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At least 235 records · Page 13

Comparison of Light-Weight Radioisotope Heater Unit (LWRHU) Historical Testing to Special Form Testing Requirements

This paper compares the Light-Weight Radioisotope Heater Unit (LWRHU) historical testing to Department of Transportation (DOT) Special Form criteria per 49 CFR Part 173, Shippers-General Requirements for Shipments and Packages, Section 469, Tests for special form Class 7 (radioactive) materials as specified in DOE-STD-1027, Hazard Categorization of DOE Nuclear Facilities. Compliance with the aforementioned criteria allows for the exclusion of radioactive sources from the facility’s nuclear material inventory. As part of a new program at Los Alamos National Laboratory (LANL), LWRHUs are planned to be moved into TA-55, PF-5 Power Source Assembly Area (PSAA) for assembly and testing activities. The PSAA Facility is categorized as a low hazard, non-nuclear facility per DOE STD-1027 and is described in TA55-PF-5-FHC-11-001, Facility Hazard Categorization of the PSAA at PF-5, TA-55. The Facility Hazard Categorization document states, there must be documentation that radioactive sources are engineered to pass the special form testing specified by DOT in 49 CFR 173.469, Tests for special form Class 7 (radioactive) materials or ANSI N43.6, Sealed Radioactive Sources - Classification. This paper documents the extensive historical environmental safety testing of the LWRHU and demonstrates its ability to survive potential launch safety accident scenarios. The testing results are used herein to demonstrate through a comparative analysis that the robust design of the LWRHU meets or exceeds the special form testing specifications in 49 CFR 173.469, enabling the LWRHU to be transported and handled in PF-5 in support of testing and assembly program.

07 ISOTOPE AND RADIATION SOURCES↗

Mechanisms Engineering Test Loop (METL) Operations and Testing Report (FY2022)

This report documents the operations, testing, maintenance, and improvements that were performed at the Mechanisms Engineering Test Loop (METL) during FY2022. The METL facility had a very successful fourth year of operations and went through some new experiences such as taking the facility from its frozen state in October 2021 and thawing the facility and also recovering from an oxide plug in one of the cold trap lines. After the facility was fully thawed, the METL staff maintained the facility in a continuous molten state – either flowing sodium or a static flow condition. METL facility continued supporting the Gear Test Assembly (GTA) testing and hosted its first 28” test vessel experiment, called the Thermal Hydraulic Experimental Test Article (THETA) which was inserted into Test Vessel 4. Work to accommodate two additional experiments, a gripper test article (GrTA) and a flow sensor test article (F-STAr) continued as they are expected to make their debut in FY2023. In addition, the steam piping for the B308 scrubber unit was replaced with stainless steel piping and controls and new parts for the scrubber were purchased – such as a new pump, new storage tank, and new blower and motor. These components will ultimately replace the existing scrubber components when those 1970’s era require replacement.

42 ENGINEERING↗

A simulation study of test fixture attachment points for vibration test optimization (MEEN 5440 Final Project)

The aerospace industry uses vibration shaker tables to perform component durability testing. These dynamic environments tests often have a hard time replicating the service environment of a component due to a mismatch in the applied force or the boundary condition. Figure 1 shows the desired outcome of a dynamic environments test. The measured responses in a lab test, ideally, should match the measured response of the service environment field test. One way to address the mismatch between field environment and lab environment is with test fixture design. The test fixture attaches the component under test to the shaker table. Single-axis shakers are the industry standard type of shaker table, and, therefore, test fixtures are often rigid in order to minimize cross-axis responses.

