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NASA NTRS2009

Sea-Level Flight Demonstration and Altitude Characterization of a LO2/LCH4 Based Accent Propulsion Lander

A 1,500 lbf thrust-class liquid oxygen (LO2)/Liquid Methane (LCH4) rocket engine was developed and tested at both sea-level and simulated altitude conditions. The engine was fabricated by Armadillo Aerospace (AA) in collaboration with NASA Johnson Space Center. Sea level testing was conducted at Armadillo Aerospace facilities at Caddo Mills, TX. Sea-level tests were conducted using both a static horizontal test bed and a vertical take-off and landing (VTOL) test bed capable of lift-off and hover-flight in low atmosphere conditions. The vertical test bed configuration is capable of throttling the engine valves to enable liftoff and hover-flight. Simulated altitude vacuum testing was conducted at NASA Johnson Space Center White Sands Test Facility (WSTF), which is capable of providing altitude simulation greater than 120,000 ft equivalent. The engine tests demonstrated ignition using two different methods, a gas-torch and a pyrotechnic igniter. Both gas torch and pyrotechnic ignition were demonstrated at both sea-level and vacuum conditions. The rocket engine was designed to be configured with three different nozzle configurations, including a dual-bell nozzle geometry. Dual-bell nozzle tests were conducted at WSTF and engine performance data was achieved at both ambient pressure and simulated altitude conditions. Dual-bell nozzle performance data was achieved over a range of altitude conditions from 90,000 ft to 50,000 ft altitude. Thrust and propellant mass flow rates were measured in the tests for specific impulse (Isp) and C* calculations.

Collins, Jacob↗
NASA NTRS2010

The Habitat Demonstration Unit Project Overview

This paper will describe an overview of the National Aeronautics and Space Administration (NASA) led multi-center Habitat Demonstration Unit (HDU) Project. The HDU project is a "technology-pull" project that integrates technologies and innovations from numerous NASA centers. This project will be used to investigate and validate surface architectures, operations concepts, and requirements definition of various habitation concepts. The first habitation configuration this project will build and test is the Pressurized Excursion Module (PEM). This habitat configuration - the PEM - is based on the Constellation Architecture Scenario 12.1 concept of a vertically oriented habitat module. The HDU project will be tested as part of the 2010 Desert Research and Technologies Simulations (D-RATS) test objectives. The purpose of this project is to develop, integrate, test, and evaluate a habitat configuration in the context of the mission architectures and surface operation concepts. A multi-center approach will be leveraged to build, integrate, and test the PEM through a shared collaborative effort of multiple NASA centers. The HDU project is part of the strategic plan from the Exploration Systems Mission Directorate (ESMD) Directorate Integration Office (DIO) and the Lunar Surface Systems Project Office (LSSPO) to test surface elements in a surface analog environment. The 2010 analog field test will include two Lunar Electric Rovers (LER) and the PEM among other surface demonstration elements. This paper will describe the overall objectives, its various habitat configurations, strategic plan, and technology integration as it pertains to the 2010 and 2011 field analog tests. To accomplish the development of the PEM from conception in June 2009 to rollout for operations in July 2010, the HDU project team is using a set of design standards to define the interfaces between the various systems of PEM and to the payloads, such as the Geology Lab, that those systems will support. Scheduled activities such as early fit-checks and the utilization of a habitat avionics test bed prior to equipment installation into PEM are planned to facilitate the integration process.

