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At least 577 records · Page 32

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NASA NTRS2009

Meteoroid and Orbital Debris Threats to NASA's Docking Seals: Initial Assessment and Methodology

The Crew Exploration Vehicle (CEV) will be exposed to the Micrometeoroid Orbital Debris (MMOD) environment in Low Earth Orbit (LEO) during missions to the International Space Station (ISS) and to the micrometeoroid environment during lunar missions. The CEV will be equipped with a docking system which enables it to connect to ISS and the lunar module known as Altair; this docking system includes a hatch that opens so crew and supplies can pass between the spacecrafts. This docking system is known as the Low Impact Docking System (LIDS) and uses a silicone rubber seal to seal in cabin air. The rubber seal on LIDS presses against a metal flange on ISS (or Altair). All of these mating surfaces are exposed to the space environment prior to docking. The effects of atomic oxygen, ultraviolet and ionizing radiation, and MMOD have been estimated using ground based facilities. This work presents an initial methodology to predict meteoroid and orbital debris threats to candidate docking seals being considered for LIDS. The methodology integrates the results of ground based hypervelocity impacts on silicone rubber seals and aluminum sheets, risk assessments of the MMOD environment for a variety of mission scenarios, and candidate failure criteria. The experimental effort that addressed the effects of projectile incidence angle, speed, mass, and density, relations between projectile size and resulting crater size, and relations between crater size and the leak rate of candidate seals has culminated in a definition of the seal/flange failure criteria. The risk assessment performed with the BUMPER code used the failure criteria to determine the probability of failure of the seal/flange system and compared the risk to the allotted risk dictated by NASA s program requirements.

deGroh, Henry C., III↗

NASA NTRS2009

Effects of Hypervelocity Impacts on Silicone Elastomer Seals and Mating Aluminum Surfaces

While in space silicone based elastomer seals planned for use on NASA's Crew Exploration Vehicle (CEV) are exposed to threats from micrometeoroids and orbital debris (MMOD). An understanding of these threats is required to assess risks to the crew, the CEV orbiter, and missions. An Earth based campaign of hypervelocity impacts on small scale seal rings has been done to help estimate MMOD threats to the primary docking seal being developed for the Low Impact Docking System (LIDS). LIDS is being developed to enable the CEV to dock to the ISS (International Space Station) or to Altair (NASA's next lunar lander). The silicone seal on LIDS seals against aluminum alloy flanges on ISS or Altair. Since the integrity of a seal depends on both sealing surfaces, aluminum targets were also impacted. The variables considered in this study included projectile mass, density, speed, incidence angle, seal materials, and target surface treatments and coatings. Most of the impacts used a velocity near 8 km/s and spherical aluminum projectiles (density = 2.7 g/cubic cm), however, a few tests were done near 5.6 km/s. Tests were also performed using projectile densities of 7.7, 2.79, 2.5 or 1.14 g/cubic cm. Projectile incidence angles examined included 0 deg, 45 deg, and 60 deg from normal to the plane of the target. Elastomer compounds impacted include Parker's S0383-70 and Esterline's ELA-SA-401 in the as received condition, or after an atomic oxygen treatment. Bare, anodized and nickel coated aluminum targets were tested simulating the candidate mating seal surface materials. After impact, seals and aluminum plates were leak tested: damaged seals were tested against an undamaged aluminum plate; and undamaged seals were placed at various locations over craters in aluminum plates. It has been shown that silicone elastomer seals can withstand an impressive level of damage before leaking beyond allowable limits. In general on the tests performed to date, the diameter of the crater in either the elastomer, or the aluminum, must be at least as big as 80% to 90% of width of the bulb of the seal before significant leakage occurs.

deGroh, Henry C., III↗

NASA NTRS2010

Low-Dead-Volume Inlet for Vacuum Chamber

Gas introduction from near-ambient pressures to high vacuum traditionally is accomplished either by multi-stage differential pumping that allows for very rapid response, or by a capillary method that allows for a simple, single-stage introduction, but which often has a delayed response. Another means to introduce the gas sample is to use the multi-stage design with only a single stage. This is accomplished by using a very small conductance limit. The problem with this method is that a small conductance limit will amplify issues associated with dead -volume. As a result, a high -vacuum gas inlet was developed with low dead -volume, allowing the use of a very low conductance limit interface. Gas flows through the ConFlat flange at a relatively high flow rate at orders of magnitude greater than through the conductance limit. The small flow goes through a conductance limit that is a double-sided ConFlat.

