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At least 649 records · Page 36

Solving Component Structural Dynamic Failures Due to Extremely High Frequency Structural Response on the Space Shuttle Program

For many years, the capabilities to determine the root-cause failure of component failures have been limited to the analytical tools and the state of the art data acquisition systems. With this limited capability, many anomalies have been resolved by adding material to the design to increase robustness without the ability to determine if the design solution was satisfactory until after a series of expensive test programs were complete. The risk of failure and multiple design, test, and redesign cycles were high. During the Space Shuttle Program, many crack investigations in high energy density turbomachines, like the SSME turbopumps and high energy flows in the main propulsion system, have led to the discovery of numerous root-cause failures and anomalies due to the coexistences of acoustic forcing functions, structural natural modes, and a high energy excitation, such as an edge tone or shedding flow, leading the technical community to understand many of the primary contributors to extremely high frequency high cycle fatique fluid-structure interaction anomalies. These contributors have been identified using advanced analysis tools and verified using component and system tests during component ground tests, systems tests, and flight. The structural dynamics and fluid dynamics communities have developed a special sensitivity to the fluid-structure interaction problems and have been able to adjust and solve these problems in a time effective manner to meet budget and schedule deadlines of operational vehicle programs, such as the Space Shuttle Program over the years.

Frady, Greg↗

Ares I-X Thermal Model Correlation and Lessons Learned

The Ares I-X vehicle launched and flew successfully on October 28, 2009. This paper will describe the correlation of the vehicle thermal model to both ground testing and flight data. A main purpose of the vehicle model and ground testing was to ensure that the avionics within the vehicle were held within their thermal limits prior to launch and during flight. The correlation of the avionics box temperatures will be shown. Also, the lessons learned in the thermal discipline during the modeling, test, correlation to test, and flight of the Ares I-X flight test vehicle will be described. Lessons learned will cover thermal modeling, as well as management of the thermal discipline, thermal team, and thermal-related actions in design, testing, and flight.

Amundsen, Ruth M.↗

Bridging the Technology Readiness "Valley of Death" Utilizing Nanosats

Incorporating new technology is a hallmark of space missions. Missions demand ever-improving tools and techniques to allow them to meet the mission science requirements. In Earth Science, these technologies are normally expressed in new instrument capabilities that can enable new measurement concepts, extended capabilities of existing measurement techniques, or totally new detection capabilities, and also, information systems technologies that can enhance data analysis or enable new data analyses to advance modeling and prediction capabilities. Incorporating new technologies has never been easy. There is a large development step beyond demonstration in a laboratory or on an airborne platform to the eventual space environment that is sometimes referred to as the "technology valley of death." Studies have shown that non-validated technology is a primary cause of NASA and DoD mission delays and cost overruns. With the demise of the New Millennium Program within NASA, opportunities for demonstrating technologies in space have been rare. Many technologies are suitable for a flight project after only ground testing. However, some require validation in a relevant or a space flight environment, which cannot be fully tested on the ground or in airborne systems. NASA's Earth Science Technology Program has initiated a nimble program to provide a fairly rapid turn-around of space validated technologies, and thereby reducing future mission risk in incorporating new technologies. The program, called In-Space Validation of Earth Science Technology (InVEST), now has five tasks in development. Each are 3U CubeSats and they are targeted for launch opportunities in the 2016 time period. Prior to formalizing an InVEST program, the technology program office was asked to demonstrate how the program would work and what sort of technologies could benefit from space validation. Three projects were developed and launched, and have demonstrated the technologies that they set out to validate. This paper will provide a brief status of the pre-InVEST CubeSats, and discuss the development and status of the InVEST program. Figure

