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The 1995 NASA Aerospace Battery Workshop

This document contains the proceedings of the 28th annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on 28-30 Nov. 1995. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-cadmium, nickel-hydrogen, nickel-metal hybride, and lithium based technologies, as well as flight and ground test data. Nickel-hydrogen modeling was also covered.

Brewer, J. C.↗

Development of a Smart Release Algorithm for Mid-Air Separation of Parachute Test Articles

The Crew Exploration Vehicle Parachute Assembly System (CPAS) project is currently developing an autonomous method to separate a capsule-shaped parachute test vehicle from an air-drop platform for use in the test program to develop and validate the parachute system for the Orion spacecraft. The CPAS project seeks to perform air-drop tests of an Orion-like boilerplate capsule. Delivery of the boilerplate capsule to the test condition has proven to be a critical and complicated task. In the current concept, the boilerplate vehicle is extracted from an aircraft on top of a Type V pallet and then separated from the pallet in mid-air. The attitude of the vehicles at separation is critical to avoiding re-contact and successfully deploying the boilerplate into a heatshield-down orientation. Neither the pallet nor the boilerplate has an active control system. However, the attitude of the mated vehicle as a function of time is somewhat predictable. CPAS engineers have designed an avionics system to monitor the attitude of the mated vehicle as it is extracted from the aircraft and command a release when the desired conditions are met. The algorithm includes contingency capabilities designed to release the test vehicle before undesirable orientations occur. The algorithm was verified with simulation and ground testing. The pre-flight development and testing is discussed and limitations of ground testing are noted. The CPAS project performed a series of three drop tests as a proof-of-concept of the release technique. These tests helped to refine the attitude instrumentation and software algorithm to be used on future tests. The drop tests are described in detail and the evolution of the release system with each test is described.

Moore, James W.↗

Hydrofluoroether (HFE) Cleaning Fluid Replacement and Qualification

This NASA Engineering and Safety Center (NESC) Technical Assessment Report addresses the urgent need to identify, test, and qualify replacement cleaning solvents and technologies following 3M’s decision to discontinue production of hydrofluoroether (HFE) products, including Novec HFE-7100, by the end of 2025. HFE-7100 is widely used across NASA for precision cleaning of ground and flight hardware, especially in oxygen system components, and as a heat transfer fluid in high-power-density thermal control systems. The assessment evaluates commercially available replacement solvents, alternative cleaning technologies, and their compatibility with NASA’s operational requirements. Key findings include the identification of viable solvent replacements, their performance in contaminant removal, materials compatibility, and oxygen system safety. The report also explores novel cleaning approaches, including aqueous, supercritical CO₂, cryogenic aerosol, plasma, UV-ozone, magnetically optimized fluids, and induced charge active filtration, highlighting their merits, limitations, and readiness for NASA adoption. The NESC provides recommendations for solvent selection, facility adaptation, and continued technology maturation to ensure mission continuity and regulatory compliance.

Alternative Cleaning Technologies↗

Assessment of the Phase-to-Ground Fault Apparent Admittance Method with Phase/Ground Boundaries to Detect Types of Electrical Faults for Protective Relays Using Signature Library and Simulated Events

Protective relays in electric power grids recognize the types of electrical faults in a few seconds. The most common detection method to detect the types of electrical faults is based on measuring the angle between the zero and negative sequence currents. However, it is not completely accurate because the phase-to-phase-ground and phase-to-ground electrical faults could have the same detection conditions. Therefore, engineers need to plot the events after an electrical fault to observe the nature of the incidents in detail. In this study, the phase-to-ground fault apparent (PGFA) admittance method with phase/ground boundaries identified the types of electrical faults located in distribution power lines and feeders. This method was based on measuring the PGFA admittance magnitudes for the faulted and nonfaulted phases, resulting in greater than zero and near zero, respectively. The PGFA admittance algorithm was built with MATLAB/Simulink software and tested with signature library and grid simulation events. The PGFA method with phase/ground boundaries was evaluated with the confusion matrix. The measured and predicted values matched in more than 90% of the tests, and the PGFA admittance method with phase/ground boundaries presented an accuracy of 94.3% and a precision of 100%.

