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NASA NTRS2004

A General Overview of the Data Acquisition and Controls Systems (DACS) of the E-Complex at NASA's Stennis Space Center

The John C. Stennis Space Center (SSC) provides test operations services to a variety of customers, including NASA, DoD, and commercial enterprises for the development of current and next-generation rocket propulsion systems. Many of these testing services are provided in the E-Complex test facilities composed of three active test stands (E1, E2, & E3) and 7 total test positions. Each test position is outfitted with unique sets of data acquisition and controls hardware and software that record both facility and test article data and enable safe operation of the test facility. This paper addresses each system in more detail including efforts to upgrade hardware and software.

Hughes, Mark S.↗

NASA NTRS2005

Development of a Work Control System for Propulsion Testing at NASA Stennis

In 1996 Stennis Space Center was given management authority for all Propulsion Testing for NASA. Over the next few years several research and development (R&D) test facilities were completed and brought up to full operation in what is known as the E-Complex Test Facility at Stennis Space Center. To construct, activate and operate these test facilities, a manual paper-based work control system was created. After utilizing this paper-based work control system for approximately three years, it became apparent that the research and development test area needed a better method to execute, monitor, and report on tasks required to further propulsion testing. The paper based system did not provide the engineers adequate visibility into work tasks or the tracking of testing or hardware discrepancies. This system also restricted the engineer s ability to utilize and access past knowledge and experiences given the severe schedule limitations for most R&D propulsion testing projects. Therefore a system was developed to meet the growing need of Test Operations called the Propulsion Test Directorate (PTD) Work Control System. This system is used to plan, perform, and track tasks that support testing and also to capture lessons learned while doing so.

Messer, Elizabeth A.↗

NASA NTRS1976

Langley facility for tests at Mach 7 of subscale, hydrogen-burning, airframe-integratable, scramjet models

Modifications to a 20-megawatt arc-heated facility for testing a hydrogen-burning, airframe-integratable, subscale, scramjet model are described. Arc-heated flow is mixed with unheated air to furnish a test flow duplicating Mach 7 flight. (Stagnation temperature is 2220 K.) Modifications to the commercially available heater to improve survivability and smoothness are described. Pitot profiles show uniform flow and a slightly thinner nozzle boundary layer than predicted. Comparison of the tunnel boundary layer, which will be ingested by the engine model, with the boundary layer that a flight engine might ingest from its vehicle forebody shows a difference in the density distribution through the boundary layer. Calculations of wall heating and transient wall temperatures of the engine model show that for a 30-sec burn, the heat sink model requires cooling at selected locations to avoid thermal-stress, cycle-life problems. Model performance predictions show that fuel equivalence ratio and nozzle exit area both have large effects on thrust. Average inlet entrance Mach number (as affected by boundary-layer ingestion) has little effect on thrust.

Boatright, W. B.↗

NASA NTRS2010

Altitude Testing of Large Liquid Propellant Engines

The National Aeronautics and Space Administration entered a new age on January 14, 2004 with President Bush s announcement of the creation the Vision for Space Exploration that will take mankind back to the Moon and on beyond to Mars. In January, 2006, after two years of hard, dedicated labor, engineers within NASA and its contractor workforce decided that the J2X rocket, based on the heritage of the Apollo J2 engine, would be the new engine for the NASA Constellation Ares upper stage vehicle. This engine and vehicle combination would provide assured access to the International Space Station to replace that role played by the Space Shuttle and additionally, would serve as the Earth Departure Stage, to push the Crew Excursion Vehicle out of Earth Orbit and head it on a path for rendezvous with the Moon. Test as you fly, fly as you test was chosen to be the guiding philosophy and a pre-requisite for the engine design, development, test and evaluation program. An exhaustive survey of national test facility assets proved the required capability to test the J2X engine at high altitude for long durations did not exist so therefore, a high altitude/near space environment testing capability would have to be developed. After several agency concepts the A3 High Altitude Testing Facility proposal was selected by the J2X engine program on March 2, 2007 and later confirmed by a broad panel of NASA senior leadership in May 2007. This facility is to be built at NASA s John C. Stennis Space Center located near Gulfport, Mississippi. 30 plus years of Space Shuttle Main Engine development and flight certification testing makes Stennis uniquely suited to support the Vision For Space Exploration Return to the Moon. Propellant handling infrastructure, engine assembly facilities, a trained and dedicated workforce and a broad and varied technical support base will all ensure that the A3 facility will be built on time to support the schedule needs of the J2X engine and the ultimate flight of the first Ares I vehicle. The A3 facility will be able to simulate pre-ignition altitude from sea-level to 100,000 feet and maintain it up to 650 seconds. Additionally the facility will be able to accommodate initial ignition, shutdown and then restart test profiles. A3 will produce up to 5000 lbm/sec of superheated steam utilizing a Chemical Steam generation system. Two separate inline steam ejectors will be used to produce a test cell vacuum to simulate the 100,000 ft required altitude. Operational capability will ensure that the facility can start up and shutdown without producing adverse pressure gradients across the J2X nozzle. The facility will have a modern thrust measurement system for accurate determination of engine performance. The latest advances in data acquisition and control will be incorporated to measure performance parameters during hotfire testing. Provisions are being made in the initial design of the new altitude facility to allow for testing of other, larger engines and potential upper stage launch vehicles that might require vacuum start testing of the engines. The new facility at Stennis Space Center will be complete and ready for hotfire operations in late 2010.

