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DOE OSTI2017

Performance Testing of Tracer Gas and Tracer Aerosol Detectors for use in Radionuclide NESHAP Compliance Testing

The Rad-NESHAP program, part of the Air Quality Compliance team of LANL’s Compliance Programs group (EPC-CP), and the Radiation Instrumentation & Calibration team, part of the Radiation Protection Services group (RP-SVS), frequently partner on issues relating to characterizing air flow streams. This memo documents the most recent example of this partnership, involving performance testing of sulfur hexafluoride detectors for use in stack gas mixing tests. Additionally, members of the Rad-NESHAP program performed a functional trending test on a pair of optical particle counters, comparing results from a non-calibrated instrument to a calibrated instrument. Prior to commissioning a new stack sampling system, the ANSI Standard for stack sampling requires that the stack sample location must meet several criteria, including uniformity of tracer gas and aerosol mixing in the air stream. For these mix tests, tracer media (sulfur hexafluoride gas or liquid oil aerosol particles) are injected into the stack air stream and the resulting air concentrations are measured across the plane of the stack at the proposed sampling location. The coefficient of variation of these media concentrations must be under 20% when evaluated over the central 2/3 area of the stack or duct. The instruments which measure these air concentrations must be tested prior to the stack tests in order to ensure their linear response to varying air concentrations of either tracer gas or tracer aerosol. The instruments used in tracer gas and aerosol mix testing cannot be calibrated by the LANL Standards and Calibration Laboratory, so they would normally be sent off-site for factory calibration by the vendor. Operational requirements can prevent formal factory calibration of some instruments after they have been used in hazardous settings, e.g., within a radiological facility with potential airborne contamination. The performance tests described in this document are intended to demonstrate the reliable performance of the test instruments for the specific tests used in stack flow characterization.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2017

Comparison of a Micro-Neutralization Test with the Rapid Fluorescent Focus Inhibition Test for Measuring Rabies Virus Neutralizing Antibodies

The rapid fluorescent focus inhibition test (RFFIT) is routinely used in the United States to measure rabies virus neutralizing antibodies (rVNA). RFFIT has a long history of reproducible and reliable results. The test has been modified over the years to use smaller volumes of reagents and samples, but requires a 50 µL minimum volume of test serum. To conduct pathogenesis studies, small laboratory animals such as mice are regularly tested for rVNA, but the minimum volume for a standard RFFIT may be impossible to obtain, particularly in scenarios of repeated sampling. To address this problem, a micro-neutralization test was developed previously. In the current study, the micro-neutralization test was compared to the RFFIT using 129 mouse serum samples from rabies vaccine studies. Using a cut-off value of 0.1 IU/mL, the sensitivity, specificity, and concordance of the micro-neutralization test were 100%, 97.5%, and 98%, respectively. The geometric mean titer of all samples above the cut-off was 2.0 IU/mL using RFFIT and 3.4 IU/mL using the micro-neutralization test, indicating that titers determined using the micro-neutralization test are not equivalent to RFFIT titers. Based on four rVNA-positive hamster serum samples, the intra-assay coefficient of variability was 24% and inter-assay coefficient of variability was 30.4%. These results support continued use of the micro-neutralization test to determine rabies virus neutralizing antibody titers for low-volume serum samples.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2021

Post-test Inspection of NASA’s Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge and Neutralizer Cathodes

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014 after demonstrating 51,184 h of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for both discharge and neutralizer cathodes. Discharge keeper erosion was found to be significantly reduced from what was observed in the NEXT 2 kh wear test and NSTAR Extended Life Test, providing adequate protection of vital cathode components throughout the test with ample lifetime remaining. The area of the discharge cathode orifice plate that was exposed by the keeper orifice exhibited net erosion, leading to cathode plate material building up in the cathode-keeper gap and causing a thermally-induced electrical short observed during the test. Significant erosion of the neutralizer cathode orifice was also found and is believed to be the root cause of an observed loss in flow margin. Deposition within the neutralizer keeper orifice as well as on the downstream surface was thicker than expected, potentially resulting in a facility-induced impact on the measured flow margin from plume mode. Neutralizer keeper wall erosion on the beam side was found to be significantly lower compared to the NEXT 2 kh wear test, likely due to the reduction in beam extraction diameter of the ion optics that resulted in decreased ion impingement. Results from the post-test inspection have led to some minor thruster design improvements.

