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NASA NTRS1985

Challenges in the development of the orbiter atmosphere revitalization subsystem

The space shuttle orbiter atmospheric revitalization subsystem provides thermal and contaminant control as well as total- and oxygen partial-pressure control of the environment within the orbiter crew cabin. Challenges that occurred during the development of this subsystem for the space shuttle orbiter are described. The design of the rotating hardware elements of the system (pumps, fans, etc.) required significant development to meet the requirements of long service life, maintainability, and high cycle-fatigue life. As a result, a stringent development program, particularly in the areas of bearing life and heat dissipation, was required. Another area requiring significant development was cabin humidity control and condensate collection.

Prince, R. N.↗

NASA NTRS1985

Bearings working group

The service life of the Space Shuttle Main Engine (SSME) turbomachinery bearings was a predominant factor in engine durability and maintenance problems. Recent data has indicated that bearing life is about one order of magnitude lower than the goal of seven and one-half hours particularly those in the High Pressure Oxidizer Turbopump (HPOTP). Bearing technology, primarily cryogenic turbomachinery bearing technology, is expanded by exploring the life and performance effects of design changes; design concept changes; materials changes; manufacturing technique changes; and lubrication system changes. Each variation is assessed against the current bearing design in full scale cryogenic tests.

Source record↗

NASA NTRS1985

Instrumentation technology overview

The Instrumentation Technology program advances the state of the art of instrumentation associated with the SSME to improve service life and performance by providing increased measurement capability. Two broad categories of instrumentation technology are sought. The first category includes sensors and systems destined to be used in and on the operational engine either during operation or between operations. These measurements supply information necessary for engine control and/or diagnostics throughout the life of the engine. The second category includes measurement systems and techniques whose application will be to engine component test stands and possibly to the test bed engine. The measurements provide the detailed information necessary to verify computer models of the performance of the various engine subsystems.

Nieberding, W. C.↗

NASA NTRS1985

Development of Design Data for Propulsion PMR-15 Composites

The continuing development of PMR-15 composite materials and their associated design properties is pacing the implementation of this technology on commercial aircraft. The guidelines that the FAA has issued regarding the certification of advanced composite structures are very significant with respect to future PMR-15 research and development activities. The FAA has issued an advisory circular dated 1-5-83 concerning guidelines for composite aircraft structures. Of particular significance to PMR-15 technology development is the reliance on combined environmental exposure and component testing, coupled with the stipulation that reliance on previous experience be limited to where common structures and materials have been used for a similar function. Critical environmental exposures for commercial propulsion structures include 50,000 cycle service life, exposure to skydrol, moisture and other fluids, and nacelle fire conditions.

Postlewaite, J.↗

NASA NTRS1985

Investigation of test methods, material properties and processes for solar cell encapsulants

The historical development of ethylene vinyl acetate (EVA) is presented, including the functional requirements, polymer selection, curing, stabilization, production and module processing. The construction and use of a new method for the accelerated aging of polymers is detailed. The method more closely resembles the conditions that may be encountered in actual module field exposure and additionally may permit service life to be predicted accurately. The use of hardboard as a low cost candidate substrate material is studied. The performance of surface antisoiling treatments useful for imparting a self cleaning property to modules is updated.

Willis, P. B.↗

NASA NTRS1986

Hubble Space Telescope meteoroid-debris protection analysis

A system level failure could occur if the Hubble Space Telescope's (ST) capability to operate as a facility on-orbit is critically reduced or when a significant reduction in the quality of science data is registered. Failure could occur if a meteoroid/debris impact damages a component of a major support subsystem or if a meteoroid/debris penetration causes straylight contamination in the light shield, forward shell, aft shroud, or through the aperture door. The ST was analyzed to find the probability of no critical penetration. This probability value was found to be 92.25% for a two-year service life. A straylight leakage repair technique was recommended for the aft shroud, the region found most likely to be critically penetrated. Fozar tape and multilayer insulation blankets are suggested as posible repair materials.