Kennedy, Kriss J.↗
NASA NTRS2010

Demonstration of a Submillimeter-Wave HEMT Oscillator Module at 330 GHz

In this work, radial transitions have been successfully mated with a HEMT-based MMIC (high-electron-mobility-transistor-based monolithic microwave integrated circuit) oscillator circuit. The chip has been assembled into a WR2.2 waveguide module for the basic implementation with radial E-plane probe transitions to convert the waveguide mode to the MMIC coplanar waveguide mode. The E-plane transitions have been directly integrated onto the InP substrate to couple the submillimeter-wave energy directly to the waveguides, thus avoiding wire-bonds in the RF path. The oscillator demonstrates a measured 1.7 percent DC-RF efficiency at the module level. The oscillator chip uses 35-nm-gate-length HEMT devices, which enable the high frequency of oscillation, creating the first demonstration of a packaged waveguide oscillator that operates over 300 GHz and is based on InP HEMT technology. The oscillator chip is extremely compact, with dimensions of only 1.085 x 320 sq mm for a total die size of 0.35 sq mm. This fully integrated, waveguide oscillator module, with an output power of 0.27 mW at 330 GHz, can provide low-mass, low DC-power-consumption alternatives to existing local oscillator schemes, which require high DC power consumption and large mass. This oscillator module can be easily integrated with mixers, multipliers, and amplifiers for building high-frequency transmit and receive systems at submillimeter wave frequencies. Because it requires only a DC bias to enable submillimeter wave output power, it is a simple and reliable technique for generating power at these frequencies. Future work will be directed to further improving the applicability of HEMT transistors to submillimeter wave and terahertz applications. Commercial applications include submillimeter-wave imaging systems for hidden weapons detection, airport security, homeland security, and portable low-mass, low-power imaging systems

Radisic, Vesna↗
NASA NTRS2010

Demonstration of an Aerocapture GN and C System Through Hardware-in-the-Loop Simulations

Aerocapture is an orbit insertion maneuver in which a spacecraft flies through a planetary atmosphere one time using drag force to decelerate and effect a hyperbolic to elliptical orbit change. Aerocapture employs a feedback Guidance, Navigation, and Control (GN&C) system to deliver the spacecraft into a precise postatmospheric orbit despite the uncertainties inherent in planetary atmosphere knowledge, entry targeting and aerodynamic predictions. Only small amounts of propellant are required for attitude control and orbit adjustments, thereby providing mass savings of hundreds to thousands of kilograms over conventional all-propulsive techniques. The Analytic Predictor Corrector (APC) guidance algorithm has been developed to steer the vehicle through the aerocapture maneuver using bank angle control. Through funding provided by NASA's In-Space Propulsion Technology Program, the operation of an aerocapture GN&C system has been demonstrated in high-fidelity simulations that include real-time hardware in the loop, thus increasing the Technology Readiness Level (TRL) of aerocapture GN&C. First, a non-real-time (NRT), 6-DOF trajectory simulation was developed for the aerocapture trajectory. The simulation included vehicle dynamics, gravity model, atmosphere model, aerodynamics model, inertial measurement unit (IMU) model, attitude control thruster torque models, and GN&C algorithms (including the APC aerocapture guidance). The simulation used the vehicle and mission parameters from the ST-9 mission. A 2000 case Monte Carlo simulation was performed and results show an aerocapture success rate of greater than 99.7%, greater than 95% of total delta-V required for orbit insertion is provided by aerodynamic drag, and post-aerocapture orbit plane wedge angle error is less than 0.5 deg (3-sigma). Then a real-time (RT), 6-DOF simulation for the aerocapture trajectory was developed which demonstrated the guidance software executing on a flight-like computer, interfacing with a simulated IMU and simulated thrusters, with vehicle dynamics provided by an external simulator. Five cases from the NRT simulations were run in the RT simulation environment. The results compare well to those of the NRT simulation thus verifying the RT simulation configuration. The results of the above described simulations show the aerocapture maneuver using the APC algorithm can be accomplished reliably and the algorithm is now at TRL-6. Flight validation is the next step for aerocapture technology development.

