Performance Evaluation and Life Testing of the SPT-100
A cyclic endurance test of the Russian 1.35 kW Stationary Plasma Thruster SPT-100 is described.
SPT-100 thrusters propulsion performance life test↗
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Composite Overwrapped Pressure Vessel (COPV) Life Test
Recent attention has been focused on how NASA and its commercial partners have been placing less emphasis on testing and have become more dependent on analytical methods when evaluating design margins for fracture-critical components. Of high concern is the possible misuse of such analytic models for thin-walled metallic liners for composite overwrapped pressure vessels (COPVs). The NASA Engineering and Safety Center (NESC) has initiated an assessment to understand the limitations of linear-elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate behavior of small cracks in thin metal liners for COPVs. It has been observed that fabrication of some thin metallic liners results in a wide variation in microstructure morphology, which results in varying microscale crack growth mechanisms. The ultimate goal is to develop and demonstrate a test-based methodology validating the safe-life requirements for COPVs with thin, elastically responding metal liners where LEFM methods are not appropriate.
Russell, Richard↗
Fatigue, Creep-Fatigue, and Thermomechanical Fatigue Life Testing of Alloys
The fatigue crack initiation resistance of an alloy is determined by conducting a series of tests over a range of values of stress amplitude or strain range. The observed number of cycles to failure is plotted against the stress amplitude or strain range to obtain a fatigue curve. The fatigue properties quoted for an alloy are typically the constants used in the equation(s) that describe the fatigue curve. Fatigue lives of interest may be as low as 10(exp 2) or higher than 10(exp 9) cycles. Because of the enormous scatter associated with fatigue, dozens of tests may be needed to confidently establish a fatigue curve, and the cost may run into several thousands of dollars. To further establish the effects on fatigue life of the test temperature, environment, alloy condition, mean stress effects, creep-fatigue effects, thermomechanical cycling, etc. requires an extraordinarily large and usually very costly test matrix. The total effort required to establish the fatigue resistance of an alloy should not be taken lightly. Fatigue crack initiation tests are conducted on relatively small and presumed to be initially crack-free, samples of an alloy that are intended to be representative of the alloy's metallurgical and physical condition. Generally, samples are smooth and have uniformly polished surfaces within the test section. Some may have intentionally machined notches of well-controlled geometry, but the surface at the root of the notch is usually not polished. The purpose of polishing is to attain a reproducible surface finish. This is to eliminate surface finish as an uncontrolled variable. Representative test specimen geometries will be discussed later. Test specimens are cyclically loaded until macroscopically observable cracks initiate and eventually grow to failure. Normally, the fatigue failure life of a specimen is defined as the number of cycles to separation of the specimen into two pieces. Alternative definitions are becoming more common, particularly for low-cycle fatigue testing, wherein some prescribed indication of impending failure due to cracking is adopted. Specific criteria will be described later. As a rule, cracks that develop during testing are not measured nor are the test parameters intentionally altered owing to the presence of cracking.
Halford, Gary R.↗
Preliminary results of the mission profile life test of a 30 cm Hg bombardment thruster
Long term tests were performed on a 30 cm Hg bombardment thruster and a power processing unit to determine lifetime characteristics. The thruster performance data and other operational characteristics taken at various times during the test segment are presented and evaluated with the life limiting mechanisms: discharge chamber erosion, deposition and spalling, external erosion, cathode degradation, and propellant isolator leakage. The control algorithms for thruster start up, steady state operation, throttle, detection and correction of off normal conditions, and shutdown are discussed.
Bechtel, R. T.↗
Accelerated battery-life testing - A concept
Test program, employing empirical, statistical and physical methods, determines service life and failure probabilities of electrochemical cells and batteries, and is applicable to testing mechanical, electrical, and chemical devices. Data obtained aids long-term performance prediction of battery or cell.
Mccallum, J.↗
Continuing life test of a xenon hollow cathode for a space plasma contactor
Implementation of a hollow cathode plasma contactor for charge control on the Space Station has required validation of long-life hollow cathodes. A test series of hollow cathodes and hollow cathode plasma contactors was initiated as part of the plasma contactor development program. An on-going wear-test of a hollow cathode has demonstrated cathode operation in excess of 10,000 hours with small changes in operating parameters. The discharge has experienced 10 shutdowns during the test, all of which were due to test facility failures or expellant replenishment. In all cases, the cathode was re-ignited at approximately 42 volts and resumed typical operation. This test represents the longest demonstrated stable operation of a high current (greater than 1 A) xenon hollow cathode reported to date.
