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NASA NTRS2015

Proportional and Integral Thermal Control System for Large Scale Heating Tests

The National Aeronautics and Space Administration Armstrong Flight Research Center (Edwards, California) Flight Loads Laboratory is a unique national laboratory that supports thermal, mechanical, thermal/mechanical, and structural dynamics research and testing. A Proportional Integral thermal control system was designed and implemented to support thermal tests. A thermal control algorithm supporting a quartz lamp heater was developed based on the Proportional Integral control concept and a linearized heating process. The thermal control equations were derived and expressed in terms of power levels, integral gain, proportional gain, and differences between thermal setpoints and skin temperatures. Besides the derived equations, user's predefined thermal test information generated in the form of thermal maps was used to implement the thermal control system capabilities. Graphite heater closed-loop thermal control and graphite heater open-loop power level were added later to fulfill the demand for higher temperature tests. Verification and validation tests were performed to ensure that the thermal control system requirements were achieved. This thermal control system has successfully supported many milestone thermal and thermal/mechanical tests for almost a decade with temperatures ranging from 50 F to 3000 F and temperature rise rates from -10 F/s to 70 F/s for a variety of test articles having unique thermal profiles and test setups.

Thermal Control System↗

NASA NTRS2015

Benefits of Spacecraft Level Vibration Testing

NASA-HDBK-7008 Spacecraft Level Dynamic Environments Testing discusses the approaches, benefits, dangers, and recommended practices for spacecraft level dynamic environments testing, including vibration testing. This paper discusses in additional detail the benefits and actual experiences of vibration testing spacecraft for NASA Goddard Space Flight Center (GSFC) and Jet Propulsion Laboratory (JPL) flight projects. JPL and GSFC have both similarities and differences in their spacecraft level vibration test approach: JPL uses a random vibration input and a frequency range usually starting at 5 Hz and extending to as high as 250 Hz. GSFC uses a sine sweep vibration input and a frequency range usually starting at 5 Hz and extending only to the limits of the coupled loads analysis (typically 50 to 60 Hz). However, both JPL and GSFC use force limiting to realistically notch spacecraft resonances and response (acceleration) limiting as necessary to protect spacecraft structure and hardware from exceeding design strength capabilities. Despite GSFC and JPL differences in spacecraft level vibration test approaches, both have uncovered a significant number of spacecraft design and workmanship anomalies in vibration tests. This paper will give an overview of JPL and GSFC spacecraft vibration testing approaches and provide a detailed description of spacecraft anomalies revealed.

Spacecraft Vibration Test↗

NASA NTRS2016

UAS Integration in the NAS Project: Flight Test 3 Data Analysis of JADEM-Autoresolver Detect and Avoid System

The Unmanned Aircraft Systems Integration in the National Airspace System project, or UAS Integration in the NAS, aims to reduce technical barriers related to safety and operational challenges associated with enabling routine UAS access to the NAS. The UAS Integration in the NAS Project conducted a flight test activity, referred to as Flight Test 3 (FT3), involving several Detect-and-Avoid (DAA) research prototype systems between June 15, 2015 and August 12, 2015 at the Armstrong Flight Research Center (AFRC). This report documents the flight testing and analysis results for the NASA Ames-developed JADEM-Autoresolver DAA system, referred to as 'Autoresolver' herein. Four flight test days (June 17, 18, 22, and July 22) were dedicated to Autoresolver testing. The objectives of this test were as follows: 1. Validate CPA prediction accuracy and detect-and-avoid (DAA, formerly known as self-separation) alerting logic in realistic flight conditions. 2. Validate DAA trajectory model including maneuvers. 3. Evaluate TCAS/DAA interoperability. 4. Inform final Minimum Operating Performance Standards (MOPS). Flight test scenarios were designed to collect data to directly address the objectives 1-3. Objective 4, inform final MOPS, was a general objective applicable to the UAS in the NAS project as a whole, of which flight test is a subset. This report presents analysis results completed in support of the UAS in the NAS project FT3 data review conducted on October 20, 2015. Due to time constraints and, to a lesser extent, TCAS data collection issues, objective 3 was not evaluated in this analysis.