Masciarelli, James↗
NASA NTRS2000

The 2001 Mars In-Situ-Propellant-Production Precursor (MIP) Flight Demonstration

The successful performance of the five individual demonstrations of MARS IN-SITU-PROPELLANT-PRODUCTION PRECURSOR (MIP) will provide both knowledge of and confidence in the reliability of this technology. At the completion of this flight demonstration, the MIP Team will be able to: a) recommend preferred hardware configurations for the intake and adsorption of carbon dioxide from the Martian atmosphere; b) understand the performance characteristics of zirconia cells to generate propellant-grade oxygen; c) understand long-term performance characteristics of advanced solar cells/arrays operated in the actual Mars environment; d) evaluate the functionality of methods to mitigate the deposition of airborne dust onto solar arrays; and e) recommend preferred hardware designs for innovative thermal management including the radiation of heat to the outside environment.

Kaplan, David I.↗
NASA NTRS2002

A Plasma Rocket Demonstration on the International Space Station

The Advanced Space Propulsion Laboratory at the NASA Johnson Space Center has been engaged in the development of a magneto-plasma rocket for several years. This type of rocket could be used in the future to propel interplanetary spacecraft. One feature of this concept is the ability to vary its specific impulse so that it can be operated in a mode that maximizes propellant efficiency or a mode that maximizes thrust. For this reason the system is called the Variable Specific Impulse Magneto-plasma Rocket or VASIMR. This ability to vary specific impulse and thrust will allow for optimum low thrust interplanetary trajectories and results in shorter trip times than is possible with fixed specific impulse systems while preserving adequate payload margins. In the development of the VASIMR technology, a series of ground-based experiments and space demonstrations are envisioned. A ground-based experiment of a low-power VASIMR prototype rocket is currently underway at the Advanced Space Propulsion Laboratory. The next step is a proposal to build and fly a 25-kilowatt VASIMR rocket as an external payload on the International Space Station. This experiment will provide an opportunity to demonstrate the performance of the rocket in space and measure the induced environment. The experiment will also utilize the space station for its intended purpose as a laboratory with vacuum conditions that cannot be matched by any laboratory on Earth. The VASIMR experiment will also blaze the trail for the wider application of advanced electric propulsion on the space station. An electric propulsion system like VASIMR, if provided with sufficient electrical power, could provide continuous drag force compensation for the space station. Drag compensation would eliminate the need for reboosting the station, an operation that will consume about 60 metric tons of propellant in a ten-year period. In contrast, an electric propulsion system would require very little propellant. In fact, a system like VASIMR can use waste hydrogen from the station's life support system as its propellant. This waste hydrogen is otherwise dumped overboard. Continuous drag compensation would also improve the microgravity conditions on the station. So electric propulsion can reduce propellant delivery requirements and thereby increase available payload capacity and at the same time improve the conditions for scientific research.

Petro, Andrew J.↗
NASA NTRS2010

Large Spun Formed Friction-Stir Welded Tank Domes for Liquid Propellant Tanks Made from AA2195: A Technology Demonstration for the Next Generation of Heavy Lift Launchers

Improving structural efficiency while reducing manufacturing costs are key objectives when making future heavy-lift launchers more performing and cost efficient. The main enabling technologies are the application of advanced high performance materials as well as cost effective manufacture processes. This paper presents the status and main results of a joint industrial research & development effort to demonstrate TRL 6 of a novel manufacturing process for large liquid propellant tanks for launcher applications. Using high strength aluminium-lithium alloy combined with the spin forming manufacturing technique, this development aims at thinner wall thickness and weight savings up to 25% as well as a significant reduction in manufacturing effort. In this program, the concave spin forming process is used to manufacture tank domes from a single flat plate. Applied to aluminium alloy, this process allows reaching the highest possible material strength status T8, eliminating numerous welding steps which are typically necessary to assemble tank domes from 3D-curved panels. To minimize raw material costs for large diameter tank domes for launchers, the dome blank has been composed from standard plates welded together prior to spin forming by friction stir welding. After welding, the dome blank is contoured in order to meet the required wall thickness distribution. For achieving a material state of T8, also in the welding seams, the applied spin forming process allows the required cold stretching of the 3D-curved dome, with a subsequent ageing in a furnace. This combined manufacturing process has been demonstrated up to TRL 6 for tank domes with a 5.4 m diameter. In this paper, the manufacturing process as well as test results are presented. Plans are shown how this process could be applied to future heavy-lift launch vehicles developments, also for larger dome diameters.

