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Panel presentation providing an overview of the Energy Systems Integration Facility (ESIF). Provided examples of thermal and power testing of computer components. Showcased the ESIF data center and testing capabilities for computer equipment at scale.
Dispensers are the top cause of maintenance events and down-time at hydrogen fueling stations. In an effort to help characterize and enable improvements in dispenser reliability, an extensive accelerated lifetime testing set-up was designed and built at NREL involving components typically part of dispensing operations at fueling stations. Device Under Test (DUTs) included different components such as normally open valves, normally closed valves, fueling nozzles, breakaways devices and filters. Conditions of testing included pressures, and flow rates similar to light duty fuel cell electric vehicles fueling at -40°C, and -20°C for thousands of cycles in hydrogen. Tested components (failed and non-failed) were disassembled at SNL and polymeric O-rings were carefully retrieved and cataloged for chemical and physical characterization. Data collected was compared to similar O-rings from unexposed or non-tested components for hydrogen effects, and failure modes. Degradation analyses, based on select polymer chemistries common across all component types, their location within components, visual assessment of damage coupled with strong hydrogen effects from chemical characterization, was completed and presented to NREL and DOE. Overall, the failure rate amongst the components was not as high as expected for the test conditions. Among the component types tested, breakaways were the most susceptible to damage under these test conditions, with fueling nozzles a close second. The proper combination of selection of the right polymer and optimum component design was found to make a strong difference in component reliability under severe dispenser operating conditions. Physical degradation of polymers, rather than chemical changes due to low temperature hydrogen exposure, is more prevalent as failure mode for these test conditions. The nature and the extent of the degradation was much less at -20°C as compared to -40°C. The damage and failure rates were higher at lower temperatures than at higher test temperatures. As expected, increasing the number of cycles at the lowest test temperature (-40°C) increased damage. This indicates that cycling at the low temperature of -40°C required by SAE J2601 can reduce component life in fuel dispensing operations
The Federal Emergency Management Agency (FEMA) stages manufactured housing units (MHUs) at key locations to be used during disasters when other housing accommodations cannot be arranged for individuals or families. Due to the unpredictability of natural disasters and the limitations of the manufactured housing industry to produce large numbers of MHUs in very short periods of time, it is necessary for FEMA to store a large number of units for many months or years. With these long storage periods come degradation issues with frames, tires, bearing, and braking systems. These types of issues are also of interest to the U.S. Department of Transportation (DOT) Federal Motor Carrier Safety Administration (FMCSA) because regulated carriers normally transport these units and 49 CFR 393.75 Tires specifies tire loading restrictions for manufactured homes. To compare the running gear (tires, brakes, drums, bearings, axles, springs, and spring mounting hardware) currently specified in the 2014 Rugged Based Performance Requirements (RBPR) and the newly recommended running gear specified in the upcoming revision to the RBPR, the Oak Ridge National Laboratory (ORNL) outlined a Longevity Test Plan, which focused on the assessment of component longevity (failure rates by component type). The Test Plan also studied the forces imparted to the MHU from the running gear from interaction with the roadway for both the running gear in the 2014 RBPR and the running gear specified in the upcoming RBPR revision. Since the assessment of component longevity and failures are also issues of concern for FMCSA, both agencies collaborated to support the research presented in this report. The tests and data collection were conducted at the Navistar Proving Grounds (NPG) in New Carlisle (near South Bend), Indiana, during the May-November 2018 period. Four alternatives for the suspension system of a typical three-bedroom MHU were considered in this test. Alternative 0 was the MHU that was selected from the FEMA staging area in Selma, Alabama. Empirical data had shown that, on average, this alternative experiences one tire failure every 150 miles (or 0.0067 tire failures per mile traveled). Before testing, Alternative 0 was equipped with similar running gear hardware, although in new condition and installed following the manufacturer’s specifications. This became the Baseline Unit, or Alternative 1. Another unit, also selected from the FEMA staging area in Selma, Alabama, was