SEARCH · Engineering Papers

Results for “test assembly”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 523 records · Page 29

All sources NASA NTRS DOE OSTI

NASA NTRS1987

Design and test of a mechanically pumped two-phase thermal control flight experiment

A flight experiment of a mechanically pumped two-phase ammonia thermal control system, incorporating a number of new component designs, has been assembled and tested in a 1-g environment. Additional microgravity tests are planned on the Space Shuttle when Shuttle flights are resumed. The primary purpose of this experiment is to evaluate the operation of a mechanically pumped two-phase ammonia system, with emphasis on determining the performance of an evaporative Two-Phase Mounting Plate. The experiment also evaluates the performance of other specially designed components, such as the two-phase reservoir for temperature control, condensing radiator/heat sink, spiral tube boiler, and pressure drop experiment. The 1-g tests have shown that start-up of the two-phase experiment is easily accomplished with only a partial fill of ammonia. The experiment maintained a constant mounting plate temperature without flow rate controls over a very wide range of heat loads, flow rates, inlet flow conditions and exit qualities. The tests also showed the successful operation of the mounting plate in the heat sharing condensing mode.

Grote, M. G.↗

NASA NTRS1975

Apollo experience report: Guidance and control systems. Lunar module stabilization and control system

A brief functional description of the Apollo lunar module stabilization and control subsystem is presented. Subsystem requirements definition, design, development, test results, and flight experiences are discussed. Detailed discussions are presented of problems encountered and the resulting corrective actions taken during the course of assembly-level testing, integrated vehicle checkout and test, and mission operations. Although the main experiences described are problem oriented, the subsystem has performed satisfactorily in flight.

Shelton, D. H.↗

NASA NTRS1982

Space Telescope design status and operations

The Space Telescope design concept is described in the context of the basic mission objectives. The orbiting telescope is designed to have 10 times better resolution, to see 50 times fainter stars and to have a much broader spectral range than the best existing ground observatories. The project is on schedule for launch in early 1985. Hardware assembly and test has started on the optical system, and the primary and secondary mirrors have been polished and coated. The five scientific instruments are beginning hardware assembly. The last major design review for the spacecraft has been completed, and good progress has been accomplished with the implementation of the pointing control system. The mission operations ground system has been defined and is under development. Control center design is complete and the science institute is under construction. The Space Telescope is designed to be serviceable in orbit and will be capable of return to the ground for refurbishment.

Speer, F. A.↗

NASA NTRS1990

Development of the CLAES instrument aperture door system

The design, assembly, and test processes followed in developing a space-qualified aperture door system are described. A blackbody calibration source is mounted inside the door, requiring the assembly to open and close a minimum of 150 cycles for instrument recalibration. Within the door system are four separate mechanisms, three of which are redundant; a pyro launch latch, a hinge bearing assembly, and a pair of pivot mechanisms. Decoupling devices within the pivot mechanisms allow an active drive unit to automatically overdrive a failed drive unit. The door is also stowable for possible Shuttle retrieval and re-entry. Illustrations and photographs of the flight hardware help acquaint the reader with the design. The aim is to pass on lessons learned in all phases of developing this spaceflight mechanism.

Stubbs, D. M.↗

NASA NTRS1989

Orbiter post-tire failure and skid testing results

An investigation was conducted at the NASA Langley Research Center's Aircraft Landing Dynamics Facility (ALDF) to define the post-tire failure drag characteristics of the Space Shuttle Orbiter main tire and wheel assembly. Skid tests on various materials were also conducted to define their friction and wear rate characteristics under higher speed and bearing pressures than any previous tests. The skid tests were conducted to support a feasibility study of adding a skid to the orbiter strut between the main tires to protect an intact tire from failure due to overload should one of the tires fail. Roll-on-rim tests were conducted to define the ability of a standard and a modified orbiter main wheel to roll without a tire. Results of the investigation are combined into a generic model of strut drag versus time under failure conditions for inclusion into rollout simulators used to train the shuttle astronauts.

