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At least 1,027 records · Page 57

The Use of Environmental Test Facilities for Purposes Beyond Their Original Design

Increasing demands from space flight project offices are requiring environmental testing facilities to become more versatile with increased capabilities. At the same time, maintaining a cost-effective approach to test operations has driven efforts to use these facilities for purposes beyond their original design. This paper presents an overview of the Jet Propulsion Laboratory's efforts to provide JPL's space flight projects with test facilities to meet unique test requirements and to serve the needs of selected outside customers. The large number of recent Mars Missions, including the Mars Pathfinder project, have required testing of components and systems in a Martian surface environment in facilities originally designed for deep space testing. The unique problems associated with performing these tests are discussed, along with practical solutions. Other unique test requirements are discussed including the use of space simulation chambers for testing high altitude balloon gondolas and the use of vacuum chambers for system level test firing of an ion propulsion engine.

Fisher, Terry C.↗

The National Transonic Facility: A Research Retrospective

An overview of the National Transonic Facility (NTF) from a research utilization perspective is provided. The facility was born in the 1970s from an internationally recognized need for a high Reynolds number test capability based on previous experiences with preflight predictions of aerodynamic characteristics and an anticipated need in support of research and development for future aerospace vehicle systems. Selection of the cryogenic concept to meet the need, unique capabilities of the facility, and the eventual research utilization of the facility are discussed. The primary purpose of the paper is to expose the range of investigations that have used the NTF since being declared operational in late 1984; limited research results are included, though many more can be found in the references.

Wahls, R. A.↗

Utilizing the US Lab Nadir Research Window for Remote Sensing Operations with The Window Observational Research Facility (WORF)

The Window Observational Research Facility (WORF) is an ISPR-based rack facility designed to take advantage of the high optical quality US Lab Nadir research window. The WORF is based on the ISS Expedite the Processing of Experiments to Space Station (EXPRESS) rack mechanical structure and electronic systems. The WORF has a unique payload volume located at the center of the rack that provides access to the window. The interior dimensions of the payload volume are 34-in. (86.36 cm) wide by 33-in. (83.82 cm) high by 23-in. (58.42 cm) deep. This facility supports the deployment of payloads such as 9 in. aerial photography cameras and 12 in. diameter optical equipment. The WORF coupled with the optical quality of the United States Lab window support the deployment of various payload disciplines. The WORF provides payloads with power, data command and control, air cooling, water cooling, and video processing. The WORF's payload mounting surfaces and interfaces include the interior payload mounting shelf and the interior and exterior aircraft-like seat tracks. The payload mounting shelf is limited to a maximum mass of 136 kg (299 pounds). The WORF can accommodate large payloads such as the commonly used Leica-Heerbrug RC-30 aerial photography camera (whose dimensions are 53.3 cm (21-in.) wide by 50.8 cm (20-in.) deep by 76.2 cm (30-in.) long). The performance characteristics of the WORF allow it to support an array of payload disciplines. The WORF provides a maximum of 3 Kw at 28 Vdc and has a maximum data rate of 10 Mbps. The WORF's unique payload volume is designed to be light-tight, down to 2.8 x 10(exp -11) Watts/cm2/steradian, and have low-reflective surfaces. This specially designed WORF interior supports payload investigations that observe low-light-level phenomenon such as aurora. Although the WORF rack does not employ any active rack isolation (i.e., vibration dampening) technology, the rack provides a very stable environment for payload operations (on the order of X microradians). The facility's software is capable of being updated during its period of deployment. The WORF project also includes a Suitcase Simulator to allow for a payload developer to verify data interfaces at his development site, a trainer rack for astronauts to learn how to operate the WORF prior to flight, and the use of the EXPRESS Functional Checkout Units to allow for payload checkout at the KSC prior to launch.

Turner, Richard↗

Ames Hybrid Combustion Facility

The report summarizes the design, fabrication, safety features, environmental impact, and operation of the Ames Hybrid-Fuel Combustion Facility (HCF). The facility is used in conducting research into the scalability and combustion processes of advanced paraffin-based hybrid fuels for the purpose of assessing their applicability to practical rocket systems. The facility was designed to deliver gaseous oxygen at rates between 0.5 and 16.0 kg/sec to a combustion chamber operating at pressures ranging from 300 to 900. The required run times were of the order of 10 to 20 sec. The facility proved to be robust and reliable and has been used to generate a database of regression-rate measurements of paraffin at oxygen mass flux levels comparable to those of moderate-sized hybrid rocket motors.

