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The James Webb Space Telescope (JWST) will be a 6 meter diameter segmented reflector that will be launched at room temperature and passively cooled to about 40 Kelvin at the L2 point.
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Testing materials for use in cages, balls, and races in cryogenic hydrogen-cooled 110-mm ball bearing
Tests were run in TRW's Combined Environment Facility to examine the degradation of thermal control materials in a simulated space environment. Thermal control materials selected for the test were those presently being used on spacecraft or predicted to be used within the next few years. The geosynchronous orbit environment was selected as the most interesting. One of the goals was to match degradation of those materials with available flight data. Another aim was to determine if degradation can adequately be determined with accelerated or short term ground tests.
This task is to design, fabricate, and spin test to failure a Ti6-4 hydrogen turbopump impeller that was built using the selective laser melting (SLM) fabrication process (fig. 1). The impeller is sized around upper stage engine requirements. In addition to the spin burst test, material testing will be performed on coupons that are built with the impeller.
Material and configuration testing for the Space Shuttle is mainly at 30 percent oxygen concentration at 70 kPa (10.2 psia). This is the worst case atmosphere during a mission and occurs 10 hours prior to extravehicular activity. The pressure is reduced from the nominal 101 kPa (14.7 paia) and the oxygen concentration is increased to 30 percent for medical reasons to prevent the bends during the extravehicular activity. NASA has tested many materials at 23.8, 25.9 and 30 percent oxygen levels for the Shuttle program. Data is given to show how flammability of material is affected by percentage of oxygen for those materials that would be considered for spacecraft applications.
New materials and component designs are needed to advance gas turbine engine technology and provide the performance and efficiency needs for future applications. In order to advance these materials, testing in combustion environments is a critical step prior to engine testing. In this work, we detail the design and the fabrication of a materials test sector in a flametube combustor facility. The facility simulates a combustion environment similar to that experienced by components in gas turbine engines. The flow regime is characterized by a combination of high-temperature, high-velocity, high-heat flux, and high-velocity that components experience in gas turbine engines. Exposure of components in this facility allows for the study of combined environmental effects and the impact on both coating and substrate durability. The test facility may operate across a wide range of pressures from 275-400 psig (1,896-2,758 kPa) and an air flow rate of 5 lb/s (2.27 kg/s). While combustion gas temperature is expected in excess of 3,000°F (1,649°C), 900°F (482°C) cooling air may be supplied to the backside of components or test articles. The flametube combustor was previously used to evaluate fuel injectors and combustion products, and the new test configuration will also allow for materials exposure to complex, engine-like conditions. The interior of the Test Section was additively manufactured from GRCop-84 and cryogenically fit and brazed to a stainless steel 304 housing. The use of a copper liner minimizes welds and with active cooling, is expected to provide better durability over traditional hardware using stainless steel or Inconel with a ceramic liner. The Test Section has two opposing removable windows approximately 230 mm x 80 mm that can accommodate articles up to 85 mm tall. This modular design allows for custom platforms to hold coupons, panels, or airfoil shapes to be tested with minimal re-engineering or fabrication. The bolted joint and sealing remains consistent, so any new testing only needs to work within the existing design footprint. This paper will provide an overview of the facility capabilities, design considerations, as well as thermal and structural analysis of the hardware. Future testing of ceramic matrix composite (CMC) airfoils and advanced environmental barrier coatings (EBCs) will also be discussed.
Materials test methods from the 1960's have been used as a starting point in evaluating materials for today's space launch vehicles. These established test methods have been modified to incorporate today's analytical laboratory equipment. The Orbital test objective was to test a wide range of materials to incorporate the revolution in polymer and composite materials that has occurred since the 1960's. Testing is accomplished in 3 stages from rough screening to detailed analytical tests. Several interesting test observations have been made during this testing and are included in the paper. A summary of the set-up, test and evaluation of long-term storage sub-scale tanks is also included. This sub-scale tank test lasted for a 7-month duration prior to being stopped due to a polar boss material breakdown. Chemical evaluations of the hydrogen peroxide and residue left on the polar boss surface identify the material breakdown quite clearly. The paper concludes with recommendations for future testing and a specific effort underway within the industry to standardize the test methods used in evaluating materials.
