Search NASA⌕ Search

SEARCH · Search NASA

Results for “Leak Testing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Performance of all-metal demountable cryogenic seals at superfluid helium temperatures

Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm, and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (9 cycles at 4.2 K), and superfluid helium temperature (4 cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak-rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10(-9) std-cc/sec, during testing.

Salerno, Louis J.↗
NASA NTRS1978

Development of flightweight static face seals for 75.84 MPa /11 000 psi/ pressure and cryogenic temperatures

The development of a static seal configuration to meet the lightweight low-leakage requirements of the Space Shuttle Main Engine (pressure carrying capability of up to 75.84 MPa) is discussed. The design features, fabrication methods, lab testing, and performance of seal are examined. Flange and bolt details of the joint assembly are considered with attention to an ultrasonic technique for measuring preload in the bolts. Methods used for leak testing in the laboratory and in the field are described; the practicality of the procedures is considered. Attention is directed to hydrogen-environment embrittlement and its influence on seal and joint design.

Daniels, C. M.↗
NASA NTRS1999

Design and Development of a Composite Dome for Experimental Characterization of Material Permeability

This paper presents the design and development of a carbon fiber reinforced plastic dome, including a description of the dome fabrication, method for sealing penetrations in the dome, and a summary of the planned test series. This dome will be used for the experimental permeability characterization and leakage validation of composite vessels pressurized using liquid hydrogen and liquid nitrogen at the Cryostat Test Facility at the NASA Marshall Space Flight Center (MSFC). The preliminary design of the dome was completed using membrane shell analysis. Due to the configuration of the test setup, the dome will experience some flexural stresses and stress concentrations in addition to membrane stresses. Also, a potential buckling condition exists for the dome due to external pressure during the leak testing of the cryostat facility lines. Thus, a finite element analysis was conducted to assess the overall strength and stability of the dome for each required test condition. Based on these results, additional plies of composite reinforcement material were applied to local regions on the dome to alleviate stress concentrations and limit deflections. The dome design includes a circular opening in the center for the installation of a polar boss, which introduces a geometric discontinuity that causes high stresses in the region near the hole. To attenuate these high stresses, a reinforcement system was designed using analytical and finite element analyses. The development of a low leakage polar boss system is also investigated.

Estrada, Hector↗
NASA NTRS1999

Analyses of Transistor Punchthrough Failures

The failure of two transistors in the Altitude Switch Assembly for the Solid Rocket Booster followed by two additional failures a year later presented a challenge to failure analysts. These devices had successfully worked for many years on numerous missions. There was no history of failures with this type of device. Extensive checks of the test procedures gave no indication for a source of the cause. The devices were manufactured more than twenty years ago and failure information on this lot date code was not readily available. External visual exam, radiography, PEID, and leak testing were performed with nominal results Electrical testing indicated nearly identical base-emitter and base-collector characteristics (both forward and reverse) with a low resistance short emitter to collector. These characteristics are indicative of a classic failure mechanism called punchthrough. In failure analysis punchthrough refers to an condition where a relatively low voltage pulse causes the device to conduct very hard producing localized areas of thermal runaway or "hot spots". At one or more of these hot spots, the excessive currents melt the silicon. Heavily doped emitter material diffuses through the base region to the collector forming a diffusion pipe shorting the emitter to base to collector. Upon cooling, an alloy junction forms between the pipe and the base region. Generally, the hot spot (punch-through site) is under the bond and no surface artifact is visible. The devices were delidded and the internal structures were examined microscopically. The gold emitter lead was melted on one device, but others had anomalies in the metallization around the in-tact emitter bonds. The SEM examination confirmed some anomalies to be cosmetic defects while other anomalies were artifacts of the punchthrough site. Subsequent to these analyses, the contractor determined that some irregular testing procedures occurred at the time of the failures heretofore unreported. These testing irregularities involved the use of a breakout box and were the likely cause of the failures. There was no evidence to suggest a generic failure mechanism was responsible for the failure of these transistors.

