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NASA NTRS2017

Sample Processor for Life on Icy Worlds (SPLIce): Design and Test Results

We report the design, development, and testing of the Sample Processor for Life on Icy Worlds (SPLIce) system, a microfluidic sample processor to enable autonomous detection of signatures of life and measurements of habitability parameters in Ocean Worlds. This monolithic fluid processing-and-handling system (Figure 1; mass 0.5 kg) retrieves a 50-L-volume sample and prepares it to supply a suite of detection instruments, each with unique preparation needs. SPLIce has potential applications in orbiter missions that sample ocean plumes, such as found in Saturns icy moon Enceladus, or landed missions on the surface of icy satellites, such as Jupiters moon Europa. Answering the question Are we alone in the universe? is captivating and exceptionally challenging. Even general criteria that define life very broadly include a significant role for water [1,2]. Searches for extinct or extant life therefore prioritize locations of abundant water whether in ancient (Mars), or present (Europa and Enceladus) times. Only two previous planetary missions had onboard fluid processing: the Viking Biology Experiments [3] and Phoenixs Wet Chemistry Laboratory (WCL) [4]. SPLIce differs crucially from those systems, including its capability to process and distribute L-volume samples and the integration autonomous control of a wide range of fluidic functions, including: 1) retrieval of fluid samples from an evacuated sample chamber; 2) onboard multi-year storage of dehydrated reagents; 3) integrated pressure, pH, and conductivity measurement; 4) filtration and retention of insoluble particles for microscopy; 5) dilution or vacuum-driven concentration of samples to accommodate instrument working ranges; 6) removal of gas bubbles from sample aliquots; 7) unidirectional flow (check valves); 8) active flow-path selection (solenoid-actuated valves); 9) metered pumping in 100 nL volume increments. The SPLIce manifold, made of three thermally fused layers of precision-machined cyclo-olefin polymer, supports all fluidic components (Figure 1) and integrated microchannels (125 x 250 m). Fluid is pumped by a stepper-motor-driven pump (Lee Co.). The functionality of the integrated MEMS pressure sensor (Honeywell) and passive check valves (Figure 2) were tested in conjunction with our newly designed integral bubble traps (Figure 3) and hydrophobic membrane-based concentrator (Figure 4). The concentrator (initially tested as a standalone component) demonstrated 5-fold vacuum-evaporative concentration. Polyethylene fused bead beds (PEFBBs; 50 porosity) store drylyophilized buffers, calibrants, and fluorescent dyes, and also promote mixing of sample with calibrant, dye, or H2O. Software-controlled automated tests demonstrated successful 1) fluid delivery to each component 2) valve and pump synchronization 3) sample aliquot delivery to instrument interface ports, and 4) rehydration of vacuum-dried fluorescent dye. In Figure 5, fluorescein on PEFBBs was rehydrated for 15 min using a pump-delivered water aliquot; it is displaced as H2O enters the bottom of the channel and pushes the dye into a check valve. Ultimately, SPLIce will fluorescently label amino acids in the sample for microchip-based electrophoretic (MCE) chiral separation and detection to seek and quantify key organic bio-signatures [5]; it will also deliver sample to a microfluidic version of WCL (mWCL) to measure soluble ions and redox-active species.

