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NASA NTRS2005

Chapter 9 - Pre-Flight Tests

Pre-flight testing is critical to the success of any flight test program. Pre-flight tests are performed to measure and evaluate the characteristics of an aircraft in a non-flying environment and to verify that these characteristics are as desired. Since aircraft systems are becoming more and more complex, conducting proper pre-flight testing to help identify system characteristics and deficiencies prior to flight is more important now than ever before. Much flight test time has been lost fixing problems that should have been found and corrected prior to flight. Accidents have occurred because pre-flight tests and verification procedures were not conducted thoroughly enough to identify the aircraft's characteristics properly or to find system discrepancies. Proper pre-flight testing helps ensure that the aircraft is ready to fly and contributes toward an efficient, productive, and safe flight test program. The reader should be aware that this Section is dedicated to the testing that should take place prior to the first flight. There are other "pre-flight" tests that take place prior to each individual flight. These latter tests are not discussed in this Section. The following paragraphs of this Section describe significant tests that are usually accomplished prior to flying a new or highly modified aircraft. Test objectives, descriptions, products, and requirements are provided in the following subsections: 9.1 Wind tunnel tests 9.2 Simulation tests 9.3 Propulsion tests 9.4 Weight and balance tests 9.5 Ground vibration tests 9.6 Structural loads tests 9.7 Gain margin tests 9.8 Verification and calibration tests 9.9 Taxi tests The specific examples given and the test facilities mentioned in this Section will illustrate the approach taken and the techniques used by the US Air Force; however, they are typical of those used by other test organizations.

Paul W Kirsten↗

NASA NTRS2015

Development of an Infrared Lamp Array for the Smap Spacecraft Thermal Balance Test

NASA launched the SMAP observatory in January 2015 aboard a Delta II into a sun-synchronous orbit around Earth. The science payload of a radar and a radiometer utilizes a shared rotating six-meter antenna to provide a global map of the Earth's soil moisture content and its freeze/thaw state on a global, high-resolution scale in this three-year mission. An observatory-level thermal balance test conducted in May/June 2014 validated the thermal design and demonstrated launch readiness as part of the planned environmental test campaign. An infrared lamp array was designed and used in the thermal balance test to replicate solar heating on the solar array and sunlit side of the spacecraft that would normally be seen in orbit. The design, implementation, and operation of an infrared lamp array used for this nineteen-day system thermal test are described in this paper. Instrumental to the smooth operation of this lamp array was a characterization test performed in the same chamber two months prior to the observatory test to provide insight into its array operation and flux uniformity. This knowledge was used to identify the lamp array power settings that would provide the worst case predicted on-orbit fluxes during eclipse, cold, and hot cases. It also showed the lamp array variation when adjustments in flux were needed. Calorimeters calibrated prior to testing determined a relationship between calorimeter temperature and lamp array flux. This allowed the team to adjust the lamp output for the desired absorbed flux on the solar array. Flux levels were within 10% of the desired value at the center of the solar array with an ability to maintain these levels within 5% during steady state cases. All tests demonstrated the infrared lamp array functionality and furthered lamp array understanding for modeling purposes. This method contributed to a high-fidelity environmental simulation, which was required to replicate the extreme on-orbit thermal environments.

Miller, Jennifer R.↗

NASA NTRS2006

Microthruster Propulsion for the Space Technology 7 (ST7) Technology Demonstration Mission