Nicolas, David P.↗
NASA NTRSDate not supplied

Metabolic Vessel for Impedance Spectroscopy and Electrochemistry (MVISE): The Ground Mapping Unit for the Lunar Explorer Instrument for Space Biology Applications (LEIA)​

The BioSensor payload on the upcoming LEIA platform aboard a CLPS lander will carry yeast to the moon to study response to radiation and lunar gravity. The LEIA BioSensor is designed to monitor metabolic activity using absorbance in conjunction with alamarBlue for measuring colorimetric changes as proxy measurement for redox potential. The science data returned from small spacecraft mission modules like LEIA is limited as it relies solely on optical measurements, necessitating a corresponding ground mapping unit that is equipped with multiple electrochemical sensors for accurate mapping of the optical data and operates fully automatically. This technology development work discusses the extensive design and optimization efforts put into the ground mapping unit, MVISE. MVISE is a custom designed, 3D-printed vessel with an agitation system, with six different electrochemical sensor probes, and ports for sample collection and a pressure release valve. The sensors provide real-time data, with dry absorbance measurements aligning with LEIA flight hardware and wet measurements demonstrating invasive sensor design enabling a comparison between the two setups. The 3D printer resin was tested for mechanical robustness, biocompatibility, and resistance to autoclave sterilization. The inner walls were coated with food-grade epoxy, ensuring a smooth finish to prevent microbial lodging and dye staining. The MVISE has successfully passed a week-long leak test and is now undergoing active biology tests. The MVISE prototype will be prepared for radiation tests, with three identical units being tested for varying radiation levels and culture compositions at the NASA Space Radiation Laboratory in November 2024. The integrated sensor approach proposed in this work will enable the accurate mapping of the BioSentinel/LEIA optical flight data to six sensor parameters on the ground unit for better science data return and will enable the first effort to evaluate classical biochemical sensor measurements by comparing and contrasting their responses.

Chinmayee Govinda Raj↗
NASA NTRS1976

High energy density capacitors for vacuum operation with a pulsed plasma load

Results of the effort of designing, fabricating, and testing of a 40 joules/lb (88.2 joules/Kg) high voltage energy storage capacitor suitable for operating a pulsed plasma thruster in a vacuum environment for millions of pulses are presented. Using vacuum brazing and heli-arc welding techniques followed by vacuum and high pressure helium leak tests it was possible to produce a hermetically sealed relatively light weight enclosure for the dielectric system. An energy density of 40 joules/lb was realized with a KF-polyvinylidene fluoride dielectric system. One capacitor was D.C. life tested at 4 KV (107.8 joules/lb) for 2,000 hours before it failed. Another exceeded 2,670 hours without failure at 38.3 joules/lb. Pulse life testing in a vacuum exceeded 300,000 discharges with testing still in progress. The D.C. life test data shows a small decrease in capacitance and an increase in dissipation factor with time. Heat transfer from the load to the capacitor must also be considered besides the self-heat generated by the capacitor.

Guman, W. J.↗
NASA NTRS2014

Effects of Low Earth Orbit on Docking Seal Materials

Spacecraft docking seals are typically made of silicone elastomers. When such seals are exposed to low Earth orbit (LEO) conditions, they can suffer damage from ultraviolet (UV) radiation and atomic oxygen (AO, or monoatomic oxygen, the predominant oxygen species in LEO). An experiment flew on the International Space Station (ISS) to measure the effects of LEO on seal materials S0383-70 and ELA-SA-401 and various mating counterface materials which included anodized aluminum. Samples flown in different orientations received different amounts of UV and AO. The hypotheses were that most of the damage would be from UV, and 10 days or more of exposure in LEO would badly damage the seals. Eighteen seals were exposed for 543 days in ram (windward), zenith (away from Earth), or wake (leeward) orientations, and 15 control samples (not flown) provided undamaged baseline leakage. To determine post-flight leak rates, each of the 33 seals were placed in an O-ring groove of a leak test fixture and pressure tested over time. Resistance temperature detectors (RTDs), pressure transducers, and LabVIEW (National Instruments) programs were used to measure and analyze the temperature and pressure and calculate leakage. Average leakage of control samples was 2.6 x 10(exp -7) lbs/day. LEO exposure did not considerably damage ELA-SA-401. The S0383-70 flight samples leaked at least 10 times more than ELA-SA-401 in all cases except one, demonstrating that ELA-SA-401 may be a more suitable sealing material in LEO. AO caused greater damage than UV; samples in ram orientation (receiving an AO fluence of 4.3 x 10(exp 21) atoms/(sq cm) and in wake (2.9x 10(exp 20) atoms/(sq cm)) leaked more than those in zenith orientation (1.58 x 10(exp 20) atoms/(sq cm)), whereas variations in UV exposure did not seem to affect the samples. Exposure to LEO did less damage to the seals than hypothesized, and the data did not support the conjecture that UV causes more damage than AO.