Life detection↗

NASA NTRS2017

The Iodine Satellite (iSat) Propellant Feed System - Design and Demonstration

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cm3 and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high Delta V maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. One of the systems under development to support such a technology is the propellant feed system, which must be capable of storing solid iodine propellant, applying heat to sublime the stored solid into the vapor phase, and then control the flow of low-pressure gaseous iodine to both the thruster and cathode. In a test conducted in 2016, a first-generation iodine propellant feed system was integrated with a cathode and Hall thruster. While this test had to be terminated, the feed system in this first test was able to support both cathode and integrated cathode and thruster operation prior to the termination of the test. In the present paper, we describe work performed since that initial integrated test. The effort uses lessons learned from the previous integrated test, retiring risk associated with the iodine propellant feed system, answering open design-space questions, and demonstrating iodine flow control in an integrated system. The work is undertaken at both the component level and then at the integrated subsystem level to systematically improve the feed system design, improving the hardware fidelity so the appearance and operation of the system are as flight-like as possible. At the component level, the work focuses on the propellant tank, the feed system tubing, the valves used to control the flow to the cathode and thruster, and the heaters that maintain the temperature of the flowpaths and keep iodine from redepositing and clogging the system. Work on the propellant reservoir focuses on fabricating a tank that matches the geometry of the flight design, which allows for the identification of flight tank fabrication issues that may arise and permits thermal testing of a tank possessing the same size and thermal mass as the flight design, which can be used to anchor thermal modeling of the component. This is critical for finalizing the tank heater power requirements that feed into the heater design. All metallic materials in the feed system are hastelloy or Inconel, as these materials are resistant to chemical attack by the highly-reactive iodine vapor. The tubing in the iodine feed system must possess ports to permit a neutral gas purge of the system that clear impurities after iodine is loaded into the propellant tank. A procedure is discussed whereby these ports are crimped and sealed after the purge process is completed so as to not re-expose the iodine system to air. The valves are a critical component for control of the flow to the thruster and the cathode. Significant effort has gone into upgrading the materials of the valves to make them more resistant to chemical attack and into developing an understanding of the use of these valves during the startup and operation of the cathode and thruster. The heaters that line the entire feed system are designed to draw minimal power from the power processing unit (PPU) while still having the capacity to maintain all the feed system components at the temperatures required to discourage iodine deposition inside components downstream of the propellant tank exit. The heaters possess two separate resistive traces, giving the design redundancy should a failure occur in the primary heater circuit of one of the heater zones. The task of operating a feed system in conjunction with a thruster and cathode is undertaken in a series of sub-steps. The system is first assembled and operated on xenon gas, using the valves for cathode startup and thruster control based on measurement of the discharge current. After startup and control on xenon are demonstrated, the thruster will be transitioned to iodine operation, demonstrating thruster startup and feed system control while using a xenon-fed cathode. Finally, the last step is to integrate an iodine-compatible cathode with the system, demonstrate autonomous cathode start-up with open-loop control and thruster start-up with closed-loop control for multiple cycles.

Polzin, Kurt A.↗

NASA NTRS2019

Thermal design and validation of Mars 202 gas Dust Removal Tool (gDRT)

As part of the science goals for the planned Mars 2020 mission, two instruments, PIXL and SHERLOC, intend to study the Mars surface at a close scale. These two instruments are planned to be used on smooth rock surfaces that are free of dust and other particles. Such surfaces are prepared by using a drill with an abrading drill bit; residual dust and particles are then blown away using a compressed gas system—the Gas Dust Removal Tool (gDRT). Early in the design process a risk of valve leakage below the vendor’s -20C rating was identified. To mitigate this risk a parallel path was implemented: 1) qualify the valves to operate at -135C, and 2) develop thermal control capability to elevated temperatures in case qualification efforts are unsuccessful. While qualification efforts are ongoing, it is expected that the valves will be qualified to an operating temperature of -135C. In the event that qualification is not successful, thermal control has been realized via a thermally isolated valve configuration and thermostatically controlled heaters. Thermal testing of gDRT has validated this design and enabled thermal model correlation in order to provide more accurate survival energy predictions. The resulting energy consumption for heating the valves at the Jezero landing site represents a minimal impact to the Rover energy budget.

Novak, Keith↗

NASA NTRSDate not supplied

High Pressure Vent Line Mishap: Investigation Summary

During testing on the E-1 Test Stand, the High Pressure (HP) Liquid Hydrogen (LH) vent line was displaced off its supports, damaging the expansion joints (EJ), piping, and pipe supports of the line. The damage to the vent line is believed to have occurred during Cell 3 testing on Thursday, September 21, during the first test of the day. The fuel systems being used for Cell 3 testing are connected to the LP and HP LH Vent systems and are being used in Liquid Natural Gas (LNG) service. The Cell 3 interface bleed valve that discharges to the HP LH Vent system was inadvertently left at 100% open during the chill-in process for longer than the typical amount of time. Since this valve is usually at a lower set point or intermittently closed during the chill-in process, more than the typical amount of LNG flowed into the vent line as pre-test procedures continued as normal. The open bleed valve was noticed before test preparations were completed and prior to refilling of the HP LH Tank before test. The test sequence was started, run, and shutdown normally. Video of the flare stack showed an atypical discharge of liquid at the flare stack exit. Pressure downstream of the Cell 3 interface bleed valve (a valve connected to the southernmost part of the vent system) spiked to a higher-than-normal level. No evidence of damage was captured at the time of the event. The system was used in a typical fashion after the event and for 4 subsequent tests on Thursday and Friday, before the damage was observed. A drive-by inspection of the flare stack was performed on Friday (September 22nd) morning before sunrise and before test activities began, but no damage of the vent line was observed at that time. No abnormal system behavior was observed during testing on Friday. The damage was discovered and reported to NASA Test Operations on Monday, initiating the Incident Response Team. The Mishap appointment letter was issued September 27th to formally initiate the Mishap Investigation.

