TFAWS Short Course - Thermal Testing
This short course will review the basics of thermal vacuum testing, including some Goddard history, and the development of our GEVS document.
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This short course will review the basics of thermal vacuum testing, including some Goddard history, and the development of our GEVS document.
The testing of a thermal protection system (TPS) in multiple arc jets and laser facilities is critical not only to determine the ability of a material to withstand the harsh aerothermal environments but is also required to collect relevant data that allows construction of a thermal response model of the TPS for flight design. The present talk provides an overview of recent arcjet testing of the HEEET material, one of the families of materials from the 3D Woven TPS program, being developed under NASAs Heatshield for Extreme Entry Environment Technology (HEEET) project.
In January, 1964, a test program was begun on the thermal design of the Ranger Block III Spacecraft. The tests were performed i n the newly operational JPL 25' Space Simulator over a period of 6 months . The objectives of these tests were two-fold: A. To evaluate the 25' Space Simulator as a facility for proving the thermal design of spacecrafts, and B. To verify .the thermal design of the Ranger Block III spacecraft. These two objectives are complimentary in the test series performed and are difficult to separate into distinct categories. An important part of the first objective was to learn what type of test preparation, instrumentation, and analysis was required for the meaningful evaluation of test data from the 25' Space Simulator tests. Although some experience had been gained in testing of components and incomplete spacecrafts in smaller solar simulation chambers during the early part of the Ranger program, we knew little about testing of a complete spacecraft in the 25' Space Simulator when this test program began. Test analysis requires that the energy absorbed by various spacecraft components be known. This requires a knowledge of the area of solar absorption or sunlit area, the solar energy flux density on the area, and the effective absorptance of that area. Most of the problems encountered were associated with the determination of the last two quantities since the sunlit area may be obtained directly by inspection of spacecraft surfaces. This paper will present a discussion of our experiences during the Ranger Block III thermal test series on the Thermal Test Model (TCM). The TCM was thermally equivalent to the flight type Ranger spacecraft except for the lack of an antenna dish and solar panels. Flight type structural hardware was used with surface finishes equivalent to those of the flight spacecraft. Aluminum blocks simulated the spacecraft electronics thermal masses with resistance heaters simulating the electronic power dissipation. The discussion will be presented in a semi-chronological order and will be divided into the following areas: 1. Determination of solar simulation flux density on spacecraft surfaces. 2. Problems related to decollimation of the solar simulation source. 3. Determination of effective absorptance in the solar simulation spectrum.
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Two effects of noncollimation of solar light beams in spacecraft thermal testing simulation chamber
Thermal performance tests that were conducted on the life sciences passive GN2 freezer project are summarized as well as the improvements to the freezers to improve the thermal performance of the containers. Procedures were developed, based upon these tests, to initially charge the freezers with LN2 and verify that the freezer performance is adequate for the mission duration. Improvements were made to the corvac sample tube to limit the amount of breakage due to thermal expansion of the liquid during freezing. A method of verifying the freezer vacuum insulative integrity was defined as well as a procedure for refurbishment of the internal vacuum level. Freezer modifications were made to ease the reevacuation of the containers. The orientation of the freezer in a 1-G environment, after being charged, had to remain in a vertical position. The LN2 boiloff rate increased significantly in a horizontal position. This resulted in a stowage definition in the spacecraft prior to launch. Functional testing, using the SL-1 mission timeline showed that the freezer will maintain samples in the frozen state for the duration of the mission.
When embarking on a retrofit of a building envelope, it is critical to understand the composition of its assembly. This practice is currently done by destructive and invasive material testing or demolition, which is sometimes not possible when in historic or protected buildings. To address this problem, in-situ thermal testing can be utilized along with machine learning classification algorithms to infer the composition of an assembly. In this paper, a proof-of-concept K-nearest neighbors classification model is developed to classify assembly composition from effective thermal resistance, effective thermal mass, and assembly cladding. This model was trained and tested utilizing a synthetic dataset producing an F1-score of 94.6%. This model was also validated with experimental data from a 100-year old wall assembly, confirming the model’s real-world validity. The paper presents a framework for inferring as-built envelope assemblies, all without having to damage or disturb the building and its occupants.
Sandia National Laboratories has been tasked to operate and maintain the National Solar Thermal Test Facility (NSTTF) located in Kirtland Airforce Base near Albuquerque, NM. The NSTTF provides established test platforms and experienced researchers and technologists in the field of Concentrating Solar Technologies (CST) and Concentrating Solar Power (CSP). This three-year project seeks to maintain the NSTTF for development, testing, and application of new CSP technologies that are instrumental in advancing the state-of-the-art in support of SunShot and Generation 3 CSP technology goals. In turn, these technologies will form the foundation of the global CSP industry and continue to advance the technology to new levels of efficiency, higher temperatures, lower costs, lower risk, and higher reliability. The NSTTF provides established test platforms and highly experienced researchers and technologists in the CSP field.