Zilliac, Greg↗

Integrated Component-based Data Acquisition Systems for Aerospace Test Facilities

The Multi-Instrument Integrated Data Acquisition System (MIIDAS), developed by the NASA Langley Research Center, uses commercial off the shelf (COTS) products, integrated with custom software, to provide a broad range of capabilities at a low cost throughout the system s entire life cycle. MIIDAS combines data acquisition capabilities with online and post-test data reduction computations. COTS products lower purchase and maintenance costs by reducing the level of effort required to meet system requirements. Object-oriented methods are used to enhance modularity, encourage reusability, and to promote adaptability, reducing software development costs. Using only COTS products and custom software supported on multiple platforms reduces the cost of porting the system to other platforms. The post-test data reduction capabilities of MIIDAS have been installed at four aerospace testing facilities at NASA Langley Research Center. The systems installed at these facilities provide a common user interface, reducing the training time required for personnel that work across multiple facilities. The techniques employed by MIIDAS enable NASA to build a system with a lower initial purchase price and reduced sustaining maintenance costs. With MIIDAS, NASA has built a highly flexible next generation data acquisition and reduction system for aerospace test facilities that meets customer expectations.

Ross, Richard W.↗

Langley Aerothermodynamic Facilities Complex: Enhancements and Testing Capabilities

Description, capabilities, recent upgrades, and utilization of the NASA Langley Research Center (LaRC) Aerothermodynamic Facilities Complex (AFC) are presented. The AFC consists of five hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 20, unit Reynolds number from 0.04 to 22 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of three different test gases (air, helium, and tetrafluoromethane), thereby making several of the facilities unique. The Complex represents nearly three-fourths of the conventional (as opposed to impulse)-type hypersonic wind tunnels operational in this country. AFC facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data fr generating the flight aerodynamic databook and final design of the thermal protection system (TPS) (e.g., establishment of flight limitations not to exceed TPS design limits). Modifications and enhancements of AFC hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. Examples illustrating facility utilization in recent years to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs are presented. These programs include Phase I of the Reusable Launch Vehicle (RLV) Advanced Technology Demonstrator, X-33 program, PHase II of the X-33 program, X-34 program, the Hyper-X program ( a Mach 5,7, and 10 airbreathing propulsion flight experiment), and the X-38 program (Experimental Crew Return Vehicle, X-CRV). Current upgrades/enchancements and future plans for the AFC are discussed.

Micol, J. R.↗

Facility Activation and Characterization for IPD Oxidizer Turbopump Cold-Flow Testing at NASA Stennis Space Center

The Integrated Powerhead Demonstrator (IPD) is a 250K lbf (1.1 MN) thrust cryogenic hydrogen/oxygen engine technology demonstrator that utilizes a full flow staged combustion engine cycle. The Integrated Powerhead Demonstrator (IPD) is part of NASA's Next Generation Launch Technology (NGLT) program, which seeks to provide safe, dependable, cost-cutting technologies for future space launch systems. The project also is part of the Department of Defense's Integrated High Payoff Rocket Propulsion Technology (IHPRPT) program, which seeks to increase the performance and capability of today s state-of-the-art rocket propulsion systems while decreasing costs associated with military and commercial access to space. The primary industry participants include Boeing-Rocketdyne and GenCorp Aerojet. The intended full flow engine cycle is a key component in achieving all of the aforementioned goals. The IPD Program achieved a major milestone with the successful completion of the IPD Oxidizer Turbopump (OTP) cold-flow test project at the NASA John C. Stennis Space Center (SSC) E-1 test facility in November 2001. A total of 11 IPD OTP cold-flow tests were completed. Following an overview of the NASA SSC E-1 test facility, this paper addresses the facility aspects pertaining to the activation and the cold-flow testing of the IPD OTP. In addition, some of the facility challenges encountered during the test project are addressed.