Horn, J.↗

NASA NTRS1985

Space radiation effects on an elastomer-toughened epoxy-graphite composite

An elastomer-toughened epoxy-graphite composite system (CE339/T300) was evaluated for its potential durability in the space radiation environment. The physical and chemical response of this system was characterized following exposure to radiation doses equivalent to 20 to 30 years in geosynchronous orbit using 1 MeV electrons. The results show that electrons generate extensive crosslinking and embrittlement of the matrix. This embrittlement results in chemical and mechanical property changes that would limit the service life of this epoxy system in some space structure applications.

Sykes, G. F.↗

NASA NTRS1984

The Advanced X-ray Astrophysics Facility instrument interface requirements

A variety of instruments will be placed at the focus of the Advanced X-ray Astrophysics Facility (AXAF) telescope, either by moving them into focus through the use of an instrument carousel or by moving the telescope assembly. Focal plane instrument categories under consideration for AXAF encompass high and moderate resolution X-ray cameras, X-ray spectrometers, and polarimeters; some of these instruments may require such consumables as a cryogen, in the case of solid state device cooling, or a gas, as in the case of proportional counters. Attention is presently given to interface requirements impacting on the maintenance that must be conducted over the 15-year service life of AXAF, and, especially, on the 'aspect solution' criteria that must be met to minimize stiffness stability criteria.

Weisskopf, M. C.↗

NASA NTRS1985

Design of a regenerative fuel cell system for Space Station

The NASA Space Station will employ alkaline regenerative fuel cells (RFCs) as its sole electrochemical energy storage system, in virtue of demonstrated technology readiness and a high degree of system-level design flexibility. NASA Johnson and NASA Lewis are currently engaged in the development of a 10-kW alkaline engineering model system, for 1987 delivery, which will encompass a fully autonomous 120-V system with 55 percent overall electrical efficiency and a 20,000-hr service life.

Hoberecht, M. A.↗

NASA NTRS1986

Technology and the Hubble Space Telescope

The components of the Hubble Space Telescope which is a 13.1 m long, 4.27 m in diameter, and weighs 11,000 kg are described. The telescope will be placed in a 600-km circular orbit of 28.5 deg inclination and it has an expected service life of 15 years. The optical telescope assembly contains the hyperbolic Ritchey-Chretin type primary and secondary mirrors and the optical control system. The telescope is to have a field of view of 28 arcmin in diameter. The use of the fine guidance sensors for pointing stability is examined. The optical and scientific system of the telescope are contained in the support system module. A wide-field/planetary camera, ESA-furnished faint object camera, the high-speed photometer, faint-object spectrograph, high resolution spectrograph, and ESA-furnished solar arrays are located on the telescope. The maintenance and refurbishment of the telescope are discussed. The precise lambda/20 optics, stringent cleanliness, and stable pointing of the telescope produce good image quality for astronomical and solar system science studies.

Mitchell, R. E.↗

NASA NTRS1986

Enhanced heat transfer combustor technology, subtasks 1 and 2, tast C.1

Analytical and experimental studies are being conducted for NASA to evaluate means of increasing the heat extraction capability and service life of a liquid rocket combustor. This effort is being conducted in conjunction with other tasks to develop technologies for an advanced, expander cycle, oxygen/hydrogen engine planned for upper stage propulsion applications. Increased heat extraction, needed to raise available turbine drive energy for higher chamber pressure, is derived from combustion chamber hot gas wall ribs that increase the heat transfer surface area. Life improvement is obtained through channel designs that enhance cooling and maintain the wall temperature at an accepatable level. Laboratory test programs were conducted to evaluate the heat transfer characteristics of hot gas rib and coolant channel geometries selected through an analytical screening process. Detailed velocity profile maps, previously unavailable for rib and channel geometries, were obtained for the candidate designs using a cold flow laser velocimeter facility. Boundary layer behavior and heat transfer characteristics were determined from the velocity maps. Rib results were substantiated by hot air calorimeter testing. The flow data were analytically scaled to hot fire conditions and the results used to select two rib and three enhanced coolant channel configurations for further evaluation.

Baily, R. D.↗

NASA NTRS1987

An overview of photovoltaic applications in space

An overview is given of the uses of photovoltaic (PV) power in space. The contribution of PV systems on unmanned, low Earth orbit and inner planetary missions is noted. The development of PV technology along the two paths of high efficiency and high power is discussed. The importance of increasing the service life of PV systems is covered.

