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Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024

Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption during Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customers aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facilitys available acoustic power capability becomes maximized with the test-article installed during the actual test then the customers environment requirement may become compromised. In order to understand the risk of not achieving the customers in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Stations Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

acoustic

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption During Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customer's aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facility's available acoustic power capability becomes maximized with the test-article installed during the actual test then the customer's environment requirement may become compromised. In order to understand the risk of not achieving the customer's in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Station's Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

absorption

Measurement of Test Time in the NASA Ames EAST Expansion Cone Facility in Entry 63 and Possible Techniques for Increasing Test Time

The Ames EAST facility and its modes of operation (expansion tube, expansion cone) are described. A buffer section may or may not be used between the driver and the driven tube. Previous expansion tube (without the cone) entries are reviewed. Test times of 4 to 5 microsec were achieved at shock speeds up to 11 km/s. The test conditions and results of the present entry (entry 63) (with the cone) are given. Test times were found to correlate roughly with the density ratio across the buffer gas - driven gas or driver - driven gas interface. Tests with a 12 inch long conical driver without a buffer yielded three runs with test times of ~8 km/s and 3 runs with test times of 4 to 6 microsecs. With a buffer, test times for 4 runs of ~9 microsecs and for 2 runs of 3 to 6 microsecs were obtained. Adding argon to the buffer was found not to improve the test time. Tests with a 30 inch long driver without a buffer yielded test times of 14+, ~10, 7.5 (2 runs) and 5.5 (2 runs) microsecs. Based on one shot, data for the 30 inch driver suggests that test times up to ~14 microseconds could be obtained. The repeatability of that shot, of course, must be established. Suggestions are given to increase test times further.

Electric arc shock tube

Comparison of Anthropomorphic Test Device and human Volunteer Responses in Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to validate the safety of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and the vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded in human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa Reiber

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber

Test section configuration for aerodynamic testing in shock tubes

This paper presents results of a study of the test section configuration required to minimize or alleviate interference effects on model flow produced by the presence of test section walls in the aerodynamic testing of two dimensional transonic airfoils in a shock tube. Tests at a nominal Mach number of 0.85 and a chord Reynolds number of 2,000,000 were carried out by means of schlieren photography and pressure measurements for several symmetric airfoil profiles using shock tube test sections with unmodified straight walls, contoured walls, and slotted walls with adjacent chambers. Results were compared with corresponding results from conventional wind tunnel tests of the airfoils. Results for the straight wall tests show major airfoil flow distortions. Results from contoured wall tests and those performed using a slotted wall test section developed in this study exhibit essential agreement with wind tunnel results. The collective results show that test sections for aerodynamic testing can be designed for shock tubes that will alleviate wall interference effects.

Cook, W. J.

Test program to develop vibroacoustics test criteria for the Galileo bus

In order to define random vibration test requirements for Galileo bus-mounted hardware, an extensive vibroacoustics test program was conducted on hardware available from the previous Voyager spacecraft development program. The Galileo test program consisted of acoustic tests on three configurations of the Voyager Dynamic Test Model bus and shaker random vibration tests on two flight-like bus equipment bay assemblies and one dummy equipment bay assembly. The primary goal of the acoustic tests was to define vibration levels at locations on the bus structure representative of inputs to bus equipment bay assemblies and to obtain response data on bus bay subassemblies for correlation with the vibration tests response data. The primary purpose of the vibration tests was to determine if the vibration tests excited subassembly responses at least as severely as the bus acoustic tests.

Kern, D. L.

AXAF-I Low Intensity-Low Temperature (LILT) Testing of the Development Verification Test (DVT) Solar Panel

The planned orbit of the AXAF-I spacecraft will subject the spacecraft to both short, less than 30 minutes for solar and less than 2 hours for lunar, and long earth eclipses and lunar eclipses with combined conjunctive duration of up to 3 to 4 hours. Lack of proper Electrical Power System (EPS) conditioning prior to eclipse may cause loss of mission. To avoid this problem, for short eclipses, it is necessary to off-point the solar array prior to or at the beginning of the eclipse to reduce the battery state of charge (SOC). This yields less overcharge during the high charge currents at sun entry. For long lunar eclipses, solar array pointing and load scheduling must be tailored for the profile of the eclipse. The battery SOC, loads, and solar array current-voltage (I-V) must be known or predictable to maintain the bus voltage within acceptable range. To address engineering concerns about the electrical performance of the AXAF-I solar array under Low Intensity and Low Temperature (LILT) conditions, Marshall Space Flight Center (MSFC) engineers undertook special testing of the AXAF-I Development Verification Test (DVT) solar panel in September-November 1997. In the test the DVT test panel was installed in a thermal vacuum chamber with a large view window with a mechanical "flapper door". The DVT test panel was "flash" tested with a Large Area Pulse Solar Simulator (LAPSS) at various fractional sun intensities and panel (solar cell) temperatures. The testing was unique with regards to the large size of the test article and type of testing performed. The test setup, results, and lessons learned from the testing will be presented.

