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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Lessons for Future In-Space Telerobotic Servicing from Robotic Refueling Mission

The Robotic Refueling Mission (RRM) was a multi-phased technology development effort by the National Aeronautics & Space Administration (NASA) and the Canadian Space Agency (CSA). The program leveraged the existing robotic systems and expertise of the International Space Station (ISS) program and the tool design and satellite servicing expertise of NASA’s Exploration & In-space Services (NExIS) Projects Division at Goddard Space Flight Center (GSFC) to evaluate new hardware and techniques for on-orbit telerobotic servicing. Between 2011 and 2021, two external ISS payloads housed over a dozen robotic tools and adapters designed to service a variety of existing and novel satellite interfaces. Robot operators at NASA’s Johnson Space Center (JSC) and CSA used the Special Purpose Dexterous Manipulator (SPDM) to retrieve and operate these tools for tasks such as cutting wires or multi-layer insulation blanketing, removing valve caps, mating electrical connectors, transferring fluids, and performing visual inspections inside a vehicle. Each phase of RRM involved years of preparation. Tool and interface designs were prototyped and evaluated using both NASA and Canadian ground robotic systems. Procedures were developed by GSFC engineers and vetted in partnership with JSC and CSA robot operators. GSFC engineers were trained to provide real-time support during on-orbit operations. These preparatory efforts and the successful on-orbit evaluations yielded an array of lessons for future in-space telerobotic missions. Designing robotic tools for the space environment requires special consideration of materials, indicators, and differences between ground and flight use cases and environments. When there is a limited window for on-orbit operations, devoting time and high-fidelity hardware to ground testing can be critical. Needs during potential troubleshooting are more essential to camera view quality, frame rate, and position requirements more than nominal operations. Detailed hardware manuals, nominal and contingency procedures, along with clearly defined operations team roles and protocols are vital for efficiency. RRM also demonstrated how the ISS can be utilized to increase the technology readiness levels required for future missions and led to additional technology partnerships between NExIS and the ISS program. The lessons from RRM are currently being applied to designs, operations concepts, and ground test methodology for missions such as On-orbit Servicing, Assembly, and Manufacturing1(OSAM-1)and Mars Sample Return.

Zakiya Tomlinson↗
NASA NTRSDate not supplied

ISS EVA80 EMU Water in the Helmet Failure and Associated Analytical Response

On March 23rd, 2022, during Extra-Vehicular Activity (EVA) 80 aboard the International Space Station (ISS) crew identified an 8-10-inch diameter thin film of water in the pressure bubble of the suit during repress. This launched an investigation to determine the cause of the water in the helmet as well as short- and long-term mitigation efforts to enable return to EVA as quickly as possible. The investigation analysis efforts in combination with hardware inspection and testing determined the most likely cause of the water in the helmet to be sublimator carryover as a result of high latent loading put on the system. In parallel with this investigation, efforts were being made to mitigate any future water in the helmet events. The short-term mitigation strategy developed is to install absorbent material in the pressure bubble to capture water as it enters the helmet before it can impact the astronauts. This hardware is referred to as the Helmet Absorption Band (HAB) and Helmet Absorption Pad – Extender (HAP-E). Longer-term mitigation strategies include a device to capture small water events before entering the helmet by installing a water capture system in the vent loop of the Extravehicular Mobility Unit (EMU). This effort is coined the T2 Water Capture System. Additionally, developing an on-orbit sublimator challenge test which will be able to verify sublimator performance before and after EVAs. The sublimator is the hardware which condenses water vapor and removes it from the vent loop, and this hardware is referred to as the EMU Moisture Injection Test System (EMITS). Based on the investigation and short-term water capture solutions the ISS Program decided to return to nominal EVAs on October 7, 2022. With the addition of the long-term mitigation strategies, the team hopes to be able to prevent any future water in the helmet events.

Veronica Lee Pizor↗
NASA NTRS1998

Study Methods to Standardize Thermography NDE

The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include various graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Keviar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.

Walker, James L.↗
NASA NTRS1998

Study Methods to Standardize Thermography NDE

The purpose of this work is to develop thermographic inspection methods and standards for use in evaluating structural composites and aerospace hardware. Qualification techniques and calibration methods are investigated to standardize the thermographic method for use in the field. Along with the inspections of test standards structural hardware, support hardware is designed and fabricated to aid in the thermographic process. Also, a standard operating procedure is developed for performing inspections with the Bales Thermal Image Processor (TIP). Inspections are performed on a broad range of structural composites. These materials include graphite/epoxies, graphite/cyanide-ester, graphite/silicon-carbide, graphite phenolic and Kevlar/epoxy. Also metal honeycomb (titanium and aluminum faceplates over an aluminum honeycomb core) structures are investigated. Various structural shapes are investigated and the thickness of the structures vary from as few as 3 plies to as many as 80 plies. Special emphasis is placed on characterizing defects in attachment holes and bondlines, in addition to those resulting from impact damage and the inclusion of foreign matter. Image processing through statistical analysis and digital filtering is investigated to enhance the quality and quantify the NDE thermal images when necessary.

