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The Integrated Test Facility (ITF), being built at NASA Ames-Dryden Flight Research Facility, will provide new test capabilities for emerging research aircraft. An overview of the ITF and the challenges being addressed by this unique facility are outlined. The current ITF capabilities, being developed with the X-29 Forward Swept Wing Program, are discussed along with future ITF activities.
Description of magnetic research test facility
A rocket test stand and associated subsystems are complex devices whose operation requires that certain preparatory calculations be carried out before a test. In addition, real-time control calculations must be performed during the test, and further calculations are carried out after a test is completed. The latter may be required in order to evaluate if a particular test conformed to specifications. These calculations are used to set valve positions, pressure setpoints, control gains and other operating parameters so that a desired system behavior is obtained and the test can be successfully carried out. Currently, calculations are made in an ad-hoc fashion and involve trial-and-error procedures that may involve activating the system with the sole purpose of finding the correct parameter settings. The goals of this project are to develop mathematical models, control methodologies and associated simulation environments to provide a systematic and comprehensive prediction and real-time control capability. The models and controller designs are expected to be useful in two respects: 1) As a design tool, a model is the only way to determine the effects of design choices without building a prototype, which is, in the context of rocket test stands, impracticable; 2) As a prediction and tuning tool, a good model allows to set system parameters off-line, so that the expected system response conforms to specifications. This includes the setting of physical parameters, such as valve positions, and the configuration and tuning of any feedback controllers in the loop.
The design, construction, and costs of a test facility for determining the sound transmission loss characteristics of various panels and panel treatments are described. The pressurization system and electronic equipment used in experimental testing are discussed as well as the reliability of the facility and the data gathered. Tests results are compared to pertinent acoustical theories for panel behavior and minor anomalies in the data are examined. A method for predicting panel behavior in the stiffness region is also presented.
The plans for a new test facility, including new environmental test systems, which are presently under construction, and the major environmental Test Support Equipment (TSE) used therein are addressed. This all-new Rocketdyne facility will perform space simulation environmental tests on Power Management and Distribution (PMAD) hardware to Space Station Freedom (SSF) at the Engineering Model, Qualification Model, and Flight Model levels of fidelity. Testing will include Random Vibration in three axes - Thermal Vacuum, Thermal Cycling and Thermal Burn-in - as well as numerous electrical functional tests. The facility is designed to support a relatively high throughput of hardware under test, while maintaining the high standards required for a man-rated space program.
The Environmental Test Facility (ETF), located at NASA-Marshall Space Flight Center, Huntsville, Alabama, has provided thermal vacuum testing for several major programs since the 1960's. The ETF consists of over 13 thermal vacuum chambers sized and configured to handle the majority of test payloads. Testing is performed around the clock with multiple tests being conducted simultaneously. Chamber selection to achieve the best match with test articles and juggling program schedules, at times, can be a challenge. The ETF's Sunspot chamber has had tests scheduled and operated back-to-back for several years and provides the majority of schedule conflicts. Future test programs have been identified which surpass the current Sunspot availability. This paper describes a very low cost alternate to reduce schedule conflicts by utilizing government excess equipment
In a program to investigate combustor noise, measurements were made with a YF-102 engine of combustor internal fluctuating pressure and far field noise. The relationship of far field noise to engine internal measurement was ascertained. The relationships between combustor internal measurements obtained in an engine and those obtained in a component test facility were established by using a YF-102 combustor, instrumented identically with that used in the engine tests. The combustor was operated in a component test facility over a range of conditions encompassing engine operation. A comparison of the directly measured spectra at corresponding locations in the two tests showed significant differences. The results of two point signal analyses within each combustor, were similar for both tests, indicating that the internal dynamics of the combustor as an acoustic source are preserved in a component test facility.
