Search NASA⌕ Search

SEARCH · Search NASA

Results for “component testing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Coil-On-Plug Ignition for LOX/Methane Liquid Rocket Engines in Thermal Vacuum Environments

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX) / liquid methane rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/methane propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. In order to successfully demonstrate ignition reliability in the vacuum conditions and eliminate corona discharge issues, a coil-on-plug ignition system has been developed. The ICPTA uses spark-plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark-plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp.-2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, Plum Brook testing demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/methane propulsion systems in future spacecraft.

Melcher, John C.↗
NASA NTRS2019

Fundamental Improvement of a Convergence Test for Iterative Strain-Gage Balance Load Predictions

A fundamental improvement of a convergence test for wind tunnel strain-gage balance load iterations was developed. The improvement became necessary because incorrect test results were obtained whenever the original test was applied to multi-component balances with large load capacity differences. The original test was first published in NASA TN D-6860. It uses an upper bound of the Lipschitz constant to assess convergence characteristics of balance load predictions whenever the Iterative Method is applied. The Lipschitz constant is a function of the partial derivatives of each balance load component with respect to all other load components. Unfortunately, the original definition of the convergence test overlooked the fact that the Lipschitz constant is a dimensionless quantity and that the partial derivative of one load component with respect to another load component is not always dimensionless. Therefore, an improvement of the original test was successfully developed that uses load capacities to make all inputs for the calculation of the Lipschitz constant dimensionless before use. Results from the calibration data analysis of a six-component force balance and a five-component semi-span balance are used to illustrate the application of the improved load iteration convergence test.

Strain-Gage Balance↗
NASA NTRS2013

Engineering Evaluation of International Low Impact Docking System Latch Hooks

The international Low Impact Docking System (iLIDS) provides a structural arrangement that allows for visiting vehicles to dock with the International Space Station (ISS) (Fig 1). The iLIDS docking units are mechanically joined together by a series of active and passive latch hooks. In order to preserve docking capability at the existing Russian docking interfaces, the iLIDS latch hooks are required to conform to the existing Russian design. The latch hooks are classified as being fail-safe. Since the latch hooks are fail-safe, the hooks are not fracture critical and a fatigue based service life assessment will satisfy the structural integrity requirements. Constant amplitude fatigue testing to failure on four sets of active/passive iLIDS latch hooks was performed at load magnitudes of 10, 11, and 12 kips. Failure analysis of the hook fatigue failures identified multi-site fatigue initiation that was effectively centered about the hook mid-plane (consistent with the 3D model results). The fatigue crack initiation distribution implies that the fatigue damage accumulation effectively results in a very low aspect ratio surface crack (which can be simulated as thru-thickness crack). Fatigue damage progression resulted in numerous close proximity fatigue crack initiation sites. It was not possible to determine if fatigue crack coalescence occurs during cyclic loading or as result of the fast fracture response. The presence of multiple fatigue crack initiation sites on different planes will result in the formation of ratchet marks as the cracks coalesce. Once the stable fatigue crack becomes unstable and the fast fracture advances across the remaining ligament and the plane stress condition at a free-surface will result in failure along a 45 deg. shear plane (slant fracture) and the resulting inclined edge is called a shear lip. The hook thickness on the plane of fatigue crack initiation is 0.787". The distance between the shear lips on this plane was on the order of 0.48" and it was effectively centered about the mid-plane of the section. The numerous ratchet marks between the shear lips on the fracture initiation plane are indicative of multiple fatigue initiation sites within this region. The distribution of the fatigue damage about the centerline of the hook is consistent with the analytical results that demonstrate peak stress/strain response at the mid-plane that decreases in the direction of the hook outer surfaces. Scanning electron microscope images of the failed sections detected fatigue crack striations in close proximity to the free surface of the hook radius. These findings were documented at three locations on the fracture surface : 1) adjacent to the left shear lip, 2) adjacent to the right shear lip, and 3) near the centerline of the section. The features of the titanium fracture surface did not allow for a determination of a critical crack size via identification of the region where the fatigue crack propagation became unstable. The fracture based service life projections where benchmarked with strain-life analyses. The strainrange response in the hook radius was defined via the correlated finite element models and the modified method of universal slopes was incorporated to define the strain-life equation for the titanium alloy. The strain-life assessment confirmed that the fracture based projections were reasonable for the loading range of interest. Based upon the analysis and component level fatigue test data a preliminary service life capability for the iLIDS active and passive hooks of 2 lifetimes is projected (includes a scatter factor of 4).

