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NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

For nearly two decades, NASA Glenn Research Center has been supporting the development of radioisotope power systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long-life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and three are proceeding to the fabrication phase of prototype dynamic convertors. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should be coordinated with the development of a dynamic convertor. As a result of this, Glenn has been utilizing hardware from past Stirling convertor projects, including that of the ASRG, to support controller development for the DPCs. Glenn has developed a strong knowledge base on both analog and digital Stirling DPC controllers and will continue to expand and apply that knowledge to the DPCs. Over the past 15 years, controllers were developed at Glenn, at Lockheed Martin (LM), and by the Johns Hopkins University Applied Physics Laboratory (APL). Various generations of the controllers have been developed as lessons were learned through various component- and system-level tests. Some of the tests performed were fault tolerance, flight acceptance vibration, electromagnetic interference (EMI), spacecraft integration, and extended operation. The fault tolerance test characterized the controller’s ability to handle various fault conditions, including high or low bus power consumption, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the Stirling convertor. The vibration test confirms the controller’s ability to control an Advanced Stirling Convertor (ASC) during launch. The EMI test characterized the alternating-current (AC) and direct-current (DC) magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. Spacecraft integration testing in the Radioisotope Power Systems (RPS), System Integration Laboratory (RSIL) provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long-term performance data of the system. This paper describes the history of controller development at Glenn, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗

NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

For nearly two decades, NASA Glenn Research Center (GRC) has been supporting the development of Radioisotope Power Systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and three are proceeding to the fabrication phase of prototype dynamic convertors. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should be coordinated with the development of a dynamic convertor. As a result of this, NASA GRC has been utilizing hardware from past Stirling convertor projects including that of the ASRG to support controller development for the DPC's. NASA GRC has developed a strong knowledge base on both analog and digital Stirling dynamic power convertor controllers and will continue to expand and apply that knowledge to the DPC's. Over the past 15 years, controllers were developed at GRC, at Lockheed Martin (LM) and by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL). Various generations of the controllers have been developed as lessons were learned through various component and system level tests. Some of the tests performed were fault tolerance, flight acceptance vibration, electromagnetic interference (EMI), spacecraft integration, and extended operation. The fault tolerance test characterized the controller's ability to handle various fault conditions, including high or low bus power consumptions, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the Stirling convertor. The vibration test confirms the controller's ability to control an ASC during launch. The EMI test characterized the AC and DC magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. Spacecraft integration testing in the Radioisotope Power Systems System Integration Laboratory (RSIL) provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long term performance data of the system. This paper describes the history of controller development at NASA GRC, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗

