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NASA NTRSDate not supplied

Current Status and Future Plans for Electric Motors and Drives at NASA

Current Status and Future Plans for Electric Motors and Drives at NASA: Our work advances propulsion for aircraft while reducing energy consumption, noise, emissions and the cost of air travel. We are committed to investigating the use of alternative energy sources and improving the safety and expediency of flight. Electrified Aircraft Propulsion (EAP) is the use of propulsors (propellers or fans) driven by electric motors to propel aircraft ranging from air taxis to subsonic transports. NASA is developing technology, aircraft concepts, test aircraft, and ground test facilities to turn this idea from science fiction to reality. Specifically, motors and/or generators (Electric machines) are needed on all electrified aircraft. And NASA is sponsoring or performing work to achieve power densities 2-3 times the state of the art for machines in the MW or larger class. Three major machine types are being developed: permanent magnet, induction, and wound field. Power converters are also an essential component in most EAP aircraft concepts, as they are used to convert from ac to dc power, or vice versa. Silicon carbide and gallium nitride convertors are being developed with conventional cooling as well as a cryogenically cooled converter. Future plans include demonstrating integrated flight-ready systems in both ground and flight tests; collaborating with and leveraging ARPA-E EAP programs; and supporting FAA standards development for market acceptance and safety.

Powertrain↗

NASA NTRSDate not supplied

Current Status and Future Plans for Electric Motors and Drives at NASA

Our work advances propulsion for aircraft while reducing energy consumption, noise, emissions and the cost of air travel. We are committed to investigating the use of alternative energy sources and improving the safety and expediency of flight. Electrified Aircraft Propulsion (EAP) is the use of propulsors (propellers or fans) driven by electric motors to propel aircraft ranging from air taxis to subsonic transports. NASA is developing technology, aircraft concepts, test aircraft, and ground test facilities to turn this idea from science fiction to- reality. Specifically, motors and/or generators (Electric machines) are needed on all electrified aircraft. And NASA is sponsoring or performing work to achieve power densities 2-3 times the state of the art for machines in the MW or larger class. Three major machine types are being developed: permanent magnet, induction, and wound field. Power converters are also an essential component in most EAP aircraft concepts, as they are used to convert from ac to dc power, or vice versa. Silicon carbide and gallium nitride convertors are being developed with conventional cooling as well as a cryogenically cooled converter. Future plans include demonstrating integrated flight-ready systems in both ground and flight tests; collaborating with and leveraging ARPA-E EAP programs; and supporting FAA standards development for market acceptance and safety.

Aircraft↗

NASA NTRS2005

Scramjet Development Tests Supporting the Mach 10 Flight of the X-43

The Hyper-X Project s successful third flight of the X-43 at near Mach 10 in 2004 proved the potential for airbreathing propulsion at hypersonic speeds. The engine flowpath used in the X-43 research vehicle was developed and evaluated in a systematic series of ground tests in the NASA HyPulse Shock Tunnel at conditions duplicating Mach 10 flight using a full scale height, partial width engine model of the flight engine. Tests were conducted over a range of equivalence ratios from 0.8 to 1.6 using hydrogen and a mixture of two-percent silane in hydrogen fuels. Silane gas was used as an ignition aid during the short duration of the pulse facility tests. Variation of the engine inflow conditions, pressure, temperature, and Mach number, were parametrically varied during the test entries to broaden the database over the expected uncertainty in the flight conditions. A review of the ground test technique and comparisons of the ground test pressures along with selected flight data are presented.

Rogers, R. C.↗

NASA NTRS2019

Orion Capsule Parachute Assembly System (CPAS) Overload Testing Approach and Results

The qualification of the Orion Capsule Parachute Assembly System (CPAS) system includes exposure to loads and dynamic pressures above the required values as validation of the parachutes' structural integrity. As outlined in the certification plan, each of the four parachutes of the system are to be subjected to 110% of their respective maximum dynamic pressure requirements. The Main and Drogue parachutes have satisfied this overload condition in drop testing and due to cost and schedule constraints, the Forward Bay Cover Parachute (FBCP) and Pilot parachute were subjected to the overload condition in the ground testing described in this document. The test objectives and pass/fail criteria were established and require the parachutes to achieve and maintain a target riser load (associated with a minimum of 110% dynamic pressure overload) for a minimum of three seconds while sustaining no failures of any structural members (vent hoop, radials, suspension line) or any damage which propagates into catastrophic failure of the canopy. Considering the assumptions and limitations associated with the ground testing (primarily non-uniform flow field of the ground test system and variations in parachute manufacturing), a method of establishing the desired overload condition was determined by the technical community and covers the 2-sigma bounds of the drag area distribution derived from drop testing. On June 27, 2017 the testing was executed at the High Velocity Airflow System (HiVAS) facility located at the Weapon Survivability Laboratory (WSL) at the Naval Air Warfare Center, Weapons Division (NAWCWD) China Lake. Engineering Development Unit (EDU) parachutes were used as pathfinders to gain experience with achieving the test conditions. Additional runs were executed to measure the airflow at the same location as the canopy skirt, although this data is not required to satisfy the test objectives and parachute pass/fail criteria. The qualification parachutes were successfully exposed to the target conditions and sustained only minor damage.

