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At least 271 records · Page 15

Summary of the 2012 Inductive Pulsed Plasma Thruster Development and Testing Program

Inductive pulsed plasma thrusters are spacecraft propulsion devices in which energy is capacitively stored and then discharged through an inductive coil. While these devices have shown promise for operation at high efficiency on a range of propellants, many technical issues remain before they can be used in flight applications. A conical theta-pinch thruster geometry was fabricated and tested to investigate potential improvements in propellant utilization relative to more common, flat-plate planar coil designs. A capacitor charging system is used to permit repetitive discharging of thrusters at multiple cycles per second, with successful testing accomplished at a repetition-rate of 5 Hz at power levels of 0.9, 1.6, and 2.5 kW. The conical theta-pinch thruster geometry was tested at cone angles of 20deg, 38deg, and 60deg, with single-pulse operation at 500 J/pulse and repetitionrate operation with the 38deg model quantified through direct thrust measurement using a hanging pendulum thrust stand. A long-lifetime valve was designed and fabricated, and initial testing was performed to measure the valve response and quantify the leak rate at beginning-of-life. Subscale design and testing of a capacitor charging system required for operation on a spacecraft is reported, providing insights into the types of components needed in the circuit topology employed. On a spacecraft, this system would accept as input a lower voltage from the spacecraft DC bus and boost the output to the high voltage required to charge the capacitors of the thruster.

Polzin, K. A.↗

Verification of International Space Station Component Leak Rates by Helium Accumulation Method

Discovery of leakage on several International Space Station U.S. Laboratory Module ammonia system quick disconnects (QDs) led to the need for a process to quantify total leakage without removing the QDs from the system. An innovative solution was proposed allowing quantitative leak rate measurement at ambient external pressure without QD removal. The method utilizes a helium mass spectrometer configured in the detector probe mode to determine helium leak rates inside a containment hood installed on the test component. The method was validated through extensive developmental testing. Test results showed the method was viable, accurate and repeatable for a wide range of leak rates. The accumulation method has been accepted by NASA and is currently being used by Boeing Huntsville, Boeing Kennedy Space Center and Boeing Johnson Space Center to test welds and valves and will be used by Alenia to test the Cupola. The method has been used in place of more expensive vacuum chamber testing which requires removing the test component from the system.

Underwood, Steve D.↗

Thermal Performance Testing Of Cryogenic Piping Systems

Thermal performance measurement of piping systems under actual field conditions is important for space launch development and commercial industry. Knowledge of the true insulating effectiveness is needed in system design, development, and research activities. A new 18-meter-long test apparatus for cryogenic pipelines has been developed. Three different pipelines, rigid or flexible, can be tested simultaneously. Critical factors in heat leak measurements include eliminating heat transfer at end connections and obtaining proper liquid saturation condition. Effects due to variations in the external ambient conditions like wind, humidity, and solar radiation must be minimized. The static method of liquid nitrogen evaporation has been demonstrated, but the apparatus can be adapted for dynamic testing with cryogens, chilled water, or other working fluids. This technology is suited for the development of an industry standard test apparatus and method. Examples of the heat transfer data from testing commercially available pipelines are given. Prototype pipelines are currently being tested and evaluated at the Cryogenics Test Laboratory of NASA Kennedy Space Center.

Fesmire, J. E.↗

Software Verification Toolkit (SVT): Survey on Available Software Verification Tools and Future Direction

Writing software is difficult. However, writing complex, well tested and designed, and functionally correct software is incredibly difficult. An entire field of study is devoted to the validation and verification of software to address this problem, and in this paper we analyze the landscape of currently available third party software. We have divided our analyses into three separate subsections with regards to software validation: formal methods, static analysis, and test generation. Formal verification is the most complex method in which to validate software correctness, but also the most thorough as it truly validates the mathematical validity of the source code. Static analysis generally is relegated to abstract syntax tree traversal techniques to find errors related to faulty software such as memory leaks or stack overflow issues. Automatic test generation is similar in implementation to static analysis, but pushes a bit further in verifying the boundedness of function inputs and outputs with regards to annotated or parsed criteria. The crux of this report is to analyze and describe the software tools that implement these techniques to validate and verify software. Pros and cons related to installation, utilization, and capabilities of the frameworks are described, and reproducible examples are provided with a focus on usability. The initial survey concluded that the most interesting tools of note are Z3, Isabelle/HOL, and TLA+ with regards to formal verification; and Infer, Frama-C, and SonarQube with regards to static analysis. With these tools in mind, a final conjecture is provided that describes future avenues of utilizing these tools for developing a verification framework to assist in validating existing software at Sandia National Laboratories.

