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NASA NTRS2010

Testing and Results of Vacuum Swing Adsorption Units for Spacesuit Carbon Dioxide and Humidity Control

A principal concern for extravehicular activity (EVA) space suits is the capability to control carbon dioxide (CO2) and humidity (H2O) for the crewmember. The release of CO2 in a confined or unventilated area is dangerous for human health and leads to asphyxiation; therefore, CO2 and H2O become leading factors in the design and development of the spacesuit. An amine-based CO2 and H2O vapor sorbent for use in pressure-swing re-generable beds has been developed by Hamilton Sundstrand. The application of solid-amine materials with vacuum swing adsorption technology has shown the capacity to concurrently manage CO2 and H2O levels through a fully regenerative cycle eliminating mission constraints imposed with non-regenerative technologies. Two prototype solid amine-based systems, known as rapid cycle amine (RCA), were designed to continuously remove CO2 and H2O vapor from a flowing ventilation stream through the use of a two-bed amine based, vacuum-swing adsorption system. The Engineering and Science Contract Group (ESCG) RCA is the first RCA unit implementing radial flow paths, whereas the Hamilton Sundstrand RCA was designed with linear flow paths. Testing was performed in a sea-level pressure environment and a reduced-pressure environment with simulated human metabolic loads in a closed-loop configuration. This paper presents the experimental results of laboratory testing for a full-size and a sub-scale test article. The testing described here characterized and evaluated the performance of each RCA unit at the required Portable Life Support Subsystem (PLSS) operating conditions. The test points simulated a range of crewmember metabolic rates. The experimental results demonstrate the ability of each RCA unit to sufficiently remove CO2 and H2O from a closed loop ambient or subambient atmosphere.

McMillin, Summer↗

NASA NTRS2011

An Assessment of Ares I-X Aeroacoustic Measurements with Comparisons to Pre-Flight Wind Tunnel Test Results

During the recent successful launch of the Ares I-X Flight Test Vehicle, aeroacoustic data was gathered at fifty-seven locations along the vehicle as part of the Developmental Flight Instrumentation. Several of the Ares I-X aeroacoustic measurements were placed to duplicate measurement locations prescribed in pre-flight, sub-scale wind tunnel tests. For these duplicated measurement locations, comparisons have been made between aeroacoustic data gathered during the ascent phase of the Ares I-X flight test and wind tunnel test data. These comparisons have been made at closely matching flight conditions (Mach number and vehicle attitude) in order to preserve a one-to-one relationship between the flight and wind tunnel data. These comparisons and the current wind tunnel to flight scaling methodology are presented and discussed. The implications of using wind tunnel test data scaled under the current methodology to predict conceptual launch vehicle aeroacoustic environments are also discussed.

Nance, Donald K.↗

NASA NTRS2011

Testing and Results of Vacuum Swing Adsorption Units for Spacesuit Carbon Dioxide and Humidity Control

A principal concern for extravehicular activity (EVA) spacesuits is the capability to control carbon dioxide (CO2) and humidity (H2O) for the crewmember. The release of CO2 in a confined or unventilated area is dangerous for human health and leads to asphyxiation; therefore, CO2 and H2O control become leading factors in the design and development of the spacesuit. An amine-based CO2 and H2O vapor sorbent for use in pressure-swing regenerable beds has been developed by Hamilton Sundstrand. The application of solidamine materials with vacuum swing adsorption technology has shown the capacity to concurrently manage CO2 and H2O levels through a fully regenerative cycle eliminating mission constraints imposed with nonregenerative technologies. Two prototype solid amine-based systems, known as rapid cycle amine (RCA), were designed to continuously remove CO2 and H2O vapor from a flowing ventilation stream through the use of a two-bed amine based, vacuum-swing adsorption system. The Engineering and Science Contract Group (ESCG) RCA implements radial flow paths, whereas the Hamilton Sundstrand RCA was designed with linear flow paths. Testing was performed in a sea-level pressure environment and a reduced-pressure environment with simulated human metabolic loads in a closed-loop configuration. This paper presents the experimental results of laboratory testing for a full-size and a sub-scale test article. The testing described here characterized and evaluated the performance of each RCA unit at the required Portable Life Support Subsystem (PLSS) operating conditions. The test points simulated a range of crewmember metabolic rates. The experimental results demonstrated the ability of each RCA unit to sufficiently remove CO2 and H2O from a closed loop ambient or sub-ambient atmosphere.

