Results for “Test Loop” — Page 12

NASA NTRS1979

Low cycle fatigue properties of MAR-M-246 Hf in hydrogen

The transverse, low cycle fatigue properties were determined for directionally solidified and single crystal samples of a cast nickel-base alloy proposed for use in space propulsion systems in pure or partial high pressure hydrogen environments at elevated temperatures. The test temperature was 760 C (1400F) and the pressure of the gaseous hydrogen was 34.5 MPa (5000 psig). Low cycle fatique life was established by strain controlled testing using smooth specimens and a servohydraulic closed-loop test machine modified with a high pressure environmental chamber. Results and conclusions are discussed.

Warren, J. R.↗

NASA NTRS2007

Development of a Radio Frequency Space Environment Path Emulator for Evaluating Spacecraft Ranging Hardware

The Formation Flying Testbed (FFTB) at the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) provides a hardware-in-the-loop test environment for formation navigation and control. The facility is evolving as a modular, hybrid, dynamic simulation facility for end-to-end guidance, navigation and. control (GN&C) design and analysis of formation flying spacecraft. The core capabilities of the FFTB, as a platform for testing critical hardware and software algorithms in-the-loop, have expanded to include S-band Radio Frequency (RF) modems for inter-spacecraft communication and ranging. To enable realistic simulations that require RF ranging sensors for relative navigation, a mechanism is needed to buffer the RF signals exchanged between spacecraft that accurately emulates the dynamic environment through which the RF signals travel, including the effects of medium, moving platforms, and radiated power. The Path Emulator for RF Signals (PERFS), currently under development at NASA GSFC, provides this capability. The function and performance of a prototype device are presented.

Mitchell, Jason W.↗

NASA NTRS2007

Characterization of a Prototype Radio Frequency Space Environment Path Emulator for Evaluating Spacecraft Ranging Hardware

The Formation Flying Testbed (FFTB) at the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) provides a hardware-in-the-loop test environment for formation navigation and control. The facility is evolving as a modular, hybrid, dynamic simulation facility for end-to-end guidance, navigation and control (GN&C) design and analysis of formation flying spacecraft. The core capabilities of the FFTB, as a platform for testing critical hardware and software algorithms in-the-loop, have expanded to include S-band Radio Frequency (RF) modems for interspacecraft communication and ranging. To enable realistic simulations that require RF ranging sensors for relative navigation, a mechanism is needed to buffer the RF signals exchanged between spacecraft that accurately emulates the dynamic environment through which the RF signals travel, including the effects of the medium, moving platforms, and radiated power. The Path Emulator for Radio Frequency Signals (PERFS), currently under development at NASA GSFC, provides this capability. The function and performance of a prototype device are presented.

Mitchell, Jason W.↗

NASA NTRS2021

MBSE Validation and Verification: Case Study for LADEE

The Lunar Atmosphere Dust Environment Explorer (LADEE) mission orbited the moon in order to measure the density, composition, and time variability of the lunar dust environment. The successful mission launched September 7, 2013 and was de-orbited and impacted the moon's surface on April 17, 2014. The ground-side and onboard flight software for the mission was developed using a “Model-Based Software Engineering” (MBSE) methodology combined with strong reuse of Government and Commercial Off-The Shelf (G/COTS) components. Models of the spacecraft and flight software were developed in a graphical dynamics modeling package. Flight Software requirements were prototyped and refined using the simulated models. After the model was shown to work as desired in the simulation framework, C-code software was automatically generated from the models. The auto-generated software was then tested in real-time Processor-in-the-Loop and Hardware-in-the-Loop test beds. “Traveling Road Show” test beds were used for early integration tests with payloads and other subsystems. Traditional techniques for verifying computational sciences models were used to characterize the spacecraft simulation. A lightweight set of formal methods analysis, static analysis, formal inspection, and code coverage analyses were utilized to further reduce defects in the onboard flight software artifacts. These techniques were applied early and often in the development process, iteratively increasing the capabilities of software and fidelity of vehicle models and test beds.