Daum, Jared S.↗

NASA NTRS1979

High voltage surface-charged environment test results from space flight and ground simulation experiments

Surface-charged particle interactions were investigated for a small 100 sq cm conventionally constructed solar cell panel in ground facilities and in a flight experiment. The flight data substantiated preflight ground test results showing that at high positive biases the cover glass over each solar cell enhances the coupling current and that, at high negative biases, arcs create large transients in the coupling current.

Grier, N. T.↗

NASA NTRSDate not supplied

Overview of Predictive Simulation Capability Development for Crater Evolution and Ejecta in Continuum/Rarefied Flows

As part of the Game Changing Development (GCD) Program, funded by NASA’s Space Technology Mission Directorate (STMD), the development of simulation capability for the prediction of extra-terrestrial Plume Surface Interaction (PSI) environments has been undertaken by the Fluid Dynamics Branch at NASA/MSFC. The Predictive Simulation Capability (PSC) Element is focused on creating simulation capability for the reliable and accurate prediction of PSI in Martian (~650 Pa) and Lunar (vacuum) ambient environments. In addition to the predictive simulation capability, the GCD Program also contains a companion Ground Testing Element for development of focused datasets for validation of predictive capability as well as a Flight-focused Instrumentation Element. The focus of this paper is to provide an overview and a brief status on one area of capability development through this GCD PSI project - capturing the effects of mixed continuum/rarefied flow on crater development and ejecta sheets. This includes both capability enhancements and maturation of the predictive tool, Loci/GGFS, into a production capable tool as well as validation of the tool against PSI data in Martian and Lunar environments. There are six newly developed capabilities that will be production ready by the end of the fiscal year. Newly developed capabilities must first be verified prior to being production ready, and this process includes capability demonstration, solution verification, and performance evaluation. An overview of the newly developed capabilities with respect to several test cases, including cratering simulations of the Apollo Lunar Module, will be presented. Several validation analyses have been performed to validate in Martian and more Lunar-like environments, including simulations of cratering from a subsonic flow test at Planetary Aeolian Lab (PAL) conducted in a Martian-like environment and pre-test cratering predictions of Physics Focused Ground Test (PFGT) tests planned to be performed in Martian-like and more Lunar-like environments. An overview of these validation analyses as it pertains to the capability development will be presented.

Andrew Weaver↗

NASA NTRSDate not supplied

X-57 Mod III Wing Ground Vibration Test

The X-57 “Maxwell” all-electric experimental aircraft was an electric propulsion demonstrator developed by the National Aeronautics and Space Administration to inform airworthiness standards for electrified aircraft. The development of the X-57 aircraft was separated into configuration modifications culminating in a distributed electric propulsion flight demonstrator named Modification IV (a.k.a., Mod IV). One of these configurations, the X-57 Mod III aircraft, involved flight-testing of a long, slender, high-aspect-ratio wing with two electric motors located at the wingtips. The X-57 Mod III wing ground vibration test was performed in the Flight Loads Laboratory at the National Aeronautics and Space Administration Armstrong Flight Research Center to measure the structural dynamics properties of the newly developed wing, and to confirm airworthiness of the Mod III/IV aircraft. This paper describes the testing performed to acquire the modal data and the subsequent results from the test.

Samson Truong↗

NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems for Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heatshield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heatshield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heatshield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/cm2 heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heatshield for Extreme Entry Environments (HEEET) [1]. Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions.Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions.

Mahzari, Milad↗

NASA NTRS2014

Optical Testing of the James Webb Space Telescope

The James Webb Space Telescope (JWST) will be a large infrared telescope with a 6.5-meter primary mirror, working to a 2018 launch date. Ground testing for the JWST will occur in two test campaigns, at NASAs Goddard Space Flight Center and Johnson Space Center. The talk describes the JWST and its optical ground testing, highlighting the roles of many of the University of Rochester Institute of Optics' alumni as well as current faculty and students.