97 MATHEMATICS AND COMPUTING↗

Activation of the E1 Ultra High Pressure Propulsion Test Facility at Stennis Space Center

After a decade of construction and a year of activation the El Ultra High Pressure Propulsion Test Facility at NASA's Stennis Space Center is fully operational. The El UHP Propulsion Test Facility is a multi-cell, multi-purpose component and engine test facility . The facility is capable of delivering cryogenic propellants at low, high, and ultra high pressures with flow rates ranging from a few pounds per second up to two thousand pounds per second. Facility activation is defined as a series of tasks required to transition between completion of construction and facility operational readiness. Activating the El UHP Propulsion Test Facility involved independent system checkouts, propellant system leak checks, fluid and gas sampling, gaseous system blow downs, pressurization and vent system checkouts, valve stability testing, valve tuning cryogenic cold flows, and functional readiness tests.

Messer, Bradley↗

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗

JWST's Cryogenic Position Metrology System

The James Webb Space Telescope will undergo a full system test in the cryogenic vacuum chamber A at the Johnson Spaceflight Center in order to verify the overall performance of the combined telescope and instrument suite. This will be the largest and most extensive cryogenic test ever undertaken. Early in the test system development, it was determined that precise position measurements of the overall hardware would enhance the test results. Various concepts were considered before selecting photogrammetry for this metrology. Photogrammetry has been used in space systems for decades, however cryogenic use combined with the size and the optical/thermal sensitivity of JWST creates a unique set of implementation challenges. This paper provides an overview of the JWST photogrammetric system and mitigation strategies for three key engineering design challenges: 1) the thermal design of the viewing windows to prevent excessive heat leak and stray light to the test article 2) cost effective motors and mechanisms to provide the angle diversity required, and 3) camera-flash life and reliability sufficient for inaccessible use during the number and duration of the cryogenic tests.

Whitman, Tony L.↗

Hypervelocity Impact of Composite Overwrap Pressure Vessels

There is a limited amount of hypervelocity impact (HVI) data on pressurized composite overwrapped pressure vessels (COPV). In recent years, NASA has performed HVI tests to characterize impact conditions resulting in either leak or burst of the COPVs representative of spacecraft hardware. This paper reports on the results of 40 tests that have been conducted on several types of COPV configurations, pressurized by inert gas to near the vessels rated maximum expected operating pressure (MEOP). These tests were used to better understand COPV response under HVI conditions and develop ballistic limit equations (BLE) related to these tests.

Davis, Bruce A.↗

Data Acquisition and Control Systems Laboratory

The Data Acquisition and Control Systems (DACS) Laboratory is a facility at Stennis Space Center that provides an off test-stand capability to develop data-acquisition and control systems for rocket-engine test stands. It is also used to train new employees in state-of-the-art systems, and provides a controlled environment for troubleshooting existing systems, as well as the ability to evaluate the application of new technologies and process improvements. With the SSC propulsion testing schedules, without the DACS Laboratory, it would have been necessary to perform most of the development work on actual test systems, thereby subjecting both the rocket-engine testing and development programs to substantial interference in the form of delays, restrictions on modifications of equipment, and potentially compromising software configuration control. The DACS Laboratory contains a versatile assortment of computer hardware and software, digital and analog electronic control and data-acquisition equipment, and standard electronic bench test equipment and tools. Recently completed Control System development and software verification projects include support to the joint NASA/Air Force Integrated Powerhead Demonstration (IPD) LOX & LH2 PreBurner and Turbopump ground testing programs. In other recent activities, the DACS Laboratory equipment and expertise have supported the off-stand operation of high-pressure control valves to correct valve leak problems prior to installation on the test stand. Future plans include expanding the Laboratory's capabilities to provide cryogenic control valve characterization prior to installation, thereby reducing test stand activation time.