Maynard, Bryon T.↗

NASA NTRS2005

Rehabilitation of the Rocket Vehicle Integration Test Stand at Edwards Air Force Base

Since initial use in 1958 for the X-15 rocket-powered research airplane, the Rocket Engine Test Facility has proven essential for testing and servicing rocket-powered vehicles at Edwards Air Force Base. For almost two decades, several successful flight-test programs utilized the capability of this facility. The Department of Defense has recently demonstrated a renewed interest in propulsion technology development with the establishment of the National Aerospace Initiative. More recently, the National Aeronautics and Space Administration is undergoing a transformation to realign the organization, focusing on the Vision for Space Exploration. These initiatives provide a clear indication that a very capable ground-test stand at Edwards Air Force Base will be beneficial to support the testing of future access-to-space vehicles. To meet the demand of full integration testing of rocket-powered vehicles, the NASA Dryden Flight Research Center, the Air Force Flight Test Center, and the Air Force Research Laboratory have combined their resources in an effort to restore and upgrade the original X-15 Rocket Engine Test Facility to become the new Rocket Vehicle Integration Test Stand. This report describes the history of the X-15 Rocket Engine Test Facility, discusses the current status of the facility, and summarizes recent efforts to rehabilitate the facility to support potential access-to-space flight-test programs. A summary of the capabilities of the facility is presented and other important issues are discussed.

Jones, Daniel S.↗

NASA NTRS1994

Pressure Control System Design for a Closed Crop Growth Chamber

The Controlled Ecological Life Support System (CELSS) is an area of active research at NASA. CELSS is a plant-based bioregenerative life support system for long term manned space flights where resupply is costly or impractical. The plants in a CELSS will function to convert the carbon dioxide (exhaled by the crew) into oxygen, purify non-potable water into potable quality water, and provide food for the crew. Prior to implementing a CELSS life support system, one must have knowledge on growing plants in a closed chamber under low gravity. This information will come from research to be conducted on the CELSS Test Facility that will operate on the Space Station Freedom. Currently a ground-based CELSS Test Facility is being built at NASA Ames Research Center. It is called the EDU (Engineering Development Unit). This system will allow researchers to identify issues that may cause difficulties in the development of the CELSS Test Facility and aid in the development of new needed technologies. The EDU consists of a 1 m2 crop growth chamber that is surrounded by a containment enclosure. The containment enclosure isolates the system so there is very little mass and thermal exchange with the ambient. The leakage rate is on the order of 1 % of the enclosure's volume per day (with 0.2S psi pressure difference). The thermal leakage is less than 0.5% of the electrical power supplied to the system per degree Celsius difference from the surrounding. The pressure in the containment enclosure is regulated at 62.5 Pa below the ambient by an active controller. The goal is to maintain this set point for a variety of conditions, such as a range of operating temperatures, heat load variations that occur when the lights are turned on and off, and fluctuations in ambient pressure. In addition certain transition tracking performance is required. This paper illustrates the application of some advanced systems control methods to the task of synthesizing the EDU's pressure control system.

Tsai, K.↗

NASA NTRS1993

A new facility for advanced rocket propulsion research

A new test facility was constructed at the NASA Lewis Research Center Rocket Laboratory for the purpose of conducting rocket propulsion research at up to 8.9 kN (2000 lbf) thrust, using liquid oxygen and gaseous hydrogen propellants. A laser room adjacent to the test cell provides access to the rocket engine for advanced laser diagnostic systems. The size and location of the test cell provide the ability to conduct large amounts of testing in short time periods, with rapid turnover between programs. These capabilities make the new test facility an important asset for basic and applied rocket propulsion research.

