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All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Altitude Testing of Large Liquid Propellant Engines

The National Aeronautics and Space Administration entered a new age on January 14, 2004 with President Bush s announcement of the creation the Vision for Space Exploration that will take mankind back to the Moon and on beyond to Mars. In January, 2006, after two years of hard, dedicated labor, engineers within NASA and its contractor workforce decided that the J2X rocket, based on the heritage of the Apollo J2 engine, would be the new engine for the NASA Constellation Ares upper stage vehicle. This engine and vehicle combination would provide assured access to the International Space Station to replace that role played by the Space Shuttle and additionally, would serve as the Earth Departure Stage, to push the Crew Excursion Vehicle out of Earth Orbit and head it on a path for rendezvous with the Moon. Test as you fly, fly as you test was chosen to be the guiding philosophy and a pre-requisite for the engine design, development, test and evaluation program. An exhaustive survey of national test facility assets proved the required capability to test the J2X engine at high altitude for long durations did not exist so therefore, a high altitude/near space environment testing capability would have to be developed. After several agency concepts the A3 High Altitude Testing Facility proposal was selected by the J2X engine program on March 2, 2007 and later confirmed by a broad panel of NASA senior leadership in May 2007. This facility is to be built at NASA s John C. Stennis Space Center located near Gulfport, Mississippi. 30 plus years of Space Shuttle Main Engine development and flight certification testing makes Stennis uniquely suited to support the Vision For Space Exploration Return to the Moon. Propellant handling infrastructure, engine assembly facilities, a trained and dedicated workforce and a broad and varied technical support base will all ensure that the A3 facility will be built on time to support the schedule needs of the J2X engine and the ultimate flight of the first Ares I vehicle. The A3 facility will be able to simulate pre-ignition altitude from sea-level to 100,000 feet and maintain it up to 650 seconds. Additionally the facility will be able to accommodate initial ignition, shutdown and then restart test profiles. A3 will produce up to 5000 lbm/sec of superheated steam utilizing a Chemical Steam generation system. Two separate inline steam ejectors will be used to produce a test cell vacuum to simulate the 100,000 ft required altitude. Operational capability will ensure that the facility can start up and shutdown without producing adverse pressure gradients across the J2X nozzle. The facility will have a modern thrust measurement system for accurate determination of engine performance. The latest advances in data acquisition and control will be incorporated to measure performance parameters during hotfire testing. Provisions are being made in the initial design of the new altitude facility to allow for testing of other, larger engines and potential upper stage launch vehicles that might require vacuum start testing of the engines. The new facility at Stennis Space Center will be complete and ready for hotfire operations in late 2010.

Maynard, Bryon T.↗
NASA NTRS1972

High altitude flight test of a disk gap band parachute deployed behind a bluff body at a Mach number of 2.69

A flight test was conducted with a 55-foot diameter disk-gap-band parachute located at a trailing distance of 4.4 forebody diameters behind a 15-foot diameter bluff-body planetary entry aeroshell and attached instrumented payload. At the time of parachute deployment the aeroshell-payload combination was oscillating through an angle-of-attack range of plus or minus 40 deg. Continued oscillatory motion of the aeroshell-payload combination and similar motion of the parachute caused rapid changes in parachute shape and loading which resulted in extensive cloth damage in the band and outer disk-edge areas of the parachute canopy. During steady-state descent the damage parachute provided an effective-drag coefficient of about 0.33 which was about 60 percent of that expected.

Eckstrom, C.↗
NASA NTRS1973

Spacecraft separation systems mechanisms: Characteristics/performance during high altitude flight test from NASA Wallops Station, Va.

The applications of various separation mechanisms to meet flight mission goals within the physical and environmental constraints of a single stage rocket test vehicle are considered. Each separation concept was selected from the numerous choices available on the basis of its unique requirement and the flight test vehicle incorporated several different concepts. Attention to specific requirements and thoroughness in design and testing were essential to success since there is no specific single answer to separation problems.