The verification and certification of new structural material concepts for advanced high speed flight vehicles relies greatly on thermal testing with infrared quartz lamps. The basic quartz heater system characteristics and design considerations are presented. Specific applications are illustrated with tests that were conducted for the X-15, the Space Shuttle, and YF-12 flight programs.
Optimal design for improving thermal performance of existing spacecraft thermally actuated louver system by increasing open-to-closed emittance ratio
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In this study, the Integrated Data Collection Analysis (IDCA) program has conducted a proficiency test for small-scale safety and thermal (SSST) testing of homemade explosives (HMEs). Described here are statistical analyses of the results from this test for impact, friction, electrostatic discharge, and differential scanning calorimetry analysis of the RDX Class 5 Type II standard. The material was tested as a well-characterized standard several times during the proficiency test to assess differences among participants and the range of results that may arise for well-behaved explosive materials.
The James Webb Space Telescope (JWST), successor to the Hubble Space Telescope, will be the largest astronomical telescope ever sent into space. To observe the very first light of the early universe, JWST requires a large deployed 6.5-meter primary mirror cryogenically cooled to less than 50 Kelvin. Three scientific instruments are further cooled via a large radiator system to less than 40 Kelvin. A fourth scientific instrument is cooled to less than 7 Kelvin using a combination pulse-tube Joule-Thomson mechanical cooler. Passive cryogenic cooling enables the large scale of the telescope which must be highly folded for launch on an Ariane 5 launch vehicle and deployed once on orbit during its journey to the second Earth-Sun Lagrange point. Passive cooling of the observatory is enabled by the deployment of a large tennis court sized five layer Sunshield combined with the use of a network of high efficiency radiators. A high purity aluminum heat strap system connects the three instrument's detector systems to the radiator systems to dissipate less than a single watt of parasitic and instrument dissipated heat. JWST's large scale features, while enabling passive cooling, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone of most space missions' thermal verification plans. This paper describes the JWST Core 2 Test, which is a cryogenic thermal balance test of a full size, high fidelity engineering model of the Observatory's 'Core' area thermal control hardware. The 'Core' area is the key mechanical and cryogenic interface area between all Observatory elements. The 'Core' area thermal control hardware allows for temperature transition of 300K to approximately 50 K by attenuating heat from the room temperature IEC (instrument electronics) and the Spacecraft Bus. Since the flight hardware is not available for test, the Core 2 test uses high fidelity and flight-like reproductions.
Analysis of thermal test errors resulting from imperfectly collimated solar simulation beams - relative energy flux density and relative energy in penumbrae of various shadowing objects
This report details operations and maintenance (O&M) activities performed across Fiscal Years 2022 through 2024 in support of the continued capabilities of the National Solar Thermal Testing Facility (NSTTF) at Sandia National Laboratories. The NSTTF O&M project is funded by the U.S. Department of Energy Solar Energy Technologies Office (SETO) to support research activities and testing on behalf of external customers at the facility under award number CPS 38491. During the project period, the NSTTF made progress in the areas of site metrics, site maintenance and utilization tracking, and customer engagement. The O&M project also supported special initiatives including procurement of a heat exchanger for particle concentrating solar thermal processes and a scoping and cost study for refurbishment and repair of component in the NSTTF heliostat field.
In January 2004, two Mars Exploration Rovers (MER) landed on the surface of Mars to begin their mission as robotic geologists. A year prior to these historic landings, both rovers and the spacecraft that delivered them to Mars, were completing a series of environmental tests in facilities at the Jet Propulsion Laboratory. This paper describes the test program undertaken to validate the thermal design and verify the workmanship integrity of both rovers and the spacecraft. The spacecraft, which contained the rover within the aeroshell, were tested in a 7.5 m diameter thermal vacuum chamber. Thermal balance was performed for the near earth (hot case) condition and for the near Mars (cold case) condition. A solar simulator was used to provide the solar boundary condition on the solar array. IR lamps were used to simulate the solar heat load on the aeroshell for the off-sun attitudes experienced by the spacecraft during its cruise to Mars. Each rover was tested separately in a 3.0 m diameter thermal vacuum chamber over conditions simulating the warmest and coldest expected Mars diurnal temperature cycles. The environmental tests were conducted in a quiescent nitrogen atmosphere at a pressure of 8 to 10 Torr. In addition to thermal balance testing, the science instruments on board the rovers were tested successfully in the extreme environmental conditions anticipated for the mission. A solar simulator was not used in these tests.