DOE OSTI2022

Thermocouple Testing in Support of the AGR-5/6/7 Experiment

This report documents thermocouple testing performed in IRC Lab C-15 over a period of seven years. This testing supported selection and characterization of the thermocouple set used in the AGR-5/6/7 experiment. The following summary was taken directly from the report. Temperature measurement is a challenging aspect of very high temperature irradiation experiments because commonly used high-temperature commercial thermocouples such as platinum-rhodium (Types S, R, and B) and tungsten-rhenium (Type C), suffer dramatic drift because of neutron-induced transmutation. As a result, these types of thermocouples, which are used routinely for industrial temperature measurements outside of reactors, are used only in very special circumstances for reactor experiments. Conversely, because of their low neutron cross-sections, Type N thermocouples are affected to only a limited extent by neutron irradiation. However, the use of these nickel-based thermocouples is limited when the temperature exceeds 1050°C due to drift arising from minor alloying elements migrating from the thermocouple's metal sheath to the thermoelements. This change in the composition of the thermo-elements results in significant decalibration of the signal. The issues described above were recognized during the early planning stages of the final AGR experiment (designated AGR-5/6/7), and a thermocouple furnace testing program was performed over a seven-year period (2014-2019, 2021) to first select and then characterize the best thermocouple set for the high temperature regions of the AGR-5/6/7 irradiation experiment. The calculated temperature range of the AGR-5/6/7 experiment was 600–1500°C. For temperatures below 1000°C standard Type N thermocouples were deemed adequate. The furnace testing campaign identified two thermocouple types suitable for measuring temperatures above 1000°C, a Mo/Nb thermocouple developed at INL called HTIR-TC, and a Type N thermocouple developed by Cambridge University (called herein Cambridge Type N), which featured a custom high nickel alloy sheath. One of the original goals of the furnace testing program was to identify a thermocouple capable of low drift operation near the peak temperature expected in AGR-5/6/7, i.e., about 1400°C. The HTIR-TC design appeared promising in this regard, however a manufacturing difficulty proved to be a barrier and instead the furnace testing focused on drift performance at 1250°C. The manufacturing difficulty was that the Nb sheaths of the HTIR-TCs experienced extreme embrittlement when heat treated at 1600°C or greater. Heat treatment is needed to stabilize the emf output of this TC type, and the higher the heat treatment temperature the higher the peak temperature of stable operation. Because of the sheath embrittlement the heat treatment temperature had to be lowered to 1450°C resulting in a stable operating temperature of about 1250°C. One of the successes of the furnace testing program was identification of a shortcoming in the heat treatment procedure that had been traditionally used in the production of HTIR-TCs. The shortcoming was that the entire heated length of the HTIR-TC sensor was not being heat treated, but rather only the part of the sensor expected to experience temperatures above 1000°C. The problem manifested itself when the thermocouples were removed from the heat treat furnace and placed in another furnace with a different geometry, their indicated temperatures would be widely scattered, but mostly in the negative direction. The solution was to heat treat the entire heated length of the sensor. Since the deepest immersion depth in the AGR-5/6/7 experiment was about 40 inches, a heat treatment length of 48 inches was used. After this change was implemented, thermocouples which were moved into a new environment with a different temperature profile (i.e., a different furnace), produced accurate temperature measurements. Although assembly of the AGR-5/6/7 experiment was completed in September of 2017 (and irradiation begun in 2018), furnace testing of thermocouples continued in 2018 and 2019. The main purpose of this testing was to establish very long-term drift characteristics of the HTIR and Cambridge Type N thermocouples installed in the experiment. Representative thermocouples from the same lots as those installed in the AGR-5/6/7 experiment were used. Additionally, thermocouples of different designs, (particularly variations on the HTIR-TC design) were "piggy-backed" on this testing program to provide insights for instrumenting future very high temperature irradiation experiments. This two-year testing program demonstrated that HTIR-TCs and Cambridge Type N TCs could operate at 1250°C for up to 10,000 hrs (and in some cases longer) while experiencing negative drifts on the order of 2-4°C/1000 hrs. This performance was considered acceptable given the extreme operating environment the sensors faced.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1982

Inert gas test of two 12-cm magnetostatic thrusters

Comparative performance tests were conducted with 12 cm line and ring magnetic cusp thrusters. Shell anode and magnetoelectrostatic containment boundary anode configurations were evaluated with each magnet array. The best performance was achieved with the 12-cm ring cusp-shell anode configuration. Argon operation of this configuration produced 65-81 percent mass utilization efficiency at 170-208 watts/single-charged-equivalent (SCE) ampere beam. Xenon test results showed 75-95 percent utilization at 162-188 watts/SCE ampere beam.

Ramsey, W. D.↗

NASA NTRS1981

Traction contact performance evaluation at high speeds

The results of traction tests performed on two fluids are presented. These tests covered a pressure range of 1.0 to 2.5 GPa, an inlet temperature range of 30 'C to 70 'C, a speed range of 10 to 80 m/sec, aspect ratios of .5 to 5 and spin from 0 to 2.1 percent. The test results are presented in the form of two dimensionless parameters, the initial traction slope and the maximum traction peak. With the use of a suitable rheological fluid model the actual traction curves measured can now be reconstituted from the two fluid parameters. More importantly, the knowledge of these parameters together with the fluid rheological model, allow the prediction of traction under conditions of spin, slip and any combination thereof. Comparison between theoretically predicted traction under these conditions and those measured in actual traction tests shows that this method gives good results.

Tevaarwerk, J. L.↗

NASA NTRS2002

Advanced Control Surface Seal Development at NASA GRC for 3rd Generation RLV

NASA's Glenn Research Center (GRC) is developing advanced control surface seal technologies for the 3rd Generation RLV program. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig are being developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. High temperature ceramic preloading devices are being developed and evaluated as ways to improve seal resiliency.

Dunlap, Patrick H., Jr.↗

NASA NTRS2013

Performance Measurement of Advanced Stirling Convertors (ASC-E3)

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing data of the Advanced Stirling Convertor (ASC). The latest version of the ASC (ASC-E3, to represent the third cycle of engineering model test hardware) is of a design identical to the forthcoming flight convertors. For this generation of hardware, a joint Sunpower and GRC effort was initiated to improve and standardize the test support hardware. After this effort was completed, the first pair of ASC-E3 units was produced by Sunpower and then delivered to GRC in December 2012. GRC has begun operation of these units. This process included performance verification, which examined the data from various tests to validate the convertor performance to the product specification. Other tests included detailed performance mapping that encompassed the wide range of operating conditions that will exist during a mission. These convertors were then transferred to Lockheed Martin for controller checkout testing. The results of this latest convertor performance verification activity are summarized here.

