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Selection and application of calibration and control instrumentation influenced by the extremes in the temperature environment to be found in cryogenic tunnels are described. The instrumentation and data acquisition system used in the Langley 0.3 m transonic tunnel are described along with typical calibration data obtained in a 20 by 60 cm two dimensional test section.
Benefits of Atomic Layer Deposition (ALD) for UV instruments and application are: (1) Ultrathin, highly conformal, and uniform films over arbitrarily large surface area (2) High quality films (density, roughness, conductivity, etc.) (3) Angstrom level control of stoichiometry, interfaces, and surface properties (3a) Multilayer nanolaminates/nanocomposites (3b) Low temperature surface engineering UV flight applications enabled by ALD. (1) Anti -reflective coatings/Mirrors/Filters/Optics for UV/Vis/NIR Detectors (2) Surface Passivation for III -N detectors
Spacecraft environmental control and life support systems (ECLSS) include a number of air revitalization (AR) technologies to provide breathable air and a comfortable living environment to the crew. Crew health and comfort is ensured by controlling human produced CO2 (1 kg person-1 day-1) and water vapor (~2 kg person-1 day-1), and by removing trace contaminants (TCs) from cabin air. These life support functions on-board the International Space Station (ISS) are carried out by the Carbon Dioxide Removal Assembly (CDRA), the Water Processor Assembly (WPA), and the trace contaminant control system (TCCS). During the development of the TCCS, new analytical and theoretical methods were developed in the 1970s for characterizing adsorption and desorption characteristics of activated carbons for the purpose of designing suitable AR technologies required for controlling airborne trace contaminants within spacecraft cabins during long exploration missions. The TCCS removes harmful volatile organic compounds and other trace contaminants from the circulating air. It consists of a granular activated carbon (GAC) bed for the removal of high molecular weight contaminants and ammonia followed by a heated catalytic bed for low molecular weight hydrocarbons. The high temperature catalytic oxidizer (HTCO) of the TCCS, which operates at 400°C and requires 120W average power, removes low molecular weight compounds such as carbon monoxide (CO), formaldehyde (CH2O), and methane (CH4), that pass through the GAC bed. The Air Revitalization Laboratory at the Kennedy Space Center (KSC) was established to develop new analytical methods for evaluating emerging ECLSS technologies for use in future AR architectures. General properties of adsorbents and catalysts are required for trace contaminant control system design calculations and vendor-supplied data are seldom available at relevant process conditions of interest to spacecraft cabin applications. To address this shortcoming, appropriate testbeds were developed to measure the desired properties of AR technologies being considered for use in ECLS architectures. Generally, the testbeds developed at KSC challenge the test media (activated carbon, impregnated activated carbon, catalysts, zeolites, solid amines, or pleated filters) with simulated spacecraft gas streams containing representative mixtures of trace contaminants (volatile organic compounds, ammonia, CO, CO2, or siloxanes) at the flow rates, temperatures, and relative humidity that will be encountered within manned spacecraft. Work performed at KSC funded by NASA’s Advanced Exploration (AES) Program has included: Identifying candidate sorbents to replace commercially obsolete impregnated carbons for NH3 control within the TCCS, characterizing their adsorptive capacities using simulated spacecraft gas streams, and ranking their appropriateness in various AR applications; evaluating novel low temperature catalysts for controlling CO and formaldehyde by traditional and photocatalytic methods for trace contaminant control; development of analytical methods to assess regenerable solid amine performance for CO2 control via pressure swing adsorption. The Air Revitalization lab was also funded to study trace contaminant control by other NASA programs. These include: screening of candidate sorbents for the design of new Charcoal HEPA Integrated Particle Scrubber (CHIPS) filters for removing siloxanes from cabin air; characterizing the performance of an impregnated activated carbon at low humidity for use in ORION ECLS; screening of sorbents for protecting the Sabatier 2.0 catalyst from DMSO2, siloxanes, NH3, and solid amine byproducts.
