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All sourcesNASA NTRSDOE OSTI
NASA NTRS1976

Liquid-metal magnetohydrodynamic system evaluation

The present study emphasizes a direct coal-fired design using a bubbly two-component flow of sodium and argon in the MHD generator and a Rankine steam-bottoming plant. Two basic cycles were studied, corresponding to argon temperatures of 922 and 1089 K at the duct inlet. The MHD duct system consisted of multiple ducts arranged in clusters and separated by iron magnet pole pieces. The ducts, each with an output of about 100 MW, were parallel to the flow, but were connected in series electrically to provide a higher MHD voltage. With channel efficiencies of 80%, a pump efficiency of 90%, and a 45% efficient steam-bottoming plant, the overall efficiency of the 1089 K liquid-metal MHD power plant was 43%.

Holman, R. R.↗
NASA NTRS2022

Design of Hypervelocity Flow Generator (HFG) and Its Diagnostics

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

Hypervelocity flow↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRS1993

Test Results of the RS-44 Integrated Component Evaluator Liquid Oxygen/Hydrogen Rocket Engine

An advanced LOX/LH2 expander cycle rocket engine, producing 15,000 lbf thrust for Orbital Transfer Vehicle missions, was tested to determine ignition, transition, and main stage characteristics. Detail design and fabrication of the pump fed RS44 integrated component evaluator (ICE) was accomplished using company discretionary resources and was tested under this contracted effort. Successful demonstrations were completed to about the 50 percent fuel turbopump power level (87,000 RPM), but during this last test, a high pressure fuel turbopump (HPFTP) bearing failed curtailing the test program. No other hardware were affected by the HPFTP premature shutdown. The ICE operations matched well with the predicted start transient simulations. The tests demonstrated the feasibility of a high performance advanced expander cycle engine. All engine components operated nominally, except for the HPFTP, during the engine hot-fire tests. A failure investigation was completed using company discretionary resources.

Sutton, R. F.↗
NASA NTRS1980

Emergency Lightning System

Super Vacuum Manufacturing Company's Stem-Lite Emergency Lighting System is widely used by fire, police, ambulance and other emergency service departments. The lights -- four floodlights which provide 2,000 watts of daytime equivalent visibility and a high-intensity flashing beacon can be elevated 10 feet above the roof of an emergency vehicle by means of an extendible mast. The higher elevation expands the effective radius of the floodlights and increases the beacon's visibility to several miles affording extra warning time to approaching traffic. When not in use, the light can be retracted into the compact rooftop housing. Stem-Lite also includes a generator which can serve to power such emergency equipment as pumps and drills, and a dashboard-mounted control panel for switching the lights and extending or retracting the mast.

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NASA NTRS2004

Acoustic Modeling and Analysis for the Space Shuttle Main Propulsion System Liner Crack Investigation

Cracks were found on bellows flow liners in the liquid hydrogen feedlines of several space shuttle orbiters in 2002. An effort to characterize the fluid environment upstream of the space shuttle main engine low-pressure fuel pump was undertaken to help identify the cause of the cracks and also provide quantitative environments and loads of the region. Part of this effort was to determine the duct acoustics several inches upstream of the low-pressure fuel pump in the region of a bellows joint. A finite element model of the complicated geometry was made using three-dimensional fluid elements. The model was used to describe acoustics in the complex geometry and played an important role in the investigation. Acoustic mode shapes and natural frequencies of the liquid hydrogen in the duct and in the cavity behind the flow liner were determined. Forced response results were generated also by applying an edgetone-like forcing to the liner slots. Studies were conducted for state conditions and also conditions assuming two-phase entrapment in the backing cavity. Highly instrumented single-engine hot fire data confirms the presence of some of the predicted acoustic modes.

Casiano, Matthew J.↗
NASA NTRS1993

Monolithic Continuous-Flow Bioreactors

Monolithic ceramic matrices containing many small flow passages useful as continuous-flow bioreactors. Ceramic matrix containing passages made by extruding and firing suitable ceramic. Pores in matrix provide attachment medium for film of cells and allow free movement of solution. Material one not toxic to micro-organisms grown in reactor. In reactor, liquid nutrients flow over, and liquid reaction products flow from, cell culture immobilized in one set of channels while oxygen flows to, and gaseous reaction products flow from, culture in adjacent set of passages. Cells live on inner surfaces containing flowing nutrient and in pores of walls of passages. Ready access to nutrients and oxygen in channels. They generate continuous high yield characteristic of immobilized cells, without large expenditure of energy otherwise incurred if necessary to pump nutrient solution through dense biomass as in bioreactors of other types.

