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NASA NTRS2007

Progress in Flaps Down Flight Reynolds Number Testing Techniques at the NTF

A series of NASA/Boeing cooperative low speed wind tunnel tests was conducted in the National Transonic Facility (NTF) between 2003 and 2004 using a semi-span high lift model representative of the 777-200 aircraft. The objective of this work was to develop the capability to acquire high quality, low speed (flaps down) wind tunnel data at up to flight Reynolds numbers in a facility originally optimized for high speed full span models. In the course of testing, a number of facility and procedural improvements were identified and implemented. The impact of these improvements on key testing metrics data quality, productivity, and so forth - was significant, and is discussed here, together with the relevance of these metrics as applied to cryogenic wind tunnel testing in general. Details of the improvements at the NTF are discussed in AIAA-2006-0508 (Recent Improvements in Semi-span Testing at the National Transonic Facility). The development work at the NTF culminated with validation testing of a 787-8 semi-span model at full flight Reynolds number in the first quarter of 2006.

Payne, Frank↗

NASA NTRS2010

NASA Tech Briefs, March 2010

Topics covered include: Software Tool Integrating Data Flow Diagrams and Petri Nets; Adaptive Nulling for Interferometric Detection of Planets; Reducing the Volume of NASA Earth-Science Data; Reception of Multiple Telemetry Signals via One Dish Antenna; Space-Qualified Traveling-Wave Tube; Smart Power Supply for Battery-Powered Systems; Parallel Processing of Broad-Band PPM Signals; Inexpensive Implementation of Many Strain Gauges; Constant-Differential-Pressure Two-Fluid Accumulator; Inflatable Tubular Structures Rigidized with Foams; Power Generator with Thermo-Differential Modules; Mechanical Extraction of Power From Ocean Currents and Tides; Nitrous Oxide/Paraffin Hybrid Rocket Engines; Optimized Li-Ion Electrolytes Containing Fluorinated Ester Co-Solvents; Probabilistic Multi-Factor Interaction Model for Complex Material Behavior; Foldable Instrumented Bits for Ultrasonic/Sonic Penetrators; Compact Rare Earth Emitter Hollow Cathode; High-Precision Shape Control of In-Space Deployable Large Membrane/Thin-Shell Reflectors; Rapid Active Sampling Package; Miniature Lightweight Ion Pump; Cryogenic Transport of High-Pressure-System Recharge Gas; Water-Vapor Raman Lidar System Reaches Higher Altitude; Compact Ku-Band T/R Module for High-Resolution Radar Imaging of Cold Land Processes; Wide-Field-of-View, High-Resolution, Stereoscopic Imager; Electrical Capacitance Volume Tomography with High-Contrast Dielectrics; Wavefront Control and Image Restoration with Less Computing; Polarization Imaging Apparatus; Stereoscopic Machine-Vision System Using Projected Circles; Metal Vapor Arcing Risk Assessment Tool; Performance Bounds on Two Concatenated, Interleaved Codes; Parameterizing Coefficients of a POD-Based Dynamical System; Confidence-Based Feature Acquisition; Algorithm for Lossless Compression of Calibrated Hyperspectral Imagery; Universal Decoder for PPM of any Order; Algorithm for Stabilizing a POD-Based Dynamical System; Mission Reliability Estimation for Repairable Robot Teams; Processing AIRS Scientific Data Through Level 3; Web-Based Requesting and Scheduling Use of Facilities; AutoGen Version 5.0; Time-Tag Generation Script; PPM Receiver Implemented in Software; Tropospheric Emission Spectrometer Product File Readers; Reporting Differences Between Spacecraft Sequence Files; Coordinating "Execute" Data for ISS and Space Shuttle; Database for Safety-Oriented Tracking of Chemicals; Apparatus for Cold, Pressurized Biogeochemical Experiments; Growing B Lymphocytes in a Three-Dimensional Culture System; Tissue-like 3D Assemblies of Human Broncho-Epithelial Cells; Isolation of Resistance-Bearing Microorganisms; Oscillating Cell Culture Bioreactor; and Liquid Cooling/Warming Garment.

