Engineering topics

Mason, Lee S.

Publications and source records attributed to Mason, Lee S..

At least 55 records · Page 3

NASA NTRS2002

Stirling Technology Development at NASA GRC

The Department of Energy, Stirling Technology Company (STC), and NASA Glenn Research Center (NASA Glenn) are developing a free-piston Stirling convertor for a high-efficiency Stirling Radioisotope Generator (SRG) for NASA Space Science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. NASA Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. Recent testing, of 55-We Technology Demonstration Convertors (TDC's) built by STC includes mapping, of a second pair of TDC's, single TDC testing, and TDC electromagnetic interference and electromagnetic compatibility characterization on a nonmagnetic test stand. Launch environment tests of a single TDC without its pressure vessel to better understand the convertor internal structural dynamics and of dual-opposed TDC's with several engineering mounting structures with different natural frequencies have recently been completed. A preliminary life assessment has been completed for the TDC heater head, and creep testing of the IN718 material to be used for the flight convertors is underway. Long-term magnet aging tests are continuing to characterize any potential aging in the strength or demagnetization resistance of the magnets used in the linear alternator (LA). Evaluations are now beginning on key organic materials used in the LA and piston/rod surface coatings. NASA Glenn is also conducting finite element analyses for the LA, in part to look at the demagnetization margin on the permanent magnets. The world's first known integrated test of a dynamic power system with electric propulsion was achieved at NASA Glenn when a Hall-effect thruster was successfully operated with a free-piston Stirling power source. Cleveland State University is developing a multidimensional Stirling computational fluid dynamics code to significantly improve Stirling loss predictions and assist in identifying convertor areas for further improvements. This paper will update the status and results for these efforts.

Thieme, Lanny G.↗

NASA NTRS2001

Stirling Technology Development at NASA GRC

The Department of Energy, Stirling Technology Company (STC), and NASA Glenn Research Center (NASA Glenn) are developing a free-piston Stirling convertor for a high efficiency Stirling Radioisotope Generator (SRG) for NASA Space Science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. NASA Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. Recent testing of 55-We Technology Demonstration Convertors (TDCs) built by STC includes mapping of a second pair of TDCs, single TDC testing, and TDC electromagnetic interference and electromagnetic compatibility characterization on a nonmagnetic test stand. Launch environment tests of a single TDC without its pressure vessel to better understand the convertor internal structural dynamics and of dual-opposed TDCs with several engineering mounting structures with different natural frequencies have recently been completed. A preliminary life assessment has been completed for the TDC heater head, and creep testing of the IN718 material to be used for the flight convertors is underway. Long-term magnet aging tests are continuing to characterize any potential aging in the strength or demagnetization resistance of the magnets used in the linear alternator (LA). Evaluations are now beginning on key organic materials used in the LA and piston/rod surface coatings. NASA Glenn is also conducting finite element analyses for the LA, in part to look at the demagnetization margin on the permanent magnets. The world's first known integrated test of a dynamic power system with electric propulsion was achieved at NASA Glenn when a Hall-effect thruster was successfully operated with a free-piston Stirling power source. Cleveland State University is developing a multidimensional Stirling computational fluid dynamics code to significantly improve Stirling loss predictions and assist in identifying convertor areas for further improvements. This paper will update the status and results for these efforts.

Thieme, Lanny G.↗

NASA NTRS2001

NASA's Hall Thruster Program

NASA's Hall thruster program has base research and focused development efforts in support of the Advanced Space Transportation Program, Space-Based Program, and various other programs. The objective of the base research is to gain an improved understanding of the physical processes and engineering constraints of Hall thrusters to enable development of advanced Hall thruster designs. Specific technical questions that are current priorities of the base effort are: (1) How does thruster life vary with operating point? (2) How can thruster lifetime and wear rate be most efficiently evaluated? (3) What are the practical limitations for discharge voltage as it pertains to high specific impulse operation (high discharge voltage) and high thrust operation (low discharge voltage)? (4) What are the practical limits for extending Hall thrusters to very high input powers? and (5) What can be done during thruster design to reduce cost and integration concerns? The objective of the focused development effort is to develop a 50 kW-class Hall propulsion system, with a milestone of a 50 kW engineering model thruster/system by the end of program year 2006. Specific program wear 2001 efforts, along with the corporate and academic participation, are described.