Zoeckler, Joseph G.↗

NASA NTRS1975

Facility and test support equipment for the manned thermal vacuum tests of the Apollo Soyuz docking module

In order to accommodate manned thermal-vacuum testing of the Apollo-Soyuz docking module (ASDM), modifications to the facility, cleanliness and access control, and special test equipment were required. Facility modifications discussed briefly include: the addition of an oxygen supply system; the modification of manlock (ML) piping for cleaning and access controls; the addition of a nitrogen diluent system; the removal of manlock internal lights and the addition of external lights as well as fusing all power circuits over 10 watts; the removal/containment of flammable materials; the upgrading of a ML fire suppression system; and the addition of a garment donning station for cleanliness control. Special test equipment discussed include: an access tunnel for crew ingress/egress; a support device for the docking module (DM) and simulators; a command module thermal simulator; a DM infrared (IR) simulator; a docking system IR simulator; a metabolic heat load simulator; and a television camera simulator.

Pearson, O. L.↗

NASA NTRS2001

A High-Lift Building Block Flow: Turbulent Boundary Layer Relaminarization

A working wind tunnel test facility has been constructed at the University of Notre Dame's Hessert Center. The relaminarization test facility has been constructed in the 1.5m x 1.5m (5ft x 5 ft) atmospheric wind tunnel and generates a Re(theta)=4694 turbulent boundary layer in nominally zero-pressure gradient before it is exposed to the Case #1 pressure gradient (K approximately equal to 4.2 x 10(exp -6), which is believed to be sufficient to achieve relaminarization. Future work to be conducted will include measuring the response of the turbulent boundary layer to the favorable pressure gradients created in the test facility and documenting this response in order to understand the underlying flow physics responsible for relaminarization. It is the goal of this research to have a better understanding of accelerated turbulent boundary layers which will aid in the development of future flow diagnostic utilities to be implemented in applied aerodynamic research.

Bourassa, Corey↗

NASA NTRS2011

Morpheus Lander Testing Campaign

NASA s Morpheus Project has developed and tested a prototype planetary lander capable of vertical takeoff and landing designed to serve as a testbed for advanced spacecraft technologies. The Morpheus vehicle has successfully performed a set of integrated vehicle test flights including hot-fire and tether tests, ultimately culminating in an un-tethered "free-flight" This development and testing campaign was conducted on-site at the Johnson Space Center (JSC), less than one year after project start. Designed, developed, manufactured and operated in-house by engineers at JSC, the Morpheus Project represents an unprecedented departure from recent NASA programs and projects that traditionally require longer development lifecycles and testing at remote, dedicated testing facilities. This paper documents the integrated testing campaign, including descriptions of test types (hot-fire, tether, and free-flight), test objectives, and the infrastructure of JSC testing facilities. A major focus of the paper will be the fast pace of the project, rapid prototyping, frequent testing, and lessons learned from this departure from the traditional engineering development process at NASA s Johnson Space Center.

Hart, Jeremy J.↗

NASA NTRS1990

Scramjet testing from Mach 4 to 20 - Present capability and needs for the nineties

Consideration is given to the development of testing methods for the National Aerospace Plane (NASP) program, focusing on techniques for simulating and testing scramjet engines and scramjet engine components during flight from Mach 4 to Mach 20. The flight conditions associated with the NASP are outlined and the stagnation temperatures and pressures required to simulate flight up to orbital speeds are presented. The types of test facilities needed for scramjet propulsion testing are discussed, including combustion-heated facilities, electric arc-heated facilities, convection-heated facilities, shock tunnels, and expansion tubes. Issues related to assessing the flow quality in the scramjet ground testing facilities are examined, including uniformity, contamination, dissociation, ionization, nonequilibrium, and turbulence. Direct-connect combustor versus free-jet scramjet engine tests are compared and the capabilities of current and near-future scramjet engine test facilities are evaluated.

Thomas, Scott R.↗

NASA NTRS1992

Development of a skin friction gauge for use in an impulse facility

Tests of a prototype skin friction gauge at Mach 3.2 in a small free piston shock tunnel demonstrate the effectiveness of the design concept and the calibration against theoretical skin friction values in a simple flow. The gauge has a rise time of about 20 microsec, sufficiently short for most shock tunnel applications and approaching the rise times needed for expansion tube applications.