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NASA NTRS2011

CFD Validation with Experiment and Verification with Physics of a Propellant Damping Device

This paper will document our effort in validating a coupled fluid-structure interaction CFD tool in predicting a damping device performance in the laboratory condition. Consistently good comparisons of "blind" CFD predictions against experimental data under various operation conditions, design parameters, and cryogenic environment will be presented. The power of the coupled CFD-structures interaction code in explaining some unexpected phenomena of the device observed during the technology development will be illustrated. The evolution of the damper device design inside the LOX tank will be used to demonstrate the contribution of the tool in understanding, optimization and implementation of LOX damper in Ares I vehicle. It is due to the present validation effort, the LOX damper technology has matured to TRL 5. The present effort has also contributed to the transition of the technology from an early conceptual observation to the baseline design of thrust oscillation mitigation for the Ares I within a 10 month period.

Yang, H. Q.↗

NASA NTRS1975

Bringing wings of change - NASA's airfoil research program

A review is presented of progress in attaining technical objectives in three areas of semiautomatic airfoil development: software, hardware, and applications. Software objectives seek improved mathematical models and computer codes for flow analysis and design optimization for a variety of conditions. The 17-step iterative computer model used in designing the GA (W)-1 airfoil is effective but not yet fully automated; with present methods only single-point computer optimization is possible. Hardware objectives calling for improvement in test facilities and techniques are met in part by the introduction of the Langley (F-3C) wind tunnel for independent evaluation of transonic Mach number and Reynolds effects up to 12-16 million, and by a two-dimensional test section for the Langley 1/3 transonic cryogenic tunnel which will extend the Reynolds number to 50 million. The current status of low-speed, thin, and rotorcraft airfoil development programs is discussed.

Pierpont, P. K.↗

NASA NTRS2006

Reducing Stray Light To Characterize Nirspec Subsystems: The Focal Plane Array And Micro-Shutter Array

The James Webb Space Telescope (JWST) is an infrared, space-based telescope scheduled for launch in 2013. JWST includes four scientific instruments, including the Near Infrared Spectrometer (NIRSpec), which operates in the wavelength range from 0.6 to 5 microns. NASA/Goddard Space Flight Center (GSFC) is responsible for two NIRSpec subsystems: the detector subsystem, with its focal plane array (FPA), and the micro-shutter subsystem, with its micro-shutter array (MSA). The FPA is comprised of two side-by-side Rockwell Scientific HgCdTe 2kx2k detectors, with detectors and readout electronics optimized for low noise. The MSA is a GSFC developed micro-electro-mechanical system (MEMS) that serves as a programmable slit mask, allowing NIRSpec to obtain simultaneous spectra of >100 objects in a single field of view. We present the optical characterization test plan of the FPA. The test plan is driven by many requirements: cryogenic operating temperature, a flight-like beam shape, and multi-wavelength photon flux from 1 to 60,000 per second, thus low stray light is critical. We use commercial optical modeling software to predict stray light effects at the FPA. We also present the optical contrast test plan of the MSA. Since each individual shutter element operates in on/off fashion, the most important optical metric is contrast. The MSA structure is designed to minimize stray and scattered light, and the test setup reduces stray light such that the optical contrast requirement is met.

Connelly, Joseph A.↗

NASA NTRS2007

Thermal Properties of Double-Aluminized Kapton at Low Temperatures

Double-aluminized kapton (DAK) is commonly used in multi-layer insulation blankets in cryogenic systems. NASA plans to use individual DAK sheets in lightweight deployable shields for satellites carrying instruments. A set of these shields will reflect away thermal radiation from the sun, the earth, and the instrument's warm side and allow the instrument's cold side to radiate its own heat to deep space. In order to optimally design such a shield system, it is important to understand the thermal characteristics of DAK down to low temperatures. We describe experiments which measured the thermal conductivity and electrical resistivity down to 4 Kelvin and the emissivity down to 10 Kelvin.

Tuttle, J.↗

NASA NTRS1987

Sorption compressor/mechanical expander hybrid refrigeration

Experience with Deep Space Network (DSN) ground-based cryogenic refrigerators has proved the reliability of the basic two-stage Gifford-McMahon helium refrigerator. A very long life cryogenic refrigeration system appears possible by combining this expansion system or a turbo expansion system with a hydride sorption compressor in place of the usual motor driven piston compressor. To test the feasibility of this system, a commercial Gifford-McMahon refrigerator was tested using hydrogen gas as the working fluid. Although no attempt was made to optimize the system for hydrogen operation, the refrigerator developed 1.3 W at 30 K and 6.6 W at 60 K. The results of the test and of theoretical performances of the hybrid compressor coupled to these expansion systems are presented.