Ion engine↗

NASA NTRSDate not supplied

Description of Cloud Characterization and Icing Test for a 3D Heated Test Article at the NASA Icing Research Tunnel

This paper describes the cloud characterization and icing tests conducted with a 3D heated test article in Winter/Spring 2022 at the NASA Icing Research Tunnel. The intent is to present analyzed results from these recently conducted tests in a future technical paper. The test article, whose geometry is representative of an inter-compressor duct and strut region of a turbofan engine, has been designed and constructed to study the physics of supercooled water icing and ice crystal icing. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, a scale to measure ice mass, and other instruments will aid in characterizing the icing behavior. The aim of these tests is to generate ice accretions on the SIDRM test article under well-characterized conditions. To that end, a suite of instruments was utilized to characterize the ice crystal clouds at the test section in a separate test series. The icing measurements collected during the SIDRM model tests will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assess the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost effective way.

Ice crystal icing↗

NASA NTRSDate not supplied

Description of Cloud Characterization and Icing Tests for a 3D Heated Test Article at the NASA Icing Research Tunnel

Ice crystal icing, heated test article, engine ici↗

DOE OSTI2015

1.5 nm fabrication of test patterns for characterization of metrological systems

Any metrology tool is only as good as it is calibrated. The characterization of metrology systems requires test patterns at a scale about ten times smaller than the measured features. The fabrication of patterns with linewidths down to 1.5 nm is described. The test sample was designed in such a way that the distribution of linewidths appears to be random at any location. This pseudorandom test pattern is used to characterize dimensional metrology equipment over its entire dynamic range by extracting the modulation transfer function of the system. The test pattern contains alternating lines of silicon and tungsten silicide, each according to its designed width. As a result, the fabricated test samples were imaged using a transmission electron microscope, a scanning electron microscope, and an atomic force microscope. (C) 2015 American Vacuum Society.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Technical analysis of filter testing at the U.S. Department of Energy Filter Test Facility

The U.S. Department of Energy (DOE) technical standard DOE-STD-3020-2015 requires verification testing at the Filter Test Facility (FTF) of high-efficiency particulate air (HEPA) filters to be installed in nuclear facility (Hazard Category 1, 2, 3, and radiological facilities) confinement ventilation systems, or to be installed in habitability systems (e.g., filters for protection of workers required to act for the control and mitigation of emergency situations). Filters in these applications perform a safety function in accident situations, are designated as important to safety, or are necessary for habitability systems. Different FTFs have operated for decades, and results of tests are available to examine the need for and benefits of continued execution of 100 percent QA verification testing. The objective of this study and resulting report was to assess the need for 100 percent QA testing at the current FTF in Maryland, based on an examination of a database of test results from 2013 to August 2020. Filters that require independent testing per DOE-STD-3020-2015 to be installed in nuclear facilities are sent to the FTF before being shipped to the facilities. The FTF examines the documentation (e.g., certificates of compliance, results of particle penetration and airflow resistance testing by the manufacturers, labels affixed to filters and packages, and other requirements specified in purchase orders by the nuclear facility operators), implements visual inspections of the physical state of the filters, and checks the dimensions of frames. Filters that meet the documentation and visual inspection requirements are subjected to particle penetration and airflow resistance testing. In case of rejections, the filters are shipped back to the manufacturers, at the cost of the manufacturers, for replacement. Filters that pass all tests are shipped to the nuclear facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Gear Test Assembly – Report Experimental Testing and Gear Analysis (FY2021 Midyear Report)