Pride, J. D.↗
NASA NTRS2009

Test Plan for the Technology Maturation of Supersonic Inflatable Aerodynamic Decelerators

Supersonic inflatable aerodynamic decelerators (IADs) are drag devices intended to be deployed at high Mach numbers. In the application considered here they assist in the descent and landing of spacecraft on Mars. Although promising, present IAD technology is not yet sufficiently mature for use in the near future. This paper describes a technology maturation plan for tension cone IADs using subscale test articles to reduce development costs. As envisioned, the proposed test plan includes three phases: wind tunnel tests (subsonic), unpowered high-altitude flight tests (transonic), and powered high-altitude tests (supersonic). This test plan is based on a building block approach in which successful completion of each phase adds to the understanding of the behavior of IADs and reduces the risk of the subsequent, more expensive phases. By properly scaling the IADs, test articles of the same size and nearly the same construction can be used for all three phases. The final phase is a dynamically scaled flight test with IAD deployment at the same Mach number as the full-scale vehicle on Mars. Two full-scale example cases are presented: one for a single-stage system (15 m dia. IAD to subsonic retropropulsion), and another for a two-stage system (10.5 m dia. IAD to subsonic parachute). Using scale factors of 0.333 and 0.476 yield subscale test IADs of 5 m dia. The dynamically scaled powered flight test starts at Mach 4 and an altitude of 33.5 km. Existing balloons and rocket motors are shown to be adequate to meet the required test conditions.

Kelly, Jenny R.↗
NASA NTRSDate not supplied

HALE-X -- A USFS-NASA Partnership with Swift Engineering to Demonstrate Sustained IR Imagery for Weeks to Months with Next Generation Solar-electric Uncrewed Aircraft Systems UAS

HALE-X (High Altitude Long Endurance experiment) is an innovative partnership between the US Forest Service, NASA and Swift Engineering designed to test high altitude UAS capabilities for providing persistent, real-time mapping and intelligence over a wildfire incident. Platform and payload testing is scheduled to occur during summer 2021 at SpacePort America and adjacent airspace in New Mexico.

HALE-X↗
NASA NTRS2000

The Use of Environmental Test Facilities for Purposes Beyond Their Original Design

Increasing demands from space flight project offices are requiring environmental testing facilities to become more versatile with increased capabilities. At the same time, maintaining a cost-effective approach to test operations has driven efforts to use these facilities for purposes beyond their original design. This paper presents an overview of the Jet Propulsion Laboratory's efforts to provide JPL's space flight projects with test facilities to meet unique test requirements and to serve the needs of selected outside customers. The large number of recent Mars Missions, including the Mars Pathfinder project, have required testing of components and systems in a Martian surface environment in facilities originally designed for deep space testing. The unique problems associated with performing these tests are discussed, along with practical solutions. Other unique test requirements are discussed including the use of space simulation chambers for testing high altitude balloon gondolas and the use of vacuum chambers for system level test firing of an ion propulsion engine.

Fisher, Terry C.↗
NASA NTRS2004

Evolution of a Mars Airplane Concept for the ARES Mars Scout Mission

ARES (Aerial Regional-scale Environmental Survey of Mars) is a proposed Mars Scout mission using an airplane to provide high-value science measurements in the areas of atmospheric chemistry, surface geology and mineralogy, and crustal magnetism. The use of an airplane for robotic exploration of Mars has been studied for over 25 years. There are, however, significant challenges associated with getting an airplane to Mars and flying through the thin, carbon dioxide Martian atmosphere. The traditional wisdom for aircraft design does not always apply for this type of vehicle and geometric, aerodynamic, and mission constraints result in a limited feasible design space. The ARES airplane design is the result of a concept exploration and evolution involving a number of trade studies, downselects, and design refinements. Industry, university, and NASA partners initially proposed a number of different concepts, drawing heavily on past Mars airplane design experience. Concept downselects were conducted with qualitative evaluation and high level analyses, focused on the most important parameters for the ARES mission. Following a successful high altitude test flight of the basic configuration, additional design refinement led to the current design. The resulting Mars airplane concept enables the high-value science objectives of the ARES mission to be accomplished while also fulfilling the desire for a simple, low-risk design.