42 ENGINEERING↗

Application of modified profile analysis to function testing of the motion/no-motion issue in an aircraft ground-handling simulation

A recent modification of the methodology of profile analysis, which allows the testing for differences between two functions as a whole with a single test, rather than point by point with multiple tests is discussed. The modification is applied to the examination of the issue of motion/no motion conditions as shown by the lateral deviation curve as a function of engine cut speed of a piloted 737-100 simulator. The results of this application are presented along with those of more conventional statistical test procedures on the same simulator data.

Parrish, R. V.↗

Failure Investigation of WB-57 Aircraft Engine Cowling

The NASA Johnson Space Center (JSC) in Houston, Texas is the home of the NASA WB-57 High Altitude Research Program. Three fully operational WB-57 aircraft are based near JSC at Ellington Field. The aircraft have been flying research missions since the early 1960's, and continue to be an asset to the scientific community with professional, reliable, customer-oriented service designed to meet all scientific objectives. The NASA WB-57 Program provides unique, high-altitude airborne platforms to US Government agencies, academic institutions, and commercial customers in order to support scientific research and advanced technology development and testing at locations around the world. Mission examples include atmospheric and earth science, ground mapping, cosmic dust collection, rocket launch support, and test bed operations for future airborne or spaceborne systems. During the return from a 6 hour flight, at 30,000 feet, in the clean configuration, traveling at 175 knots indicated airspeed, in un-accelerated flight with the auto pilot engaged, in calm air, the 2-man crew heard a mechanical bang and felt a slight shudder followed by a few seconds of high frequency vibration. The crew did not notice any other abnormalities leading up to, or for the remaining 1 hour of flight and made an uneventful landing. Upon taxi into the chocks, the recovery ground crew noticed the high frequency long wire antenna had become disconnected from the vertical stabilizer and was trailing over the left inboard wing, and that the left engine upper center removable cowling panel was missing, with noticeable damage to the left engine inboard cowling fixed structure. The missing cowling panel was never recovered. Each engine cowling panel is attached to the engine nacelle using six bushings made of 17-4 PH steel. The cylinder portions of four of the six bushings were found still attached to the aircraft (Fig 1). The other two bushings were lost with the panel. The other four bushings exhibited ratchet marks (multiple fatigue origins) which initiated in the sharp radius of the flange/cylinder fillet and were observed 300 degrees around the flange perimeter (Fig 2-3). Low stress, high cycle fatigue (HCF) was observed on the fracture surfaces of all four bushings (Fig 4). To improve the cowling panel joint design and enable return to flight, new cowling bushings with thicker flanges and a larger machined flange/cylinder fillet radius were installed on all cowling panels. In addition, a spacer was added to the joint to achieve the proper stack tolerance. Finally, a time change requirement for all cowling bushings was instituted.

Martinez, J. E.↗

The Green Propellant Infusion Mission Thruster Performance Testing for Plume Diagnostics

The Green Propellant Infusion Mission (GPIM) is sponsored by NASA's Space Technology Mission Directorate (STMD) Technology Demonstration Mission (TDM) office. The goal of GPIM is to advance the technology readiness level of a green propulsion system, specifically, one using the monopropellant, AF-M315E, by demonstrating ground handling, spacecraft processing, and on-orbit operations. One of the risks identified for GPIM is potential contamination of sensitive spacecraft surfaces from the effluents in the plumes of AF-M315E thrusters. NASA Glenn Research Center (GRC) is conducting activities to characterize the effects of AF-M315E plume impingement and deposition. GRC has established individual plume models of the 22-N and 1-N thrusters that will be used on the GPIM spacecraft. The model simulations will be correlated with plume measurement data from Laboratory and Engineering Model 22-N, AF-M315E thrusters. The thrusters are currently being tested in a small rocket, altitude facility at NASA GRC. A suite of diagnostics, including Raman spectroscopy, Rayleigh spectroscopy, and Schlieren imaging are being used to acquire plume measurements of AF-M315E thrusters. Plume data will include temperature, velocity, relative density, and species concentration. The plume measurement data will be compared to the corresponding simulations of the plume model. The GRC effort will establish a data set of AF-M315E plume measurements and a plume model that can be used for future AF-M315E applications.