Daugherty, Robert H.↗

DOE OSTI2026

Pixel-Strip Module Testing and Performance Analysis for the CMS Phase-2 Outer Tracker Upgrade

In response to the demanding environment of the High-Luminosity Large Hadron Collider (HL-LHC), the Compact Muon Solenoid (CMS) Experiment's Outer Tracker is being replaced with a lighter, higher-granularity, radiation-tolerant silicon detector capable of providing tracking information directly to the Level-1 trigger system. The new Outer Tracker consists of Pixel-Strip (PS) and Strip-Strip (2S) transverse momentum (pT) modules, which are assembled and tested at, among other centers, Fermilab's Silicon Detector Facility. PS modules consist of a pixel sensor, a strip sensor, and multiple application-specific integrated circuits (ASICs). This poster studies the performance of MaPSAs, silicon macro-pixel sensors bump-bonded to 16 macro-pixel ASICS. It presents the testing procedures for MaPSAs and MaPSA-strip sensor sub-assemblies, as well as the results of calibration and performance studies of two PS modules before and after irradiation. These results assess the impact of irradiation on module performance, providing insight into the modules' expected performance in the HL-LHC environment.

Kimrey, Emerson [Scripps College]↗

DOE OSTI2025

Guarded Hot Cylinder Apparatus for Characterization of Thermal Insulation Systems and Materials at Liquid Hydrogen Temperatures

As interest in liquid hydrogen (LH2) continues to grow within the energy and mobility sectors, so does the demand for testing capabilities at deep cryogenics temperatures. However, cost-, complexity-, and safety-related challenges associated with handling LH2 effectively limit the landscape of possible options. As an alternative, LH2 temperatures can be accessed via a helium-based cryogenic refrigerator, or “cryocooler”. Recently, NASA and its partners CB&I and Shell began the development of a cryocooler-based calorimeter to characterize the thermal performance of insulations and other materials down to 20 K. Deemed the Guarded Hot Cylinder (GHC), the apparatus utilizes a small vacuum chamber in conjunction with a GM cryocooler and trim heater to control the cold boundary temperature. A sealed, cylindrical copper cup bolts to the cryocooler and houses the material specimen, with an internal, cylindrical test heater assembly to maintain the warm boundary. The steady-state heat load, traveling radially through the specimen, is measured via the electrical input power to the test heater and then used to evaluate the material’s absolute thermal performance. Initial checkout and validation of the GHC using a common bulk-fill insulation material showed close agreement with published data from standardized LN2 boiloff calorimetry testing. The instrument is now considered a lab standard, with the goal of incorporating it into the ASTM C1774 standard in the future, and it is in continuous use, examining insulation materials for next-generation LH2 applications.

Swanger, Adam (ORCID:000000021487592X)↗

NASA NTRS1994

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Greenberg, H. S.↗

NASA NTRS1987

EASE/ACCESS ground processing at Kennedy Space Center

The Kennedy Space Center (KSC) Payload Management and Operations Directorate is responsible for the processing of Space Shuttle payloads. The KSC responsibilities begin prior to hardware arrival at the launch site and extend until the experiments are returned to the investigators after the flight. The KSC involvement with the integration and checkout of payloads begins with participation in experiment, Mission Peculiar Equipment (MPE), and integrated payload design reviews. This involvement also includes participation in assembly and testing of flight hardware at the appropriate design center, university, or private corporation. Once the hardware arrives at the launch site, KSC personnel install the experiments and MPE onto a carrier in the Operations and Checkout (O & C) building. Following integration, the payload is functionally tested and then installed into the orbiter. After the mission, the payload is removed from the orbiter, deintegrated in the O & C building, and the experiments are turned over to the mission manager. One of the many payloads process at KSC consisted of two space construction experiments: the Experimental Assembly of Structures in Extravehicular Activity (EASE) and the Assembly Concept for Construction of Erectable Space Structures (ACCESS). The details of EASE/ACCESS integration, testing, and deintegration are addressed and how this mission can serve as a guide for future space construction payloads is discussed.