McMillin, Summer D.↗

NASA NTRS2011

Overview of Orion Crew Module and Launch Abort Vehicle Dynamic Stability

With the retirement of the Space Shuttle, NASA is designing a new spacecraft, called Orion, to fly astronauts to low earth orbit and beyond. Characterization of the dynamic stability of the Orion spacecraft is important for the design of the spacecraft and trajectory construction. Dynamic stability affects the stability and control of the Orion Crew Module during re-entry, especially below Mach = 2.0 and including flight under the drogues. The Launch Abort Vehicle is affected by dynamic stability as well, especially during the re-orientation and heatshield forward segments of the flight. The dynamic stability was assessed using the forced oscillation technique, free-to-oscillate, ballistic range, and sub-scale free-flight tests. All of the test techniques demonstrated that in heatshield-forward flight the Crew Module and Launch Abort Vehicle are dynamically unstable in a significant portion of their flight trajectory. This paper will provide a brief overview of the Orion dynamic aero program and a high-level summary of the dynamic stability characteristics of the Orion spacecraft.

D. Bruce Owens↗

NASA NTRS2011

Time-Frequency Analysis of Rocket Nozzle Wall Pressures During Start-up Transients

Surveys of the fluctuating wall pressure were conducted on a sub-scale, thrust- optimized parabolic nozzle in order to develop a physical intuition for its Fourier-azimuthal mode behavior during fixed and transient start-up conditions. These unsteady signatures are driven by shock wave turbulent boundary layer interactions which depend on the nozzle pressure ratio and nozzle geometry. The focus however, is on the degree of similarity between the spectral footprints of these modes obtained from transient start-ups as opposed to a sequence of fixed nozzle pressure ratio conditions. For the latter, statistically converged spectra are computed using conventional Fourier analyses techniques, whereas the former are investigated by way of time-frequency analysis. The findings suggest that at low nozzle pressure ratios -- where the flow resides in a Free Shock Separation state -- strong spectral similarities occur between fixed and transient conditions. Conversely, at higher nozzle pressure ratios -- where the flow resides in Restricted Shock Separation -- stark differences are observed between the fixed and transient conditions and depends greatly on the ramping rate of the transient period. And so, it appears that an understanding of the dynamics during transient start-up conditions cannot be furnished by a way of fixed flow analysis.

Baars, Woutijn J.↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗

NASA NTRS2012

NASA High-Speed 2D Photogrammetric Measurement System

The object of this report is to provide users of the NASA high-speed 2D photogrammetric measurement system with procedures required to obtain drop-model trajectory and impact data for full-scale and sub-scale models. This guide focuses on use of the system for vertical drop testing at the NASA Langley Landing and Impact Research (LandIR) Facility.

Dismond, Harriett R.↗

NASA NTRS2011

CFD Study of the Hydrocarbon Boost Low-Pressure Inducer and Kicker in the Presence of a Circumferential Groove

Results are presented of a computational fluid dynamics (CFD) study done in support of Marshall Space Flight Center's (MSFC) sub-scale water flow experiments of the Hydrocarbon Boost (HCB) Oxidizer Turbopump (OTP) being developed by the Air Force Research Laboratory (AFRL) and Aerojet. A circumferential groove may be added to the pump to reduce synchronous cavitation and subsequent bearing loads at a minimal performance cost. However, the energy may reappear as high order cavitation (HOC) that spans a relatively large frequency range. Thus, HOC may have implications for the full-scale OTP inducer in terms of reduced structural margin at higher mode frequencies. Simulations using the LOCI/Stream CFD program were conducted in order to explore the fluid dynamical impact of the groove on the low-pressure inducer and kicker. It was found that the circumferential groove has minimal head performance impact, but causes back-flowing high-swirl fluid to interact with the nearly-axial incoming fluid just above the inducer blades. The high-shear interface between the fluids is Kelvin-Helmholtz unstable, resulting in trains of low pressure regions or 'pearls' forming near the upstream edge of the groove. When the static pressure in these regions becomes low enough and they get cut by the blade leading edge, HOC is thought to occur. Although further work is required, the numerical models indicate that HOC will occur in the runbox of the AFRL/Aerojet HCB OTP. Comparisons to the ongoing water flow experiments will be discussed, as well as possible designs that may mitigate HOC while continuing to reduce synchronous cavitation. December 2011 MSS/LPS/SPS Joint Subcommittee Meeting ABSTRACT SUBMITTAL FORM