42 ENGINEERING↗

Scoping Study for Fast Flux Testing in the Advanced Test Reactor

The value of fast spectrum reactors remains prominent in the nuclear technology portfolio. The performance of these reactors can be maximized with advancements in nuclear fuel technologies, but development of these technologies is currently held back by lack of fast spectrum test reactors available to the United States. Spectral modification of experiment positions in the thermal spectrum Advanced Test Reactor (ATR) has long been used to support fast reactor fuel development, but these methods have not been progressed to their full potential. This study investigated the use of concentric rings of aluminum-clad fuel plates in ATR flux traps and thermal neutron absorbing filters to increase fast neutron flux on test specimens. This concept was termed the Boosted Energy Advanced Spectrum Test (BEAST). This approach will enable irradiation of advanced fuel designs in prototypic-length fuel pins and representative flux environment to support post irradiation exams, enable transient testing, and produce the type of data that will permit lead test assembly irradiations in true Sodium Fast Reactors (SFRs) when they become available. Neutronic predictions were performed to investigate BEAST design options and thermal hydraulic models were produced to ensure feasibility of BEAST. Two versions were considered based on the geometric limitations of ATR’s small and large flux traps. The small version was found to be preferable due to slightly higher fast flux and fast-to-thermal neutron ratio. Perhaps more influentially, the small flux trap option was also preferred to avoid conflict with ongoing very high temperature reactor fuel irradiation programs in ATR’s large northeast flux trap. The small flux trap option provided less than half the test volume of the large version, but still had adequate volume for seven SFR pins in cross section which could be stacked two-high in ATR’s 1.2m long core to accommodate up to 14 EBR-II size pins. The preference for the small flux trap configuration should be revisited if additional collaborative test programs emerge with the need to irradiate a significant volume of additional specimens. Calculations were performed regarding a lithium deuteride ring to convert thermal neutrons into 14 MeV fusion neutrons. At the time this report was written these calculations were partially complete and it remains to be seen whether the concept would be worth including in BEAST. Given the preference for the small flux trap option, which does not afford enough room for the 14 MeV ring, it was concluded to defer future work on the lithium deuteride ring. This decision could be revisited if fusion material research programs emerge for collaborative testing in BEAST. A cadmium-lined specimen holder design was found to be adequate in filtering thermal neutrons and preferred over other neutron absorbers based on past experience with cadmium baskets. It was acknowledged that cadmium-bearing hardware would become depleted and need to be replaced occasionally, which appeared feasible from a mechanical design perspective. Neutronic studies investigated different enrichment levels in the booster fuel using uranium-molybdenum alloy dispersion fuel which has performed well in past ATR irradiations. Both options were able to drive fuel pins to SFR-like fission heating rates. The high enriched booster fuel option outperformed the low enriched option by ~20% on key metrics including fast flux and fast-to-thermal ratio, but the low enriched option was favored in order to broaden options for potential fuel suppliers. The preferred BEAST design options including cadmium filter with low enriched booster fuel in the small flux trap configuration was predicted to achieve 6.2E14 n/cm2sec fast flux (>0.1 MeV) with a fast-to-thermal ratio of 44.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗

Flight tests of Viking parachute system in three Mach number regimes. 1: Vehicle description, test operations, and performance

Flight qualifications for parachutes were tested on full-scale simulated Viking spacecraft at entry conditions for the Viking 1975 mission to Mars. The vehicle was carried to an altitude of 36.6 km for the supersonic and transonic tests by a 980.000 cu m balloon. The vehicles were released and propelled to test conditions with rocket engines. A 117,940 cu m balloon carried the test vehicle to an altitude of 27.5 km and the conditions for the subsonic tests were achieved in free fall. Aeroshell separation occurred on all test vehicles from 8 to 14 seconds after parachute deployment. This report describes: (1) the test vehicle; (2) methods used to insure that the test conditions were achieved; and (3) the balloon system design and operations. The report also presents the performance data from onboard and ground based instruments and the results from a statistical trajectory program which gives a continuous history of test-vehicle motions.

Lundstrom, R. R.↗

Phase 2 program on ground test of refanned JT8D turbofan engines and nacelles for the 727 airplane. Volume 3: Ground tests