flight test↗

NASA NTRS2016

Green Propellant Test Capabilities of the Altitude Combustion Stand at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC) is committed to providing simulated altitude rocket test capabilities to NASA programs, other government agencies, private industry partners, and academic partners. A primary facility to support those needs is the Altitude Combustion Stand (ACS). ACS provides the capability to test combustion components at a simulated altitude up to 100,000 ft. (approx.0.2 psia/10 Torr) through a nitrogen-driven ejector system. The facility is equipped with an axial thrust stand, gaseous and cryogenic liquid propellant feed systems, data acquisition system with up to 1000 Hz recording, and automated facility control system. Propellant capabilities include gaseous and liquid hydrogen, gaseous and liquid oxygen, and liquid methane. A water-cooled diffuser, exhaust spray cooling chamber, and multi-stage ejector systems can enable run times up to 180 seconds to 16 minutes. The system can accommodate engines up to 2000-lbf thrust, liquid propellant supply pressures up to 1800 psia, and test at the component level. Engines can also be fired at sea level if needed. The NASA GRC is in the process of modifying ACS capabilities to enable the testing of green propellant (GP) thrusters and components. Green propellants are actively being explored throughout government and industry as a non-toxic replacement to hydrazine monopropellants for applications such as reaction control systems or small spacecraft main propulsion systems. These propellants offer increased performance and cost savings over hydrazine. The modification of ACS is intended to enable testing of a wide range of green propellant engines for research and qualification-like testing applications. Once complete, ACS will have the capability to test green propellant engines up to 880 N in thrust, thermally condition the green propellants, provide test durations up to 60 minutes depending on thrust class, provide high speed control and data acquisition, as well as provide advanced imaging and diagnostics such as infrared (IR) imaging.

Testing↗

NASA NTRS2017

Aerodynamic Coefficients from Aeroballistic Range Testing of Deployed- and Stowed-SIAD SFDT Models

This report documents a ballistic-range test campaign conducted in 2012 in order to estimate the aerodynamic stability characteristics of two configurations of the Supersonic Flight Dynamics Test (SFDT) vehicle prior to its initial flight in 2014. The SFDT vehicle was a test bed for demonstrating several new aerodynamic decelerator technologies then being developed under the Low-Density Supersonic Decelerator (LDSD) Project. Of particular interest here is the Supersonic Inflatable Aerodynamic Decelerator (SIAD), an inflatable attached torus used to increase the drag surface area of an entry vehicle during the supersonic portion of the entry trajectory. Two model configurations were tested in the ballistic range: one representing the SFDT vehicle prior to deployment of the SIAD, and the other representing the nominal shape with the SIAD inflated. Both models were fabricated from solid metal, and therefore, the effects of the flexibility of the inflatable decelerator were not considered. The test conditions were chosen to match, as close as possible, the Mach number, Reynolds number, and motion dynamics expected for the SFDT vehicle in flight, both with the SIAD stowed and deployed. For SFDT models with the SIAD stowed, 12 shots were performed covering a Mach number range of 3.2 to 3.7. For models representing the deployed SIAD, 37 shots were performed over a Mach number range of 2.0 to 3.8. Pitch oscillation amplitudes covered a range from 0.7 to 20.6 degrees RMS. Portions of this report (data analysis approach, aerodynamic modeling, and resulting aerodynamic coefficients) were originally published as an internal LDSD Project report [1] in 2012. In addition, this report provides a description of the test design approach, the test facility, and experimental procedures. Estimated non-linear aerodynamic coefficients, including pitch damping, for both model configurations are reported, and the shot-by-shot trajectory measurements, plotted in comparison with calculated trajectories based on the derived non-linear aerodynamic coefficients, are provided as appendices. Since the completion of these tests, two full-scale SFDT flights have been successfully conducted: one in June 2014 [2, 3], and one in June 2015 [3].

Ground Test↗

NASA NTRS2014

Overview of the 6m HIAD Inflatable Structure and Flexible TPS Static Load Test Series

To support NASAs long term goal of landing humans on Mars, technologies which enable the landing of heavy payloads are being developed. Current entry, decent, and landing technologies are not practical for this class of payloads due to geometric constraints dictated by current launch vehicle fairing limitations. Therefore, past and present technologies are now being explored to provide a mass and volume efficient solution to atmospheric entry, including Hypersonic Inflatable Aerodynamic Decelerators (HIADs). At the beginning of 2014, a 6m HIAD inflatable structure with an integrated flexible thermal protection system (TPS) was subjected to a static load test series to verify the designs structural performace. The 6m HIAD structure was constructed in a stacked toroid configuration using nine inflatable torus segments composed of fiber reinforced thin films, which were joined together using adhesives and high strength textile woven structural straps to help distribute the loads throughout the inflatable structure. The 6m flexible TPS was constructed using multiple layers of high performance materials to protect the inflatable structure from heat loads that would be seen during atmospheric entry. To perform the static load test series, a custom test fixture was constructed. The fixture consisted of a structural tub rim with enough height to allow for displacement of the inflatable structure as loads were applied. The bottom of the tub rim had an airtight seal with the floor. The centerbody of the inflatable structure was attached to a pedestal mount as seen in Figure 1. Using an impermeable membrane seal draped over the test article, partial vacuum was pulled beneath the HIAD, resulting in a uniform static pressure load applied to the outer surface. During the test series an extensive amount of instrumentation was used to provide many data sets including: deformed shape, shoulder deflection, strap loads, cord loads, inflation pressures, and applied static load.In this overview, the 6m HIAD static load test series will be discussed in detail, including the 6m HIAD inflatable structure and flexible TPS design, test setup and execution, and finally initial results and conclusions from the test series.