Sass, J. P.↗

Space Communications Emulation Facility

Establishing space communication between ground facilities and other satellites is a painstaking task that requires many precise calculations dealing with relay time, atmospheric conditions, and satellite positions, to name a few. The Space Communications Emulation Facility (SCEF) team here at NASA is developing a facility that will approximately emulate the conditions in space that impact space communication. The emulation facility is comprised of a 32 node distributed cluster of computers; each node representing a satellite or ground station. The objective of the satellites is to observe the topography of the Earth (water, vegetation, land, and ice) and relay this information back to the ground stations. Software originally designed by the University of Kansas, labeled the Emulation Manager, controls the interaction of the satellites and ground stations, as well as handling the recording of data. The Emulation Manager is installed on a Linux Operating System, employing both Java and C++ programming codes. The emulation scenarios are written in extensible Markup Language, XML. XML documents are designed to store, carry, and exchange data. With XML documents data can be exchanged between incompatible systems, which makes it ideal for this project because Linux, MAC and Windows Operating Systems are all used. Unfortunately, XML documents cannot display data like HTML documents. Therefore, the SCEF team uses XML Schema Definition (XSD) or just schema to describe the structure of an XML document. Schemas are very important because they have the capability to validate the correctness of data, define restrictions on data, define data formats, and convert data between different data types, among other things. At this time, in order for the Emulation Manager to open and run an XML emulation scenario file, the user must first establish a link between the schema file and the directory under which the XML scenario files are saved. This procedure takes place on the command line on the Linux Operating System. Once this link has been established the Emulation manager validates all the XML files in that directory against the schema file, before the actual scenario is run. Using some very sophisticated commercial software called the Satellite Tool Kit (STK) installed on the Linux box, the Emulation Manager is able to display the data and graphics generated by the execution of a XML emulation scenario file. The Emulation Manager software is written in JAVA programming code. Since the SCEF project is in the developmental stage, the source code for this type of software is being modified to better fit the requirements of the SCEF project. Some parameters for the emulation are hard coded, set at fixed values. Members of the SCEF team are altering the code to allow the user to choose the values of these hard coded parameters by inserting a toolbar onto the preexisting GUI.

Hill, Chante A.↗

Atomic Oxygen Lamp Cleaning Facility Fabricated and Tested

NASA Lewis Research Center's Atomic Oxygen Lamp Cleaning Facility was designed to produce an atomic oxygen plasma within a metal halide lamp to remove carbon-based contamination. It is believed that these contaminants contribute to the high failure rate realized during the production of these lamps. The facility is designed to evacuate a metal halide lamp and produce a radio frequency generated atomic oxygen plasma within it. Oxygen gas, with a purity of 0.9999 percent and in the pressure range of 150 to 250 mtorr, is used in the lamp for plasma generation while the lamp is being cleaned. After cleaning is complete, the lamp can be backfilled with 0.9999-percent pure nitrogen and torch sealed. The facility comprises various vacuum components connected to a radiation-shielded box that encloses the bulb during operation. Radiofrequency power is applied to the two parallel plates of a capacitor, which are on either side of the lamp. The vacuum pump used, a Leybold Trivac Type D4B, has a pumping speed of 4-m3/hr, has an ultimate pressure of <8x10-4, and is specially adapted for pure oxygen service. The electronic power supply, matching network, and controller (500-W, 13.56-MHz) used to supply the radiofrequency power were purchased from RF Power Products Inc. Initial test results revealed that this facility could remove the carbon-based contamination from within bulbs.

