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This paper presents the studies carried out to determine the source of the surface distortions on the M1 mirror as well as comparison and model validation during testing. This research was carried out at the Jet Propulsion Laboratory, California Institute of Technology, under a contract with the National Aeronautics and Space Administration.
The SKYLAB Operations Handbook (SOH) is a contractual document. The SOH (Volume 1) is system-oriented and not specifically designed for utilization by any special group. Volume 1 is the description portion of the SOH. It provides the description of all Command-Service Module (CSM) systems.
The High-Temperature-Superconductivity (HTS) group of the RF Technology Branch, Space Electronics Division, is actively involved in the fabrication and cryogenic characterization of planar microwave components for space applications. This process requires fast, reliable, and accurate measurement techniques not readily available. A new calibration standard/test fixture that enhances the integrity and reliability of the component characterization process has been developed. The fixture consists of 50 omega thru, reflect, delay, and device under test gold lines etched onto a 254 microns (0.010 in) thick alumina substrate. The Thru-Reflect-Line (TRL) fixture was tested at room temperature using a 30 omega, 7.62 mm (300 mil) long, gold line as a known standard. Good agreement between the experimental data and the data modelled using Sonnet's em(C) software was obtained for both the return (S(sub 11)) and insertion (S( 21)) losses. A gold two-pole bandpass filter with a 7.3 GHz center frequency was used as our Device Under Test (DUT), and the results compared with those obtained using a Short-Open-Load-Thru (SOLT) calibration technique.
SiC/SiC composites are excellent material candidates for high temperature applications where the performance requirements are high strength, high creep-rupture resistance, high environmental durability, and high thermal conductivity. In the past, the NASA UEET program has demonstrated fabrication of high-performance SiC/SiC flat panels reinforced by Sylramic-iBN SiC fibers. Currently NASA UEET is scaling up this SiC/SiC system by fabrication of more complex shaped components using the same fiber type. This paper reports the effects of various fiber architectures on the processing, mechanical, and durability behavior of small-diameter 0.5" ID SiC/SiC tubes, which are potential sub-elements for leading edges and cooling channels in turbine vanes and blades. Nine different fiber architectures were utilized for construction of seamless tube preforms, from simple 2D jelly-rolling to complex braiding, pin-weaving, filament-winding and 3D orthogonal weaving with approximately 5% fibers in the thru-thickness direction. Using the BN interphase and Sic matrix processing steps established for the flat panels, SiC/SiC tubes were fabricated with wall thicknesses of approximately 60 mils and total fiber fractions of approximately 35%. The "D" split ring tests for hoop tensile properties, micro-structural examinations for relationship between fiber architecture formation and matrix infiltration, and the low-pressure burner rig tests for the high temperature durability under thru-thickness thermal gradient were conducted. The better matrix infiltration and higher hoop strength were achieved using the tri-axial braided and the three-float pin woven SiC/SiC tubes. In general, it needs not only higher hoop direction fibers but also axial direction fibers for the higher hoop strength and the better infiltration, respectively. These results are analyzed to offer general guidelines for selecting fiber pre-form architectures and SiC/SiC processes that maximize tube hoop strength, thru-thickness thermal conductivity, and burner-rig durability under a high thermal gradient.
A 0.013 scale model of the solid rocket booster (SRB) used to launch the space shuttle was tested at a Mach number of 3.7 and Reynolds numbers of 1,500,000 and 3,500,000 per foot. The objective of the test was to obtain aerodynamic heat transfer data on the surface of scaled models of the SRB at simulated full scale reentry flight conditions. Three separate models were utilized to measure film coefficients over an angle of attack range from 0 deg to 180 deg at 0 deg sideslip. All three models were representations of the MCR0200 baseline configuration and varied only by the way they were mounted in the tunnel. Model A, sting mounted thru the model base, was utilized for testing between 0 deg and 40 deg angle of attack. Model B was blade mounted from the top of the model and was tested between 60 deg and 120 deg angle of attack. Model C was sting mounted thru the model nose and utilized for testing between 140 deg and 180 deg angle of attack.