Walker, James L.↗
NASA NTRS1997

Experimental Analysis of a Rocket Based Combined Cycle (RBCC) Engine in a Direct-Connect Test Facility

The object of this study is to investigate the operation of a RBCC at ramjet and scramjet flight conditions using a direct-connect test facility. The apparatus being tested is a single strut-rocket within a dual-mode ram/scramjet combustor. The gaseous hydrogen/oxygen, linear strut-rocket was supplied by Aerojet Propulsion Company. The hardware is being tested in the Direct Connect Supersonic Combustion Test Facility at NASA Langley Research Center. The test facilities hydrogen/oxygen vitiated heater is capable of flight total enthalpies to Mach 8. A Mach 2.5 facility nozzle mates the heater to the combustor duct. The rocket ejector will ordinarily operate in a fuel-rich mode. Additional fuel injection is provided by a pair of parallel injectors located at the base of the strut body. Instrumentation on the test apparatus includes a unique, direct thrust measurement system. Performance predictions for the anticipated test conditions have been made using a one-dimensional, thermodynamic analysis code. Results from the code show the dependence of overall thrust and specific impulse on rocket chamber pressure, rocket fuel equivalence ratio, and overall fuel equivalence ratio. Once the experimental test series begins, the inferred combustion efficiency as a function of axial location and the thermal choke region (where applicable) can also be determined using this code. Upon completion of the experimental test series, measurements will be used to calculate thrust, specific impulse, etc. Measured and calculated values will be compared to those found analytically. If appropriate, the code will be tailored to better predict hardware operation. Conclusions will be drawn as to the fuel-rich rocket's overall effect on ramjet and scramjet performance. Also, comparisons will be made between the integrated thrust calculated from the static pressure taps located along the duct and the thrust measured by the direct thrust measurement system.

K. Nelson↗
DOE OSTI2022

Power Electronic Hardware-in-the-Loop (PE-HIL): Testing Individual Controllers in Large-Scale Power Electronics Systems

Large power electronics systems like multi-port autonomous reconfigurable solar power plant (MARS) are increasingly being researched upon to integrate emerging energy sources. MARS connects photovoltaic (PV) systems and energy storage systems (ESSs) to high-voltage direct current (HVdc) links/grids and high-voltage alternating current (ac) transmission grids. As these large power electronics systems incorporate complex hierarchical control systems that are close-by and communicate fast, the control systems require an unique power electronic hardware-in-the-loop (PE-HIL) real-time architecture to evaluate individual controllers. In this paper, a PE-HIL real-time architecture is proposed to evaluate one of the hundreds to thousands of digital signal processors (DSPs) that are a part of the complex hierarchical control system. The DSP connects to a central processing unit (CPU) and a field programmable gate array (FPGA) that form a part of the upper levels of the control system. The DSP is part of the lower level of the control system. The proposed PE-HIL architecture is tested and evaluated. Preliminary test results are presented to showcase the concept.

Debnath, Suman↗
NASA NTRS1982

Space Telescope design status and operations

The Space Telescope design concept is described in the context of the basic mission objectives. The orbiting telescope is designed to have 10 times better resolution, to see 50 times fainter stars and to have a much broader spectral range than the best existing ground observatories. The project is on schedule for launch in early 1985. Hardware assembly and test has started on the optical system, and the primary and secondary mirrors have been polished and coated. The five scientific instruments are beginning hardware assembly. The last major design review for the spacecraft has been completed, and good progress has been accomplished with the implementation of the pointing control system. The mission operations ground system has been defined and is under development. Control center design is complete and the science institute is under construction. The Space Telescope is designed to be serviceable in orbit and will be capable of return to the ground for refurbishment.

Speer, F. A.↗
NASA NTRS1998

Optical Closed-Loop Propulsion Control System Development

The overall objective of this program was to design and fabricate the components required for optical closed-loop control of a F404-400 turbofan engine, by building on the experience of the NASA Fiber Optic Control System Integration (FOCSI) program. Evaluating the performance of fiber optic technology at the component and system levels will result in helping to validate its use on aircraft engines. This report includes descriptions of three test plans. The EOI Acceptance Test is designed to demonstrate satisfactory functionality of the EOI, primarily fail-safe throughput of the F404 sensor signals in the normal mode, and validation, switching, and output of the five analog sensor signals as generated from validated optical sensor inputs, in the optical mode. The EOI System Test is designed to demonstrate acceptable F404 ECU functionality as interfaced with the EOI, making use of a production ECU test stand. The Optical Control Engine Test Request describes planned hardware installation, optical signal calibrations, data system coordination, test procedures, and data signal comparisons for an engine test demonstration of the optical closed-loop control.

