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NASA NTRSDate not supplied

Fracture Mechanics Testing of Titanium 6AL-4V in LMP-103S Propellant

Propellant tank safe-life analysis is a spacecraft propulsion subsystem Launch Range processing requirement. The material property inputs for the safe-life analysis include the stress intensity factor for environment-assisted cracking (KEAC). The KEAC for titanium alloy Ti 6Al-4V in LMP-103S propellant was determined experimentally using an innovative test method following ASTM E1681, Standard Test Method for Determining Threshold Stress Intensity Factor for Environment-Assisted Cracking of Metallic Materials. This effort was a collaboration between NASA Goddard Space Flight Center and NASA Kennedy Space Center to expose the test specimens in the propellant, while loaded in the test fixtures, for 1000- hour (42 days) at 50°C. Two test rounds have been completed to date; 1) testing mechanically loaded specimens but without propellant and 2) testing mechanically loaded specimens wetted with LMP-103S propellant. The dry test was to evaluate the crack growth without exposure to the LMP-103S propellant, and further assess the un-wetted stress intensity factor for the full 1000-hour duration. The second round of testing included the propellant soak for the requisite 1000- hour at 50°C. Current results show that the threshold intensity factor for environment-assisted cracking (exposed to LMP103S) is 22.5 ksi√in for the bulk material and 36. 2 ksi√in for the weld material. A generic ‘candidate’ tank geometry and material thickness is developed for a damage tolerance of known surface cracks below the nondestructive inspection technique detection limit. Evaluations with and without the use of a threshold intensity factor for environment-assisted cracking is performed for the required 4x propellant tank service life using the software tool NASGRO. SP2024_00239

Green propulsion↗

NASA NTRS1997

Laser Shearographic Inspection for Debonds in Sprayed On Foam Insulation (SOFI)

Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Adams, F. W.↗

NASA NTRS1975

Data report for tests on the heat transfer effects of the 0.0175-scale Rockwell International Space Shuttle Vehicle model 22-OT in the AEDC 50-inch B wind tunnel (OH4B), volume 3

Results of wind tunnel heat transfer tests of 0.0175-scale Rockwell International Space Shuttle Vehicle configurations for orbiter alone, tank alone, and orbiter plus external tank are presented. Body flap shielding of SSME's during simulated entry was also investigated. The tests were conducted at Mach 8 for thirteen Reynolds number per foot values ranging from 0.5 million to 3.72 million.

Foster, T. F.↗

NASA NTRS2006

The F-15B Lifting Insulating Foam Trajectory (LIFT) Flight Test

A series of flight tests has been performed to assess the structural survivability of space shuttle external tank debris, known as divots, in a real flight environment. The NASA F-15B research test bed aircraft carried the Aerodynamic Flight Test Fixture configured with a shuttle foam divot ejection system. The divots were released in flight at subsonic and supersonic test conditions matching points on the shuttle ascent trajectory. Very high-speed digital video cameras recorded the divot trajectories. The objectives of the flight test were to determine the structural survivability of the divots in a real flight environment, assess the aerodynamic stability of the divots, and provide divot trajectory data for comparison with debris transport models. A total of 10 flights to Mach 2 were completed, resulting in 36 successful shuttle foam divot ejections. Highspeed video was obtained at 2,000 pictures per second for all of the divot ejections. The divots that were cleanly ejected remained structurally intact. The conical frustum-shaped divots tended to aerodynamically trim in both the subsonic and supersonic free-stream flow.

Corda, Stephen↗

NASA NTRS2015

Numerical Investigation of Microgravity Tank Pressure Rise Due to Boiling

The ability to control self-pressurization in cryogenic storage tanks is essential for NASAs long-term space exploration missions. Predictions of the tank pressure rise in Space are needed in order to inform the microgravity design and optimization process. Due to the fact that natural convection is very weak in microgravity, heat leaks into the tank can create superheated regions in the liquid. The superheated regions can instigate microgravity boiling, giving rise to pressure spikes during self-pressurization. In this work, a CFD model is developed to predict the magnitude and duration of the microgravity pressure spikes. The model uses the Schrage equation to calculate the mass transfer, with a different accommodation coefficient for evaporation at the interface, condensation at the interface, and boiling in the bulk liquid. The implicit VOF model was used to account for the moving interface, with bounded second order time discretization. Validation of the models predictions was carried out using microgravity data from the Tank Pressure Control Experiment, which flew aboard the Space Shuttle Mission STS-52. Although this experiment was meant to study pressurization and pressure control, it underwent boiling during several tests. The pressure rise predicted by the CFD model compared well with the experimental data. The ZBOT microgravity experiment is scheduled to fly on February 2016 aboard the ISS. The CFD model was also used to perform simulations for setting parametric limits for the Zero-Boil-Off Tank (ZBOT) Experiments Test Matrix in an attempt to avoid boiling in the majority of the test runs that are aimed to study pressure increase rates during self-pressurization. *Supported in part by NASA ISS Physical Sciences Research Program, NASA HQ, USA