Stirling Cycle↗

DOE OSTI2017

Quantitative Approach to Failure Mode and Effect Analysis for Linear Accelerator Quality Assurance

Purpose: To determine clinic-specific linear accelerator quality assurance (QA) TG-142 test frequencies, to maximize physicist time efficiency and patient treatment quality. Methods and Materials: A novel quantitative approach to failure mode and effect analysis is proposed. Nine linear accelerator-years of QA records provided data on failure occurrence rates. The severity of test failure was modeled by introducing corresponding errors into head and neck intensity modulated radiation therapy treatment plans. The relative risk of daily linear accelerator QA was calculated as a function of frequency of test performance. Results: Although the failure severity was greatest for daily imaging QA (imaging vs treatment isocenter and imaging positioning/repositioning), the failure occurrence rate was greatest for output and laser testing. The composite ranking results suggest that performing output and lasers tests daily, imaging versus treatment isocenter and imaging positioning/repositioning tests weekly, and optical distance indicator and jaws versus light field tests biweekly would be acceptable for non-stereotactic radiosurgery/stereotactic body radiation therapy linear accelerators. Conclusions: Failure mode and effect analysis is a useful tool to determine the relative importance of QA tests from TG-142. Because there are practical time limitations on how many QA tests can be performed, this analysis highlights which tests are the most important and suggests the frequency of testing based on each test's risk priority number.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

NASA NTRS2025

Details of Adhering and Testing Artificial Ice Shapes to the High Lift Common Research Model in the National Transonic Facility

There is currently interest in conducting flight Reynolds number aerodynamic performance testing for iced airplane configurations. There has only been limited testing in the past, none of which has resulted in publicly available data. Consequently, there is virtually no documented knowledge for conducting icing related testing at flight Reynolds number where testing in cryogenic conditions is required. The National Transonic Facility (NTF) is a cryogenic wind tunnel at NASA Langley Research Center that is capable of achieving flight Reynolds numbers on subscale models. A large number of aerodynamic tests have been performed in this facility for uniced subscale model configurations. Through the collaborations associated with the High Lift Common Research Model, a test campaign was conducted to fill the existing research gaps with publicly available data. This resulted in a requirement that NASA develop a suitable level of competency for performing icing related tests in cryogenic environments. This document provides information about the challenges faced during the test campaign, how the issues were mitigated, and preserves the institutional knowledge gained by providing recommendations that will be used to reduce risk for future testing.

Iced Aerodynamics↗

NASA NTRS2010

Sublimator Driven Coldplate Engineering Development Unit Test Results

The Sublimator Driven Coldplate (SDC) is a unique piece of thermal control hardware that has several advantages over a traditional thermal control scheme. The principal advantage is the possible elimination of a pumped fluid loop, potentially increasing reliability and reducing complexity while saving both mass and power. Because the SDC requires a consumable feedwater, it can only be used for short mission durations. Additionally, the SDC is ideal for a vehicle with small transport distances and low heat rejection requirements. An SDC Engineering Development Unit was designed and fabricated. Performance tests were performed in a vacuum chamber to quantify and assess the performance of the SDC. The test data was then used to develop correlated thermal math models. Nonetheless, an Integrated Sublimator Driven Coldplate (ISDC) concept is being developed. The ISDC couples a coolant loop with the previously described SDC hardware. This combination allows the SDC to be used as a traditional coldplate during long mission phases and provides for dissimilar system redundancy

Sheth, Rubik B.↗

DOE OSTI2018

Crystalline Silicotitanate ion exchange media long-term storage evaluation

Crystalline Silicotitanate a (CST) ion exchange media is produced in an engineered form, known as IONSIV™ IE-911. This material has been tested extensively for use in removing 137 Cs from Savannah River Site (SRS) and Hanford site tank waste. This inorganic material is highly selective for removing cesium ions, even in the presence of high concentrations of sodium and potassium ions and is tolerant of the harsh conditions of the varying tank chemistries. A batch of caustic washed IE-911 that had been produced by the supplier and received at SRS in 2001 was tested to verify that it was still in good condition after the extended storage. This testing involved standard batch contacts to measure the removal of Cs from simulated tank waste. This report describes the results of testing performed to verify that the IE-911 matches the performance of previous batches of this media. To confirm that the performance of IE-911 is similar to previous batches and that no degradation had occurred during storage, batch contact testing was performed using SRNL’s standard methodology using a non-radioactive SRS Average Waste Simulant composition utilized in previous studies. Batch contact kinetics testing was also conducted to determine cesium loading on this batch versus time. The cesium equilibrium loading isotherm in SRS simulant at 23°C was compared to ZAM isotherm model predictions and previous test results with IE-911 media. The measured and predicted distribution coefficients and cesium loading (“Q”) are shown in Table ES-1. The physical properties of the material were also determined, including density, moisture content, and particle size.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2001

