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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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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1971

Bipropellant shut-off valve

An advanced design of an all metal, fast response, bipropellant, shut-off valve for use on long duration space missions is reported. The valve provides the flow control capability for a 1,000 lb thrust, bipropellant engine using oxygen difluoride and diborane as propellants. The shutoff seal selection is a soft-on-hard metal concept. The soft seal is a spherical shell that seats against a hard conical seat. Beryllium copper and beryllium nickel seals were selected to seal against an electrolyzed Inconel 718 seat. Poppet shaft sealing is achieved by use of hydroformed, Inconel 718 bellows. Two valve assemblies were fabricated and subjected to a series of tests including leak, response time, flow capacity, dry cycles, water cycles, liquid nitrogen cycles, liquid fluorine cycles, and lead-lag operation cycles. These tests demonstrated the ability of the valve to meet design goals.

Smith, J. V.↗
NASA NTRS2015

Helium Mass Spectrometer Leak Detection: A Method to Quantify Total Measurement Uncertainty

In applications where leak rates of components or systems are evaluated against a leak rate requirement, the uncertainty of the measured leak rate must be included in the reported result. However, in the helium mass spectrometer leak detection method, the sensitivity, or resolution, of the instrument is often the only component of the total measurement uncertainty noted when reporting results. To address this shortfall, a measurement uncertainty analysis method was developed that includes the leak detector unit's resolution, repeatability, hysteresis, and drift, along with the uncertainty associated with the calibration standard. In a step-wise process, the method identifies the bias and precision components of the calibration standard, the measurement correction factor (K-factor), and the leak detector unit. Together these individual contributions to error are combined and the total measurement uncertainty is determined using the root-sum-square method. It was found that the precision component contributes more to the total uncertainty than the bias component, but the bias component is not insignificant. For helium mass spectrometer leak rate tests where unit sensitivity alone is not enough, a thorough evaluation of the measurement uncertainty such as the one presented herein should be performed and reported along with the leak rate value.

error analysis↗
NASA NTRS2015

A Battery Certification Testbed for Small Satellite Missions

A battery pack consisting of standard cylindrical 18650 lithium-ion cells has been chosen for small satellite missions based on previous flight heritage and compliance with NASA battery safety requirements. However, for batteries that transit through the International Space Station (ISS), additional certification tests are required for individual cells as well as the battery packs. In this manuscript, we discuss the development of generalized testbeds for testing and certifying different types of batteries critical to small satellite missions. Test procedures developed and executed for this certification effort include: a detailed physical inspection before and after experiments; electrical cycling characterization at the cell and pack levels; battery-pack overcharge, over-discharge, external short testing; battery-pack vacuum leak and vibration testing. The overall goals of these certification procedures are to conform to requirements set forth by the agency and identify unique safety hazards. The testbeds, procedures, and experimental results are discussed for batteries chosen for small satellite missions to be launched from the ISS.

Certification↗
NASA NTRS2023

JC-13 Fluorocarbon Tech Discussion

The end goal of this presentation is to make aware JEDEC members of needed modifications /updates in standards that use fluorocarbon electrical fluids to address test sensitivity (discuss potential root cause of False/Passes) and change of content in standards when mentioning trademark names of electrical fluids to be phase out by 3M due to PFAs content.

Gross leak test↗
NASA NTRS1993

Effect of temperature and O-ring gland finish on sealing ability of Viton V747-75

As a part of the redesign project of the Space Shuttle solid rocket motor (SRM) following the Challenger accident, the field joint was redesigned to minimize the relative joint motion caused by internal motor pressurization during ignition. The O-ring seals and glands for the field joint were designed both to accommodate structural deflections and to promote pressure-assisted sealing. Tests were conducted in various face seal fixtures to evaluate the ability of Viton V747-75 O-rings to seal for a range of temperatures and surface finishes of the redesigned O-ring gland. The effect of surface finish on the sealing performance and wear characteristics of the O-rings was evaluated during simulated launch conditions that included low-frequency vibrations, gap openings, and rapid pressurizations. The effect of contamination on the sealing performance was also investigated. The O-rings sealed throughout the 75 deg F leak check test and for the seal tests from 50 deg F to 120 deg F for the range of surface finishes investigated. Although abrasions were found in the O-rings from pressurization against the rougher finishes, these abrasions were not detrimental to sealing. Below 50 deg F, Viton V747-75 O-rings were insufficiently resilient to track the test gap opening.