Jankovsky, Robert S.↗

NASA NTRS2001

1000 Hours of Testing Completed on 10-kW Hall Thruster

Between the months of April and August 2000, a 10-kW Hall effect thruster, designated T- 220, was subjected to a 1000-hr life test evaluation. Hall effect thrusters are propulsion devices that electrostatically accelerate xenon ions to produce thrust. Hall effect propulsion has been in development for many years, and low-power devices (1.35 kW) have been used in space for satellite orbit maintenance. The T-220, shown in the photo, produces sufficient thrust to enable efficient orbital transfers, saving hundreds of kilograms in propellant over conventional chemical propulsion systems. This test is the longest operation ever achieved on a high-power Hall thruster (greater than 4.5 kW) and is a key milestone leading to the use of this technology for future NASA, commercial, and military missions.

Mason, Lee S.↗

NASA NTRS2000

Spacecraft Impacts with Advanced Power and Electric Propulsion

A study was performed to assess the benefits of advanced power and electric propulsion systems for various space missions. Advanced power technologies that were considered included multiband gap and thin-film solar arrays, lithium batteries, and flywheels. Electric propulsion options included Hall effect thrusters and Ion thrusters. Several mission case studies were selected as representative of future applications for advanced power and propulsion systems. These included a low altitude Earth science satellite, a LEO communications constellation, a GEO military surveillance satellite, and a Mercury planetary mission. The study process entailed identification of overall mission performance using state-of-the-art power and propulsion technology, enhancements made possible with either power or electric propulsion advances individually, and the collective benefits realized when advanced power and electric propulsion are combined. Impacts to the overall spacecraft included increased payload, longer operational life, expanded operations and launch vehicle class step-downs.

Mason, Lee S.↗

NASA NTRS2000

4.5-kW Hall Effect Thruster Evaluated

As part of an Interagency Agreement with the Air Force Research Lab (AFRL), a space simulation test of a Russian SPT 140 Hall Effect Thruster was completed in September 1999 at Vacuum Facility 6 at the NASA Glenn Research Center at Lewis Field. The thruster was subjected to a three-part test sequence that included thrust and performance characterization, electromagnetic interference, and plume contamination. SPT 140 is a 4.5-kW thruster developed under a joint agreement between AFRL, Atlantic Research Corp, and Space Systems/Loral, and was manufactured by the Fakal Experimental Design Bureau of Russia. All objectives were satisfied, and the thruster performed exceptionally well during the 120-hr test program, which comprised 33 engine firings. The Glenn testing provided a critical contribution to the thruster development effort, and the large volume and high pumping speed of this vacuum facility was key to the test s success. The low background pressure (1 10 6 torr) provided a more accurate representation of space vacuum than is possible in most vacuum chambers. The facility had been upgraded recently with new cryogenic pumps and sputter shielding to support the active electric propulsion program at Glenn. The Glenn test team was responsible for all test support equipment, including the thrust stand, power supplies, data acquisition, electromagnetic interference measurement equipment, and the contamination measurement system.

Mason, Lee S.↗

NASA NTRS2000

A Comparison of Brayton and Stirling Space Nuclear Power Systems for Power Levels from 1 Kilowatt to 10 Megawatts

An analytical study was conducted to assess the performance and mass of Brayton and Stirling nuclear power systems for a wide range of future NASA space exploration missions. The power levels and design concepts were based on three different mission classes. Isotope systems, with power levels from 1 to 10 kW, were considered for planetary surface rovers and robotic science. Reactor power systems for planetary surface outposts and bases were evaluated from 10 to 500 kW. Finally, reactor power systems in the range from 100 kW to 10 mW were assessed for advanced propulsion applications. The analysis also examined the effect of advanced component technology on system performance. The advanced technologies included high temperature materials, lightweight radiators, and high voltage power management and distribution.

