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NASA NTRS1985

Design and testing of an energy-absorbing crewseat for the F/FB-111 aircraft. Volume 2: Data from seat testing

The unacceptably high injury rate during the escape sequence (including the ejection and ground impact) of the crew module for F/FB-111 aircraft is reviewed. A program to determine if the injury potential could be reduced by replacing the existing crewseats with energy absorbing crewseats is presented. An energy absorbing test seat is designed using much of the existing seat hardware. An extensive dynamic seat test series, designed to duplicate various crew module ground impact conditions is conducted at a sled test facility. Comparative tests with operational F-111 crewseats are also conducted. After successful dynamic testing of the seat, more testing is conducted with the seats mounted in an F-111 crew module. Both swing tests and vertical drop tests are conducted. The vertical drop tests are used to obtain comparative data between the energy absorbing and operational seats. Volume 1 describes the energy absorbing test seat and testing conducted, and evaluates the data from both test series. Volume 2 presents the data obtained during the seat test series, while Volume 3 presents the data from the crew module test series.

Shane, S. J.↗

NASA NTRS2010

HIFiRE Direct-Connect Rig (HDCR) Phase I Ground Test Results from the NASA Langley Arc-Heated Scramjet Test Facility

The initial phase of hydrocarbon-fueled ground tests supporting Flight 2 of the Hypersonic International Flight Research Experiment (HIFiRE) Program has been conducted in the NASA Langley Arc-Heated Scramjet Test Facility (AHSTF). The HIFiRE Program, an Air Force-lead international cooperative program includes eight different flight test experiments designed to target specific challenges of hypersonic flight. The second of the eight planned flight experiments is a hydrocarbon-fueled scramjet flight test intended to demonstrate dual-mode to scramjet-mode operation and verify the scramjet performance prediction and design tools. A performance goal is the achievement of a combusted fuel equivalence ratio greater than 0.7 while in scramjet mode. The ground test rig, designated the HIFiRE Direct Connect Rig (HDCR), is a full-scale, heat sink, direct-connect ground test article that duplicates both the flowpath lines and the instrumentation layout of the isolator and combustor portion of the flight test hardware. The primary objectives of the HDCR Phase I tests are to verify the operability of the HIFiRE isolator/combustor across the Mach 6.0-8.0 flight regime and to establish a fuel distribution schedule to ensure a successful mode transition prior to the HiFIRE payload Critical Design Review. Although the phase I test plans include testing over the Mach 6 to 8 flight simulation range, only Mach 6 testing will be reported in this paper. Experimental results presented here include flowpath surface pressure, temperature, and heat flux distributions that demonstrate the operation of the flowpath over a small range of test conditions around the nominal Mach 6 simulation, as well as a range of fuel equivalence ratios and fuel injection distributions. Both ethylene and a mixture of ethylene and methane (planned for flight) were tested. Maximum back pressure and flameholding limits, as well as a baseline fuel schedule, that covers the Mach 5.84-6.5 test space have been identified.

Hass, Neal E.↗

NASA NTRS2010

Ares I-X Flight Test Vehicle Modal Test

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, was launched on October 28, 2009. Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle was not practical within project constraints, modal tests for several configurations during vehicle stacking were defined to calibrate the FEM. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report describes the test requirements, constraints, pre-test analysis, test execution and results for the Ares I-X flight test vehicle modal test on the Mobile Launcher Platform. Initial comparisons between pre-test predictions and test data are also presented.

Buehrle, Ralph D.↗

NASA NTRS2013

Structural Benchmark Creep Testing for Microcast MarM-247 Advanced Stirling Convertor E2 Heater Head Test Article SN18

This report provides test methodology details and qualitative results for the first structural benchmark creep test of an Advanced Stirling Convertor (ASC) heater head of ASC-E2 design heritage. The test article was recovered from a flight-like Microcast MarM-247 heater head specimen previously used in helium permeability testing. The test article was utilized for benchmark creep test rig preparation, wall thickness and diametral laser scan hardware metrological developments, and induction heater custom coil experiments. In addition, a benchmark creep test was performed, terminated after one week when through-thickness cracks propagated at thermocouple weld locations. Following this, it was used to develop a unique temperature measurement methodology using contact thermocouples, thereby enabling future benchmark testing to be performed without the use of conventional welded thermocouples, proven problematic for the alloy. This report includes an overview of heater head structural benchmark creep testing, the origin of this particular test article, test configuration developments accomplished using the test article, creep predictions for its benchmark creep test, qualitative structural benchmark creep test results, and a short summary.

life (durability)↗

NASA NTRS2016

Hot-Fire Test Results of an Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged-Combustion Integrated Test Article

