Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Test Fixture”

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.

At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

Second heated jettison test on the Centaur standard shroud

The second in a planned series of heated jettison tests on the Centaur Standard Shroud was conducted on January 16, 1974. The first 250-second portion of the test sequence involved heating the shroud with a specially-built fixture designed to provide a simulation of the heating environment encountered by the shroud during its ascent through the earth's atmosphere. The two heater halves, which were mounted on a rail system, were then retracted. This was followed by the jettison of the two shroud halves into catch nets positioned at 90 deg to the heater rails. The condition which made this test unique compared to the others in the test series was the alignment of the maximum thermal line with the shroud separation plane. Information on the test hardware, configuration, and sequence is presented. Shroud thermal and deflection data encountered during the heating portion of the test sequence are compared with free-skin design temperatures in various graphical formats.

Source record↗
NASA NTRS2001

CM-2 Environmental / Modal Testing of Spacehab Racks

Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that launches on Shuttle mission STS 107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the Shuttle.

McNelis, Mark E.↗
NASA NTRS2001

CM-2 Environmental/Modal Testing of SPACEHAB Racks

Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that will launch on shuttle mission STS-107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack-level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the shuttles.

McNelis, Mark E.↗
NASA NTRS1997

Seal Sample Fixtures

The development of the International Space Station is critically dependent upon development and testing of materials that will require exposure to the space environment. The seals between the modules are one of the more important examples. The choice of seals depends upon the seal materials' susceptibility to atomic oxygen, UV radiation, and the combined external space environment. Also, the choice of thermal control materials depends on their susceptibility to the space environment. The Space Environmental Branch at MSFC developed a flight experiment to provide information on the effects of the space environment on seal and thermal control materials. The experiment, called the Passive Optical Sample Array (POSA), involved exposing several different material samples to the atomic oxygen, UV radiation, and combined effects of the space environment. The POSA experiment is currently flying on the Russian Mir space station. It was necessary during the assembly of POSA to develop an understanding of available fabrication and metrology techniques in order to develop several monitoring systems for the experiment. The report briefly describes the tasks and the work performed in preparing the samples for the POSA experiment.

White, Edwin↗
DOE OSTI2023

Stabilizing a strongly nonlinear structure through shaker dynamics in fixed frequency voltage control tests

Bifurcations are commonly encountered during force controlled swept and stepped sine testing of nonlinear structures, which generally leads to the so-called jump-down or jump-up phenomena between stable solutions. There are various experimental closed-loop control algorithms, such as control-based continuation and phase-locked loop, to stabilize dynamical systems through these bifurcations, but they generally rely on specialized control algorithms that are not readily available with many commercial data acquisition software packages. A recent method was developed to experimentally apply sequential continuation using the shaker voltage that can be readily deployed using commercially available software. By utilizing the stabilizing effects of electrodynamic shakers and the force dropout phenomena in fixed frequency voltage control sine tests, this approach has been demonstrated to stabilize the unstable branch of a nonlinear system with three branches, allowing for three multivalued solutions to be identified within a specific frequency bandwidth near resonance. Recent testing on a strongly nonlinear system with vibro-impact nonlinearity has revealed jumping behavior when performing sequential continuation along the voltage parameter, like the jump phenomena seen during more traditional force controlled swept and stepped sine testing. Here, this paper investigates the stabilizing effects of an electrodynamic shaker on strongly nonlinear structures in fixed frequency voltage control tests using both numerical and experimental methods. The harmonic balance method is applied to the coupled shaker-structure system with an electromechanical model to simulate the fixed voltage control tests and predict the stabilization for different parameters of the model. The simulated results are leveraged to inform the design of a set of experiments to demonstrate the stabilization characteristics on a fixture-pylon assembly with a vibro-impact nonlinearity. Through numerical simulation and experimental testing on two different strongly nonlinear systems, the various parameters that influence the stability of the coupled shaker-structure are revealed to better understand the performance of fixed frequency voltage control tests.

42 ENGINEERING↗
NASA NTRS2008

HST Super Lightweight Interchangeable Carrier (SLIC) Static Test

The HST Super Light Weight Interchangeable Carrier Static Test program calls for a total of 15 load cases with an average of 9 simultaneous push/pull locations per load case. This testing program represents the most complex static test ever attempted at Goddard Space Flight Center. Many unique multi-pull fixtures were designed to apply the simultaneous loading. Additionally, a total of 600 channels of data required processing for each loadcase. A total of 1100 separate strain gages were installed on SLIC. A team of 15 trained technicians were needed to apply test loads via mechanical hand pumps for several load cases. All 15 load cases were successfully conducted within 15 weeks. The ManTech team successfully tested all SLIC 1200 interface clips to the required testing loads. Several unique designs were needed to address testing challenges as loadline interference, Payload Safety, payload flexibility and opposing load applications.