Stachulla, M.↗
NASA NTRS2011

Fault Detection, Isolation and Recovery (FDIR) Portable Liquid Oxygen Hardware Demonstrator

The Fault Detection, Isolation and Recovery (FDIR) hardware demonstration will highlight the effort being conducted by Constellation's Ground Operations (GO) to provide the Launch Control System (LCS) with system-level health management during vehicle processing and countdown activities. A proof-of-concept demonstration of the FDIR prototype established the capability of the software to provide real-time fault detection and isolation using generated Liquid Hydrogen data. The FDIR portable testbed unit (presented here) aims to enhance FDIR by providing a dynamic simulation of Constellation subsystems that feed the FDIR software live data based on Liquid Oxygen system properties. The LO2 cryogenic ground system has key properties that are analogous to the properties of an electronic circuit. The LO2 system is modeled using electrical components and an equivalent circuit is designed on a printed circuit board to simulate the live data. The portable testbed is also be equipped with data acquisition and communication hardware to relay the measurements to the FDIR application running on a PC. This portable testbed is an ideal capability to perform FDIR software testing, troubleshooting, training among others.

Oostdyk, Rebecca L.↗
NASA NTRS2010

The 2010 Field Demonstration of the Solar Carbothermal Reduction of Regolith to Produce Oxygen

This slide presentation reviews a demonstration of the use of solar carbothermal reduction processing of regolith to produce oxygen and silicon from silica. A contractor developed the Carbothermal Regolith Reduction Module to demonstrate the extraction of oxygen from lunar regolith simulant using concentrated solar energy at a site that has similar terrain to the moon and Mars.

Muscatello, Anthony↗
NASA NTRS2011

Integration Process for the Habitat Demonstration Unit

The Habitat Demonstration Unit (HDU) is an experimental exploration habitat technology and architecture test platform designed for analog demonstration activities. The HDU previously served as a test bed for testing technologies and sub-systems in a terrestrial surface environment. in 2010 in the Pressurized Excursion Module (PEM) configuration. Due to the amount of work involved to make the HDU project successful, the HDU project has required a team to integrate a variety of contributions from NASA centers and outside collaborators The size of the team and number of systems involved With the HDU makes Integration a complicated process. However, because the HDU shell manufacturing is complete, the team has a head start on FY--11 integration activities and can focus on integrating upgrades to existing systems as well as integrating new additions. To complete the development of the FY-11 HDU from conception to rollout for operations in July 2011, a cohesive integration strategy has been developed to integrate the various systems of HDU and the payloads. The highlighted HDU work for FY-11 will focus on performing upgrades to the PEM configuration, adding the X-Hab as a second level, adding a new porch providing the astronauts a larger work area outside the HDU for EVA preparations, and adding a Hygiene module. Together these upgrades result in a prototype configuration of the Deep Space Habitat (DSH), an element under evaluation by NASA's Human Exploration Framework Team (HEFT) Scheduled activates include early fit-checks and the utilization of a Habitat avionics test bed prior to installation into HDU. A coordinated effort to utilize modeling and simulation systems has aided in design and integration concept development. Modeling tools have been effective in hardware systems layout, cable routing, sub-system interface length estimation and human factors analysis. Decision processes on integration and use of all new subsystems will be defined early in the project to maximize the efficiency of both integration and field operations. In addition a series of tailored design reviews are utilized to quickly define the systems and their integration into the DSH configuration. These processes are necessary to ensure activities, such as partially reversing integration of the X-Hab second story of the HDU and deploying and stowing the new work porch for transportation to the JSC Rock Yard and to the Arizona Black Point Lava Flow Site are performed with minimal or no complications. In addition, incremental test operations leading up to an Integrated systems test allows for an orderly systems test program. For FY-11 activities, the HDU DSH will act as a laboratory utilizing a new X-Hab inflatable second floor with crew habitation features. In addition to the day to day operations involving maintenance of the HDU and exploring the surrounding terrain, testing and optimizing the use of the new X-Hab, work porch, Hygiene Module, and other sub-system enhancements will be the focus of the FY-11 test objectives. The HDU team requires a successful integration strategy using a variety of tools and approaches to prepare the DSH for these test objectives. In a challenging environment where the prototyping influences the system design, as well as Vice versa, results of the HDU DSH field tests will influence future designs of habitat systems.