Green Propellants↗

Ground noise measurements during static and flyby operations of the Cessna 02-T turbine powered airplane

The field noise measurements on the Cessna 02-T turbine powered propeller aircraft are presented. The objective of the study was to obtain the basic noise characteristics of the aircraft during static ground runs and flyover tests, to identify the sources of the noise, and to correlate the noises with the aircraft operating conditions. The results are presented in the form of a overall noise levels, radiation patterns, and frequency spectra. The noise characteristics of the turbine powered aircraft are compared with those of the reciprocating engine powered aircraft.

Hilton, D. A.↗

Airborne laser topographic mapping results from initial joint NASA/US Army Corps of Engineers experiment

Initial results from a series of joint NASA/US Army Corps of Engineers experiments are presented. The NASA Airborne Oceanographic Lidar (AOL) was exercised over various terrain conditions, collecting both profile and scan data from which river basin cross sections are extracted. Comparisons of the laser data with both photogrammetry and ground surveys are made, with 12 to 27 cm agreement observed over open ground. Foliage penetration tests, utilizing the unique time-waveform sampling capability of the AOL, indicate 50 cm agreement with photogrammetry (known to have difficulty in foliage covered terrain).

Krabill, W. B.↗

Takeoff predictions for powered-lift aircraft

Takeoff predictions for powered lift short takeoff (STO) aircraft have been added to NASA Ames Research Center's aircraft synthesis (ACSYNT) code. The new computer code predicts the aircraft engine and nozzle settings required to achieve the minimum takeoff roll. As a test case, it predicted takeoff around rolls and nozzle settings for the YAV-8B Harrier that were close to the actual values. Analysis of takeoff performance for an ejector-augmentor design and a vectoring-nozzle design indicated that ground roll can be decreased, for either configuration, by horizontally moving the rear thrust vector closer to the center of gravity, by increasing the vertical position of the ram drag-vector, or by moving the rear thrust vector farther below the center of gravity.

Wardwell, Douglas A.↗

NACA Investigation of a Jet-Propulsion System Applicable to Flight

Following a brief history of the NACA investigation of jet-propulsion, a discussion is given of the general investigation and analyses leading to the construction of the jet-propulsion ground-test mock-up. The results of burning experiments and of test measurements designed to allow quantitative flight-performance predictions of the system are presented and correlated with calculations. These calculations are then used to determine the performance of the system on the ground and in the air at various speeds and altitudes under various burning conditions. The application of the system to an experimental airplane is described and some performance predictions for this airplane are made. It was found that the main fire could be restricted to an intense, small, and short annular blue flame burning steadily and under control in the intended combustion space. With these readily obtainable combustion conditions, the combustion chamber the nozzle walls and the surrounding structure could be maintained at normal temperatures. The system investigated was found to be capable of burning one-half the intake air up the fuel rates of 3 pounds per second. Calculations were shown to agree well with experiment. It was concluded that the basic features of the jet-propulsion system investigation in the ground-test mock-up were sufficiently developed to be considered applicable to flight installation. Calculations indicated that an airplane utilizing this jet-propulsion system would have unusual capabilities in the high-speed range above the speeds of conventional aircraft and would, in addition, have moderately long cruising ranges if only the engine were used.

DUCTS↗

Flight Test Measurements From The Tu-144LL Structure/Cabin Noise Follow-On Experiment

This follow-on flight experiment on the TU-144LL Supersonic Flying Laboratory, conducted during the period September 1998 to April 1999, was a continuation of previous Structure/Cabin Noise Experiment 2.1. Data was obtained over a wide range of altitudes and Mach numbers. Measured were: turbulent boundary layer pressure fluctuations on the fuselage over its length; structural response on skin panels using accelerometers; and flow direction over three windows using 'flow cones'. The effect of steps in the flow was also measured using two window blank pairs; each pair bridged by a plate which created small sharp forward and aft facing steps. The effect of transducer flushness with the exterior surface was also measured during flight. Height test points were chosen to cover much of the TU-144's flight envelope, as well as to obtain as large a unit Reynolds number range as possible at various Mach numbers: takeoff, subsonic, transonic, and supersonic cruise conditions up to Mach 2. Data on engine runups and background noise were acquired on the ground. The data in the form of time histories of the acoustic signals, together with auxiliary data and basic MATLAB processing modules, are available on CD-R disks.