The requirements of the Space Shuttle bipropellant reaction control system engine technology contract and the scheduled contract effort are presented herein. The requirements included an engine concept scalable from 400 to 1100 lbf, with a 100 mission life employing N2O4/MMH propellants. Emphasis is placed on reusability and minimum post-flight servicing. The engine components are reviewed and their selection is supported by tradeoff analyses, thrust chamber firing test data, materials test data, and metallurgical evaluations. The materials test data indicate that the proposed silicide coated columbium chamber and uncoated columbium injector have the potential of meeting the mission life requirements. The engine valve trade studies resulted in the selection of a torque motor operated bipropellant valve configuration. Fuel vortex film cooling of the insulated chamber is described together with the fuel vortex film cooling scaling parameter and its verification by test data to a thrust level of 5500 lbf.
Tests of magnetic materials from 800 to 1600 F
Contents include the following: Why ablative thermal protections - TPS. Ablative TPS chronology: strategic reentry systems, solid rocket motor nozzles, space (manned missions and planetary entry probes). Ablation mechanisms. Ablation material testing. Ablative material testing.
Feasibility of Scout launched small lifting reentry vehicle for testing materials and thermostructures of full scale reentry vehicles
The SRM propellant and polymer materials structural test program has potentially wide application to the testing and structural analysis of polymer materials and other materials generally characterized as being made of viscoelastic materials. The test program will provide a basis for characterization of the dynamic failure criteria for Solid Rocket Motor (SRM) propellant, insulation, inhibitor and liners. This experimental investigation will also endeavor to obtain a consistent complete set of materials test data. This test will be used to improve and revise the presently used theoretical math models for SRM propellant, insulators, inhibitor, liners, and O-ring seals.
The material testing results described in this paper were part of a material development program of vendor-supplied, proposed heat shield materials. The goal of this program was to develop low density, rigid material systems with an appreciable weight savings over phenolic-impregnated carbon ablator (PICA) while improving material response performance. New technologies, such as PICA-like materials in honeycomb or materials with variable density through-the-thickness were tested. The material testing took place at the Wright-Patterson Air Force Base Laser Hardened Materials Laboratory (LHMEL) using a 10.6 micron CO2 laser operating with the test articles immersed in a nitrogen-gas environment at 1 atmosphere pressure. Test measurements included thermocouple readings of in-depth temperatures, pyrometer readings of surface temperatures, weight scale readings of mass loss, and sectioned-sample readings of char depth. Two laser exposures were applied. The first exposure was at an irradiance of 450 W/cm2 for 50 or 60 seconds to simulate an aerocapture maneuver. The second laser exposure was at an irradiance of 115 W/cm2 for 100 seconds to simulate a planetary entry. Results from Rounds 1 and 2 of these screening tests are summarized.
Certain materials useful in space sensor construction were tested for their noncontaminating compatibility with channel electron multipliers. Gain profiles indicate that the materials tested do not adversely affect the lifetimes of the multipliers. These materials are, therefore, shown to be safe for use with channel electron multipliers in space instrumentation even for the most stringent long lifetime mission requirements. The tests indicate that the multipliers which are to be flown on an extended space mission will have adequate lifetimes to return satisfactory data throughout the entire mission.
Test methods require reference materials to standardize and maintain quality control. Various materials have been evaluated as possible reference materials, including a sample of bisphenol A polycarbonate without additives. Screening tests for relative toxicity under various experimental conditions were performed using male mice exposed to pyrolysis effluents over a 200-800 C temperature range. It was found that the bisphenol A polycarbonate served as a suitable reference material as it is available in large quantities, and does not significantly change with time.
Spacecraft reentry flight tests for determining performance of heat shields made of charring ablating material
The test facility presented herein uses a groundbased rocket combustor to test the durability of new ceramic composite and metallic materials in a rocket engine thermal environment. A gaseous H2/02 rocket combustor (essentially a ground-based rocket engine) is used to generate a high temperature/high heat flux environment to which advanced ceramic and/or metallic materials are exposed. These materials can either be an integral part of the combustor (nozzle, thrust chamber etc) or can be mounted downstream of the combustor in the combustor exhaust plume. The test materials can be uncooled, water cooled or cooled with gaseous hydrogen.