Martinez, J.↗
NASA NTRS2003

Mercury Conditions for the MESSENGER Mission Simulated in High- Solar-Radiation Vacuum Tests

The MESSENGER (Mercury Surface, Space Environment, Geochemistry, and Ranging) spacecraft, planned for launch in March 2004, will perform two flybys of Mercury before entering a year-long orbit of the planet in September 2009. The mission will provide opportunities for detailed characterization of the surface, interior, atmosphere, and magnetosphere of the closest planet to the Sun. The NASA Glenn Research Center and the MESSENGER spacecraft integrator, the Johns Hopkins University Applied Physics Laboratory, have partnered under a Space Act Agreement to characterize a variety of critical components and materials under simulated conditions expected near Mercury. Glenn's Vacuum Facility 6, which is equipped with a solar simulator, can simulate the vacuum and high solar radiation anticipated in Mercury orbit. The MESSENGER test hardware includes a variety of materials and components that are being characterized during the Tank 6 vacuum tests, where the hardware will be exposed to up to 11 suns insolation, simulating conditions expected in Mercury orbit. In 2002, ten solar vacuum tests were conducted, including beginning of life, end of life, backside exposure, and solar panel thermal shock cycling tests. Components tested include candidate solar array panels, sensors, thermal shielding materials, and communication devices. As an example, for the solar panel thermal shock cycling test, two candidate solar array panels were suspended on a lift mechanism that lowered the panels into a liquid-nitrogen-cooled box. After reaching -140 C, the panels were then lifted out of the box and exposed to the equivalent of 6 suns (8.1 kilowatts per square meters). After five cold soak/heating cycles were completed successfully, there was no apparent degradation in panel performance. An anticipated 100-hr thermal shield life test is planned for autumn, followed by solar panel flight qualification tests in winter. Glenn's ongoing support to the MESSENGER program has been instrumental in identifying design solutions and validating thermal performance models under a very aggressive development schedule. The test data have assisted Johns Hopkins engineers in selecting a flight solar array vendor and a thermal shield design. MESSENGER is one in a series of missions in NASA's Discovery Program. Infrared thermography provides data on the thermal gradients in the MESSENGER components during high solar insolation vacuum testing.

Wong, Wayne A.↗
NASA NTRS1983

Flight service evaluation of composite components on Bell 206L and Sikorsky S-76 helicopters

Progress on two programs to evaluate composite structural components in flight service on commercial helicopters is described. Thirty-six ship sets of composite components that include the litter door, baggage door, forward fairing, and vertical fin were installed on Bell Model 206L helicopters that are operating in widely different climatic areas. Four horizontal stabilizers and ten tail rotor spars that are production components on the S-76 helicopter were tested after prescribed periods of service to determine the effects of the operating environment on their performance. Concurrent with the flight evaluation, specimens from materials used to fabricate the components were exposed in ground racks and tested at specified intervals to determine the effects of outdoor environments. Results achieved from 14,000 hours of accumulated service on the 206L components, tests on a S-76 horizontal stabilizer after 1600 hours of service, tests on a S-76 tail rotor spar after 2300 hours service, and two years of ground based exposure of material coupons are reported.

Baker, D. J.↗
DOE OSTI2021

Quantifying adherence of oxide scales on steels exposed to high temperature and pressure steam

Oxide scale exfoliation is a major concern in fossil fuel power generation because it can cause tube blockages and erode valves and steam turbine components downstream. There is still considerable scientific and commercial interest to improve the mechanistic understanding of oxide failures by developing models to predict exfoliation and the extent of tube blockage as a function of operating conditions and component geometries. Tensile testing inside a scanning electron microscope was conducted on ferritic–martensitic and austenitic steel specimens with the steam side (Fe,Cr)-rich oxides grown after exposures for up to 1000 h in steam with ~100 ppb O 2 at 276 bar and 550°C. Multiple oxide layer cracks and delamination events were observed and analyzed in detail during the tests. Results from the testing agreed well with earlier observations that had identified the failure location at the outer–inner oxide layer for all tested materials. Calculated adhesion energies identified the outer–inner oxide interface of alloy 347HFG as the weakest interface.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Study of η(1405)/η(1475) in $J/\psi \to \gamma {K}_S^0{K}_S^0{\pi}^0$ decay

