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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 NTRSDate not supplied

A Summary of the NEXT-C Flight Thruster Proto-flight Testing

Aerojet Rocketdyne (AR), under contract to NASA Glenn Research Center, built, tested and delivered the first flight version of the NEXT-C (NASA Evolutionary Xenon Thruster – Commercial) engine system. This system is comprised of a 7 kW thruster and power processing unit which are the commercial variants of the NEXT prototype thruster and power processing unit. In addition to developing the NEXT-C engine system for potential future NASA science missions, AR is dedicated to ensuring that this propulsion system is viable for commercial users and a wider variety of commercial applications. This paper will focus on the performance of the first flight model thruster, SN001, and presents an overview of the proto-flight testing environments and data obtained. For this first flight thruster, the proto-flight test sequence involved characterizing the performance of the thruster, in addition to vibration and thermal vacuum testing of the thruster. Between each of these environmental tests, the performance of the thruster was verified, ensuring that the environmental exposures, i.e. vibration and TVAC, did not affect the thruster performance. Specifically, the proto-flight data obtained included discharge chamber, optics and neutralizer performance. Faraday probe and ExB data obtained in the regions downstream of the thruster are presented and used to calculate thrust, and therefore specific impulse and total efficiency. Lastly, data are presented showing how the centroid of the ion beam, assumed to be indicative of the thrust vector location, varies throughout the entire proto-flight test campaign. The proto-flight testing of the NEXT-C PPU is documented in a previously published paper by Bontempo4. Following the proto-flight testing of the thruster, the thruster and its PPU successfully completed a System Integrated Test (SIT) tailored to the DART Mission. After the completion of the proto-flight testing, the SN001 thruster and SN002 PPU were delivered to APL for use on the DART mission.

Ion thruster↗
NASA NTRS1974

Simulator verification techniques study. Integrated simulator self test system concepts

Software and hardware requirements for implementing hardware self tests are presented in support of the development of training and procedures development simulators for the space shuttle program. Self test techniques for simulation hardware and the validation of simulation performance are stipulated. The requirements of an integrated simulator self system are analyzed. Readiness tests, fault isolation tests, and incipient fault detection tests are covered.

Montoya, G.↗
NASA NTRSDate not supplied

Advanced Modeling of Control-Structure Interaction in Thrust Vector Control Systems

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. During the development of the SLS TVC system, a family of advanced dynamics models were developed to extend and compliment the simplified quasi-linear “simplex” model historically used for flight control design and stability analysis. The importance of these advanced models became increasingly evident after ambient and hot fire testing of the Core Stage, which revealed a number of findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. One driving factor for these results was a higher-than-expected degree of coupling between the TVC system, the engine dynamics, and the Core Stage structure. This paper is the third installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, a new method of modeling rocket vehicle thrust vectoring servoelastic dynamics is presented. In this approach, the load dynamics are replaced by a detailed finite element model containing both the rigid body and elastic modes. A partitioning technique is used to compute the effective compliance from the modal data and obtain accurate simulation results using a reduced number of generalized coordinates. Coupled backup structure and nozzle attach compliance effects on multiple engines are captured in higher fidelity than with a spring approximation, eliciting novel effects due to the complex load paths involved in the Core Stage structure. Validation of the model is demonstrated using a variety of structural/modal, laboratory, and full-scale hot fire test data.

Launch Vehicles↗
NASA NTRSDate not supplied

Advanced Modeling of Control-Structure Interaction in Thrust Vector Control Systems

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. During the development of the SLS TVC system, a family of advanced dynamics models were developed to extend and compliment the simplified quasi-linear “simplex” model historically used for flight control design and stability analysis. The importance of these advanced models became increasingly evident after ambient and hot fire testing of the Core Stage, which revealed a number of findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. One driving factor for these results was a higher-than-expected degree of coupling between the TVC system, the engine dynamics, and the Core Stage structure. This paper is the third installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, a new method of modeling rocket vehicle thrust vectoring servoelastic dynamics is presented. In this approach, the load dynamics are replaced by a detailed finite element model containing both the rigid body and elastic modes. A partitioning technique is used to compute the effective compliance from the modal data and obtain accurate simulation results using a reduced number of generalized coordinates. Coupled backup structure and nozzle attach compliance effects on multiple engines are captured in higher fidelity than with a spring approximation, eliciting novel effects due to the complex load paths involved in the Core Stage structure. Validation of the model is demonstrated using a variety of structural/modal, laboratory, and full-scale hot fire test data.

