critical testing in 2017 and the launch of a major new capability for deep space human exploration. SLS continues to pursue a 2018 first launch of Exploration Mission 1 (EM-1). At NASA's Michoud Assembly Facility near New Orleans, LA, Boeing completed welding of structural test and flight liquid hydrogen tanks, and engine sections. Test stands for core stage structural tests at NASA's Marshall Space Flight Center, Huntsville, AL. neared completion. The B2 test stand at NASA's Stennis Space Center, MS, completed major structural renovation to support core stage green run testing in 2018. Orbital ATK successfully test fired its second qualification solid rocket motor in the Utah desert and began casting the motor segments for EM-1. Aerojet Rocketdyne completed its series of test firings to adapt the heritage RS-25 engine to SLS performance requirements. Production is under way on the first five new engine controllers. NASA also signed a contract with Aerojet Rocketdyne for propulsion of the RL10 engines for the Exploration Upper Stage. United Launch Alliance delivered the structural test article for the Interim Cryogenic Propulsion Stage to MSFC for tests and construction was under way on the flight stage. Flight software testing at MSFC, including power quality and command and data handling, was completed. Substantial progress is planned for 2017. Liquid oxygen tank production will be completed at Michoud. Structural testing at Marshall will get under way. RS-25 hotfire testing will verify the new engine controllers. Core stage horizontal integration will begin. The core stage pathfinder mockup will arrive at the B2 test stand for fit checks and tests. EUS will complete preliminary design review. This paper will discuss the technical and programmatic successes and challenges of 2016 and look ahead to plans for 2017.

Askins, Bruce↗

Overview of Integrated Random Vibration Testing of the NASA Orion Crew Survival Suit

The launch ascent and abort random vibration environments from NASA’s Orion spacecraft drove the need to test the NASA Orion Crew Survival Suit as an integrated system with exposure to the design levels. In order to properly characterize component responses, a series of integrated tests were designed to incorporate the interaction between a crew member, suit, seat, and the attenuation system. The first Development Test (2017) included human subjects, and was performed with early development seat and suit components, and low level inputs. It provided a baseline for frequency response and behavior of the integrated system. The next two tests, Development Test (2019) and Qualification Test (2020), used manikin surrogates to represent the crew member and increasing levels of component hardware fidelity in order to test to higher input levels. Testing was performed at NASA Johnson Space Center (JSC) and Kennedy Space Center (KSC) Vibration Labs and provided the input levels required to represent the ascent and abort vehicle profiles as well as recorded component response behavior from accelerometer instrumentation and high speed cameras. Inspection of the suit and related components showed that for all seat orientations, and input environments, no damage occurred. Additional pre and post-test checks confirmed the functionality of all suited hardware. Response data of the suited components generally showed heavy attenuation across most of the tested frequency range. Transmissibility plots showed some amplification of components at lower frequency ranges. Overall this series of integrated tests showed that 1) the use of surrogate manikins in the tests were adequate for representing crew in a vibration environment, 2) full vibration levels for ascent and abort were heavily attenuated in the suit components and were non-damaging, and 3) the suit and related components are qualified for the Orion random vibration environments.

Jeffrey D Suhey↗

Overview of Integrated Random Vibration Testing of the NASA Orion Crew Survival Suit

The launch ascent and abort random vibration environments from NASA’s Orion spacecraft drove the need to test the NASA Orion Crew Survival Suit as an integrated system with exposure to the design levels. In order to properly characterize component responses, a series of integrated tests were designed to incorporate the interaction between a crew member, suit, seat, and the attenuation system. The first Development Test (2017) included human subjects, and was performed with early development seat and suit components, and low level inputs. It provided a baseline for frequency response and behavior of the integrated system. The next two tests, Development Test (2019) and Qualification Test (2020), used manikin surrogates to represent the crew member and increasing levels of component hardware fidelity in order to test to higher input levels. Testing was performed at NASA Johnson Space Center (JSC) and Kennedy Space Center (KSC) Vibration Labs and provided the input levels required to represent the ascent and abort vehicle profiles as well as recorded component response behavior from accelerometer instrumentation and high speed cameras. Inspection of the suit and related components showed that for all seat orientations, and input environments, no damage occurred. Additional pre and post-test checks confirmed the functionality of all suited hardware. Response data of the suited components generally showed heavy attenuation across most of the tested frequency range. Transmissibility plots showed some amplification of components at lower frequency ranges. Overall this series of integrated tests showed that 1) the use of surrogate manikins in the tests were adequate for representing crew in a vibration environment, 2) full vibration levels for ascent and abort were heavily attenuated in the suit components and were non-damaging, and 3) the suit and related components are qualified for the Orion random vibration environments.