Sechkar, Edward A.↗

Facility and Methods Developed for Simulated Space Vacuum Ultraviolet Exposure Testing of Polymer Films

Vacuum ultraviolet (VUV) radiation of wavelengths between 115 and 200 nm produced by the Sun in the space environment can degrade polymer films, producing changes in their optical, mechanical, and chemical properties. These effects are particularly important for thin polymer films being considered for ultralightweight space structures, because, for most polymers, VUV radiation is absorbed in a thin surface layer. The NASA Glenn Research Center has developed facilities and methods for long-term ground testing of polymer films to evaluate space environmental VUV radiation effects. VUV exposure can also be used as part of combined or sequential simulated space environmental exposures to determine combined damaging effects with other aspects of the space environment, which include solar ultraviolet radiation, solar flare x-rays, electron and proton radiation, atomic oxygen (for low-Earth-orbit missions), and temperature effects. Because the wavelength sensitivity of VUV damage is not well known for most materials, Glenn's VUV facility uses a broad-spectrum deuterium lamp with a magnesium fluoride window that provides output between 115 and 200 nm. Deuterium lamps of this type were characterized by the National Institute of Standards and Technology and through measurements at Glenn. Spectral irradiance measurements show that from approximately 115 to 160 nm, deuterium lamp irradiance can be many times that of air mass zero solar irradiance, and as wavelength increases above approximately 160 nm, deuterium lamp irradiance decreases in comparison to the Sun. The facility is a cryopumped vacuum chamber that achieves a system pressure of approximately 5310(exp -6) torr. It contains four individual VUV-exposure compartments in vacuum, separated by water-cooled copper walls to minimize VUV radiation and any sample contamination cross interactions between compartments. Each VUV-exposure compartment contains a VUV deuterium lamp, a motor-controlled sample stage coupled with a moveable cesium iodide VUV phototube, and two thermocouples for temperature measurement. The vacuum chamber and exterior equipment is shown. Each VUV lamp is located at the top of the chamber with its projection-tube pushed through an O-ring compression fitting. The lamp assemblies are located on ports that can be isolated from the rest of the vacuum chamber, permitting maintenance or replacement of the lamps without breaking vacuum in the main chamber where the samples are located. A view of two of the four interior VUV-exposure compartments, including the moveable sample stages and detector holders is also shown. Glenn is using this facility to support testing of Next Generation Space Telescope sunshield materials that is being led by the NASA Goddard Space Flight Center and to develop an understanding of the wavelength, intensity, and temperature dependence of VUV-induced polymer degradation.

Dever, Joyce A.↗

Experimental Validation: Subscale Aircraft Ground Facilities and Integrated Test Capability

Experimental testing is an important aspect of validating complex integrated safety critical aircraft technologies. The Airborne Subscale Transport Aircraft Research (AirSTAR) Testbed is being developed at NASA Langley to validate technologies under conditions that cannot be flight validated with full-scale vehicles. The AirSTAR capability comprises a series of flying sub-scale models, associated ground-support equipment, and a base research station at NASA Langley. The subscale model capability utilizes a generic 5.5% scaled transport class vehicle known as the Generic Transport Model (GTM). The AirSTAR Ground Facilities encompass the hardware and software infrastructure necessary to provide comprehensive support services for the GTM testbed. The ground facilities support remote piloting of the GTM aircraft, and include all subsystems required for data/video telemetry, experimental flight control algorithm implementation and evaluation, GTM simulation, data recording/archiving, and audio communications. The ground facilities include a self-contained, motorized vehicle serving as a mobile research command/operations center, capable of deployment to remote sites when conducting GTM flight experiments. The ground facilities also include a laboratory based at NASA LaRC providing near identical capabilities as the mobile command/operations center, as well as the capability to receive data/video/audio from, and send data/audio to the mobile command/operations center during GTM flight experiments.

Bailey, Roger M.↗

Miniature On-Board Angle of Attack Measurement System for Hypersonic Facilities

The most prevalent method of establishing model angle of attack (AoA) in hypersonic wind tunnel facilities is using an encoder in the model support system then calculating sting/balance deflections based on balance output. This method has been shown to be less accurate than on-board methods in subsonic and transonic facilities and preliminary indications, as compared to optical methods, show large discrepancies in a hypersonic facility as well. With improvements in Micro-Electro- Mechanical Systems (MEMS) accelerometer technology more accurate onboard AoA measurement systems are now available for the small models usually found in hypersonic research facilities.