Launch Vehicles↗
NASA NTRS1965

Systems integration

Qualifications testing of basic design and acceptance testing of workmanship for Relay I satellite - systems integration

RELAY I SATELLITE↗
NASA NTRS2001

Revalidation of the NASA Ames 11-by 11-Foot Transonic Wind Tunnel with a Commercial Airplane Model

The 11-By 11-Foot Transonic leg of the Unitary Plan Wind Tunnel (UPWT) was modernized to improve tunnel performance, capability, productivity, and reliability. Wind tunnel tests to demonstrate the readiness of the tunnel for a return to production operations included an Integrated Systems Test (IST), calibration tests, and airplane validation tests. One of the two validation tests was a 0.037-scale Boeing 777 model that was previously tested in the 11-By 11-Foot tunnel in 1991. The objective of the validation tests was to compare pre-modernization and post-modernization results from the same airplane model in order to substantiate the operational readiness of the facility. Evaluation of within-test, test-to-test, and tunnel-to-tunnel data repeatability were made to study the effects of the tunnel modifications. Tunnel productivity was also evaluated to determine the readiness of the facility for production operations. The operation of the facility, including model installation, tunnel operations, and the performance of tunnel systems, was observed and facility deficiency findings generated. The data repeatability studies and tunnel-to-tunnel comparisons demonstrated outstanding data repeatability and a high overall level of data quality. Despite some operational and facility problems, the validation test was successful in demonstrating the readiness of the facility to perform production airplane wind tunnel%, tests.

Kmak, Frank J.↗
NASA NTRS2018

NASA's Space Launch System Moves into Testing and Integration

NASA's Space Launch System (SLS) has moved from design and manufacturing into testing and integration for its first flight as early as December 2019. In 2017, the NASA/industry team completed manufacturing of all major structural elements for the launch vehicle for Exploration Mission-I (EM-1 ). That work included shipping the first major flight hardware element to the launch site. The team processed all four RS-25 engines for stage integration, cast all 10 booster flight motor segments, and manufactured all five major sections of the core stage. The program also completed major structural work on the B-2 test stand at Stennis Space Center, which will be used for the core stage "green run" test; delivered the core stage and engine simulators used for training; and much of the transportation equipment for the core stage. Engineers completed structural testing on the upper stage/payload section of the vehicle as well as the engine section test article. In 2018, the program will deliver the Orion Stage Adapter (OSA) to Exploration Ground Systems (EGS) at KSC and send the test articles for the core stage liquid hydrogen tank, liquid oxygen tank, and intertank to NASA's Marshall Space Flight center for structural testing. Additionally, workers will begin the challenging process of integrating the major sections of the 212-foot EM-1 core stage. This work is focused on the initial Block 1 variant of SLS, capable of launching more than 70 metric tons (t) to low Earth orbit (LEO). However, work concurrently is underway on the Block lB variant, which will enable 105 t to LEO and more than 37t to trans-lunar injection (TLI). Block lB will be the workhorse vehicle of NASA's lunar exploration plans. As the needs of the nation's deep space exploration program grow, SLS performance is designed to evolve to a payload mass of 130 t to LEO and up to 45t to TLI. The advantages of this mass - as well as volume- are critical to the entire exploration architecture for deep space exploration. They translate to greater capability, greater infrastructure and operational simplicity, less overall mission risk, and opportunities to accomplish unprecedented exploration and discovery. This paper will discuss SLS progress to date and planned future work.