Naylor, Guy↗

NASA NTRS2008

Evaluation of Separation Mechanism Design for the Orion/Ares Launch Vehicle

As a part of the preliminary design work being performed for the Orion vehicle, the Orion to Spacecraft Adaptor (SA) separation mechanism was analyzed and sized, with findings presented here. Sizing is based on worst case abort condition as a result of an anomaly driving the launch vehicle engine thrust vector control hard-over causing a severe vehicle pitch over. This worst case scenario occurs just before Upper Stage Main Engine Cut-Off (MECO) when the vehicle is the lightest and the damping effect due to propellant slosh has been reduced to a minimum. To address this scenario and others, two modeling approaches were invoked. The first approach was a detailed 2-D (Simulink) model to quickly assess the Service Module Engine nozzle to SA clearance for a given separation mechanism. The second approach involved the generation of an Automatic Dynamic Analysis of Mechanical Systems (ADAMS) model to assess secondary effects due to mass centers of gravity that were slightly off the vehicle centerline. It also captured any interference between the Solar Arrays and the Spacecraft Adapter. A comparison of modeling results and accuracy are discussed. Most notably, incorporating a larger SA flange diameter allowed for a natural separation of the Orion and its engine nozzle even at relatively large pitch rates minimizing the kickoff force. Advantages and disadvantages of the 2-D model vs. a full 3-D (ADAMS) model are discussed as well.

Konno, Kevin E.↗

NASA NTRS2010

Full-Scale System for Quantifying Loads and Leak Rates of Seals for Space Applications

NASA is developing advanced space-rated vacuum seals in support of future space exploration missions to low-Earth orbit and other destinations. These seals may be 50 to 60 in. (127 to 152 cm) in diameter and must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air for extended missions to the International Space Station or the Moon. Seal compression loads must be below prescribed limits so as not to overload the mechanisms that compress them during docking or mating, and seal adhesion forces must be low to allow two mated systems to separate when required. NASA Glenn Research Center has developed a new test apparatus to measure leak rates and compression and adhesion loads of candidate full-scale seals under simulated thermal, vacuum, and engagement conditions. Tests can be performed in seal-on-seal or seal-on-flange configurations at temperatures from -76 to 140 F (-60 to 60 C) under operational pressure gradients. Nominal and off-nominal mating conditions (e.g., incomplete seal compression) can also be simulated. This paper describes the main design features of the test apparatus as well as techniques used to overcome some of the design challenges.

Dunlap, Patrick H., Jr.↗

NASA NTRS2011

Space Shuttle Program (SSP) Orbiter Main Propulsion System (MPS) Gaseous Hydrogen (GH2) Flow Control Valve (FCV) Poppet Eddy Current (EC) Inspection Probability of Detection (POD) Study

The Director of the NASA Engineering and Safety Center (NESC), requested an independent assessment of the anomalous gaseous hydrogen (GH2) flow incident on the Space Shuttle Program (SSP) Orbiter Vehicle (OV)-105 during the Space Transportation System (STS)-126 mission. The main propulsion system (MPS) engine #2 GH2 flow control valve (FCV) LV-57 transition from low towards high flow position without being commanded. Post-flight examination revealed that the FCV LV-57 poppet had experienced a fatigue failure that liberated a section of the poppet flange. The NESC assessment provided a peer review of the computational fluid dynamics (CFD), stress analysis, and impact testing. A probability of detection (POD) study was requested by the SSP Orbiter Project for the eddy current (EC) nondestructive evaluation (NDE) techniques that were developed to inspect the flight FCV poppets. This report contains the findings and recommendations from the NESC assessment.