Jones, J. A.↗

NASA NTRS2006

Increasing Efficiency at the NTF by Optimizing Model AoA Positioning

The National Transonic Facility (NTF) at NASA Langley Research Center (LaRC) is a national resource for aeronautical research and development. The government, military and private industries rely on the capability of this facility for realistic flight data. Reducing the operation costs and keeping the NTF affordable is essential for aeronautics research. The NTF is undertaking an effort to reduce the time between data points during a pitch polar. This reduction is being driven by the operating costs of a cryogenic facility. If the time per data point can be reduced, a substantial cost savings can be realized from a reduction in liquid nitrogen (LN2) consumption. It is known that angle-of-attack (AoA) positioning is the longest lead-time item between points. In January 2005 a test was conducted at the NTF to determine the cause of the long lead-time so that an effort could be made to improve efficiency. The AoA signal at the NTF originates from onboard instrumentation then travels through a number of different systems including the signal conditioner, digital voltmeter, and the data system where the AoA angle is calculated. It is then fed into a closed loop control system that sets the model position. Each process along this path adds to the time per data point affecting the efficiency of the data taking process. Due to the nature of the closed loop feed back AoA control and the signal path, it takes approximately 18 seconds to take one pitch pause point with a typical AoA increment. Options are being investigated to reduce the time delay between points by modifying the signal path. These options include: reduced signal filtering, using analog channels instead of a digital volt meter (DVM), re-routing the signal directly to the AoA control computer and implementing new control algorithms. Each of these has potential to reduce the positioning time and together the savings could be significant. These timesaving efforts are essential but must be weighed against possible loss of data quality. For example, a reduction in filtering can introduce noise into the signal and using analog channels could result in some loss of accuracy. Data quality assessments need to be performed concurrently with timesaving techniques since data quality parameters are essential in maintaining facility integrity. This paper will highlight time saving efforts being undertaken or studied at the NTF. It will outline the instrumentation and computer systems involved in setting of the model pitch attitude then suggest changes to the process and discuss how these system changes would effect the time between data points. It also discusses the issue of data quality and how the potential efficiency changes in the system could affect it. Lastly, it will discuss the possibility of using an open loop control system and give some pros and cons of this method.

Crawford, Bradley L.↗

NASA NTRS1985

Space Transportatioin System (STS) propellant scavenging system study. Volume 3: Cost and work breakdown structure-dictionary

Fundamentally, the volumes of the oxidizer and fuel propellant scavenged from the orbiter and external tank determine the size and weight of the scavenging system. The optimization of system dimensions and weights is stimulated by the requirement to minimize the use of partial length of the orbiter payload bay. Thus, the cost estimates begin with weights established for the optimum design. Both the design, development, test, and evaluation and theoretical first unit hardware production costs are estimated from parametric cost weight scaling relations for four subsystems. For cryogenic propellants, the widely differing characteristics of the oxidizer and the fuel lead to two separate tank subsystems, in addition to the electrical and instrumentation subsystems. Hardwares costs also involve quantity, as an independent variable, since the number of production scavenging systems is not firm. For storable propellants, since the tankage volume of the oxidizer and fuel are equal, the hardware production costs for developing these systems are lower than for cryogenic propellants.

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NASA NTRS1989

High accuracy motor controller for positioning optical filters in the CLAES Spectrometer

The Etalon Drive Motor (EDM), a precision etalon control system designed for accurate positioning of etalon filters in the IR spectrometer of the Cryogenic Limb Array Etalon Spectrometer (CLAES) experiment is described. The EDM includes a brushless dc torque motor, which has an infinite resolution for setting an etalon filter to any desired angle, a four-filter etalon wheel, and an electromechanical resolver for angle information. An 18-bit control loop provides high accuracy, resolution, and stability. Dynamic computer interaction allows the user to optimize the step response. A block diagram of the motor controller is presented along with a schematic of the digital/analog converter circuit.