Sarver-Verhey, Timothy R.↗
Life testing of metal-ceramic CO2 lasers
The main purpose of this program was to determine the life characteristics of nine space-qualified, metal-ceramic CO2 lasers. Lifetimes ranged between about 400 hours to over 2000 hours (the limit of testing) with a high degree of consistency in like groups. In all cases the tubes which had failed could be restored to near their original power by doubling the cathode current for 30 minutes. Periodic rejuvenation allowed operation for the full 2000 hours on all tubes. The failure mechanism appears to involve formation of NiO and C on the nickel cathode emission surface with subsequent absorption of tube gases.
Fahlen, T. S.↗
Methodology for Life Testing of Refractory Metal/Sodium Heat Pipes
The focus of this work was to establish an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. To accomplish this goal acceleration is required to compress 10 years of operational life into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Specific test series have been identi3ed, based on American Society for Testing and Materials (ASTM) specifications, to investigate long term corrosion rates. The refractory metal selected for demonstration purposes is a Molybdenum-44.5%Rhenium alloy formed by powder metallurgy. The heat pipe makes use of an annular crescent wick design formed by hot isostatic pressing of Molybdenum-Rhenium wire mesh. The heat pipes are filled using vacuum distillation and purity sampling is considered. Testing of these units is round-the-clock with 6-month destructive and non-destructive inspection intervals to identify the onset and level of corrosion. Non-contact techniques are employed for providing power to the evaporator (radio frequency induction heating at I to 5 kW per unit) and calorimetry at the condenser (static gas gap coupled water cooled calorimeter). The planned operating temperature range would extend from 1123 to 1323 K. Accomplishments prior to project cancellation included successful demonstration of the heat pipe wick fabrication technique, establishment of all engineering designs, baselined operational test requirements and procurement/assembly of supporting test hardware systems.
Martin, James J.↗
Life testing of secondary silver-zinc cells for the orbiting maneuvering vehicle
Over the past 5 years, extensive testing has been performed at the Marshall Space Flight Center (MSFC) on a variety of secondary (rechargeable) silver-zinc (Ag-Zn) cells for the Orbital Maneuvering Vehicle (OMV). The first tests performed were to determine the feasibility of using such a cell in a long-life (18-month), low-Earth-orbit (LEO) application. Results from these tests were promising, so testing continued with a 250-Ah cell that was specifically designed for this type of application. Once again, results from the tests were promising. Following a review of the data from these previous tests, slight modifications to the 250-Ah design were necessary to alleviate problem areas. Currently, MSFC is testing a 350-Ah design that has incorporated these changes and is the baseline design for the OMV. This test began in mid-November, 1989, and will be complete in the spring of 1991, barring any substantial offline time. A report is presented on the preliminary results from the first few months of this test and they are compared to results obtained in previous tests done at MFSC.
Brewer, Jeffrey C.↗
Refractory Metal Heat Pipe Life Test - Test Plan and Standard Operating Procedures
Refractory metal heat pipes developed during this project shall be subjected to various operating conditions to evaluate life-limiting corrosion factors. To accomplish this objective, various parameters shall be investigated, including the effect of temperature and mass fluence on long-term corrosion rate. The test series will begin with a performance test of one module to evaluate its performance and to establish the temperature and power settings for the remaining modules. The performance test will be followed by round-the-clock testing of 16 heat pipes. All heat pipes shall be nondestructively inspected at 6-month intervals. At longer intervals, specific modules will be destructively evaluated. Both the nondestructive and destructive evaluations shall be coordinated with Los Alamos National Laboratory. During the processing, setup, and testing of the heat pipes, standard operating procedures shall be developed. Initial procedures are listed here and, as hardware is developed, will be updated, incorporating findings and lessons learned.