equipped with better axles (i.e., axles that were rated for 7,000lbs as opposed to 6,000lbs for the Baseline Unit) and better tires. This became the Upgrade Unit, or Alternative 2. At the end of the Longevity Test, the Upgrade Unit was mounted with radial tires. This became Alternative 3.Alternative 1 (Baseline Unit) had, on average, one tire failure every 251 miles (or 0.0040 tire failures per mile traveled). So, by simply following the correct manufacturer’s specifications for the assembly of the transportation system, a reduction of 41% in the per mile tire failure was achieved. In the same test, Alternative 2 (Upgrade Unit) showed, on average, one tire failure every 728 miles traveled (or 0.0014 tire failure s per mile traveled). When the Upgrade Unit was mounted with radial tires in the last part of the test, no tire failures were observed for the 2,400 miles tested. That is, in the case of the radial tires (Alternative 3) the tire failure was less than one per 2,400 miles traveled (or less than 0.0004 tire failures per mile traveled). The data collected for the Longevity Test showed that the maximum accelerations were registered in all cases at the center of the MHU in the vertical direction. The overall maximum was registered by the Baseline Unit, Alternative 1. If that value is normalized to 100%, then the Upgrade Unit (Alternative 2) showed, on average, 81% at the same location, and Alternative 3 (radial-tire test) 59%. That is, the upgraded transportation system showed a reduction of 19% and 41% in the vertical accelerations transmitted to MHU at its center when regular and radial tires, respectively, were used. As part of the Test Protocol, NPG conducted a visual inspection of the MHUs and transportation system at the end of each test day. ORNL reviewed all the inspection reports in an attempt to determine if there was any difference in the damage that the Baseline and Upgrade MHUs showed during the test. The Upgrade Unit always showed lower accelerations transmitted to the MHU than the Baseline Unit. In most cases, these differences were statistically significant. The FEMA inspection report, conducted by a FEMA certified inspector at the end of the tests, included a shorter list of damaged items for the Baseline Unit than for the Upgrade Unit, although similar type of damages was described for both units. This may be an indication that, although lower than those of the Baseline Unit, the accelerations transmitted by the Upgrade Unit were above the threshold at which MHU elements start to fail.
A tool to facilitate the generation and publication of test data was created to test the individual components of a command and control system designed to launch spacecraft. Specifically, this tool was built to ensure messages are properly passed between system components. The tool can also be used to test whether the appropriate groups have access (read/write privileges) to the correct messages. The messages passed between system components take the form of unique identifiers with associated values. These identifiers are alphanumeric strings that identify the type of message and the additional parameters that are contained within the message. The values that are passed with the message depend on the identifier. The data generation tool allows for the efficient creation and publication of these messages. A configuration file can be used to set the parameters of the tool and also specify which messages to pass.
Samples of FEP-encapsulated silicon solar cells and various potential encapsulation or cover materials were subjected to both accelerated and real-time testing. The durability of the samples was determined by measuring changes in solar cell output or optical transmission as a function of exposure. The tests revealed some problem areas in the structural integrity of the materials, e.g., delamination and cracking in FEP. These problems were probably related to defects in fabrication. FEP and Aclar had the least transmission loss after accelerated exposure equivalents of 5 and 3 years, respectively.
As part of the recovery project of the National Spherical Tokamak Experiment–Upgrade (NSTX-U), the divertor plasma-facing components (PFCs) were redesigned to handle significantly higher heat fluxes and longer pulse lengths than NSTX. The design process resulted in a castellated, graphite PFC tile. To verify the thermal performance of this design, dedicated electron beam, high heat flux (HHF) testing was carried out on a de-optimized mock-up PFC target. These tests demonstrated that the tile design is itself robust to large, localized thermal gradients. No mechanical damage to the mock-up was observed during HHF testing, though the actual PFC tile mechanical tie-down was not tested. Rather, when the surface temperature exceeded the sublimation temperature of graphite, carbon blooms from the mock-up tile surface were observed. Finally, this resulted in 1 to 2 mm of surface material ablating from the mock-up after repeated, highly localized electron beam exposures.
