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NASA NTRSDate not supplied

Aluminum to Stainless-Steel Joints for Cryogenic Applications

Aluminum to stainless-steel joints are necessary for cryogenic applications such as cryogenic fluid management and combustion devices. Supplemental development in this area was required for a test program at NASA Marshall Space Flight Center (MSFC) of an Al6061-RAM2 additively manufacturing liquid rocket nozzle. The test program identified a risk for installing stainless-steel fluid fittings to aluminum manifolds. To address this, a literature search was completed for various joint designs, and three designs were down selected to be cryogenic pressure cycle tested at MSFC. The test pieces were subsequently burst tested with ambient temperature water. This paper provides an overview of the literature review, down selected designs, test setup, test results, and fractography. The test results informed design decisions for the Al6061-RAM2 nozzle, and the recommended design proved to be a robust option with no notable issues identified during hot-fire testing.

Tessa M. Fedotowsky↗

NASA NTRS2018

The James Webb Space Telescope: Observatory Status and Preparations for Launch

The James Webb Space Telescope (JWST) is a large (6.5 meter) segmented aperture telescope equipped with near- and mid-infrared instruments (0.6-28 microns), all of which are passively cooled to approximately 40 degrees Kelvin by a 5-layer sunshield while the mid-infrared instrument is actively cooled to 7 degrees Kelvin. The JWST telescope recently completed its cryogenic test program and the sunshield has been fully integrated and deployed. JWST is currently in the final stages of the test program at the Observatory level. The current estimated JWST performance metrics will be presented, such as the image quality, pointing stability, sensitivity, and stray light backgrounds. The JWST development status and future plans will be described for the final testing, launch, and commissioning.

McElwain, Michael↗

NASA NTRS1992

Space Station Freedom thermal control and life support system design

The Space Station Freedom thermal control system (TCS) and environmental control and life support system (ECLSS) are reviewed. Differences in the TCS and ECLSS are discussed between the early man-tended configuration (MTC) compared to the eventual evolutions to the permanently manned configuration (PMC). Concurrent analytical and developmental testing programs are included in the systems discussions as well as a description of an early 1993 flight test program on elements of the PMC water recovery system. Recent TCS design changes to the air cooling of rack mounted equipment are discussed. An overview of all TCS and ECLSS subsystems is included.

Wegrich, R. D.↗

NASA NTRS1998

Thruster Injector Faceplate Testing in Support of the Aerojet Rocket-Based Combined Cycle (RBCC) Concept

To satisfy RBCC rocket thruster requirements of high performance and a minimum amount of free hydrogen at plume boundary, a new impinging injector element using gaseous hydrogen and gaseous oxygen as the propellants has been designed. Analysis has shown that this injector design has potential to provide a high specific impulse (Isp) while minimizing the amount of free hydrogen that is available to be burned with incoming secondary flow. Past studies and test programs have shown that gas/gas-impinging elements typically result in high injector face temperatures due to combustion occurring close to the face. Since this design is new, there is no hot fire experience with this element. Objectives of this test program were to gain experience and hot fire test data on this new rocket thruster element design and injector faceplate pattern. Twenty-two hot fire tests were run with maximum mixture ratio (MR) and chamber pressure (Pc) obtained at 7.25 and 1,822 psia, respectively. Post-test scanning microscope (SEM) images show only slight faceplate erosion during testing. This injector element design performed well and can be operated at design conditions: (1) Pc of 2,000 psia and MR of 7.0 and (2) Pc of 1,000 psia and MR of 5.0.

Fazah, M. M.↗

NASA NTRS1972

Space shuttle horizontal flight test plan

A horizontal takeoff flight test concept for testing space shuttle vehicles is presented. The guidelines used in planning and support requirements for the flight tests are developed. Details of the test program are provided. The instrumentation requirements are defined. The limitations imposed by the short flight endurance and restricted maneuvering capability of the shuttle booster/orbiter in the horizontal mode are described. The test program covers the following investigations. (1) stall and lift boundary tests, (2)takeoff and landing tests, (3) level flight speed power tests, (4) longitudinal and laterial directional dynamic stability, and (5) static directional stability.

Mosley, R. L.↗

NASA NTRS1982

An evaluation of vertical drag and ground effect using the RSRA rotor balance system

A flight test program utilizing the Rotor Systems Research Aircraft (RSRA) main rotor balance system was conducted to obtain data for the helicopter configuration. The test program is discussed along with the employed data reduction methods, and the results. NASA 740, the RSRA used for the vertical drag test, was in the standard helicopter configuration. The 31-foot radius blades have a linear twist of eight degrees and NACA 0012 airfoil sections. Aspects of instrumentation are considered, taking into account the data recording system, the static calibration facility, and aspects of data calibration and processing. Attention is given to the test procedure, data analysis methods, balance measurements, the ground effect, and vertical drag. It is found that the RSRA rotor balance system is capable of providing high quality performance data. The vertical drag of the RSRA is 4%, compared to 2.9% predicted.