Crawford, Bradley L.↗

Cryogenic Test Capability at Marshall Space Flight Center's X-ray Cryogenic Test Facility

Marshall Space Flight Center's X-ray & Cryogenic Test Facility (XRCF) has been performing sub-liquid nitrogen temperature testing since 1999. Optical wavefront measurement, thermal structural deformation, mechanism functional & calibration, and simple cryo-conditioning tests have been completed. Recent modifications have been made to the facility in support of the James Webb Space Telescope (JWST) program. The chamber's payload envelope and the facility s refrigeration capacity have both been increased. Modifications have also been made to the optical instrumentation area improving access for both the installation and operation of optical instrumentation outside the vacuum chamber. The facility's capabilities, configuration, and performance data will be presented.

Kegley, Jeffrey↗

Marshall Space Flight Center's Impact Testing Facility Capabilities

Marshall Space Flight Center's (MSFC) Impact Testing Facility (ITF) serves as an important installation for space and missile related materials science research. The ITF was established and began its research in spacecraft debris shielding in the early 1960% then played a major role in the International Space Station debris shield development. As NASA became more interested in launch debris and in-flight impact concerns, the ITF grew to include research in a variety of impact genres. Collaborative partnerships with the DoD led to a wider range of impact capabilities being relocated to MSFC as a result of the closure of Particle Impact Facilities in Santa Barbara, California. The Particle Impact Facility had a 30 year history in providing evaluations of aerospace materials and components during flights through rain, ice, and solid particle environments at subsonic through hypersonic velocities. The facility's unique capabilities were deemed a "National Asset" by the DoD. The ITF now has capabilities including environmental, ballistic, and hypervelocity impact testing utilizing an array of air, powder, and two-stage light gas guns to accommodate a variety of projectile and target types and sizes. Relocated test equipment was dated and in need of upgrade. Numerous upgrades including new instrumentation, triggering circuitry, high speed photography, and optimized sabot designs have been implemented. Other recent research has included rain drop demise characterization tests to obtain data for inclusion in on-going model development. Future ITF improvements will be focused on continued instrumentation and performance enhancements. These enhancements will allow further, more in-depth, characterization of rain drop demise characterization and evaluation of ice crystal impact. Performance enhancements also include increasing the upper velocity limit of the current environmental guns to allow direct environmental simulation for missile components. The current and proposed ITF capabilities range from rain to micrometeoroids allowing the widest test parameter range possible for materials investigations in support of space, atmospheric, and ground environments. These test capabilities including hydrometeor, single/multi-particle, ballistic gas grins, exploding wire gun, and light gas guns combined with Smooth Particle Hydrodynamics Code (SPHC) simulations represent the widest range of impact test capabilities in the country.

Evans, Steve↗

Marshall Space Flight Center's Impact Testing Facility Capabilities

Marshall Space Flight Center's (MSFC) Impact Testing Facility (ITF) serves as an important installation for space and missile related materials science research. The ITF was established and began its research in spacecraft debris shielding in the early 1960s, then played a major role in the International Space Station debris shield development. As NASA became more interested in launch debris and in-flight impact concerns, the ITF grew to include research in a variety of impact genres. Collaborative partnerships with the DoD led to a wider range of impact capabilities being relocated to MSFC as a result of the closure of Particle Impact Facilities in Santa Barbara, California, The Particle Impact Facility had a 30 year history in providing evaluations of aerospace materials and components during flights through rain, ice, and solid particle environments at subsonic through hypersonic velocities. The facility's unique capabilities were deemed a 'National Asset' by the DoD, The ITF now has capabilities including environmental, ballistic, and hypervelocity impact testing utilizing an array of air, powder, and two-stage light gas guns to accommodate a variety of projectile and target types and sizes. Relocated test equipment was dated and in need of upgrade. Numerous upgrades including new instrumentation, triggering circuitry, high speed photography, and optimized sabot designs have been implemented. Other recent research has included rain drop demise characterization tests to obtain data for inclusion in on-going model development. Future ITF improvements will be focused on continued instrumentation and performance enhancements. These enhancements will allow further, more in-depth, characterization of rain drop demise characterization and evaluation of ice crystal impact. Performance enhancements also include increasing the upper velocity limit of the current environmental guns to allow direct environmental simulation for missile components. The current and proposed ITF capabilities range from rain to micrometeoroids allowing the widest test parameter range possible for materials investigations in support of space, atmospheric, and ground environments. These test capabilities including hydrometeor, single/multi-particle, ballistic gas guns, exploding wire gun, and light gas guns combined with Smooth Particle Hydrodynamics Code (SPHC) simulations represent the widest range of impact test capabilities in the country.