The NASA Refan Program included full-scale performance and noise ground tests of both a current production (JT8D-15) and a refanned (JT8D-115) engine. A description of the two ground tests including detailed propulsion, noise, and structural test results is presented. The primary objectives of the total test program were comparison of JT8D-15 and JT8D-115 overall propulsion system performance and noise characteristics and determination of incremental component noise levels. Other objectives of the test program included: (1) determination of acoustic treatment effectiveness; (2) measurement of internal sound pressure levels; (3) measurement of inlet and exhaust hardware performance; (4) determination of center-engine surge margin; and (5) evaluation of certain structural characteristics associated with the 727 refan center-engine inlet duct and JT8D refan engine exhaust system. The JT8D-15 and -115 tests were conducted during September 1974 and January to March 1975, respectively. Analyses of the test data indicated that the JT8D-115, as compared to the JT8D-15, demonstrates a 12.5 percent to 13.2 percent reduction in static specific fuel consumption, and a reduction of 6 to 7 PNdB in a weighted average value of static tone corrected perceived noise level. Separated into noise components, a significant reduction was shown for the inlet fan, aft fan, exhaust duct flow, turbine, and jet noises. However, core noise was increased. Photographs of test stands and test equipment are shown.

Source record↗

Electric vehicle chassis dynamometer test methods at JPL and their correlation to track tests

Early in its electric vehicle (EV) test program, JPL recognized that EV test procedures were too vague and too loosely defined to permit much meaningful data to be obtained from the testing. Therefore, JPL adopted more stringent test procedures and chose the chassis dynamometer rather than the track as its principal test technique. Through the years, test procedures continued to evolve towards a methodology based on chassis dynamometers which would exhibit good correlation with track testing. Based on comparative dynamometer and track test results on the ETV-1 vehicle, the test methods discussed in this report demonstrate a means by which excellent track-to-dynamometer correlation can be obtained.

Marte, J.↗

Design and testing of an energy-absorbing crewseat for the F/FB-111 aircraft. Volume 3: Data from crew module testing

Over the past years, several papers and reports have documented the unacceptably high injury rate during the escape sequence (including the ejection and ground impact) of the crew module for F/FB-111 aircraft. This report documents a program to determine if the injury potential could be reduced by replacing the existing crewseats with energy absorbing crewseats. An energy absorbing test seat was designed using much of the existing seat hardware. An extensive dynamic seat test series, designed to duplicate various crew module ground impact conditions, was conducted at a sled test facility. Comparative tests with operational F-111 crewseats were also conducted. After successful dynamic testing of the seat, more testing was conducted with the seats mounted in an F-111 crew module. Both swing tests and vertical drop tests werre conducted. The vertical drop tests were used to obtain comparative data between the energy absorbing and operational seats.

Shane, S. J.↗

Propfan test assessment testbed aircraft flutter model test report

The PropFan Test Assessment (PTA) program includes flight tests of a propfan power plant mounted on the left wind of a modified Gulfstream II testbed aircraft. A static balance boom is mounted on the right wing tip for lateral balance. Flutter analyses indicate that these installations reduce the wing flutter stabilizing speed and that torsional stiffening and the installation of a flutter stabilizing tip boom are required on the left wing for adequate flutter safety margins. Wind tunnel tests of a 1/9th scale high speed flutter model of the testbed aircraft were conducted. The test program included the design, fabrication, and testing of the flutter model and the correlation of the flutter test data with analysis results. Excellent correlations with the test data were achieved in posttest flutter analysis using actual model properties. It was concluded that the flutter analysis method used was capable of accurate flutter predictions for both the (symmetric) twin propfan configuration and the (unsymmetric) single propfan configuration. The flutter analysis also revealed that the differences between the tested model configurations and the current aircraft design caused the (scaled) model flutter speed to be significantly higher than that of the aircraft, at least for the single propfan configuration without a flutter boom. Verification of the aircraft final design should, therefore, be based on flutter predictions made with the test validated analysis methods.

Jenness, C. M. J.↗

Experience with some repeat tests on the 9 inch chord CAST-10-2/DOA 2 airfoil model in the Langley 0.3-m TCT adaptive wall test section