Approximately five years ago, the National Aeronautics and Space Administration (NASA) Stennis Space Center (SSC) resumed operation of its large rocket engine test facilities after thirty years of contractor control. During this period, contactors used their own proprietary Data Acquisition System (DAS) to record and process rocket propulsion test data. The transition from a contractor managed facility to a NASA managed facility posed a difficult challenge. In order to support the commercial space launch initiative, SSC needed to develop a software replacement for the contractor proprietary DAS. This replacement software would enable SSC to operate propulsion test facilities more cost effectively and to be more readily able to adapt software for reuse, while at the same time provide internal and external customers with reliable population test data. Therefore, SSC developed in-house, a non-proprietary software suite of applications to replace the previously used proprietary DAS. The requirements for the DAS suite included recording and processing propulsion test data. This capability eliminates the necessity for customers to provide a DAS or rely on a competitor's DAS. An additional benefit of owning the software suite included enabling the ability to add additional features and functionality at a lower cost. The Rocket Propulsion Test (RPT) Program Office reviewed consideration for funding this project with the caveat that development of the software included availability for use with minimal modifications to all SSC test facilities and RPT centers: Marshall Space Flight Center (MSFC), White Sands Test Facility (WSTF), and Glenn Research Center (GRC) Plum Brook Station. Based upon this guideline, SSC created the NASA Data Acquisition System (NDAS) software suite. The ability to use the software at multiple centers, even though each field center uses differing DAS hardware with different capabilities, drove a requirement that the software design be portable with minimal modifications to the software. Then, with software release requirements, evaluations, and approvals completed, the NDAS software suite could also become available to other government agencies, corporations, universities, and the general United States public.
Shuttle to Space station docking has become an important issue in the last few years. Docking sensors have been proposed that will provide high precision measurements required for the fuel efficient rendezvous and docking of space vehicles. These sensors will also be used for satellite servicing and orbital assembly. The performance of the docking sensors must be tested before they are implemented in a space environment. A Six-Degree-of-Freedom (6-DOF) Test Facility has been developed at the Tracking & Communications Section, Johnson Space Center to test the static and dynamic accuracies of docking sensors. A candidate sensor is evaluated by comparing the sensor's static position and velocity measurements to the more accurate 6-DOF system. The 6-DOF Test Facility's hardware is fully integrated. Software has been developed in-house to support system operation. The system has been tested statically and the operational parameters verified. System accuracies remain to be determined. Dynamic testing of the facility is expected to begin shortly. Several companies such as McDonnell Douglas, Autonomous Technologies, and General Dynamics are scheduled to test sensors in the next few months. The 6-DOF facility will be available for use in November 1991. This presentation describes the subcomponents, operation, and capabilities of the 6-DOF Test Facility. Discussions will be held on system accuracies. Additional applications of the 6-DOF system will also be addressed.
In the spring and summer of 2019, experiments were conducted at the High Temperature Test Facility (HTTF) that form the basis of an upcoming high-temperature gas-cooled reactor (HTGR) thermal hydraulics (T/H) benchmark. HTTF is an integral effects test facility for HTGR T/H modeling validation. This paper presents RELAP5-3D models of two of those experiments: PG-27, a pressurized conduction cooldown (PCC); and PG-29, a depressurized conduction cooldown (DCC). These models used the RELAP5-3D model of HTTF originally developed by Paul Bayless as a starting point. The sensitivity analysis and uncertainty quantification code, RAVEN was used to perform calibration studies for the steady-state portion of PG-27. Here we developed four PG-27 calibrations based on steady-state conditions. These calibrations all used an effective thermal conductivity equal to 36 % of the measured thermal conductivity, but they differed with respect to the frictional pressure drops and radial conduction models. These models all captured the trends in steady-state temperature distributions and transient temperature behavior well. All four calibrations show room for improvement in predicting the transient temperature rise. The smallest error in temperature rise during the transient was a 21 % underprediction, and the largest was a 48 % underprediction. The errors in transient temperature rise are largely a result of a mismatch in power density between the RELAP5-3D model and the experiment due to the location of active heater rods along the boundary between heat structures in the model. The best of these calibrations was applied to PG-29 to model the DCC. Once again, temperatures during the transient were underpredicted but trends in temperature were captured. The RELAP5-3D model captured trends in the data but could not reproduce measured temperatures exactly. This result is not attributed to deficiencies in the experimental data or to RELAP5–3D itself. Rather, this result likely arises due to the some of the assumptions and decisions made when the RELAP5-3D model was first developed, prior to the execution of HTTF experiments. An agreement in prediction of temperature trends but challenges reproducing HTTF temperatures within measurement uncertainty is consistent with previous analyses of HTTF in the literature. Future RELAP5-3D validation activities centered around HTTF may be able to provide greater insight into the code’s capabilities for HTGR modeling with a more finely nodalized model.