Rizzi, Stephen A.↗

Education, Technology, and Media: A Peak into My Summer Internship at NASA Glenn Research Center in Cleveland, Ohio

My name is James Moon and I am a senor at Tennessee State University where my major is Aeronautical and Industrial Technology with a concentration in industrial electronics. I am currently serving my internship in the Engineering and Technical Services Directorate at the Glenn Research Center (GRC). The Engineering and Technical Service Directorate provides the services and infrastructure for the Glenn Research Center to take research concepts to reality. They provide a full range of integrated services including engineering, advanced prototyping and testing, facility management, and information technology for NASA, industry, and academia. Engineering and Technical Services contains the core knowledge in Information Technology (IT). This includes data systems and analysis, inter and intranet based systems design and data security. Including the design and development of embedded real-time sohare applications for flight and supporting ground systems, Engineering and Technical Services provide a wide range of IT services and products specific to the Glenn Research Center research and engineering community.

Moon, James↗

The Business Case for Spiral Development in Heavy Lift Launch Vehicle Systems

Performance capabilities of a specific combination of the Space Shuttle external tank and various liquid engines in an in-line configuration, two-stage core vehicle with multiple redesigned solid rocket motor strap-ons are reexamined. This concept proposes using existing assets, hardware, and capabilities that are already crew-rated, flight certified, being manufactured under existing contracts, have a long history of component and system ground testing, and have been flown for over 20 yr. This paper goes beyond describing potential performance capabilities of specific components to discuss the overall system feasibility-from end to end, start to finish-describing the inherent cost advantages of the Spiral Development concept, which builds on existing capabilities and assets, as opposed to starting up a "fresh sheet" heavy-lift launch vehicle program from scratch.

Farr, Rebecca A.↗

The Nuclear Thermal Propulsion Stage (NTPS): A Key Space Asset for Human Exploration and Commercial Missions to the Moon

The nuclear thermal rocket (NTR) has frequently been discussed as a key space asset that can bridge the gap between a sustained human presence on the Moon and the eventual human exploration of Mars. Recently, a human mission to a near Earth asteroid (NEA) has also been included as a "deep space precursor" to an orbital mission of Mars before a landing is attempted. In his "post-Apollo" Integrated Space Program Plan (1970 to 1990), Wernher von Braun, proposed a reusable Nuclear Thermal Propulsion Stage (NTPS) to deliver cargo and crew to the Moon to establish a lunar base initially before sending human missions to Mars. The NTR was selected because it was a proven technology capable of generating both high thrust and high specific impulse (Isp approx. 900 s)-twice that of today's best chemical rockets. During the Rover and NERVA programs, 20 rocket reactors were designed, built and successfully ground tested. These tests demonstrated the (1) thrust levels; (2) high fuel temperatures; (3) sustained operation; (4) accumulated lifetime; and (5) restart capability needed for an affordable in-space transportation system. In NASA's Mars Design Reference Architecture (DRA) 5.0 study, the "Copernicus" crewed NTR Mars transfer vehicle used three 25 klbf "Pewee" engines-the smallest and highest performing engine tested in the Rover program. Smaller lunar transfer vehicles-consisting of a NTPS with three approx. 16.7 klbf "SNRE-class" engines, an in-line propellant tank, plus the payload-can be delivered to LEO using a 70 t to LEO upgraded SLS, and can support reusable cargo delivery and crewed lunar landing missions. The NTPS can play an important role in returning humans to the Moon to stay by providing an affordable in-space transportation system that can allow initial lunar outposts to evolve into settlements capable of supporting commercial activities. Over the next decade collaborative efforts between NASA and private industry could open up new exploration and commercial opportunities for both organizations. With efficient NTP, commercial habitation and crew delivery systems, a "mobile cislunar research station" can transport crews to small NEAs delivered to the E-ML2 point. Also possible are week-long "lunar tourism" missions that can carry passengers into lunar orbit for sightseeing (and plenty of picture taking), then return them to Earth orbit where they would re-enter and land using a small reusable lifting body based on NASA's HL-20 design. Mission descriptions, key vehicle features and operational characteristics are described and presented.