Lach, Cynthia L.↗
NASA NTRS2008

The Summer of Hydrogen

Ground crew veterans at Kennedy Space Center still talk about what they call "the summer of hydrogen"-the long, frustrating months in 1990 when the shuttle fleet was grounded by an elusive hydrogen leak that foiled our efforts to fill the orbiter's external fuel tank. Columbia (STS-35) was on Launch Pad A for a scheduled May 30 launch when we discovered the hydrogen leak during - tanking. The external fuel tank is loaded through the orbiter. Liquid hydrogen flows through a 17-inch umbilical between the orbiter and the tank. During fueling, we purge the aft fuselage with gaseous nitrogen to reduce the risk of fire, and we have a leak-detection system in the mobile launch platform, which samples (via tygon tubing) the atmosphere in and around the vehicle, drawing it down to a mass spectrometer that analyzes its composition. When we progressed to the stage of tanking where liquid hydrogen flows through the vehicle, the concentration of hydrogen approached four percent-the limit above which it would be dangerously flammable. We had a leak. We did everything we could think of to find it, and the contractor who supplied the flight hardware was there every day, working alongside us. We did tanking tests, which involved instrumenting the suspected leak sources, and cryo-loaded the external tank to try to isolate precisely where the leak originated. We switched out umbilicals; we replaced the seals between the umbilical and the orbiter. We inspected the seals microscopically and found no flaws. We replaced the recirculation pumps, and we found and replaced a damaged teflon seal in a main propulsion system detent cover, which holds the prevalve-the main valve supplying hydrogen to Space Shuttle Main Engine 3 -in the open position. The seal passed leak tests at ambient temperature but leaked when cryogenic temperatures were applied. We added new leak sensors-up to twenty at a time and tried to be methodical in our placements to narrow down the possible sources of the problem. We even switched orbiters, sending Columbia back to the Vehicle Assembly Building and bringing out Atlantis, scheduled to fly as STS-38. Two shuttles on their mobile launchers passing in the night was a majestic sight, but not one you want to see if you're trying to get an orbiter launched. None of this told us where the leak was, or if we were dealing with more than one leak source.

Weber, Philip↗
NASA NTRS2012

Sapphire Viewports for a Venus Probe

A document discusses the creation of a viewport suitable for use on the surface of Venus. These viewports are rated for 500 C and 100 atm pressure with appropriate safety factors and reliability required for incorporation into a Venus Lander. Sapphire windows should easily withstand the chemical, pressure, and temperatures of the Venus surface. Novel fixture designs and seals appropriate to the environment are incorporated, as are materials compatible with exploration vessels. A test cell was fabricated, tested, and leak rate measured. The window features polish specification of the sides and corners, soft metal padding of the sapphire, and a metal C-ring seal. The system safety factor is greater than 2, and standard mechanical design theory was used to size the window, flange, and attachment bolts using available material property data. Maintenance involves simple cleaning of the window aperture surfaces. The only weakness of the system is its moderate rather than low leak rate for vacuum applications.

Bates, Stephen↗
NASA NTRSDate not supplied

Remodeling BioSentinel’s Microbial Metabolism Measurement System

BioSentinel, the first biological CubeSat beyond low Earth orbit, will investigate how Saccharomyces cerevisiae responds to ionizing radiation using optical measurements of a colorimetric metabolic indicator dye (alamarBlue). To map optical data to more detailed metabolic measurements, a microbial culture system for ground testing was designed consisting of a 400 mL beaker and a rubber stopper with pass-through holes for its five sensor probes (electrical conductivity, pH, oxidation-reduction potential, dissolved oxygen, optical density). The initial design had several drawbacks. It was only partially reusable due to its one-time sealants: Teflon tape and parafilm. A steady increase in oxygen levels within the sensor’s testingdata indicated the design was not sufficiently airtight. Degradation of the rubber stopper’s elasticity due to sterilization and reinsertion of the probes led to poor robustness and eventual replacement. The vessel’s large headspace didn’t reproduce flight conditions and a large culture volume required more reagents. The system has been redesigned to contain a rigid, biocompatible polycarbonate disc lid that allows for threaded inserts. The culture vessel’s height will be reduced from 110 mm to 65 mm to decrease overhead space and material costs. A more reliable seal will be achieved with a gasket and clamps. The optical probe records absorbance at four wavelengths to characterize cell density and alamarBlue dye ratios. A pneumatically operated plunger draws media through the hollow interior of the probe. Currently, deformation of the silicone on the plunger causes asymmetrical movement and a drift from its initial state. Designs are being developed to limit the plunger’s travel for a more accurate measurement cycle. The remodeled system is under construction and will be tested for leaks and accuracy. The measurements collected will be used to provide additional insight into the optical data returned from the BioSentinel mission.

Astrobiology↗
NASA NTRS1978

A small gas inlet system for orbital mass-spectrometer calibrations

A gas inlet system is described for generating precise gas pressures that are to be used as calibration references for the mass spectrometers aboard the dual air density Explorer satellites. This gas inlet system was developed as an inflight calibration technique in which a known amount of onboard gas is released in the satellite cavity and is detected by the mass spectrometer. Although several flight mass spectrometer experiments have been proposed, none make use of the inflight calibration technique described in this report. Laboratory measurements and calibration of the metering leak technique for the gas inlet systems are discussed. The systems tested have metering leak rates between 2 and 4 microliters/sec at 298 K for argon-40, and they produce molecular flow up to 100 torr, which is the highest test pressure in this experiment. Test data show that metering leak rates are reproducible within 1 percent of established means for helium-3, helium-4, and argon-40.