Thatcher, John B.↗

NASA NTRS1993

Small rocket research and technology

Small chemical rockets are used on nearly all space missions. The small rocket program provides propulsion technology for civil and government space systems. Small rocket concepts are developed for systems which encompass reaction control for launch and orbit transfer systems, as well as on-board propulsion for large space systems and earth orbit and planetary spacecraft. Major roles for on-board propulsion include apogee kick, delta-V, de-orbit, drag makeup, final insertions, north-south stationkeeping, orbit change/trim, perigee kick, and reboost. The program encompasses efforts on earth-storable, space storable, and cryogenic propellants. The earth-storable propellants include nitrogen tetroxide (NTO) as an oxidizer with monomethylhydrazine (MMH) or anhydrous hydrazine (AH) as fuels. The space storable propellants include liquid oxygen (LOX) as an oxidizer with hydrazine or hydrocarbons such as liquid methane, ethane, and ethanol as fuels. Cryogenic propellants are LOX or gaseous oxygen (GOX) as oxidizers and liquid or gaseous hydrogen as fuels. Improved performance and lifetime for small chemical rockets are sought through the development of new predictive tools to understand the combustion and flow physics, the introduction of high temperature materials to eliminate fuel film cooling and its associated combustion inefficiency, and improved component designs to optimize performance. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Results indicate that modeling of the injector and combustion process in small rockets needs improvement. High temperature materials require the development of fabrication processes, a durability data base in both laboratory and rocket environments, and basic engineering property data such as strength, creep, fatigue, and work hardening properties at both room and elevated temperature. Promising materials under development include iridium-coated rhenium and a ceramic composite of mixed hafnium carbide and tantalum carbide reinforced with graphite fibers.

Schneider, Steven↗

NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

Volz, M. P.↗

NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Volz, M. P.↗

NASA NTRS2014

Micro-Spec: an Integrated, Direct-Detection Spectrometer for Far-Infrared and Submillimeter Astronomy

The far-infrared and submillimeter portions of the electromagnetic spectrum provide a unique view of the astrophysical processes present in the early universe. Our ability to fully explore this rich spectral region has been limited, however, by the size and cost of the cryogenic spectrometers required to carry out such measurements. Micro-Spec (u-Spec) is a high-sensitivity, direct-detection spectrometer concept working in the 450-1000 micromillimeter wavelength range which will enable a wide range of flight missions that would otherwise be challenging due to the large size of current instruments with the required spectral resolution and sensitivity. The spectrometer design utilizes two internal antenna arrays, one for transmitting and one for receiving, superconducting microstrip transmission lines for power division and phase delay, and an array of microwave kinetic inductance detectors (MKIDs) to achieve these goals. The instrument will be integrated on a approximately 10 square cm silicon chip and can therefore become an important capability under the low background conditions accessible via space and high-altitude borne platforms. In this paper, an optical design methodology for Micro-Spec is presented, with particular attention given to its twodimensional diffractive region, where the light of different wavelengths is focused on the different detectors. The method is based on the maximization of the instrument resolving power and minimization of the RMS phase error on the instrument focal plane. This two-step optimization can generate geometrical configurations given specific requirements on spectrometer size, operating spectral range and performance. A point design with resolving power of 257, an RMS phase error less than 0.1 radians and four stigmatic points was developed for initial demonstration and will be the basis of future instruments with resolving power up to about 1200.

microwave kinetic inductance detectors (MKIDs)↗

NASA NTRS2018

Off-Nominal Planning for the Cryogenic Vacuum Test of the JWST Optical Telescope Element/Integrated Science Instrument Module at JSC

The cryogenic thermal vacuum/thermal balance test of the James Webb Space Telescope (JWST) combined Optical Telescope Element (OTE)/Integrated Science Instrument Module (ISIM), known as the OTIS, at the Johnson Space Center (JSC) Chamber A in 2017 was likely the most complex test ever performed by NASA for an unmanned mission. The test of the combined flight Optical Telescope and ISIM elements was prefaced by years of modifications to chamber facilities, and included three extensive precursor tests of non-flight and flight hardware to establish safe and optimal test operational procedures. One critical part of the test preparation was planning for off-nominal events that could arise, including appropriate responses. In some cases, assurance of personnel and payload safety required modification of original test hardware and procedures which had to be validated before the final test could begin. This planning proved especially prescient for the OTIS test, as Hurricane Harvey struck the Houston area during the test in August 2017, and consequences for the precious payload could have been severe. This paper describes the extent of the thermal off-nominal planning undertaken for the OTIS test, including including safing for hurricanes, and some real-life effects of Hurricane Harvey on the test conduct. Documentation of the consequences and mitigations for these events are discussed. The importance of off-nominal planning for future thermal vacuum/thermal balance tests is illustrated.