Jeffrey Suhey↗

Flying Unmanned Aircraft: A Pilot's Perspective

The National Aeronautics and Space Administration (NASA) is pioneering various Unmanned Aircraft System (UAS) technologies and procedures which may enable routine access to the National Airspace System (NAS), with an aim for Next Gen NAS. These tools will aid in the development of technologies and integrated capabilities that will enable high value missions for science, security, and defense, and open the door to low-cost, extreme-duration, stratospheric flight. A century of aviation evolution has resulted in accepted standards and best practices in the design of human-machine interfaces, the displays and controls of which serve to optimize safe and efficient flight operations and situational awareness. The current proliferation of non-standard, aircraft-specific flight crew interfaces in UAS, coupled with the inherent limitations of operating UAS without in-situ sensory input and feedback (aural, visual, and vestibular cues), has increased the risk of mishaps associated with the design of the "cockpit." The examples of current non- or sub- standard design features range from "annoying" and "inefficient", to those that are difficult to manipulate or interpret in a timely manner, as well as to those that are "burdensome" and "unsafe." A concerted effort is required to establish best practices and standards for the human-machine interfaces, for the pilot as well as the air traffic controller. In addition, roles, responsibilities, knowledge, and skill sets are subject to redefining the terms, "pilot" and "air traffic controller", with respect to operating UAS, especially in the Next-Gen NAS. The knowledge, skill sets, training, and qualification standards for UAS operations must be established, and reflect the aircraft-specific human-machine interfaces and control methods. NASA s recent experiences flying its MQ-9 Ikhana in the NAS for extended duration, has enabled both NASA and the FAA to realize the full potential for UAS, as well as understand the implications of current limitations. Ikhana is a Predator-B/Reaper UAS, built by General Atomics, Aeronautical Systems, Inc., and modified for research. Since 2007, the aircraft has been flown seasonally with a wing-mounted pod containing an infrared scanner, utilized to provide real-time wildfire geo-location data to various fire-fighting agencies in the western U.S. The multi-agency effort included an extensive process to obtain flight clearance from the FAA to operate under special provisions, given that UAS in general do not fully comply with current airspace regulations (e.g. sense-and-avoid requirements).

Pestana, Mark E.↗

Testing of a Liquid Oxygen/Liquid Methane Reaction Control Thruster in a New Altitude Rocket Engine Test Facility

A relocated rocket engine test facility, the Altitude Combustion Stand (ACS), was activated in 2009 at the NASA Glenn Research Center. This facility has the capability to test with a variety of propellants and up to a thrust level of 2000 lbf (8.9 kN) with precise measurement of propellant conditions, propellant flow rates, thrust and altitude conditions. These measurements enable accurate determination of a thruster and/or nozzle s altitude performance for both technology development and flight qualification purposes. In addition the facility was designed to enable efficient test operations to control costs for technology and advanced development projects. A liquid oxygen-liquid methane technology development test program was conducted in the ACS from the fall of 2009 to the fall of 2010. Three test phases were conducted investigating different operational modes and in addition, the project required the complexity of controlling propellant inlet temperatures over an extremely wide range. Despite the challenges of a unique propellant (liquid methane) and wide operating conditions, the facility performed well and delivered up to 24 hot fire tests in a single test day. The resulting data validated the feasibility of utilizing this propellant combination for future deep space applications.