Alexander, Doug

Dynamic Response Testing in an Electrically Heated Reactor Test Facility

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Standard testing allows one to fully assess thermal, heat transfer, and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. The integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and full nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics, and assess potential design improvements at a relatively small fiscal investment. Initial system dynamic response testing was demonstrated on the integrated SAFE-100a heat pipe cooled, electrically heated reactor and heat exchanger hardware, utilizing a one-group solution to the point kinetics equations to simulate the expected neutronic response of the system (Bragg-Sitton, 2005). The current paper applies the same testing methodology to a direct drive gas cooled reactor system, demonstrating the applicability of the testing methodology to any reactor type and demonstrating the variation in system response characteristics in different reactor concepts. In each testing application, core power transients were controlled by a point kinetics model with reactivity feedback based on core average temperature; the neutron generation time and the temperature feedback coefficient are provided as model inputs. Although both system designs utilize a fast spectrum reactor, the method of cooling the reactor differs significantly, leading to a variable system response that can be demonstrated and assessed in a non-nuclear test facility.

Bragg-Sitton, Shannon M.

Cluster Development Test 2: An Assessment of a Failed Test

On 31 July 2008 the National Aeronautics and Space Administration Crew Exploration Vehicle Parachute Assembly System team conducted the final planned cluster test of the first generation parachute recovery system design. The two primary test objectives were to demonstrate the operation of the complete parachute system deployed from a full scale capsule simulator and to demonstrate the test technique of separating the capsule simulator from the Low Velocity Air Drop pallet used to extract the test article from a United States Air Force C-17 aircraft. The capsule simulator was the Parachute Test Vehicle with an accurate heat shield outer mold line and forward bay compartment of the Crew Exploration Vehicle Command Module. The Parachute Test Vehicle separated cleanly from the pallet following extraction, but failed to reach test conditions resulting in the failure of the test and the loss of the test assets. No personnel were injured. This paper will discuss the design of the test and the findings of the team that investigated the test, including a discussion of what were determined to be the root causes of the failure.

Machin, Ricardo A.

Virtual Shaker Testing: Simulation Technology Improves Vibration Test Performance

In the field of vibration testing, the interaction between the structure being tested and the instrumentation hardware used to perform the test is a critical issue. This is particularly true when testing massive structures (e.g. satellites), because due to physical design and manufacturing limits, the dynamics of the testing facility often couples with the test specimen one in the frequency range of interest. A further issue in this field is the standard use of a closed loop real-time vibration control scheme, which could potentially shift poles and change damping of the aforementioned coupled system. Virtual shaker testing is a novel approach to deal with these issues. It means performing a simulation which closely represents the real vibration test on the specific facility by taking into account all parameters which might impact the dynamic behavior of the specimen. In this paper, such a virtual shaker testing approach is developed. It consists of the following components: (1) Either a physical-based or an equation-based coupled electro-mechanical lumped parameter shaker model is created. The model parameters are obtained from manufacturer's specifications or by carrying out some dedicated experiments; (2) Existing real-time vibration control algorithm are ported to the virtual simulation environment; and (3) A structural model of the test object is created and after defining proper interface conditions structural modes are computed by means of the well-established Craig-Bampton CMS technique. At this stage, a virtual shaker test has been run, by coupling the three described models (shaker, control loop, structure) in a co-simulation routine. Numerical results have eventually been correlated with experimental ones in order to assess the robustness of the proposed methodology.

Ricci, Stefano

Acoustic Testing of Flight Hardware Using Loudspeakers: How Much do We Know About This Method of Testing?