Holland, Randy↗

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗

Structural Dynamic Testing Results for Air-Independent Proton Exchange Membrane (PEM) Fuel Cell Technologies for Space Applications

In 2016, the NASA Advanced Exploration Systems (AES) project office funded research at the NASA Glenn Research Center to evaluate the maturity of the Proton Exchange Membrane (PEM) fuel cell technology and its viability for supporting launch vehicle and space applications. This technology evaluation included vibration, reactant purity, and vacuum exposure sensitivity testing. The evaluation process did not include microgravity testing. This paper discusses the vibration sensitivity testing of two air-independent fuel cell stacks provided by different vendors to assess the ability of currently available fuel cell stack hardware to survive the projected random vibrational environment that would be encountered in an upper stage launch vehicle. Baseline performance testing was utilized to quantify stack performance and overboard leak rate at standard atmospheric conditions in order to provide a reference for post-test comparison. Both fuel cell stacks were tested at a random vibration qualification level of 10.4 grms for five minutes in each axis. Low-level sinusoidal sweeps were conducted before and after each random vibration level run to see if any significant change in resonances were detected. Following vibration facility testing, the baseline performance testing was repeated. Test results demonstrated no measurable change in fuel cell electrochemical or mechanical performance, indicating that the two evaluated PEM fuel cell stacks may be suitable for space applications pending microgravity testing.

Gilligan, Ryan P.↗

A ground test measurement system for the shuttle entry air data system

The Ground Test Measurement System (GTMS) for determining vacuum decay leak rate within the orifice tubing assembly of SEADS is described. The system can also monitor the absolute pressure in the tubing assembly under certain conditions. The GTMS determines leak rate by measuring vacuum-pressure decay which can be converted into leakage flow rate. Results of performance testing and operation of the GTMS are given.

Schutte, P. C.↗

Exploration Extravehicular Mobility Unit (xEMU) Chamber B Thermal Vacuum “Suit 2” Pressure Garment System Test Article Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test results from the “Suit 2” Pressure Garment System (PGS) test article. The primary objective of the “Suit 2” PGS test article was to evaluate system-level suit heat leak and Environmental Protection Garment (EPG) thermal performance. Eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and a heater cage surrounding the test article. This paper will principally focus on system-level thermal results from the “Suit 2” PGS test article. This paper will examine data collected from one-hundred and seventy thermocouples located in critical locations inside and outside of the suit, as well as seven resistance thermometers (RTDs) for calorimetry to determine total heat flux in and out of the suit. The test data will be compared against the system-level PGS thermal models for model validation. To conclude, this paper will address knowledge gaps presented by unmanned xPGS thermal vacuum testing and the current state of lunar xPGS thermal modeling and testing.

xEMU↗

Study of multilayered insulation pipe penetration. Thermal acoustic oscillation

Tests were conducted to determine the net heat leak to a source of liquid nitrogen caused by a metal penetration through the blanket of multilayer insulation. The conditions under which the tests were conducted are described. A graph of the theoretical and experimental temperature distribution is developed for comparison. The variables involved in the computer program to process the data are defined. A study was conducted to develop analytical methods for predicting the effect and magnitudes of thermoacoustic oscillations on the penetration heat leak to cryogens. The oscillations develop as a result of large thermal gradients imposed on a compressible fluid. The predominant amplitudes and frequencies of the thermal acoustic oscillations were investigated.

Lovin, J. K.↗

Energy Efficient High-Pressure Turbine Leakage Technology Report

The leakage test program was one of such supporting technology programs structured to provide guidance to the Energy Efficient Engine High Pressure Turbine Component Design Effort. Leakage reduction techniques were identified and evaluated. Test models were used to simulate component leak paths and to evaluate leakage reduction techniques. These models simulated the blade/disk attachment, the vane inner platform attachment, and the vane outer platform attachment combined with the blade outer airseal. Disk blade attachment testing indicated that leakage in this area could be reduced to very low levels by paying careful attention to the tolerances along the contact surface between the blade vibration damper and the blade platform contact surface. The aim of feather seal testing was to achieve a goal for an effective leakage gap of one mil (.001 inch) per inch of feather seal length. Results indicated that effective gaps even below the goal level were achievable by (1) maintaining close tolerances between feather seals and their slots to minimize end gaps and limit seal rotation, (2) avoiding feather seal overlap, and (3) minimizing feather seal intersections. W seals were shown to be effective leakage control devices. Wire rope, in its present state of development, was shown not to be an effective sealing concept for application to the component design.