A co-operative testing program is in progress between the Langley Research Center (NASA) and the National Aeronautical Establishment (NAE, Canada) to validate two different techniques of airfoil testing at transonic speeds. The procedure employed is to test the same airfoil model in the NAE two-dimensional tunnel and the Langley 0.3-m Transonic Cryogenic Tunnel (0.3-m TCT). The airfoil model used in testing was CAST-10-2/DOA-2 super-critical airfoil. The Langley 0.3-m TCT has a relatively small cross section of 13 in x 13 in, giving a (h/c) ratio of 1.44 for the same 9 in chord model. The approach employed in the 0.3-m TCT aims towards eliminating the wall effects by using active walls. The top and bottom walls are flexible. By changing the wall shapes during a test in an iterative manner, the wall interference effects are reduced. The method employed to change the wall shapes is the adaptive wall technique. The current test program provided an opportunity to validate the adaptive wall technique in the 0.3-m TCT. The relatively long chord airfoil represents a severe test case to test the efficacy of the adaptive wall technique under cryogenic conditions. The program also involved removal of side wall boundary-layer thus increasing the complexity of the wall adaptation technique. This paper deals with some salient results obtained regarding repeatability of test data and possible residual interference effects.

Murthy, A. V.↗

A simulated lightning effects test facility for testing live and inert missiles and components

Details of a simulated lightning effects test facility for testing live and inert missiles, motors, and explosive components are described. The test facility is designed to simulate the high current, continuing current, and high rate-of-rise current components of an idealized direct strike lightning waveform. The Lightning Test Facility was in operation since May, 1988, and consists of: 3 separate capacitor banks used to produce the lightning test components; a permanently fixed large steel safety cage for retaining the item under test (should it be ignited during testing); an earth covered bunker housing the control/equipment room; a charge/discharge building containing the charging/discharging switching; a remotely located blockhouse from which the test personnel control hazardous testing; and interconnecting cables.

Craven, Jeffery D.↗

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.

Soderman, Paul T.↗

A Boundary Scan Test Vehicle for Direct Chip Attach Testing

To facilitate the new faster, better and cheaper spacecraft designs, smaller more mass efficient avionics and instruments are using higher density electronic packaging technologies such as direct chip attach (DCA). For space flight applications, these technologies need to have demonstrated reliability and reasonably well defined fabrication and assembly processes before they will be accepted as baseline designs in new missions. As electronics shrink in size, not only can repair be more difficult, but 49 probing" circuitry can be very risky and it becomes increasingly more difficult to identify the specific source of a problem. To test and monitor these new technologies, the Direct Chip Attach Task, under NASA's Electronic Parts and Packaging Program (NEPP), chose the test methodology of boundary scan testing. The boundary scan methodology was developed for interconnect integrity and functional testing at hard to access electrical nodes. With boundary scan testing, active devices are used and failures can be identified to the specific device and lead. This technology permits the incorporation of "built in test" into almost any circuit and thus gives detailed test access to the highly integrated electronic assemblies. This presentation will describe boundary scan, discuss the development of the boundary scan test vehicle for DCA and current plans for testing of direct chip attach configurations.

Parsons, Heather A.↗

Combined Loads Test Fixture for Thermal-Structural Testing Aerospace Vehicle Panel Concepts

A structural test requirement of the National Aero-Space Plane (NASP) program has resulted in the design, fabrication, and implementation of a combined loads test fixture. Principal requirements for the fixture are testing a 4- by 4-ft hat-stiffened panel with combined axial (either tension or compression) and shear load at temperatures ranging from room temperature to 915 F, keeping the test panel stresses caused by the mechanical loads uniform, and thermal stresses caused by non-uniform panel temperatures minimized. The panel represents the side fuselage skin of an experimental aerospace vehicle, and was produced for the NASP program. A comprehensive mechanical loads test program using the new test fixture has been conducted on this panel from room temperature to 500 F. Measured data have been compared with finite-element analyses predictions, verifying that uniform load distributions were achieved by the fixture. The overall correlation of test data with analysis is excellent. The panel stress distributions and temperature distributions are very uniform and fulfill program requirements. This report provides details of an analytical and experimental validation of the combined loads test fixture. Because of its simple design, this unique test fixture can accommodate panels from a variety of aerospace vehicle designs.