Loudspeakers have been used for acoustic qualification of spacecrafts, reflectors, solar panels, and other acoustically responsive structures for more than a decade. Even though a lot of hardware has been acoustic tested using this method, the nature of the acoustic field generated by controlling an ensemble of speakers with and without the hardware in the test volume has not been thoroughly investigated. Limited measurements from some of the recent speaker tests used to qualify flight hardware have indicated significant spatial variation of the acoustic field within the test volume. Also structural responses have been reported to differ when similar tests were performed using reverberant chambers. Unlike the reverberant chamber acoustic test, for which the acoustic field in most chambers is known to be diffuse except below several tens of Hz where acoustic standing waves and large spatial variations exist, the characteristics of the acoustic field within the speaker test volume has not been quantified. It has only been recently that a detailed acoustic field characterization of speaker testing has been made at Jet Propulsion Laboratory (JPL) with involvement of various organizations. To address the impact of non-uniform acoustic field on structures, a series of acoustic tests were performed using a flat panel and a 3-ft cylinder exposed to the field controlled by speakers and repeated in a reverberant chamber. The analysis of the data from this exercise reveals that there are significant differences both in the acoustic field and in the structural responses. In this paper the differences between the two methods are reviewed in some detail and the over- or under-testing of articles that could pose un-anticipated structural and flight qualification issues are discussed. A framework for discussing the validity of the speaker acoustic testing method with the current control system and a path forward for improving it will be provided.

Acoustics

Historical Evolution of NASA Standard Materials Testing with Hypergolic Propellants and Ammonia (NASA Standard 6001 Test 15)

The NASA Johnson Space Center White Sands Test Facility (WSTF) has performed testing of hazardous and reactive aerospace fluids, including hypergolic propellants, with materials since the 1960s with the Apollo program. Amongst other test activities, Test 15 is a NASA standard test for evaluating the reactivity of materials with selected aerospace fluids, in particular hydrazine, monomethylhydrazine, uns-dimethylhydrazine, Aerozine 50, dinitrogen tetroxide oxidizers, and ammonia. This manuscript provides an overview of the history of Test 15 over a timeline ranging from prior to its development and first implementation as a NASA standard test in 1974 to its current refinement. Precursor documents to NASA standard tests, as they are currently known, are reviewed. A related supplementary test, international standardization, and enhancements to Test 15 are also discussed. Because WSTF was instrumental in the development and implementation of Test 15, WSTF experience and practices are referred to in this manuscript.

Greene, Benjamin

Space Suit Portable Life Support System Test Bed (PLSS 1.0) Development and Testing

A multi-year effort has been carried out at NASA-JSC to develop an advanced extra-vehicular activity Portable Life Support System (PLSS) design intended to further the current state of the art by increasing operational flexibility, reducing consumables, and increasing robustness. Previous efforts have focused on modeling and analyzing the advanced PLSS architecture, as well as developing key enabling technologies. Like the current International Space Station Extra-vehicular Mobility Unit PLSS, the advanced PLSS comprises three subsystems required to sustain the crew during extra-vehicular activity including the Thermal, Ventilation, and Oxygen Subsystems. This multi-year effort has culminated in the construction and operation of PLSS 1.0, a test bed that simulates full functionality of the advanced PLSS design. PLSS 1.0 integrates commercial off the shelf hardware with prototype technology development components, including the primary and secondary oxygen regulators, Ventilation Subsystem fan, Rapid Cycle Amine swingbed carbon dioxide and water vapor removal device, and Spacesuit Water Membrane Evaporator heat rejection device. The overall PLSS 1.0 test objective was to demonstrate the capability of the Advanced PLSS to provide key life support functions including suit pressure regulation, carbon dioxide and water vapor removal, thermal control and contingency purge operations. Supplying oxygen was not one of the specific life support functions because the PLSS 1.0 test was not oxygen rated. Nitrogen was used for the working gas. Additional test objectives were to confirm PLSS technology development components performance within an integrated test bed, identify unexpected system level interactions, and map the PLSS 1.0 performance with respect to key variables such as crewmember metabolic rate and suit pressure. Successful PLSS 1.0 testing completed 168 test points over 44 days of testing and produced a large database of test results that characterize system level and component performance. With the exception of several minor anomalies, the PLSS 1.0 test rig performed as expected; furthermore, many system responses trended in accordance with pre-test predictions.

Watts, Carly