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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2013

Autonomous Cryogenic Load Operations: Knowledge-Based Autonomous Test Engineer

The Knowledge-Based Autonomous Test Engineer (KATE) program has a long history at KSC. Now a part of the Autonomous Cryogenic Load Operations (ACLO) mission, this software system has been sporadically developed over the past 20 years. Originally designed to provide health and status monitoring for a simple water-based fluid system, it was proven to be a capable autonomous test engineer for determining sources of failure in the system. As part of a new goal to provide this same anomaly-detection capability for a complicated cryogenic fluid system, software engineers, physicists, interns and KATE experts are working to upgrade the software capabilities and graphical user interface. Much progress was made during this effort to improve KATE. A display of the entire cryogenic system's graph, with nodes for components and edges for their connections, was added to the KATE software. A searching functionality was added to the new graph display, so that users could easily center their screen on specific components. The GUI was also modified so that it displayed information relevant to the new project goals. In addition, work began on adding new pneumatic and electronic subsystems into the KATE knowledge base, so that it could provide health and status monitoring for those systems. Finally, many fixes for bugs, memory leaks, and memory errors were implemented and the system was moved into a state in which it could be presented to stakeholders. Overall, the KATE system was improved and necessary additional features were added so that a presentation of the program and its functionality in the next few months would be a success.

Schrading, J. Nicolas↗

NASA NTRS1998

Summer Work Experience: Determining Methane Combustion Mechanisms and Sub-Scale Diffuser Properties for Space Transporation System Engine Testing

To assess engine performance during the testing of Space Shuttle Main Engines (SSMEs), the design of an optimal altitude diffuser is studied for future Space Transportation Systems (STS). For other Space Transportation Systems, rocket propellant using kerosene is also studied. Methane and dodecane have similar reaction schemes as kerosene, and are used to simulate kerosene combustion processes at various temperatures. The equations for the methane combustion mechanism at high temperature are given, and engine combustion is simulated on the General Aerodynamic Simulation Program (GASP). The successful design of an altitude diffuser depends on the study of a sub-scaled diffuser model tested through two-dimensional (2-D) flow-techniques. Subroutines given calculate the static temperature and pressure at each Mach number within the diffuser flow. Implementing these subroutines into program code for the properties of 2-D compressible fluid flow determines all fluid characteristics, and will be used in the development of an optimal diffuser design.

Williams, Powtawche N.↗

NASA NTRS1991

Engineering Test Satellite VI (ETS-VI)

The Engineering Test Satellite-VI (ETS-VI) is being developed as the third Japanese three-axis stabilized engineering test satellite to establish the 2-ton geostationary operational satellite bus system and to demonstrate the high performance satellite communication technology for future operational satellites. The satellite is expected to be stationed at 154 deg east latitude. It will be launched from the Tanegashima Space Center in Japan by a type H-II launch vehicle. The Deep Space Network (DSN) will support the prelaunch compatibility test, data interface verification testing, and launch rehersals. The DSN primary support period is from launch through the final AEF plus 1 hour. Contingency support is from final AEF plus 1 hour until launch plus 1 month. The coverage will consist of all the 26-m antennas as prime and the 34-m antennas at Madrid and Canberra as backup. Maximum support will consist of two 8-hour tracks per station for a 7-day period, plus the contingency support, if required. Information is given in tabular form for DSN support, telemetry, command, and tracking support responsibility.

Horii, M.↗

NASA NTRSDate not supplied

Wear Test of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first wear test of the 12.5 kW Advanced Electric Propulsion System Engineering Test Unit 2 (AEPS ETU-2) thruster produced by Aerojet Rocketdyne. The ETU-2 Wear Test accumulated approximately 730 hours of operation split between the nominal 600 V/12.5 kW condition and the 300 V/6.25 kW condition previously identified as the worst-case erosion condition.

Jason D. Frieman↗

NASA NTRSDate not supplied

Extended Wear Testing of the 12-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first wear test of the 12 kW Advanced Electric Propulsion System (AEPS) intended to isolate the impact of discharge current on component wear rates. Testing was led by Aerojet Rocketdyne and performed with the AEPS Engineering Test Unit 2 (ETU-2) thruster. In total, approximately 860 hours of operation were accumulated split between operating conditions of 600 V/9 kW, 600 V/11 kW, and 600 V/12 kW. Thruster performance and stability were invariant throughout the wear test for all thruster throttle conditions and shown to be equal to the values previously measured with ETU-2. Inner front pole cover erosion rates were found to be invariant to discharge current as the measurements at all three operating conditions were equal to within the empirical uncertainty. Outer front pole cover erosion rates were found to be equal for the 600 V/9 kW and 600 V/12 kW conditions with operation at 600 V/11 kW yielding elevated erosion rates. Overall, the data shows that the AEPS thruster design has a high probability of meeting lifetime and performance requirements as the design proceeds to flight production and qualification.