Evans, Steve↗

Marshall Space Flight Center's Impact Testing Facility Capabilities

Marshall Space Flight Center s (MSFC) Impact Testing Facility (ITF) serves as an important installation for space and missile related materials science research. The ITF was established and began its research in spacecraft debris shielding in the early 1960s, then played a major role in the International Space Station debris shield development. As NASA became more interested in launch debris and in-flight impact concerns, the ITF grew to include research in a variety of impact genres. Collaborative partnerships with the DoD led to a wider range of impact capabilities being relocated to MSFC as a result of the closure of Particle Impact Facilities in Santa Barbara, California. The Particle Impact Facility had a 30 year history in providing evaluations of aerospace materials and components during flights through rain, ice, and solid particle environments at subsonic through hypersonic velocities. The facility s unique capabilities were deemed a "National Asset" by the DoD. The ITF now has capabilities including environmental, ballistic, and hypervelocity impact testing utilizing an array of air, powder, and two-stage light gas guns to accommodate a variety of projectile and target types and sizes. Numerous upgrades including new instrumentation, triggering circuitry, high speed photography, and optimized sabot designs have been implemented. Other recent research has included rain drop demise characterization tests to obtain data for inclusion in on-going model development. The current and proposed ITF capabilities range from rain to micrometeoroids allowing the widest test parameter range possible for materials investigations in support of space, atmospheric, and ground environments. These test capabilities including hydrometeor, single/multi-particle, ballistic gas guns, exploding wire gun, and light gas guns combined with Smooth Particle Hydrodynamics Code (SPHC) simulations represent the widest range of impact test capabilities in the country.

Finchum, Andy↗

Ground Handling of Batteries at Test and Launch-site Facilities

Ground handling of flight as well as engineering batteries at test facilities and launch-site facilities is a safety critical process. Test equipment interfacing with the batteries should have the required controls to prevent a hazardous failure of the batteries. Test equipment failures should not induce catastrophic failures on the batteries. Transportation requirements for batteries should also be taken into consideration for safe transportation. This viewgraph presentation includes information on the safe handling of batteries for ground processing at test facilities as well as launch-site facilities.

Jeevarajan, Judith A.↗

Constellation Training Facility Support

The National Aeronautics and Space Administration is developing the next set of vehicles that will take men back to the moon under the Constellation Program. The Constellation Training Facility (CxTF) is a project in development that will be used to train astronauts, instructors, and flight controllers on the operation of Constellation Program vehicles. It will also be used for procedure verification and validation of flight software and console tools. The CxTF will have simulations for the Crew Exploration Vehicle (CEV), Crew Module (CM), CEV Service Module (SM), Launch Abort System (LAS), Spacecraft Adapter (SA), Crew Launch Vehicle (CLV), Pressurized Cargo Variant CM, Pressurized Cargo Variant SM, Cargo Launch Vehicle, Earth Departure Stage (EDS), and the Lunar Surface Access Module (LSAM). The Facility will consist of part-task and full-task trainers, each with a specific set of mission training capabilities. Part task trainers will be used for focused training on a single vehicle system or set of related systems. Full task trainers will be used for training on complete vehicles and all of its subsystems. Support was provided in both software development and project planning areas of the CxTF project. Simulation software was developed for the hydraulic system of the Thrust Vector Control (TVC) of the ARES I launch vehicle. The TVC system is in charge of the actuation of the nozzle gimbals for navigation control of the upper stage of the ARES I rocket. Also, software was developed using C standards to send and receive data to and from hand controllers to be used in CxTF cockpit simulations. The hand controllers provided movement in all six rotational and translational axes. Under Project Planning & Control, support was provided to the development and maintenance of integrated schedules for both the Constellation Training Facility and Missions Operations Facilities Division. These schedules maintain communication between projects in different levels. The CxTF support provided is one that requires continuous maintenance since the project is still on initial development phases.

Flores, Jose M.↗