Earth Science↗

HIAD on ULA (HULA) Orbital Reentry Flight Experiment Concept

This paper describes a proposed orbital velocity reentry flight test of a Hypersonic Inflatable Aerodynamic Decelerator (HIAD). The flight test builds upon ground development activities that continue to advance the materials, design, and manufacturing techniques for the inflatable structure and flexible thermal protection system (F-TPS) that comprise the inflatable heat shield. While certain aspects of material and system performance can be assessed using a variety of ground testing capabilities, only orbital velocity energy on a trajectory through the gradient density of the atmosphere can impart the combined aerodynamic and aeroheating design environments in real time. To achieve this at limited cost, the HIAD would be delivered to a spin-stabilized entry trajectory as a secondary payload on the Centaur stage of a United Launch Alliance (ULA) Atlas V launch vehicle. Initial trajectory studies indicate that the combination of launch vehicle capability and achievable reentry vehicle ballistic numbers make this a strategic opportunity for technology development. This 4 to 6 meter diameter scale aeroshell flight, referred to as HIAD on ULA (HULA), would also contribute to ULA asset recovery development. ULA has proposed that a HIAD be utilized as part of the Sensible, Modular, Autonomous Return Technology (SMART) initiative to enable recovery of the Vulcan launch vehicle booster main engines [1], including a Mid-Air Recovery (MAR) to gently return these assets for reuse. Whereas HULA will attain valuable aerothermal and structural response data toward advancing HIAD technology, it may also provide a largest-to-date scaled flight test of the MAR operation, which in turn would allow the examination of a nearly pristine post-entry aeroshell. By utilizing infrared camera imaging, HULA will also attain aft-side thermal response data, enhancing understanding of the aft side aerothermal environment, an area of high uncertainty. The aeroshell inflation will utilize a heritage design compressed gas system to minimize development costs. The data will be captured to both an onboard recorder and a recorder that is jettisoned and recovered separately from the reentry vehicle to mitigate risk. This paper provides an overview, including the architecture and flight concept of operations, for the proposed HULA flight experiment.

Dinonno, J. M.↗

Demonstration of a 600 Watt Hybrid Iodine-Xenon Electric Propulsion System

This paper reviews recent iodine compatible electric propulsion technologies evaluated at the NASA Glenn Research Center. The work culminated in a 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed thruster with xenon fed cathode). The test demonstrated that (i) a Hall-effect thruster operates with nearly identical performance whether employing iodine or xenon propellant, (ii) careful selection of propulsion system materials and coatings can result in durable iodine-compatible hardware, and (iii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment. The work was motivated by advancements in capability of very dense small-spacecraft (<500 kg), but spacecraft still lacking very dense in-space propulsion to provide the large delta-v capabilities (3 to 10 km/s) required for many high-value NASA exploration and science missions. Volume limitations of small-spacecraft not only require dense propulsion systems, but more so dense propellants. NASA identifies xenon and iodine as having both favorable storage densities and propulsive properties to enable many NASA small-spacecraft mission scenarios. While xenon is inert and well-proven in spaceflight applications, iodine has triple the storage density of xenon and stores at low pressures, permitting use of conformal tank designs. Unlike xenon, iodine does raise concerns related to its reactivity with most materials, potential spacecraft-propellant interactions, impact on ground test facilities, and challenges to acceptance test iodine propulsion systems prior to flight. This work begins to address these challenges. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, G. F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300degC over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall informfuture iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 degrees C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

V/STOL and STOL ground effects and testing techniques

The ground effects associated with V/STOL operation were examined and an effort was made to develop the equipment and testing techniques needed for that understanding. Primary emphasis was on future experimental programs in the 40 x 80 and the 80 x 120 foot test sections and in the outdoor static test stand associated with these facilities. The commonly used experimental techniques are reviewed and data obtained by various techniques are compared with each other and with available estimating methods. These reviews and comparisons provide insight into the limitations of past studies and the testing techniques used and identify areas where additional work is needed. The understanding of the flow mechanics involved in hovering and in transition in and out of ground effect is discussed. The basic flow fields associated with hovering, transition and STOL operation of jet powered V/STOL aircraft are depicted.

Kuhn, R. E.↗

System Level Aerothermal Testing for the Adaptive Deployable Entry and Placement Technology (ADEPT)

The Adaptive Deployable Entry and Placement Technology (ADEPT), a mechanically deployable entry vehicle technology, has been under development at NASA since 2011. As part of the technical maturation of ADEPT, designs capable of delivering small payloads (10 kg) are being considered to rapidly mature sub 1 m deployed diameter designs. The unique capability of ADEPT for small payloads comes from its ability to stow within a slender volume and deploy to achieve a mass efficient drag surface with a high heat rate capability. The low ballistic coefficient results in entry heating and mechanical loads that can be met by a revolutionary three-dimensionally woven carbon fabric supported by a deployable skeleton structure. This carbon fabric has test proven capability as both primary structure and payload thermal protection system. In order to rapidly advance ADEPTs technical maturation, the project is developing test methods that enable thermostructural design requirement verification of ADEPT designs at the system level using ground test facilities. Results from these tests are also relevant to larger class missions and help us define areas of focused component level testing in order to mature material and thermal response design codes. The ability to ground test sub 1 m diameter ADEPT configurations at or near full-scale provides significant value to the rapid maturation of this class of deployable entry vehicles. This paper will summarize arc jet test results, highlight design challenges, provide a summary of lessons learned and discuss future test approaches based upon this methodology.