Kelly, G. M.↗

NASA NTRS1998

Modeling of a Two-Phase Jet Pump with Phase Change, Shocks and Temperature-Dependent Properties

One of the primary motivations behind this work is the attempt to understand the physics of a two-phase jet pump which constitutes part of a flow boiling test facility at NASA-Marshall. The flow boiling apparatus is intended to provide data necessary to design highly efficient two-phase thermal control systems for aerospace applications. The facility will also be capable of testing alternative refrigerants and evaluate their performance using various heat exchangers with enhanced surfaces. The test facility is also intended for use in evaluating single-phase performance of systems currently using CFC refrigerants. Literature dealing with jet pumps is abundant and covers a very wide array of application areas. Example application areas include vacuum pumps which are used in the food industry, power station work, and the chemical industry; ejector systems which have applications in the aircraft industry as cabin ventilators and for purposes of jet thrust augmentation; jet pumps which are used in the oil industry for oil well pumping; and steam-jet ejector refrigeration, to just name a few. Examples of work relevant to this investigation includes those of Fairuzov and Bredikhin (1995). While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the author apart from that of Anand (1992) who was able to account for condensation shocks. Thus, one of the objectives of this work is to model the dynamics of fluid interaction between a two-phase primary fluid and a subcooled liquid secondary fluid which is being injected employing atomizing spray injectors. The model developed accounts for phase transformations due to expansion, compression, and mixing. It also accounts for shock waves developing in the different parts of the jet pump as well as temperature and pressure dependencies of the fluid properties for both the primary two-phase mixture and the secondary subcooled liquid. The research effort on which this document partly reports described a relatively simple model capable of describing the performance of a two-phase flow jet pump. The model is based on the isentropic homogeneous expansion/compression hypothesis and is capable of fully incorporating the effects of shocks in both the mixing chamber and the throat/diffuser parts of the pump. The physical system chosen is identical to that experimentally tested by Fairuzov and Bredikhin (1995) and should therefore be relatively easy to validate.

Sherif, S. A.↗

NASA NTRS1975

Supersonic CO electric-discharge lasers

Laser modeling activity is described which involved addition of an option allowing N2 as a second diatomic gas. This option is now operational and a few test cases involving N2/CO mixtures were run. Results from these initial test cases are summarized. In the laboratory, a CW double-discharge test facility was constructed and tested. Features include: water-cooled removable electrodes, O-ring construction to facilitate cleaning and design modifications, increased discharge length, and addition of a post-discharge observation section. Preliminary tests with this facility using N2 yielded higher power loadings than obtained in the first-generation facility. Another test-section modification, recently made and as yet untested, will permit injection of secondary gases into the cathode boundary layer. The objective will be to vary and enhance the UV emission spectrum from the auxiliary discharge, thereby influencing the level of photoionization in the main discharge region.

Hason, R. K.↗

NASA NTRS1994

John C. Stennis Space Center Overview

An overview of research being conducted at the John C. Stennis Space Center is given. The Space Center is not only a NASA Space Flight Center, but also houses facilities for 22 other governmental agencies. The programs described are Stennis' High Heat Flux Facility, the Component Test Facility (used to test propulsion rockets and for the development of the National Aerospace Plane), oceanographic and remote sensing research, and contributions to the development of Space Station Freedom.

Source record↗

NASA NTRS2010

Investigating Dynamics of Eccentricity in Turbomachines

A methodology (and hardware and software to implement the methodology) has been developed as a means of investigating coupling between certain rotordynamic and hydrodynamic phenomena in turbomachines. Originally, the methodology was intended for application in an investigation of coupled rotordynamic and hydrodynamic effects postulated to have caused high synchronous vibration in the space shuttle s high-pressure oxygen turbopump (HPOTP). The methodology can also be applied in investigating (for the purpose of developing means of suppressing) undesired hydrodynamic rotor/stator interactions in turbomachines in general. The methodology and the types of phenomena that can be investigated by use of the methodology are best summarized by citing the original application as an example. In that application, in consideration of the high synchronous vibration in the space-shuttle main engine (SSME) HPOTP, it was determined to be necessary to perform tests to investigate the influence of inducer eccentricity and/or synchronous whirl motion on inducer hydrodynamic forces under prescribed flow and cavitation conditions. It was believed that manufacturing tolerances of the turbopump resulted in some induced runout of the pump rotor. Such runout, if oriented with an inducer blade, would cause that blade to run with tip clearance smaller than the tip clearances of the other inducer blades. It was hypothesized that the resulting hydraulic asymmetry, coupled with alternating blade cavitation, could give rise to the observed high synchronous vibration. In tests performed to investigate this hypothesis, prescribed rotor whirl motions have been imposed on a 1/3-scale water-rig version of the SSME LPOTP inducer (which is also a 4-biased inducer having similar cavitation dynamics as the HPOTP) in a magnetic-bearing test facility. The particular magnetic-bearing test facility, through active vibration control, affords a capability to impose, on the rotor, whirl orbits having shapes and whirl rates prescribed by the user, and to simultaneously measure the resulting hydrodynamic forces generated by the impeller. Active control also made it possible to modulate the inducer-blade running tip clearance and consequently effect alternating blade cavitation. The measured hydraulic forces have been compared and correlated with shroud dynamic-pressure measurements.

