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Holographic detection of unbonded or delaminated surfaces of materials and structures is improved by using helium instead of air in vacuum test chamber. Helium has index of refraction closer to vacuum (unity) than air. Therefore changes in chamber pressure during test do not alter index of refraction as much as they do with air. With air, much of detail is lost, particularly in curved areas.
Surface temperature gradients were measured with miniature thermocouples installed in a 58.5 cm (23-inch) square window. Test measurements at 25 locations were made under vacuum and with the window operating in radiant heat transfer mode. The analysis of thermocouple design and installation is presented along with a lead wire routing scheme to allow for both differential and absolute temperature measurements while using a minimum number of signal feedthru paths through the test chamber wall. Typical test data and operational precautions are presented along with the accuracy analysis for installation effects and measurement effects to support differential temperature measurement precision values of + or - 0.06 C RMS + or - 0.1 F RMS).
Lewis Research Center is presently conducting thermal cycle testing of solar array blanket coupons that represent the baseline design for Space Station Freedom. Four coupons were fabricated as part of the Photovoltaic Array Environment Protection (PAEP) Program, NAS 3-25079, at Lockheed Missile and Space Company. The objective of the testing is to demonstrate the durability or operational lifetime of the solar array welded interconnect design within the durability or operational lifetime of the solar array welded interconnect design within a low earth orbit (LEO) thermal cycling environment. Secondary objectives include the observation and identification of potential failure modes and effects that may occur within the solar array blanket coupons as a result of thermal cycling. The objectives, test articles, test chamber, performance evaluation, test requirements, and test results are presented for the successful completion of 60,000 thermal cycles.
Testing was performed to determine the maximum RSRM igniter adapter-to-igniter chamber joint deflection at the crown of the inner joint primary seal. The deflection data was gathered to support igniter inner joint gasket resiliency predictions which led to launch commit criteria temperature determinations. The proximity (deflection) gage holes for the first test (Test No. 1) were incorrectly located; therefore, the test was declared a non-test. Prior to Test No. 2, test article configuration was modified with the correct proximity gage locations. Deflection data were successfully acquired during Test No. 2. However, the proximity gage deflection measurements were adversely affected by temperature increases. Deflections measured after the temperature rise at the proximity gages were considered unreliable. An analysis was performed to predict the maximum deflections based on the reliable data measured before the detectable temperature rise. Deflections to the primary seal crown location were adjusted to correspond to the time of maximum expected operating pressure (2,159 psi) to account for proximity gage bias, and to account for maximum attach and special bolt relaxation. The maximum joint deflection for the igniter inner joint at the crown of the primary seal, accounting for all significant correction factors, was 0.0031 in. (3.1 mil). Since the predicted (0.003 in.) and tested maximum deflection values were sufficiently close, the launch commit criteria was not changed as a result of this test. Data from this test should be used to determine if the igniter inner joint gasket seals are capable of maintaining sealing capability at a joint displacement of (1.4) x (0.0031 in.) = 0.00434 inches. Additional testing should be performed to increase the database on igniter deflections and address launch commit criteria temperatures.
An investigation was conducted using a 1.2 MW RF induction heater facility to aid in developing the technology necessary for designing a self critical fissioning uranium plasma core reactor. Pure, high temperature uranium hexafluoride (UF6) was injected into an argon fluid mechanically confined, steady state, RF heated plasma while employing different exhaust systems and diagnostic techniques to simulate and investigate some potential characteristics of uranium plasma core nuclear reactors. The development of techniques and equipment for fluid mechanical confinement of RF heated uranium plasmas with a high density of uranium vapor within the plasma, while simultaneously minimizing deposition of uranium and uranium compounds on the test chamber peripheral wall, endwall surfaces, and primary exhaust ducts, is discussed. The material tests and handling techniques suitable for use with high temperature, high pressure, gaseous UF6 are described and the development of complementary diagnostic instrumentation and measurement techniques to characterize the uranium plasma, effluent exhaust gases, and residue deposited on the test chamber and exhaust system components is reported.
Research currently under way on technology for uranium plasma core reactors is reviewed. A feeder system to provide a controlled and steady flow of UF6 at rates up to 5 g/sec and temperatures up to 500 K into rf plasma test chambers operating at pressures of up to 20 atm has been developed. Plasma emission and dye laser absorption measurements have been used to estimate the radial distribution of uranium atom number density within the plasma. X-ray absorption equipment and techniques have also been employed to measure the amount of uranium in the plasma, and dc plasma torch experiments have shown variations in plasma VUV emission with temperature. Analysis of residues deposited on various test-chamber components after plasma tests reveals traces of several uranium oxides, including UO2F2, and various exhaust duct configurations with flow augmentation are under investigation as means of preventing uranium deposition. Other areas of research include off- and on-line exhaust gas diagnostics, and a UF6/Ar injection, separation and recirculation system.
