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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

Facility design consideration for continuous mix production of class 1.3 propellant

In November of 1989, NASA awarded the Advanced Solid Rocket Motor (ASRM) contract to Lockheed Missiles and Space Company (LMSC) for production of advanced solid rocket motors using the continuous mix process. Aerojet ASRM division (AAD) was selected as the facility operator and RUST International Corporation provided the engineering, procurement, and construction management services. The continuous mix process mandates that the mix and cast facilities be 'close-coupled' along with the premix facilities, creating unique and challenging requirements for the facility designer. The classical approach to handling energetic materials-division into manageable quantities, segregation, and isolation-was not available due to these process requirements and quantities involved. This paper provides a description of the physical facilities, the continuous mix process, and discusses the monitoring and detection techniques used to mitigate hazards and prevent an incident.

Williamson, K. L.↗

Characteristics of a gelled liquid hyprogen polyphenylene oxide (PPO) foam open-cell insulation system, phase 1

A large scale gel production and storage facility and a small scale facility, the latter used for detailed visual examination of the gel/PPO foam interface, were developed. A subcontract was given to investigate techniques for the production of gelled liquid hydrogen, develop a process design for scale-up to a 1.89 cu m (500 gallon) gel production and storage facility, determine gel transfer characteristics, determine the solubility rate of gaseous helium in the gel, and investigate the gross gel/PPO foam interfacial phenomena. An inside-tank process for scaled-up production of gelled liquid hydrogen was selected. No detectable gel structure degradation occurred during repeated shearing. The viscosity of gelled liquid hydrogen at shear rates of 300/sec and higher is 2 to 5-fold greater than that of neat liquid hydrogen. No clogging problems were encountered during the transfer of gelled liquid hydrogen through warmed transfer lines. The solubility rate of helium in liquid hydrogen was significantly reduced by the presence of gel structure. The boil-off rates from gelled liquid hydrogen were reduced from 25 to 50 percent compared to those observed for the neat liquid hydrogen under compatible conditions. The polyphenylene oxide (PPO) foam insulation was found to be compatible with liquid ethane.

Source record↗

Nonterrestrial utilization of materials: Automated space manufacturing facility

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility.

Source record↗

PERF - A new approach to the experimental study of radiative aerodynamic heating and radiative blockage by ablation products

The present work describes a facility designed to validate the various aspects of radiative flow field theory, including the absorption of shock layer radiation by ablation products. The facility is capable of producing radiation with a spectrum similar to that of an entry vehicle shock layer and is designed to allow measurements at vacuum ultraviolet wavelengths where the most significant absorption by ablation products is predicted to occur. The design concept of the facility is presented along with results of theoretical analyses carried out to assess its research potential. Experimental data obtained during tests that simulated earth and Venusian entry and in which simulated ablation products were injected into the stagnation region flow field are discussed.

Walberg, G.↗

The GreenLab Research Facility: A Micro-Grid Integrating Production, Consumption and Storage of Clean Energy

There is a large gap between the production and demand for energy from alternative fuel and alternative renewable energy sources. The NASA Glenn Research Center (GRC) has initiated a laboratory-pilot study that concentrates on using biofuels as viable alternative fuel resources for the field of aviation, as well as, utilizing wind and solar technologies as alternative renewable energy resources, and in addition, the use of pumped water for storage of energy that can be retrieved through hydroelectric generation. This paper describes the GreenLab Research Facility and its power and energy sources with .recommendations for worldwide expansion and adoption of the concept of such a facility

McDowell Bomani, Bilal Mark↗

Extraterrestrial processing and manufacturing of large space systems, volume 2, chapters 7-14 and appendices

Production and support equipment specifications are described for the space manufacturing facility (SMF). Defined production equipment includes electromagnetic pumps for liquid metal, metal alloying furnaces, die casters, electron beam welders and cutters, glass forming for structural elements, and rolling. A cost analysis is presented which includes the development, the aquisition of all SMF elements, initial operating cost, maintenance and logistics cost, cost of terrestrial materials, and transportation cost for each major element. Computer program listings and outputs are appended.