For future applications to precision formation flying missions, NASA's New Millennium Program is scheduled to test colloid micro-Newton thrusters (CMNTs) on the ST7 technology demonstration mission. These CMNTs are part of a disturbance reduction system (DRS) on the ESA SMART-2 Spacecraft or LISA Pathfinder. The goal of the ST7 DRS is to demonstrate technologies necessary to meet the nanometer precision positioning control requirements of the LISA mission. In order to achieve these goals, the CMNTs are required to demonstrate a thrust resolution of less than 0.1 micro-N and a thrust noise of less than 0.1 micro-N/[square root]Hz for thrust levels between 5 and 30 micro-N. Developed by Busek Co. with support from JPL in testing an design, the CMNT has been developed over the last four years into a flight-ready microthrust system. The development, validation testing, and flight unit production of the CMNTs are described. Development tests and analysis include preliminary wear tests, propellant loading process verification, flow testing, and performance verification. Validation and flight unit verification includes thermal and structural analysis, life testing, thermal and dynamic load testing, and performance verification. Final delivery of the units is planned in 2007 with and planned launch and flight demonstration 2009.

microthruster↗

NASA NTRS1987

Space Station propulsion system test bed and control system testing results

The test bed fabricated to demonstrate hydrogen/oxygen propulsion technology readiness for the IOC Space Station application is described and test results are presented. The reliability and safety of the O2/H2 system was demonstrated with blowdowns and thruster firings. The flexibility of the system was demonstrated through the addition of an electrolysis supply module.

Norman, A. M.↗

NASA NTRS2005

Finite Element Analysis and Test Correlation of a 10-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA's future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from vibration tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS2005

Structural Analysis of an Inflation-Deployed Solar Sail With Experimental Validation

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from structural dynamics tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS1973

Analysis of test data film generated by the lunar sounder (S-209)

The analysis of test films pertaining to the readiness of the Apollo 17 radar equipment is discussed. Emphasis is placed on the evaluation of the lunar sounder equipment. The lunar sounder experiment was to examine the lunar surface at three different radar frequencies of 2 meters, 60 meters, and 20 meters. Test films were made on the lunar sounder system to describe the purpose of the test, to describe the experiments used for analysis, and to provide conclusions reached after analysis.

Massey, N.↗

NASA NTRS1972

Analyses and tests confirm design of proprotor aircraft.

Discussion of the design features of a 300-knot tilt-proprotor VTOL aircraft having proprotors 25 ft in diameter, an empty weight of 7390 pounds, a maximum VTOL gross weight of 12,400 pounds, and a design dive speed of 300 knots. Proprotor stability analysis covering aeroelastic stability characteristics and flight mode stability characteristics is included. An evaluation of the proprotor design is made on the basis of aerodynamic and aeroelastic model tests and full-scale performance tests. The test results and other obtained research data suggest the readiness of this aircraft design for construction and flight tests.

Edenborough, H. K.↗

NASA NTRS2017

Battery Data MI Importer Template Quick Start Guide

In order to ensure the persistent availability and reliability of test data generated over the course of the project, the M-SHELLS Project has decided to store acquired test data, as well as associated pedigree information, in the Granta Materials Intelligence (MI) database. To facilitate that effort, an importer template and associated graphical user interface (GUI) software have been developed, with this guide providing the operating instructions for their use. The template and automation software GUI are contained in the BatteryDataImporter.xlsm Excel workbook, and are to be used to import M-SHELLS summary, or pedigree, data and the associated raw test data results into an importer template-based file, formatted in such a way as to be ready for immediate upload to the Test Data: Battery Performance table of the Granta MI database. The provided GUI enables the user to select the appropriate summary data file(s), with each file containing the required information to identify any associated raw test data file(s) to be processed. In addition to describing the setup and operation of the importer template and GUI software, this guide also provides instructions for uploading processed data to the database and for viewing the data following upload.

Levinson, Laurie H.↗

NASA NTRS1982

Advanced turboprop testbed systems study. Volume 1: Testbed program objectives and priorities, drive system and aircraft design studies, evaluation and recommendations and wind tunnel test plans

The establishment of propfan technology readiness was determined and candidate drive systems for propfan application were identified. Candidate testbed aircraft were investigated for testbed aircraft suitability and four aircraft selected as possible propfan testbed vehicles. An evaluation of the four candidates was performed and the Boeing KC-135A and the Gulfstream American Gulfstream II recommended as the most suitable aircraft for test application. Conceptual designs of the two recommended aircraft were performed and cost and schedule data for the entire testbed program were generated. The program total cost was estimated and a wind tunnel program cost and schedule is generated in support of the testbed program.