Meyer, Michael L.↗

Understanding the role of segmentation on process-structure–property predictions made via machine learning

Here, the present study investigated the effect of porosity surface determination methods on performance of machine learning models used to predict the tensile properties of AlSi10Mg processed by laser powder bed fusion from micro-computed tomography data. Machine learning models applied in this work include support vector machines, neural networks, decision trees, and Bayesian classifiers. The effects of isosurface thresholding and local gradient approaches for porosity segmentation, as well as image filtering schemes, on model precision were evaluated for samples produced under differing levels of global energy density.

36 MATERIALS SCIENCE↗

Comparison of Fission Product Release Predictions using PARFUME with Results from the AGR-2 Irradiation Experiment

The PARFUME (PARticle FUel ModEl) code was used to predict fission product release from tristructural isotropic (TRISO) coated fuel particles and compacts during the second irradiation experiment (AGR-2) of the Advanced Gas Reactor Fuel Development and Qualification Program. The PARFUME model for the Advanced Gas reactor (AGR)GR-2 experiment used the fuel compact volume average temperature for each of the 560 days of irradiation to calculate the release of fission products of silver, cesium, and strontium from a representative particle for a select number of AGR -2 compacts. In addition, safety tests were performed on 15 compacts ranging from 1500 to 1800°C to determine fission product release at temperatures that bound reactor accident conditions. PARFUME was used to calculate the fission product release of silver, cesium, strontium, and krypton during these safety tests. Post-irradiation examination (PIE) measurements provided the data on release of fission products from the fuel compacts and fuel particles, and retention of fission products in the compacts outside the silicon carbide (SiC) layer. The predicted fraction release from PARFUME was then compared to PIE measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Verification and Validation of the General Mission Analysis Tool (GMAT)

This paper describes the processes and results of Verification and Validation (V&V) efforts for the General Mission Analysis Tool (GMAT). We describe the test program and environments, the tools used for independent test data, and comparison results. The V&V effort produced approximately 13,000 test scripts that are run as part of the nightly buildtest process. In addition, we created approximately 3000 automated GUI tests that are run every two weeks. Presenting all test results are beyond the scope of a single paper. Here we present high-level test results in most areas, and detailed test results for key areas. The final product of the V&V effort presented in this paper was GMAT version R2013a, the first Gold release of the software with completely updated documentation and greatly improved quality. Release R2013a was the staging release for flight qualification performed at Goddard Space Flight Center (GSFC) ultimately resulting in GMAT version R2013b.

GMAT↗

Qualification Status of Non-Asbestos Internal Insulation in the Reusable Solid Rocket Motor Program

This paper provides a status of the qualification efforts associated with NASA's RSRMV non-asbestos internal insulation program. For many years, NASA has been actively engaged in removal of asbestos from the shuttle RSRM motors due to occupation health concerns where technicians are working with an EPA banned material. Careful laboratory and subscale testing has lead to the downselect of a organic fiber known as Polybenzimidazol to replace the asbestos fiber filler in the existing synthetic rubber copolymer Nitrile Butadiene - now named PBI/NBR. Manufacturing, processing, and layup of the new material has been a challenge due to the differences in the baseline shuttle RSRM internal insulator properties and PBI/NBR material properties. For this study, data gathering and reduction procedures for thermal and chemical property characterization for the new candidate material are discussed. Difficulties with test procedures, implementation of properties into the Charring Material Ablator (CMA) codes, and results correlation with static motor fire data are provided. After two successful five segment motor firings using the PBI/NBR insulator, performance results for the new material look good and the material should eventually be qualified for man rated use in large solid rocket motor applications.