For the advanced engines in the future, knowledge of the physical parameters of aerospace components is necessary on the test stand and in flight. NASA GRC is leveraging expertise in thin films and high temperature materials to measure hot section gas and surface temperature, heat flux and static and dynamic strain. The current challenges of instrumentation technology are to further develop systems packaging and component testing of specialized sensors, further develop instrumentation techniques on complex surfaces, improve sensor durability, and to address needs for extreme temperature applications. Applications of thin film ceramic sensors as replacement for noble metals are being investigated. Technologies demonstrated in aeronautics and space applications are outlined.
The Highly Accurate Cost Estimating Model (HACEM) is a software system for estimating the costs of testing rocket engines and components at Stennis Space Center. HACEM is built on a foundation of adaptive-network-based fuzzy inference systems (ANFIS) a hybrid software concept that combines the adaptive capabilities of neural networks with the ease of development and additional benefits of fuzzy-logic-based systems. In ANFIS, fuzzy inference systems are trained by use of neural networks. HACEM includes selectable subsystems that utilize various numbers and types of inputs, various numbers of fuzzy membership functions, and various input-preprocessing techniques. The inputs to HACEM are parameters of specific tests or series of tests. These parameters include test type (component or engine test), number and duration of tests, and thrust level(s) (in the case of engine tests). The ANFIS in HACEM are trained by use of sets of these parameters, along with costs of past tests. Thereafter, the user feeds HACEM a simple input text file that contains the parameters of a planned test or series of tests, the user selects the desired HACEM subsystem, and the subsystem processes the parameters into an estimate of cost(s).
An advanced LOX/LH2 expander cycle rocket engine, producing 15,000 lbf thrust for Orbital Transfer Vehicle missions, was tested to determine ignition, transition, and main stage characteristics. Detail design and fabrication of the pump fed RS44 integrated component evaluator (ICE) was accomplished using company discretionary resources and was tested under this contracted effort. Successful demonstrations were completed to about the 50 percent fuel turbopump power level (87,000 RPM), but during this last test, a high pressure fuel turbopump (HPFTP) bearing failed curtailing the test program. No other hardware were affected by the HPFTP premature shutdown. The ICE operations matched well with the predicted start transient simulations. The tests demonstrated the feasibility of a high performance advanced expander cycle engine. All engine components operated nominally, except for the HPFTP, during the engine hot-fire tests. A failure investigation was completed using company discretionary resources.
Nuclear Thermal Propulsion (NTP) systems are actively being developed for future crewed missions to Mars. NTP systems excel in missions where both high thrust and high specific impulse are required, but modern NTP systems currently do not have a Technology Readiness Level (TRL) high enough for use in crewed space exploration. TRLs are used to demonstrate the level of rigor with which a component/system has been tested/demonstrated for its intended use. While space systems technology in general must be qualified as a unit, nuclear technology must be first demonstrated to meet qualification level requirements both at the fuel (component) level and the reactor (subsystem) level. Here, in this paper, historic NTP development programs are surveyed to identify a testing and development strategy that can be effectively implemented to allow for NTP reactor development. Based on this strategy, required facilities to enable such activities are identified. Current domestic experimental capabilities to support NTP qualification are limited to separate effects testing of individual components. Separate effects testing is found extensively in historic NTP development efforts but is not sufficient for full fuel and reactor qualification. Combined effects testing allows for an accurate assessment of fuel performance but is not achievable for NTP conditions in existing facilities. Assessment of historic development programs suggests that an intermediate, subscale test facility is necessary to advance NTP TRLs. A solution to meet this need is proposed, namely the Subscale Maturation of Advanced Reactor Technologies (SMART) facility. SMART will mitigate risk to NTP development by enabling performance and reactor physics demonstrations of NTP subsystems. A SMART facility could be built by modifying existing nuclear test facilities, which may potentially enable schedule and cost savings. To pursue reactor qualification beyond the subscale, a new ground test facility will be necessary. This ground test facility should be developed concurrently with SMART to allow for the facility to be operational in time for expedited NTP engine demonstration.