Model-Based Software Engineering, Validation and V↗

NASA NTRS1988

Study of toluene stability for an Organic Rankine Cycle (ORC) space-based power system

The design, fabrication, assembly, and endurance operation of a dynamic test loop, built to evaluate the thermal stability of a proposed Organic Rankine Cycle (ORC) working fluid, is discussed. The test fluid, toluene, was circulated through a heater, simulated turbine, regenerator, condenser and pump to duplicate an actual ORC system. The maximum nominal fluid temperature, 750 F, was at the turbine simulator inlet. Samples of noncondensible gases and liquid toluene were taken periodically during the test. The samples were analyzed to identify the degradation products formed and the quantity of these products. From these data it was possible to determine the degradation rate of the working fluid and the generation rate of noncondensible gases. A further goal of this work was to relate the degradation observed in the dynamic operating loop to degradation obtained in isothermal capsule tests. This relationship was the basis for estimating the power loop degradation in the Space Station Organic Rankine Cycle system.

Havens, Vance↗

NASA NTRS1965

Impurity and liquid level measurements for the Faret loop

Self-seeking liquid sodium level and sodium impurity measurements for fast reactor test loop

SODIUM↗

DOE OSTI2020

Thermal Hydraulic Experimental Test Article (FY2020 Status Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed. Since the FY19 THETA status report, the THETA primary system components have been assembled and tested using de-ionized water. Some results of this testing at select Richardson and Reynolds numbers are included herein. The custom THETA sodium flowmeter (permanent magnet submersible sodium flowmeter) has been built and calibrated using sodium in an auxiliary facility against a NIST traceable vortex shedder type flowmeter. The permanent magnet flowmeter showed excellent performance, following the theoretical equation for measured voltage quite well, with an error < 3.5% at flow rates ranging from 3-24 GPM at temperatures up to 400 °C. The secondary sodium system for heat rejection from intermediate heat exchanger has been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger have been procured.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Thermal Hydraulic Experimental Test Article - Report of THETA Commissioning for METL Testing

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, [1], further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned before installing into METL test vessel #4. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Thermal Hydraulic Experimental Test Article (FY21 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time. Following installation of THETA into vessel #4, all data acquisition and control systems were brought online and commissioned at room temperature in the argon gas space of the empty vessel. The vessel zone 1 heaters were reinstalled and the flange was then insulated. The vessel 4 heaters were brought to a temperature of 100 °C and the THETA pump was jogged at 600 RPM to ensure it was functioning correctly. The secondary, AC Conduction based electromagnetic pump from CMI Novacast (product number CA-15) was ordered and will be delivered in late calendar year 2021. The custom designed permanent magnet based secondary flowmeter was designed, a drawing package and manufacturing specification created and quote requested from a machine shop. The intermediate heat exchanger design was completed and a drawing package is currently in progress. During the middle of calendar year 2021 the Building 308 sodium scrubber system was shut down in order to replaced some corroded piping and facilitate improvements on the system, thus requiring the sodium in METL to remain frozen. This has imposed a delay in filling vessel 4 with sodium to begin THETA testing. Sodium testing is expected to begin in early fiscal year 2022 as all THETA primary systems are operational.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Thermal Hydraulic Experimental Test Article - Status Report FY20 Q2

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (like a redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed, most primary component have been fabricated, primary components are being assembled in preparation for initial testing, and procurement is continuing with the secondary system components. Since the FY19 THETA status report, The THETA primary system components are at Argonne National Laboratory (ANL) and have been dry assembled. The secondary sodium system for heat rejection from intermediate heat exchanger has all been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger has been procured.

42 ENGINEERING↗

DOE OSTI2023

Gripper Test Assembly Status of Fabrication and Assembly Report – FY2023

The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1988

Design and testing of a high power spacecraft thermal management system

The design and test results are presented of an ammonia hybrid capillary pumped loop thermal control system which could be used for heat acquisition and transport on future large space platforms and attached payloads, such as those associated with the NASA Space Station. The High Power Spacecraft Thermal Management System (HPSTM) can operate as either a passive, capillary pumped two phase thermal control system, or, when additional pressure head is required, as a mechanically pumped loop. Testing has shown that in the capillary mode, the HPSTM evaporators can acquire a total heat load of between 600 W and 24 kW, transported over 10 meters, at a maximum heat flux density of 4.3 W/sq cm. With the mechanical pump circulating the ammonia, a heat acquisition potential of 52 kW was demonstrated for 15 minutes without an evaporator failure. These results represent a significant improvement over the maximum transport capability previously displayed in other capillary systems. The HPSTM system still retains the proven capillary capabilities of heat load sharing and flow control between evaporator plates, rapid power cycling, and nonuniform heating in both the capillary and hybrid operating modes.