Using a sample of (10 . 09 ± 0 . 04) × 10 9 J/ψ decays collected with the BESIII detector, partial wave analyses of the decay $ J/\psi \to \gamma {K}_S^0{K}_S^0{\pi}^0$ are performed within the ${K}_S^0{K}_S^0{\pi}^0$ invariant mass region below 1.6 GeV/ c 2 . The covariant tensor amplitude method is used in both mass independent and mass dependent approaches. Both analysis approaches exhibit dominant pseudoscalar and axial vector components, and show good consistency for the other individual components. Furthermore, the mass dependent analysis reveals that the ${K}_S^0{K}_S^0{\pi}^0$ invariant mass spectrum for the pseudoscalar component can be well described with two isoscalar resonant states using relativistic Breit-Wigner model, i.e., the η (1405) with a mass of $1391.7\pm {0.7}_{-0.3}^{+11.3}$ MeV/ c 2 and a width of $60.8\pm {1.2}_{-12.0}^{+5.5}$ MeV, and the η (1475) with a mass of $1507.6\pm {1.6}_{-32.2}^{+15.5}$ MeV/ c 2 and a width of $115.8\pm {2.4}_{-10.9}^{+14.8}$ MeV. The first and second uncertainties are statistical and systematic, respectively. Alternate models for the pseudoscalar component are also tested, but the description of the ${K}_S^0{K}_S^0{\pi}^0$ invariant mass spectrum deteriorates significantly.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2018

Metallization of Carbon Fiber Reinforced Polymers for Lightning Strike Protection

Carbon fiber reinforced polymers (CFRPs) are increasingly used in the latest generations of aircraft, but their low electrical conductivity is a concern for lightning strike protection. During the past few years, development of lightning strike protection solutions for CFRP has attracted increasing interest, and cold spray is one coating approach to achieving this. In this work, pure tin coatings and tin–copper composite coatings were cold sprayed on CFRP as possible lightning strike protection materials. The coatings were subjected to various mechanical and electrical characterizations. The effect of annealing on electrical conductivity was also examined. Furthermore, continuous current injection tests, which duplicated component C of a lightning waveform, were performed on the coatings. The results showed that the cold-sprayed coatings can provide effective protection to the CFRP underneath when subjected to currents up to 200 A with 1-s duration.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Numerical and experimental analysis of precooled desiccant system

This paper presents a numerical and experimental study of four novel, desiccant air-conditioning systems based on pre-cooling of the ambient air. The purpose of the study is to: 1) establish which configuration is most profitable for the future studies through numerical and experimental methods; 2) verify the concept of precooled system and confirm that it is working in experimental conditions (for this purpose two prototypes of evaporative cooling units were developed and compared for different operation arrangements with desiccant wheel); 3) Analyze practical aspects of the systems, which includes water consumption analysis, economic analysis and establishing operational modes during a cooling season in temperate climate conditions (the proposed solution has a significant advantage during operation in a temperate climate, since it can utilize its first evaporative cooler the only source of cooling energy when the humidity of outdoor air allows to to meet the latent cooling load). Four arrangements of the system with different dew point evaporative air cooler prototypes were selected and developed for comparative analysis. The system was simulated as a whole, also, each component was individually tested on measurement station. develop the optimal arrangement of the system through numerical and experimental analysis. Four different performance indicators were considered: thermal COP (Coefficient Of Performance), the ERR (Energy Efficiency Ratio), coefficient a describing the potential in compensating indoor cooling loads, water consumption ratio. Also costs of the systems were compared through economic analysis. It was established that arrangement which is characterized by best-averaged performance in terms of all considered factors is a unit combined with two different types of evaporative coolers (marked as System B)- this is caused by the favorable arrangement of two units, where one is better suited to the pre-cooler role, while the other is better suited as the post-cooler.