Fatigue Life Methodology for Bonded Composite Skin/Stringer Configurations

A methodology is presented for determining the fatigue life of composite structures based on fatigue characterization data and geometric nonlinear finite element (FE) analyses. To demonstrate the approach, predicted results were compared to fatigue tests performed on specimens which represented a tapered composite flange bonded onto a composite skin. In a first step, tension tests were performed to evaluate the debonding mechanisms between the flange and the skin. In a second step, a 2D FE model was developed to analyze the tests. To predict matrix cracking onset, the relationship between the tension load and the maximum principal stresses transverse to the fiber direction was determined through FE analysis. Transverse tension fatigue life data were used to -enerate an onset fatigue life P-N curve for matrix cracking. The resulting prediction was in good agreement with data from the fatigue tests. In a third step, a fracture mechanics approach based on FE analysis was used to determine the relationship between the tension load and the critical energy release rate. Mixed mode energy release rate fatigue life data were used to create a fatigue life onset G-N curve for delamination. The resulting prediction was in good agreement with data from the fatigue tests. Further, the prediction curve for cumulative life to failure was generated from the previous onset fatigue life curves. The results showed that the methodology offers a significant potential to Predict cumulative fatigue life of composite structures.

Krueger, Ronald↗

NASA NTRS1992

Performance of a 12-GHz fiber-optic system for beam-waveguide antenna stability testing

A 12-GHz fiber-optic system is a critical part of a test configuration that was proposed for measuring the fractional frequency stability of the Deep Space Station (DSS)-13 beam-waveguide (BWG) antenna. This fiber-optic system is used to carry Ku-band (12-GHz) signals from a reference antenna to the DSS-13 BWG pedestal room. Tests performed only on the fiber-optic system portion of the overall test configuration showed that the 12-GHz fiber-optic system (installed at DSS-13) has a frequency stability of about 1.1 x 10(exp -16) for sampling time tau = 1000 sec for a nighttime run. This preliminary result establishes the lowest noise floor that can probably be achieved for the test configuration that will be used to measure the frequency stability of the DSS-13 BWG antenna.

Otoshi, T. Y.↗

DOE OSTI2013

IMPLEMENTING PRIMARY CREEP CALCULATIONS DURING STRESS CHANGES AND REVERSALS IN THE FUEL PERFORMANCE CODE FRAPCON-3

Recently, the creep models in FRAPCON-3.4 were used to model the creep tests performed in IFA-699 up through cycle 4. IFA-699 is an instrumented test rig in the Halden Boiling Water Reactor that is being used to perform in-reactor creep experiments under changing stress conditions. The cladding creep tests in IFA-699 were on four fresh fuel segments with Zircaloy-4, E110, M-MDA, and M5™ cladding. These fuel segments were loaded in a test rig and placed in a PWR loop and operated under PWR conditions. Each of the test fuel rods were connected to gas lines in order to apply tensile and compressive stresses to the cladding. Diameters of the cladding were measured by diameter gages at several intervals to measure the creep behavior of the cladding as a function of time. The creep tests were performed at a temperature of around 360°C and fast neutron flux of 1.8 to 2.4×1017 n/m²-s (depends on specimen location). During the four cycles of operation, hoop stresses of -75, -50, +30, and +110 MPa were applied to the specimens. In addition to providing assessment of the FRAPCON-3.4 creep modeling, the creep model comparisons were also used to provide insight into the nature of primary creep following stress changes, whether creep behavior is symmetric under tensile and compressive loading, and the effect of fast fluence on creep rate. It was determined that creep strain should be calculated as a function of effective stress rather than hoop stress. This accounts for the observed difference between creep under compressive and tensile stress for the same hoop stress. It was also determined that the primary creep changes in proportion to the change in stress following stress change or stress reversal. Finally, it was observed that the irradiation creep rate decreases somewhat with increasing fluence. The creep model in FRAPCON-3.4 has already been developed to be a function of effective stress and includes a term that decreases the irradiation creep rate with increasing fluence. A new mathematical formulation has been developed that is suitable for a fuel performance code to calculate the primary creep strain under conditions of changing stress and stress reversal. The creep model in FRAPCON-3.4 and the formulation for calculating primary creep under changing stress conditions will be described in this paper. Comparisons to data will also be provided.