The Gear Test Assembly (GTA) has completed three experimental campaigns at the Mechanisms Engineering Test Loop (METL) facility. The most recent campaign tested Inconel 718 spur gears, tapered roller bearings of 52100 bearing steel with no heat treatment, and a lantern ring shaft seal with spring-loaded fasteners. Testing was performed in Test Vessel 1 (TV1) with 250°C sodium that had an oxide concentration of <10ppm. Testing began in February 2021 and was ended in March 2021 when a thrust bearing assembly failed, requiring shutdown and maintenance. The third experimental campaign completed 1,568 simulated fuel assembly maneuvers before the thrust bearing failure. The GTA was removed from TV1 and cleaned in the Carbonation System. The GTA is currently being prepared for the next experimental campaign. Nondestructive examination methods have been developed at Argonne to monitor the health of the GTA spur gears. Eddy current testing (ECT) and ultrasonic testing (UT) were performed prior to sodium testing and after each experimental campaign. The NDE has shown that the primary damage mechanism is mechanical wear on the gear tooth surface. Several larger nicks are observable on the gear faces, with additional large nicks present on the edges of the gear teeth. While this damage is observable, the overall health of the gears is adequate for more in-sodium testing. A total of 12,752 simulated fuel assembly maneuvers have been completed using this set of gears.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1990

Testing of 3-D models in 2-D adaptive wall test sections

Considerable effort was devoted to the development of two-dimensional adaptive wall test sections. The development of fully three-dimensional test sections, however, has not had this same level of effort expended. The limitations on three-dimensional research are the result of the complexity of both the mechanical design and operational aspects. Typical of the mechanical complexities are lack of readily available model and flow visualization access, and problems of sealing between adjacent walls for multi-wall types of test sections. The operational aspects are complicated by the necessity for many measurements of the boundary conditions which can be very time consuming. In three-dimensional testing, it is impossible to remove all of the boundary interference. It will be necessary, therefore, to apply residual corrections to the data. The more complex the test section shape, the more complex the calculation of the residual corrections becomes. From both the viewpoint of test section complexity and of ease of residual corrections, a simplified test section geometry is desirable. To aid in the design of simplified test sections, several researchers investigated the capability of using two-dimensional adaptive wall test sections to perform three-dimensional testing. By use of this type of design, the inherent complications and limitations of the fully three-dimensional design are avoided. Strategies of adaptation used for this application are described, as well as, sample results and a discussion of some limitations of the technique.

Wedemeyer, Erich H.↗

NASA NTRS1991

Recommended fine positioning test for the Development Test Flight (DTF-1) of the NASA Flight Telerobotic Servicer (FTS)

Test procedures are proposed for the NASA DTF (Development Test Flight)-1 positioning tests of the FTS (Flight Telerobotic Servicer). The unique problems associated with the DTF-1 mission are discussed, standard robot performance tests and terminology are reviewed and a very detailed description of flight-like testing and analysis is presented. The major technical problem associated with DTF-1 is that only one position sensor can be used, which will be fixed at one location, with a working volume which is probably smaller than some of the robot errors to be measured. Radiation heating of the arm and the sensor could also cause distortions that would interfere with the test. Two robot performance testing committees have established standard testing procedures relevant to the DTF-1. Due to the technical problems associated with DTF-1, these procedures cannot be applied directly. These standard tests call for the use of several test positions at specific locations. Only one position, that of the position sensor, can be used by DTF-1. Off-line programming accuracy might be impossible to measure and in that case it will have to be replaced by forward kinetics accuracy.

Dagalakis, N.↗

NASA NTRS1992

The design of test-section inserts for higher speed aeroacoustic testing in the Ames 80- by 120-foot wind tunnel

An engineering feasibility study was made of aeroacoustic inserts designed for large-scale acoustic research on aircraft models in the 80- by 120-Foot Wind Tunnel at NASA Ames Research Center. The goal was to find test-section modifications that would allow improved aeroacoustic testing at airspeeds equal to and above the current 100 knots limit. Results indicate that the required maximum airspeed drives the design of a particular insert. Using goals of 200, 150, and 100 knots airspeed, the analysis led to a 30 x 60 ft open-jet test section, a 40 x 80 ft open-jet test section, and a 70 x 110 ft closed test section with enhanced wall lining respectively. The open-jet inserts would be composed of a nozzle, collector, diffuser, and acoustic wedges incorporated in the existing 80 x 120 ft test section. The closed test section would be composed of approximately 5-ft acoustic wedges covered by a porous plate attached to the test-section walls of the existing 80 x 120. All designs would require a double row of acoustic vanes between the test section and fan drive to attenuate fan noise and, in the case of the open-jet designs, to control flow separation at the diffuser downstream end. The inserts would allow virtually anechoic acoustics studies of large helicopter models, jets, and V/STOL aircraft models in simulated flight. Model scale studies would be necessary to optimize the aerodynamic and acoustic performance of any of the designs. Successful development of acoustically transparent walls, though not strictly necessary to the project, would lead to a porous-wall test section that could be substituted for any of the open-jet designs, and thereby eliminate many aerodynamic and acoustic problems characteristic of open-jet shear layers.