CMC hot-section components in advanced engines for power and propulsion will typically require high cracking strength, high ultimate strength and strain, high creep- rupture resistance, and high thermal conductivity in all directions. In the past, NASA has demonstrated fabrication of a variety of SiC/SiC flat panels and round tubes with various 2D fiber architectures using the high-modulus high-performance Sylramic-iBN Sic fiber and Sic-based matrices derived by CVI, MI, and/or PIP processes. The thermo- mechanical properties of these CMC have shown state-of-the-art performance, but primarily in the in-plane directions. Currently NASA is extending the thermostructural capability of these SiC/SiC systems in the thru-thickness direction by using various 2.5D and 3D fiber architectures. NASA is also using specially designed fabrication steps to optimize the properties of the BN-based interphase and Sic-based matrices. In this study, Sylramic-iBN/SiC panels with 2D plain weave, 2.5D satin weave, 2.5D ply-to-ply interlock weave, and 3D angle interlock fiber architectures, all woven at AITI, were fabricated using matrix densification routes previously established between NASA and GEPSC for CVI-MI processes and between NASA and Starfire-Systems for PIP processes. Introduction of the 2.5 D fiber architecture along with an improved matrix process was found to increase inter-laminar tensile strength from 1.5 -2 to 3 - 4 ksi and thru-thickness thermal conductivity from 15-20 to 30-35 BTU/ft.hr.F with minimal reduction in in-plane strength and creep-rupture properties. Such improvements should reduce thermal stresses and increase the thermostructural operating envelope for SiC/SiC engine components. These results are analyzed to offer general guidelines for selecting fiber architectures and constituent processes for high-performance SiC/SiC engine components.
There are numerous engineering design problems where the use of wires to transfer power and communicate data thru the walls of a structure is prohibitive or significantly difficult that it may require a complex design. Using physical feedthroughs in such systems may make them susceptible to leakage of chemicals or gasses, loss of pressure or vacuum, as well as difficulties in providing adequate thermal or electrical insulation. Moreover, feeding wires thru a wall of a structure reduces the strength of the structure and makes the structure prone to cracking due to fatigue that can result from cyclic loading and stress concentrations. One area that has already been identified to require a wireless alternative to electrical feedthroughs is the container of the Mars Sample Return Mission, which will need wireless sensors to sense a pressure leak and to avoid potential contamination. The idea of using elastic or acoustic waves to transfer power was suggested recently by [Y. Hu, et al., July 2003]. This system allows for the avoidance of cabling or wiring. The technology is applicable to the transfer of power for actuation, sensing and other tasks inside any sealed container or vacuum/pressure vessel. An alternative approach to the modeling presented previously [Sherrit et a., 2005] used network analysis to solve the same problem in a clear and expandable manner. Experimental tests on three different designs of these devices were performed. The three designs used different methods of coupling the piezoelectric element to the wall. In the first test the piezoelectric material was bolted using a backing structure. In the second test the piezoelectric was clamped after the application of grease and finally the piezoelectric element was attached using a conductive epoxy. The mechanical clamp with grease produced the highest measured efficiency of 53% however this design was the least practical from a fabrication viewpoint. The power transfer efficiency of conductive epoxy joint was 40% and the stress bolts (12%).