Moates, Deborah J.↗

NASA NTRS2014

Direct Energy Conversion for Nuclear Propulsion at Low Specific Mass

The project will continue the FY13 JSC IR&D (October-2012 to September-2013) effort in Travelling Wave Direct Energy Conversion (TWDEC) in order to demonstrate its potential as the core of a high potential, game-changing, in-space propulsion technology. The TWDEC concept converts particle beam energy into radio frequency (RF) alternating current electrical power, such as can be used to heat the propellant in a plasma thruster. In a more advanced concept (explored in the Phase 1 NIAC project), the TWDEC could also be utilized to condition the particle beam such that it may transfer directed kinetic energy to a target propellant plasma for the purpose of increasing thrust and optimizing the specific impulse. The overall scope of the FY13 first-year effort was to build on both the 2012 Phase 1 NIAC research and the analysis and test results produced by Japanese researchers over the past twenty years to assess the potential for spacecraft propulsion applications. The primary objective of the FY13 effort was to create particle-in-cell computer simulations of a TWDEC. Other objectives included construction of a breadboard TWDEC test article, preliminary test calibration of the simulations, and construction of first order power system models to feed into mission architecture analyses with COPERNICUS tools. Due to funding cuts resulting from the FY13 sequestration, only the computer simulations and assembly of the breadboard test article were completed. The simulations, however, are of unprecedented flexibility and precision and were presented at the 2013 AIAA Joint Propulsion Conference. Also, the assembled test article will provide an ion current density two orders of magnitude above that available in previous Japanese experiments, thus enabling the first direct measurements of power generation from a TWDEC for FY14. The proposed FY14 effort will use the test article for experimental validation of the computer simulations and thus complete to a greater fidelity the mission analysis products originally conceived for FY13.

Scott, John H.↗

DOE OSTI2024

Performance of Oak Ridge National Laboratory spallation neutron source proton power upgrade cavities and cryomodule production

The Proton Power Upgrade initiative at Oak Ridge National Lab’s Spallation Neutron Source aims to greatly boost the capability of proton beam power. This upgrade involves the integration of seven additional cryomodules, each housing four six-cell high-beta ( β = 0.81 ) superconducting radio frequency cavities. These cavities, manufactured and processed by Research Instruments in Germany, underwent meticulous treatment, including electropolishing as the bulk and final vital step. Upon delivery to Jefferson Lab, a total of 28 cavities for seven cryomodules, along with an additional four cavities for a spare cryomodule, underwent thorough vertical qualification tests, meeting the required specifications. Following cavity tanking and subsequent rf testing, the assembly of eight cryomodules was successfully executed, with all 32 cavities demonstrating compliance with acceptance criteria. The transportation of the cryomodule to SNS for high-power testing in the tunnel yielded exceptional results. Notably, the performance surpassed specifications, in terms of quality factor and accelerating gradient. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Progress in the Development of the Nb 3 Sn MQXFB Quadrupole for the HiLumi Upgrade of the LHC

The high-luminosity upgrade of the Large Hadron Collider (HL-LHC) requires new high field and large-aperture quadrupole magnets for the low-beta inner triplets (MQXF). With a nominal operating gradient of 132.2 T/m in a 150 mm aperture and a conductor peak field of 11.3 T, the new quadrupole magnets are based on Nb 3 Sn superconducting technology. After a series of short models constructed in close collaboration by LARP (LHC Accelerator Research Program) and CERN, the development program is entering in the series production phase with CERN on one side and the US Accelerator Upgrade Project (US-AUP) on the other side assembling and testing full-length magnets. This paper describes the status of the development activities at CERN, in particular on the cold powering test of the first MQFXB prototype and on the construction of the second full scale prototype. Critical operations such as reaction heat treatment, coil impregnation and magnet assembly are discussed. Finally, the plan towards the series production is described.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Thermal Hydraulic Experimental Test Article (FY2020 Status Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed. Since the FY19 THETA status report, the THETA primary system components have been assembled and tested using de-ionized water. Some results of this testing at select Richardson and Reynolds numbers are included herein. The custom THETA sodium flowmeter (permanent magnet submersible sodium flowmeter) has been built and calibrated using sodium in an auxiliary facility against a NIST traceable vortex shedder type flowmeter. The permanent magnet flowmeter showed excellent performance, following the theoretical equation for measured voltage quite well, with an error < 3.5% at flow rates ranging from 3-24 GPM at temperatures up to 400 °C. The secondary sodium system for heat rejection from intermediate heat exchanger has been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger have been procured.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1976