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. For the thrust chamber assembly of the test article, several configurations of new main injectors, using relatively conventional gas-centered swirl coaxial injector elements, were designed and fabricated. The design and fabrication of these main injectors are described in a companion paper at this JANNAF meeting. New ablative combustion chambers were fabricated based on hardware previously used at NASA for testing at similar size and pressure. An existing oxygen/RP-1 oxidizer-rich subscale preburner injector from a previous NASA-funded program, along with existing and new inter-connecting hot gas duct hardware, were used to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Results from independent hot-fire tests of the preburner injector in a combustion chamber with a sonic throat are described in companion papers at this JANNAF conference. The resulting integrated test article - which includes the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was assembled at Test Stand 116 at the East Test Area of the NASA Marshall Space Flight Center. The test article was well instrumented with static and dynamic pressure, temperature, and acceleration sensors to allow the collected data to be used for combustion analysis model development. Hot-fire testing was conducted with main combustion chamber pressures ranging from 1400 to 2100 psia, and main combustion chamber mixture ratios ranging from 2.4 to 2.9. Different levels of fuel film cooling injected from the injector face were examined ranging from none to about 12% of the total fuel flow. This paper presents the hot-fire test results of the integrated test article. Combustion performance, stability, thermal, and compatibility characteristics of both the preburner and the thrust chamber are described. Another companion paper at this JANNAF meeting includes additional and more detailed test data regarding the combustion dynamics and stability characteristics.

Hulka, J. R.↗

NASA NTRSDate not supplied

In-Situ Ice Adhesion Testing using the Deformed Skin Adhesion Test

There exists a plethora of ice adhesion testing methods such as centrifuge-based methods, push/pull methods, and lap joint shear tests. However, these methods often cannot be done in-situ during an icing spray and require researcher handling/preparation prior to testing. Additionally, many of these methods test ice accretions that are not representative of the ice shapes that grow on airframes which can have unintended consequences such as edge or corner stress concentrations. In order to mitigate the issues present with other ice adhesion tests a novel, hands-free, in-situ test method imbedded into the leading edge of the airfoil has been developed and tested in the NASA Glenn Research Center Icing Research Tunnel. The mechanics of the new test method are discussed with finite element simulations being used to highlight the fundamental mechanics of this test method. The testing procedures used during the experimental test campaign are discussed along with the icing cloud test matrix. Analysis of the force-displacement results highlights the repeatability of the test method with regards to both sample behavior across several days of testing and different ice shapes. The results from first run of the day showed a significant discrepancy from subsequent runs and differential image analysis was used to determine differences in the interfacial bonding states between runs.

Ice Adhesion↗

NASA NTRSDate not supplied

In-Situ Ice Adhesion Testing using the Deformed Skin Adhesion Test

Ice Adhesion↗

NASA NTRS1989

Transient Pressure Test Article Test Program

The Transient Pressure Test Article (TPTA) test program is being conducted at a new test facility located in the East Test Area at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC) in Huntsville, Alabama. This facility, along with the special test equipment (STE) required for facility support, was constructed specifically to test and verify the sealing capability of the Redesigned Solid Rocket Motor (RSRM) field, igniter, and nozzle joints. The test article consists of full scale RSRM hardware loaded with inert propellant and assembled in a short stack configuration. The TPTA is pressurized by igniting a propellant cartridge capable of inducing a pressure rise rate which stimulates the ignition transient that occurs during launch. Dynamic loads are applied during the pressure cycle to simulate external tank attach (ETA) strut loads present on the ETA ring. Sealing ability of the redesigned joints is evaluated under joint movement conditions produced by these combined loads since joint sealing ability depends on seal resilience velocity being greater than gap opening velocity. Also, maximum flight dynamic loads are applied to the test article which is either pressurized to 600 psia using gaseous nitrogen (GN2) or applied to the test article as the pressure decays inside the test article on the down cycle after the ignition transient cycle. This new test facility is examined with respect to its capabilities. In addition, both the topic of test effectiveness versus space vehicle flight performance and new aerospace test techniques, as well as a comparison between the old SRM design and the RSRM are presented.

Vibbart, Charles M.↗

NASA NTRS1991

A portable Ka-band front-end test package for beam-waveguide antenna performance evaluation. Part 2: Tests on the antenna

In part one of this article, a description was given of a Ka-band test package developed to enable testing of the Deep Space Station (DDS) 13 34-m beam-waveguide (BWG) antenna at 32 GHz. Test results were given for the Ka-band test package in an on-the-ground test configuration. This article is a companion article concerned with Ka-band test results for the test package in an on-the-antenna test configuration. Included are Ka-band zenith noise-temperature values, tipping-curve data, and subreflector test results obtained at the Cassegrain focal point, as well as at the final BWG focal point (located in a subterranean pedestal room). Test results show that, through the use of the Ka-band test package, the BWG antenna performance was successfully evaluated at Ka-band. The Ka-band test package operated well in all of the different antenna test configurations.