A continuous 50-hour test was conducted to determine the effect of maximum cruise-power operation at ultra-lean fuel-air mixture and increased spark advance on the mechanical conditions of cylinder components. The test was conducted on a nine-cylinder air-cooled radial engine at the following conditions:brake horsepower, 750; engine speed, 1900 rpm; brake mean effective pressure, 172 pounds per square inch; fuel-air ratio, 0.052; spark advance, 30 deg B.T.C.; and maximum rear-spark-plug-bushing temperature, 400 F. In addition to the data on corrosion and wear, data are presented and briefly discussed on the effect of engine operation at the conditions of this test on economy, knock, preignition, and mixture distribution. Cylinder, piston, and piston-ring wear was small and all cylinder component were in good condition at the conclusion of the 50-hour test except that all exhaust-valve guides were bellmouthed beyond the Army's specified limit and one exhaust-valve face was lightly burned. It is improbable that the light burning in one spot of the valve face would have progressed further because the burn was filled with a hard deposit so that the valve face formed an unbroken seal and the mating seat showed no evidence of burning. The bellmouthing of the exhaust-valve guides is believed to have been a result of the heavy carbon and lead-oxide deposits, which were present on the head end of the guided length of the exhaust-valve stem. Engine operational the conditions of this test was shown to result In a fuel saving of 16.8 percent on a cooled-power basis as compared with operation at the conditions recommended for this engine by the Army Air Forces for the same power.
The International Space Station (ISS has Qualification and Acceptance Environmental Test Requirements document, SSP 41172 that includes many environmental tests such as Thermal vacuum & Cycling, Depress/Repress, Sinusoidal, Random, and Acoustic Vibration, Pyro Shock, Acceleration, Humidity, Pressure, Electromatic Interference (EMI)/Electromagnetic Compatibility (EMCO), etc. This document also includes (13) leak test methods for Pressure Integrity Verification of the ISS Elements, Systems, and Components. These leak test methods are well known, however, the test procedure for specific leak test method shall be written and implemented paying attention to the important procedural steps/details that, if omitted or deviated, could impact the quality of the final product and affect the crew safety. Such procedural steps/details for different methods include, but not limited to: - Sequence of testing, f or example, pressurization and submersion steps for Method I (Immersion); - Stabilization of the mass spectrometer leak detector outputs fo r Method II (vacuum Chamber or Bell jar); - Proper data processing an d taking a conservative approach while making predictions for on-orbit leakage rate for Method III(Pressure Change); - Proper Calibration o f the mass spectrometer leak detector for all the tracer gas (mostly Helium) Methods such as Method V (Detector Probe), Method VI (Hood), Method VII (Tracer Probe), Method VIII(Accumulation); - Usage of visibl ility aides for Method I (Immersion), Method IV (Chemical Indicator), Method XII (Foam/Liquid Application), and Method XIII (Hydrostatic/Visual Inspection); While some methods could be used for the total leaka ge (either internal-to-external or external-to-internal) rate requirement verification (Vacuum Chamber, Pressure Decay, Hood, Accumulation), other methods shall be used only as a pass/fail test for individual joints (e.g., welds, fittings, and plugs) or for troubleshooting purposes (Chemical Indicator, Detector Probe, Tracer Probe, Local Vacuum Chamber, Foam/Liquid Application, and Hydrostatic/Visual Inspection). Any isolation of SSP 41172 requirements have led to either retesting of hardware or accepting a risk associated with the potential system or component pressure integrity problem during flight.