Coker, Robert↗

NASA NTRS2011

Water Flow Testing and Unsteady Pressure Analysis of a Two-Bladed Liquid Oxidizer Pump Inducer

The unsteady fluid dynamic performance of a cavitating two-bladed oxidizer turbopump inducer was characterized through sub-scale water flow testing. While testing a novel inlet duct design that included a cavitation suppression groove, unusual high-frequency pressure oscillations were observed. With potential implications for inducer blade loads, these high-frequency components were analyzed extensively in order to understand their origins and impacts to blade loading. Water flow testing provides a technique to determine pump performance without the costs and hazards associated with handling cryogenic propellants. Water has a similar density and Reynolds number to liquid oxygen. In a 70%-scale water flow test, the inducer-only pump performance was evaluated. Over a range of flow rates, the pump inlet pressure was gradually reduced, causing the flow to cavitate near the pump inducer. A nominal, smooth inducer inlet was tested, followed by an inlet duct with a circumferential groove designed to suppress cavitation. A subsequent 52%-scale water flow test in another facility evaluated the combined inducer-impeller pump performance. With the nominal inlet design, the inducer showed traditional cavitation and surge characteristics. Significant bearing loads were created by large side loads on the inducer during synchronous cavitation. The grooved inlet successfully mitigated these loads by greatly reducing synchronous cavitation, however high-frequency pressure oscillations were observed over a range of frequencies. Analytical signal processing techniques showed these oscillations to be created by a rotating, multi-celled train of pressure pulses, and subsequent CFD analysis suggested that such pulses could be created by the interaction of rotating inducer blades with fluid trapped in a cavitation suppression groove. Despite their relatively low amplitude, these high-frequency pressure oscillations posed a design concern due to their sensitivity to flow conditions and test scale. The amplitude and frequency of oscillations varied considerably over the pump s operating space, making it difficult to predict blade loads.

Schwarz, Jordan B.↗

NASA NTRS2011

CFD Study of the J2-X LOX Two-Bladed Inducer in the Presence of a Circumferential Groove

Results are presented of a computational fluid dynamics (CFD) study done in support of water flow experiments of the J-2X Oxidizer Turbopump (OTP) 2-bladed inducer with a circumferential groove that were conducted at Marshall Space Flight Center (MSFC). Sub-scale water flow testing results indicate that the circumferential groove greatly reduces synchronous cavitation and subsequent bearing loads at a minimal performance cost, but the energy reappears as high order cavitation (HOC) that spans a relatively large frequency range. Thus, HOC may have implications for the full-scale OTP inducer in terms of reduced structural margin at higher mode frequencies. Simulations using the LOCI-Stream CFD program were conducted in order to explore the root physical cause of the HOC. It was found that the axial recirculation pattern in the circumferential groove causes high-swirl fluid to interact with the nearly-axial incoming fluid just above the inducer blades. The high-shear interface between the fluids is Kelvin-Helmholtz unstable, resulting in trains of low pressure regions or 'pearls' forming near the upstream edge of the groove. When the pressure in these regions becomes low enough and they get cut by the blade leading edge, HOC is thought to occur. Although further work is required, the numerical models indicate that the root cause of HOC is hydrodynamic. That is, the pearls are always present, even when cavitation is not. Comparisons to ongoing water flow experiments will be discussed, as well as predictions for the full-scale OTP inducer.