Jason D Frieman↗

NASA NTRSDate not supplied

Extended Wear Testing of the 12-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first wear test of the 12 kW Advanced Electric Propulsion System (AEPS) intended to isolate the impact of discharge current on component wear rates. Testing was led by Aerojet Rocketdyne and performed with the AEPS Engineering Test Unit 2 (ETU-2) thruster. In total, approximately 860 hours of operation were accumulated split between operating conditions of 600 V/9 kW, 600 V/11 kW, and 600 V/12 kW. Thruster performance and stability were invariant throughout the wear test for all thruster throttle conditions and shown to be equal to the values previously measured with ETU-2. Inner front pole cover erosion rates were found to be invariant to discharge current as the measurements at all three operating conditions were equal to within the empirical uncertainty. Outer front pole cover erosion rates were found to be equal for the 600 V/9 kW and 600 V/12 kW conditions with operation at 600 V/11 kW yielding rates that were comparable to those on the inner front pole cover. Overall, the data shows that the AEPS thruster design has a high probability of meeting lifetime and performance requirements as the design proceeds to flight production and qualification.

HERMeS↗

NASA NTRSDate not supplied

Characterization Test of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the detailed characterization testof the 12.5 kW Advanced Electric Propulsion System Engineering Test Unit 2 (AEPS ETU-2) thruster produced by Aerojet Rocketdyne. This test campaign had two major goals: to assessthe risk of design compliance with thruster requirements and providea comparison to the previously-tested NASA Hall Effect Rocket with Magnet Shielding Technology Demonstration Units (HERMeS TDUs) from which the AEPS ETU design was derived.

AEPS↗

NASA NTRS2005

Introduction to Flight Test Engineering [Introduction Aux Techniques Des Essais En Vol]

Flight test is at the core of what organizations must do in order to validate the operation and systems on an aircraft. While the AGARDograph series 300 and 160 series deal with aspects of this testing, this volume pulls it all together as an introduction to the process required to do effective flight test engineering. This volume was originally published in 1995. Its utility has been proven in that many flight test organizations and universities have requested copies for their engineers and students. It was felt that re-issuing it in a new format designed for electronic publication would be valuable to the community. This second printing changes none of the text, but rather reformats it. All the original references to AGARD (instead of RTO) are left in place so that none of the flavor of the original publication is lost. This is the Introductory Volume to the Flight Test Techniques Series. It is a general introduction to the various activities and aspects of Flight Test Engineering that must be considered when planning, conducting, and reporting a flight test program. Its main intent is to provide a broad overview to the novice engineer or to other people who have a need to interface with specialists within the flight test community. The first two Sections provide some insight into the question of why flight test and give a short history of flight test engineering. Sections 3 through 10 deal with the preparation for flight testing. They provide guidance on the preliminary factors that must be considered; the composition of the test team; the logistic support requirements; the instrumentation and data processing requirements; the flight test plan; the associated preliminary ground tests; and last, but by no means least, discuss safety aspects. Sections 11 through 27 describe the various types of flight tests that are usually conducted during the development and certification of a new or modified aircraft type. Each Section offers a brief introduction to the topic under consideration, and the nature and the objectives of the tests to be conducted. It lists the test instrumentation (and, where appropriate, other test equipment and facilities) required, describes the test maneuvers to be executed, and indicates the way in which the test data is selected, analyzed, and presented. The various activities that should take place between test flights are presented next. Items that are covered are: who to debrief; what type of reports to send where: types of data analysis required for next flight; review of test data to make a comparison to predicted data and some courses of action if there is not good agreement; and comments on selecting the next test flight. The activities that must take place upon completion of the test program are presented. The types of reports and briefings that should take place and a discussion of some of the uses of the flight test data are covered. A brief forecast is presented of where present trends may be leading.

Test facilities↗

NASA NTRS1984

Comparison of free-piston Stirling engine model predictions with RE1000 engine test data

Predictions of a free-piston Stirling engine model are compared with RE1000 engine test data taken at NASA-Lewis Research Center. The model validation and the engine testing are being done under a joint interagency agreement between the Department of Energy's Oak Ridge National Laboratory and NASA-Lewis. A kinematic code developed at Lewis was upgraded to permit simulation of free-piston engine performance; it was further upgraded and modified at Lewis and is currently being validated. The model predicts engine performance by numerical integration of equations for each control volume in the working space. Piston motions are determined by numerical integration of the force balance on each piston or can be specified as Fourier series. In addition, the model Fourier analyzes the various piston forces to permit the construction of phasor force diagrams. The paper compares predicted and experimental values of power and efficiency and shows phasor force diagrams for the RE1000 engine displacer and piston. Further development plans for the model are also discussed.