Flemming, R. J.↗

NASA NTRS2003

Improved Testing Capability and Adaptability Through the Use of Wireless Sensors

From the first Saturn V rocket booster (S-II-T) testing in 1966 and the routine Space Shuttle Main Engine (SSME) testing beginning in 1975, to more recent test programs such as the X-33 Aerospike Engine, the Integrated Powerhead Development (IPD) program, and the Hybrid Sounding Rocket (HYSR), Stennis Space Center (SSC) continues to be a premier location for conducting large-scale testing. Central to each test program is the capability for sensor systems to deliver reliable measurements and high quality data, while also providing a means to monitor the test stand area to the highest degree of safety and sustainability. Sensor wiring is routed along piping and through cable trenches, making its way from the engine test area, through the test stand area and to the signal conditioning building before final transfer to the test control center. When sensor requirements lie outside the reach of the routine sensor cable routing, the use of wireless sensor networks becomes particularly attractive due to their versatility and ease of installation. As part of an on-going effort to enhance the testing capabilities of Stennis Space Center, the Test Technology and Development group has found numerous applications for its sensor-adaptable wireless sensor suite. While not intended for critical engine measurements or control loops, in-house hardware and software development of the sensor suite can provide improved testing capability for a range of applications including the safety monitoring of propellant storage barrels and as an experimental test-bed for embedded health monitoring paradigms.

Solano, Wanda M.↗

NASA NTRS1965

<space cell test progra., life cycle tests< monthly progress report, period ending 31 jul. 1965

NASA space cell test program on life cycle tests

LIFE↗

NASA NTRS1997

Flight Testing the X-36: The Test Pilots Perspective

The X-36 is a 28% scale, remotely piloted research aircraft, designed to demonstrate tailless fighter agility. Powered by a modified Williams International F-112 jet engine, the X-36 uses thrust vectoring and a fly-by-wire control system. Although too small for an onboard pilot, a full-sized remote cockpit was designed to virtually place the test pilot into the aircraft using a variety of innovative techniques. To date, 22 flights have been flown, successfully completing the second phase of testing. Handling qualities have been matching predictions; the test operation is flown similarly to that for full sized manned aircraft. All takeoffs, test maneuvers and landings are flown by the test pilot, affording a greater degree of flexibility and the ability to handle the inevitable unknowns which may occur during highly experimental test programs. The cockpit environment, cues, and display techniques used in this effort have proven to enhance the 'virtual' test pilot's awareness and have helped ensure a successful RPV test program.

Walker, Laurence A.↗

NASA NTRS2000

On Fast Post-Processing of Global Positioning System Simulator Truth Data and Receiver Measurements and Solutions Data

Post-processing of data, related to a GPS receiver test in a GPS simulator and test facility, is an important step towards qualifying a receiver for space flight. Although the GPS simulator provides all the parameters needed to analyze a simulation, as well as excellent analysis tools on the simulator workstation, post-processing is not a GPS simulator or receiver function alone, and it must be planned as a separate pre-flight test program requirement. A GPS simulator is a critical resource, and it is desirable to move off the pertinent test data from the simulator as soon as a test is completed. The receiver and simulator databases are used to extract the test data files for postprocessing. These files are then usually moved from the simulator and receiver systems to a personal computer (PC) platform, where post-processing is done typically using PC-based commercial software languages and tools. Because of commercial software systems generality their functions are notoriously slow and more than often are the bottleneck even for short duration simulator-based tests. There is a need to do post-processing faster and within an hour after test completion, including all required operations on the simulator and receiver to prepare and move off the post-processing files. This is especially significant in order to use the previous test feedback for the next simulation setup or to run near back-to-back simulation scenarios. Solving the post-processing timing problem is critical for a pre-flight test program success. Towards this goal an approach was developed that allows to speed-up post-processing by an order of a magnitude. It is based on improving the post-processing bottleneck function algorithm using a priory information that is specific to a GPS simulation application and using only the necessary volume of truth data. The presented postprocessing scheme was used in support of a few successful space flight missions carrying GPS receivers.

Kizhner, Semion↗

NASA NTRS2003

Implementation of Wireless and Intelligent Sensor Technologies in the Propulsion Test Environment

Solano, Wanda M.↗

NASA NTRS1993

Flight-determined engine exhaust characteristics of an F404 engine in an F-18 airplane

Personnel at the NASA Langley Research Center (NASA-Langley) and the NASA Dryden Flight Research Facility (NASA-Dryden) recently completed a joint acoustic flight test program. Several types of aircraft with high nozzle pressure ratio engines were flown to satisfy a twofold objective. First, assessments were made of subsonic climb-to-cruise noise from flights conducted at varying altitudes in a Mach 0.30 to 0.90 range. Second, using data from flights conducted at constant altitude in a Mach 0.30 to 0.95 range, engineers obtained a high quality noise database. This database was desired to validate the Aircraft Noise Prediction Program and other system noise prediction codes. NASA-Dryden personnel analyzed the engine data from several aircraft that were flown in the test program to determine the exhaust characteristics. The analysis of the exhaust characteristics from the F-18 aircraft are reported. An overview of the flight test planning, instrumentation, test procedures, data analysis, engine modeling codes, and results are presented.