Stephanopoulos, Gregory↗
NASA NTRS2002

The Awful Truth About Zero-Gravity: Space Acceleration Measurement System; Orbital Acceleration Research Experiment

Earth's gravity holds the Shuttle in orbit, as it does satellites and the Moon. The apparent weightlessness experienced by astronauts and experiments on the Shuttle is a balancing act, the result of free-fall, or continuously falling around Earth. An easy way to visualize what is happening is with a thought experiment that Sir Isaac Newton did in 1686. Newton envisioned a mountain extending above Earth's atmosphere so that friction with the air would be eliminated. He imagined a cannon atop the mountain and aimed parallel to the ground. Firing the cannon propels the cannonball forward. At the same time, Earth's gravity pulls the cannonball down to the surface and eventual impact. Newton visualized using enough powder to just balance gravity so the cannonball would circle the Earth. Like the cannonball, objects orbiting Earth are in continuous free-fall, and it appears that gravity has been eliminated. Yet, that appearance is deceiving. Activities aboard the Shuttle generate a range of accelerations that have effects similar to those of gravity. The crew works and exercises. The main data relay antenna quivers 17 times per second to prevent 'stiction,' where parts stick then release with a jerk. Cooling pumps, air fans, and other systems add vibration. And traces of Earth's atmosphere, even 200 miles up, drag on the Shuttle. While imperceptible to us, these vibrations can have a profound impact on the commercial research and scientific experiments aboard the Shuttle. Measuring these forces is necessary so that researchers and scientists can see what may have affected their experiments when analyzing data. On STS-107 this service is provided by the Space Acceleration Measurement System for Free Flyers (SAMS-FF) and the Orbital Acceleration Research Experiment (OARE). Precision data from these two instruments will help scientists analyze data from their experiments and eliminate outside influences from the phenomena they are studying during the mission.

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NASA NTRS2023

Passive Rocket Diffuser Testing: Reacting Flow Performance of Advanced Configurations

Upper stage rocket engines are optimized for operation at the edge of space. Ground testing often requires simulation of high-altitude environments to prevent damage from off-design operation. Passive supersonic diffusers are an effective means of establishing the partial vacuum needed around the nozzle exit. The low cost of diffusers relative to active vacuum sources (ejectors, pumps, etc.) provides a perpetual incentive to improve their performance and expand the envelope of passively testable engines. Second-throat diffusers have been the de facto standard for rocket testing since the 1950s, and numerous studies have focused on parametric optimization of the topology. Yet, even the best second-throat designs may require more driving pressure than an upper stage engine can provide. To overcome conventional limits, engineers at NASA’s Stennis Space Center (SSC) adapted an obscure cold-flow diffuser topology to the extremes of immersion in supersonic combustion products. Aerodynamic experimentation was conducted at SSC’s E-3 test stand to quantify the performance of prototypical hot-fire spike diffuser hardware and enable direct comparison to prior states of the art. A LO X /GH 2 thruster was contoured to approximate the regeneratively-cooled nozzle of an upper-stage engine and fired into 28 downstream diffuser configurations: 16 second-throat, 2 centerbody, and 10 spike. Temperature and pressure were recorded along the test article walls for a range of chamber pressures spanning 3.5 - 5.0 MPa. The second-throat configurations with the lowest start and unstart pressure ratios were shown to outperform equivalent systems in literature and taken as baselines for evaluation of advanced diffuser performance. Compared to these exemplars, centerbody diffusers decreased start pressure ratio by 11% but increased unstart pressure ratio by 15%. Spike diffusers reduced start and unstart pressure ratios by 24% and 9%, respectively.

Rocket↗
NASA NTRSDate not supplied

Nodal Modeling of Tank Pressurization and Draining using a Multi-Node-Ullage Approach