White Sands Test Facility (WSTF) was requested to perform ambient temperature hydrostatic pressurization testing of a Space Transportation System (STS) 40-in. Kevlar Composite Overwrapped Pressure Vessel (COPV). The 40-in. vessel was of the same design and approximate age as the STS Main Propulsion System (MPS) and Orbiter Maneuvering System (OMS) vessels. The NASA Engineering Safety Center (NESC) assembled a team of experts and conducted an assessment that involved a review of national Kevlar COPY data. During the review, the STS COPVs were found to be beyond their original certification of ten years. The team observed that the likelihood of STS COPV Stress rupture, a catastrophic burst before leak failure mode, was greater than previously believed. Consequently, a detailed assessment of remaining stress rupture life became necessary. Prior to STS-114, a certification deviation was written for two flights of OV-103 (Discovery) and OV-104 (Atlantis) per rationale that was based on an extensive review of the Lawrence Livermore National Laboratories, COPV data, and revisions to the STS COPV stress levels. In order to obtain flight rationale to extend the certification deviation through the end of the Program, the Orbiter Project Office has directed an interagency COPV team to conduct further testing and analysis to investigate conservatism in the stress rupture model and evaluate material age degradation. Additional analysis of stress rupture life requires understanding the fiber stresses including stress that occurs due to thru-wall composite compression in COPV components. Data must be obtained at both zero gauge pressure (pre-stress) and at the component operating pressure so that this phenomenon can be properly evaluated. The zero gauge pressure stresses are predominantly a result of the autofrettage process used during vessel manufacture. Determining these pre-stresses and the constitutive behavior of the overwrap at pressure will provide necessary information to better predict the remaining life of the STS COPVs. The primary test objective is obtaining data to verify the hypothesis of a radially oriented thru-thickness stress-riser in the COPV composite whose magnitude is a function of the applied pressure and the load history. The anticipated load dependent response follows from the constitutive behavior of the composite overwrap so data to quantify its nonlinear and time dependent response will be sought. The objective of the Fiber Braggs Gratings (FBGs) were to advance the state-of-the-art by developing techniques using FBG sensors that are capable of assessing stress-rupture degradation in Kevlar COPVs in a health monitoring mode (1). Moreover, they sought to answer questions of how embedded sensors affect overall integrity of the structure. And lastly, they sought to provide an important link in the overall stress rupture study that will help close the loop on the COPV fabrication process. NDE inspection methods will be used from start to finish and FBG will be an integral link within the overall chain.
A series of contracts were issued by the Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) un der the auspices of the Exploration Systems Mission Directorate to de velop and expand the maturity of candidate technologies considered to be important for future space exploration. One such technology was to determine the viability of incorporating non-toxic propellants for R eaction Control Subsystems (RCS). Contract NAS8-01109 was issued to A erojet to develop a dual thrust Reaction Control Engine (RCE) that ut ilized liquid oxygen and ethanol as the propellants. The dual thrust RCE incorporated a primary thrust level of 870 lbf, and a vernier thru st level of 10 - 30 lbf. The preferred RCS approach for the dual thru st RCE was to utilize pressure-fed liquid oxygen (LOX) and ethanol pr opellants; however, previous dual thrust feasibility testing incorporated GOX/Ethanol igniters as opposed to LOX/Ethanol igniters in the de sign. GOX/Ethanol was easier to ignite, but this combination had syst em design implications of providing GOX for the igniters. A LOX/Ethan ol igniter was desired; however, extensive LOX/Ethanol ignition data over the anticipated operating range for the dual thrust RCE did not e xist. Therefore, Aerojet designed and tested a workhorse LOX igniter to determine LOX/Ethanol ignition characteristics as part of a risk m itigation effort for the dual thrust RCE design. The objective of the ignition testing was to demonstrate successful ignition from GOX to LOX, encompassing potential two-phase flow conditions anticipated being present in real mission applications. A workhorse igniter was desig ned to accommodate the full LOX design flowrate, as well as a reduced GOX flowrate. It was reasoned that the initial LOX flow through the igniter would flash to GOX due to the latent heat stored in the hardwa re, causing a reduced oxygen flowrate because of a choked, or sonic, flow condition through the injection elements. As LOX flow continued, the hardware would chill-in, with the injected oxygen flow transitioning from cold GOX through two'phase flow to subcooled LOX. The Workh orse igniter was well instrumented: Pressure and temperature instrumentation permitted oxygen state points to be determined in the igniter oxidizer manifold, and gas-side igniter chamber thermocouples provide d chamber thermal profile characteristics. The cold flow chamber pres sure (Pc) for each test was determined and coupled with the igniter chamber diameter (De) to calculate the characteristic quench parameter (Pc x Dc), which was plotted as a function of core mixture ratio, MRc . Ignition limits were determined over a broad range of valve inlet conditions, and ignition was demonstrated with oxygen inlet conditions that ranged from subcooled 210 deg R LOX to 486 deg R GOX. Once ign ited at cold GOX conditions, combustion was continuous as the hardwar e chilled in and the core mixture ratio transitioned from values near 1.0 to over 12.5. Pulsing is required in typical RCS engines; therefore, the workhorse igniter was pulse tested to verify the ability to pr ovide the required ignition for a pulsing RCE. The minimum electrical pulse width (EPW) of the dual thrust RCE was 0.080 seconds. Igniter pulse tests were performed at three conditions: (1) an EPW of 0.080 se conds at 25% duty cycle for 400 pulses; (2) an EPW of 0.160 seconds a nd a 5% duty cycle for 124 pulses; (3) an EPW of 0.160 seconds and a 50% duty cycle for 380 pulses. Successful ignition of LOX/Ethanol was demonstrated over a broad range of valve inlet conditions, with the empirically determined LOX/Ethanol ignition limits extending the previous database established for GOX/Ethanol ignition limits. Although th e observed chill-in characteristics of the hardware varied significan tly with flowrate, ignition was readily achieved. Combustion was marg inal at extremely fuel-rich conditions, and it fluctuated as the oxygen passed rough the twophase flow regime during the period of hardware chill-in. Pulse testing showed good repeatability with 100 percent r e-ignition for all pulses. Certain pulse-to-pulse repeatability requirements for actual RCS operation may necessitate establishment of mini mum oxygen flow rates and engine thrust levels for satisfactory engin e performance.