Smith, Stephen C.↗
NASA NTRS2019

Software Tool for Tracking & Mapping the NASA Orion AA-2 Test Flight Ejectable Data Recorders in Real Time

On 2 July 2019, the NASA Ascent Abort 2 flight took place off the Florida coast to test the emergency systems to separate the Orion Crew Module (CM) from the future Space Launch System rocket in the event of a malfunction. During this high-altitude test, instrumentation data was recorded on twelve customized buoyant Ejectable Data Recorders (EDRs) and subsequently jettisoned from the CM in mid-air. Upon release, the EDRs activated their GPS-Iridium beacon systems and began transmitting Short Burst Data (SBD) messages via the Iridium satellite network to relay their individual location and system health information. To locate, track and retrieve each EDR from the ocean surface in real-time, multiple open-source programming tools (Python and Linux shells) were developed for parsing the incoming Iridium binary SBD messages. For this, a Linux laptop was used to receive the Iridium-generated emails containing the SBD messages and autonomously execute the parsing tools. The received SBD data contained location, timestamp and health status information that was translated, saved, and subsequently used for simultaneously generating a continuously updated color-coded tabular display summary and unique KML files used with Google Earth to track their locations. Once their locations were known, dedicated recovery vessels retrieved all EDRs from the ocean. An additional tool was also developed in order to generate 5- and 10-minute geolocation predictions for each EDR by deriving the displacement distance, elapsed time, displacement heading and velocity based on the latest known information available. The recovery vessels were also tracked with the use of a separate commercial GPS beacon system. After jettison, 67% of the EDRs transmitted valid data by the time they were retrieved from the ocean. However, the real-time information presented by the plotting tool allowed for the ready depiction of EDR dispersal patterns and reference drift trajectories, which contributed to the recovery of all twelve EDRs and the AA-2 flight data. Lastly, the available data showed that the distance between the software’s reported drift/predicted locations and the recovery locations did not exceed 38 meters, therefore demonstrating the advantages of this software tool for supporting real-time tracking and recovery efforts of beacon devices.

Moxey, Lucas↗
NASA NTRS1992

Project Ares 3

The mission of Project Ares is to design and fabricate an Earth prototype, autonomous flying rover capable of flying on the Martian surface. The project was awarded to California State University, Northridge (CSUN) in 1989 where an in-depth paper study was completed. The second year's group, Project Ares 2, designed and fabricated a full-scale flight demonstration aircraft. Project Ares 3, the third and final group, is responsible for propulsion system design and installation, controls and instrumentation, and high altitude testing. The propulsion system consists of a motor and its power supply, geartrain, and propeller. The motor is a four-brush DC motor powered by a 50-V NiCd battery supply. A pulley and belt arrangement is used for the geartrain and includes light weight, low temperature materials. The propeller is constructed from composite materials which ensures high strength and light weight, and is specifically developed to provide thrust at extremely high altitudes. The aircraft is controlled with a ground-based radio control system and an autopilot which will activate in the event that the control signal is lost. A transponder is used to maintain radar contact for ground tracking purposes. The aircraft possesses a small, onboard computer for collecting and storing flight data. To safeguard the possibility of computer failure, all flight data is transmitted to a ground station via a telemetry system. An initial, unpowered, low-level test flight was completed in August of 1991. Testing of systems integration in the second low-level test flight resulted in loss of elevator control which caused considerable damage on landing. Complete failure analysis and repairs are scheduled for September of 1992.

Raymer, Dan↗
NASA NTRS1999

Chance Encounter with a Stratospheric Kerosene Rocket Plume from Russia over California

During a routine ER-2 aircraft high-altitude test flight on April 18, 1997, an unusual aerosol cloud was detected at 20 km altitude near the California coast at about 370 degrees N latitude. Not visually observed by the ER-2 pilot, the cloud was characterized bv high concentration of soot and sulfate aerosol in a region over 100 km in horizontal extent indicating that the source of the plume was a large hydrocarbon fueled vehicle, most likely a launch vehicle powered only by rocket motors burning liquid oxygen and kerosene. Two Russian Soyuz rockets could conceivably have produced the plume. The first was launched from the Baikonur Cosmodrome, Kazakhstan on April 6th; the second was launched from Plesetsk, Russia on April 9. Air parcel trajectory calculations and long-lived tracer gas concentrations in the cloud indicate that the Baikonur rocket launch is the most probable source of the plume. The parcel trajectory calculations do not unambiguously trace the transport of the Soyuz plume from Asia to North America, illustrating serious flaws in the point-to-point trajectory calculations. This chance encounter represents the only measurement of the stratospheric effects of emissions from a rocket powered exclusively with hydrocarbon fuel.