In order to improve the understanding of particle vitiation effects in hypersonic propulsion test facilities, a quasi-one dimensional numerical tool was developed to efficiently model reacting particle-gas flows over a wide range of conditions. Features of this code include gas-phase finite-rate kinetics, a global porous-particle combustion model, mass, momentum and energy interactions between phases, and subsonic and supersonic particle drag and heat transfer models. The basic capabilities of this tool were validated against available data or other validated codes. To demonstrate the capabilities of the code a series of computations were performed for a model hypersonic propulsion test facility and scramjet. Parameters studied were simulated flight Mach number, particle size, particle mass fraction and particle material.
The inventory covers free jet and direct connect altitude cells, sea level static thrust stands, sea level test cells with ram air, and propulsion wind tunnels. Free jet altitude cells and propulsion wind tunnels are used for evaluation of complete inlet-engine-exhaust nozzle propulsion systems under simulated flight conditions. These facilities are similar in principal of operation and differ primarily in test section concept. The propulsion wind tunnel provides a closed test section and restrains the flow around the test specimen while the free jet is allowed to expand freely. A chamber of large diameter about the free jet is provided in which desired operating pressure levels may be maintained. Sea level test cells with ram air provide controlled, conditioned air directly to the engine face for performance evaluation at low altitude flight conditions. Direct connect altitude cells provide a means of performance evaluation at simulated conditions of Mach number and altitude with air supplied to the flight altitude conditions. Sea level static thrust stands simply provide an instrumented engine mounting for measuring thrust at zero airspeed. While all of these facilities are used for integrated engine testing, a few provide engine component test capability.
A thermal model of the dewar and optical system of the Cryogenic Optical Test Facility at NASA-Ames Research Center was developed using the computer codes SINDA and MONTE CARLO. The model was based on the geometry, boundary conditions, and physical properties of the test facility and was developed to investigate heat transfer mechanisms and temperatures in the facility and in test mirrors during cryogenic optical tests. A single-arch, fused-natural-quartz mirror was the first mirror whose thermal loads and temperature distributions were modeled. From the temperature distribution, the thermal gradients in the mirror were obtained. The model predicted that a small gradient should exist for the single arch mirror. This was later verified by the measurement of mirror temperatures. The temperatures, predicted by the model at various locations within the dewar, were in relatively good agreement with the measured temperatures. The model is applicable to both steady-state and transient cooldown operations.
NASA Lewis Research Center (LeRC) presently accommodates a total of six combustor test facilities with unique capabilities. The facilities are used to evaluate combustor and afterburner concepts for future engine applications, and also to test the survivability and performance of innovative high temperature materials, new instrumentation, and engine components in a realistic jet engine environment. The facilities provide a variety of test section interfaces and lengths to allow for flametube, sector and component testing. The facilities can accommodate a wide range of operating conditions due to differing capabilities in the following areas: inlet air pressure, temperature, and flow; fuel flow rate, pressure, and fuel storage capacity; maximum combustion zone temperature; cooling water flow rate and pressure; types of exhaust - atmospheric or altitude; air heater supply pressure; and types of air heaters - vitiated or nonvitiated. All of the facilities have provisions for standard gas (emissions) analysis, and a few of the facilities are equipped with specialized gas analysis equipment, smoke and particle size measurement devices, and a variety of laser systems. This report will present some of the unique features of each of the high temperature/high pressure combustor test facilities at NASA LeRC.
The Rocket Based Combined Cycle (RBCC) engine is expected to evolve based upon past combined-cycle propulsion test experience/data and new extensive test data. Currently, it is envisioned that a portion of the component and system testing will be pursued at NASA Stennis Space Center (SSC). To realize the greatest benefit of the test data, uncertainty analyses are being performed on the relevant RBCC components and systems to be tested at NASA SSC to ascertain the needed measurement requirements. These studies pertain to the existing E-Complex test stands as well as a new facility, E-4. This paper describes the approach used in the studies and gives examples to demonstrate the approach and the usefulness of the results. Future work will greatly increase the reliability of the test data while minimizing costs by focusing expenditures in the proper areas that are critical to program success and not allowing resources to be wasted in areas that are not significant relative to overall program goals.
In February 2017, aerodynamic and acoustic testing was completed on a scale-model high bypass ratio turbofan rotor, R4, in an internal flow component test facility. The objective of testing was to determine the aerodynamic and acoustic impact of fan casing treatments designed to reduce noise. The baseline configuration consisted of the R4 rotor with a hardwall fan case. Data are presented for a baseline acoustic run with fan exit instrumentation removed to give a clean acoustic configuration.
Large vacuum facility tests of MPD arc thrustor