pressure rise↗

NASA NTRS2007

Modeling Spacecraft Fuel Slosh at Embry-Riddle Aeronautical University

As a NASA-sponsored GSRP Fellow, I worked with other researchers and analysts at Embry-Riddle Aeronautical University and NASA's ELV Division to investigate the effect of spacecraft fuel slosh. NASA's research into the effects of fuel slosh includes modeling the response in full-sized tanks using equipment such as the Spinning Slosh Test Rig (SSTR), located at Southwest Research Institute (SwRI). NASA and SwRI engineers analyze data taken from SSTR runs and hand-derive equations of motion to identify model parameters and characterize the sloshing motion. With guidance from my faculty advisor, Dr. Sathya Gangadharan, and NASA flight controls analysts James Sudermann and Charles Walker, I set out to automate this parameter identification process by building a simple physical experimental setup to model free surface slosh in a spherical tank with a simple pendulum analog. This setup was then modeled using Simulink and SimMechanics. The Simulink Parameter Estimation Tool was then used to identify the model parameters.

Schlee, Keith L.↗

NASA NTRS2012

CRYogenic Orbital TEstbed Ground Test Article Thermal Analysis

The purpose of this study was to anchor thermal and fluid system models to CRYOTE ground test data. The CRYOTE ground test artide was jointly developed by Innovative Engineering Solutions, United Launch Alliance and NASA KSC. The test article was constructed out of a titanium alloy tank, Sapphire 77 composite skin (similar to G10), an external secondary payload adapter ring, thermal vent system, multi layer insulation and various data acquisition instrumentation. In efforts to understand heat loads throughout this system, the GTA (filled with liquid nitrogen for safety purposes) was subjected to a series of tests in a vacuum chamber at Marshall Space Flight Center. By anchoring analytical models against test data, higher fidelity thermal environment predictions can be made for future flight articles which would eventually demonstrate critical cryogenic fluid management technologies such as system chilldown, transfer, pressure control and long term storage. Significant factors that influenced heat loads included radiative environments, multi-layer insulation performance, tank fill levels and pressures and even contact conductance coefficients. This report demonstrates how analytical thermal/fluid networks were established and includes supporting rationale for specific thermal responses.