The purpose of the pressurization system in liquid rocket propulsion is to control the pressure in the gas space of the propellant tank (known as the ullage space) and the propellant mass flowrate to the engine. A mathematical model is required to predict the amount of pressurant necessary to ensure that pressure and temperature levels inside the tank remain within acceptable limits and that the propellant pressure leaving the tank satisfies the net positive suction pressure (NPSP) requirement of the pump feeding the engine. Nodal codes typically model tank pressurization and draining using a single node to represent the ullage and a single node to represent the propellant. As the tank drains, the ullage node grows and the propellant node shrinks. The heat transfer between ullage to wall and ullage to propellant is governed by natural convection. Designers of liquid propulsion systems often use empirical correlations to estimate the “Collapse Factor” which represents the ratio of pressurant required with heat transfer and the amount of pressurant required without heat transfer. A single node ullage model of tank pressurization was developed using GFSSP to compute the collapse factor reasonably well and later was used to model tank pressurization during test firing of the FASTRAC rocket engine. The predicted tank pressure compared well with the test data. In the early 1970’s, pressurization and drain tests with liquid methane were performed at NASA Lewis Research Center in a vacuum chamber. A 5 ft diameter spherical aluminum tank was tested to drain from 95% to 5% full using gaseous helium, hydrogen, nitrogen and methane as pressurant. Tests were conducted with different pressurant inlet temperatures and drain times. Measured data include pressurant requirement, amount of pressurant condensed, and ullage and wall temperatures at various heights in the ullage space at the end of draining. A single node GFSSP model was developed to simulate helium pressurization of the methane tank. Predicted helium consumption was 8-23% less than measured. The average error of the six test cases was 16%. A single ullage node with multiple solid node model was developed using Thermal Desktop. Predicted helium consumption compares with the test data within 2%. This paper describes the development of a GFSSP multi-node ullage model of the test configuration and compares the predicted pressurant consumption for both helium and autogenous pressurization using gaseous methane with experimental as well as TD predictions.

Nodal Model↗
NASA NTRS2009

A3 Subscale Rocket Hot Fire Testing

This paper gives a description of the methodology and results of J2-X Subscale Simulator (JSS) hot fire testing supporting the A3 Subscale Diffuser Test (SDT) project at the E3 test facility at Stennis Space Center, MS (SSC). The A3 subscale diffuser is a geometrically accurate scale model of the A3 altitude simulating rocket test facility. This paper focuses on the methods used to operate the facility and obtain the data to support the aerodynamic verification of the A3 rocket diffuser design and experimental data quantifying the heat flux throughout the facility. The JSS was operated at both 80% and 100% power levels and at gimbal angle from 0 to 7 degrees to verify the simulated altitude produced by the rocket-rocket diffuser combination. This was done with various secondary GN purge loads to quantify the pumping performance of the rocket diffuser. Also, special tests were conducted to obtain detailed heat flux measurements in the rocket diffuser at various gimbal angles and in the facility elbow where the flow turns from vertical to horizontal upstream of the 2nd stage steam ejector.

Saunders, G. P.↗
NASA NTRS2009

Single Longitudinal Mode, High Repetition Rate, Q-switched Ho:YLF Laser for Remote Sensing

Ho:YLF/LuLiF lasers have specific applications for remote sensing such as wind-speed measurement and carbon dioxide (CO2) concentration measurement in the atmosphere because the operating wavelength (around 2 m) is located in the eye-safe range and can be tuned to the characteristic lines of CO2 absorption and there is strong backward scattering signal from aerosol (Mie scattering). Experimentally, a diode pumped Ho:Tm:YLF laser has been successfully used as the transmitter of coherent differential absorption lidar for the measurement of with a repetition rate of 5 Hz and pulse energy of 75 mJ [1]. For highly precise CO2 measurements with coherent detection technique, a laser with high repetition rate is required to averaging out the speckle effect [2]. In addition, laser efficiency is critically important for the air/space borne lidar applications, because of the limited power supply. A diode pumped Ho:Tm:YLF laser is difficult to efficiently operate in high repetition rate due to the large heat loading and up-conversion. However, a Tm:fiber laser pumped Ho:YLF laser with low heat loading can be operated at high repetition rates efficiently [3]. No matter whether wind-speed or carbon dioxide (CO2) concentration measurement is the goal, a Ho:YLF/LuLiF laser as the transmitter should operate in a single longitudinal mode. Injection seeding is a valid technique for a Q-switched laser to obtain single longitudinal mode operation. In this paper, we will report the new results for a single longitudinal mode, high repetition rate, Q-switched Ho:YLF laser. In order to avoid spectral hole burning and make injection seeding easier, a four mirror ring cavity is designed for single longitudinal mode, high repetition rate Q-switched Ho:YLF laser. The ramp-fire technique is chosen for injection seeding.