Off-Nominal Planning↗

NASA NTRS1999

Nanoporous Silica Thermal Insulation for Space Shuttle Cryogenic Tanks: A Case Study

Nanoporous silica (with typical 10-50 nm porous radii) has been benchmarked for thermal insulators capable of maintaining a 150 K/cm temperature gradient. For cryogenic use in aerospace applications, the combined features for low-density, high thermal insulation factors, and low temperature compatibility are demonstrated in a prototype sandwich structure between two propulsion tanks. Theoretical modelling based on a nanoscale fractal structure suggest that the thermal conductivity scales proportionally (exponent, 1.7) with the material density-lower density increases the thermal insulation rating. Computer simulations, however, support the optimization tradeoff between material strength (Young moduli, proportional to density with exponent, 3.7), the characteristic (colloidal silica, less than 5 nm) particle size, and the thermal rating. The results of these simulations indicate that as nanosized particles are incorporated into the silica backbone, the resulting physical properties will be tailored by the smallest characteristic length and their fractal interconnections (dimension and fractal size). The application specifies a prototype panel which takes advantage of the processing flexibility inherent in sol-gel chemistry.

Noever, David A.↗

NASA NTRS2008

NASA Tech Briefs, August 2008

Customizable Digital Receivers for Radar Two-Camera Acquisition and Tracking of a Flying Target Visual Data Analysis for Satellites A Data Type for Efficient Representation of Other Data Types Hand-Held Ultrasonic Instrument for Reading Matrix Symbols Broadband Microstrip-to-Coplanar Strip Double-Y Balun A Topographical Lidar System for Terrain-Relative Navigation Programmable Low-Voltage Circuit Breaker and Tester Electronic Switch Arrays for Managing Microbattery Arrays Topics covered include: Lower-Dark-Current, Higher-Blue-Response CMOS Imagers; Fabricating Large-Area Sheets of Single-Layer Graphene by CVD; Support for Diagnosis of Custom Computer Hardware; Providing Goal-Based Autonomy for Commanding a Spacecraft; Dynamic Method for Identifying Collected Sample Mass; Optimal Planning and Problem-Solving; Attitude-Control Algorithm for Minimizing Maneuver Execution Errors; Grants Document-Generation System; Heat-Storage Modules Containing LiNO3 3H2O and Graphite Foam; Precipitation-Strengthened, High-Temperature, High-Force Shape Memory Alloys; Improved Relief Valve Would Be Less Susceptible to Failure; Safety Modification of Cam-and-Groove Hose Coupling; Using Composite Materials in a Cryogenic Pump; Using Electronic Noses to Detect Tumors During Neurosurgery; Producing Newborn Synchronous Mammalian Cells; Smaller, Lower-Power Fast-Neutron Scintillation Detectors; Rotationally Vibrating Electric-Field Mill; Estimating Hardness from the USDC Tool-Bit Temperature Rise; Particle-Charge Spectrometer; Automated Production of Movies on a Cluster of Computers; FIDO-Class Development Rover; and Tone-Based Command of Deep Space Probes Using Ground Antennas.

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NASA NTRS1992

Mechanical cooler-to-Dewar interfacing in a long-lifetime, hybrid stored cryogen system

The means for making efficient use of mechanical coolers to limit the parasitic heating into the Dewar are addressed. Thermal efficiency is achieved by minimizing the parasitic heating and thermal impedance of the cooler-to-Dewar interface within the mechanical constraints. The important issues related to compatibility with the instrument system are also briefly discussed. Parasitic heating from the nonoperating (reserved or failed) cooler pair can be reduced with an active thermal switch that isolates the cooler cold tips from the cold finger. An analysis was performed to determine the optimal switch-operating characteristics for this application. Requirements associated with the use of the coolers, analyses performed, and the interface design concept are discussed.

Hopkins, R. A.↗