Clayton, Louie↗

Screening and qualification methodology for SiC end plug processing methods

Deployment of SiC-ceramic-based fuel cladding for light water reactors requires a hermetic end plug–to–cladding joint that can withstand neutron irradiation during normal operation and maintain integrity during design-basis accidents. Reactor experiments have shown that some SiC composite tubes with SiC end plugs can retain hermeticity after irradiation. However, achieving consistent joint performance under irradiation remains a key challenge. Resolving this issue is essential to enable integral irradiation testing and to demonstrate fuel integrity under commercial-reactor irradiation conditions. This report aims to: (1) provide guidance for designing radiation-tolerant end plug joints for SiC cladding; (2) demonstrate experimental methods to detect processing defects that are unstable under neutron irradiation at light-water-reactor-relevant temperatures and doses; and (3) outline a step-by-step approach for designing and conducting reactor experiments to screen joining methods. The resulting data will be used to improve joint processing and to define critical defect types and sizes that must be detected and eliminated through non-destructive evaluation for quality assurance. Based on prior irradiation experiments at the High Flux Isotope Reactor, differential swelling among the cladding, bonding layer, and end plug was identified as an underlying mechanism for irradiation-induced joint degradation. Accordingly, this effect must be considered in the design of radiation-tolerant joining techniques. In this work, miniature SiC end plug joint specimens irradiated during the previous project were analyzed using X-ray computed tomography to characterize the joint microstructure. Digital volume correlation of the tomography data quantified radiation-induced microstructural changes and enabled evaluation of defect-related risks. Finally, ongoing neutron irradiation efforts using larger specimen volumes are presented. These efforts aim to statistically assess joint performance and to build a microstructure–performance (e.g., leak-tightness) dataset to inform processing improvements and quality control.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Propulsion system filter sizing considerations for the Galileo spacecraft

Filtration capacity of the Galileo propulsion system has been investigated. Ground testing of flight spare components has been conducted to determine the representative number and size distribution of particulate matter collected in flow tests. For these tests and for filter qualification tests, a number of effects were examined. The influence of gravitational particle settling on ground test results vs the flight environment was considered. Centrifugal effects inherent in the test apparatus and/or the propulsion system could have an influence. Variability among particle sizing techniques was explored. The influence of size distribution, particle shape, and density in the choice of a particulate test material was studied. Characteristics for AC Coarse Dust (an industry standard filter test media), microscopic polymer beads, and aluminum oxide particulate test matter are listed. Filtration tests were conducted using AC Coarse Dust and mixtures containing components of AC Coarse Dust. These results are expected to be useful data for filter sizing of future spacecraft.

Jan, Darrell L.↗

MSAT PIM and multipactor test program

The MSAT satellite system will provide telephone, fax and low data rate communication services to mobile users throughout North America. The space segment of the MSAT system must supply high radiated power densities on the ground to allow communication with small mobile terminals. Therefore, the high power handling requirement (multipactor, PIM and thermal dissipation) are very important performance parameters for mobile satellite communication systems. Large separate transmit and receive L-Band deployable reflectors are used on MSAT to reduce the risk of PIM (passive intermodulation). In addition, PIM and multipactor avoidance were major design drivers for the L-Band high power transmit output network and antenna. This paper provides an overview of the designs selected and the extensive qualification and verification program undertaken on MSAT to meet the challenging PIM and multipactor requirements. The test campaigns at component, sub-system and system levels and the associated test results are presented. The manufacturing and assembly approaches taken to allow the PIM and Multipactor to be met are also briefly described.

Patenaude, Y.↗

Analytical Redundancy Using Kalman Filters for Rocket Engine Sensor Validation

The use of sensor redundancy is crucial in aerospace systems to maintain safe, reliable operation. While hardware redundancy is more common in application, analytical redundancy can provide a viable alternative in systems where the installation of multiple redundant sensors is not viable. To this end, the use of Kalman filters to analytically validate sensor measurements within rocket engines was explored. First, a dynamic model of the RS 25 engine, a derivative of the Space Shuttle Main Engine (SSME), was reduced to a subset of relations, focused around the main combustion chamber pressure. These relations were used within the Kalman filter algorithm to generate an estimate of sensor measurements to be compared with true measurements for data validation purposes. By using a bank of Kalman filters, the residuals between the estimated and true measurements were used to detect and isolate sensor faults. Through fault simulations, the sensor validation performance of this Kalman filter bank design was compared to a hardware redundancy check. Sensor bias and drift faults of various magnitudes were injected into nominal RS 25 engine test data. Results for both approaches show comparable fault detection with most bias faults found nearly instantaneously by both algorithms. Drift fault detection results show certain cases where one algorithm is faster than the other. The key advantage of the Kalman filter algorithm is shown in fault isolation performance where it can isolate faults between two redundant sensors while the hardware redundancy comparisons cannot.