LNG↗

DOE OSTI2020

Flow and pressure estimators in a waste heat recovery system

An apparatus includes a pump circuit structured to receive pump data indicative of an operating characteristic of a pump feeding a fluid to a waste heat recovery (WHR) system; a flow circuit structured to receive valve position data indicative of a position of a valve downstream of the pump, estimate a flow rate of the fluid exiting the pump, and estimate the flow rate of the fluid exiting the valve; and a pressure circuit structured to receive pressure data indicative of the pressure of the fluid exiting the valve, estimate a change in pressure of the fluid across the WHR system, and determine a pressure of the fluid in a hot section of the WHR system based on the pressure of the fluid exiting the valve and the change in the pressure of the fluid across the WHR system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Cooler for optics transmitting high intensity light

A system and an apparatus having an optic and a cooling system for cooling the optic. In one example an optically addressed light valve forms the optic. The cooling system includes first and second windows on opposing surfaces of the optically addressed light valve which constrain a cooling fluid to flow over the opposing surfaces. The fluid pressure outside the optically addressed light valve is low enough that it does not compress a liquid crystal gap of the optically addressed light valve. The cooling fluid is also transparent to a high powered light beam which is projected through the first and second windows, and also through the optically addressed light valve, during an additive manufacturing operation.

42 ENGINEERING↗

DOE OSTI2021

Cold start strategy and system for gasoline direct injection compression ignition engine

A method for starting a compression ignition engine having at least one cylinder with a reciprocating piston located therein, an intake valve configured to control the intake of air to an intake port of the cylinder and an exhaust valve configured to control the expulsion of gas from an exhaust port of the cylinder. The method includes the steps of: cranking the engine, conditioning intake air at the intake port of the cylinder to raise the temperature of air in the cylinder, controlling a valve timing the intake valve and/or the exhaust valve to allow the piston to compress the air within the cylinder, thereby increasing the temperature of the air within the cylinder, and injecting fuel into the cylinder when the air within the cylinder has been heated to a temperature sufficient to support compression ignition of a gasoline and air mixture within the cylinder.

Sellnau, Mark C.↗

DOE OSTI2022

Technology Enablers for Advanced Gasoline Compression Ignition Engines

To meet current emission regulations and increasingly demanding global fleet CO2 standards on fuel economy and future trends towards life cycle GHG emissions, advanced combustion engines remain significant in the passenger vehicle sector to achieve high efficiency and low emissions over the full operating range. Lean burn gasoline compression ignition (GCI) technology has shown to have the most potential in reaching these goals, although it faces challenges in the operating range. In this study, an advanced GCI engine is considered with the capability to operate under two combustion modes, namely low temperature combustion (LTC) and GCI. They are enabled with the use of two Hyundai in-house developed technologies; an advanced valve control mechanism known as continuously variable valve duration (CVVD) and a high-pressure gasoline injection system. At low load, the engine utilizes dual CVVD and dual CVVT (continuously variable valve timing) mechanisms for both intake and exhaust valvetrains to enable NVO (negative valve overlap) to trap hot residuals. The hot residuals enable low load auto-ignition, and the phasing control of that auto-ignition is achieved by varying the degrees of NVO, and in turn, the amount of hot residuals. This is done in real time with respect to the changes in engine loads or operating conditions, significantly improving cylinder-phasing control in LTC mode, and subsequently is able to realize a fuel economy gain and reduced emission benefits. Early direct injection during NVO or intake stroke is used to form homogenous or quasi-homogenous air-fuel mixture for LTC. At mid to high loads, late direct injection of gasoline or GCI mode is employed to take advantage of the high volatility and high resistance to auto-ignition of gasoline fuel, so that diesel-engine like high combustion efficiency can be achieved with lower soot emissions for the same NOx level as diesel combustion. In this paper, the key control and fueling technologies that enable this multiple mode combustion are introduced, and the resultant analysis on engine test and CFD simulation at LTC and GCI operating conditions are presented in detail.