Martin, J. J.↗
Performance and Life Tests of a Regenerative Blower for EVA Suit Ventilation
Ventilation fans for future space suits must meet demanding performance specifications, satisfy stringent safety requirements for operation in an oxygen atmosphere, and be able to increase output to operate in buddy mode. A regenerative blower is an attractive choice due to its ability to meet these requirements at low operating speed. This paper describes progress in the development and testing of a regenerative blower designed to meet requirements for ventilation subsystems in a future space suit Portable Life Support Systems (PLSS). The blower assembly includes a custom-designed motor that has significantly improved in efficiency during this development effort. The blower was tested at both nominal and buddy mode operating points and head/flow performance and power consumption were measured. The blower was operated for over 1000 hours to demonstrate safe operation in an oxygen test loop at prototypical pressures. In addition, the blower demonstrated operation with the introduction of simulated lunar dust.
Izenson, Mike↗
Evaluation program for secondary spacecraft cells: Seventeenth annual report of cycle life test
Acceptance tests were conducted on nickel cadmium, silver cadmium, and silver zinc cells to insure that all cells put into the life cycle program meet the specifications outlined in the respective purchase contracts. Statistical information is presented on cell performance characteristics and limitations. Weaknesses discovered in cell design are reported and aid in research and development efforts toward improving the reliability of space batteries. Battery weaknesses encountered in satellite programs such as IMP, NIMBUS, OGO, OAO, SAS, and TETR were studied and remedied through special tests.
Harkness, J. D.↗
Cycle life test. Evaluation program for secondary spacecraft cells
Considerable research is being done to find more efficient and reliable means of starting electrical energy for orbiting satellites. Rechargeable cells offer one such means. A test program is described which has been established in order to further the evaluation of certain types of cells and to obtain performance and failure data as an aid to their continued improvement. The purpose of the program is to determine the cycling performance capabilities of packs of cells under different load and temperature conditions. The various kinds of cells tested were nickel-cadmium, silver-cadmium, and silver-zinc sealed cells. A summary of the results of the life cycling program is given in this report.
Harkness, J. D.↗
Life-test methodology for mechanical components
System is based on examining and testing each part of item under evaluation to determine whether aging processes, wear, or other inherent failure modes are likely to limit life to less than that required. Procedure may be applied to many long-life devices where statistical reliability analysis would be impractical.
Dufrane, K. F.↗
Life test of a xenon hollow cathode for a space plasma contractor
A plasma contacting device using a hollow cathode for plasma production has been baselined for use on the Space Station. This application will require reliable, continuous operation of the cathode at electron emission currents of between 0.75 and 10 A for two years (17,500 hours). In order to validate life-time capability, a hollow cathode, operated in a diode configuration, has been tested for more than 8600 hours of stable discharge operation as of March 30, 1994. This cathode is operated at a steady-state emission current of 12.0 and a fixed xenon flow rate of 4.5 sccm. Discharge voltage and cathode temperature have remained relatively stable at approximately 12.9 V and 1260 C during the test. The test has experienced 7 shutdowns to date. In all instances, the cathode was reignited at about 42 V and resumed stable operation. This test represents the longest demonstration of stable operation of high current (greater than 1A) xenon hollow cathodes reported to date.
Sarver-Verhey, Timothy R.↗
Nickel-Hydrogen Battery Cell Life Test Program Update for the International Space Station
NASA and Boeing North America are responsible for constructing the electrical power system for the International Space Station (ISS), which circles the Earth every 90 minutes in a low Earth orbit (LEO). For approximately 55 minutes of this orbit, the ISS is in sunlight, and for the remaining 35 minutes, the ISS is in the Earth s shadow (eclipse). The electrical power system must not only provide power during the sunlight portion by means of the solar arrays, but also store energy for use during the eclipse. Nickel-hydrogen (Ni/H2) battery cells were selected as the energy storage systems for ISS. Each battery Orbital Replacement Unit (ORU) comprises 38 individual series-connected Ni/H2 battery cells, and there are 48 battery ORU s on the ISS. On the basis of a limited Ni/H2 LEO data base on life and performance characteristics, the NASA Glenn Research Center at Lewis Field commenced testing through two test programs: one in-house and one at the Naval Surface Warfare Center in Crane, Indiana.
Miller, Thomas B.↗
Life testing of 10 cm × 10 cm fuel-electrode-supported solid oxide cells in reversible operation
Not provided.
Energy & Fuels↗
Fatigue life testing in gaseous hydrogen: crack initiation
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Leon Cazares, Fernando Daniel↗