Piryk, David↗

NASA NTRS2022

Design of Hypervelocity Flow Generator (HFG) and Its Diagnostics

Ground facilities for hypersonic research are a key element for successful development of aerodynamically proven hypervelocity vehicles. Design concepts and diagnostics of a hypervelocity flow generator (HFG) were made as a test platform for hypersonic/hypervelocity spacecraft models at the NASA Langley Research Center. The HFG is a hypersonic flow field generator using optically heated gas which is blown into an 80 cu m vacuum chamber. The vacuum chamber is kept at a stable vacuum pressure with a combination of three large vacuum pumps, while the HFG is in the test mode. The HFG provides a relatively small test section with approximately a 20 cm window. This facility was designed to generate 2.45 km/sec of flow speed, and potentially generate a continuous flow with the nozzle and vacuum system. The window in test section provides a direct view of the shock wave around a model in order to measure temperature, pressure, and density profile within the shock layer. One of the key test goals under this project is to understand why the emission spectra from the standing shockwave plasma predicted by Lora-Loran codes are significantly different from the measured emission spectra from the Flight Investigation Reentry Environment (FIRE II) Flight. The correct estimate of the thermal loading on the leading edge of hypersonic vehicles greatly affects the aerodynamic design, the material selection for the vehicle, and the cooling requirement and can be obtained by the precise modeling of emission spectra from shockwave plasma. However, the estimation of thermal loading is not an easy task due to complex non-equilibrium radiative process within high temperature shock layers that still falls into a category of cold plasma. Direct flight experiments are the most desirable, but not a cost-effective approach. Analysis by computational fluid dynamics (CFD) offers many test flexibilities. However, the CFD codes must be fully tested and validated with experimental data before the codes are effectively used for practical design. Large discrepancies between experiments and codes appear in hypersonic/hypervelocity flow regimes at high altitudes of 60 km ~ 90 km. This HFG facility offers some important parameters for CFD code validation, such as collision cross-sections, relaxation times, reaction rate coefficients and transportation coefficients. The HFG test facility is based on the ejection flow of high temperature gas heated over to 3500 K through a nozzle. The tungsten gas chamber of the HFG is heated up to a desired temperature by a 60 kW optical power beam source. This system consists of an optical power source, a thermal chamber, an expansion nozzle, a test section, and an 80 cu m vacuum tank. 60 kW optical input power is obtained from the 150 kW Vortek arc lamp system (by Vortek Industries, Vancouver, Canada). This optical beam is focused to heat the gas chamber within which a flow media is heated. The maximum achievable temperature of the flow medium reached approximately 3500 K or even higher but is limited by the melting point of the chamber material used. The exhaust velocity through the nozzle was determined by the stagnation temperature and the molecular weight of the working medium at the test section. To provide design parameters, a NASA Chemical Equilibrium with Application (CEA) computer program is used for the simulation of aerothermal data. This CEA program can calculate chemical equilibrium and properties of complex mixtures using shock tube parameters. For nitrogen gas at 2666 K stagnation temperature, the maximum achievable velocity at the test section is approximately 2.45 km/sec which is within the range of the thermal velocity of 8000 K shock layer. Based on the calculation through the CEA program, the design parameters of a HFG were determined and implemented for the test section that includes an expansion nozzle. The installed test section of the experimental facility can sustain a condition of a re-entry vehicle from the Space at an altitude of 60-90 km. After installation of the HFG, the system was fully tested and its operational parameters were measured. An 80 cu m vacuum chamber of HFG was set at 1 torr level to keep a stable downstream condition. The pumping time to reach the minimum vacuum pressure (~ 1 torr) at the test chamber from atmospheric pressure was approximately an hour using Kinney (MBV-14000/MB -1600/KT-300) and Stokes (Model 1772 and 412) pumps. Such a setup condition allowed a continued stable operation of the HFG experiment with flowrates through 1-, 3-, or 5-mm diameters of nozzle throat. The flow characteristics of the HFG for various operating conditions were performed using a focused Schlieren method. At 0.8 torr chamber pressure, a barrel shock was observed at the test section. With a sphere obstacle of 12 mm diameter in the flow, a bow shock (~ 2-mm thickness) was observed by a focused Schlieren visualization method.

Hypervelocity flow↗

NASA NTRS1984

IAPS (8-cm) ion thruster cyclic endurance test

Attention is given to the cyclic endurance qualification test, performed in a vacuum facility with a liquid nitrogen-cooled cryosurface and a frozen mercury target, to which a mercury-ion thruster representative of Ion Auxiliary Propulsion System (IAPS) thrusters was subjected. At the time that the endurance test was successfully concluded, upon consumption of the IAPS propellant tank's mercury, 8,471 hours of 'beam-on time' and 599 cycles had been accumulated. The system's Power Electronics Unit accumulated 10,268 hours of test time with high voltage applied to the operating thruster or dummy load.

Dulgeroff, C. R.↗

NASA NTRS2016

Green Monopropellant Status at Marshall Space Flight Center

NASA Marshall Space Flight Center is continuing investigations into the use of green monopropellants as a replacement for hydrazine in spacecraft propulsion systems. Work to date has been to push technology development through multiple activities designed to understand the capabilities of these technologies. Future work will begin to transition to mission pull as these technologies are mature while still keeping a solid goal of pushing technology development as opportunities become available. The AF-M315E activities began with hot-fire demonstration testing of a 1N monopropellant thruster in FY 14 and FY15. Following successful completion of the preliminary campaign, changes to the test stand to accommodate propellant conditioning capability and better control of propellant operations was incorporated to make testing more streamlined. The goal is to conduct hot-fire testing with warm and cold propellants using the existing feed system and original thruster design. Following the 1N testing, a NASA owned 100 mN thruster will be hot-fire tested in the same facility to show feasibility of scaling to smaller thrusters for cubesat applications. The end goal is to conduct a hot-fire test of an integrated cubesat propulsion system using an SLM printed propellant tank, an MSFC designed propulsion system electronic controller and the 100 mN thruster. In addition to the AF-M315E testing, MSFC is pursuing hot-fire testing with LMP-103S. Following our successful hot-fire testing of the 22N thruster in April 2015, a test campaign was proposed for a 440N LMP-103S thruster with Orbital ATK and Plasma Processes. This activity was funded through the Space Technology Mission Directorate (STMD) ACO funding call in the last quarter of CY15. Under the same funding source a test activity with Busek and Glenn Research Center for testing of 5N AF-M315E thrusters was proposed and awarded. Both activities are in-work with expected completion of hot-fire testing by the end of FY17. MSFC is continuing to coordinate with the AF and academia on understanding the chemical reactions that occur in AF-M315E. An on-going investigation of the catalyst bed species using Raman Spectroscopy through the NASA Technology Research Fellowship Program (NSTRF) is looking for ways to minimize the amount of computation required by understanding the intermediate species created in the catalyst bed. The MSFC team is also working with commercial partners through Cooperative Agreement Notices (CAN's). Partnerships with commercial and academia include work in non-catalytic ignition of AF-M315, spark ignition of hybrid cubesat systems, printed SLM tanks, and dual-mode (electric and chemical) propulsion systems is continuing.