Bai, Yingxin↗
NASA NTRS2021

Responses of Florida Scrub Vegetation to Water Additions from a Groundwater Treatment Project and to Hurricane Disturbance

Florida scrub is a fire-maintained shrub vegetation of well-drained, sandy soils; dominant species include several species of Quercus and Serenoa repens. In a remediation project, treated groundwater was distributed through an exfiltration gallery into intact scrub. We established eight permanent line-intercept transects (15 m length) in the site in April 2002, four close to the exfiltration gallery and four more distant from it. We sampled vegetation, < 0.5 m and ≥ 0.5 m, along each transect and measured vegetation height at four points (0, 5, 10, 15 m) annually through 2019. The initial phase of the project operated from October 2002 to early March 2004 (494 days) and distributed 1.74 x 10^8 L of water. The final phase of the project occurred from March 2005 through August 2008 (1251 days) and distributed 1.90 x 10^8 L of water. Pumping raised the water table near the exfiltration gallery. Vegetation height did not differ between the near and far transects initially. Vegetation height increased in the near transects by 2004 with the greatest percent change in 2003 and 2004 as did total cover ≥ 0.5 m. Total cover < 0.5 m and bare ground were similar initially in the near and far transects and declined in the near transects by 2004. Scrub species, particularly the dominant scrub oaks, increased height and cover in response to water additions with no loss of dominant scrub species and no establishment of mesophytes. Hurricane Frances (September 2004) reduced cover ≥ 0.5 m the following year. Hurricane Matthew (October 2016) and Hurricane Irma (September 2017) caused greater damage including breaking limbs as reflected in reduced height and total cover ≥ 0.5 m probably because the older, taller scrub was more vulnerable to wind damage.

Florida scrub↗
NASA NTRS2007

Performance Optimization of Storable Bipropellant Engines to Fully Exploit Advanced Material Technologies

This paper summarizes the work performed to dale on the NASA Cycle 3A Advanced Chemical Propulsion Technology Program. The primary goals of the program are to design, fabricate, and test high performance bipropellant engines using iridium/rhenium chamber technology to obtain 335 seconds specific impulse with nitrogen tetroxide/hydrazine propellants and 330 seconds specific impulse with nitrogen tetroxide/monomethylhydrazine propellants. Aerojet has successfully completed the Base Period of this program, wherein (1) mission and system studies have been performed to verify system performance benefits and to determine engine physical and operating parameters, (2) preliminary chamber and nozzle designs have been completed and a chamber supplier has been downselected, (3) high temperature, high pressure off-nominal hot fire testing of an existing state-of-the-art high performance bipropellant engine has been completed, and (4) thermal and performance data from the engine test have been correlated with new thermal models to enable design of the new engine injector and injector/chamber interface. In the next phase of the program, Aerojet will complete design, fabrication, and test of the nitrogen tetroxide/hydrazine engine to demonstrate 335 seconds specific impulse, and also investigate improved technologies for iridium/rhenium chamber fabrication. Achievement of the NRA goals will significantly benefit NASA interplanetary missions and other government and commercial opportunities by enabling reduced launch weight and/or increased payload. At the conclusion of the program, the objective is to have an engine ready for final design and qualification for a specific science mission or commercial application. The program also constitutes a stepping stone to future, development, such as higher pressure pump-fed in-space storable engines.

Miller, Scott↗
NASA NTRS2008

The Summer of Hydrogen

Ground crew veterans at Kennedy Space Center still talk about what they call "the summer of hydrogen"-the long, frustrating months in 1990 when the shuttle fleet was grounded by an elusive hydrogen leak that foiled our efforts to fill the orbiter's external fuel tank. Columbia (STS-35) was on Launch Pad A for a scheduled May 30 launch when we discovered the hydrogen leak during - tanking. The external fuel tank is loaded through the orbiter. Liquid hydrogen flows through a 17-inch umbilical between the orbiter and the tank. During fueling, we purge the aft fuselage with gaseous nitrogen to reduce the risk of fire, and we have a leak-detection system in the mobile launch platform, which samples (via tygon tubing) the atmosphere in and around the vehicle, drawing it down to a mass spectrometer that analyzes its composition. When we progressed to the stage of tanking where liquid hydrogen flows through the vehicle, the concentration of hydrogen approached four percent-the limit above which it would be dangerously flammable. We had a leak. We did everything we could think of to find it, and the contractor who supplied the flight hardware was there every day, working alongside us. We did tanking tests, which involved instrumenting the suspected leak sources, and cryo-loaded the external tank to try to isolate precisely where the leak originated. We switched out umbilicals; we replaced the seals between the umbilical and the orbiter. We inspected the seals microscopically and found no flaws. We replaced the recirculation pumps, and we found and replaced a damaged teflon seal in a main propulsion system detent cover, which holds the prevalve-the main valve supplying hydrogen to Space Shuttle Main Engine 3 -in the open position. The seal passed leak tests at ambient temperature but leaked when cryogenic temperatures were applied. We added new leak sensors-up to twenty at a time and tried to be methodical in our placements to narrow down the possible sources of the problem. We even switched orbiters, sending Columbia back to the Vehicle Assembly Building and bringing out Atlantis, scheduled to fly as STS-38. Two shuttles on their mobile launchers passing in the night was a majestic sight, but not one you want to see if you're trying to get an orbiter launched. None of this told us where the leak was, or if we were dealing with more than one leak source.