Fields, Roger A.↗

Post Test Evaluation of HSCT Nozzle Acoustic Liner Subcomponents Subjected to a Hot Acoustic Durability Test

The acoustic liner system designed for use in the High Speed Civil Transport (HSCT) was tested in a thermal-acoustic environment. Five ceramic matrix composite (CMC) acoustic tile configurations, five bulk acoustic absorbers, and one thermal protection system design were tested. The CMC acoustic tiles were subjected to two 2 3/4 hr ambient temperature acoustic exposures to measure their dynamic response. One exposure was conducted on the tiles alone and the second exposure included the tiles and the T-foam bulk absorber. The measured tile RMS strains were small. With or without the T-foam absorber, the dynamic strains were below strain levels that would cause damage during fatigue loading. After the ambient exposure, a 75-hr durability test of the entire acoustic liner system was conducted using a thermal-acoustic cycle that approximated the anticipated service cycle. Acoustic loads up to 139 dB/Hz and temperatures up to 1670 F (910 C) were employed during this 60 cycle test. During the durability test, the CMC tiles were exposed to temperatures up to 1780 F and a transient through thickness gradient up to 490 F. The TPS peak temperatures on the hot side of the panels ranged from 750 to 1000 F during the 60 cycles. The through thickness delta T ranged from 450 to 650 F, varying with TPS location and cycle number. No damage, such as cracks or chipping, was observed in the CMC tiles after completion of the testing. However, on tile warped during the durability test and was replaced after 43 or 60 cycles. No externally observed damage was found in this tile. No failure of the CMC fasteners occurred, but damage was observed. Cracks and missing material occurred, only in the fastener head region. No indication of damage was observed in the T-foam acoustic absorbers. The SiC foam acoustic absorber experienced damage after about 43 cycles. Cracking in the TPS occurred around the attachment holes and under a vent. In spite of the development of damage, the TPS maintained its insulative capability throughout the durability test. The durability test results demonstrate damage-tolerant CMC tile, CMC fastener, TPS, and T-foam absorber designs for the combined thermal and acoustic engine nozzle environment.

Verrilli, Michael J.↗

Using the Integrated Vehicle Health Management Research Test and Integration Plan Wiki to Identify Synergistic Test Opportunities

The National Aeronautics and Space Administration (NASA) and the aviation industry have recognized a need for developing a method to identify and combine resources to carry out research and testing more efficiently. The Integrated Vehicle Health Management (IVHM) Research Test and Integration Plan (RTIP) Wiki is a tool that is used to visualize, plan, and accomplish collaborative research and testing. Synergistic test opportunities are developed using the RTIP Wiki, and include potential common resource testing that combines assets and personnel from NASA, industry, academia, and other government agencies. A research scenario is linked to the appropriate IVHM milestones and resources detailed in the wiki, reviewed by the research team members, and integrated into a collaborative test strategy. The scenario is then implemented by creating a test plan when appropriate and the research is performed. The benefits of performing collaborative research and testing are achieving higher Technology Readiness Level (TRL) test opportunities with little or no additional cost, improved quality of research, and increased communication among researchers. In addition to a description of the method of creating these joint research scenarios, examples of the successful development and implementation of cooperative research using the IVHM RTIP Wiki are given.

Koelfgen, Syri J.↗

James Webb Space Telescope Integrated Science Instrument Module Thermal Balance/Thermal Vacuum Test Configuration and Test Planning at NASA's Goddard Space Flight Center

The James Webb Space Telescope (JWST) is the next of the great observatories , scheduled to be launched in 2014. Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center s (GSFC) Space Environment Simulator (SES). The test enclosure surrounding the instruments during the integrated ISIM-level thermal balance testing is complex, and is designed to simulate as closely as possible the in-flight conductive and radiative thermal environment around the ISIM. Thermal control and measurement of parasitic sources of heat leak into the test volume is critical, as the dissipation plus known parasitics in the flight ISIM is approximately 454 mW, and additional parasitics attributed to the flight enclosure itself are nearly equal to this, resulting in the energy balance of the inflight ISIM being less than 1.0 W. Sources of test-induced parasitics must be carefully controlled and measured, and the ability to thermally control the test environment is critical to enable accurate thermal balance testing and thermal model correlation. This paper describes the test configuration and plans for the ISIM-level thermal vacuum/thermal balance testing at GSFC.

Glazer, Stuart↗