Soderman, Paul T.↗

NASA NTRS1994

Ni-MH storage test and cycle life test

Gates Aerospace Batteries is conducting two long term test programs to fully characterize the NiMH cell technology for aerospace applications. The first program analyzes the effects of long term storage upon cell performance. The second program analyzes cycle life testing and preliminary production lot testing. This paper summarizes these approaches to testing the NiMH couple and culminates with initial storage and testing recommendations. Long term storage presents challenges to deter the adverse condition of capacity fade in NiMH cells. Elevated but stabilized pressures and elevated but stabilized end-of-charge voltages also appear to be a characteristic phenomenon of long term storage modes. However, the performance degradation is dependent upon specific characteristics of the metal-hydride alloy. To date, there is no objective evidence with which to recommend the proper method for storage and handling of NiMH cells upon shipment. This is particularly critical due to limited data points that indicate open circuit storage at room temperature for 60 to 90 days will result in irrecoverable capacity loss. Accordingly a test plan was developed to determine what method of mid-term to long-term storage will prevent irrecoverable capacity loss. The explicit assumption is that trickle charging at some rate above the self-discharge rate will prevent the irreversible chemical changes to the negative electrode that result in the irrecoverable capacity loss. Another premise is that lower storage temperatures, typically 0 C for aerospace customers, will impede any negative chemical reactions. Three different trickle charge rates are expected to yield a fairly flat response with respect to recoverable capacity versus baseline cells in two different modes of open circuit. Specific attributes monitored include: end-of-charge voltage, end-of-charge pressure, mid-point discharge voltage, capacity, and end-of-discharge pressure. Cycle life testing and preliminary production lot testing continue to dominate the overall technology development effort at GAB. The cell life test program reflects continuing improvements in baseline cell designs. Performance improvements include lower and more stable charge voltages and pressures. The continuing review of production lot testing assures conformance to the design criteria and expectations. This is especially critical during this period of transferring technology from research and development status to production.

Dell, R. Dan↗

NASA NTRS1998

Integrated Advanced Microwave Sounding Unit-A (AMSU-A). Engineering Test Report: AMSU-A1 EOS Instrument, (S/N 202) Qualification Level Vibration Tests of August/September 1998, (S/O 565632, OC-417) Plus Addendum A

The purpose of this report is to present a qualification level vibration testing performed on the S/N 202, EOS AMSU-A1 Instrument was vibration tested to qualification levels per the Ref. 1 shop order. The instrument withstood the 8 g sine sweep test, the 7.5 Grms random vibration test, and the 18.75 g sine burst test in each of the three orthogonal axes. Some loss of transmissibility, however, is seen in the lower reflector after Z-axis random vibration. The test sequence was not without incidence. Failure of Channel 7 in the Limited Performance Test (LPT) performed after completion of the 1 st (X-axis) axis vibration sequence, required replacement of the DRO and subsequent re-testing of the instrument. The post-vibration comprehensive performance test (CPT) was successfully run after completion of the three axes of vibration with the replacement component installed in the instrument. Passing the CPT signified the successful completion of the S/N 202 A1 qualification vibration testing.