Burnside, Christopher G.↗

NASA NTRS1973

Results of tests in the MSFC 14 x 14 inch trisonic wind tunnel on a .004 scale model of the Rockwell International Space Shuttle Vehicle 3, (integrated configuration)

Experimental aerodynamic investigations were conducted during mid-July, 1973 on a .004 scale model of the Rockwell International integrated configuration Space Shuttle Vehicle 3. The purpose of the tests was three fold: (1) to determine the static stability characteristics of the integrated vehicle, utilizing the Vehicle 3 orbiter configuration; (2) to determine the effect of interstage structure and tank external fuel lines on the integrated vehicle aerodynamic characteristics; (3) to determine the effects of the aft interstage structure on orbiter aerodynamic loads. Data were recorded on the integrated vehicle (test no. 579) at angles of attack and sideslip ranging from -10 deg to 10 deg over a Mach number schedule from 0.6 to 4.96. Data were obtained on the orbiter alone in the presence of the external tank with SRB attached (test no. 580) at angles of attack from -10 deg to 10 deg over a Mach number range from .6 to 1.96. Plotted data are presented in the body axis system.

Allen, E. C.↗

NASA NTRS1972

Aerodynamic characteristics of the North American Rockwell space shuttle delta-wing orbiter (110C) alone and with belly-mounted external oxygen/hydrogen tanks (M equals 0.6 to 5.0)

Experimental aerodynamic investigations were conducted at the MSFC 14 x 14 inch trisonic wind tunnel on a .0044 scale model of the space shuttle orbiter, 110C. The test configurations included the orbiter alone and with external oxygen/hydrogen belly tanks. The six component aerodynamic force and moment data obtained cover a Mach number range from 0.6 to 4.96 at angles of attack from 10 to 60 deg at 0 deg sideslip angle and -10 to 10 deg at -6 deg sideslip angle. Reynolds number per unit length varied somewhat with Mach number but was a nominal 6.8 million per foot.

Allen, E. C.↗

NASA NTRS1974

Developments in low-gravity cryogenic propellant acquisition and thermal control systems

Development programs are described for two low-gravity cryogenic propellant acquisition systems: a full-screen liner system, and a refillable start-tank. First, based on experimental LH2 screen flow data, the fluid-dynamic characteristics of an integrated screen/thermodynamic vent system were analyzed for a design compared to 17.5 cu fg supercritical life-support systems, and for a Tug orbital LH2/LQ2 resupply system. Second, the analysis, design, fabrication, and test of a 10 cu ft, annular-screen start-tank with a wall-mounted thermodynamic vent was performed. The test program demonstrated that the system expelled LH2 against 1-g and performed properly over a range of conditions.

Cady, E. C.↗

NASA NTRS2008

The Development of NDE Techniques for Large Cryogenic Storage Tanks

Objectives of this project are: (1) Develop and demonstrate NDE techniques to evaluate the condition of large cryogenic Dewars (typically 50,000 to 900,000 gaL). (2) These tanks are used across NASA for launch pads, engine test stands, cryogenic wind tunnels and other facilities: they represent a major investment. (3) Issues addressed: (1) Insulation integrity of existing Dewars (powdered insulation under vacuum or sometimes ambient pressure (LO2), (2) Post fabrication insulation verification without full chill-down to avoid thermal cycling the tank (fatigue limitation of piping and compaction of Perlite).

Youngquist, Robert↗

NASA NTRS1980

Hydroelastic vibration analysis of partially liquid-filled shells using a series representation of the liquid

A series representation of the oscillatory behavior of incompressible nonviscous liquids contained in partially filled elastic tanks is presented. Each term is selected on the basis of hydroelastic vibrations in circular cylindrical tanks. Using a complementary energy principle, the superposition of terms is made to approximately satisfy the liquid-tank interface compatibility. This analysis is applied to the gravity sloshing and hydroelastic vibrations of liquids in hemispherical tanks and in a typical elastic aerospace propellant tank. With only a few series terms retained, the results correlate very well with existing analytical results, NASTRAN-generated analytical results, and experimental test results. Hence, although each term is based on a cylindrical tank geometry, the superposition can be successfully applied to noncylindrical tanks.