Hypersonic↗

Shuttle remote manipulator system hardware test facility

The shuttle remote manipulator (RMS) is designed and built for operations in a zero gravity environment. As such, the ground test facility for the integrated RMS must simulate conditions which support verification of the overall system performance. In order to allow ground test operations, a test facility was constructed with an area of 60 ft. x 120 ft. and extremely tight tolerances on floor flatness and slope. An air bearing support structure was designed for the RMS to operate with 4 degrees of freedom. The RMS system test facility and systems tests conducted to date are described.

Wagner-Bartak, C. G.↗

E-4 Test Facility Design Status

Combined-cycle propulsion technology is a strong candidate for meeting NASA space transportation goals. Extensive ground testing of integrated air-breathing/rocket system (e.g., components, subsystems and engine systems) across all propulsion operational modes (e.g., ramjet, scramjet) will be needed to demonstrate this propulsion technology. Ground testing will occur at various test centers based on each center's expertise. Testing at the NASA John C. Stennis Space Center will be primarily concentrated on combined-cycle power pack and engine systems at sea level conditions at a dedicated test facility, E-4. This paper highlights the status of the SSC E-4 test Facility design.

Ryan, Harry↗

New Developments in Retropropulsion Testing for Mars Entry, Descent and Landing

NASA’s plans for landing human-scale payloads on Mars in the next decade require that retrorockets be used to decelerate the atmospheric entry vehicle continuously from supersonic conditions through soft touchdown. Conventional Mars entry vehicle architectures that include a single parachute for supersonic-to-subsonic descent are not scalable to the sizes needed to land humans on Mars (~20 metric tons). The major aerosciences risks are the uncertainties in predicting aerodynamic stability and performance during powered free-flight and landing. These risks are influenced partially by current limitations in relevant data and testing methods. Consequently, trajectory simulations currently depend on unvalidated powered descent and landing aerodynamics models. NASA engineers have identified gaps in testing methods that, if addressed, would improve the ability to validate these models. There are gaps in capabilities to test multi-engine hot-gas retropropulsion systems in US wind tunnels. This is partially due to the successful use of parachutes as decelerators for human spaceflight at Earth and for the entire Mars lander program to date. Retropulsion test data historically and to this day are limited to using high pressure air jets, at comparatively low temperatures,as engine plume simulants on subscale wind tunnel models. Additionally, the ability to directly measure aerodynamic interference force and moments is limited by existing flow-through balance capabilities. This paper briefly covers historical and recent test data, and identifies new ground test techniques as a means to provide more relevant test data for powered flight and landing aerodynamic model validation.These techniques include using heated inert gases as a substitute for combustion products, additively manufactured 6-component flow-through force and moment balances, and off-body quantitative diagnostic measurements.

Retropropulsion↗

Spacecraft Priming Analysis and Research Test Apparatus: Number 1 (SPARTAN 1), Test and Analysis Results

Spacecraft with Earth-storable propellants are required by range safety to launch with propellant isolated from the thrusters for ground operations, which is often accomplished by placing a pyrotechnic, or a latching isolation valve between the tank and the thrusters. Once on-orbit, downstream lines are vented out to space through the thrusters and are left evacuated and at vacuum pressure. Propellant isolation valve then opens and floods the lines with high velocity propellant which can lead to a significant pressure surge upon filling. Replicating this event during ground testing using water as a propellant simulant has always been difficult and costly to accurately perform due to the low vacuum pressure targeted on the downstream side of the system. This report describes the Spacecraft Priming Analysis and Research Test Apparatus (SPARTA) at Marshall Space Flight Center’s (MSFC) Component Development Area (CDA) and the initial test series meant to be a pathfinder for construction methods and test procedures to reduce the cost of future testing. The test data collected are critical to analytical models as the details to replicate prior ground tests are often lacking in enough detail to adequately model the test that was conducted. This report also describes the Thermal Desktop/FloCAD analysis that was performed alongside the test series. The test methods defined for this campaign showed a dramatic improvement on heritage test procedures. Test pace increased due to faster drying and pulling vacuum more effectively. Results generated in this test matched analytical predictions very well and provide a releasable set of test data to be leveraged on future NASA and commercial partner spacecraft development programs.

spacecraft↗

NASA's Unsteady Pressure-Sensitive Paint Research and Operational Capability Developments