Gasoline compression ignition, low temperature com↗

DOE OSTI2025

Forced flow transient safety analysis of irradiation device with adjustable orifice for research reactor fuel assemblies

The Belgium Reactor 2 (BR2) of the Belgian Nuclear Research Centre (SCK CEN) has several irradiation devices or rigs that are dedicated to the fuel performance and qualification demonstration testing of research reactor fuels. In support of the U.S. High Performance Research Reactor (USHPRR) LEU conversion project, a new flexible irradiation apparatus, MUSTANG-R, has been constructed. SCK CEN has completed the design and safety study, in cooperation with Idaho National Laboratory (INL) and Argonne National Laboratory (ANL), to allow for the irradiation testing of a full-size fuel assembly in a 200 mm diameter channel in the BR2 reactor. The moveable valve is a key design feature of the device and acts like an adjustable orifice enhancing or restricting the flow through a coolant channel inlet located in the BR2 upper plenum. This moveable valve allows the flow through the device to be adjusted prior to each BR2 cycle to obtain the necessary conditions for the fuel qualification test. This ensures accurate and representative thermal-hydraulic conditions of the fuel design are achieved. The device was designed and qualified as passively safe, implying verification by a combination of mechanical and thermal-hydraulic analysis and testing. This includes characterization of the safety margin required for a scenario where the moveable valve is assumed to be erroneously closed during irradiation. A simplified and conservative method is proposed for analyzing the corresponding forced flow transient using a critical heat flux criterion. In conclusion, this allows the required minimum valve opening to be determined for the experiments' design and safety studies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Extreme Miller cycle with high intake boost for improved efficiency and emissions in heavy-duty diesel engines

This study experimentally investigates the impact of extreme Miller cycle strategies paired with high intake manifold pressures on the combustion process, emissions, and thermal efficiency of heavy-duty diesel engines. Well-controlled experiments isolating the effect of Miller cycle strategies on the combustion process were conducted at constant engine speed and load (1160 rpm, 1.76 MPa net IMEP) on a single cylinder research engine equipped with a fully-flexible hydraulic valve train system. Late intake valve closing (LIVC) timing strategies were compared to a conventional intake valve profile under either constant cylinder composition, constant engine-out NO x emission, or constant overall turbocharger efficiency (η TC ) to investigate the operating constraints that favor Miller cycle operation over the baseline strategy. Furthermore, utilizing high boost with conventional intake valve closing timing resulted in improved fuel consumption at the expense of sharp increases in peak cylinder pressures, engine-out NO x emissions, and reduced exhaust temperatures. Miller cycle without EGR at constant λ demonstrated LIVC strategies effectively reduce engine-out NO x emissions by up to 35%. However, Miller cycle associated with very aggressive LIVC timings led to fuel consumption penalties due to increased pumping work and exhaust enthalpy. LIVC strategies allowed for increased charge dilution at the baseline NO x constraint of 3.2 g/kWh, resulting in significant fuel consumption benefits over the baseline case without compromising exhaust temperatures or peak cylinder pressures. As Miller cycle implementation was shown to affect the boundary conditions dictating η TC , the LIVC and conventional IVC cases were studied at an equivalent η TC point representative of high boost operation. With high boost, LIVC yielded reduced NO x emissions, reduced peak cylinder pressures, and elevated exhaust temperatures compared to the conventional IVC case without compromising fuel consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Measurement of needle and armature dynamics in a gasoline direct injector by high-speed neutron imaging