The Lunar Reconnaissance Orbiter (LRO) project had a rapid development schedule starting with project conception in spring of 2004, instrument and launch vehicle selection late in 2005 and then launch in early 2009. The lunar thermal environment is one of the harshest in our solar system with the heavy infrared loading of the moon due to low albedo, lack of lunar atmosphere, and low effective regolith conduction. This set of constraints required a thermal design which maximized performance (minimized radiator area and cold control heater power) and minimized thermal hardware build at the orbiter level (blanketing, and heater service). The orbiter design located most of the avionics on an isothermalized heat pipe panel called the IsoThermal Panel (ITP). The ITP was coupled by dual bore heat pipes to an Optical Solar Reflector (OSR) covered heat pipe radiator. By coupling all of the avionics to one system, the hardware was simplified. The seven instruments were mainly heritage instruments which resulted in their desired radiators being located by their heritage design. This minimized instrument redesigns and therefore allowed them to be delivered earlier, though it resulted in a more complex orbiter level blanket and heater service design. Three of the instruments were mounted on a tight pointing M55J optical bench that needed to be covered in heaters to maintain pointing. Two were mounted to spacecraft controlled radiators. One was mounted to the ITP Dual Bores. The last was mounted directly to the bus structure on the moon facing panel. The propulsion system utilized four-20 pound insertion thrusters and eight-5 pound attitude control thrusters (ACS) in addition to 1000 kg of fuel in two large tanks. The propulsion system had a heater cylinder and a heated mounting deck for the insertion thrusters which coupled most of the propulsion design together simplifying the heater design. The High Gain Antenna System (HGAS) and Solar Array System (SAS) used dual axis actuator gimbal systems. HGAS required additional boom heaters to cool the approximately 10 W of RF losses thru the rotary joints and wave guides from the 40 W Ka system. By design this module needed a fair amount of heater, blanketing, and radiator complexity. The SAS system required a separate cable wrap radiator to help cool the Solar Array harness which dissipated 30 W thru the actuators and cable wraps. This module also was complex.
Pure tone hearing threshold data has been collected on astronauts since the early days of spaceflight. Between 1981 and 2001 (STS-1 thru 108) it was found that of the 608 shuttle astronauts, 17% returned home with a significant hearing threshold shift, and of that 6% had permanent changes in the high frequencies. Believed to be due to prolonged noise exposure on the space crafts. (Hart, 2006) As NASA aimed for longer duration missions the uncertainty about the effects of month-long noise exposure needed to be addressed. To avoid constraining crewmembers to constant earplug usage, and satisfying budget demands, a focused effort on overcoming the issues began. Noise monitoring systems were introduced onto the International Space Station (ISS) and astronauts were given education on the noise environment aboard the ISS, the hazards of noise induced hearing loss, hearing conservation principles, and countermeasure strategies (earplugs, noise cancellation headsets). As well as being trained on a new countermeasure effort that had been in trial testing on prior shuttle missions (STS-6 thru 8), On-Orbit Hearing Assessment (OOHA). (Hart, 2006) OOHA was implemented to routinely monitor the hearing thresholds of crewmembers who are on orbit for longer than 30 days. Flight Surgeons on ground monitor these test for significant hearing changes while aboard. Between 2000 and 2021 the ISS OOHA system (EarQ) recorded changes in the low frequency hearing thresholds. Low frequency hearing changes are not typically caused by noise exposure, and it was initially believed that these changes were due to environmental noise interference. In 2021 an ISS software upgrade (KUDUwave) allowed for a more comprehensive hearing assessment. The new testing system allowed for additional tests that helped describe the type of hearing loss being experienced and determine the influence of ambient noise or other environmental factors. OOHA Data indicates a low frequency hearing shift in 40% of all tests and 60% of all crewmembers. Since 2021, OOHA results (using the KUDUwave) suggest that these shifts are sensorineural and are not the result of ambient noise. While hearing shifts are seen at both 250 and 500 Hz, metrics tracking these shifts have only used 500 Hz data. The lack of 250 Hz has prevented accurate reporting of low frequency hearing shift recovery. The aim of this study is to capture 250 Hz data and accurately present low frequency hearing loss recovery.