Tew, R. C., Jr.↗

NASA NTRS1984

Comparison of free-piston Stirling engine model predictions with RE1000 engine test data

Tew, R. C.↗

NASA NTRS1965

Electric propulsion engine test chamber Patent

Electric propulsion engine test chamber

Childs, J. H.↗

NASA NTRS1980

Engineering test facility design definition

The Engineering Test Facility (ETF) is the major focus of the Department of Energy (DOE) Magnetohydrodynamics (MHD) Program to facilitate commercialization and to demonstrate the commercial operability of MHD/steam electric power. The ETF will be a fully integrated commercial prototype MHD power plant with a nominal output of 200 MW sub e. Performance of this plant is expected to meet or surpass existing utility standards for fuel, maintenance, and operating costs; plant availability; load following; safety; and durability. It is expected to meet all applicable environmental regulations. The current design concept conforming to the general definition, the basis for its selection, and the process which will be followed in further defining and updating the conceptual design.

Bercaw, R. W.↗

NASA NTRS2014

Validation Ice Crystal Icing Engine Test in the Propulsion Systems Laboratory at NASA Glenn Research Center

The Propulsion Systems Laboratory (PSL) is an existing altitude simulation jet engine test facility located at NASA Glenn Research Center in Clevleand, OH. It was modified in 2012 with the integration of an ice crystal cloud generation system. This paper documents the inaugural ice crystal cloud test in PSLthe first ever full scale, high altitude ice crystal cloud turbofan engine test to be conducted in a ground based facility. The test article was a Lycoming ALF502-R5 high bypass turbofan engine, serial number LF01. The objectives of the test were to validate the PSL ice crystal cloud calibration and engine testing methodologies by demonstrating the capability to calibrate and duplicate known flight test events that occurred on the same LF01 engine and to generate engine data to support fundamental and computational research to investigate and better understand the physics of ice crystal icing in a turbofan engine environment while duplicating known revenue service events and conducting test points while varying facility and engine parameters. During PSL calibration testing it was discovered than heated probes installed through tunnel sidewalls experienced ice buildup aft of their location due to ice crystals impinging upon them, melting and running back. Filtered city water was used in the cloud generation nozzle system to provide ice crystal nucleation sites. This resulted in mineralization forming on flow path hardware that led to a chronic degradation of performance during the month long test. Lacking internal flow path cameras, the response of thermocouples along the flow path was interpreted as ice building up. Using this interpretation, a strong correlation between total water content (TWC) and a weaker correlation between median volumetric diameter (MVD) of the ice crystal cloud and the rate of ice buildup along the instrumented flow path was identified. For this test article the engine anti-ice system was required to be turned on before ice crystal icing would occur. The ice crystal icing event, an uncommanded reduction in thrust, was able to be turned on and off by manipulating cloud TWC. A flight test point where no ice crystal icing event occurred was also duplicated in PSL. Physics based computational tools were successfully used to predict tunnel settings to induce ice buildup along the low pressure compression system flow path for several test points at incrementally lower altitudes, demonstrating that development of ice crystal icing scaling laws is potentially feasible. Analysis of PSL test data showed that uncommanded reduction in thrust occurs during ice crystal cloud on operation prior to fan speed reduction. This supports previous findings that the reduction of thrust for this test article is due to ice buildup leading to a restricted airflow from either physical or aerodynamic blockage in the engine core flow path.

Ice Crystal Icing↗

NASA NTRS1981

Magnetohydrodynamics (MHD) Engineering Test Facility (ETF) 200 MWe power plant. Conceptual Design Engineering Report (CDER). Volume 4: Supplementary engineering data

The reference conceptual design of the Magnetohydrodynamic Engineering Test Facility (ETF), a prototype 200 MWe coal-fired electric generating plant designed to demonstrate the commercial feasibility of open cycle MHD is summarized. Main elements of the design are identified and explained, and the rationale behind them is reviewed. Major systems and plant facilities are listed and discussed. Construction cost and schedule estimates, and identification of engineering issues that should be reexamined are also given. The latest (1980-1981) information from the MHD technology program are integrated with the elements of a conventional steam power electric generating plant. Supplementary Engineering Data (Issues, Background, Performance Assurance Plan, Design Details, System Design Descriptions and Related Drawings) is presented.