TPS↗

NASA NTRS2020

Sensor Chip Assembly (SCA) Test Report

This report summarizes the measured performance for the Sensor Chip Assembly (SCA), which is identified in Table 1. The SCA architecture is a substrate-removed HgCdTe detector with an area of 4096x4096 pixels (with a reference pixel area of four pixels deep around all four sides, available to substitute corresponding image pixels) and a pixel pitch of 10 μm. This SCA has been tested at the Goddard Space Flight Center (GSFC/NASA) Detector Characterization Laboratory (DCL). Teledyne (the vendor) classifies its detectors into different grades based on testing performed at its facility. The classification of this SCA and the tested dates are included in Table 1 below. The tests performed on this array are derived from the document WFIRST-PROC-09220_WFIRST-SCA-ATP_-.docx. A summary of the test parameters, requirements, and test results is presented in Table 2. The details of each test are subsequently described in the report. In the Summary (Table 2), SCA results are reported at an operating temperature of 95K, and 1.0 V bias voltage. In the detailed section of each test, the results for 90 K (1.0V bias voltage) and 95 K (0.5V bias voltage) are also reported. For all cases, the frame time used is 2.764 seconds. Reference pixel correction was applied to every raw frame.

WFIRST SCA TEST REPORT↗

NASA NTRS2020

Habitability Lessons Learned from Field Testing of a Small Pressurized Rover

From 2008 to 2010, the NASA Small Pressurized Rover was tested in the Arizona desert in anticipation of human lunar surface missions. These tests were multi-day mission simulations with crew living in and conducting simulated lunar surface EVAs from the rover prototypes for 3, 7, or 14 days. This two-person surface spacecraft represents a departure from most previous lunar architectures, which either featured Apollo-class unpressurized rovers or large pressurized rovers – in some cases up to the scale of being considered mobile outposts. This paper will discuss the history of the Small Pressurized Rover, some of the values of field testing, the rover’s design evolution including the two prototypes tested in the field, key features and advantages of the SPR, the field test site location, the 2008, 2009, and 2010 field tests, habitability lessons learned from the testing, comparisons with follow-on laboratory/high bay testing, and recommendations for third generation rover design and flight vehicle development.

Pressurized Rover↗

NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

NASA NTRS2021

Plug20 Test Report

This report documents a test of aircraft exhaust nozzle designs applicable to commercial supersonic aircraft as envisioned in the 2025-2035 time frame. The test is primarily intended to provide data about the noise such aircraft would produce during landing and takeoff (LTO) operation, specifically the jet noise component of this noise. The tests were conducted at the NASA Glenn Research Center’s Aero-Acoustic Propulsion Laboratory in March 2020. The tests used the High-Flow Jet Exhaust Rig in the Nozzle Acoustic Test Rig which simulates the flow from a dual-stream turbofan engine in a flight stream. Seven exhaust configurations were tested with various combinations of internal mixer and external plug, and covered engine cycles having nozzle pressures from 1.5 to 2.3 at a flight speed of Mach 0.3. A few unheated flow conditions were also tested to tie results to other baseline test results. Data acquired and included in this report are 1) far-field acoustic spectra, 2) phased array measurements of noise source distributions, and 3) background-oriented schlieren of the flow near the nozzles. These data, along with the nozzle geometry in CAD format, are given as Appendices and are available online.