Short term oscillator instability and phase jitter of telemetry signals using Pioneer 6 thru Pioneer 9 telemetry system as examples
The activities of the Toxic Hazards Research Unit (THRU) for the period of June 1970 through May 1971 reviewed. Modification of the animal exposure facilities primarily for improved human safety but also for experimental integrity and continuity are discussed. Acute toxicity experiments were conducted on hydrogen fluoride (HF), hydrogen chloride (HCl), nitrogen dioxide (NO2), and hydrogen cyanide (HCN) both singly and in combination with carbon dioxide (CO). Additional acute toxicity experiments were conducted on oxygen difluoride (OF2) and chlorine pentafluoride (ClF5). Subacute toxicity studies were conducted on methylisobutylketone and dichloromethane (methylene dichloride). The interim results of further chronic toxicity experiments on monomethylhydrazine (MMH) are also described.
The principles of the Varestraint test were applied to the evaluation of refractory metal alloys. This required development of a special test apparatus employing a modest specimen size for improved economy and compatible with the high purity inert atmosphere required for welding these alloys. Minimum specimen size is desirable because of the high cost of these alloys and also to permit timely testing of limited production developmental alloys. The Varestraint apparatus satisfies these requirements by providing a timely and economic test for hot crack sensitivity. This test can be used both for alloy development and production surveillance. The test apparatus was designed for use in vacuum purged dry boxes and is completely compatible with high purity inert atmosphere. Augmented strain can be varied continuously from 1/4% thru 4%. In addition to varying the augmented strain, the primary Varestraint variable, the effect on hot cracking of varying other weld parameters such as unit weld length heat input have also been studied. Test reproducibility, in terms of bending or strain rate, was demonstrated using high speed photography.
The performance capability was assessed of operators performing simulated space tasks using manipulator systems which had compliance and force feedback varied. Two manipulators were used, the E-2 electromechanical man-equivalent (force, reach, etc.) master-slave system and a modified CAM 1400 hydraulic master-slave with 100 lbs force capability at reaches of 24 ft. The CAM 1400 was further modified to operate without its normal force feedback. Several experiments and simulations were performed. The first two involved the E-2 absorbing the energy of a moving mass and secondly, guiding a mass thru a maze. Thus, both work and self paced tasks were studied as servo compliance was varied. Three simulations were run with the E-2 mounted on the CAM 1400 to evaluate the concept of a dexterous manipulator as an end effector of a boom-manipulator. Finally, the CAM 1400 performed a maze test and also simulated the capture of a large mass as the servo compliance was varied and with force feedback included and removed.
NASA's current plans and priorities through the mid-1980s are briefly presented including the fly-thru mission to Comet d'Arrest in 1976, Grand-Tour missions to the outer planets, and the Venus Explorer program.
The activities of the Toxic Hazards Research Unit (THRU) for the period of June 1971 through May 1972 are reviewed in this report. Acute inhalation toxicity experiments were conducted on hydrogen chloride (HCl) gas and aerosol, ethyl bromide (C2H5Br), hydrogen bromide (HBr), hydrogen sulfide (H2S), ammonia (NH3), chlorine (CL2), and silane (SiH4). Subacute toxicity studies were conducted on chlorine pentafluoride (ClF5), dichloromethane (CH2Cl2) and coal tar volatiles. Further toxicity studies of subacute and chronic responses to inhaled monomethylhydrazine (MMH) are also described.