Poppel, Gary L.↗
NASA NTRS2003

JSC Metal Finishing Waste Minimization Methods

THe paper discusses the following: Johnson Space Center (JSC) has achieved VPP Star status and is ISO 9001 compliant. The Structural Engineering Division in the Engineering Directorate is responsible for operating the metal finishing facility at JSC. The Engineering Directorate is responsible for $71.4 million of space flight hardware design, fabrication and testing. The JSC Metal Finishing Facility processes flight hardware to support the programs in particular schedule and mission critical flight hardware. The JSC Metal Finishing Facility is operated by Rothe Joint Venture. The Facility provides following processes: anodizing, alodining, passivation, and pickling. JSC Metal Finishing Facility completely rebuilt in 1998. Total cost of $366,000. All new tanks, electrical, plumbing, and ventilation installed. Designed to meet modern safety, environmental, and quality requirements. Designed to minimize contamination and provide the highest quality finishes.

Sullivan, Erica↗
NASA NTRS2007

Test Analysis Guidelines

Development of analysis guidelines for Exploration Life Support (ELS) technology tests was completed. The guidelines were developed based on analysis experiences gained from supporting Environmental Control and Life Support System (ECLSS) technology development in air revitalization systems and water recovery systems. Analyses are vital during all three phases of the ELS technology test: pre-test, during test and post test. Pre-test analyses of a test system help define hardware components, predict system and component performances, required test duration, sampling frequencies of operation parameters, etc. Analyses conducted during tests could verify the consistency of all the measurements and the performance of the test system. Post test analyses are an essential part of the test task. Results of post test analyses are an important factor in judging whether the technology development is a successful one. In addition, development of a rigorous model for a test system is an important objective of any new technology development. Test data analyses, especially post test data analyses, serve to verify the model. Test analyses have supported development of many ECLSS technologies. Some test analysis tasks in ECLSS technology development are listed in the Appendix. To have effective analysis support for ECLSS technology tests, analysis guidelines would be a useful tool. These test guidelines were developed based on experiences gained through previous analysis support of various ECLSS technology tests. A comment on analysis from an experienced NASA ECLSS manager (1) follows: "Bad analysis was one that bent the test to prove that the analysis was right to begin with. Good analysis was one that directed where the testing should go and also bridged the gap between the reality of the test facility and what was expected on orbit."

Jeng, Frank F.↗
NASA NTRSDate not supplied

Calorimeter Heat Flux Trends in NASA’s Subscale Rotating Detonation Rocket Engine

A calorimeter-style rotating detonation rocket engine (RDRE) outer chamber body was designed, additively manufactured in GRCop-42, and hot-fire tested in test cell 105 at NASA Marshall Space Flight Center (MSFC) in Huntsville, AL in August 2024. Steady-state, spatially resolved heat flux and chamber pressure were measured at 13 and 9 locations from the injector face, respectively, for a variety of test conditions and hardware configurations with gaseous methane and oxygen propellants. The 2-in. diameter highly instrumented design, enabled by metal additive manufacturing (AM), allowed for simultaneous measurement of heat flux and chamber pressure through 44 long duration hot-fire tests without failure. Of the 44 tests, only 3 of the tests featured chamber pressures below 100 psia and are discussed in this work. Heat flux trends for this subscale hardware are explored with respect to local propellant mass flux for several different injectors, chamber lengths, and chamber “subsonic” area ratios (contraction ratios). Results show that for increasing chamber pressure, a reduced amount of energy per kilogram of propellant is transferred to the wall. Switching injectors affects the near-face heat flux and chamber pressure profiles. Chamber length does not noticeably affect the heat flux profile but increases bulk heat load. A subsonic area ratio greater than 1 reduces heat losses to the wall compared to a straight annulus case. Equivalence ratio shift did not significantly affect heat flux. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analyses were performed to delineate 3-D heat transfer and coolant mass flow maldistribution effects and create a calorimeter transfer function to transform heat flux data and mitigate the profile distortions. Additional CFD/CHT simulations were performed using experimental data as boundary conditions to assess local nucleate boiling propensity during testing and to assess projected hot wall temperatures for future fatigue assessment. Vapor fractions were observed locally for several cases. It is anticipated that this effort will provide a common framework for coolant system design/analysis in calorimeter systems for rocket-based and air-breathing combustors, ensuring greater repeatability in calorimetry measurements across the research community.