Heffer, R.↗

NASA NTRS2007

High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing: Analysis and Initial Test Results

Non-nuclear testing can be a valuable tool in the development of a space nuclear power system, providing system characterization data and allowing one to work through various fabrication, assembly and integration issues without the cost and time associated with a full ground nuclear test. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Testing with non-optimized heater elements allows one to assess thermal, heat transfer. and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. High fidelity thermal simulators that match both the static and the dynamic fuel pin performance that would be observed in an operating, fueled nuclear reactor can vastly increase the value of non-nuclear test results. With optimized simulators, the integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and fueled nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics and assess potential design improvements at relatively small fiscal investment. Initial conceptual thermal simulator designs are determined by simple one-dimensional analysis at a single axial location and at steady state conditions; feasible concepts are then input into a detailed three-dimensional model for comparison to expected fuel pin performance. Static and dynamic fuel pin performance for a proposed reactor design is determined using SINDA/FLUINT thermal analysis software, and comparison is made between the expected nuclear performance and the performance of conceptual thermal simulator designs. Through a series of iterative analyses, a conceptual high fidelity design is developed: this is followed by engineering design, fabrication, and testing to validate the overall design process. Test results presented in this paper correspond to a "first cut" simulator design for a potential liquid metal (NaK) cooled reactor design that could be applied for Lunar surface power. Proposed refinements to this simulator design are also presented.

Bragg-Sitton, Shannon M.↗

NASA NTRS2010

Ares I-X Flight Test Vehicle: Stack 5 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA's Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the first modal test that was performed on the top section of the vehicle referred to as Stack 5, which consisted of the spacecraft adapter, service module, crew module and launch abort system simulators. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 5 modal test.

Buehrle, Ralph D.↗

NASA NTRS2010

Ares I-X Flight Test Vehicle:Stack 1 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA s Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the second modal test that was performed on the middle section of the vehicle referred to as Stack 1, which consisted of the subassembly from the 5th segment simulator through the interstage. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 1 modal test.

Buehrle, Ralph D.↗

NASA NTRS2011

HIFiRE Direct-Connect Rig (HDCR) Phase I Scramjet Test Results from the NASA Langley Arc-Heated Scramjet Test Facility

A series of hydrocarbon-fueled direct-connect scramjet ground tests has been completed in the NASA Langley Arc-Heated Scramjet Test Facility (AHSTF) at simulated Mach 8 flight conditions. These experiments were part of an initial test phase to support Flight 2 of the Hypersonic International Flight Research Experimentation (HIFiRE) Program. In this flight experiment, a hydrocarbon-fueled scramjet is intended to demonstrate transition from dual-mode to scramjet-mode operation and verify the scramjet performance prediction and design tools A performance goal is the achievement of a combusted fuel equivalence ratio greater than 0.7 while in scramjet mode. The ground test rig, designated the HIFiRE Direct Connect Rig (HDCR), is a full-scale, heat sink test article that duplicates both the flowpath lines and a majority of the instrumentation layout of the isolator and combustor portion of the flight test hardware. The primary objectives of the HDCR Phase I tests were to verify the operability of the HIFiRE isolator/combustor across the simulated Mach 6-8 flight regime and to establish a fuel distribution schedule to ensure a successful mode transition. Both of these objectives were achieved prior to the HiFIRE Flight 2 payload Critical Design Review. Mach 8 ground test results are presented in this report, including flowpath surface pressure distributions that demonstrate the operation of the flowpath in scramjet-mode over a small range of test conditions around the nominal Mach 8 simulation, as well as over a range of fuel equivalence ratios. Flowpath analysis using ground test data is presented elsewhere; however, limited comparisons with analytical predictions suggest that both scramjet-mode operation and the combustion performance objective are achieved at Mach 8 conditions.

Cabell, Karen↗

NASA NTRS2013

A Boilerplate Capsule Test Technique for the Orion Parachute Test Program

The test program developing parachutes for the Orion/MPCV includes drop tests of a Parachute Test Vehicle designed to emulate the wake of the Orion capsule. Delivery of this test vehicle to the initial velocity, altitude, and orientation required for the test is a difficult problem involving multiple engineering disciplines. The available delivery of aircraft options imposed constraints on the test vehicle development and concept of operations. This paper describes the development of this test technique. The engineering challenges include the extraction from an aircraft and separation of two aerodynamically unstable vehicles, one of which will be delivered to a specific orientation with reasonably small rates. The desired attitude is achieved by precisely targeting the separation point using on-board monitoring of the motion. The design of the test vehicle is described. The trajectory simulations and other analyses used to develop this technique and predict the behavior of the test article are reviewed in detail. The application of the technique on several successful drop tests is summarized.

Moore, James W.↗