Mccabe, Michael E., Jr.↗

NASA NTRS1992

Experimental testing of prototype face gears for helicopter transmissions

An experimental program to test the feasibility of using face gears in a high-speed and high-power environment was conducted. Four face gear sets were tested, two sets at a time, in a closed-loop test stand at pinion rotational speeds to 19,100 rpm and to 271 kW. The test gear sets were one-half scale of the helicopter design gear set. Testing the gears at one-eighth power, the test gear set had slightly increased bending and compressive stresses when compared to the full scale design. The tests were performed in the LeRC spiral bevel gear test facility. All four sets of gears successfully ran at 100 percent of design torque and speed for 30 million pinion cycles, and two sets successfully ran at 200 percent of torque for an additional 30 million pinion cycles. The results, although limited, demonstrated the feasibility of using face gears for high-speed, high-load applications.

Handschuh, R.↗

NASA NTRS2016

Determination of Heritage SSME Pogo Suppressor Resistance and Inertance from Waterflow Pulse Testing

Waterflow tests of a heritage Space Shuttle Main Engine pogo suppressor were performed to experimentally quantify the resistance and inertance provided by the suppressor. Measurements of dynamic pressure and flow rate in response to pulsing flow were made throughout the test loop. A unique system identification methodology combined all sensor measurements with a one-dimensional perturbational flow model of the complete water flow loop to spatially translate physical measurements to the device under test. Multiple techniques were then employed to extract the effective resistance and inertance for the pogo suppressor. Parameters such as steady flow rate, perturbational flow rate magnitude, and pulse frequency were investigated to assess their influence on the behavior of the pogo suppressor dynamic response. These results support validation of the RS-25 pogo suppressor performance for use on the Space Launch System Core Stage.

McDougal, Chris↗

DOE OSTI2020

Status of GTA Gear Inspection after Testing in Sodium

The Mechanisms Engineering Test Loop (METL) is an intermediate-scale liquid metal experimental facility that provides purified reactor-grade (R-grade) sodium to various experimental test vessels. In these test vessels, components that are required to operate in an advanced fast reactor can be tested in a prototypical sodium environment. Experiments conducted in METL significantly assist in the development and maturation of systems and components for advanced reactors. The METL facility consists of multiple test segments including: a purification and diagnostic loop (cold trap was designed after EBR-II), two 18” diameter test vessels with 150 L capacities capable of operating in static or dynamic flow at 538°C, two 28” diameter test vessels with 644 L capacities capable of operating in static or dynamic flow at 650°C, a 3,180 L dump tank with 21 instrumentation ports, and the infrastructure to expand capacity in the future.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2018

Orion Optical Navigation Progress Toward Exploration: Mission 1

Optical navigation of human spacecraft was proposed on Gemini and implemented successfully on Apollo as a means of autonomously operating the vehicle in the event of lost communication with controllers on Earth. It shares a history with the "method of lunar distances" that was used in the 18th century and gained some notoriety after its use by Captain James Cook during his 1768 Pacific voyage of the HMS Endeavor. The Orion emergency return system utilizing optical navigation has matured in design over the last several years, and is currently undergoing the final implementation and test phase in preparation for Exploration Mission 1 (EM-1) in 2019. The software development is being worked as a Government Furnished Equipment (GFE) project delivered as an application within the Core Flight Software of the Orion camera controller module. The mathematical formulation behind the initial ellipse fit in the image processing is detailed in Christian. The non-linear least squares refinement then follows the technique of Mortari as an estimation process of the planetary limb using the sigmoid function. The Orion optical navigation system uses a body fixed camera, a decision that was driven by mass and mechanism constraints. The general concept of operations involves a 2-hour pass once every 24 hours, with passes specifically placed before all maneuvers to supply accurate navigation information to guidance and targeting. The pass lengths are limited by thermal constraints on the vehicle since the OpNav attitude generally deviates from the thermally stable tail-to-sun attitude maintained during the rest of the orbit coast phase. Calibration is scheduled prior to every pass due to the unknown nature of thermal effects on the lens distortion and the mounting platform deformations between the camera and star trackers. The calibration technique is described in detail by Christian, et al. and simultaneously estimates the Brown-Conrady coefficients and the Star Tracker/Camera interlock angles. Accurate attitude information is provided by the star trackers during each pass. Figure 1 shows the various phases of lunar return navigation when the vehicle is in autonomous operation with lost ground communication. The midcourse maneuvers are placed to control the entry interface conditions to the desired corridor for safe landing. The general form of optical navigation on Orion is where still images of the Moon or Earth are processed to find the apparent angular diameter and centroid in the camera focal plane. This raw data is transformed into range and bearing angle measurements using planetary data and precise star tracker inertial attitude. The measurements are then sent to the main flight computer's Kalman filter to update the onboard state vector. The images are, of course, collected over an arc to converge the state and estimate velocity. The same basic technique was used by Apollo to satisfy loss-of-comm, but Apollo used manual crew sightings with a vehicle-integral sextant instead of autonomously processing optical imagery. The software development is past its Critical Design Review, and is progressing through test and certification for human rating. In support of this, a hardware-in-the-loop test rig was developed in the Johnson Space Center Electro-Optics Lab to exercise the OpNav system prior to integrated testing on the Orion vehicle. Figure 2 shows the rig, which the test team has dubbed OCILOT (Orion Camera In the Loop Optical Testbed). Analysis performed to date shows a delivery that satisfies an allowable entry corridor as shown in Figure 3.