Gardner, W. B.↗

Hydrogen leak detection in the Space Shuttle

This study focuses on a helium gas jet flowing into room air. Measurements of helium concentration and velocity in the jet-air mixture are reported. The objective is to learn about jet characteristics so that dynamically similar hydrogen leaks may be located in the Space Shuttle. The hazardous gas detection system (HGDS) in the mobile launch pad uses mass spectrometers to monitor the shuttle environment for leaks. The mass spectrometers are fed by long sample tubes which draw gas from the payload bay, mid body, aft engine compartment and external tank. The overall purpose of this study is to improve the HGDS especially in its potential for locating hydrogen leaks. A rapid-response leak detection experiment was designed, built, and tested, following on the work done in this program last summer. The apparatus included a Perkin Elmer MGA-1200 mass spectrometer and air velocity transducer, both monitored by a Macintosh IIFX computer using LabVIEW software. A jet of helium flowing into the lab air simulated a gas leak. Steady helium or hydrogen-nitrogen jets were logged for concentration and velocity, and the power spectral density of each was computed. Last year, large eddies and vortices were visually seen with Schlieren imaging, and they were detected in the time plots of the various instruments. The response time of the MGA-1200 was found in the range of 0.05 to 0.1 sec. Pulsed concentration waves were clearly detected at 25 cycles per sec by spectral analysis of MGA data. No peaks were detected in the power spectrum, so in the present study, 10 Hz bandwidth-averaged power levels were examined at regular frequency intervals. The practical consequences of last year's study are as follows: sampling frequency should be increased above the present rate of 1 sample per second so that transients could be observed and analyzed with frequency response methods. Many more experiments and conditions were observed in this second summer, including the effects of orifice diameter, jet velocity, sample tube design, radial effects, vertical flow, and low hydrogen concentrations (1 percent). A frequent observation was that the power spectrum, calculated from the Fourier transform of concentration fluctuations, gives a separate piece of information from concentration. Many of the tests suggest that power is high where mixing occurs at the helium-air interface. This fact is apparently independent of the concentration level, which could be high or low, but depends on the sample location relative to the jet (leak) origin, whereas high concentration may be due to a strong leak far away or a small leak close to the sample tube. If the power is low for any concentration level, this would signify helium is arriving at the sample tube by diffusion, not chaotic mixing caused by the jet interaction with air. The practical result is to propose a modification of the HGDL mass spectrometer data sampling and software so that sampling rates could be capable of observing at least 25 Hz fluctuations.

Barile, Ronald G↗

Evaluation of a Brayton cycle recuperator after 21,000 hours of ground testing

A metallographic examination was conducted on a Brayton cycle recuperator and associated ducting after 21,000 hours of ground testing in air. At the hot (turbine) end, the recuperator operated at a nominal temperature of 675 C. The type 347 stainless-steel recuperator performed satisfactorily in the ground test even though the primary working fluid leaked to the atmosphere periodically. The leakage path was located at plate-bar braze joints which cracked as a result of thermal stresses. The welded type 347 stainless steel ducting a type 347/Hastelloy X bellows survived the ground test with no apparent loss of ductility or integrity. Some apparent aging embrittlement was observed in the Hastelloy X ducting but the serviceability was not affected.

Moore, T. J.↗

SULI Report - Development of a Molten Salt Circulation Loop for in-situ Spectroscopy

This project supports the development of real time optical monitoring capabilities for molten salt reactor (MSR) environments by designing, testing, and refining a molten salt circulation loop suitable for combined laser induced breakdown spectroscopy (LIBS) and ultraviolet visible (UV Vis) absorption measurements. Online spectroscopic monitoring is increasingly important for nuclear safeguards, corrosion tracking, and material accountancy, yet MSR process fluids present substantial challenges due to their chemical complexity and hazards such as high temperatures and radiation. To address these needs, this work focuses on Phase I, the development of a room temperature aqueous circulation loop that serves as a surrogate platform for evaluating flow behavior, optical access, and component performance prior to high temperature salt operation. Initial testing identified several practical issues—including leaks, obstructions, and two-phase flow through the absorption cell—that were systematically resolved through hardware replacement, flow path redesign, and venturi pressure optimization. Relocating the flow cell upstream of the primary venturi enabled periods of stable single-phase flow, demonstrating the feasibility of integrating optical diagnostics into a circulation system. The results of Phase I provide essential design insight for Phase II, which will incorporate furnace compatible materials and LiCl KCl eutectic salt. Completion of the molten salt system will deliver a reusable testbed for evaluating multimodal spectroscopic techniques, advancing nondestructive, real time monitoring tools for future MSR and nuclear fuel cycle applications.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