Baun, Daniel↗

NASA NTRS1999

Pre-Flight Testing of Spaceborne GPS Receivers using a GPS Constellation Simulator

The NASA Goddard Space Flight Center (GSFC) Global Positioning System (GPS) applications test facility has been established within the GSFC Guidance Navigation and Control Center. The GPS test facility is currently housing the Global Simulation Systems Inc. (GSSI) STR2760 GPS satellite 40-channel attitude simulator and a STR4760 12-channel navigation simulator. The facility also contains a few other resources such as an atomic time standard test bed, a rooftop antenna platform and a radome. It provides a new capability for high dynamics GPS simulations of space flight that is unique within the aerospace community. The GPS facility provides a critical element for the development and testing of GPS based technologies i.e. position, attitude and precise time determination used on-board a spacecraft, suborbital rocket balloon. The GPS simulation system is configured in a transportable rack and is available for GPS component development as well as for component, spacecraft subsystem and system level testing at spacecraft integration and tests sites. The GPS facility has been operational since early 1996 and has utilized by space flight projects carrying GPS experiments, such as the OrbView-2 and the Argentine SAC-A spacecrafts. The SAC-A pre-flight test data obtained by using the STR2760 simulator and the comparison with preliminary analysis of the GPS data from SAC-A telemetry are summarized. This paper describes pre-flight tests and simulations used to support a unique spaceborne GPS experiment. The GPS experiment mission objectives and the test program are described, as well as the GPS test facility configuration needed to verify experiment feasibility. Some operational and critical issues inherent in GPS receiver pre-flight tests and simulations using this GPS simulation, and test methodology are described. Simulation and flight data are presented. A complete program of pre-flight testing of spaceborne GPS receivers using a GPS constellation simulator is detailed.

Kizhner, Semion↗

NASA NTRS1999

Pre-Flight Testing of Spaceborne GPS Receivers Using a GPS Constellation Simulator

The NASA Goddard Space Flight Center (GSFC) Global Positioning System (GPS) applications test facility has been established within the GSFC Guidance Navigation and Control Center. The GPS test facility is currently housing the Global Simulation Systems Inc. (GSSI) STR2760 GPS satellite 40-channel attitude simulator and a STR4760 12-channel navigation simulator. The facility also contains a few other resources such as an atomic time standard test bed, a rooftop antenna platform and a radome. It provides a new capability for high dynamics GPS simulations of space flight that is unique within the aerospace community. The GPS facility provides a critical element for the development and testing of GPS based technologies i.e. position, attitude and precise time determination used on-board a spacecraft, suborbital rocket or balloon. The GPS simulator system is configured in a transportable rack and is available for GPS component development as well as for component, spacecraft subsystem and system level testing at spacecraft integration and test sites. The GPS facility has been operational since early 1996 and has been utilized by space flight projects carrying GPS experiments, such as the OrbView-2 and the Argentine SAC-A spacecrafts. The SAC-A pre-flight test data obtained by using the STR2760 simulator and the comparison with preliminary analysis of the GPS data from SAC-A telemetry are summarized. This paper describes pre-flight tests and simulations used to support a unique spaceborne GPS experiment. The GPS experiment mission objectives and the test program are described, as well as the GPS test facility configuration needed to verify experiment feasibility. Some operational and critical issues inherent in GPS receiver pre-flight tests and simulations using this GPS simulator, and test methodology are described. Simulation and flight data are presented. A complete program of pre-flight testing of spaceborne GPS receivers using a GPS constellation simulator is detailed.

Kizhner, Semion↗