The Long Duration Exposure Facility (LDEF) carried a remarkable variety of electrical, mechanical, thermal, and optical systems, subsystems, and components. Nineteen of the fifty-seven experiments flown on LDEF contained functional systems that were active on-orbit. Almost all of the other experiments possessed at least a few specific components of interest to the Systems Special Investigation Group (Systems SIG), such as adhesives, seals, fasteners, optical components, and thermal blankets. Almost all top level functional testing of the active LDEF and experiment systems has been completed. Failure analysis of both LDEF hardware and individual experiments that failed to perform as designed has also been completed. Testing of system components and experimenter hardware of interest to the Systems SIG is ongoing. All available testing and analysis results were collected and integrated by the Systems SIG. An overview of our findings is provided. An LDEF Optical Experiment Database containing information for all 29 optical related experiments is also discussed.
This report describes the development of a family of passively-actuated surveillance test articles, suitable for use in an in-situ reactor test program monitoring the degradation in structural material properties caused by the reactor environment. The test articles apply creep-fatigue-type cyclic load to a test section driven by changes in the reactor coolant temperature converted to mechanical force by differential thermal expansion. The report describes three types of test articles, all of which apply the load to a 316H test section using Alloy 617 as the driver material. The three types of specimens each serve a unique purpose: (1) initial proof-of-concept, (2) validation of the models used to size the specimens to achieve a given strain range, and (3) demonstration that the articles can be miniaturized for use in an actual operating reactor. In addition to the specimen design, fabrication, and testing, this report describes the outline of two types of in-situ monitoring programs, using the test article. Monitoring programs such as these could be a critical component in gaining regulator acceptance for Molten Salt Reactor (MSR) designs using structural materials for which there is little long-term experimental environmental testing or operating experience available for calibrating the component structural design.
A viewgraph presentation outlines NASA's goals for the Second and Third Generation Reusable Launch Vehicles, placing emphasis on improving safety and decreasing the cost of transporting payloads to orbit. The use of ceramic matrix composite (CMC) technology is discussed. The development of CMC components, such as the Simplex CMC Blisk, cooled CMC nozzle ramps, cooled CMC thrust chambers, and CMC gas generators, are described, including challenges, test results, and likely future developments.
The Test Laboratory at NASA's Marshall Space Flight Center has over 50 facilities across 400+ acres inside a secure, fenced facility. The entire Center is located inside the boundaries of Redstone Arsenal, a 40,000 acre military reservation. About 150 Government and 250 contractor personnel operate facilities capable of all types of propulsion and structural testing, from small components to engine systems and structural strength, structural dynamic and environmental testing. We have tremendous engineering expertise in research, evaluation, analysis, design and development, and test of space transportation systems, subsystems, and components.
The Neutron Imaging team has deployed novel, active detection systems along two lines of sight at NIF. Studies aimed to characterize NIS sensitivity to implosion shape will be carried out to further extend reconstruction capabilities. Additionally, an improved camera timing system that will reduce uncertainties stemming from bang time jitter will also be fielded. The NIF GRH data recording system is more then 10 years old needs to be updated. Bandwidth and noise are a key limiting factor for improving data quality. New high bandwidth and low noise components will be tested at OMEGA in advance before fielding the components at NIF.
Tests, test results, examination and evaluation by Underwriters Laboratory, Inc., of a single family solar heating and hot water system consisting of collector, storage, control, transport, and data acquisition are presented. The structural characteristics of the solar flat plate collectors were evaluated according to snow and wind loads indicated in various building codes to determine their suitability for use both Michigan and Pennsylvania where prototype systems were installed. The flame spread classification of the thermal insulation is discussed and the fire tests conducted on components are described. The operation and dielectrics withstand tests of the energy transport module indicate the module is capable of rated air delivery. Tests of the control panel indicate the relay coil temperatures exceed the temperature limits allowed for the insulating materials involved.