42 ENGINEERING↗
DOE OSTI2021

Thermal runaway mechanism of lithium-ion battery with LiNi 0.8 Mn 0.1 Co 0.1 O 2 cathode materials

Battery safety is critical to the application of lithium-ion batteries, especially for high energy density battery applied in electric vehicles. In this paper, the thermal runaway mechanism of LiNi 0.8 Co 0.1 Mn 0.1 O 2 based lithium-ion battery is illustrated. And the reaction between cathode and flammable electrolyte is proved as the trigger of the thermal runaway accident. In detail, with differential scanning calorimeter tests for battery components, the material combination contributing to thermal runaway was decoupled. Characterization with synchrotron X-ray diffraction and transmission electron microscopy with in-situ heating proved that the vigorous exothermic reaction is initiated by the liberated oxygen species. The pulse of highly active oxygen species reacted quickly with the electrolyte, accompanied with tremendous heat release, which accelerated the phase transformation of charged cathode. Also, the mechanism is verified by a confirmatory experiment when the highly active oxygen species were trapped by anion receptor, the phase transformation of the charged cathode was inhibited. Clarifying the thermal runaway mechanism of LiNi 0.8 Co 0.1 Mn 0.1 based lithium-ion battery may light the way to battery chemistries of both high energy density and high safety.

25 ENERGY STORAGE↗
DOE OSTI2025

Proton Exchange Membrane (PEM) Water Electrolysis: Cell-Level Considerations for Gigawatt-Scale Deployment

Hydrogen produced with no greenhouse gas emissions is termed “green hydrogen” and will be essential to reaching decarbonization targets set forth by nearly every country as per the Paris Agreement. Proton exchange membrane water electrolyzers (PEMWEs) are expected to contribute substantially to the green hydrogen market. However, PEMWE market penetration is insignificant, accounting for less than a gigawatt of global capacity. Achieving substantive decarbonization via green hydrogen will require PEMWEs to reach capacities of hundreds of gigawatts by 2030. This paper serves as an overarching roadmap for cell-level improvements necessary for gigawatt-scale PEMWE deployment, with insights from three well-established hydrogen technology companies included. Analyses will be presented for economies of scale, renewable energy prices, government policies, accelerated stress tests, and component-specific improvements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Design and calibration of an optically segmented single volume scatter camera for neutron imaging

The Optically Segmented Single Volume Scatter Camera (OS-SVSC) aims to image neutron sources for non-proliferation applications using the kinematic reconstruction of elastic double-scatter events. Our prototype system consists of 64 EJ-204 organic plastic scintillator bars, each measuring 5mm × 5mm × 200mm and individually wrapped in Teflon tape. The scintillator array is optically coupled to two silicon photomultiplier ArrayJ-60035 64P-PCB arrays, each comprised of 64 individual 6x6mm J-Series sensors arranged in an 8 × 8 array. We report on the design details, including component selections, mechanical design and assembly, and the electronics system. The described design leveraged existing off-the-shelf solutions to support the rapid development of a phase 1 prototype. Several valuable lessons were learned from component and system testing, including those related to the detector's mechanical structure and electrical crosstalk that we conclude originates in the commercial photodetector arrays and the associated custom breakout cards. We detail our calibration efforts, beginning with calibrations for the electronics, based on the IRS3D application-specific integrated circuits, and their associated timing resolutions, ranging from 3090ps. With electronics calibrations applied, energy and position calibrations were performed for a set of edge bars using 22 Na and 90 Sr, respectively, reporting an average resolution of 12.07±0.03mm for energy depositions between 900keVee and 1000keVee. We further demonstrate a position calibration method for the internal bars of the matrix using cosmic-ray muons as an alternative to emission sources that cannot easily access these bars, with an average measured resolution of 14.86+-0.29mm for depositions between 900keVee and 1000keVee. The coincident time resolution reported between pairs of bars measured up to 400ps from muon acquisitions. Energy and position calibration values measured with muons are consistent with those obtained using particle emission sources.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Lycoris - A large-area, high resolution beam telescope