Otoshi, T. Y.↗

NASA NTRS2012

Correlation Results for a Mass Loaded Vehicle Panel Test Article Finite Element Models and Modal Survey Tests

High-fidelity Finite Element Models (FEMs) were developed to support a recent test program at Marshall Space Flight Center (MSFC). The FEMs correspond to test articles used for a series of acoustic tests. Modal survey tests were used to validate the FEMs for five acoustic tests (a bare panel and four different mass-loaded panel configurations). An additional modal survey test was performed on the empty test fixture (orthogrid panel mounting fixture, between the reverb and anechoic chambers). Modal survey tests were used to test-validate the dynamic characteristics of FEMs used for acoustic test excitation. Modal survey testing and subsequent model correlation has validated the natural frequencies and mode shapes of the FEMs. The modal survey test results provide a basis for the analysis models used for acoustic loading response test and analysis comparisons

Maasha, Rumaasha↗

NASA NTRS2017

Temporary Thermocouple Attachment for Thermal/Vacuum Testing at Non-Extreme Temperatures - Test Results

Post-test examination and data analysis that followed a two week long vacuum test showed that numerous self-stick thermocouples became detached from the test article. The thermocouples were reattached with thermally conductive epoxy and the test was repeated to obtain the required data. Because the thermocouple detachment resulted in significant expense and rework, it was decided to investigate the temporary attachment methods used around NASA and to perform a test to assess their efficacy. The present work describes the testing that was performed in early and mid-2017. The test article and the temporary thermocouple attachment methods tested are described. During the first test, fully half of the thermocouples detached - although the detachment showed subtly in the data for some. The second test was performed to confirm the data from the first test and to investigate the effect of test article and thermocouple grounding. The results of the testing over temperatures ranging from -150 to 200degF are detailed and preliminary recommendations are made for temporary thermocouple attachment methods.

Wright, Sarah E.↗

NASA NTRS2018

NASA Plum Brook Station In-Space Propulsion Facility Test Stand Characterization Hot Fire Test

A test facility modification to enable small scale altitude propulsion testing at the NASA Glenn Research Center's In-Space Propulsion (ISP) Facility was verified with a hot fire test campaign. As the facility's primary steam supply system undergoes refurbishment, the alternate facility configuration, known as the "vacuum accumulator" mode, would enable rocket engine testing up to 10,000 lbf thrust. The NASA Johnson Space Center developed the vehicle for the verification test campaign: the Integrated Cryogenic Propulsion Test Article (ICPTA). Constructed primarily from assets of the former Morpheus Project, the ICPTA provided an integrated liquid oxygen (LOX) / liquid methane (LCH4) propulsion system including a 2,800 lbf thrust main engine. The ISP Facility's vacuum accumulator configuration leveraged the large test volume of the facility and a diffuser insert to maintain altitude conditions. During hot fire, the ICPTA main engine "started" the diffuser insert constructed for the test campaign. As a result, the test chamber upstream of the diffuser insert remained at altitude conditions throughout the hot fire. Upon engine shut down, a backflow deflector mitigated blow back into the test chamber by restricting the mass flow and redirecting it away from the test article. The test campaign successfully characterized the performance of the vacuum accumulator configuration. In addition, it provided an opportunity to collect data for an integrated LOX / LCH4 propulsion system in an altitude and thermal vacuum environment.

Rocket Engine Testing↗

NASA NTRS2000

Test Execution Control Tool: Automating Testing in Spacecraft Integration and Test

In the era of faster, better, cheaper, JPL aims to develop and integrate an ever increasing number of spacecraft subsystems and instruments.

Test Execution Automating Testing Spacecraft Integ↗

NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗

NASA NTRS2014

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption during Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customers aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facilitys available acoustic power capability becomes maximized with the test-article installed during the actual test then the customers environment requirement may become compromised. In order to understand the risk of not achieving the customers in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Stations Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

acoustic↗

NASA NTRS2014

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption During Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customer's aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facility's available acoustic power capability becomes maximized with the test-article installed during the actual test then the customer's environment requirement may become compromised. In order to understand the risk of not achieving the customer's in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Station's Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

absorption↗

NASA NTRS2023

Measurement of Test Time in the NASA Ames EAST Expansion Cone Facility in Entry 63 and Possible Techniques for Increasing Test Time

The Ames EAST facility and its modes of operation (expansion tube, expansion cone) are described. A buffer section may or may not be used between the driver and the driven tube. Previous expansion tube (without the cone) entries are reviewed. Test times of 4 to 5 microsec were achieved at shock speeds up to 11 km/s. The test conditions and results of the present entry (entry 63) (with the cone) are given. Test times were found to correlate roughly with the density ratio across the buffer gas - driven gas or driver - driven gas interface. Tests with a 12 inch long conical driver without a buffer yielded three runs with test times of ~8 km/s and 3 runs with test times of 4 to 6 microsecs. With a buffer, test times for 4 runs of ~9 microsecs and for 2 runs of 3 to 6 microsecs were obtained. Adding argon to the buffer was found not to improve the test time. Tests with a 30 inch long driver without a buffer yielded test times of 14+, ~10, 7.5 (2 runs) and 5.5 (2 runs) microsecs. Based on one shot, data for the 30 inch driver suggests that test times up to ~14 microseconds could be obtained. The repeatability of that shot, of course, must be established. Suggestions are given to increase test times further.

Electric arc shock tube↗

NASA NTRSDate not supplied

Comparison of Anthropomorphic Test Device and human Volunteer Responses in Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to validate the safety of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and the vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded in human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa Reiber↗