Bradley, E. S.↗

NASA NTRS1976

MIUS integration and subsystems test program

The MIUS Integration and Subsystems Test (MIST) facility at the Lyndon B. Johnson Space Center was completed and ready in May 1974 for conducting specific tests in direct support of the Modular Integrated Utility System (MIUS). A series of subsystems and integrated tests was conducted since that time, culminating in a series of 24-hour dynamic tests to further demonstrate the capabilities of the MIUS Program concepts to meet typical utility load profiles for a residential area. Results of the MIST Program are presented which achieved demonstrated plant thermal efficiencies ranging from 57 to 65 percent.

Beckham, W. S., Jr.↗

NASA NTRS2008

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

NASA is maturing test and evaluation plans leading to flight readiness of the Ares I crew launch vehicle. Key development, qualification, and verification tests are planned . Upper stage engine sea-level and altitude testing. First stage development and qualification motors. Upper stage structural and thermal development and qualification test articles. Main Propulsion Test Article (MPTA). Upper stage green run testing. Integrated Vehicle Ground Vibration Testing (IVGVT). Aerodynamic characterization testing. Test and evaluation supports initial validation flights (Ares I-Y and Orion 1) and design certification.

Cockrell, Charles↗

NASA NTRS1989

Space station propulsion test bed

A test bed was fabricated to demonstrate hydrogen/oxygen propulsion technology readiness for the intital operating configuration (IOC) space station application. The test bed propulsion module and computer control system were delivered in December 1985, but activation was delayed until mid-1986 while the propulsion system baseline for the station was reexamined. A new baseline was selected with hydrogen/oxygen thruster modules supplied with gas produced by electrolysis of waste water from the space shuttle and space station. As a result, an electrolysis module was designed, fabricated, and added to the test bed to provide an end-to-end simulation of the baseline system. Subsequent testing of the test bed propulsion and electrolysis modules provided an end-to-end demonstration of the complete space station propulsion system, including thruster hot firings using the oxygen and hydrogen generated from electrolysis of water. Complete autonomous control and operation of all test bed components by the microprocessor control system designed and delivered during the program was demonstrated. The technical readiness of the system is now firmly established.

Briley, G. L.↗

NASA NTRS2000

Performance of Titanium Optics on a NASA 30 Cm Ion Thruster

The results of performance tests with two titanium optics sets are presented and compared to those of molybdenum optics. All tests were conducted on a 30 cm ion thruster that was nearly identical to the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) thruster design. Optics performance tests were conducted over a thruster input power range of 0.5 to 4.6 kW. Optics performance including impingement-limited total voltages, electron backstreaming limits, screen grid ion transparencies, near-field beam current density profiles, beam divergence angles, and beam divergence thrust correction factors were determined throughout this power range. The impingement-limited total voltages for titanium optics were within 10 to 55 V of those for molybdenum optics. Electron backstreaming limit magnitude as a function of peak beam current density for both molybdenum and titanium optics were within a few volts of each other, indicating similar hot grid gaps for these two grid materials during steady-state operation. Beam divergence half-angles at 90 percent of the total beam current and thrust correction factors for both titanium optics sets were within one degree and one percent, respectively, of those for molybdenum optics. When thruster power was increased to 2.3 kW immediately following discharge ignition, the titanium screen grid came into contact with the accelerator grid within five minutes of ignition. Relative to molybdenum, titanium's larger thermal expansion and smaller thermal conductivity likely caused the screen grid to thermally expand more relative to the accelerator grid during startup.