In the last three years, several advancements have been made to produce a new state-of-the-art capability in the field of Aerosciences. NASA’s Aerosciences Evaluations and Test Capabilities (AETC) Portfolio Office has funded a multi-year project to produce the unsteady Pressure-Sensitive Paint (uPSP) technology as an operational capability in key ground test facilities at NASA. The research and development has primarily been conducted at NASA Ames Research Center’s (ARC) Unitary Plan Wind Tunnel (UPWT) 11-by 11-ft Transonic Wind Tunnel (TWT). The NASA ARC UPWT is one of the ground test facilities under NASA AETC’s Portfolio Office. AETC’s goals are to provide the tools to deliver the technology innovations and breakthroughs necessary to address increasingly complex research and development challenges. AETC’s integrated approach will consider the complimentary high-end compute capabilities necessary to advance analysis in conjunction with ground experimental capabilities. The uPSP Capability Challenge Project is a demonstration of several different technologies: 1) the unsteady Pressure-Sensitive Paint (uPSP) technology, and 2) Project: Red Rover, establishing a secure, reliable, fast connection between experimental and computation facilities, leveraging NASA’s computational resources within the High-End Compute Capability (HECC) Project for processing, storing, and sharing data efficiently. This project demonstrates the technical diversity and technical inclusion need to advance the field of Aerosciences. The approach to combine subject matter experts in experimental methods, optical methods, production wind tunnel testing, network engineering, high-end computing, signal processing, grid generation, and visualization while establishing the required infrastructure for subject matter experts to have access to the data while the wind tunnel test is being conducted. The most recent advancements for the uPSP technology have focused on three key areas: development of data products, robust processing pipeline, operational efficiencies and uncertainty quantification.

buffet↗

Traction Control Design and Integration Onboard the Mars Science Laboratory Curiosity Rover

The Mars Science Laboratory (MSL) Curiosity rover experienced increasing wheel damage beginning in October 2013. While the wheels were designed to operate with considerable damage, the rate at which damage was occurring was unexpected and raised concerns regarding wheel lifetime. The Jet Propulsion Laboratory (JPL) has now developed and deployed new software on Curiosity that reduces the forces acting on the wheels. Our new Traction Control algorithm adapts each wheel’s speed to fit the terrain it drives over. It does not rely on any a priori knowledge of the terrain, and instead leverages the rover’s measured attitude rates and suspension angles, together with a rigid-body kinematics model, to estimate the real-time wheel-terrain contact angles and ideal, no-slip wheel angular rates. In addition, free-floating “wheelies” are detected and autonomously corrected. In this paper, we describe the algorithm, its ground testing campaign and associated challenges, and finally its validation and performance in flight. Ground test data demonstrates reductions in the forces acting on the wheels and validates the wheelie-damping capability. Secondary benefits in some terrains include a reduction in heading deviations while climbing rocks, with a reduction in slip in certain sandy terrains. Preliminary validation from flight data confirms these findings.

Maimone, Mark↗

Modeling Entry Systems to Explore Our Solar System

Exploration of our Solar System is a foundational element of NASA’s identity. Delivering a scientific payload through an atmosphere to the surface of a planetary body requires safely navigating the extreme temperatures and stresses generated by flying many times the speed of sound. An entry system is the outer shell of a vehicle designed to protect the payload and, as a single point of failure for a mission, reliability is paramount. Unfortunately, it is not possible to fully replicate the flight environment in ground test facilities – so how do we confidently design a vehicle that needs to work the first time, every time? Modeling and simulation are critical tools for filling gaps in ground test capability and providing traceability from ground to flight. Modeling an entry system is a truly interdisciplinary effort, requiring knowledge of fluid dynamics, high-temperature chemistry, radiation, materials science, structural dynamics, guidance and control – and, finally, the mathematical and computing capability to pull it all together. In this talk, Dr. Michael Barnhardt will discuss the latest research in modeling entry systems and how it is being used in NASA’s exploration missions.

Entry systems↗

Thermal Desktop Modeling of the 2016 CRYOTE-2 Tank Chill and Fill Tests

The storing and transfer of cryogenic propellants is an enabling technology for NASA as it moves to expand future missions into low Earth orbit (LEO) and beyond. The transfer of cryogenic propellants is of particular interest because it has never been successfully demonstrated in microgravity. Several ground tests have been conducted in past decades examining various tank chilldown and fill methods. Creating accurate models using these historical datasets is a vital step toward developing appropriate modeling tools to form pre-test predictions for eventual flight and ground tests of various novel injector concepts. The goal of this work was to create a working model in Thermal Desktop using data from the CRYOTE-2 experiments whose purpose was to demonstrate the chill and fill process in a spherical receiver tank parametrically examining the effect of injection method, receiver tank initial wall temperature and initial state, supply pressure, and mass flow rate on the NVF process. These tests were conducting using liquid nitrogen with different injectors with different injection patterns. The focus of the current work is on one particular spray nozzle. The pressure rise inside the tank, the fill level, and the change in the outside wall temperature were all tracked and compared with test data. The Thermal Desktop model was able to accurately predict each of these metrics for this nozzle within 11.0%, 22.0%, and 7.0%, respectively.

Cryogenic Tank Chilldown↗