Chambers, William V.↗
NASA NTRS1996

Effects of Core Thickness and Fiber Orientation on Composite Beam Stiffness

This laboratory experiment is intended for students in an introductory polymer materials and processes course or engineering materials course. It can be conducted as an introduction to the hand lay-up process, with additional observations regarding the stiffness of the completed composite beams based on core thickness and fiber orientation. Students gain hands-on experience with the hand lay-up process by constructing glass/epoxy composite panels. Each lab group produces a panel with different core thickness or fiber orientation. The panels are then cut into strips and tested for flexural stiffness in a three-point bending fixture. Students plot deflection versus load data for composite beams with two different fiber orientations, two core thicknesses and one beam with laminate plies only (no core). The deflection plots highlight the effects of core thickness and fiber orientation on composite beam stiffness.

Hillsman, Vernon S.↗
NASA NTRS2014

Mounting for Fabrication, Metrology, and Assembly of Full Shell Grazing Incidence Optics

Future x-ray telescopes will likely require lightweight mirrors to attain the large collecting areas needed to accomplish the science objectives. Understanding and demonstrating processes now is critical to achieving sub-arcsecond performance in the future. Consequently, designs not only of the mirrors but of fixtures for supporting them during fabrication, metrology, handling, assembly, and testing must be adequately modeled and verified. To this end, MSFC is using finite-element modeling to study the effects of mounting on full-shell grazing-incidence mirrors, during all processes leading to flight mirror assemblies. Here we report initial results of this study.

Roche, Jacqueline M.↗
NASA NTRS2014

Direct Polishing of Full-Shell, High-Resolution X-Ray Optics

Future x-ray telescopes will likely require lightweight mirrors to attain the large collecting areas needed to accomplish the science objectives. Understanding and demonstrating processes now is critical to achieving sub-arcsecond performance in the future. Consequently, designs not only of the mirrors but of fixtures for supporting them during fabrication, metrology, handling, assembly, and testing must be adequately modeled and verified. To this end, MSFC is using finite-element modeling to study the effects of mounting on thin, full-shell grazing-incidence mirrors, during all processes leading to a flight.

X-Ray Optics↗
NASA NTRS2012

TPSAS-NF1676L-13539-DND

The performance of variable stiffness composite panels is characterized using experiments and structural analyses. Fabricated using a fiber placement system, the fiber angle in these panels varies continuously within each ply. Measured panel shapes and thermal responses are correlated with finite element analyses. Large geometric imperfections require unique fixtures to both straighten the panel edges and provide structural test boundary conditions. Panels show linear prebuckling and nonlinear postbuckling under applied end shortening, which occur at higher loads than a baseline panel. Panel responses to in-plane loading are computed using geometric and materially nonlinear analyses that include mechanical prestresses and measured imperfections. Analytical strains and displacements also correlate well with measured results.

Chauncey Wu↗
DOE OSTI2026

Memorial Pools Energy Efficiency Retrofits

The National September 11 Memorial & Museum completed a retrofit of the submergible LED lighting fixtures in its North and South Memorial Pools, located at the World Trade Center site in New York City. The two one-acre pools are illuminated nightly by custom LED fixtures set into their base, and the original lights — in place since 2011 — had begun reaching the end of their useful life, leaving sections of the pools dim or dark. Rather than fully replacing the fixtures, the project team worked with the original manufacturer, Acuity Brands, to retrofit and reuse existing components across all eight pool walls (34 fixtures per wall), reducing cost and waste. Fixtures were shipped in custom crates to Minnesota for retrofitting, then reinstalled onsite by Memorial & Museum staff and contractor ABM. The team addressed two key technical challenges during the project: early leakage in retrofitted fixtures, resolved by introducing vacuum-sealing and nitrogen-fill testing before shipment; and chord damage during transit, resolved with custom-designed shipping crates. All eight pool walls were successfully retrofitted and reinstalled by August 27, 2025, ahead of the 25th anniversary of the September 11, 2001 attacks. Sitewide electrical consumption in September 2025 reflected an approximate 7% reduction, contributing to the institution's broader net-zero and LEED Gold sustainability goals.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2008