Smith, A.↗
NASA NTRS1993

Liquid oxygen (LO2) propellant conditioning concept testing

Testing of a simplified LO2 propellant conditioning concept for future expendable launch vehicles is discussed. Four different concepts are being investigated: no-bleed, low-bleed, use of a recirculation line, and He bubbling. A full-scale test article, which is a facsimile of a propellant feed duct with an attached section to simulate heat input from an LO2 turbopump, is to be tested at the Cold Flow Facility of the Marshall Space Flight Center West Test Area. Work to date includes: design and fabrication of the test article, design of the test facility and initial fabrication, development of a test matrix and test procedures, initial predictions of test output, and heat leak calibration and heat exchanger tests on the test articles.

Perry, Gretchen L. E.↗
NASA NTRS1993

Liquid Oxygen (LO2) propellant conditioning concept testing

Marshall Space Flight Center (MSFC) and industry contractors have undertaken activities to develop a simplified liquid oxygen (LO2) propellant conditioning concept for future expendable launch vehicles. The objective of these activities is to reduce operations costs and timelines and to improve safety of these vehicles. The approach followed has been to identify novel concepts through system level studies and demonstrate the feasibility of these concepts through small-scale and full-scale testing. Testing will also provide data for design guidelines and validation of analytical models. Four different concepts are being investigated: no-bleed, low-bleed, use of a recirculation line, and helium (He) bubbling. This investigation is being done under a Joint Institutional Research and Development (JIRAD) program currently in effect between MSFC and General Dynamics Space Systems (GDSS). A full-scale test article, which is a facsimile of a propellant feed duct with an attached section to simulate heat input from a LO2 turbopump, will be tested at the Cold Flow Facility at MSFC's West Test Area. Liquid nitrogen (LN2), which has similar properties to LO2, will be used in place of LO2 for safety and budget reasons. Work to date includes design and fabrication of the test article, design of the test facility and initial fabrication, development of a test matrix and test procedures, initial predictions of test output, and heat leak calibration and heat exchanger tests on the test article. The tests for all propellant conditioning concepts will be conducted in the summer of 1993, with the final report completed by October, 1993.

Perry, Gretchen L. E.↗
NASA NTRS1978

Pressure and heat-transfer distributions in a simulated wing-elevon cove with variable leakage at a free-stream Mach number of 6.9

A concern that ingestion of hot boundary-layer gas past a small, localized seal failure in the cove between the Space Shuttle wing and elevon might threaten unprotected elevon structures led to wind-tunnel tests to define cove environment as a function of leak area. The tests were conducted in the Langley 8-foot high-temperatures structures tunnel using a full-scale representation of the Space Shuttle wing-elevon juncture on the reentry surface. Pressure and heating rates were obtained for both attached and separated turbulent flows on the wing at the cove entrance. Results indicated that (1) for attached turbulent flow on the wing, cove heating progressively increased in severity independent of leak aspect ratio as leak area increased to 100 percent of cove entrance area and (2), for separated turbulent flow over the wing, cove environment was intolerably severe.

Deveikis, W. D.↗
NASA NTRS1983

Locating Small Leaks in Large Structures

Test tool for detecting minute leads in bimetal joints, welds, or other locations employs fine-control valve and hypodermic needle. Test item is connected in conventional manner to helium mass spectrometer tuned to read extremely small amounts of helium gas. Uniqueness of method is ability to detect tiny leaks, through surfaces, not discoverable by gross coverage of test structures by helium gas.

Lawler, W. F.↗
NASA NTRS1998

Large Scale Testing of a Foam/Multilayer Insulation Thermal Control System (TCS) for Cryogenic Upper Stages