Gill, Tracy↗
NASA NTRS2011

Demonstrating the Operational Value of Atmospheric Infrared Sounder (AIRS) Retrieved Profiles in the Pre-Convective Environment

The Short-term Prediction Research and Transition Center (SPoRT) is a collaborative partnership between NASA and operational forecasting partners, including a number of National Weather Service offices. SPoRT provides real-time NASA products and capabilities to its partners to address specific operational forecast challenges. One operational forecast challenge is forecasting convective weather in data-void regions such as large bodies of water (e.g. Gulf of Mexico). To address this forecast challenge, SPoRT produces a twice-daily three-dimensional analysis that blends a model first-guess from the Advanced Research Weather Research and Forecasting (WRF-ARW) model with retrieved profiles from the Atmospheric Infrared Sounder (AIRS) -- a hyperspectral sounding instrument aboard NASA's Aqua satellite that provides temperature and moisture profiles of the atmosphere. AIRS profiles are unique in that they give a three dimensional view of the atmosphere that is not available through the current rawinsonde network. AIRS has two overpass swaths across North America each day, one valid in the 0700-0900 UTC timeframe and the other in the 1900-2100 UTC timeframe. This is helpful because the rawinsonde network only has data from 0000 UTC and 1200 UTC at specific land-based locations. Comparing the AIRS analysis product with control analyses that include no AIRS data demonstrates the value of the retrieved profiles to situational awareness for the pre-convective (and convective) environment. In an attempt to verify that the AIRS analysis was a good representation of the vertical structure of the atmosphere, both the AIRS and control analyses are compared to a Rapid Update Cycle (RUC) analysis used by operational forecasters. Using guidance from operational forecasters, convective available potential energy (CAPE) was determined to be a vital variable in making convective forecasts and is used herein to demonstrate the utility of the AIRS profiles in changing the vertical thermodynamic structure of the atmosphere in the pre-convective and convective environment. CAPE is an important metric because of it is a quantitative measure of atmospheric stability, which is necessary information when forecasting for convective weather. Case studies from the summer of 2010 were examined, and most impact from the AIRS retrieved profiles occurred over the data-void Gulf of Mexico with fields of convective potential closer to the RUC than the CNTL. Mixed results were found when AIRS retrieved profiles were used over land, so more cases need to be examined to determine whether AIRS would be an effective tool over land. Additional analyses of problematic convective forecasts over the Gulf Coast will be needed to determine the operational impact of AIRS. SPoRT eventually plans to transition the AIRS product to select Weather Forecast Office (WFO) partners, pending the outcome of these additional analyses.

Kozlowski, Danielle M.↗
NASA NTRS2011

Challenges of Cold Conditioning and Static Testing the Ares Demonstration Motor (DM-2)

The Ares first stage rocket is a "human-rated" motor capable of producing and sustaining 3.5 million pounds of thrust throughout it s two-minute burn period. A series of demonstration motors (DM) will be tested in different conditioned environments to confirm they meet all design specifications. The second demonstration motor (DM-2) was designated to be a "cold motor", this means the internal propellant mean bulk temperature (PMBT) was 40 +5\-3 F. The motor was subjected to subfreezing temperatures for two months.