Geelhood, Kenneth J.↗

NASA NTRS1985

RE-1000 free-piston Stirling engine update

A free piston Stirling engine was tested. The tests performed over the past several years on the single cylinder engine were designed to investigate the dynamics of a free piston Stirling engine. The data are intended to be used primarily for computer code validation. The tests designed to investigate the sensitivity of the engine performance to variations in working space pressure, heater and cooler temperatures, regenerator porosity, power piston mass and displacer dynamics were completed. In addition, some data were recorded with alternate working fluids. A novel resonant balance system for the engine was also tested. Some preliminary test results of the tests performed are presented along with an outline of future tests to be run with the engine coupled to a hydraulic output unit. A description of the hydraulic output unit is given.

Schreiber, J. G.↗

NASA NTRS1985

RE-1000 free-piston Stirling engine update

Schreiber, J.↗

NASA NTRS2014

CO2 Washout Testing Using Various Inlet Vent Configurations in the Mark-III Space Suit

Requirements for using a space suit during ground testing include providing adequate carbon dioxide (CO2) washout for the suited subject. Acute CO2 exposure can lead to symptoms including headache, dyspnea, lethargy and eventually unconsciousness or even death. Symptoms depend on several factors including inspired partial pressure of CO2 (ppCO2), duration of exposure, metabolic rate of the subject and physiological differences between subjects. Computational Fluid Dynamic (CFD) analysis has predicted that the configuration of the suit inlet vent has a significant effect on oronasal CO2 concentrations. The main objective of this test is to characterize inspired oronasal ppCO2 for a variety of inlet vent configurations in the Mark-III space suit across a range of workload and flow rates. As a secondary objective, results will be compared to the predicted CO2 concentrations and used to refine existing CFD models. These CFD models will then be used to help design an inlet vent configuration for the Z-2 space suit, which maximizes oronasal CO2 washout. This test has not been completed, but is planned for January 2014. The results of this test will be incorporated into this paper. The testing methodology used in this test builds upon past CO2 washout testing performed on the Z-1 suit, Rear Entry I-Suit (REI) and the Enhanced Mobility Advanced Crew Escape Suit (EM-ACES). Three subjects will be tested in the Mark-III space suit with each subject performing two test sessions to allow for comparison between tests. Six different helmet inlet vent configurations will be evaluated during each test session. Suit pressure will be maintained at 4.3 psid. Subjects will wear the suit while walking on a treadmill to generate metabolic workloads of approximately 2000 and 3000 BTU/hr. Supply airflow rates of 6 and 4 actual cubic feet per minute (ACFM) will be tested at each workload. Subjects will wear an oronasal mask with an open port in front of the mouth and will be allowed to breathe freely. Oronasal ppCO2 will be monitored real-time via gas analyzers with sampling tubes connected to the oronasal mask. Metabolic rate will be calculated from the total oxygen consumption and CO2 production measured by additional gas analyzers at the air outlet from the suit. Real-time metabolic rate measurements will be used to adjust the treadmill workload to meet target metabolic rates. This paper provides detailed descriptions of the test hardware, methodology and results, as well as implications for future inlet vent design and ground testing in the Mark-III.

Korona, F. Adam↗

DOE OSTI2017

Optimal Nested Test Plan for Combinatorial Quantitative Group Testing

We consider the quantitative group testing problem where the objective is to identify defective items in a given population based on results of tests performed on subsets of the population. Under the quantitative group testing model, the result of each test reveals the number of defective items in the tested group. The minimum number of tests achievable by nested test plans was established by Aigner and Schughart in 1985 within a minimax framework. Furthermore, the optimal nested test plan offering this performance, however, was not obtained. In this paper, we establish the optimal nested test plan in a closed form. This optimal nested test plan is also order optimal among all test plans as the population size approaches infinity. Using heavy-hitter detection as a case study, we show via simulation examples orders of magnitude improvement of the group testing approach over two prevailing sampling-based approaches in detection accuracy and counter consumption. Other applications include anomaly detection and wideband spectrum sensing in cognitive radio systems.

97 MATHEMATICS AND COMPUTING↗