Honeycutt, John↗
NASA NTRS2008

The NASA Evolutionary Xenon Thruster (NEXT): NASA's Next Step for U.S. Deep Space Propulsion

NASA s Evolutionary Xenon Thruster (NEXT) project is developing next generation ion propulsion technologies to enhance the performance and lower the costs of future NASA space science missions. This is being accomplished by producing Engineering Model (EM) and Prototype Model (PM) components, validating these via qualification-level and integrated system testing, and preparing the transition of NEXT technologies to flight system development. The project is currently completing one of the final milestones of the effort, that is operation of an integrated NEXT Ion Propulsion System (IPS) in a simulated space environment. This test will advance the NEXT system to a NASA Technology Readiness Level (TRL) of 6 (i.e., operation of a prototypical system in a representative environment), and will confirm its readiness for flight. Besides its promise for upcoming NASA science missions, NEXT may have excellent potential for future commercial and international spacecraft applications.

Schmidt, George R.↗
NASA NTRS1989

Development of the XV-15 tiltrotor research aircraft - Lessons learned

The initial ground rules that guided the decision process during the initial stages of the XV-15 tiltrotor aircraft development are reviewed and reevaluated. A full flight-envelope nonlinear simulation mathematical model is outlined, along with the advantages of a multiaircraft program. Direct involvement of government engineers in all aspects of the program is considered to be beneficial, while the ejection-seat test requirement is not. Utilization of existing components - a rotor, transmissions, and engines - is analyzed, and emphasis is placed on integrated system test plans responsible for producing two reliable aircraft through a complete checkout of the aircraft subsystems before the start of the fligth program. Wind-tunnel and fatigue test requirements are presented, and the decision to go with an all mechanical control system design is addressed.

Schroers, Laurel G.↗
NASA NTRS2000

Flow Quality Measurements in the NASA Ames Upgraded 11-by 11-Foot Transonic Wind Tunnel

Among the many upgrades designed and implemented in the NASA Ames 11-by 11-Foot Transonic Wind Tunnel over the past few years, several directly affect flow quality in the test section: a turbulence reduction system with a honeycomb and two screens, a flow smoothing system in the back leg diffusers, an improved drive motor control system, and a full replacement set of composite blades for the compressor. Prior to the shut-down of the tunnel for construction activities, an 8-foot span rake populated with flow instrumentation was traversed in the test section to fully document the flow quality and establish a baseline against which the upgrades could be characterized. A similar set of measurements was performed during the recent integrated system test trials, but the scope was somewhat limited in accordance with the primary objective of such tests, namely to return the tunnel to a fully operational status. These measurements clearly revealed substantial improvements in flow angularity and significant reductions in turbulence level for both full-span and semi-span testing configurations, thus making the flow quality of the tunnel one of the best among existing transonic facilities.

Amaya, Max A.↗
NASA NTRS1984

Ground test challenges in the development of the Space Shuttle orbiter auxiliary power unit

A conventional aircraft hydraulic system design approach was selected to provide fluid power for the Space Shuttle Orbiter. Developing the power unit, known as the Auxiliary Power Unit (APU), to drive the hydraulic pumps presented a major technological challenge. A small, high speed turbine drive unit powered by catalytically decomposed hydrazine and operating in the pulse mode was selected to meet the requirement. Because of limitations of vendor test facilities, significant portions of the development, flight qualification, and postflight anomaly testing of the Orbiter APU were accomplished at the Johnson Space Center (JSC) test facilities. This paper discusses the unique requirements of attitude, gravity forces, pressure profiles, and thermal environments which had to be satisfied by the APU, and presents the unique test facility and simulation techniques employed to meet the ground test requirements. In particular, the development of the zero-g lubrication system, the development of necessary APU thermal control techniques, the accomplishment of integrated systems tests, and the postflight investigation of the APU lube oil cooler behavior are discussed.