Borowski, Stanley K.↗

Ground test of a large scale 'D' vented thrust deflecting nozzle

Future V/STOL aircraft will require efficient techniques for changing the thrust vector from the vertical direction for VTOL operation to the horizontal direction for conventional flight. Most V/STOL concepts utilize thrust vectoring nozzles to provide this variation in the thrust vector direction. An experimental test program was initiated to demonstrate the capabilities of a large scale 'D' vented thrust deflecting system coupled with a high bypass ratio turbofan engine. Data were obtained for a 'D' vented nozzle mounted behind a YTF-34-F5 turbofan engine. Preliminary data are presented for a variety of test conditions. Attention is given to aspects of 'D' vented nozzle design, the test apparatus, engine-nozzle compatibility, exit area variation, longitudinal vectoring performance, nozzle temperature distribution, and large scale - small scale comparisons.

Rosenberg, E. W.↗

Advanced Solar and Load Forecasting Incorporating HD Sky Imaging (Phase III)

Due to rapidly changing sky conditions, the available solar irradiance for energy generation is subject to wide swings in amplitude. As the market penetration of solar energy continues to increase rapidly, these variations in solar power generation are beginning to have an impact on grid stability and increased wear on power switches. Solar power forecasting plays a critical role in operations for Independent System Operators (ISOs) and utilities. Accurate forecasts help maintain grid reliability, optimize generation from renewables, and reduce operating costs. Of particular interest to the ISOs and utilities are sudden changes in solar irradiance, termed “ramp events,” due to the movement of clouds. One significant impact of ramp events on the grid is additional ancillary service requirements necessary to manage such variability. Ramp events can also cause voltage fluctuations in the distribution grids and trigger actions of automated line equipment (e.g., tap changers), leading to additional maintenance costs. In high penetration solar regions, forecasts must be made for both transmission-connected and distribution-connected resources – either behind the meter or in front of it. Particularly for distributed solar energy resources, forecasting can be a challenge due to the lack of visibility of the energy resource. Brookhaven National Laboratory (BNL) has been working towards nowcasting Global Horizontal Irradiance (GHI) using low-cost technologies for several years now. The Solar NowCasting technology being developed by BNL is a 0 – 30 min solar “nowcasting” technology applicable to a scale covering both large generating facilities and residential, distributed solar installations that relies on a network of ground-based high-definition (HD) cameras and surface pyranometers. GHI forecasts are being produced for both regions using 8 ground-based HD cameras and at least 2 surface pyranometers. When stitched together, the camera images can be used to forecast the impact of clouds on available solar irradiance over a domain of ~50 km 2 . Phase I of the project was the engineering scale up conceptual design stage. Phase II was the initial field test and demonstration, in which the technology was scaled up by a factor of 20 times and successfully demonstrated in eastern Long Island. In Phase III, an additional forecasting network was added in upstate NY and both networks are currently being operated until at least a full year of data is gathered by the Albany network to allow for the collection of sufficient data to evaluate performance against the persistence and smart persistence models using the Solar Arbiter.

14 SOLAR ENERGY↗

Flight effects on fan noise with static and wind tunnel comparisons

A flight test program utilizing a JT15D-1 turbofan engine has been conducted with the objectives of studying flight effects on fan noise and evaluating the simulation effectiveness of both a wind tunnel and a static test configuration that incorporated an inlet control device (ICD). In conjunction with synchronized laser-radar tracking and meteorological profile information, data obtained from a linear array of ground microphones was narrowband-analyzed and ensemble-averaged to yield highly accurate far-field flight acoustic results. Utilizing appropriate corrections, flight, wind tunnel, and static acoustic data were normalized to a static-equivalent, 100-foot radius, lossless reference condition. Data comparisons showed that both the static test with ICD and wind tunnel were generally very effective in simulating flight blade-passage-frequency (BPF) noise levels. However, differences were observed in broadband noise levels and in the details of the multiple-pure-tone harmonics.

Preisser, J. S.↗