Miller, R. H.↗

Production and Distribution of Global Products From MODIS

The Moderate Resolution Imaging Spectroradiometer was launched on the EOS Terra spacecraft in December 1999 and will also fly on EOS Aqua in December 2000. With 36 spectral bands from the visible through thermal infrared and spatial resolution of 250m to 1 kilometer, each MODIS instrument will image the entire Earth surface in 2 days. This paper traces the flow of MODIS data products from the receipt of Level 0 data at the EDOS facility, through the production and quality assurance process to the Distributed Active Archive Centers (DAACs), which ship products to the user community. It describes where to obtain products and plans for reprocessing MODIS products. As most components of the ground system are severely limited in their capacity to distribute MODIS products, it also describes the key characteristics of MODIS products and their metadata that allow a user to optimize their selection of products given anticipate bottlenecks in distribution.

Masuoka, Edward↗

Dual Mode Shock-Expansion/Reflected-Shock Tunnel

NASA s HYPULSE facility at GASL has been reconfigured to permit free jet testing of the Hyper-X flowpath at flight Mach numbers of 7 and 10. Among the required changes are addition of a converging-diverging nozzle to permit operation in a reflected shock tunnel mode, a 7 ft. diameter test cabin and a 30 in. diameter contoured nozzle. However, none of these changes were allowed to interfere with rapid recovery of the prior shock-expansion tunnel mode of operation, and indeed certain changes should enhance facility usefulness and productivity in either mode. A previously-developed shock-induced detonation mode of driving the facility has been successfully applied to both reflected shock tunnel operation at Mach 10 flight conditions, with tailored interface operation, and shock-expansion tunnel operation at flight conditions corresponding to Mach numbers from 12 to 25. Tailored interface operation at Mach 7 has been achieved with an unheated helium driver. In the present paper, the rationale for a dual mode shock expansion/reflected shock tunnel is discussed, and the capabilities and limitations for each mode are outlined. The physical changes in the HYPULSE facility to achieve dual mode capability are also described. Limited calibration data obtained to date in the new reflected shock tunnel mode are presented and the anticipated flight simulation map with dual mode operation is also outlined.

Erdos, John I.↗

Recent Cycle Time Reduction at Langley Research Center

The NASA Langley Research Center (LaRC) has been engaged in an effort to reduce wind tunnel test cycle time in support of Agency goals and to satisfy the wind tunnel testing needs of the commercial and military aerospace communities. LaRC has established the Wind Tunnel Enterprise (WTE), with goals of reducing wind tunnel test cycle time by an order of magnitude by 2002, and by two orders of magnitude by 2010. The WTE also plans to meet customer expectations for schedule integrity, as well as data accuracy and quality assurance. The WTE has made progress towards these goals over the last year with a focused effort on technological developments balanced by attention to process improvements. This paper presents a summary of several of the WTE activities over the last year that are related to test cycle time reductions at the Center. Reducing wind tunnel test cycle time, defined here as the time between the freezing of loft lines and delivery of test data, requires that the relationship between high productivity and data quality assurance be considered. The efforts have focused on all of the drivers for test cycle time reduction, including process centered improvements, facility upgrades, technological improvements to enhance facility readiness and productivity, as well as advanced measurement techniques. The application of internet tools and computer modeling of facilities to allow a virtual presence of the customer team is also presented.

Kegelman, Jerome T.↗

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗

Space Station Freedom as an engineering experiment station: An overview

In this presentation, the premise that Space Station Freedom has great utility as an engineering experiment station will be explored. There are several modes in which it can be used for this purpose. The most obvious are space qualification, process development, in space satellite repair, and materials engineering. The range of engineering experiments which can be done at Space Station Freedom run the gamut from small process oriented experiments to full exploratory development models. A sampling of typical engineering experiments are discussed in this session. First and foremost, Space Station Freedom is an elaborate experiment itself, which, if properly instrumented, will provide engineering guidelines for even larger structures which must surely be built if humankind is truly 'outward bound.' Secondly, there is the test, evaluation and space qualification of advanced electric thruster concepts, advanced power technology and protective coatings which must of necessity be tested in the vacuum of space. The current approach to testing these technologies is to do exhaustive laboratory simulation followed by shuttle or unmanned flights. Third, the advanced development models of life support systems intended for future space stations, manned mars missions, and lunar colonies can be tested for operation in a low gravity environment. Fourth, it will be necessary to develop new protective coatings, establish construction techniques, evaluate new materials to be used in the upgrading and repair of Space Station Freedom. Finally, the industrial sector, if it is ever to build facilities for the production of commercial products, must have all the engineering aspects of the process evaluated in space prior to a commitment to such a facility.