Chaffee, N. H.↗
NASA NTRS2017

13kW Advanced Electric Propulsion Flight System Development and Qualification

The next phase of robotic and human deep space exploration missions is enhanced by high performance, high power solar electric propulsion systems for large-scale science missions and cargo transportation. Aerojet Rocketdynes Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS includes a magnetically-shielded, long-life Hall thruster, power processing unit (PPU), xenon flow controller (XFC), and intrasystem harnesses. The Hall thruster, originally developed and demonstrated by NASAs Glenn Research Center and the Jet Propulsion Laboratory, operates at input powers up to 12.5kW while providing a specific impulse over 2600s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95 to 140V, consistent with operation beyond the orbit of Mars. The integrated system is continuously throttleable between 3 and 13.3kW. The program has completed the system requirement review; the system, thruster, PPU and XFC preliminary design reviews; development of engineering models, and initial system integration testing. This paper will present the high power AEPS capabilities, overall program and design status and the latest test results for the 13.3kW flight system development and qualification program.

Jackson, Jerry↗
DOE OSTI2024

Integrated Off-gas System: A Preconceptual Design of an Integrated Off-Gas Treatment System

The U.S. has a vested interest in the advancement of nuclear energy to achieve aggressive net-zero goals, with reprocessing and recycling of used nuclear fuels (UNF) playing a vital role. It will not be possible to meet U.S. regulatory requirements without robust off-gas treatment, so it is crucial to advance treatment technologies to facilitate the design of future reprocessing facilities. For many years, teams of researchers across the U.S. Department of Energy (DOE) National Laboratory complex have been investigating off-gas treatment technologies for the capture and removal of volatile radionuclides (i.e., 85 Kr, Xe, 14 C, and 129 I) and oxides of nitrogen (NO X ) that are produced from reprocessing. These investigations have been focused on developing individual technologies for the capture of Kr, Xe, iodine, and CO 2 . Capture technologies for each constituent were tested independently from one another by utilizing nonradioactive surrogates to simulate simplified off-gas streams. The tests have been relatively small, laboratory-scale experiments of up to approximately 1 L/minute total gas flow rate. To increase the readiness of these technologies for deployment, an integrated test system with a larger-scale capacity is needed to bridge the gap between promising bench scale and fully scalable UNF reprocessing off-gas treatment. This document contains the goals, design basis, functional requirements, preconceptual design, and cost estimates for an integrated off-gas demonstration system for the capture and removal of NO x , Kr, Xe, CO 2 , and iodine at 10× higher throughput than earlier laboratory studies. The order-of-magnitude cost estimate for this system is approximately $\$$886,000. Next phases include conceptual design, detailed design, fabrication, and commissioning.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2012

Extensible Adaptable Simulation Systems: Supporting Multiple Fidelity Simulations in a Common Environment

Common practice in the development of simulation systems is meeting all user requirements within a single instantiation. The Joint Polar Satellite System (JPSS) presents a unique challenge to establish a simulation environment that meets the needs of a diverse user community while also spanning a multi-mission environment over decades of operation. In response, the JPSS Flight Vehicle Test Suite (FVTS) is architected with an extensible infrastructure that supports the operation of multiple observatory simulations for a single mission and multiple mission within a common system perimeter. For the JPSS-1 satellite, multiple fidelity flight observatory simulations are necessary to support the distinct user communities consisting of the Common Ground System development team, the Common Ground System Integration & Test team, and the Mission Rehearsal Team/Mission Operations Team. These key requirements present several challenges to FVTS development. First, the FVTS must ensure all critical user requirements are satisfied by at least one fidelity instance of the observatory simulation. Second, the FVTS must allow for tailoring of the system instances to function in diverse operational environments from the High-security operations environment at NOAA Satellite Operations Facility (NSOF) to the ground system factory floor. Finally, the FVTS must provide the ability to execute sustaining engineering activities on a subset of the system without impacting system availability to parallel users. The FVTS approach of allowing for multiple fidelity copies of observatory simulations represents a unique concept in simulator capability development and corresponds to the JPSS Ground System goals of establishing a capability that is flexible, extensible, and adaptable.