Ground vibration tests or modal surveys are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, thermoelastic vibration testing techniques are not well established and are not routinely performed for supporting hypersonic flutter analysis. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. High-temperature materials have the unique property of increasing in stiffness when heated. When these materials are incorporated into a hot-structure, which includes metallic components that decrease in stiffness with increasing temperature, the interaction between the two materials systems needs to be understood because that interaction could ultimately affect the hypersonic flutter analysis. Performing a high-temperature modal survey will expand the research database for hypersonics and will help build upon the understanding of the dual material interaction. This paper will discuss the vibration testing of the Carbon-Silicon Carbide Ruddervator Subcomponent Test Article which is a truncated version of the full-scale X-37 hot-structure control surface. In order to define the modal characteristics of the test article during the elevated-temperature modal survey, two series of room-temperature modal test configurations had to be performed. The room-temperature test series included one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary condition) in NASA Dryden's Flight Loads Lab large nitrogen test chamber.
In aircraft systems with digital controls, fiberoptics has advantages over wire systems because of its inherent immunity to electromagnetic noise (EMI) and electromagnetic pulses (EMP). It also offers a weight benefit when metallic conductors are replaced by optical fibers. To take full advantage of the benefits of optical waveguides, passive optical sensors are also being developed to eliminate the need for electrical power to the sensor. Fiberoptics may also be used for controlling actuators on engine and airframe. In this application, the optical fibers, connectors, etc. will be subjected to high temperature and vibrations. This paper discussed the use of fiberoptics in aircraft propulsion systems together with the optical sensors and optically controlled actuators being developed to take full advantage of the benefits which fiberoptics offers. The requirements for sensors and actuators in advanced propulsion systems are identified. The benefits of using fiberoptics in place of conventional wire systems are discussed as well as the environmental conditions under which the optical components must operate.
In aircraft systems with digital controls, fiberoptics has advantages over wire systems because of its inherent immunity to electromagnetic noise (EMI) and electromagnetic pulses (EMP). It also offers a weight benefit when metallic conductors are replaced by optical fibers. To take full advantage of the benefits of optical waveguides, passive optical sensors are also being developed to eliminate the need for electrical power to the sensor. Fiberoptics may also be used for controlling actuators on engine and airframe. In this application, the optical fibers, connectors, etc. will be subjected to high temperature and vibrations. This paper discussed the use of fiberoptics in aircraft propulsion systems together with the optical sensors and optically controlled actuators being developed to take full advantage of the benefits which fiberoptics offers. The requirements for sensors and actuators in advanced propulsion systems are identified. The benefits of using fiberoptics in place of conventional wire systems are discussed as well as the environmental conditions under which the optical components must operate.
Diverting valves for directing water flow in cooling system for burners in high temperature test tunnel
Fluid state vortex valve secondary injection control system shows considerable promise for future application to solid propellant rocket engine thrust vector control. The single axis injection system tested would be capable of providing secondary injection thrust vector control using 2000 deg F gas.
The microstructure of reaction sintered silicon nitride (RSSN) was changed over a wide range by varying the grain density, grain size of the silicon starting powder, nitriding conditions, and by introducing artificial pores. The influence of single microstructural parameters on mechanical properties like room temperature strength, creep behavior, and resistance to thermal shock was investigated. The essential factors influencing these properties were found to be total porosity, pore size distribution, and the fractions of alpha and beta Si3N4. In view of high temperature engineering applications of RSSN, potentials for optimizing the material's properties by controlled processing are discussed.
Standard and advanced bonded joint concepts were evaluated to develop a data base for the design and analysis of advanced composite joints for use at elevated temperatures (561K (550F)). Design concepts for specific joint applications and the fundamental parameters controlling the static strength characteristics of such joints were identified. Test results are presented for rail shear and sandwich beam compression tests and tension tests of moisture conditioned specimens and bonded on "T" sections. Coefficients of thermal expansion data are presented for A7F (LARC 13 Amide-imide modified) adhesion. Static discriminator test results for type 1 and type 2 bonded and bolted preliminary attachment concepts are presented and discussed.