Wasel, Robert A.↗

NASA NTRS1987

Gas adsorption/absorption heat switch, phase 1

The service life and/or reliability of far-infrared sensors on surveillance satellites is presently limited by the cryocooler. The life and/or reliability, however, can be extended by using redundant cryocoolers. To reduce parasitic heat leak, each stage of the inactive redundant cryocooler must be thermally isolated from the optical system, while each stage of the active cryocooler must be thermally connected to the system. The thermal break or the thermal contact can be controlled by heat switches. Among different physical mechanisms for heat switching, mechanically activated heat switches tend to have low reliability and, furthermore, require a large contact force. Magnetoresistive heat switches are, except at very low temperatures, of very low efficiency. Heat switches operated by the heat pipe principle usually require a long response time. A sealed gas gap heat switch operated by an adsorption pump has no mechanical motion and should provide the reliability and long lifetime required in long-term space missions. Another potential application of a heat switch is the thermal isolation of the optical plane during decontamination.

Chan, C. K.↗

NASA NTRS1986

Space radiation effects on the dimensional stability of a toughened epoxy graphite composite

The effects of a simulated space radiation environment on the dimensional stability of an elastomer-toughened epoxy-graphite composite were determined. The response of the material was characterized following exposure to radiation doses equivalent to geosynchronous orbit lifetimes ranging from 6 months to 30 years. The results show that radiation interacts with the epoxy matrix to embrittle the composite, beginning at relatively low total doses (10 to the 7th power rads). The embrittlement results in thermal expansion changes and significant laminate microcracking during thermal cycling. These property changes could limit the service life of this material in some spacecraft applications.

Sykes, G. F.↗

NASA NTRS1986

Load cell verification of the uprated high pressure oxygen turbopump for the Space Shuttle Main Engine

The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.

Beatty, R. F.↗

NASA NTRS1986

Composite tubes for the Space Station truss structure

The reference configuration of NASA's Space Station includes a large truss structure to support the various modules and solar arrays. This truss structure will be constructed from tubular members approximately 2 in. in diameter and up to 23 ft in length. The important design considerations for this structure are light weight, high stiffness, dimensional stability, and long-term durability. Continuous graphite fiber reinforced polymer matrix composite materials can meet the structural requirements, and are leading candidates for the tubular truss members. However, there are concerns regarding the durability of composites during the long-term exposure to atomic oxygen and thermal cycling that will be encountered during the Space Station service life. This paper discusses space environmental factors and their effect on composite materials, and provides estimates of the changes in mechanical and thermal properties of composites exposed to long-term Space Station conditions. The effect of low velocity impact and handling damage on composite tube properties is also discussed.

Bowles, David E.↗

NASA NTRS1986

Cryogenic implications of orbit selection of the Space Infrared Telescope Facility (SIRTF)

An investigation has been conducted to determine how the choice of orbit for NASA's prospective Space IR Telescope Facility (SIRTF), between polar (99-deg) and low inclination (28.5-deg) alternatives, will affect the performance of the all-superfluid He-cooled IR optics employed. While the dewar design met both the service life and 200-micron background-limited performance criteria in the case of the polar orbit mission, the alternative orbit allowed the background-limited criteria to be met only 50 percent of the time. It is accordingly recommended that the 200-micron background-limited observations be made only for a limited portion of the mission, while meeting the 100-micron limit at all times.

Lee, J. H.↗

NASA NTRS1988

Experience with duplex bearings in narrow angle oscillating applications

Duplex ball bearings are matched pairs on which the abutting faces of the rings have been accurately ground so that when the rings are clamped together, a controlled amount of interference (preload) exists across the balls. These bearings are vulnerable to radial temperature gradients, blocking in oscillation and increased sensitivity to contamination. These conditions decrease the service life of these bearings. It was decided that an accelerated thermal vacuum life test should be conducted. The test apparatus and results are described and the rationale is presented for reducing a multiyear life test on oil lubricated bearings to less than a year.

Phinney, D. D.↗