Rose, M. Frank↗

Numerical aerodynamic simulation facility. Preliminary study extension

The production of an optimized design of key elements of the candidate facility was the primary objective of this report. This was accomplished by effort in the following tasks: (1) to further develop, optimize and describe the function description of the custom hardware; (2) to delineate trade off areas between performance, reliability, availability, serviceability, and programmability; (3) to develop metrics and models for validation of the candidate systems performance; (4) to conduct a functional simulation of the system design; (5) to perform a reliability analysis of the system design; and (6) to develop the software specifications to include a user level high level programming language, a correspondence between the programming language and instruction set and outline the operation system requirements.

Source record↗

Common Data Acquisition Systems (DAS) Software Development for Rocket Propulsion Test (RPT) Test Facilities

The advent of the commercial space launch industry and NASA's more recent resumption of operation of Stennis Space Center's large test facilities after thirty years of contractor control resulted in a need for a non-proprietary data acquisition systems (DAS) software to support government and commercial testing. The software is designed for modularity and adaptability to minimize the software development effort for current and future data systems. An additional benefit of the software's architecture is its ability to easily migrate to other testing facilities thus providing future commonality across Stennis. Adapting the software to other Rocket Propulsion Test (RPT) Centers such as MSFC, White Sands, and Plumbrook Station would provide additional commonality and help reduce testing costs for NASA. Ultimately, the software provides the government with unlimited rights and guarantees privacy of data to commercial entities. The project engaged all RPT Centers and NASA's Independent Verification & Validation facility to enhance product quality. The design consists of a translation layer which provides the transparency of the software application layers to underlying hardware regardless of test facility location and a flexible and easily accessible database. This presentation addresses system technical design, issues encountered, and the status of Stennis development and deployment.

Hebert, Phillip W., Sr.↗

Common Data Acquisition Systems (DAS) Software Development for Rocket Propulsion Test (RPT) Test Facilities - A General Overview

The advent of the commercial space launch industry and NASA's more recent resumption of operation of Stennis Space Center's large test facilities after thirty years of contractor control resulted in a need for a non-proprietary data acquisition system (DAS) software to support government and commercial testing. The software is designed for modularity and adaptability to minimize the software development effort for current and future data systems. An additional benefit of the software's architecture is its ability to easily migrate to other testing facilities thus providing future commonality across Stennis. Adapting the software to other Rocket Propulsion Test (RPT) Centers such as MSFC, White Sands, and Plumbrook Station would provide additional commonality and help reduce testing costs for NASA. Ultimately, the software provides the government with unlimited rights and guarantees privacy of data to commercial entities. The project engaged all RPT Centers and NASA's Independent Verification & Validation facility to enhance product quality. The design consists of a translation layer which provides the transparency of the software application layers to underlying hardware regardless of test facility location and a flexible and easily accessible database. This presentation addresses system technical design, issues encountered, and the status of Stennis' development and deployment.

Hebert, Phillip W., Sr.↗

Western Aeronautical Test Range

This viewgraph presentation reviews the work of the Western Aeronautical Test Range (WATR). NASA's Western Aeronautical Test Range is a network of facilities used to support aeronautical research, science missions, exploration system concepts, and space operations. The WATR resides at NASA's Dryden Flight Research Center located at Edwards Air Force Base, California. The WATR is a part of NASA's Corporate Management of Aeronautical Facilities and funded by the Strategic Capability Asset Program (SCAP). Maps show the general location of the WATR area that is used for aeronautical testing and evaluation. The products, services and facilities of WATR are discussed,

Sakahara, Robert D.↗

Antimatter Requirements and Energy Costs for Near-Term Propulsion Applications

The superior energy density of antimatter annihilation has often been pointed to as the ultimate source of energy for propulsion. However, the limited capacity and very low efficiency of present-day antiproton production methods suggest that antimatter may be too costly to consider for near-term propulsion applications. We address this issue by assessing the antimatter requirements for six different types of propulsion concepts, including two in which antiprotons are used to drive energy release from combined fission/fusion. These requirements are compared against the capacity of both the current antimatter production infrastructure and the improved capabilities that could exist within the early part of next century. Results show that although it may be impractical to consider systems that rely on antimatter as the sole source of propulsive energy, the requirements for propulsion based on antimatter-assisted fission/fusion do fall within projected near-term production capabilities. In fact, a new facility designed solely for antiproton production but based on existing technology could feasibly support interstellar precursor missions and omniplanetary spaceflight with antimatter costs ranging up to $6.4 million per mission.

Schmidt, G. R.↗