Ennix, Kimberly A.↗

NASA NTRS1973

An investigation of a sterile access technique for the repair and adjustment of sterile spacecraft

A description is presented of a unique system for the sterilization and sterile repair of spacecraft and the results of a test program designed to assess the biological integrity and engineering reliability of the system. This trailer-mounted system, designated the model assembly sterilizer for testing (MAST), is capable of the dry-heat sterilization of spacecraft and/or components less than 2.3 meters in diameter at temperatures up to 433 K and the steam sterilization of components less than 0.724 meter in diameter. Sterile access to spacecraft is provided by two tunnel suits, called the bioisolator suit systems (BISS), which are contiguous with the walls of the sterilization chambers. The test program was designed primarily to verify the biological and engineering reliability of the MAST system by processing simulated space hardware. Each test cycle simulated the initial sterilization of a spacecraft, sterile repair of a failed component, removal of the spacecraft from the MAST for mating with the bus, and a sterile recycle repair.

Farmer, F. H.↗

NASA NTRS2008

A Capable and Temporary Test Facility on a Shoestring Budget: The MSL Touchdown Test Facility

The Mars Science Laboratory mission (MSL) has undertaken a developmental Touchdown Test Program that utilizes a full-scale rover vehicle and an overhead winch system to replicate the skycrane landing event. Landing surfaces consisting of flat and sloped granular media, planar, rigid surfaces, and various combinations of rocks and slopes were studied. Information gathered from these tests was vital for validating the rover analytical model, validating certain design or system behavior assumptions, and for exploring events and phenomenon that are either very difficult or too costly to model in a credible way. This paper describes this test program, with a focus on the creation of test facility, daily test operations, and some of the challenges faced and lessons learned along the way.

rover↗

NASA NTRS1978

Space Shuttle Orbiter Approach and Landing Test: Final Evaluation Report

The Approach and Landing Test Program consisted of a series of steps leading to the demonstration of the capability of the Space Shuttle orbiter to safely approach and land under conditions similar to those planned for the final phases of an orbital flight. The tests were conducted with the orbiter mounted on top of a specially modified carrier aircraft. The first step provided airworthiness and performance verification of the carrier aircraft after modification. The second step consisted of three taxi tests and five flight tests with an inert unmanned orbiter. The third step consisted of three mated tests with an active manned orbiter. The fourth step consisted of five flights in which the orbiter was separated from the carrier aircraft. For the final two flights, the orbiter tail cone was replaced by dummy engines to simulate the actual orbital configuration. Landing gear braking and steering tests were accomplished during rollouts following the free flight landings. Ferry testing was integrated into the Approach and Landing Test Program to the extent possible. In addition, four ferry test flights were conducted with the orbiter mated to the carrier aircraft in the ferry configuration after the free-flight tests were completed.

Source record↗

NASA NTRS2013

International Space Station (ISS) Soyuz Vehicle Descent Module Evaluation of Thermal Protection System (TPS) Penetration Characteristics

The descent module (DM) of the ISS Soyuz vehicle is covered by thermal protection system (TPS) materials that provide protection from heating conditions experienced during reentry. Damage and penetration of these materials by micrometeoroid and orbital debris (MMOD) impacts could result in loss of vehicle during return phases of the mission. The descent module heat shield has relatively thick TPS and is protected by the instrument-service module. The TPS materials on the conical sides of the descent module (referred to as backshell in this test plan) are exposed to more MMOD impacts and are relatively thin compared to the heat shield. This test program provides hypervelocity impact (HVI) data on materials similar in composition and density to the Soyuz TPS on the backshell of the vehicle. Data from this test program was used to update ballistic limit equations used in Soyuz TPS penetration risk assessments. The impact testing was coordinated by the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group [1] in Houston, Texas. The HVI testing was conducted at the NASA-JSC White Sands Hypervelocity Impact Test Facility (WSTF) at Las Cruces, New Mexico. Figure

Davis, Bruce A.↗

NASA NTRS1992

Design and analysis of seals for extended service life

Space Station Freedom is being developed for a service life of up to thirty years. As a consequence, the design requirements for the seals to be used are unprecedented. Full scale testing to assure the selected seals can satisfy the design requirements are not feasible. As an alternative, a sub-scale test program has been developed by MSFC to calibrate the analysis tools to be used to certify the proposed design. This research has been conducted in support of the MSFC Integrated Seal Test Program. The ultimate objective of this research is to correlate analysis and test results to qualify the analytical tools, which in turn, are to be used to qualify the flight hardware. This research is totally focused on O-rings that are compressed by perpendicular clamping forces. In this type of seal the O-ring is clamped between the sealing surfaces by loads perpendicular to the circular cross section.

Bower, Mark V.↗

NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