Inlets for high angles of attack

Different inlet designs for high angle of attack STOL and VTOL applications were tested in a subsonic wind tunnel. Three removable entry lips having contraction ratios of 1.30, 1.34 and 1.38 were tested with a single diffuser. The internal contour of each entry lip was an ellipse with a major to minor axis of 2.0. Each lip and diffuser assembly was tested to determine its tolerance to angle of attack, first with a conventional centerbody and then with an extended centerbody. Results indicate that a large improvement in separation angle (determined as a function of lip contraction ratio and inlet flow) was obtained for the extended centerbody for all contraction ratios. Improved inlet tolerance to angle of attack was obtained by reducing the adverse pressure gradient downstream of the throat.

Miller, B. A.↗

NASA NTRS2010

Mars Science Laboratory CHIMRA: A Device for Processing Powdered Martian Samples

The CHIMRA is an extraterrestrial sample acquisition and processing device for the Mars Science Laboratory that emphasizes robustness and adaptability through design configuration. This work reviews the guidelines utilized to invent the initial CHIMRA and the strategy employed in advancing the design; these principles will be discussed in relation to both the final CHIMRA design and similar future devices. The computational synthesis necessary to mature a boxed-in impact-generating mechanism will be presented alongside a detailed mechanism description. Results from the development testing required to advance the design for a highly-loaded, long-life and high-speed bearing application will be presented. Lessons learned during the assembly and testing of this subsystem as well as results and lessons from the sample-handling development test program will be reviewed.

Sunshine, Daniel↗

NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in 2014 with more planned for 2015, including firing tests of both main propulsion elements and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will still deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 metric tons to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware. An RS-25 liquid propellant engine was hotfire-tested at NASA's Stennis Space Center, Miss. for the first time since 2009 exercising and validating the new engine controller, the renovated A-1 test stand, and the test teams. Four RS-25s will power the SLS core stage. A qualification five-segment solid rocket motor incorporating several design, material, and process changes was scheduled to be test-fired in March at the prime contractor's facility in Utah. The booster also successfully completed its Critical Design Review (CDR) validating the planned design. All six major manufacturing tools for the core stage are in place at the Michoud Assembly Facility in Louisiana, and have been used to build numerous pieces of confidence, qualification, and even flight hardware, including barrel sections, domes and rings used to assemble the world's largest rocket stage. SLS Systems Engineering accomplished several key tasks including vehicle avionics software and hardware build and testing, scale model acoustic and base heating tests. Construction of the Interim Cryogenic Propulsion Stage (ICPS) began. Advanced development provided a look into the future of SLS. Shell buckling knockdown factor testing refined decades-old design margins that added thousands of pounds to rocket payloads. Adaptive manufacturing and structured light scanning development promised to cut the cost and time associated with manufacturing and testing. This paper will provide an overview of the progress made over the past year and provide a glimpse of 2015 milestones and beyond on the way to the first launch in 2018.

May, Todd↗

NASA NTRS2015

NASA's Space Launch System Program Update

May, Todd↗

DOE OSTI2026

BIL High Speed Fuel Cell Stack Manufacturing

General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.

08 HYDROGEN↗