In modern spark ignition engines, precise delivery of fuel with gasoline direct injection has become increasingly important in the effort to meet ever stricter efficiency and emissions regulations. Use of multiple small close-coupled injections has become more common in attempt to precisely control fuel distribution in the cylinder, but these strategies are hindered by nonlinear injection effects due to operation in the ballistic region of the solenoid-operated valve and due to armature bounce at the end of injection. Understanding the internal dynamics of the injector is crucial to minimizing and controlling non-linearity and shot-to-shot variation, but the experimental techniques available to date are capable only of tracking the position of either the top of the needle (via laser sensors or by monitoring current and voltage in the solenoid coil) or the bottom of the needle (via transparent nozzles or high-speed x-ray imaging). Furthermore, a complete picture of the axial and radial motion of valve needle has until now remained elusive. In this work, we present high-speed ensemble neutron transmission imaging of an entire 8-hole gasoline direct injector operating at 200 bar, allowing for both visualization and quantification of the actuation dynamics including lift and wobble of the valve ball, oscillation and bending of the valve needle, lift, rocking, and bounce of the armature, compression of the springs, and radial swelling of the solenoid during energization. Because neutrons offer high penetration through the metal injector while also being sensitive to the 1 H nuclei in fuel molecules, it is also possible to simultaneously see the fluid dynamics of the injection process, including filling of the sac volume, emanation of the spray through the nozzle holes and into the downstream gas, and the formation and evolution of fuel films on the tip of the injector and the walls of the spray container.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

FY23 Report on Water NSTF Testing at Two-Phase Conditions: Off-normal Scenarios

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report details the experimental activities and upgrades performed during the program’s fifth year of water-based operation. The theme of this year of testing was examining off-normal scenarios. In practice, that meant examining scenarios with blockages or other design basis conditions. From a maintenance and capability standpoint that meant assessing valving options for implementing blockages, assessing drain and refill capabilities, and ensuring in all cases that operators could safely, efficiently, and repeatably bring the facility to an off-normal condition and return it to the normal operating state. In one notable case, no solution existed, nor was a solution commercially available, that met the facility needs for implementing blockages within the two-phase region of the chimney. A valve and feedthrough were custom-designed for NSTF to operate submerged in saturated water while being safely actuated from outside the tank. The fifth year of testing included eight matrix tests consisting of 162 hours of active heating, 9,735 kWh of electrical heating, with seven tests classified as Accepted per NQA-1 and one as Trending. All matrix tests were performed at two-phase flow conditions. The power parametric series from previous years was extended to include another scenario with a decay load equivalent to 1.75 MWt, full scale, further resolving the system flow oscillation response as a function of input power. A depletion test was performed to extend previous work and examine the system’s approach to stagnation and geysering that were not previously observed. This test began at an initial inventory level of 50%, prototypic power of 2.1 MWt, and employed an accelerated drain of 0.75 gpm plus boiloff until stagnation conditions were achieved and multiple geysering events were recorded. Further exploring the geysering phenomenon was a separate effects test examining static boiling in the risers and chimney. This static boiling test was performed at 48 kWe, a higher power than testing in the previous year, and included enhancements to the drain system to remove inventory in a better-controlled and more reliable manner. Two tests were performed, at prototypic conditions of 1.4 MWt and 2.4 MWt, respectively, examining the system response to throttled conditions in the singlephase region of the piping. A ball valve immediately before he riser inlet header was increasingly throttled, progressing the system through a repeatable pattern of two-phase oscillations and stable regimes before ultimately inducing stagnation and geysering. Concluding the year, two tests were performed at baseline conditions of 70% initial inventory level and 2.1 MWt of prototypic decay heat to examine both repeatability and the response to throttling within the two-phase region, at the inventory tank inlet using the custom valve mentioned above. The first such test repeated transient operating conditions and revealed significant sensitivity t

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1972

A method for calculating transient thrust and flow-rate levels for Mariner type attitude control nitrogen gas jets

The purpose of this report is to define and program the transient pneumatic flow equations necessary to determine, for a given set of conditions (geometry, pressures, temperatures, valve on time, etc.), the total nitrogen impulse and mass flow per pulse for the single pulsing of a Mariner type reaction control assembly valve. The rates of opening and closing of the valves are modeled, and electrical pulse durations from 20 to 100 ms are investigated. In developing the transient flow analysis, maximum use was made of the steady-state analysis. The impulse results are also compared to an equivalent square-wave impulse for both the Mariner Mars 1971 (MM'71) and Mariner Mars 1964 (MM'64) systems. It is demonstrated that, whereas in the MM'64 system, the actual impulse was as much as 56 percent higher than an assumed impulse (which is the product of the steady-state thrust and value on time i.e., the square wave), in the MM'71 system, these two values were in error in the same direction by only approximately 4 percent because of the larger nozzle areas and shorter valve stroke used.