Source record↗

NASA NTRS2014

Validation Ice Crystal Icing Engine Test in the Propulsion Systems Laboratory at NASA Glenn Research Center

The Propulsion Systems Laboratory (PSL) is an existing altitude simulation jet engine test facility located at NASA Glenn Research Center in Cleveland, OH. It was modified in 2012 with the integration of an ice crystal cloud generation system. This paper documents the inaugural ice crystal cloud test in PSL--the first ever full scale, high altitude ice crystal cloud turbofan engine test to be conducted in a ground based facility. The test article was a Lycoming ALF502-R5 high bypass turbofan engine, serial number LF01. The objectives of the test were to validate the PSL ice crystal cloud calibration and engine testing methodologies by demonstrating the capability to calibrate and duplicate known flight test events that occurred on the same LF01 engine and to generate engine data to support fundamental and computational research to investigate and better understand the physics of ice crystal icing in a turbofan engine environment while duplicating known revenue service events and conducting test points while varying facility and engine parameters. During PSL calibration testing it was discovered than heated probes installed through tunnel sidewalls experienced ice buildup aft of their location due to ice crystals impinging upon them, melting and running back. Filtered city water was used in the cloud generation nozzle system to provide ice crystal nucleation sites. This resulted in mineralization forming on flow path hardware that led to a chronic degradation of performance during the month long test. Lacking internal flow path cameras, the response of thermocouples along the flow path was interpreted as ice building up. Using this interpretation, a strong correlation between total water content (TWC) and a weaker correlation between median volumetric diameter (MVD) of the ice crystal cloud and the rate of ice buildup along the instrumented flow path was identified. For this test article the engine anti-ice system was required to be turned on before ice crystal icing would occur. The ice crystal icing event, an uncommanded reduction in thrust, was able to be turned on and off by manipulating cloud TWC. A flight test point where no ice crystal icing event occurred was also duplicated in PSL. Physics based computational tools were successfully used to predict tunnel settings to induce ice buildup along the low pressure compression system flow path for several test points at incrementally lower altitudes, demonstrating that development of ice crystal icing scaling laws is potentially feasible. Analysis of PSL test data showed that uncommanded reduction in thrust occurs during ice crystal cloud on operation prior to fan speed reduction. This supports previous findings that the reduction of thrust for this test article is due to ice buildup leading to a restricted airflow from either physical or aerodynamic blockage in the engine core flow path.

Turbofan Engine↗

NASA NTRS1981

Magnetohydrodynamics (MHD) Engineering Test Facility (ETF) 200 MWe power plant Conceptual Design Engineering Report (CDER)

The reference conceptual design of the magnetohydrodynamic (MHD) Engineering Test Facility (ETF), a prototype 200 MWe coal-fired electric generating plant designed to demonstrate the commercial feasibility of open cycle MHD, is summarized. Main elements of the design, systems, and plant facilities are illustrated. System design descriptions are included for closed cycle cooling water, industrial gas systems, fuel oil, boiler flue gas, coal management, seed management, slag management, plant industrial waste, fire service water, oxidant supply, MHD power ventilating

Source record↗

NASA NTRS1981

Magnetohydrodynamics (MHD) Engineering Test Facility (ETF) 200 MWe power plant. Conceptual Design Engineering Report (CDER). Volume 2: Engineering. Volume 3: Costs and schedules

Engineering design details for the principal systems, system operating modes, site facilities, and structures of an engineering test facility (ETF) of a 200 MWE power plant are presented. The ETF resembles a coal-fired steam power plant in many ways. It is analogous to a conventional plant which has had the coal combustor replaced with the MHD power train. Most of the ETF components are conventional. They can, however, be sized or configured differently or perform additional functions from those in a conventional coal power plant. The boiler not only generates steam, but also performs the functions of heating the MHD oxidant, recovering seed, and controlling emissions.

Source record↗

NASA NTRS2018

Best Practices for Training the Structures Flight Test Engineer

The Structures Flight from 412th Test Wing and the Aerostructures Branch at NASA Armstrong Flight Research Center at Edwards Air Force Base have developed a set of best practices for training a structures flight test engineer. These practices represent the hard-won lessons learned and best practices from training generations of engineers to perform high risk envelope expansion and developmental flight test. Collectively, these organizations have tested many of the world's most advanced and innovative aircraft, including the B-2, C-17, F-22, F-35, RQ-4, X-29, F-18 High Angle of Attack Research Vehicle, X-53, G-III Adaptive Compliant Trailing Edge, and X-56.

flight tests↗