James Webb Telescope↗

NASA NTRS1988

The NASA Integrated Test Facility and its impact on flight research

NASA-Ames' Integrated Test Facility (ITF), when completed, will provide ground test facilities for the safe and efficient testing of advanced research aircraft with fully integrated flight control, propulsion systems, structures, and aerodynamic configurations. Flight test risk will be minimized through the reduction of differences between flight and ground test environments; the latter will involve the interfacing of real-time flight simulation with the actual aircraft through a simulation-interface device. The test process and the collection and management of test data will be automated. Attention is given to preliminary ITF results for the X-29 aircraft.

Mackall, D. A.↗

NASA NTRS2004

A Revised Approach to the ULDB Design

The National Aeronautics and Space Administration Balloon Program has experienced problems in the scaling up of the proposed Ultra Long Duration Balloon. Full deployment of the balloon envelope has been the issue for the larger balloons. There are a number of factors that contribute to this phenomenon. Analytical treatments of the deployment issue are currently underway. It has also been acknowledged that the current fabrication approach using foreshortening is costly, labor intensive, and requires significant handling during production thereby increasing the chances of inducing damage to the envelope. Raven Industries has proposed a new design and fabrication approach that should increase the probability of balloon deployment, does not require foreshortening, will reduce the handling, production labor, and reduce the final balloon cost. This paper will present a description of the logic and approach used to develop this innovation. This development consists of a serial set of steps with decision points that build upon the results of the previous steps. The first steps include limited material development and testing. This will be followed by load testing of bi-axial reinforced cylinders to determine the effect of eliminating the foreshortening. This series of tests have the goal of measuring the strain in the material as it is bi-axially loaded in a condition that closely replicated the application in the full-scale balloon. Constant lobe radius pumpkin shaped test structures will be designed and analyzed. This matrix of model tests, in conjunction with the deployment analyses, will help develop a curve that should clearly present the deployment relationship for this kind of design. This will allow the "design space" for this type of balloon to be initially determined. The materials used, analyses, and ground testing results of both cylinders and small pumpkin structures will be presented. Following ground testing, a series of test flights, staged in increments of increasing suspended load and balloon volume, will be conducted. The first small scale test flight has been proposed for early Spring 2004. Results of this test flight of this new design and approach will presented. Two additional domestic test flights from Ft. Sumner, New Mexico, and Palestine, Texas, and one circumglobal test flight from Australia are planned as part of this development. Future plans for both ground testing and test flights will also be presented.

Smith, Michael↗

NASA NTRS1986

Ground vibration test results for Drones for Aerodynamic and Structural Testing (DAST)/Aeroelastic Research Wing (ARW-1R) aircraft

The drones for aerodynamic and structural testing (DAST) project was designed to control flutter actively at high subsonic speeds. Accurate knowledge of the structural model was critical for the successful design of the control system. A ground vibration test was conducted on the DAST vehicle to determine the structural model characteristics. This report presents and discusses the vibration and test equipment, the test setup and procedures, and the antisymmetric and symmetric mode shape results. The modal characteristics were subsequently used to update the structural model employed in the control law design process.

Cox, T. H.↗

NASA NTRSDate not supplied

Flow Visualization for Plume-Surface Interaction Testing Within Large-Scale Vacuum Environments at Conditions Relevant to Lunar and Martian Landers

Interactions between rocket exhaust plumes and the landing surface during powered spacecraft descent on the Moon and Mars pose significant risks to the landing vehicle, landing site, and nearby infrastructure. Understanding the underlying plume-surface interaction phenomena through ground test data can provide critical insights on the sensitivities of parameters such as the spacecraft altitude and thrust. In the present work, we summarize a scaled ground test recently conducted within a 20-ft vacuum chamber environment located in the historical East Test Area at the NASA Marshall Space Flight Center. The ground test featured a Mach 5.3 inert gas plume impinging upon an instrumented flat plate. Planar laser-induced fluorescence, which is a 2D laser-based flow field measurement technique, was performed at this test area for the first time to visualize salient flow features such as the barrel shock, stagnation shock, and wall jet. Measurements were obtained at discrete lander altitudes, made dimensionless using the nozzle exit diameter, corresponding to h/D = 10, 8, 5, 4, 3, and 2. The stagnation pressures of the plume were varied from approximately 0.04 to 1 MPa, providing sensitivity to the engine thrust of a powered spacecraft. The unique test facility allowed for near-lunar conditions to be obtained at initial vacuum chamber pressures less than 0.1 Pa. Martian-relevant measurements were also performed at ambient pressures near 600 Pa. Furthermore, a third set of measurements were obtained at so called lunar-relevant conditions near 3 Pa chamber pressure