In recent years, there was a growing need for electronics capable of sustained high-temperature operation for aerospace propulsion system instrumentation, control and condition monitoring, and integrated sensors. The desired operating temperature in some applications exceeds 600 C, which is well beyond the capability of currently available semiconductor devices. Silicon carbide displays a number of properties which make it very attractive as a semiconductor material, one of which is the ability to retain its electronic integrity at temperatures well above 600 C. An IR-100 award was presented to NASA Lewis in 1983 for developing a chemical vapor deposition process to grow single crystals of this material on standard silicon wafers. Silicon carbide devices were demonstrated above 400 C, but much work remains in the areas of crystal growth, characterization, and device fabrication before the full potential of silicon carbide can be realized. The presentation will conclude with current and future high-temperature electronics program plans. Although the development of silicon carbide falls into the category of high-risk research, the future looks promising, and the potential payoffs are tremendous.
In most structural response and stability problems, the structural damping is a significant parameter, and its prediction is often an educated guess because of uncertainties in damping values. Present practice is to assume a conservative lower bound of the damping value, which can result in the 'overdesign' of structures because the experimentally determined damping may be as much as an order of magnitude larger than the value used for the design. This paper presents the concept of adaptive damping, whose objective is to use the damping material's temperature dependence as a control parameter to adjust the damping value. The present application is to limit the response of a structure when subjected to high excitation forces. Preliminary results show a doubling of the damping ratio in a simple beam structure.
The semiconducting properties of electronic grade silicon carbide crystals, such as wide energy bandgap, make it particularly attractive for high temperature applications. Applications for high temperature electronic devices include instrumentation for engines under development, engine control and condition monitoring systems, and power conditioning and control systems for space platforms and satellites. Discrete prototype SiC devices were fabricated and tested at elevated temperatures. Grown p-n junction diodes demonstrated very good rectification characteristics at 870 K. A depletion-mode metal-oxide-semiconductor field-effect transistor was also successfully fabricated and tested at 770 K. While optimization of SiC fabrication processes remain, it is believed that SiC is an enabling high temperature electronic technology.
Panels with integral stiffeners made with woven fabric in two-dimensional, cross-ply layups. Local skin buckling does not cause collapse of panels, and ultimate failure occurs at loads 10 to 20 percent above buckling loads. For panels subjected to in-plane loading, separation of stiffeners from panel skins was not problem. High-temperature structural applications on advanced aircraft and spacecraft include leading edges, fairings, and control surfaces.
DC/DC converters are widely used in power management, conditioning, and control of space power systems. Deep space applications require electronics that withstand cryogenic temperature and meet a stringent radiation tolerance. In this work, the performance of an advanced, radiation-hardened (rad-hard) commercial DC/DC converter module was investigated at cryogenic temperatures. The converter was investigated in terms of its steady state and dynamic operations. The output voltage regulation, efficiency, terminal current ripple characteristics, and output voltage response to load changes were determined in the temperature range of 20 to -140 C. These parameters were obtained at various load levels and at different input voltages. The experimental procedures along with the results obtained on the investigated converter are presented and discussed.
Precision Combustion, Inc. (PCI) and NASA’s Marshall Space Flight Center (MSFC) have been developing, characterizing, and optimizing high temperature catalytic oxidizers (HTCO) based on PCI’s patented Microlith technology to meet the requirements of future extended human spaceflight explorations. Previous efforts focused on integrating PCI’s HTCO unit with a compact, simple recuperative heat exchanger to reduce the overall system size and weight. Significant improvement was demonstrated over traditional approaches of integrating the HTCO with an external recuperative heat exchanger. While the critical target performance metrics were achieved, the thermal effectiveness of PCI’s recuperator remained a potential area of improvement to further reduce the energy requirements of the integrated system. Using the same material combinations and an improved recuperator design, the redesigned prototype has experimentally demonstrated 20 – 30% reduction (flow dependent) in steady state power consumption compared to the earlier prototype without compromising the destruction efficiency of methane and volatile organic compounds (VOCs). Moreover, design modifications and improvements allow our redesigned prototype to be more easily manufactured compared to traditional brazed plate-fin recuperator designs. The redesigned prototype was delivered to MSFC for validation testing. Here, we report and discuss the performance of the improved prototype HTCO unit with a high efficiency recuperative heat exchanger based on testing at PCI and MSFC. The device is expected to provide a reliable and robust means of disposing of trace levels of methane and VOCs by oxidizing them into carbon dioxide and water in order to maintain clean air in enclosed spaces, such as crewed spacecraft cabins.