We note that a high-resolution beam telescope is one of the most important and demanding infrastructure components at any test beam facility. Its main purpose is to provide reference particle tracks from the incoming test beam particles to the test beam users, which allows measurement of the performance of the device-under-test (DUT). LYCORIS, a six-plane compact beam telescope with an active area of ~ 10 x 10 cm 2 (extensible to 10 x 20 cm 2 ) was installed at the DESY II Test Beam Facility in 2019, to provide a precise momentum measurement in a 1 T solenoid magnet or to provide tracking over a large area. The overall design of Lycoris will be described as well as the performance of the chosen silicon sensor. The 25 μm pitch micro-strip sensor used for Lycoris was originally designed for the SiD detector concept for the International Linear Collider. It adopts a second metallization layer to route signals from strips to the bump-bonded KPiX ASIC and uses a wire-bonded flex cable for the connection to the DAQ and the power supply system. This arrangement eliminates the need for a dedicated hybrid PCB. Its performance was tested for the first time in this project. The system has been evaluated at the DESY II Test Beam Facility in several test-beam campaigns and has demonstrated an average single-point resolution of 7.07 μm.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

MagMicro with Ultra-High Energy Resolution (FY19 Q3 Progress Report)

The fabrication of the MMC detector arrays involves two photolithographic procedures. The first is to fabricate the Nb magnetization coil and pick-up coils, the SQUID preamplifiers and the associated wiring. This is done on a full 4” Si wafer, which is subsequently diced into ~0.5 cm2 SQUID chips and ~1 cm2 detector chips. The detector chips are then processed separately by depositing and patterning the paramagnetic Ag:Er sensor and support structures and then electroplating the Au absorber. In Q3, we have successfully completed the full wafer processing for the 32-pixel MMC detector arrays, diced the 4” wafer into the smaller chips and tested the individual components. The coils have the required critical current, the heat switches have a critical temperature in the desired range, and the SQUIDs have the required low noise. Unfortunately, the sputter deposition of the paramagnetic Ag:Er sensor failed several times. We spent considerable time to trace the problem to contaminations of the purifier for the Ar sputtering gas that had been exposed to atmosphere for an extended time during an earlier clean room upgrade. We then determined that the purifier is not essential for high-quality Ag:Er sensor films (Fig. 1), and successfully deposited the Ag:Er sensor film on the ~1 cm 2 detector chip.

42 ENGINEERING↗
DOE OSTI2018

Mu2e Calorimeter Readout System

• Mu2e waveform digitizer conceptually defined and designed • All relevant components chosen and tested individually both under radiation and magnetic field, with good results • Compatibility between Microsemi SoC and ADC (ADS4229) demonstrated • First digitizer prototype constructed: tests progressing smoothly • New prototype radiation tolerance tests planned at Helmholtz Zentrum Dresden Rossendorf in June 2018

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Seismic Spatial Gradients and Machine Learning-Based Classifiers for Explosion Monitoring (LDRD 218327)

This final report summarizes the work completed under the Laboratory Directed Research and Development (LDRD) project “Seismic Spatial Gradients as a Machine Learning-Based Classifier for Explosion Monitoring.” The overarching goal of the project was to explore the efficacy of using machine learning-based classification algorithms where the input data are the spatial gradient of the seismic wavefield collected at a single point on the Earth’s surface. The methods that I describe here are in direct contrast to conventional methods of seismic discrimination which typically rely on a spatially extended network of instruments and physics-based wavefield attributes such as, for example, the ratio between $\textit{P}$ and $\textit{S}$ waves. Rather, we use the spatial gradient of the seismic wavefield observed at a single point on the Earth’s surface and data processing approaches inspired by the machine learning community. We tested two algorithms, a neural network and a modified version of principal component analysis termed Spectrally Filtered Principal Component Analysis (SFPCA). To test these algorithms, we first conducted a series of numerical tests using synthetic data and then conducted a small-scale controlled field experiment. The tests using synthetic data showed that both algorithms had high success rates on gradiometric data, even when simulated noise was added to the signal. Furthermore, we found that using seismic spatial gradients increased the performance of our discrimination algorithms when compared to using just the traditional translational motion seismic data. The tests with field data also showed a high degree of discriminative success.

58 GEOSCIENCES↗