Mason, Lee S.↗

NASA NTRS1999

Solar Stirling for Deep Space Applications

A study was performed to quantify the performance of solar thermal power systems for deep space planetary missions. The study incorporated projected advances in solar concentrator and energy conversion technologies. These technologies included inflatable structures, lightweight primary concentrators, high efficiency secondary concentrators, and high efficiency Stirling convertors. Analyses were performed to determine the mass and deployed area of multi-hundred watt solar thermal power systems for missions out to 40 astronomical units. Emphasis was given to system optimization, parametric sensitivity analyses, and concentrator configuration comparisons. The results indicated that solar thermal power systems are a competitive alternative to radioisotope systems out to 10 astronomical units without the cost or safety implications associated with nuclear sources.

Mason, Lee S.↗

NASA NTRS1999

A Solar Dynamic Power Option for Space Solar Power

A study was performed to determine the potential performance and related technology requirements of Solar Dynamic power systems for a Space Solar Power satellite. Space Solar Power is a concept where solar energy is collected in orbit and beamed to Earth receiving stations to supplement terrestrial electric power service. Solar Dynamic systems offer the benefits of high solar-to-electric efficiency, long life with minimal performance degradation, and high power scalability. System analyses indicate that with moderate component development, SD systems can exhibit excellent mass and deployed area characteristics. Using the analyses as a guide, a technology roadmap was -enerated which identifies the component advances necessary to make SD power generation a competitive option for the SSP mission.

Mason, Lee S.↗

NASA NTRS1999

Surface Nuclear Power for Human Mars Missions

The Design Reference Mission for NASA's human mission to Mars indicates the desire for in-situ propellant production and bio-regenerative life systems to ease Earth launch requirements. These operations, combined with crew habitation and science, result in surface power requirements approaching 160 kilowatts. The power system, delivered on an early cargo mission, must be deployed and operational prior to crew departure from Earth. The most mass efficient means of satisfying these requirements is through the use of nuclear power. Studies have been performed to identify a potential system concept using a mobile cart to transport the power system away from the Mars lander and provide adequate separation between the reactor and crew. The studies included an assessment of reactor and power conversion technology options, selection of system and component redundancy, determination of optimum separation distance, and system performance sensitivity to some key operating parameters. The resulting system satisfies the key mission requirements including autonomous deployment, high reliability, and cost effectiveness at a overall system mass of 12 tonnes and a stowed volume of about 63 cu m.

Mason, Lee S.↗

NASA NTRS1999

Technology Projections for Solar Dynamic Power

Solar Dynamic power systems can offer many potential benefits to Earth orbiting satellites including high solar-to-electric efficiency, long life without performance degradation, and high power capability. A recent integrated system test of a 2 kilowatt SD power system in a simulated space environment has successfully demonstrated technology readiness for space flight. Conceptual design studies of SD power systems have addressed several potential mission applications: a 10 kilowatt LEO satellite, a low power Space Based Radar, and a 30 kilowatt GEO communications satellite. The studies show that with moderate component development, SD systems can exhibit excellent mass and deployed area characteristics. Using the conceptual design studies as a basis, a SD technology roadmap was generated which identifies the component advances necessary to assure SD systems a competitive advantage for future NASA, DOD, and commercial missions.

Mason, Lee S.↗

NASA NTRS1999

800 Hours of Operational Experience from a 2 kW(sub e) Solar Dynamic System

From December 1994 to September 1998, testing with a 2 kW(sub e) Solar Dynamic power system resulted in 33 individual tests, 886 hours of solar heating, and 783 hours of power generation. Power generation ranged from 400 watts to over 2 kW(sub e), and SD system efficiencies have been measured up to 17 per cent, during simulated low-Earth orbit operation. Further, the turbo-alternator-compressors successfully completed 100 start/stops on foil bearings. Operation was conducted in a large thermal/vacuum facility with a simulated Sun at the NASA Lewis Research Center. The Solar Dynamic system featured a closed Brayton conversion unit integrated with a solar heat receiver, which included thermal energy storage for continuous power output through a typical low-Earth orbit. Two power conversion units and three alternator configurations were used during testing. This paper will review the test program, provide operational and performance data, and review a number of technology issues.