Joseph Hernandez-McCloskey↗
NASA NTRS1962

Saturn: A Giant Thrust into Space

The film provides an introduction and overview of the Saturn launch vehicle. It is designed with stages to drop off as fuel is spent. There may be two, three, or four stages, depending on the payload. The Saturn rocket will be used to send Apollo missions to the Moon and back. Guidance systems and booster engine rockets are based on proven mechanisms. Scale models are used to test the engines. Hardware, airframes, guidance systems, instrumentation, and the rockets are produced at sites throughout the country. The engines go to Marshall Space Flight Center for further tests. After partial assembly, the vehicle is shipped to Cape Canaveral in large pieces where it is assembled using specially built equipment and structures. Further trials are performed to assure successful launches.

Source record↗
NASA NTRS2019

ADEPT Sounding Rocket One Flight Test Overview

On September 12th 2018, a sounding rocket flight test was conducted on a mechanically-deployed atmospheric entry system known as the Adaptable Deployable Entry and Placement Technology (ADEPT). The purpose of the Sounding Rocket One (SR-1) test was to gather critical flight data for evaluating the vehicle's in-space deployment performance and supersonic stability. This flight test was a major milestone in a technology development campaign for Nano-ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range, New Mexico on a SpaceLoft XL rocket manufactured by UP Aerospace. This paper describes the system components, hardware development campaign, test execution, and test conclusions.

Cassell, Alan↗
NASA NTRS2019

ADEPT Sounding Rocket One Flight Test Overview

On September 12th, 2018, a sounding rocket flight test was conducted on a mechanically-deployed atmospheric entry system known as the Adaptable Deployable Entry and Placement Technology (ADEPT). The purpose of the Sounding Rocket One (SR-1) test was to gather critical flight data for evaluating the vehicle's in-space deployment performance and supersonic stability. This flight test was a major milestone in a technology development campaign for Nano-ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range, New Mexico on a SpaceLoft XL rocket manufactured by UP Aerospace. This paper describes the system components, hardware development campaign, test execution, and test conclusions.

Cassell, Alan M.↗
NASA NTRS2016

NASA's Space Launch System Marks Critical Design Review

With completion of its Critical Design Review (CDR) in 2015, NASA is deep into the manufacturing and testing phases of its new Space Launch System (SLS) for beyond-Earth exploration. This CDR was the first in almost 40 years for a NASA human launch vehicle and marked another successful milestone on the road to the launch of a new era of deep space exploration. The review marked the 90-percent design-complete, a final look at the design and development plan of the integrated vehicle before full-scale fabrications begins and the prelude to the next milestone, design certification. Specifically, the review looked at the first of three increasingly capable configurations planned for SLS. This "Block I" design will stand 98.2 meters (m) (322 feet) tall and provide 39.1 million Newtons (8.8 million pounds) of thrust at liftoff to lift a payload of approximately 70 metric tons (154,000 pounds). This payload is more than double that of the retired space shuttle program or other current launch vehicles. It dramatically increases the mass and volume of human and robotic exploration. Additionally, it will decrease overall mission risk, increase safety, and simplify ground and mission operations - all significant considerations for crewed missions and unique, high-value national payloads. The Block 1 SLS will launch NASA's Orion Multi-Purpose Crew Vehicle (MPCV) on an uncrewed flight beyond the moon and back and the first crewed flight around the moon. The current design has a direct evolutionary path to a vehicle with a 130t lift capability that offers even more flexibility to reduce planetary trip times, simplify payload design cycles, and provide new capabilities such as planetary sample returns. Every major element of SLS has hardware in production or testing, including flight hardware for the Exploration 1 (EM-1) test flight. In fact, the SLS MPCV-to-Stage-Adapter (MSA) flew successfully on the Exploration Flight Test (EFT) 1 launch of a Delta IV and Orion spacecraft in December 2014. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Singer, Chris↗
NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗
DOE OSTI2021

Technology Development for Modular, Low-Cost, High-Temperature Recuperators for Supercritical CO 2 Power Cycles (Final Report)

The program’s focus was to evaluate, advance, and demonstrate recuperator design concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low-cost recuperators. Emphasis was placed on recompression closed Brayton cycles having a turbine inlet temperature exceeding 700°C and differential pressures on the order of 200 bar and were scalable to accommodate plant sizes from 10 to 1,000 MWe. The primary objectives of the first budget period, which included conceptual design, preliminary development, and prototype fabrication and testing, were accomplished. A new recuperator design concept, stacked-sheet heat exchanger (SSHX), was realized during the project. The design was taken from paper to hardware and successfully tested. The SSHX prototype recuperator met or exceeded program thermal, hydraulic and performance/cost metrics goals. The first budget period was extended to retire risk in scaling the recuperator from the kWt to MWt thermal capacity scale. The fabrication and design requirements for the budget period one extension were met. Delays associated with the Covid-19 pandemic prevented the fabrication and testing of the industrial scale prototype.

14 SOLAR ENERGY↗