Ferrera, J. D.↗

NASA NTRS1973

Optical-to-optical interface device

Studies were conducted on the performance of a photoactivated dc liquid crystal light valve. The dc light valve is a thin film device that consists of two transparent electrodes, deposited on glass substrates, that enclose a thin film photoconductor (cadmium sulfide) and a thin layer of a nematic liquid crystal that operates in the dynamic scattering mode. The work was directed toward application of the light valve to high resolution non-coherent light to coherent light image conversion. The goal of these studies was to improve the performance and quality of the already existing dc light valve device and to evaluate quantitatively the properties and performance of the device as they relate to the coherent optical data processing application. As a result of these efforts, device sensitivity was improved by a factor of ten, device resolution was improved by a factor of three, device lifetime was improved by two-orders of magnitude, undesirable secondary liquid crystal scattering effects were eliminated, the scattering characteristics of the liquid crystal were thoroughly documented, the cosmetic quality of the devices was dramatically improved, and the performance of the device was fully documented.

Jacobson, A. D.↗

NASA NTRS1973

System for calibrating pressure transducer

A system for calibrating a pressure transducer which has a reference portion and an active portion is reported. A miniature selector valve is positioned immediately adjacent the pressure transducer. A reference pressure, known pressure, and unknown pressure can be selectively admitted to the active side of the pressure transducer by the selector valve to enable calibration of the transducer. A valve admits pressure to the selector valve which has a piston and floating piston arrangement which allows proper selection with very small linear movement.

Rollins, G. N.↗

NASA NTRS1974

Airflow control system for supersonic inlets

In addition to fixed and variable bleed devices provided for controlling the position of a terminal shock wave in a supersonic inlet, a plurality of free piston valves are disposed around the periphery of a cowling of a supersonic engine inlet. The free piston valves are disposed in dump passageways, each of which begin at a bleed port in the cowling that is located in the throat region of the inlet, where the diameter of the centerbody is near maximum, and terminates at an opening in the cowling adjacent a free piston valve. Each valve is controlled by reference pressure.

Mitchell, G. A.↗

NASA NTRS1974

Design of mechanical components for long-term performance

Review of the results of a NASA program designed to study advanced techniques for determining the long-term performance of rocket engine components. Aging and operational degradation mechanisms of metal valve seats are identified. Characterization of metal valve seat surfaces by optical signature analysis is described. The results of the development of a long-life 'zero leakage' metal valve seal designed to avoid failure by contamination, stress/strain, fatigue, and the deterioration of the surface by wear is reported. An analysis of a specific seat design showed that material strain prevention along all axes would prevent these failures. The design provided for refurbishment of the sealing surfaces during each valve cycle, thereby preventing cumulative surface damage.

Salvinski, R. J.↗

NASA NTRS1965

Postflight Evaluation of Atlas-Centaur AC-5 (Launched 2 March 1965)

The Atlas-Centaur AC-5 vehicle was launched from ETR Complex 36A on March 2., 1965 at 8:25.04 a.m. EST. Within about 1 second after launch the thrust of the Atlas booster engine decayed rapidly; the vehicle settled back on the launch pad and was quickly destroyed by fire and explosion. Considerable damage was sustained by the launch complex and its associated equipment. Loss of booster engine thrust was due to fuel depletion at the turbopump inlets, which is attributed to closure of the fuel prevalve or the staging valve. To preclude the recurrence of either of these fuel valving malfunctions, the following corrective action has been taken: The remote control actuator has been replaced by manual operation of the Atlas fuel prevalve; the internal passage dimensions in the staging valve have been increased to lessen the hydraulic load on the valve poppet. In addition to the Atlas fuel system malfunction, a failure in the power control circuitry of the Centaur guidance computer resulted in partial removal of power at umbilical ejection. To prevent such a guidance system failure on future flights some redundant circuitry has been eliminated and more rigorous checkout procedures have been adopted. No further anomalies were discovered in the telemetered data prior to the Atlas booster thrust decay. A prime objective of the AC-5 flight was to place a dynamic model of the Surveyor spacecraft in a simulated lunar transfer trajectory. An important facet of this problem is the demonstration of a launch-on-time capability in accordance with the proper Earth-moon relation. The window opening time was established at 8:25 a.m. EST; thus the actual launch occurred within 4 seconds of the planned time.

Source record↗