Shaltens, Richard K.↗

NASA NTRS1998

High-Temperature, High-Flux Multifoil Shield Developed for Space Applications

Spacecraft employing solar dynamic power systems typically use parabolic, point focus concentrators to collect solar power and direct it to the aperture of a heat receiver. Solar fluxes several thousand times the intensity of one solar constant are typically produced in the focal plane of such concentrators. Under heat loading this severe, passively cooled surfaces constructed of most engineering materials would rapidly melt. Therefore, high-temperature shielding is required to protect heat receiver surfaces and other spacecraft surfaces that may be exposed to high flux. To meet this challenge for the joint U.S./Russian Solar Dynamic Flight Demonstration Program, AlliedSignal Aerospace and the NASA Lewis Research Center developed a high-temperature, high-flux multifoil shield tolerant of extreme heat loading conditions in a vacuum environment. The shield is passively cooled, obviating the need for pumped fluid loops and/or heat pipe cooling systems with their attendant cost, mass, complexity, and reliability issues.

Kerslake, Thomas W.↗

NASA NTRS1997

High-Flux, High-Temperature Thermal Vacuum Qualification Testing of a Solar Receiver Aperture Shield

As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.

Kerslake, Thomas W.↗

NASA NTRS1997

Experimental Data for Two Different Alternator Configurations in a Solar Brayton Power System

A solar dynamic (SD) space power system has been under test at the NASA Lewis Research Center since 1994. The SD Ground Test Demonstration (GTD) system includes a solar concentrator, heat receiver with thermal energy storage, Brayton power conversion unit, and radiator installed in a thermal-vacuum chamber with a solar simulator. The Brayton unit has been operated with two different turboalternator compressor (TAC) assemblies, one which included a Rice Lundell alternator and another which incorporated a permanent magnet (PM) alternator. The Rice alternator was part of the mini-Brayton rotating unit, designed and built during the 1970's and refurbished for the GTD. The PM TAC was a development unit from the Joint US/Russian SD Flight Project. This paper highlights the operational differences (and similarities) between the Rice and PM TAC configurations including a comparative evaluation of startup characteristics and operating performance. The two alternator configurations were tested under similar thermal conditions, as an interchangeable component within the SD system. The electrical characteristics of the two units, however, dictated the use of significantly different power conditioning and control strategies. The electrical control architectures are described and compared. Test data are presented on TAC startup and system operating performance for both configurations.

Mason, Lee S.↗

NASA NTRS1996

Alignment and Initial Operation of an Advanced Solar Simulator

A solar simulator utilizing nine 30-kW xenon arc lamps was built to provide radiant power for testing a solar dynamic space power system in a thermal vacuum environment. The advanced solar simulator achieved the following values specific to the solar dynamic system: (1) a subtense angle of 1 deg; (2) the ability to vary solar simulator intensity up to 1.7 kW/sq m; (3) a beam diameter of 4.8 m; and (4) uniformity of illumination on the order of +/-10%. The flexibility of the solar simulator design allows for other potential uses of the facility.

Jaworske, Donald A.↗

NASA NTRS1996

Alignment and Initial Operation of an Advanced Solar Simulator

Jaworske, Donald A.↗

NASA NTRS1996

Early Results from Solar Dynamic Space Power System Testing

A government/industry team designed, built and tested a 2-kWe solar dynamic space power system in a large thermal vacuum facility with a simulated Sun at the NASA Lewis Research Center. The Lewis facility provides an accurate simulation of temperatures, high vacuum and solar flux as encountered in low-Earth orbit. The solar dynamic system includes a Brayton power conversion unit integrated with a solar receiver which is designed to store energy for continuous power operation during the eclipse phase of the orbit. This paper reviews the goals and status of the Solar Dynamic Ground Test Demonstration project and describes the initial testing, including both operational and performance data. System testing to date has accumulated over 365 hours of power operation (ranging from 400 watts to 2.0-W(sub e)), including 187 simulated orbits, 16 ambient starts and 2 hot restarts. Data are shown for an orbital startup, transient and steady-state orbital operation and shutdown. System testing with varying insolation levels and operating speeds is discussed. The solar dynamic ground test demonstration is providing the experience and confidence toward a successful flight demonstration of the solar dynamic technologies on the Space Station Mir in 1997.

Shaltens, Richard K.↗