Housner, J. M.↗

NASA NTRS2003

Propulsion Flight-Test Fixture

NASA Dryden Flight Research Center s new Propulsion Flight Test Fixture (PFTF), designed in house, is an airborne engine-testing facility that enables engineers to gather flight data on small experimental engines. Without the PFTF, it would be necessary to obtain such data from traditional wind tunnels, ground test stands, or laboratory test rigs. Traditionally, flight testing is reserved for the last phase of engine development. Generally, engines that embody new propulsion concepts are not put into flight environments until their designs are mature: in such cases, either vehicles are designed around the engines or else the engines are mounted in or on missiles. However, a captive carry capability of the PFTF makes it possible to test engines that feature air-breathing designs (for example, designs based on the rocket-based combined cycle) economically in subscale experiments. The discovery of unknowns made evident through flight tests provides valuable information to engine designers early in development, before key design decisions are made, thereby potentially affording large benefits in the long term. This is especially true in the transonic region of flight (from mach 0.9 to around 1.2), where it can be difficult to obtain data from wind tunnels and computational fluid dynamics. In January 2002, flight-envelope expansion to verify the design and capabilities of the PFTF was completed. The PFTF was flown on a specially equipped supersonic F-15B research testbed airplane, mounted on the airplane at a center-line attachment fixture, as shown in Figure 1. NASA s F-15B testbed has been used for several years as a flight-research platform. Equipped with extensive research air-data, video, and other instrumentation systems, the airplane carries externally mounted test articles. Traditionally, the majority of test articles flown have been mounted at the centerline tank-attachment fixture, which is a hard-point (essentially, a standardized weapon-mounting fixture). This hard-point has large weight margins, and, because it is located near the center of gravity of the airplane, the weight of equipment mounted there exerts a minimal effect on the stability and controllability of the airplane. The PFTF (see Figure 2) includes a one-piece aluminum structure that contains space for instrumentation, propellant tanks, and feed-system components. The PFTF also houses a force balance, on which is mounted the subscale engine or other experimental apparatus that is to be the subject of a flight test. The force balance measures a combination of inertial and aerodynamic forces and moments acting on the experimental apparatus.

Palumbo, Nate↗

NASA NTRS1999

The X-33 Flight Test Challenge

Low cost access to space has eluded present launch system technologies. Our objective is to reduce the cost of putting a payload into space from $10,000 per pound to $1000 per pound. In July 1996, a cooperative agreement was initiated between the Lockheed Martin Skunk Works and NASA to help accomplish this goal. The X-33 is the first step in the process to make low cost space access a reality. The X-33 is a suborbital, hypersonic lifting body, proof of concept of a reusable launch vehicle. The X-33 flight test program will validate technologies such as a metallic thermal protection system, Linear Aerospike Engines, use of tanks and struts as fundamental structural elements, as well as quick turnaround time. Flight testing will begin in July 2000, with launches originating from Edwards Air Force Base and initial landings at Michael Army Airfield in Utah. Data collected from these flight tests will aid in the decision to build an economically viable single stage to orbit reusable launch vehicle. This paper will explore the technical challenges facing the X-33 Flight Test Team.

Borden, David↗

NASA NTRS1982

Experiments on fuel heating for commercial aircraft

An experimental jet fuel with a -33 C freezing point was chilled in a wing tank simulator with superimposed fuel heating to improve low temperature flowability. Heating consisted of circulating a portion of the fuel to an external heat exchanger and returning the heated fuel to the tank. Flowability was determined by the mass percent of unpumpable fuel (holdup) left in the simulator upon withdrawal of fuel at the conclusion of testing. The study demonstrated that fuel heating is feasible and improves flowability as compared to that of baseline, unheated tests. Delayed heating with initiation when the fuel reaches a prescribed low temperature limit, showed promise of being more efficient than continuous heating. Regardless of the mode or rate of heating, complete flowability (zero holdup) could not be restored by fuel heating. The severe, extreme-day environment imposed by the test caused a very small amount of subfreezing fuel to be retained near the tank surfaces even at high rates of heating. Correlations of flowability established for unheated fuel tests also could be applied to the heated test results if based on boundary-layer temperature or a solid index (subfreezing point) characteristic of the fuel.

Friedman, R.↗