sensors↗

Stirling Research Laboratory Providing Independent Performance Verification of Convertors for a Stirling Radioisotope Generator

The Department of Energy (DOE), Germantown, Maryland, Stirling Technology Company (STC), Kennewick, Washington, and NASA Glenn Research Center are developing a free-piston Stirling convertor for a high-efficiency Stirling Radioisotope Generator for NASA Space Science missions. This generator is being developed for multimission use, including providing electric power for unmanned Mars rovers and for deep space missions. STC is developing the 55-W Technology Demonstration Convertor (TDC) under contract to DOE. Glenn is conducting an in-house technology project to assist in developing the convertor for readiness for space qualification and mission implementation. As part of this effort, a Stirling Research Laboratory was established to test the TDC's and related technologies. A key task is providing an independent verification and validation of the TDC performance. Four TDC's are now being tested at Glenn. Acceptance testing has been completed for all convertors, and in general, performance agreed well with that achieved by STC prior to the delivery of the convertors. Performance mapping has also been completed on two of the convertors over a range of hot-end temperatures (450 to 650 C), cold-end temperatures (80 to 120 C), and piston amplitudes (5.2 to 6.2 mm). These test data are available online at http://www.grc.nasa.gov/WWW/tmsb/. The TDC's can be tested in either a horizontal orientation with dual-opposed convertors or in a vertical orientation with a single convertor. Synchronized dual-opposed pairs are used for dynamically balanced operation that results in very low levels of vibration. The Stirling Research Laboratory also supports launch environment testing of the TDC's in Glenn's Structural Dynamics Laboratory and electromagnetic interference and electromagnetic compatibility characterization and reduction efforts. In addition, the TDC's will be used for long-term endurance testing, and preparations are underway for unattended operation.

Thieme, Lanny G.↗

2024 Nasa Lunabotics University Competition: Site Preparation With Bulk Regolith

Introduction: Lunabotics provides accredited institutions of higher learning students (vocational-technical, college, university) an opportunity to apply the NASA systems engineering process to design and build a prototype robot. This robot would be capable of performing the proposed operations on the Lunar surface in support of future Artemis mission goals. Lunabotics features a systems engineering design challenge to engage students in the next phase of hu-man space exploration supporting the Artemis missions. This two-semester event encourages students to design and build an autonomous or telerobotic robot designed to traverse the simulated Lunar surface and complete the assigned construction tasks. The number of teams accepted into this challenge is not predetermined but is based on the scores and overall quality of the Project Management Plans received and other factors. The culmination of the Lunabotics virtual challenge will be the design, build and operation of a functional prototype Lunar robot. Teams are required to submit the following: (1) Project Management Plan, (2) Systems Engineering Paper, a (3) STEM Engage-ment Report, and a (4) Proof of Life Video. This is an optional item, but to qualify for the grand prize a team must also submit a: (5) Presentation and Demonstration. Background: The NASA Lunabotics University Competition was first held in 2010 as a follow on to the NASA Regolith Excavation Challenge [1]. The high level of interest and participation from over 50 universities each year has led to a sustained annual competi-ion cadence: it has been held every May for the past 14 years [2,3]. Over 6,000 students have participated and been inspired to pursue Science, Technology, En-gineering and Mathematics careers (STEM). 2024 Competition: The necessary lunar surface tasks are evolving to meet the NASA Artemis Mission requirements. In the past Lunabotics challenges we gathered data to support Lunar mining for consuma-bles in the Lunar regolith. Now, in 2024, the task is to gather data on Lunar site preparation and construction by designing and building a robot that will traverse the chaotic Lunar terrain and construct a regolith-based berm. The goal is to build a berm structure which would be useful to the Artemis Mission for blast and ejecta protection during lunar landings and launches, shading cryogenic propellant tank farms, providing radiation protection around a nuclear power plant and other mission critical uses. Lunabotics will consist of three separate events this year. The first event is NASA’s Lunabotics Project Development Challenge, where teams submit various deliverables to be scored by judges. The second event will be the University of Central Florida (UCF) Lunabotics Qualification challenge, in the Exolith laboratory, where teams will put their de-signs to the test. The top ten scoring teams from the Qualification challenge are then invited to the third and final event, NASA’s Lunabotics On-Site Challenge at Kennedy Space Center in Florida. This presentation will summarize the results and lessons learned from the NASA Lunabotics University Competition held in May 2024.