Jet noise↗

NASA NTRSDate not supplied

Comparing Simulation Results from CHARM and RotCFD to the Multirotor Test Bed Experimental Data

Advanced multirotor vertical flight aircraft concepts are emerging faster than rigorous individualized tests can investigate their utility and performance. There are several analysis tools that predict multirotor performance and flow characteristics, but the accuracy of these predictions is still being debated due to lack of experimental data from multirotor tests that are needed to validate the analyses. The objective of this paper is to simulate multirotor configurations using two different mid-fidelity rotorcraft analysis tools, Comprehensive Hierarchical Aeromechanics Rotorcraft Model (CHARM) and Rotorcraft Computational Fluid Dynamics (RotCFD), and compare the simulation results to experimental data from a wind tunnel test of the Multirotor Test Bed (MTB). The MTB, developed by NASA Ames Research Center, is a new capability for testing a wide array of advanced vertical take-off and landing (VTOL) rotor configurations, with a primary focus on testing in the U.S. Army 7-by 10-Foot Wind Tunnel at NASA Ames Research Center. The MTB was designed to allow adjustment of the vertical, lateral, and longitudinal placement of up to six rotors, as well as allow tilt adjustment of each rotor and pitch adjustment of the whole assembly. The six-axis load cells under each rotor give the MTB the capability of measuring the rotor performance in a wide array of configurations. The overall goal of the MTB project is to help gain a better understanding of the performance, control, interactional aerodynamics, and acoustics of multirotor and tilting-rotor systems. For the work presented here, the MTB data were used to validate RotCFD and CHARM results for several multirotor test configurations. With confidence in both analyses established by the validation exercise, additional simulations were performed to explore quadrotor configurations that will be tested during the MTB’s second wind tunnel entry planned for 2022. This second tunnel entry will examine quadrotor configurations that represent published NASA reference designs for urban air mobility concept vehicles. Results from this paper confirm the ability of RotCFD and CHARM to simulate multirotor aerodynamic interactions on individual rotor performance under edgewise forward-flight conditions.

CHARM↗

NASA NTRSDate not supplied

Feasibility study for remote psychoacoustic testing of human response to urban air mobility vehicle noise

NASA will remotely administer a psychoacoustic test in late summer of 2022 as the first of two phases of a cooperative Urban Air Mobility (UAM) vehicle noise human response study. This study relies on the cooperation of multiple government agencies, academia, and industry to assemble a wide range of UAM vehicle sounds. This database of sounds will be used to create a rich database of human response to UAM noise that would be challenging for a single organization to acquire. The development of the remote test method to study human response to aviation noise was prompted by the novel coronavirus pandemic. The feasibility portion of the study described in this work will demonstrate and refine the remote test method for use in the implementation phase. This paper details the method for remotely administering the psychoacoustic test and the sound stimuli to be used in the Feasibility Test. Comparisons of annoyance response data from previous in-person tests will be used to demonstrate the viability of the remote test method. The paper also describes an effort to determine if providing a contextual cue to test subjects influences the annoyance response.

Remote psychoacoustic test↗

NASA NTRSDate not supplied

Recent Langley Aerothermodynamic Laboratory Testing (2019-2022)

In support of flight programs, multiple wind tunnel entries were conducted on reentry vehicle configurations to investigate blunt body aeroheating environments. Blunt body block thermal protection system (TPS) roughness, the Low-Earth Orbit Flight Test of an Inflatable Decelerator aeroshell scalloping, and a woven TPS all were tested to determine the effects of those parameters on increased surface heating to the vehicle. Commercial Crew Program studies also utilized the speed and ease of testing in the LAL to analyze parametric databases of low-earth reentry configurations, like the Boeing CST-100, and vehicles designed to travel to the moon or Mars, such as the SpaceX Starship. LAL wind tunnel investigations also supported several DoD and AFRL flight projects, such as HIFiRE 6 and BOLT. External customers leveraged the LAL testing capability to advance their research programs, including UPSTAR, RocketLab, and Lawrence Livermore National Laboratory. Academia groups benefitted from the inexpensive cost to test in the tunnels for many university collaborations, such as studies conducted in partnership with the University of Maryland on a flat plate, using a pressure rake and investigating fluid structure interactions. Multiple studies in collaboration with Purdue considered boundary layer transition on various cone configurations. Another study was conducted using a cone with shaped roughness elements borrowed from the Arnold Engineering Development Complex. Internal testing included studies using a phosphor thermography system that can measure higher temperatures than the current LAL phosphor capability and a characterization study of the noise in the wind tunnel flow. The breadth of testing across research and commercial paradigms, both internal and external to NASA, different configurations, a variety of test techniques and aerodynamic and aerothermal environments will be discussed in this overview presentation of the recent work conducted in the LAL.

wind tunnel test↗

NASA NTRSDate not supplied

Design and Analysis of A Jet Stretcher for High-Altitude Supersonic Free Jet Testing