Quinn, Shyla↗
NASA NTRS2011

X-33 Reusable Launch Vehicle Demonstrator, Spaceport and Range

The X-33 was a suborbital reusable spaceplane demonstrator, in development from 1996 to early 2001. The intent of the demonstrator was to lower the risk of building and operating a full-scale reusable vehicle fleet. Reusable spaceplanes offered the potential to lower the cost of access to space by an order of magnitude, compared with conventional expendable launch vehicles. Although a cryogenic tank failure during testing ultimately led to the end of the effort, the X-33 team celebrated many successes during the development. This paper summarizes some of the accomplishments and milestones of this X-vehicle program, from the perspective of an engineer who was a member of the team throughout the development. X-33 Program accomplishments include rapid, flight hardware design, subsystem testing and fabrication, aerospike engine development and testing, Flight Operations Center and Operations Control Center ground systems design and construction, rapid Environmental Impact Statement NEPA process approval, Range development and flight plan approval for test flights, and full-scale system concept design and refinement. Lessons from the X-33 Program may have potential application to new RLV and other aerospace systems being developed a decade later.

Letchworth, Gary F.↗
NASA NTRS2011

Online Oxide Contamination Measurement and Purification Demonstration

Liquid metal sodium-potassium (NaK) has advantageous thermodynamic properties indicating its use as a fission reactor coolant for a surface (lunar, martian) power system. A major area of concern for fission reactor cooling systems is system corrosion due to oxygen contaminants at the high operating temperatures experienced. A small-scale, approximately 4-L capacity, simulated fission reactor cooling system employing NaK as a coolant was fabricated and tested with the goal of demonstrating a noninvasive oxygen detection and purification system. In order to generate prototypical conditions in the simulated cooling system, several system components were designed, fabricated, and tested. These major components were a fully-sealed, magnetically-coupled mechanical NaK pump, a graphite element heated reservoir, a plugging indicator system, and a cold trap. All system components were successfully demonstrated at a maximum system flow rate of approximately 150 cc/s at temperatures up to 550 C. Coolant purification was accomplished using a cold trap before and after plugging operations which showed a relative reduction in oxygen content.

Bradley, D. E.↗
NASA NTRS2011

SpaceCube Demonstration Platform

A document discusses how the HST SM4 SpaceCube flight spare was modified to create an experiment called the Space- Cube Demonstration Platform (SC DP) for use on the MISSE7 Space Station payload (in collaboration with NRL). It is designed to serve as an on-orbit platform for demonstrating advanced fault tolerance technologies. A simple C&DH (command and data handling) system was developed for the Virtex4 FPGAs (field programmable gate arrays). Both Virtex4s on each SpaceCube run the same program, and both receive incoming telemetry. The rad-hard service FPGA performs simple error checking to verify that the incoming telemetry is valid. The SpaceCube framework was modified to allow for new program files to be sent from the ground, to be stored on the SpaceCube, and to be executed through ground commands. Each SpaceCube Virtex4 FPGA has resources set aside for experiments that are functionally isolated from the C&DH system. The experiments communicate to the C&DH system through a set of dual port memories, and this area is where the fault-tolerance experiments are executed. With the use of Xilinx commercial Virtex4 FX60 FPGAs, the fault tolerant framework allows the system to recover from radiation upsets that occur in the rad-soft parts (Virtex4 FPGA logic, embedded PPCs in Virtex4 FPGAs, SDRAM and Flash), the C&DH system that runs simultaneously on both Virtex4 FPGAs that uses a robust telemetry packet structure, checksums, and the rad-hard service FPGA to validate incoming telemetry. The ability to be reconfigured from the ground while in orbit is a novel benefit, as well as is the onboard compression capabilities that allow compressed files from the ground to be uploaded to the SpaceCube.