Leakage↗
NASA NTRS1981

Design and fabrication of a stringer stiffened discrete-tube actively cooled panel for a hypersonic aircraft

A 0.61 x 1.22 m (2 x 4 ft) test panel was fabricated and delivered to the Langley Research Center for assessment of the thermal and structural features of the optimized panel design. The panel concept incorporated an aluminum alloy surface panel actively cooled by a network of discrete, parallel, redundant, counterflow passage interconnected with appropriate manifolding, and assembled by adhesive bonding. The cooled skin was stiffened with a mechanically fastened conventional substructure of stringers and frames. A 40 water/60 glycol solution was the coolant. Low pressure leak testing, radiography, holography and infrared scanning were applied at various stages of fabrication to assess integrity and uniformity. By nondestructively inspecting selected specimens which were subsequently tested to destruction, it was possible to refine inspection standards as applied to this cooled panel design.

Anthony, F. M.↗
DOE OSTI2025

Novel Technology of Non-Contact Real-Time Radiation Damage Sensor for High Power Targets

High-power proton beams planned for forthcoming long-baseline neutrino experiments will subject solid targets to unprecedented radiation damage, threatening reliability and increasing costs. To address this challenge, we are building a real-time, non-contact sensor that tracks damage by measuring broadband laser reflectivity changes from the target surface. A low-power super-continuum Class 3B laser illuminates the sample inside a vacuum test chamber while a high-resolution fiber-coupled spectrometer captures S- and P-polarized light; spectral shifts reveal defect-driven variations in optical constants. My internship goal is to design, build, and commission this prototype by implementing a laser-safety interlock and light shield, integrating remote-operation cameras, and fabricating modular 3-D-printed mounts that enable tool-free swaps without disturbing alignment. The laser, spectrometer, and vacuum chamber have been delivered; interlock hardware, cameras, and mounts are in final assembly, and leak testing of the chamber is underway. Upcoming work will focus on initial calibration of the sensor and executing first beam-irradiation studies.

Pumarino, Rafael↗
NASA NTRS2009

Pressure Effects on the Self-Extinguishment Limits of Aerospace Materials

The Orion Crew Exploration Vehicle Module (CM) is being designed to operate in an atmosphere of up to 30% oxygen at a pressure of 10.2 psia for lunar missions. Spacecraft materials selection is based on an upward flammability test conducted in a closed chamber under the worst expected conditions of pressure and oxygen concentration. Material flammability depends on both oxygen concentration and pressure but, since oxygen concentration is the primary driver, all materials are certified in the 30% oxygen, 10.2 psia environment. Extensive data exist from the Shuttle Program at this condition which used relatively the same test methodology as currently used in the Constellation Program. When the CM returns to Earth, a snorkel device will be activated after splashdown to provide outside air to the crew; however, for operational reasons, it is desirable to maximize the time the crew is able to breathe cabin air before the snorkel device is activated. To maximize this time, it has been proposed to raise the partial pressure of oxygen in the CM immediately before reentry while maintaining the total cabin pressure at 14.7 psia. In addition, it has been proposed to leak-test the Orion CM with ambient air at a maximum pressure of 17.3 psia. No data exist to assess how high the cabin oxygen concentration can be at 14.7 psia or 17.3 psia. One is to re-test a large number of materials at these pressures at a significant cost. However, since the maximum oxygen concentration (MOC) at which a material will self-extinguish has been determined for a variety of spacecraft materials as a function of pressure, a second alternative is to use existing data to estimate the MOC at 14.7 psia and 17.3 psia. This data will be examined in this paper and an analysis presented to determine the oxygen concentrations at the increased pressures that will result in self-extinguishment of a material. This analysis showed that the oxygen concentration for the Orion CM at 14.7 psia cannot be set higher than 25.6% without potentially invalidating the materials flammability certification in 30% oxygen at 10.2 psia for some materials. Materials certified under these conditions would still be self-extinguishing in ambient air at 17.3 psia. alternative

Hirsch, David B.↗
NASA NTRS2017

International Space Station (ISS) Bacterial Filter Elements (BFEs): Filter Efficiency and Pressure Testing of Returned Units

The air revitalization system aboard the International Space Station (ISS) provides the vital function of maintaining a clean cabin environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of sedimentation due to the microgravity environment in Low Earth Orbit (LEO). The ISS Environmental Control and Life Support (ECLS) system architecture in the U.S. Segment uses a distributed particulate filtration approach consisting of traditional High-Efficiency Particulate Adsorption (HEPA) media filters deployed at multiple locations in each U.S. Segment module; these filters are referred to as Bacterial Filter Elements, or BFEs. These filters see a replacement interval, as part of maintenance, of 2-5 years dependent on location in the ISS. In this work, we present particulate removal efficiency, pressure drop, and leak test results for a sample set of 8 BFEs returned from the ISS after filter replacement. The results can potentially be utilized by the ISS Program to ascertain whether the present replacement interval can be maintained or extended to balance the on-ground filter inventory with extension of the lifetime of ISS beyond 2024. These results can also provide meaningful guidance for particulate filter designs under consideration for future deep space exploration missions.