Coker, Robert↗

NASA NTRS2011

Characterization of Axial Inducer Cavitation Instabilities via High Speed Video Recordings

Sub-scale water tests were undertaken to assess the viability of utilizing high resolution, high frame-rate digital video recordings of a liquid rocket engine turbopump axial inducer to characterize cavitation instabilities. These high speed video (HSV) images of various cavitation phenomena, including higher order cavitation, rotating cavitation, alternating blade cavitation, and asymmetric cavitation, as well as non-cavitating flows for comparison, were recorded from various orientations through an acrylic tunnel using one and two cameras at digital recording rates ranging from 6,000 to 15,700 frames per second. The physical characteristics of these cavitation forms, including the mechanisms that define the cavitation frequency, were identified. Additionally, these images showed how the cavitation forms changed and transitioned from one type (tip vortex) to another (sheet cavitation) as the inducer boundary conditions (inlet pressures) were changed. Image processing techniques were developed which tracked the formation and collapse of cavitating fluid in a specified target area, both in the temporal and frequency domains, in order to characterize the cavitation instability frequency. The accuracy of the analysis techniques was found to be very dependent on target size for higher order cavitation, but much less so for the other phenomena. Tunnel-mounted piezoelectric, dynamic pressure transducers were present throughout these tests and were used as references in correlating the results obtained by image processing. Results showed good agreement between image processing and dynamic pressure spectral data. The test set-up, test program, and test results including H-Q and suction performance, dynamic environment and cavitation characterization, and image processing techniques and results will be discussed.

Arellano, Patrick↗

NASA NTRS2012

Thermodynamic Vent System for an On-Orbit Cryogenic Reaction Control Engine

A report discusses a cryogenic reaction control system (RCS) that integrates a Joule-Thompson (JT) device (expansion valve) and thermodynamic vent system (TVS) with a cryogenic distribution system to allow fine control of the propellant quality (subcooled liquid) during operation of the device. It enables zero-venting when coupled with an RCS engine. The proper attachment locations and sizing of the orifice are required with the propellant distribution line to facilitate line conditioning. During operations, system instrumentation was strategically installed along the distribution/TVS line assembly, and temperature control bands were identified. A sub-scale run tank, full-scale distribution line, open-loop TVS, and a combination of procured and custom-fabricated cryogenic components were used in the cryogenic RCS build-up. Simulated on-orbit activation and thruster firing profiles were performed to quantify system heat gain and evaluate the TVS s capability to maintain the required propellant conditions at the inlet to the engine valves. Test data determined that a small control valve, such as a piezoelectric, is optimal to provide continuously the required thermal control. The data obtained from testing has also assisted with the development of fluid and thermal models of an RCS to refine integrated cryogenic propulsion system designs. This system allows a liquid oxygenbased main propulsion and reaction control system for a spacecraft, which improves performance, safety, and cost over conventional hypergolic systems due to higher performance, use of nontoxic propellants, potential for integration with life support and power subsystems, and compatibility with in-situ produced propellants.

Hurlbert, Eric A.↗

NASA NTRS2012

Flight Test Results on the Stability and Control of the F-15 Quiet Spike(TradeMark) Aircraft

The Quiet Spike F-15B flight research program investigated supersonic shock reduction using a 24-ft sub-scale telescoping nose boom on an F-15B airplane. The program primary flight test objective was to collect flight data for aerodynamic and structural models validation up to 1.8 Mach. Other objectives were to validate the mechanical feasibility of a morphing fuselage at the operational conditions and determine the near-field shock wave characterization. The stability and controls objectives were to assess the effect of the spike on the stability, controllability, and handling qualities of the aircraft and to ensure adequate stability margins across the entire research flight envelop. The two main stability and controls issues were the effects of the telescoping nose boom influenced aerodynamics on the F-15B aircraft flight dynamics and air data and angle of attack sensors. This paper reports on the stability and controls flight envelope clearance methods and flight test analysis of the F-15B Quiet Spike. Brief pilot commentary on typical piloting tasks, approach and landing, refueling task, and air data sensitivity to the flight control system are also discussed in this report.

Moua, Cheng M.↗

NASA NTRS2012

Error Estimates of the Ares I Computed Turbulent Ascent Longitudinal Aerodynamic Analysis

Numerical predictions of the longitudinal aerodynamic characteristics for the Ares I class of vehicles, along with the associated error estimate derived from an iterative convergence grid refinement, are presented. Computational results are based on an unstructured grid, Reynolds-averaged Navier-Stokes analysis. The validity of the approach to compute the associated error estimates, derived from a base grid to an extrapolated infinite-size grid, was first demonstrated on a sub-scaled wind tunnel model at representative ascent flow conditions for which the experimental data existed. Such analysis at the transonic flow conditions revealed a maximum deviation of about 23% between the computed longitudinal aerodynamic coefficients with the base grid and the measured data across the entire roll angles. This maximum deviation from the wind tunnel data was associated with the computed normal force coefficient at the transonic flow condition and was reduced to approximately 16% based on the infinite-size grid. However, all the computed aerodynamic coefficients with the base grid at the supersonic flow conditions showed a maximum deviation of only about 8% with that level being improved to approximately 5% for the infinite-size grid. The results and the error estimates based on the established procedure are also presented for the flight flow conditions.