Soulas, George C.↗

NASA NTRSDate not supplied

Flight Environment HEPA Filter Testing for Lunar Dust Removal Capability

Lunar dust is an abrasive regolith that can cause critical damage to hardware and crew. Its morphology and chemical makeup differs from typical earth dust due to space weathering effects. Current space missions require extensive air filtration of lunar dust to ensure mission success; as such filtration testing is paramount in verifying the dust-removal capabilities of the system. Previous testing at NASA GRC consisted of two stages: testing a flat high efficiency particulate air (HEPA) media sheet at various pressure ranges (Stage 1) and testing a pleated HEPA filter at different humidity and dust levels (Stage 2). This testing was done to buy-down risk when testing the flight-qualification HEPA filter for the proposed Stage 3 test. Stage 3 testing used a flight-ready HEPA filter to measure its performance characteristics to verify programmatic requirements. This included measuring lunar dust loading versus pressure drop performance and establishing a maximum capacity based on the allowable pressure drop, determining the HEPA filter efficiency utilizing two separate methodologies, and assessing if the lunar dust caused the HEPA filter to experience any damage. Additionally, dust removal from the HEPA filter was performed using a vacuum to ascertain if the filter life can be prolonged. These test results will aid the program in verifying programmatic requirements and ensuring risk buydown before this HEPA filter takes flight.

HEPA↗

NASA NTRS2001

Investigation of Keeper Erosion in the NSTAR Ion Thruster

The goal of the present investigation was to determine the cause for the difference in the observed discharge keeper erosion between the 8200 hr wear test of a NASA Solar Electric Propulsion Technology Applications Readiness (NSTAR) engineering model thruster and the ongoing extended life test (ELT) of the NSTAR flight spare thruster. During the ELT, the NSTAR flight spare ion thruster experienced unanticipated erosion of the discharge cathode keeper. Photographs of the discharge keeper show that the orifice has enlarged to slightly more than twice the original diameter. Several differences between the ELT and the 8200 hr wear test were initially identified to determine any effects which could lead to the erosion in the ELT. In order to identify the cause of the ELT erosion, emission spectra from an engineering model thruster were collected to assess the dependence of keeper erosion on operating conditions. Keeper ion current was measured to estimate wear. Additionally, post-test inspection of both a copper keeper-cap was conducted, and the results are presented. The analysis indicated that the bulk of the ion current was collected within 2-mm radially of the orifice. The estimated volumetric wear in the ELT was comparable to previous wear tests. Redistribution of the ion current on the discharge keeper was determined to be the most likely cause of the ELT erosion. The change in ion current distribution was hypothesized to caused by the modified magnetic field of the flight assemblies.

Domonkos, Matthew T.↗

NASA NTRSDate not supplied

SLS Ignition Overpressure-Sound Suppression System Performance Evaluated Against Historical Configurations

During the start-up of a number of launch vehicles that include solid rocket motor (SRM), the ignition transient and acoustic environments are mitigated by the implementation of a water spray system located immediately below the SRM nozzle exit plane (NEP). For NASA’s Space Launch System (SLS), this water system is referred to as the Ignition Overpressure / Sound Suppression (IOP/SS) system. The SLS Induced Environments (IE) technical discipline conducted a comprehensive evaluation of the design and as-tested performance of the IOP/SS water that will operate underneath both Boosters during the Artemis I launch. As part of this evaluation, flow rates and imagery from a number of integrated launch pad / mobile launcher IOP/SS flow tests were studied. Additional insight was leveraged from the Shuttle heritage IOP/SS system that includes data and imagery from a number of Flight Readiness Firings (FRF) and water flow tests. Lastly, the IE study included a qualitive comparison of the Shuttle and SLS systems to the equivalent water flow systems for Titan and Atlas V and determined that the NASA water flow systems are substantially different than those supporting other launch vehicles.

Ignition Overpressure↗

NASA NTRSDate not supplied

SLS Ignition Overpressure-Sound Suppression System Performance Evaluated Against Historical Configurations

Ignition Overpressure↗