Plume Surface Interaction↗

NASA NTRSDate not supplied

Flow Visualization for Plume-Surface Interaction Testing Within Large-Scale Vacuum Environments at Conditions Relevant to Lunar and Martian Landers

Plume Surface Interaction↗

NASA NTRS2002

Finite Element Analysis of Wrinkled Membrane Structures for Sunshield Applications

The deployable sunshield is an example of a gossamer structure envisioned for use on future space telescopes. The basic structure consists of multiple layers of pretensioned, thin-film membranes supported by deployable booms. The prediction and verification of sunshield dynamics has been identified as an area in need of technology development due to the difficulties inherent in predicting nonlinear structural behavior of the membranes and because of the challenges involved. in ground testing of the full-scale structure. This paper describes a finite element analysis of a subscale sunshield that has been subjected to ground testing in support of the Next Generation Space Telescope (NGST) program. The analysis utilizes a nonlinear material model that accounts for wrinkling of the membranes. Results are presented from a nonlinear static preloading analysis and subsequent dynamics analyses to illustrate baseline sunshield structural characteristics. Studies are then described which provide further insight into the effect of membrane. preload on sunshield dynamics and the performance of different membrane modeling techniques. Lastly, a comparison of analytical predictions and ground test results is presented.

Johnston, John D.↗

NASA NTRS1965

Flight reentry experiments

The foregoing discussion has show the way in which flight testing supplements, extends, and reinforces the usefulness of data from ground test facilities. Flight tests can provide an anchor point in evaluating ground test data. Although flight tests can avoid some of the inherent problems of ground facilities, they are expensive, putting a premium on each test to provide the most data that can be acquired. The portions of the reentry flight spectrum which can be simulated by "hot" and "cold" ground facilities are reviewed and some of the current flight programs for obtaining data in the Apollo Reentry Envelope are discussed. The programs are categorized as to (1) environment (heating), (2) materials response, (3) communication problems, and (4) observables. A discussion of the launch vehicles, unknown parameters, and methods of data acquisition for each program is presented.

Radio Attenuation↗

NASA NTRS1983

Analysis and testing of large space structures

Considerations and approaches to the ground testing of large space structures are discussed. The large size combined with the loading due to gravity makes testing of the complete structure difficult. Gravitational stiffening, suspension effects, virtual air mass, preloads, and air damping alter the dynamic characteristics. Low resonant frequencies and high modal densities within the frequency range of interest combine with small motions and accelerations to make testing difficult. Mechanism complexities and nonlinearities associated with space-erected/assembled structures cause structural complexity regardless of other considerations. Ground test approaches include scale models, element and substructure tests, and structural linearization. Analytical approaches are also discussed.

Stahle, C. V.↗

NASA NTRS2012

Determining Damping Trends from a Range of Cable Harness Assemblies on a Launch Vehicle Panel from Test Measurements

The team of authors at Marshall Space Flight Center (MSFC) has been investigating estimating techniques for the vibration response of launch vehicle panels excited by acoustics and/or aero-fluctuating pressures. Validation of the approaches used to estimate these environments based on ground tests of flight like hardware is of major importance to new vehicle programs. The team at MSFC has recently expanded upon the first series of ground test cases completed in December 2010. The follow on tests recently completed are intended to illustrate differences in damping that might be expected when cable harnesses are added to the configurations under test. This validation study examines the effect on vibroacoustic response resulting from the installation of cable bundles on a curved orthogrid panel. Of interest is the level of damping provided by the installation of the cable bundles and whether this damping could be potentially leveraged in launch vehicle design. The results of this test are compared with baseline acoustic response tests without cables. Damping estimates from the measured response data are made using a new software tool that employs a finite element model (FEM) of the panel in conjunction with advanced optimization techniques. This paper will report on the \damping trend differences. observed from response measurements for several different configurations of cable harnesses. The data should assist vibroacoustics engineers to make more informed damping assumptions when calculating vibration response estimates when using model based analysis approach. Achieving conservative estimates that have more flight like accuracy is desired. The paper may also assist analysts in determining how ground test data may relate to expected flight response levels. Empirical response estimates may also need to be adjusted if the measured response used as an input to the study came from a test article without flight like cable harnesses.

Smith, Andrew↗