Weber, Philip↗
NASA NTRS1992

A neural network-based estimator for the mixture ratio of the Space Shuttle Main Engine

In order to properly utilize the available fuel and oxidizer of a liquid propellant rocket engine, the mixture ratio is closed loop controlled during main stage (65 percent - 109 percent power) operation. However, because of the lack of flight-capable instrumentation for measuring mixture ratio, the value of mixture ratio in the control loop is estimated using available sensor measurements such as the combustion chamber pressure and the volumetric flow, and the temperature and pressure at the exit duct on the low pressure fuel pump. This estimation scheme has two limitations. First, the estimation formula is based on an empirical curve fitting which is accurate only within a narrow operating range. Second, the mixture ratio estimate relies on a few sensor measurements and loss of any of these measurements will make the estimate invalid. In this paper, we propose a neural network-based estimator for the mixture ratio of the Space Shuttle Main Engine. The estimator is an extension of a previously developed neural network based sensor failure detection and recovery algorithm (sensor validation). This neural network uses an auto associative structure which utilizes the redundant information of dissimilar sensors to detect inconsistent measurements. Two approaches have been identified for synthesizing mixture ratio from measurement data using a neural network. The first approach uses an auto associative neural network for sensor validation which is modified to include the mixture ratio as an additional output. The second uses a new network for the mixture ratio estimation in addition to the sensor validation network. Although mixture ratio is not directly measured in flight, it is generally available in simulation and in test bed firing data from facility measurements of fuel and oxidizer volumetric flows. The pros and cons of these two approaches will be discussed in terms of robustness to sensor failures and accuracy of the estimate during typical transients using simulation data.

Guo, T. H.↗
NASA NTRS2023

South Repeater Building (Swmu 121) Pilot Study Work Plan, Kennedy Space Center, Florida

This document is a Pilot Study Work Plan for a groundwater remediation system at the South Repeater Building (N6-1118) located at the John F. Kennedy Space Center (KSC), Florida. Aqueous fire-fighting foam was applied near the building in the late 1990s during a wildfire. Per- and polyfluoroalkyl substances (PFAS) are components of the foam. Sampling completed at and near the South Repeater Building identified PFAS in groundwater, surface water and soil. KSC is planning to design and install a groundwater remediation system to address the potential for off-Center migration of PFAS compounds in groundwater. This Pilot Study Work Plan outlines subsurface hydrogeologic data that will be collected to use in the construction of a groundwater flow model that will guide the design of a full-scale remediation system. This document was prepared by AECOM Technical Services, Inc., for NASA under Indefinite Delivery Indefinite Quantity Contract 80KSC019D0010, Task Order 80KSC019F0096.

PFAS↗
NASA NTRS1994

Develop advanced nonlinear signal analysis topographical mapping system

The Space Shuttle Main Engine (SSME) has been undergoing extensive flight certification and developmental testing, which involves some 250 health monitoring measurements. Under the severe temperature, pressure, and dynamic environments sustained during operation, numerous major component failures have occurred, resulting in extensive engine hardware damage and scheduling losses. To enhance SSME safety and reliability, detailed analysis and evaluation of the measurements signal are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce catastrophic system failure risks and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. The basic objective of this contract are threefold: (1) develop and validate a hierarchy of innovative signal analysis techniques for nonlinear and nonstationary time-frequency analysis. Performance evaluation will be carried out through detailed analysis of extensive SSME static firing and flight data. These techniques will be incorporated into a fully automated system; (2) develop an advanced nonlinear signal analysis topographical mapping system (ATMS) to generate a Compressed SSME TOPO Data Base (CSTDB). This ATMS system will convert tremendous amount of complex vibration signals from the entire SSME test history into a bank of succinct image-like patterns while retaining all respective phase information. High compression ratio can be achieved to allow minimal storage requirement, while providing fast signature retrieval, pattern comparison, and identification capabilities; and (3) integrate the nonlinear correlation techniques into the CSTDB data base with compatible TOPO input data format. Such integrated ATMS system will provide the large test archives necessary for quick signature comparison. This study will provide timely assessment of SSME component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. The final result of this program will yield an ATMS system of nonlinear and nonstationary spectral analysis software package integrated with the Compressed SSME TOPO Data Base (CSTDB) on the same platform. This system will allow NASA engineers to retrieve any unique defect signatures and trends associated with different failure modes and anomalous phenomena over the entire SSME test history across turbo pump families.

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