Abdol-Hamid, Khaled S.↗

NASA NTRS2012

Analysis of Control Strategies for Aircraft Flight Upset Recovery

This paper proposes a framework for studying the ability of a control strategy, consisting of a control law and a command law, to recover an aircraft from ight conditions that may extend beyond the normal ight envelope. This study was carried out (i) by evaluating time responses of particular ight upsets, (ii) by evaluating local stability over an equilibrium manifold that included stall, and (iii) by bounding the set in the state space from where the vehicle can be safely own to wings-level ight. These states comprise what will be called the safely recoverable ight envelope (SRFE), which is a set containing the aircraft states from where a control strategy can safely stabilize the aircraft. By safe recovery it is implied that the tran- sient response stays between prescribed limits before converging to a steady horizontal ight. The calculation of the SRFE bounds yields the worst-case initial state corresponding to each control strategy. This information is used to compare alternative recovery strategies, determine their strengths and limitations, and identify the most e ective strategy. In regard to the control law, the authors developed feedback feedforward laws based on the gain scheduling of multivariable controllers. In regard to the command law, which is the mechanism governing the exogenous signals driving the feed- forward component of the controller, we developed laws with a feedback structure that combines local stability and transient response considera- tions. The upset recovery of the Generic Transport Model, a sub-scale twin-engine jet vehicle developed by NASA Langley Research Center, is used as a case study.

Crespo, Luis G.↗

NASA NTRS2012

Supersonic Retropropulsion Technology Development in NASA's Entry, Descent, and Landing Project

NASA's Entry, Descent, and Landing (EDL) space technology roadmap calls for new technologies to achieve human exploration of Mars in the coming decades [1]. One of those technologies, termed Supersonic Retropropulsion (SRP), involves initiation of propulsive deceleration at supersonic Mach numbers. The potential benefits afforded by SRP to improve payload mass and landing precision make the technology attractive for future EDL missions. NASA's EDL project spent two years advancing the technological maturity of SRP for Mars exploration [2-15]. This paper summarizes the technical accomplishments from the project and highlights challenges and recommendations for future SRP technology development programs. These challenges include: developing sufficiently large SRP engines for use on human-scale entry systems; testing and computationally modelling complex and unsteady SRP fluid dynamics; understanding the effects of SRP on entry vehicle stability and controllability; and demonstrating sub-scale SRP entry systems in Earth's atmosphere.

Edquist, Karl T.↗

NASA NTRS2012

Development and Calibration of a System-Integrated Rotorcraft Finite Element Model for Impact Scenarios

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber (DEA) under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. The presence of this energy absorbing device reduced the peak impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to a system-integrated finite element model of the test article developed in parallel with the test program. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests were conducted to evaluate the impact performances of various components and subsystems, including new crush tubes and the DEA blocks. Parameters defined for the system-integrated finite element model were determined from these tests. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the full-scale crash test without the DEA. This combination of heuristic and quantitative methods identified modeling deficiencies, evaluated parameter importance, and proposed required model changes. The multidimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and copilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. One lesson learned was that this approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and pretest predictions. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, potentially reducing overall development costs.

Annett, Martin S.↗

NASA NTRS2008

Overview of LIDS Docking Seals Development

NASA is developing a new docking system to support future space exploration missions to low-Earth orbit, the Moon, and Mars. This mechanism, called the Low Impact Docking System (LIDS), is designed to connect pressurized space vehicles and structures including the Crew Exploration Vehicle, International Space Station, and lunar lander. NASA Glenn Research Center (GRC) is playing a key role in developing the main interface seal for this new docking system. These seals will be approximately 147 cm (58 in.) in diameter. GRC is evaluating the performance of candidate seal designs under simulated operating conditions at both sub-scale and full-scale levels. GRC is ultimately responsible for delivering flight hardware seals to NASA Johnson Space Center around 2013 for integration into LIDS flight units.

Dunlap, Pat↗