Lunabotics↗

Results of FY 2023 Alloy 617 and Alloy 709 High-Temperature Crack-Growth Testing

This report summarizes the work performed at Idaho National Laboratory under the “Creep, fatigue and creep-fatigue crack growth tests” task of the “Long-Term VHTR Material Qualification – INL” work package. Work was performed this year to validate the crack growth monitoring setup used with the test frames against both continuous crack length monitoring using an optical camera, as well as post-mortem analysis of marker bands on the fracture surface. Delays prevented the use of a gauge to measure load-line displacement for early tests, and so the creep-fatigue crack growth setup was evaluated using the actuator displacement for a load-line displacement setup. While not ideal, this allowed examination of the shortcomings with the current software setup that was originally designed for performing stress corrosion crack growth rate studies. The method for data collection was modified to link the crack growth monitoring software with Instron’s Wave Matrix software. Once the load-line displacement gauge arrived, the crack growth equipment was successfully modified to permit continuous monitoring of both load-line displacement and crack length. This is critical for creep-fatigue and creep crack growth rate studies for ductile material, as it permits the C* and Ct analyses. Test results are shown for Alloy 617 fatigue and creep-fatigue (without the gauge for load-line displacement measurements), as well as creep-fatigue of Alloy 709, which was performed with the completed test setup, allowing for crack length and load-line displacement monitoring.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Qualification of a Null Lens Using Image-Based Phase Retrieval

In measuring the figure error of an aspheric optic using a null lens, the wavefront contribution from the null lens must be independently and accurately characterized in order to isolate the optical performance of the aspheric optic alone. Various techniques can be used to characterize such a null lens, including interferometry, profilometry and image-based methods. Only image-based methods, such as phase retrieval, can measure the null-lens wavefront in situ - in single-pass, and at the same conjugates and in the same alignment state in which the null lens will ultimately be used - with no additional optical components. Due to the intended purpose of a Dull lens (e.g., to null a large aspheric wavefront with a near-equal-but-opposite spherical wavefront), characterizing a null-lens wavefront presents several challenges to image-based phase retrieval: Large wavefront slopes and high-dynamic-range data decrease the capture range of phase-retrieval algorithms, increase the requirements on the fidelity of the forward model of the optical system, and make it difficult to extract diagnostic information (e.g., the system F/#) from the image data. In this paper, we present a study of these effects on phase-retrieval algorithms in the context of a null lens used in component development for the Climate Absolute Radiance and Refractivity Observatory (CLARREO) mission. Approaches for mitigation are also discussed.

Bolcar, Matthew R.↗

Towards in-situ certification of additively manufactured parts: the vital roles of physics-based and data-driven models

Certifying additively manufactured (AM) parts in-situ at the completion of a build is an enticing prospect, as it can help reduce the high costs associated with post-build testing and evaluation. However, achieving this goal presents significant challenges that may keep it aspirational for the foreseeable future. Nonetheless, incremental progress can pave the way forward. A critical aspect of in-situ certification involves continuous quality checking due to the random nature of the AM process and the difficulties in detecting defects or anomalies once layers are built over. While real-time in-situ monitoring strategies assisted by machine learning (ML) play a pivotal role in auditing part quality, they must ideally be supported by real-time (or near real-time) adaptive process control enabled by ML-assisted decision-making. By analyzing in-situ monitoring data in real-time (or near real- time) to dynamically adjust manufacturing parameters, such intervention can ensure AM parts are built to meet stringent certification standards. This can be achieved virtually by using high-fidelity performance models for the physical testing and evaluation tasks. In this short editorial, we discuss the key contributions made by data-driven and physics-based models in providing intelligence to the monitoring and process control tasks underpinning in-situ certification and in the simulation of the build’s performance under test and service conditions. While our focus lies in metal AM, the concepts discussed here are also relevant to other AM processes.

: In-situ monitoring↗