Filtration↗
NASA NTRS2017

International Space Station (ISS) Bacterial Filter Elements (BFEs): Filter Efficiency and Pressure Drop Testing of Returned Units

The air quality control equipment aboard the International Space Station (ISS) and future deep space exploration vehicles provide the vital function of maintaining a clean cabin environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of sedimentation. The ISS Environmental Control and Life Support (ECLS) system architecture in the U.S. Segment uses a distributed particulate filtration approach consisting of traditional High-Efficiency Particulate Air (HEPA) filters deployed at multiple locations in each U.S. Seg-ment module; these filters are referred to as Bacterial Filter Elements, or BFEs. In our previous work, we presented results of efficiency and pressure drop measurements for a sample set of two returned BFEs with a service life of 2.5 years. In this follow-on work, we present similar efficiency, pressure drop, and leak tests results for a larger sample set of six returned BFEs. The results of this work can aid the ISS Program in managing BFE logistics inventory through the stations planned lifetime as well as provide insight for managing filter element logistics for future exploration missions. These results also can provide meaningful guidance for particulate filter designs under consideration for future deep space exploration missions.

ISS Air Quality↗
NASA NTRS1996

Design Enhancement and Improved Post-Actuation Test Method for a 1/4 inch Normally Closed Pyro Valve

The NASA/JPL Cassini mission to Saturn will launch in October, 1997 and arrive at Saturn in the year 2004 with a 4 year mission to orbit the planet. The main propulsion thrust vector and attitude control for the spacecraft is supplied by the Cassini Propulsion Module Subsystem (C-PMS). This system will use numerous ordnance-actuated, normally-closed (NC) pyro valves to perform mission critical tasks over the 11 year mean mission duration (NMD). The proper operation of this NC valve requires it to isolate fluid flow until commanded open. Once open, the valve must allow an unobstructed flow path and seal internally to prevent leakage external to the valve. This paper documents a design evolution to a qualified, Viking heritage design with improvements in design details that control external leakage to levels that support the planetary mission of this spacecraft. In addition, it addresses an improved post-actuation leak test technique, used to better detect gas leakage past the valve's primary metal-to-metal internal seal.

Cassini↗
NASA NTRS2017

Filter Efficiency and Pressure Testing of Returned ISS Bacterial Filter Elements (BFEs)

The air quality control equipment aboard the International Space Station (ISS) and future deep space exploration vehicles provide the vital function of maintaining a clean cabin environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of sedimentation. The ISS Environmental Control and Life Support (ECLS) system architecture in the U.S. Segment uses a distributed particulate filtration approach consisting of traditional High-Efficiency Particulate Air (HEPA) filters deployed at multiple locations in each U.S. Seg-ment module; these filters are referred to as Bacterial Filter Elements, or BFEs. In our previous work, we presented results of efficiency and pressure drop measurements for a sample set of two returned BFEs with a service life of 2.5 years. In this follow-on work, we present similar efficiency, pressure drop, and leak tests results for a larger sample set of six returned BFEs. The results of this work can aid the ISS Program in managing BFE logistics inventory through the stations planned lifetime as well as provide insight for managing filter element logistics for future exploration missions. These results also can provide meaningful guidance for particulate filter designs under consideration for future deep space exploration missions.

ISS Air Quality↗
NASA NTRS1972

Nondestructive testing of Scout rocket motors

The nondestructive tests applied to Scout rocket motors were reviewed and appraised. Analytical techniques were developed to evaluate the capabilities of the radiographic and ultrasonic procedures used. Major problem areas found were the inadequacy of high voltage radiography for detecting unbonds and propellant cracks having narrow widths, the inability to relate the ultrasonic signals received from flat-bottomed holes in standards to those received from real defects and in the general area of the specification of acceptance criteria and how these were to be met. To counter the deficiencies noted, analyses were conducted to the potential utility of radiometric, acoustic, holographic and thermographic techniques for motor and nozzle bond inspection, a new approach to qualifying magnetic particle inspection and the application of acoustic emission analysis to the evaluation of proof and leak test data.

Oaks, A. E.↗
NASA NTRS1966

Liquid propulsion systems

Bladder and expulsion devices for spacecraft liquid propulsion systems - pinhole leak test fixture, heat sterilization of ethylene propylene with hydrazine, and metal diaphragms

PROPYLENE↗