SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
System utilizes array of acoustical transducers to detect cracks and leaks in liquefied natural gas (LNG) containers onboard ships. In addition to detecting leaks, device indicates location and leak rate.
A laser Doppler velocimeter was used to measure the velocity distributions for particles entering a vacuum chamber from the atmosphere through calibrated leaks. The relative number of particles per velocity interval was obtained for particulates of three size distributions and two densities passing through six different leak geometries. The velocity range 15 to 320 meters per second was investigated. Peak particle velocities were found to occur in the 15 to 150 meters per second range depending upon type of particle and leak geometry. A small fraction of the particles were found to have velocities in the 150 to 320 meters per second range.
A gas inlet system is described for generating precise gas pressures that are to be used as calibration references for the mass spectrometers aboard the dual air density Explorer satellites. This gas inlet system was developed as an inflight calibration technique in which a known amount of onboard gas is released in the satellite cavity and is detected by the mass spectrometer. Although several flight mass spectrometer experiments have been proposed, none make use of the inflight calibration technique described in this report. Laboratory measurements and calibration of the metering leak technique for the gas inlet systems are discussed. The systems tested have metering leak rates between 2 and 4 microliters/sec at 298 K for argon-40, and they produce molecular flow up to 100 torr, which is the highest test pressure in this experiment. Test data show that metering leak rates are reproducible within 1 percent of established means for helium-3, helium-4, and argon-40.
A concern that ingestion of hot boundary-layer gas past a small, localized seal failure in the cove between the Space Shuttle wing and elevon might threaten unprotected elevon structures led to wind-tunnel tests to define cove environment as a function of leak area. The tests were conducted in the Langley 8-foot high-temperatures structures tunnel using a full-scale representation of the Space Shuttle wing-elevon juncture on the reentry surface. Pressure and heating rates were obtained for both attached and separated turbulent flows on the wing at the cove entrance. Results indicated that (1) for attached turbulent flow on the wing, cove heating progressively increased in severity independent of leak aspect ratio as leak area increased to 100 percent of cove entrance area and (2), for separated turbulent flow over the wing, cove environment was intolerably severe.
An experimental aerodynamic heating investigation was conducted to determine effects of hot boundary-layer ingestion into the cove on the windward surface between a wing and elevon for cove seal leak areas nominally between 0 and 100 percent of cove entrance area. Pressure and heating-rate distributions were obtained on the wing and elevon surfaces and on the cove walls of a full-scale model that represented a section of the cove region on the space shuttle orbiter. Data were obtained for both attached and separated turbulent boundary layers upstream of the unswept cove entrance. Average free-stream Mach number was 6.9, average free-stream unit Reynolds numbers were 1.31 x 10 to the 6th power and 4.40 x 10 to the 6th power per meter (0.40 x 10 to the 6th power and 1.34 x 10 to the 6th power per foot), and average total temperature was 1888 K (3400 R). Cove pressures and heating rates varied as a function of seal leak area independent of leak aspect ratio. Although cove heating rates for attached flow did not appear intolerable, it was postulated that convective heating in the cove may increase with time. For separated flow, the cove environment was considered too severe for unprotected interior structures of control surfaces.
Space-compatible cryogenic valves are now required to operate between room and liquid helium temperatures. A remotely controllable cryogenic valve is described, which is made of bellows-type stainless steel and is operated by a miniature dc motor with integral gearset (485:1) at a nominal voltage of 28 Vdc. The power transmission provides a further reduction of 7.2:1 to give an overall gear ratio of nearly 3500:1, assuring reliability of operation at low temperatures. Valve performance (leak rate) data are presented at LN2, LHe, and SfHe temperatures at delivered torques of 18, 27, 31, and 35 N-m. At a closing torque of 31 N-m, a leak rate of 0.028 scc/sec was achieved at 2 K, while at a torque of 18 N-m the leak rate at 300 K was less than 3 x 10 to the -9th scc/sec.
The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.
Fourteen years after completion of Ford's 39-foot space simulation chamber, leaks began to appear in its LN2 shroud. Although the shroud had been tight since its acceptance, cracks appeared in 1983 in some of the field welds of the one inch tubes which interconnect the LN2 panels. The resulting leaks were large enough to prevent pump down to high vacuum and could be heard easily when the chamber was at ambient conditions. New cracks appeared during each thermal cycle making it impossible to utilize the chamber for thermal vacuum testing. The analysis presented here implies that many, if not all, of the aluminum LN2 shrouds now in use may be in various stages of fatigue failure. The probability is high that fatigue cracks are working through the aluminum tubing in heat-affected zones of some field welds. The cracks may not be apparent yet, but after the shroud has experienced a certain number of thermal cycles these cracks will work through the material and become serious leaks. Fortunately, appropriate planning, analysis, and checking can, with a relatively small expenditure of money, help to avoid large and unexpected shroud failures and keep the chamber operational as long as it is needed.
Plume emission spectrometry and optical leak detection are described as two new applications of optical techniques to reusable rocket engine condition monitoring. Plume spectrometry has been used with laboratory flames and reusable rocket engines to characterize both the nominal combustion spectra and anomalous spectra of contaminants burning in these plumes. Holographic interferometry has been used to identify leaks and quantify leak rates from reusable rocket engine joints and welds.
A prototype superfluid helium bayonet for potential space applications has been developed and evaluated with a low heat leak test apparatus. Measured heat leak of the 13 mm (1/2 inch) bayonet pair is 0.21 W at 1.8 K with an uncertainty of +0.09/-0.05 W. Bayonets are fabricated with thin, electron beam (EB) welded tubes which are EB welded to machined nose and flange pieces. Low heat leak structural integrity is provided by a 0.9 mm thickness of filament wound fiberglass-epoxy. Superfluid creep is restricted by KEL-F nose seals which form vacuum-tight extensions to the bayonet cold end pieces.
Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm, and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (9 cycles at 4.2 K), and susperfluid helium temperature (4 cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak-rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10(-9) std-cc/sec, during testing.
Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm, and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (9 cycles at 4.2 K), and superfluid helium temperature (4 cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak-rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10(-9) std-cc/sec, during testing.
The theory and experimental verification of a method of detecting fluid-mass loss, expansion-chamber pressure loss, or excessive vapor build-up in NASA's Airborne Information Management System (AIMS) are presented. The primary purpose of this leak-detection method is to detect the fluid-mass loss before the volume of vapor on the liquid side causes a temperature-critical part to be out of the liquid. The method detects the initial leak after the first 2.5 pct of the liquid mass has been lost, and it can be used for detecting subsequent situations including the leaking of air into the liquid chamber and the subsequent vapor build-up.
A subscale pool boiler test apparatus to evaluate boiling stability developed a leak after being operated with boiling NaK for 791.4 hr at temperatures from 700 to 750 C. The boiler was constructed using Inconel 625 with a type 304L stainless steel wick for the boiler and type 316 stainless steel for the condenser. The boiler assembly was metallurgically evaluated to determine the cause of the leak and to assess the effects of the NaK on the materials. It was found that the leak was caused by insufficient (about 30 pct.) joint penetration in a butt joint. There was no general corrosion of the construction materials, but the room temperature ductility of the Inconel 625 was only about 6.5 pct. A crack in the heat affected zone of the Inconel 625 near the Inconel 625 to type 316 stainless steel butt joint was probably caused by excessive heat input. The crack was observed to have a zone depleted of iron at the crack surface and porosity below that zone. The mechanism of the iron depletion was not conclusively determined.
Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (nine cycles at 4.2K) and superfluid helium temperature (four cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10 exp -9 std cu cm/s, during testing.
The full scope of this program was to have included development tests, design and production of custom test equipment and acceptance and qualification testing of prototype and protoflight coupling hardware. This program was performed by Ball Aerospace Systems Division, Boulder, Colorado until its premature termination in May 1991. Development tests were performed on cryogenic face seals and flow control devices at superfluid helium (He II) conditions. Special equipment was developed to allow quantified leak detection at large leak rates up to 8.4 x 10(exp -4) SCCS. Two major fixtures were developed and characterized: The Cryogenic Test Fixture (CTF) and the Thermal Mismatch Fixture (Glovebox). The CTF allows the coupling hardware to be filled with liquid nitrogen (LN2), liquid helium (LHe) or sub-cooled liquid helium when hardware flow control valves are either open or closed. Heat leak measurements, internal and external helium leakage measurements, cryogenic proof pressure tests and external load applications are performed in this fixture. Special reusable MLI closures were developed to provide repeatable installations in the CTF. The Thermal Mismatch Fixture allows all design configurations of coupling hardware to be engaged and disengaged while measuring applied forces and torques. Any two hardware components may be individually thermally preconditioned within the range of 117 deg K to 350 deg K prior to engage/disengage cycling. This verifies dimensional compatibility and operation when thermally mismatched. A clean, dry GN2 atmosphere is maintained in the fixture at all times. The first shipset of hardware was received, inspected and cycled at room temperature just prior to program termination.
The NASA Thermal Trajectory analysis model for predicting the vertical performance of balloons is described in terms of two critical refinements and recent results. The model employs heat-balance equations and a vertical equation of motion, and revised methods are employed to predict maximum balloon volume, balloon shape, and the continuous computation of gas loss. Also incorporated are modeling techniques for assessing the solar radiation input that can affect the load tapes, and autoballast control algorithms are employed. The model permits the evaluation of the presence of cap layers as well as the effects of small leaks and programmed venting. The revised model is shown to give good predictions of balloon performance during flight in terms of altitude changes, descent rates, gas-mass flow, and leak potential. The model is found to be more versatile due to autoballasting and leak analysis, and good prediction are possible for the float phase and descent of current balloon shapes.
The burn rates of the pyrotechnic TiH2/KClO4/Viton with a mass ratio of 30/65/5 have been measured as a function of pressure in nitrogen up to 312 MPa(45 Kpsi). The burn rates were fit to R = a pn, with a = 2.055 cm/sec/MPan and n = 0.472 between 0.15 MPa (22 psi) and 21.6 MPa (3.13 Kpsi) and a = 4.38 cm/sec/MPan and n = 0.266 between 70 MPa (10.15 Kpsi) and 312 MPa (45.25 Kpsi). The decrease in slope at the higher pressures is attributed to a diffusion limited reaction. No acoustically driven flame instabilities or large conductive-to-convective burn transitions were observed. Solid reaction products were analyzed by x-ray diffraction and scanning electron microscopy (SEM). X-ray diffraction detected only TiO2 and KC1. SEM showed that the particle size of the reaction products increased as the nitrogen pressure increased. There were no anomalous characteristics of the burn of this pyrotechnic that could be interpreted as a cause of the o-ring blow-by problem in the forward shear bolt assembly. Three NASA SKD26100098-301 pressure cartridges were fired into a fixed volume vessel that was sealed with an O-ring. A maximum pressure of 181.7 MPa(26,350 psi) was reached in around 100 ,mu sec for two shots fired into a volume of 16.3 cm3(0.996 in3). A maximum pressure of 33,460 psi was reached for one shot fired into a volume of 9.55 cm3(0.583 in3). The O-ring burned through on one shot in the larger volume and leaked on the other two thereby simulating the effects of an O-ring leak. The results imply that the piston in the shear bolt assembly would receive a large impulse even if there was a leak in an O-ring seal.