Newman, P. A.↗
NASA NTRS2014

Nuclear Thermal Propulsion Ground Test History

Nuclear Thermal Propulsion (NTP) was started in ~1955 under the Atomic Energy Commission as project Rover and was assigned to Los Alamos National Laboratory. The Nevada Test Site was selected in 1956 and facility construction began in 1957. The KIWI-A was tested on July 1, 1959 for 5 minutes at 70MW. KIWI-A1 was tested on July 8, 1960 for 6 minutes at 85MW. KIWI-A3 was tested on October 10, 1960 for 5 minutes at 100MW. The National Aeronautics and Space Administration (NASA) was formed in 1958. On August 31, 1960 the AEC and NASA established the Space Nuclear Propulsion Office and named Harold Finger as Director. Immediately following the formation of SNPO, contracts were awarded for the Reactor In Flight Test (RIFT), master plan for the Nuclear Rocket Engine Development Station (NRDS), and the Nuclear Engine for Rocket Vehicle Application (NERVA). From December 7, 1961 to November 30, 1962, the KIWI-B1A, KIWI-B1B, and KIWI-B4A were tested at test cell A. The last two engines were only tested for several seconds before noticeable failure of the fuel elements. Harold Finger called a stop to any further hot fire testing until the problem was well understood. The KIWI-B4A cold flow test showed the problem to be related to fluid dynamics of hydrogen interstitial flow causing fuel element vibrations. President Kennedy visited the NTS one week after the KIWI-B4A failure and got to see the engine starting to be disassembled in the maintenance facility. The KIWI-B4D and KIWI-B4E were modified to not have the vibration problems and were tested in test cell C. The NERVA NRX program started testing in early 1964 with NRX-A1 cold flow test series (unfueled graphite core), NRX-A2 and NRX-A3 power test series up to 1122 MW for 13 minutes. In March 1966, the NRX-EST (Engine System Test) was the first breadboard using flight functional relationship and total operating time of 116 minutes. The NRX-EST demonstrated the feasibility of a hot bleed cycle. The NRX-A5 had multiple start-ups in May-June 1966 with 30.75 minutes accumulative operating time at or above 1GW. The NRX-A6 was tested in December 1969 and ran for 62 minutes at 1100 MW. Each engine had post-test examination and found various structure anomalies which were identified for correction and the fuel element corrosion rate was reduced. The Phoebus series of research reactors began testing at test cell C, in June 1965 with Phoebus 1A. Phoebus 1A operated for 10.5 minutes at 1100 MW before unexpected loss of propellant and leading to an engine breakdown. Phoebus 1B ran for 30 minutes in February of 1967. Phoebus 2A was the highest steady state reactor built at 5GW. Phoebus 2A ran for 12 minutes at 4100 MW demonstrating sufficient power is available. The Peewee test bed reactor was tested November- December 1968 in test cell C for 40 minutes at 500MW with overall performance close to pre-run predictions. The XE' engine was the only engine tested with close to a flight configuration and fired downward into a diffuser at the Engine Test Stand (ETS) in 1969. The XE' was 1100 MW and had ~28 start-ups. The nuclear furnace NF-1 was operated at 44 MW with multiple test runs at 90 minutes in the summer of 1972. The NF-1 was the last NTP reactor tested. The Rover/NERVA program was cancelled in 1973. However, before cancellation, a lot of other engineering work was conducted by Aerojet on a 75, 000 lbf prototype flight engine and by Los Alamos on a ~16,000 lbf "Small Engine" nuclear rocket design. The ground test history of NTP at the NRDS also offers many lessons learned on how best to setup, operate, emergency shutdown, and post-test examine NTP engines. The reactor and engine maintenance and disassembly facilities were used for assembly and inspection of radioactive engines after testing. Most reactor/ engines were run at test cell A or test cell C with open air exhaust. The Rover/NERVA program became aware of a new environmental regulation that would restrict the amount of radioactive particulates allowed to be release in open air and successfully demonstrated a scrubber concept with the NF-1. The ETS stand was the only one with a high altitude test chamber used for XE'. The ETS and other test cells showed the effects the engine's radiation had on the facility materials and instrumentation as well as side effects the ground test facility has back on the engine operation. The breakdown of Phoebus 1A at test cell C showed how the site was cleaned up and back to operation for five more engines before the program was cancelled.

Gerrish, Harold P.↗