Holt, Greg N.↗

NASA NTRS2001

Geoscience Laser Altimeter System (GLAS) Instrument: Flight Loop Heat Pipe (LHP) Acceptance Thermal Vacuum Test

Two loop heat pipes (LHPs) are to be used for tight thermal control of the Geoscience Laser Altimeter System (GLAS) instrument, planned for flight in late 2001. The LHPs are charged with Propylene as a working fluid. One LHP will be used to transport 110 W from a laser to a radiator, the other will transport 160 W from electronic boxes to a separate radiator. The application includes a large amount of thermal mass in each LHP system and low initial startup powers. The initial design had some non-ideal flight design compromises, resulted in a less than ideal charge level for this design concept with a symmetrical secondary wick. This less than ideal charge was identified as the source of inadequate performance of the flight LHPs during the flight thermal vacuum test in October of 2000. We modified the compensation chamber design, re-built and charged the LHPs for a final LHP acceptance thermal vacuum test. This test performed March of 2001 was 100% successful. This is the last testing to be performed on the LHPs prior to instrument thermal vacuum test. This sensitivity to charge level was shown through varying the charge on a Development Model Loop Heat Pipe (DM LHP) and evaluating performance at various fill levels. At lower fills similar to the original charge in the flight units, the same poor performance was observed. When the flight units were re-designed and filled to the levels similar to the initial successful DM LHP test, the flight units also successfully fulfilled all requirements. This final flight Acceptance test assessed performance with respect to startup, low power operation, conductance, and control heater power, and steady state control. The results of the testing showed that both LHPs operated within specification. Startup on one of the LHPs was better than the other LHP because of the starter heater placement and a difference in evaporator design. These differences resulted in a variation in the achieved superheat prior to startup. The LHP with the lower superheat was sensitive to the thermal environment around the compensation chamber, while the LHP with the higher superheat (similar in design to DM LHP) was not. In response to the test results the placement of the starter heater will be optimized for the flight instrument testing for higher achieved superheat. This presentation discusses startup behavior, overall conductance of a radiator system, low power operation, high power operation, temperature control stability, and control heater power requirements as measured during this acceptance thermal vacuum test. A brief summary of 'lessons learned' will be included.

Baker, Charles↗

DOE OSTI2025

Status Update for the Bearing Test Article Design Development – FY2025

Argonne National Laboratory’s (ANL) Mechanism Engineering Test Loop (METL) team has completed the design of a new Bearing Test Article (BTA) to test mechanical bearings for sodium fast reactor (SFR) mechanism applications. Recognition of the need for further bearing testing arose due to failure of rolling element bearings during testing of components for in-vessel fuel handling machines (FHMs) conducted at ANL in the METL facility. While the initial concept of the BTA arose from a need for bearing testing for FHM applications, the BTA design is configurable to test bearings of various sizes, types, and materials submerged in liquid sodium. Requirements for loading, shaft speed, temperature, and bearing size range were chosen based on requirements for SFR fuel handling. Modular components in the test bearing housings and shaft sleeves allow the design to accommodate a wide range of bearing sizes without modification to the larger assembly. Loading will be applied with screw jacks on the air side of the test article that will be adjusted to apply radial, thrust, or combined loading conditions. Applied force will be measured by load cells in-line with the loading mechanisms. In FY25 we have completed the design of the test article that will be fabricated and undergo testing at the METL facility. Drawing packages for the fabrication of the test article have been drafted and are being reviewed to add part tolerances and we have started ordering off-the-shelf components. The report will summarize the development of the Bearing Test Article design starting with an overview of the entire test article, then a more detailed examination of the bearing test section, loading mechanisms, test article ports and seals, and support structures, including analysis that went into significant design choices.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