An improved test section for a supersonic or hypersonic wind tunnel is disclosed wherein the model tested is shielded from the noise normally radiated by the turbulent tunnel wall boundary layer. A vacuum plenum surrounds spaced rod elements making up the test chamber to extract some of the boundary layer as formed along the rod elements during a test to thereby delay the tendency of the rod boundary layers to become turbulent. Novel rod construction involves bending each rod slightly prior to machining the bent area to provide a flat segment on each rod for connection with the flat entrance fairing. Rods and fairing are secured to provide a test chamber incline on the order of 1 deg outward from the noise shield centerline to produce up to 65% reduction of the root mean square (rms) pressure over previously employed wind tunnel test sections at equivalent Reynolds numbers.
The sources of variability in the pneumatic impact test commonly used to screen nonmetallic materials for oxygen service and to rank batches or lots of particular materials were investigated together with the mechanism of ignition. Tests were conducted at the NASA/White Sands Test Facility in which the standard test chamber was replaced by an instrumented chamber to obtain information on the rates of pressurization, specimen heating, and time to ignition. Results showed that much of the variability in test data could be traced to the variability in system cleanliness and in the opening time of the high-speed valve. The prinicipal mechanism of ignition in the test is considered to be the heating of the gas initially in the test chamber by adiabatic compression; the presence of voids in the test materials may also be important.
The construction of a turnkey cryogenic vacuum test facility was recently completed. The facility will be used to measure and record the surface profile of large diameter and 540 kg optics under simulated space conditions. The vacuum test chamber is a vertical stainless steel cylinder with a 3.5 diameter and a 7 m tangent length. The chamber was designed to maximize optical testing quality by minimizing the vibrations between the laser interferometer and the test specimen. This was accomplished by designing the chamber for a high natural frequency and vibration isolating the chamber. An optical test specimen is mounted on a movable presentation stage. During thermal vacuum testing, the specimen may be positioned to + or - 0.00025 cm accuracy with a fine adjustment mechanism. The chamber is evacuated by a close coupled Roots-type blower and rotary vane pump package and two cryopumps. The chamber is equipped with an optically dense gaseous nitrogen cooled thermal shroud. The thermal shroud is used to cool or warm the optical test specimen at a controlled rate. A control system is provided to automatically evacuate the chamber and cooldown the test specimen to the selected control temperature.
A test facility modification to enable small scale altitude propulsion testing at the NASA Glenn Research Center's In-Space Propulsion (ISP) Facility was verified with a hot fire test campaign. As the facility's primary steam supply system undergoes refurbishment, the alternate facility configuration, known as the "vacuum accumulator" mode, would enable rocket engine testing up to 10,000 lbf thrust. The NASA Johnson Space Center developed the vehicle for the verification test campaign: the Integrated Cryogenic Propulsion Test Article (ICPTA). Constructed primarily from assets of the former Morpheus Project, the ICPTA provided an integrated liquid oxygen (LOX) / liquid methane (LCH4) propulsion system including a 2,800 lbf thrust main engine. The ISP Facility's vacuum accumulator configuration leveraged the large test volume of the facility and a diffuser insert to maintain altitude conditions. During hot fire, the ICPTA main engine "started" the diffuser insert constructed for the test campaign. As a result, the test chamber upstream of the diffuser insert remained at altitude conditions throughout the hot fire. Upon engine shut down, a backflow deflector mitigated blow back into the test chamber by restricting the mass flow and redirecting it away from the test article. The test campaign successfully characterized the performance of the vacuum accumulator configuration. In addition, it provided an opportunity to collect data for an integrated LOX / LCH4 propulsion system in an altitude and thermal vacuum environment.
An environmental test chamber providing acceleration of UV radiation and precise temperature control (+ or -)1 C was designed, constructed and tested. This chamber allows acceleration of solar ultraviolet up to 30 suns while maintaining temperature of the absorbing surface at 30 C - 60 C. This test chamber utilizes a filtered medium pressure mercury arc as the source of radiation, and a combination of selenium radiometer and silicon radiometer to monitor solar ultraviolet (295-340 nm) and total radiant power output, respectively. Details of design and construction and operational procedures are presented along with typical test data.