Piascik, Robert S.↗

NASA NTRS2011

Space Shuttle Program (SSP) Orbiter Main Propulsion System (MPS) Gaseous Hydrogen (GH2) Flow Control Valve (FCV) Poppet Eddy Current (EC) Inspection Probability of Detection (POD) Study: Appendices - Volume 2

Piascik, Robert S.↗

NASA NTRS2011

Design and Analysis of a Stiffened Composite Structure Repair Concept

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗

NASA NTRS2011

A Focus on Cryogenic Engineering for the Primordial Inflation Polarization Explorer (PIPER) Mission

Cryogenic engineering involves design and modification of equipment that is used under boiling point of nitrogen which is 77 K. The focus of this paper will be on the design of hardware for cryogenic use and a retrofit that was done to the main laboratory cryostat used to test flight components for the Primordial Inflation Polarization Explorer balloon-borne mission. Data from prior tests showed that there was a superfluid helium leak and a total disassemble of the cryostat was conducted in order to localize and fix the leak. To improve efficiency new fill tubes and clamps with modifications were added to the helium tank. Upon removal of the tank, corrosion was found on the flange face that connects to the helium cold plate and therefore had to be fully replaced and copper plated to prevent future corrosion. Indium seals were also replaced for the four fill tubes, a helium level sensor, and the nitrogen and helium tanks. Four additional shielded twisted pairs of cryogenic wire and a wire harness for the Superconducting Quantum Interference Devices (SQUIDs) were added. Finally, there was also design work done for multiple pieces that went inside the cryostat and a separate probe used to test the SQUIDs. Upon successful completion of the cryostat upgrade, tests were run to check the effectiveness and stability of the upgrades. The post-retrofit tests showed minor leaks were still present and due to this, superfluidity has still not been attained. As such there could still be a possibility of a superfluid leak appearing in the future. Regardless, the copper plating on the helium tank has elongated the need to service it by three to five years.

Rosas, Rogelio↗

NASA NTRS2011

Low-Dead-Volume Inlet for Vacuum Chamber

Gas introduction from near-ambient pressures to high vacuum traditionally is accomplished either by multi-stage differential pumping that allows for very rapid response, or by a capillary method that allows for a simple, single-stage introduction, but which often has a delayed response. Another means to introduce the gas sample is to use the multi-stage design with only a single stage. This is accomplished by using a very small conductance limit. The problem with this method is that a small conductance limit will amplify issues associated with dead-volume. As a result, a high-vacuum gas inlet was developed with low dead-volume, allowing the use of a very low conductance limit interface. Gas flows through the ConFlat flange at a relatively high flow rate at orders of magnitude greater than through the conductance limit. The small flow goes through a conductance limit that is a double-sided ConFlat.

Naylor, Guy↗

NASA NTRS2011

Improved Rare-Earth Emitter Hollow Cathode

An improvement has been made to the design of the hollow cathode geometry that was created for the rare-earth electron emitter described in Compact Rare Earth Emitter Hollow Cathode (NPO-44923), NASA Tech Briefs, Vol. 34, No. 3 (March 2010), p. 52. The original interior assembly was made entirely of graphite in order to be compatible with the LaB6 material, which cannot be touched by metals during operation due to boron diffusion causing embrittlement issues in high-temperature refractory materials. Also, the graphite tube was difficult to machine and was subject to vibration-induced fracturing. This innovation replaces the graphite tube with one made out of refractory metal that is relatively easy to manufacture. The cathode support tube is made of molybdenum or molybdenum-rhenium. This material is easily gun-bored to near the tolerances required, and finish machined with steps at each end that capture the orifice plate and the mounting flange. This provides the manufacturability and robustness needed for flight applications, and eliminates the need for expensive e-beam welding used in prior cathodes. The LaB6 insert is protected from direct contact with the refractory metal tube by thin, graphite sleeves in a cup-arrangement around the ends of the insert. The sleeves, insert, and orifice plate are held in place by a ceramic spacer and tungsten spring inserted inside the tube. To heat the cathode, an insulating tube is slipped around the refractory metal hollow tube, which can be made of high-temperature materials like boron nitride or aluminum nitride. A screw-shaped slot, or series of slots, is machined in the outside of the ceramic tube to constrain a refractory metal wire wound inside the slot that is used as the heater. The screw slot can hold a single heater wire that is then connected to the front of the cathode tube by tack-welding to complete the electrical circuit, or it can be a double slot that takes a bifilar wound heater with both leads coming out the back. This configuration replaces the previous sheathed heater design that limited the cycling-life of the cathode.