The development of high energy cryogenic upper stages is essential for the efficient delivery of large payloads to various destinations envisioned in future programs. A key element in such upper stages is cryogenic fluid management (CFM) advanced development/technology. Due to the cost of and limited opportunities for orbital experiments, ground testing must be employed to the fullest extent possible. Therefore, a system level test bed termed the Multipurpose Hydrogen Test Bed (MHTB), which is representative in size and shape (3 meter diameter by 3 meter long with a volume of 18 cubic meters) of a fully integrated space transportation vehicle liquid hydrogen propellant tank has been established. To date, upper stage studies have often baselined the foam/multilayer insulation (FMLI) combination concept; however, hardware experience with the concept is minimal and was therefore selected for the MHTB. The foam element (isofoam SS-1 171 with an average thickness of 3.5 centimeters) is designed to protect against ground hold/ascent flight environments, and allows for the use of a dry nitrogen purge as opposed to the more complex/heavy helium purge subsystem normally required with MLI in cryogenic applications. The MLI (45 layers of Double Aluminized Mylar with Dacron spacers) provides protection in the vacuum environment of space and is designed for an on-orbit storage period of 45 days. Several unique features were incorporated in the MLI concept and included: variable density MLI (reduces weight and radiation losses by changing the layer density), larger but fewer DAM perforations for venting during ascent to orbit (reduces radiation losses), and roll wrap installation of the MLI with a commercially established process to lower assembly man-hours and reduce seam heat leak. Thermal performance testing of the MHTB TCS was conducted during three test series conducted between September 1995 and May 1996. Results for the ground hold portion of the tests were as expected producing an average heat leak of 63 WattS/M2 at an average foam surface temperature of 170 K. The results of the simulated orbit hold test interval produced heat leaks ranging from 0.085 to 0.22 Watts/squareM at warm boundary temperatures of 164K and 305K, respectively. When compared to the performance for a traditional MLI system, a 60% reduction in orbital heat leak or boiloff was measured. Overall, the MHTB TCS demonstrated satisfactory performance for all mission phases required of a cryogenic upper stage.

Hastings, Leon↗
NASA NTRS2013

Hermetic Seal Leak Detection Apparatus

The present invention is a hermetic seal leak detection apparatus, which can be used to test for hermetic seal leaks in instruments and containers. A vacuum tight chamber is created around the unit being tested to minimize gas space outside of the hermetic seal. A vacuum inducing device is then used to increase the gas chamber volume inside the device, so that a slight vacuum is pulled on the unit being tested. The pressure in the unit being tested will stabilize. If the stabilized pressure reads close to a known good seal calibration, there is not a leak in the seal. If the stabilized pressure reads closer to a known bad seal calibration value, there is a leak in the seal. The speed of the plunger can be varied and by evaluating the resulting pressure change rates and final values, the leak rate/size can be accurately calculated.

Kelley, Anthony R.↗
NASA NTRS1991

Demonstration of rapid and sensitive module leak certification for Space Station Freedom

A leak detection and quantification demonstration using perflurocarbon tracer (PFT) technology was successfully performed at the NASA Marshall Space Flight Center on January 25, 1991. The real-time Dual Trap Analyzer (DTA) at one-half hour after the start of the first run gave an estimated leak rate of 0.7 mL/min. This has since been refined to be 1.15 (+ or -) 0.09 mL/min. The leak rates in the next three runs were determined to be 9.8 (+ or -) 0.7, -0.4 (+ or -) 0.3, and 76 (+ or -) 6 mL/min, respectively. The theory on leak quantification in the steady-state and time-dependent modes for a single zone test facility was developed and applied to the above determinations. The laboratory PFT analysis system gave a limit-of-detection (LOD) of 0.05 fL for ocPDCH. This is the tracer of choice and is about 100-fold better than that for the DTA. Applied to leak certification, the LOD is about 0.00002 mL/s (0.000075 L/h), a 5 order-of-magnitude improvement over the original leak certification specification. Furthermore, this limit can be attained in a measurement period of 3 to 4 hours instead of days, weeks, or months. A new Leak Certification Facility is also proposed to provide for zonal (three zones) determination of leak rates. The appropriate multizone equations, their solutions, and error analysis have already been derived. A new concept of seal-integrity certification has been demonstrated for a variety of controlled leaks in the range of module leak testing. High structural integrity leaks were shown to have a linear dependence of flow on (Delta)p. The rapid determination of leak rates at different pressures is proposed and is to be determined while subjecting the module to other external force-generating parameters such as vibration, torque, solar intensity, etc.

Dietz, R. N.↗
NASA NTRS1991

Hazardous Gas Leak Analysis in the Space Shuttle

Helium tests of the main propulsion system in the Space Shuttle and on hydrogen leaks are examined. The hazardous gas detection system (HGDS) in the mobile launch pad uses mass spectrometers (MS) to monitor the shuttle environment for leaks. The mass spectrometers are fed by long tubes to sample gas from the payload bay, mid-body, aft engine compartment, and external tank. The purpose is to improve the HGDS, especially in its potential for locating cryogen leaks. Pre-existing leak data was analyzed for transient information to determine if the leak location could be pinpointed from test data. A rapid response leak detection experiment was designed, built, and tested. Large eddies and vortices were visually seen with Schlieren imaging, and they were detected in the time plots of the various instruments. The response time of the MS was found in the range of 0.05 to 0.1 sec. Pulsed concentration waves were clearly detected at 25 cycles per sec by spectral analysis of MS data. One conclusion is that the backup HGDS sampling frequency should be increased above the present rate of 1 sample per second.

Barile, Ronald G.↗