A low frost-point humidity generator has been developed at NBS to provide a capability for calibration, testing, and research at very low levels of water vapor content in such gases as atmospheric air, carbon dioxide and nitrogen. The generator produces frost points from -30 to -100 C at ambient pressures from 500 to 200,000 pascals (0.005 to 2 atm.). This is equivalent to mixing ratios of 4 micrograms to 51 grams of water vapor per kilogram of dry air and to vapor pressures of .0014 to 38 pascals. The generated test gas can be fed to a test chamber with independent temperature control between +25 and -100 C. The uncertainty of the frost point in the test chamber is estimated not to exceed 0.05 deg C.
Apparatus holds polymer specimen at constant temperature while exposing it to oxygen plasma. Copper tube (part of cooling coil) extends into plasma chamber, supporting copper block and thermoelectric module on which specimen mounted. Copper block made small - 4.4 by 3.8 by 1.6 cm - having little effect on plasma. Used to evaluate resistances of polymer materials to plasma environments, and for analysis of gases produced by attack of plasma on polymer specimen.
Rugged optical head enables remote, nonintrusive measurements of temperatures and chemical compositions in hostile environments. Head brings laser light to system under test and carries system-scattered light to spectrograph or other instrument. Optical head beams light from laser source to test chamber, then collects backscattered light from chamber and sends it to spectrographic equipment. Lenses, prisms, and optical-fiber tips moved so that focal point precisely positioned in test chamber.
Experiments have been performed with the objective of developing a greater understanding of the physics of hot supersonic jet noise. Cold helium/air jets are used to easily and inexpensively simulate the low densities of hot air jets. The experiments are conducted at low Reynolds numbers in order to facilitate study of the large-scale turbulent structures (instability waves) that cause most of the radiated noise. Experiments have been performed on Mach 1.5 and 2.1 jets of pure air, pure helium and 10 percent helium by mass. Helium/air jets are shown to radiate more noise than pure air jets due to the increased exit velocity. Microphone spectra are usually dominated by a single spectral component at a predictable frequency. Increasing the jet's helium concentration is shown to increase the dominant frequency. The helium concentration in the test chamber is determined by calculating the speed of sound from the measured phase difference between two microphone signals. Bleeding outside air into the test chamber controls the accumulation of helium so that the hot jet simulation remains valid. The measured variation in the peak radiated noise frequency is in good agreement with the predictions of the hot jet noise theory of Tam et al.
The nozzle diffuser has an inlet in fluid communication with the narrowed inlet of an open test chamber in a conventional wind tunnel. The nozzle diffuser has a passageway extending from its inlet to an outlet in communication with the open test section. The passageway has an internal cross sectional area which increases from its inlet to its outlet and which may be defined by top and bottom isosceles trapezoid walls of a particular flare angle and by isosceles trapezoid side walls of a different flare angle. In addition, a collector having a decreasing internal cross sectional area from inlet to outlet may be provided at the opposite end of the test chamber such that its outlet is in communication with a diffuser located at this outlet.
A fail safe light activated switch was used as an emergency control link at the Langley Vortex Research Facility. In this facility aircraft models were towed through a still air test chamber by a gasoline powered vehicle which was launched from one end of a 427-meter track and attained velocities to 31 m/sec in the test chamber. A 5 mW HeNe laser with a mechanical copper provided a connecting link with the moving tow vehicle on which a silicon photodiode receiver with a specially designed amplifier provided a fail safe switching action. This system provided an emergency means of stopping the vehicle by turning off the laser to interrupt the power to the vehicle ignition and brake release systems.
SLMS (TM) a thermal technology has been demonstrated in the small 4-foot helium cryogenic test chamber located at the NASA/MSFC X-Ray Calibration Facility (XRCF). A SLMS (TM) Ultraviolet Demonstrator Mirror (UVDM) produced by Schafer under a NASA/MSFC Phase I SBIR was helium cryo tested both free standing and bonded to a Schafer designed prototype carbon fiber reinforced silicon carbide (Cesic) mount. Surface figure data was obtained with a test measurement system that featured an Instantaneous Phase Interferometer (IPI) by ADE Phase Shift. The test measurement system s minimum resolvable differential figure deformation and possible contributions from test chamber ambient to cryo window deformation are under investigation. The free standing results showed differential figure deformation of 10.4 nm rms from 295K to 27K and 3.9 nm rms after one cryo cycle. The surface figure of the UVDM degraded by lambda/70 rms HeNe once it was bonded to the prototype Cesic mount. The change was due to a small astigmatic aberration in the rototype Cesic mount due to lack of finish machining and not the bonding technique. This effect was seen in SLMST (TM) optical assembly results, which showed differential figure deformation of 46.5 nm rms from 294K to 27K, 42.9 nm rms from 294K to 77K, 28.0 nm rms from 294K to 193K and 6.2 nm rms after one cryo cycle.