Goebel, Dan M.↗

NASA NTRS2005

Variable-Pressure Washer

The variable-pressure washer (VPW) is a proposed device that is so named because (1) it would play the role similar to that played by an ordinary washer, except that (2) the clamping pressure applied by it would vary with either circumferential or radial position. In a typical contemplated application, the radially varying clamping pressure would be used to obtain more nearly uniform compression on a pair of concentric seals (e.g., an O-ring or a gasket) in an assembly that experiences larger deformations normal to the sealing surface for locations around the outer diameter of the attachment flange when compared to locations around the inner diameter. The VPW (see figure) would include two interlocking channel rings pushed axially away from each other by compression spring-like components located at two or more radial positions. Each spring would have a different stiffness based on the radial location. Overlapping splits in each interlocking channel ring would allow for the non-uniform deformation in the rings. Each spring would be held in place by retaining cups attached to the inner flat surfaces of the channel rings. A plunger attached to one channel ring on the central axis would be captured in a plunger housing attached to the other channel ring: The capture of the plunger would hold the VPW together. When the VPW was clamped between two flat surfaces, the clamping force would be distributed unevenly across the face of the washer in the radial direction. The different stiffnesses of the springs would be chosen, in conjunction with other design parameters, to obtain a specified radial variation of clamping pressure in the presence of a specified clamping force.

Smeltzer, Stanley S., III↗

NASA NTRS2005

Spill-Resistant Alkali-Metal-Vapor Dispenser

A spill-resistant vessel has been developed for dispensing an alkali-metal vapor. Vapors of alkali metals (most commonly, cesium or rubidium, both of which melt at temperatures slightly above room temperature) are needed for atomic frequency standards, experiments in spectroscopy, and experiments in laser cooling. Although the present spill-resistant alkali-metal dispenser was originally intended for use in the low-gravity environment of outer space, it can also be used in normal Earth gravitation: indeed, its utility as a vapor source was confirmed by use of cesium in a ground apparatus. The vessel is made of copper. It consists of an assembly of cylinders and flanges, shown in the figure. The uppermost cylinder is a fill tube. Initially, the vessel is evacuated, the alkali metal charge is distilled into the bottom of the vessel, and then the fill tube is pinched closed to form a vacuum seal. The innermost cylinder serves as the outlet for the vapor, yet prevents spilling by protruding above the surface of the alkali metal, no matter which way or how far the vessel is tilted. In the event (unlikely in normal Earth gravitation) that any drops of molten alkali metal have been shaken loose by vibration and are floating freely, a mesh cap on top of the inner cylinder prevents the drops from drifting out with the vapor. Liquid containment of the equivalent of 1.2 grams of cesium was confirmed for all orientations with rubbing alcohol in one of the prototypes later used with cesium.

Klipstein, William↗

NASA NTRS2004

Embedded Heaters for Joining or Separating Plastic Parts

A proposed thermal-bonding technique would make it possible to join or separate thermoplastic parts quickly and efficiently. The technique would eliminate the need for conventional welding or for such conventional fastening components as bolted flanges or interlocking hooks. The technique could be particularly useful in the sign industry (in which large quantities of thermoplastics are used) or could be used to join plastic pipes. A thin sheet of a suitable electrically conductive material would be formed to fit between two thermoplastic parts to be joined (see figure). The electrically conductive sheet and the two parts would be put together tightly, then an electrical current would be sent through the conductor to heat the thermoplastic locally. The magnitude of the current and the heating time would be chosen to generate just enough heat to cause the thermoplastic to adhere to both sides of the electrically conductive sheet. Optionally, the electrically conductive sheet could contain many small holes to provide purchase or to increase electrical resistance to facilitate the generation of heat. After thermal bonding, the electrically conductive sheet remains as an integral part of the structure. If necessary, the electrically conductive sheet can be reheated later to separate the joined thermoplastic parts.