McLaughlin, Brian J.↗
NASA NTRS1990

Experimental studies of 90 deg corner cascades in the National Full-Scale Aerodynamic Complex

Two 90 deg, fixed geometry, turning vane cascades were replaced in the 40- by 80-foot wind tunnel circuit of the National Full-Scale Aerodynamic Complex as a part of a major facility upgrade. Prior to the replacement of these vanes, small-scale, two-dimensional tests were conducted to assess the aerodynamic performance of the original, 1930's technology vane geometry and a new vane geometry which was developed using a modern cascade design code. The small scale tests were conducted in the 1/10th-Scale Cascade Test Facility and included measurements of total pressure, static pressure, and flow angularity distributions in the wake of the cascade and static pressure distributions along the vane profiles. Test results and a detailed comparison of the two vanes designs are presented. Based on these results, the new design was chosen and subsequently installed in the wind tunnel. During the integrated systems test of the upgraded facility, two of the 52 vanes in the first cascade were instrumented near midspan. The full-scale test results are presented, these show the cascade pressure loss coefficient to be slightly larger than obtained in the small-scale tests. Elements of the three-dimensional flow field upstream of the cascade, which effect can impact cascade performance, are discussed and recommendations for future research are given.

Meyn, Larry A.↗
NASA NTRS1997

Summary of Current and Future MSFC International Space Station Environmental Control and Life Support System Activities

This paper provides a summary of current work accomplished under technical task agreement (TTA) by the Marshall Space Flight Center (MSFC) regarding the Environmental Control and Life Support System (ECLSS) as well as future planning activities in support of the International Space Station (ISS). Current activities include ECLSS computer model development, component design and development, subsystem integrated system testing, life testing, and government furnished equipment delivered to the ISS program. A long range plan for the MSFC ECLSS test facility is described whereby the current facility would be upgraded to support integrated station ECLSS operations. ECLSS technology development efforts proposed to be performed under the Advanced Engineering Technology Development (AETD) program are also discussed.

Ray, Charles D.↗
NASA NTRS2016

Check Calibration of the NASA Glenn 10- by 10-Foot Supersonic Wind Tunnel (2014 Test Entry)

A check calibration of the 10- by 10-Foot Supersonic Wind Tunnel (SWT) was conducted in May/June 2014 using an array of five supersonic wedge probes to verify the 1999 Calibration. This check calibration was necessary following a control systems upgrade and an integrated systems test (IST). This check calibration was required to verify the tunnel flow quality was unchanged by the control systems upgrade prior to the next test customer beginning their test entry. The previous check calibration of the tunnel occurred in 2007, prior to the Mars Science Laboratory test program. Secondary objectives of this test entry included the validation of the new Cobra data acquisition system (DAS) against the current Escort DAS and the creation of statistical process control (SPC) charts through the collection of series of repeated test points at certain predetermined tunnel parameters. The SPC charts secondary objective was not completed due to schedule constraints. It is hoped that this effort will be readdressed and completed in the near future.

pressure measurement↗
NASA NTRS2018

NASA's Space Launch System Moves into Testing and Integration

NASA's Space Launch System (SLS) has moved from design and manufacturing into testing and integration for its first flight in fiscal year 2020. In 2017, the NASA/industry team completed manufacturing of all major structural elements for the launch vehicle for Exploration Mission-1 (EM-1). This work included shipping the first major flight hardware element to the launch site. Current work is focused on the initial Block 1 variant of SLS, capable of launching more than 70 metric tons (t) to low Earth orbit (LEO). As the needs of the nation's deep space exploration program grow, SLS performance is designed to evolve to a payload mass of 130 t to LEO and up to 45 metric tons (t) to trans-lunar injection (TLI). The advantages of this mass - as well as volume - are critical to the entire exploration architecture for deep space exploration. They translate to greater capability, greater infrastructure and operational simplicity, less overall mission risk, and opportunities to accomplish unprecedented exploration and discovery.

Honeycutt, John↗