A jet stretcher can be used to extend the region of clean flow for a test article in a supersonic free jet. The device acts to shield the article from shock waves reflected from the free jet shear layer. It can also allow for overexpanded nozzle operation through blocking shocks emanating from the nozzle lip, enlarging the potential test envelope. The FUN3D computational fluid dynamics solver was used to test a design process for developing jet stretchers. The inner surface of the axisymmetric jet stretcher was obtained from a streamline extracted from a free flight simulation around a notional test article at the intended test condition of Mach 3.2, 53,000 ft. The test article and jet stretcher were then simulated in a free jet nozzle exhaust, and the flowfield within a notional inlet aperture was compared between the installed and free flight calculations. Ambient pressure was increased until separation within the free jet nozzle finally induced disturbances at the inlet. The jet stretcher was shown to provide clean flow to the inlet at cell pressure ratios up to 2.8. A process for trimming the axisymmetric jet stretcher was also tested. This was intended to provide blockage relief for complex test articles, aiding with starting, as well as reducing weight and fabrication cost. The trimmed jet stretcher performed identically to the axisymmetric model at slightly-overexpanded conditions, but at cell pressure ratios above 1.3 allowed disturbances from the trailing edge to reach the inlet.

free jet↗

NASA NTRSDate not supplied

Design and Analysis of A Jet Stretcher for High-Altitude Supersonic Free Jet Testing

A jet stretcher can be used to extend the region of clean flow for a test article in a supersonic free jet. The device acts to shield the article from shock waves reflected from the free jet shear layer. It can also allow for overexpanded nozzle operation through blocking shocks emanating from the nozzle lip, enlarging the potential test envelope. The FUN3D computational fluid dynamics solver was used to test a design process for developing jet stretchers. The inner surface of the axisymmetric jet stretcher was obtained from a streamline extracted from a free flight simulation around a notional test article at the intended test condition of Mach 3.2, 53,000 ft. The test article and jet stretcher were then simulated in a free jet nozzle exhaust, and the flowfield within a notional inlet aperture was compared between the installed and free flight calculations. Ambient pressure was increased until separation within the free jet nozzle finally induced disturbances at the inlet. The jet stretcher was shown to provide clean flow to the inlet at cell pressure ratios up to 2.8. A process for trimming the axisymmetric jet stretcher was also tested. This was intended to provide blockage relief for complex test articles, aiding with starting, as well as reducing weight and fabrication cost. The trimmed jet stretcher performed identically to the axisymmetric model at slightly overexpanded conditions, but at cell pressure ratios above 1.3 allowed disturbances from the trailing edge to reach the inlet.

free jet↗

NASA NTRSDate not supplied

On Characterization of Flow Disturbances in Arc-Jet Testing

This paper reports computational simulations and analysis of flow characterization tests in high enthalpy arc-jet facilities at NASA Ames Research Center. Flow disturbances and their characterization are presented through case studies, and their implications for testing are discussed. The case studies include free-jet test configurations from three different arc heaters and nozzles: the 60-MW IHF 30-inch conical nozzle, the 10-MW TP3 15-inch conical nozzle, and the 20-MW AHF 12-inch conical nozzle. For all cases, test articles are placed in the jet exiting the conical nozzle, and the existence of a flow disturbance is confirmed through flow survey data using pitot pressure and heat flux probes and accompanying analysis. The paper focuses on cases where the effects of the disturbances on test article surface quantities are important. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzles and test box, including the models tested. Comparisons of computations with the experimental measurements are presented. The computations that reproduce the probe sweep data approximately are essential to interpret the arc-jet test data accurately, while providing insights into several observed calorimeter anomalies caused by flow disturbances.

Arc-jet testing↗

NASA NTRSDate not supplied

On Characterization of Flow Disturbances in Arc-Jet Testing

Arc-jet testing↗

NASA NTRSDate not supplied

The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing Within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES)

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) was designed to perform non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and materials. NTREES can simulate the thermal hydraulic environment within an NTR and has been leveraged to provide critical information on component performance and material compatibility. NTREES has the ability to expose test articles to pressurized Hydrogen gas up to 1000 psig and 225 g/s. NTREES tests are operated in a deoxygenated environment of Nitrogen or Argon pressurized up to 1000 psig. NTREES simulates fission heat through induction heating powered by a 1.2 MW AC power supply, and NTREES has recorded temperatures exceeding 3700K. To perform hot Hydrogen exposure tests on materials more rapidly and earlier in the fuel development process, NTREES must be able to test small material samples on the order of 1 square inch in volume, individual fuel assembly subcomponents, and particle materials. To meet these needs, multiple testing rigs have been developed to immerse test specimens in hot Hydrogen, with each "immersion rig" varying in its capability of sample type and performance range in order to meet the broadest range of testing needs. Herein is a discussion of a selection of these “immersion rigs.”

Nuclear Thermal Propulsion↗

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