Bryant, Melvin A., III↗

NASA NTRS2007

Chemochromic Hydrogen Sensors

As fossil fuel supplies decline, hydrogen is quickly becoming an increasingly important fuel source. Currently hydrogen is the prime fuel of today's space vehicles (e.g., Space Shuttle) and featured as a fuel for some prototype vehicles such as the BMW seven series model. Hydrogen is a colorless, odorless gas with a 4% lower explosive limit which makes leak detection a priority. In an effort to support the use of hydrogen, a chemochromic (color changing) sensor was developed that is robust, simple to use, and does not require active operation. It can be made into a thin tape which can be conveniently used for leak detection at flanges, valves, or outlets. Chemochromic sensors can be either reversible or irreversible; however, irreversible chemochromic sensors will be analyzed in this report. The irreversible sensor is useful during hazardous operations when personnel cannot be present. To actively monitor leaks, testing of the irreversible sensor against environmental effects was completed and results indicated this material is suitable for outdoor use in the harsh beachside environment of Kennedy Space Center. The experiments in this report will give additional results to the environmental testing by adding solid rocket booster residue as a variable. The primary motivation for these experiments is to prepare the sensors for the launch pad environment at the Kennedy Space Center. In an effort to simulate the atmosphere at the pads before and after launch, the chemochromic sensors are exposed to solid rocket residue under various conditions.

Wiggins, Bryan C.↗

NASA NTRS2012

Repair Concepts as Design Constraints of a Stiffened Composite PRSEUS Panel

A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. The concept is a bolted repair using metal components, so that it can easily be applied in the operational environment. The damage scenario considered is a midbay-to-midbay saw-cut with a severed stiffener, flange and skin. In a previous study several repair configurations were explored and their feasibility confirmed but refinement was needed. The present study revisits the problem under recently revised design requirements and broadens the suite of loading conditions considered. The repair assembly design is based on the critical tension loading condition and subsequently its robustness is verified for a pressure loading case. High fidelity modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic material properties for metal parts and geometrically nonlinear solutions are utilized in the finite element analysis. The best repair design is introduced, its analysis results are presented and factors influencing the design are assessed and discussed.

Przekop, Adam↗

NASA NTRS2012

Elastic-Plastic Nonlinear Response of a Space Shuttle External Tank Stringer: Thermal and Mechanical Loadings - Part 2

Elastic-plastic, large-deflection nonlinear thermo-mechanical stress analyses are performed for the Space Shuttle external tank s intertank stringers. Detailed threedimensional finite element models are developed and used to investigate the stringer s elastic-plastic response for different thermal and mechanical loading events from assembly through flight. Assembly strains caused by initial installation on an intertank panel are accounted for in the analyses. Thermal loading due to tanking was determined to be the bounding loading event. The cryogenic shrinkage caused by tanking resulted in a rotation of the intertank chord flange towards the center of the intertank, which in turn loaded the intertank stringer feet. The analyses suggest that the strain levels near the first three fasteners remain sufficiently high that a failure may occur. The analyses also confirmed that the installation of radius blocks on the stringer feet ends results in an increase in the stringer capability.

Knight, Norman F., Jr.↗

NASA NTRS2012

Dual-Compartment Inflatable Suitlock

A paper discusses a dual-compartment inflatable suitlock (DCIS) for Extra - vehicular Activity (EVA) that will allow for dust control, suit maintenance, and efficient EVA egress/ingress. The expandable (inflatable technologies) aspect of the design will allow the unit to stow in a compact package for transport. The DCIS consists of three hard, in line bulkheads, separating two cylindrical membrane-walled compartments. The inner bulkhead can be fitted with a variety of hatch types, docking flanges, and mating hardware, such as the common berthing mechanism (CBM), for the purpose of mating with vehicles, habitats, and other pressurized modules. The inner bulkhead and center bulkhead function as the end walls of the inner compartment, which, during operations, would stay pressurized, either matching the pressure of the habitat or acting as a lower-pressure transitional volume. The suited crewmember can quickly don a suit, and egress the suitlock without waiting for the compartment to depressurize. The outer compartment can be pressurized infrequently, when a long dwell time is expected prior to the next EVA, or during off-nominal suit maintenance tasks, allowing shirtsleeve inspections and maintenance of the space suits. The outer bulkhead has a pressure-assisted hatch door that stays open and stowed routinely, but can be closed for suit maintenance and pressurization as needed.

Howe, Scott↗