The Planning and Implementation of Test Facility Improvements

As engineering programs develop, and product testing begins, ideas for process improvement soon become obvious. Engineers envision new holding and handling fixtures. Additional custom-made support equipment may be needed. Perhaps modifications to the building or modifications to facility hardware are the order of the day. This is where a flexible creative test organization is needed. We need not be content with the status quo. All of these desired test innovations can make the difficult easy and improve the work flow. At times, implementing these new ideas demands more time or specialized expertise than test team members have. Through the coordinated use of labor resources, the needed improvements can still be made and in a timely fashion that supports program schedules. This presentation provides practical advice and a method whereby test personnel can creatively develop facility improvements and manage them from start to finish. You can control just how much time you invest and what part of your concepts you will personally design. By wisely defining the requirements and presenting them to the appropriate help sources (vendors, contractors, coworkers, and support departments), you can get the help you need to bring the improvements you have conceived, into fruition. Aspects of this presentation include defining requirements for test facility improvements, choosing labor resources, writing a statement of work, determining cost and benefits, securing department approval, coordinating procurement, managing the project, and training the end users. The process of successfully implementing test facility improvements is thoroughly explained. It has been tried, proven and improved over nearly 25 years of use. Whether considering a $50 improvement or a $50 million dollar improvement, this discussion will provide helpful pointers. Examples of improvements made through this process and their illustration will be included.

Oberlander, Larry↗
DOE OSTI2025

Installation and Demonstration of CNC Machining for Mechanical Test Specimens in the IFEL Hot Cell

This report documents the installation and demonstration of computer numerical control (CNC) machining capabilities in the Irradiated Fuels Examination Laboratory hot cell facility at Oak Ridge National Laboratory (ORNL). A modified Tormach PCNC 440 mill was integrated into the hot cell with custom fixturing, fines management, and manipulator-compatible interfaces to enable the fabrication of axial tension test (ATT) and ring tension test (RTT) specimens from irradiated cladding. The first irradiated specimens machined included ATT and RTT geometries harvested from the high-burnup 6XV fuel rod. Dimensional inspections confirmed that machined specimens met the ±0.025 mm tolerance envelope established in prior development; deviations were consistent with expected measurement scatter and inherent specimen variability, such as wall thickness gradients and eccentricity. Comparisons with out-of-cell metrology confirmed that in-cell machining performance aligns with baseline scatter observed under ideal conditions. This work establishes reproducible, end-to-end specimen preparation at ORNL, directly supporting the US Department of Energy’s Accident-Tolerant Fuel program by enabling reliable, traceable mechanical testing of irradiated cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Fabrication of a Nb-Ti Superconducting Closed-Loop Coil for the Next-Generation 45 GHz ECR Ion Source MARS-D

Electron Cyclotron Resonance Ion Sources (ECRISs) that utilize Nb-Ti superconducting coils for 28 GHz frequencies have been operating effectively for over twenty years. However, transitioning to higher frequencies demands stronger magnetic fields, and the conventional racetrack-and-solenoid ECRIS structures have reached their maximum capability with Nb-Ti. To address this, a Mixed Axial and Radial field System Demonstrator (MARS-D) is being developed at Lawrence Berkeley National Laboratory (LBNL). This system features an innovative Closed-Loop Coil (CLC) design that optimizes the use of the conductor fields, enabling the application of Nb-Ti in the next-generation 45 GHz ECRISs. The fabrication of the hexagonal CLC is particularly challenging due to its complex winding path and shape, the stiffness of the Nb-Ti superconducting wire, and the small bending radius. Here, to address these challenges, a series of unique fixtures and tools, as well as a pre-over-bending method, were developed for winding the CLC. To validate the winding fixtures, tools, procedures, and materials used in the coil assembly, a 4-layer practice CLC was wound, epoxy-impregnated, and then cold-tested using liquid nitrogen. The full-size MARS-D CLC is in the process of winding. This paper presents the structure of the MARS-D CLC, the winding fixtures and tools, the winding procedures, the quality control, the impregnation, the test results, and the potential future improvements.