Espinosa, Daniel↗
NASA NTRS2012

Free-Flight Terrestrial Rocket Lander Demonstration for NASA's Autonomous Landing and Hazard Avoidance Technology (ALHAT) System

The Autonomous Landing Hazard Avoidance Technology (ALHAT) Project is chartered to develop and mature to a Technology Readiness Level (TRL) of six an autonomous system combining guidance, navigation and control with terrain sensing and recognition functions for crewed, cargo, and robotic planetary landing vehicles. The ALHAT System must be capable of identifying and avoiding surface hazards to enable a safe and accurate landing to within tens of meters of designated and certified landing sites anywhere on a planetary surface under any lighting conditions. Since its inception in 2006, the ALHAT Project has executed four field test campaigns to characterize and mature sensors and algorithms that support real-time hazard detection and global/local precision navigation for planetary landings. The driving objective for Government Fiscal Year 2012 (GFY2012) is to successfully demonstrate autonomous, real-time, closed loop operation of the ALHAT system in a realistic free flight scenario on Earth using the Morpheus lander developed at the Johnson Space Center (JSC). This goal represents an aggressive target consistent with a lean engineering culture of rapid prototyping and development. This culture is characterized by prioritizing early implementation to gain practical lessons learned and then building on this knowledge with subsequent prototyping design cycles of increasing complexity culminating in the implementation of the baseline design. This paper provides an overview of the ALHAT/Morpheus flight demonstration activities in GFY2012, including accomplishments, current status, results, and lessons learned. The ALHAT/Morpheus effort is also described in the context of a technology path in support of future crewed and robotic planetary exploration missions based upon the core sensing functions of the ALHAT system: Terrain Relative Navigation (TRN), Hazard Detection and Avoidance (HDA), and Hazard Relative Navigation (HRN).

Rutishauser, David K.↗
NASA NTRS2011

Demonstration of a Fiber Optic Regression Probe in a High-Temperature Flow

The capability to provide localized, real-time monitoring of material regression rates in various applications has the potential to provide a new stream of data for development testing of various components and systems, as well as serving as a monitoring tool in flight applications. These applications include, but are not limited to, the regression of a combusting solid fuel surface, the ablation of the throat in a chemical rocket or the heat shield of an aeroshell, and the monitoring of erosion in long-life plasma thrusters. The rate of regression in the first application is very fast, while the second and third are increasingly slower. A recent fundamental sensor development effort has led to a novel regression, erosion, and ablation sensor technology (REAST). The REAST sensor allows for measurement of real-time surface erosion rates at a discrete surface location. The sensor is optical, using two different, co-located fiber-optics to perform the regression measurement. The disparate optical transmission properties of the two fiber-optics makes it possible to measure the regression rate by monitoring the relative light attenuation through the fibers. As the fibers regress along with the parent material in which they are embedded, the relative light intensities through the two fibers changes, providing a measure of the regression rate. The optical nature of the system makes it relatively easy to use in a variety of harsh, high temperature environments, and it is also unaffected by the presence of electric and magnetic fields. In addition, the sensor could be used to perform optical spectroscopy on the light emitted by a process and collected by fibers, giving localized measurements of various properties. The capability to perform an in-situ measurement of material regression rates is useful in addressing a variety of physical issues in various applications. An in-situ measurement allows for real-time data regarding the erosion rates, providing a quick method for empirically anchoring any analysis geared towards lifetime qualification. Erosion rate data over an operating envelope could also be useful in the modeling detailed physical processes. The sensor has been embedded in many regressing media to demonstrate the capabilities in a number of regressing environments. In the present work, sensors were installed in the eroding/regressing throat region of a converging-diverging flow, with the working gas heated to high temperatures by means of a high-pressure arc discharge at steady-state discharge power levels up to 500 kW. The amount of regression observed in each material sample was quantified using a later profilometer, which was compared to the in-situ erosion measurements to demonstrate the efficacy of the measurement technique in very harsh, high-temperature environments.

Korman, Valentin↗
NASA NTRS2008

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