The present conference on natural and artificial ecosystems and their application to space research encompasses both in-flight and ground-based issues of recycling and control in regenerative life support, the relationships of productivity and facility design in higher plant growth, life-support systems for manned missions to Mars, and biochemical engineering applications in space. Specific issues addressed include interface problems between material recycling systems and plants, temperature and humidity control on a lunar base, the CELSS Test-Facility Project, achieving closure in plant-growth facilities, and life-support systems for Mars transit. Also addressed are a closed equilibrated biological aquatic system, a simulated Mars outpost in the Antarctica dry valleys, analyses of human kidney-cell populations separated on the space shuttle, and the evolution of a phase-separated gravity-independent bioreactor.
Sylramic-iBN fiber is a new type of small-diameter (10-mm) SiC fiber that was developed at the NASA Glenn Research Center and was recently given an R&D 100 Award for 2001. It is produced by subjecting commercially available Sylramic (Dow Corning, Midland, MI) SiC fibers, fabrics, or preforms to a specially designed high-temperature treatment in a controlled nitrogen environment for a specific time. It can be used in a variety of applications, but it currently has the greatest advantage as a reinforcement for SiC/SiC ceramic composites that are targeted for long-term structural applications at temperatures higher than the capability of metallic superalloys. The commercial Sylramic SiC fiber, which is the precursor for the Sylramic-iBN fiber, is produced by Dow Corning, Midland, Michigan. It is derived from polymers at low temperatures and then pyrolyzed and sintered at high temperatures using boron-containing sintering aids (ref. 1). The sintering process results in very strong fibers (>3 GPa) that are dense, oxygen-free, and nearly stoichiometric. They also display an optimum grain size that is beneficial for high tensile strength, good creep resistance, and good thermal conductivity (ref. 2). The NASA-developed treatment allows the excess boron in the bulk to diffuse to the fiber surface where it reacts with nitrogen to form an in situ boron nitride (BN) coating on the fiber surface (thus the product name of Sylramic-iBN fiber). The removal of boron from the fiber bulk allows the retention of high tensile strength while significantly improving creep resistance and electrical conductivity, and probably thermal conductivity since the grains are slightly larger and the grain boundaries cleaner (ref. 2). Also, as shown in the graph, these improvements allow the fiber to display the best rupture strength at high temperatures in air for any available SiC fiber. In addition, for CMC applications under oxidizing conditions, the formation of an in situ BN surface layer creates a more environmentally durable fiber surface not only because a more oxidation-resistant BN is formed, but also because this layer provides a physical barrier between contacting fibers with oxidation-prone SiC surface layers (refs. 3 and 4). This year, Glenn demonstrated that the in situ BN treatment can be applied simply to Sylramic fibers located within continuous multifiber tows, within woven fabric pieces, or even assembled into complex product shapes (preforms). SiC/SiC ceramic composite panels have been fabricated from Sylramic-iBN fabric and then tested at Glenn within the Ultra-Efficient Engine Technology Program. The test conditions were selected to simulate those experienced by hot-section components in advanced gas turbine engines. The results from testing at Glenn demonstrate all the benefits expected for the Sylramic-iBN fibers. That is, the composites displayed the best thermostructural performance in comparison to composites reinforced by Sylramic fibers and by all other currently available high-performance SiC fiber types (refs. 3 and 5). For these reasons, the Ultra-Efficient Engine Technology Program has selected the Sylramic-iBN fiber for ongoing efforts aimed at SiC/SiC engine component development.