ECR ion sources↗
DOE OSTI2025

Discriminator Threshold Study for Scint 1

During electronics testing at NSRL, the fluence/spill is recorded from the QC1 chamber. This chamber, which is a permanent fixture on the NSRL beamline, requires calibration from an external radiation detector that can measure ion flux directly. A 1.0 × 1.0 × 0.5 cm 3 scintillator is used at the testing location to calibrate all NSRL beams for electronic experiments. A calibration factor is derived by comparing the ions observed by the scintillator and QC1 during an exposure of at least 10 5 scintillator counts or total ions.

43 PARTICLE ACCELERATORS↗
NASA NTRS1990

The test facility requirements for the thermal vacuum thermal balance test of the Cosmic Background Explorer Observatory

The Cosmic Background Explorer Observatory (COBE) underwent a thermal vacuum thermal balance test in the Space Environment Simulator (SES). This was the largest and most complex test ever conducted at this facility. The 4 x 4 m (13 x 13 ft) spacecraft weighed approx. 2223 kg (4900 lbs) for the test. The test set up included simulator panels for the inboard solar array panels, simulator panels for the flight cowlings, Sun and Earth Sensor stimuli, Thermal Radio Frequency Shield heater stimuli and a cryopanel for thermal control in the Attitude Control System Shunt Dissipator area. The fixturing also included a unique 4.3 m (14 ft) diameter Gaseous Helium Cryopanel which provided a 20 K environment for the calibration of one of the spacecraft's instruments, the Differential Microwave Radiometer. This cryogenic panel caused extra contamination concerns and a special method was developed and written into the test procedure to prevent the high buildup of condensibles on the panel which could have led to backstreaming of the thermal vacuum chamber. The test was completed with a high quality simulated space environment provided to the spacecraft. The test requirements, test set up, and special fixturing are described.

Milam, Laura J.↗
NASA NTRS1991

Test facility requirements for the thermal vacuum thermal balance test of the Cosmic Background Explorer Observatory

The Cosmic Background Explorer Observatory (COBE) underwant a thermal vacuum thermal balance test in the Space Environment Simulator (SES). This was the largest and most complex test ever conducted at this facility. The 4 x 4 m (13 x 13 ft) spacecraft weighed approx. 2223 kg (4900 lbs) for the test. The test set up included simulator panels for the inboard solar array panels, simulator panels for the flight cowlings, Sun and Earth Sensor stimuli, Thermal Radio Frequency Shield heater stimuli and a cryopanel for thermal control in the Attitude Control System Shunt Dissipator area. The fixturing also included a unique 4.3 m (14 ft) diameter Gaseous Helium Cryopanel which provided a 20 K environment for the calibration of one of the spacecraft's instruments, the Differential Microwave Radiometer. This cryogenic panel caused extra contamination concerns and a special method was developed and written into the test procedure to prevent the high buildup of condensibles on the panel which could have led to backstreaming of the thermal vacuum chamber. The test was completed with a high quality simulated space environment provided to the spacecraft. The test requirements, test set up, and special fixturing are described.

Milam, Laura J.↗
NASA NTRS2012

Plant Atrium System for Food Production in NASA's Deep Space Habitat Tests

In preparation for future human exploration missions to space, human habitat designs and concepts need to be tested to assess integration issues, power requirements, crew operations, and technology I subsystem performance. One potential subsystem for early habitats is supplemental food production. Fresh foods, such as vegetables and small fruits, could be harvested on a continuous basis to improve the diet and quality of life. The system would need to fit conveniently into the habitat and not interfere with other components or operations. To test this concept, a plant growing "atrium" was designed to surround the lift between the lower and upper modules of the Deep Space Habitat and deployed at NASA DRA TS test site in 2011 and at NASA's JSC in 20I2. With this approach, un-utilized volume provided an area for vegetable growth. For the 20 II test, mizuna, lettuce, basil, radish and sweetpotato plants were grown in trays using commercially available red I blue LED light fixtures. Seedlings were transplanted into the atrium and cared for by the crew. Plants were then harvested two weeks later following completion of the test. In 20I2, mizuna, lettuce, and radish plants were grown similarly but under flat panel banks of white LEDs. In 20 I2, the crew went through plant harvesting, including sanitizing the leafy greens and radishes, which were then consumed. Each test demonstrated successful production of vegetables within a functional hab module. The round red I blue LEDs for the 20Il test lighting cast a purple light in the hab, and were less uniformly distributed over the plant trays. The white LED panels provided broad spectrum light with more uniform distribution. Post-test questionnaires showed that the crew enjoyed tending and consuming the plants, and that the white LED light in 2012 provided welcome extra light for the main hab area.

Massa, Gioia↗