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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

System Testing of Ground Cooling System Components

This internship focused primarily upon software unit testing of Ground Cooling System (GCS) components, one of the three types of tests (unit, integrated, and COTS/regression) utilized in software verification. Unit tests are used to test the software of necessary components before it is implemented into the hardware. A unit test determines that the control data, usage procedures, and operating procedures of a particular component are tested to determine if the program is fit for use. Three different files are used to make and complete an efficient unit test. These files include the following: Model Test file (.mdl), Simulink SystemTest (.test), and autotest (.m). The Model Test file includes the component that is being tested with the appropriate Discrete Physical Interface (DPI) for testing. The Simulink SystemTest is a program used to test all of the requirements of the component. The autotest tests that the component passes Model Advisor and System Testing, and puts the results into proper files. Once unit testing is completed on the GCS components they can then be implemented into the GCS Schematic and the software of the GCS model as a whole can be tested using integrated testing. Unit testing is a critical part of software verification; it allows for the testing of more basic components before a model of higher fidelity is tested, making the process of testing flow in an orderly manner.

Unit Test↗
NASA NTRSDate not supplied

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach is building qualification and test units in addition to flight units. The test units are used to test, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective intuitive appeal of a human ecosystem in space.

Life support↗
NASA NTRS1984

Guidelines for testing and release procedures

Guidelines and procedures are recommended for the testing and release of the types of computer software efforts commonly performed at NASA/Ames Research Center. All recommendations are based on the premise that testing and release activities must be specifically selected for the environment, size, and purpose of each individual software project. Guidelines are presented for building a Test Plan and using formal Test Plan and Test Care Inspections on it. Frequent references are made to NASA/Ames Guidelines for Software Inspections. Guidelines are presented for selecting an Overall Test Approach and for each of the four main phases of testing: (1) Unit Testing of Components, (2) Integration Testing of Components, (3) System Integration Testing, and (4) Acceptance Testing. Tools used for testing are listed, including those available from operating systems used at Ames, specialized tools which can be developed, unit test drivers, stub module generators, and the use of format test reporting schemes.

Molari, R.↗
NASA NTRSDate not supplied

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide removal, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates of these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach builds qualification and test units in addition to flight units. The test units are used to find, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective amount of testing when redundant systems must have a specified reliability and confidence.

Harry W. Jones↗
NASA NTRS1983

DC-10 composite vertical stabilizer ground test program

A review of the structural configuration and ground test program is presented. Particular emphasis is placed on the testing of a full-scale stub box test subcomponent and full span ground test unit. The stub box subcomponent was tested in an environmental chamber under ambient, cold/wet, and hot/wet conditions. The test program included design limit static loads, fatigue spectrum loading to approximately two service lifetimes (with and without damage), design limit damage tolerance tests, and a final residual strength test to a structural failure. The first full-scale ground test unit was tested under ambient conditions. The test unit was to have undergone static, fatigue, and damage tolerance tests but a premature structural failure occurred at design limit load during the third limit load test. A failure theory was developed which explains the similarity in types of failure and the large load discrepancy at failure between the two test articles. The theory attributes both failures to high stress concentrations at the edge of the lower rear spar access opening. A second full-scale ground test unit has been modified to incorporate the various changes resulting from the premature failure. The article has been assembled and is active in the test program.

Palmer, J. M., Jr.↗
DOE OSTI2017

Test Report of Special Form Qualification Testing for the ORNL U ZipCan

This test report describes the special form testing activities performed on the two ZiPCans. One prototype test unit was subjected to the tests stipulated by 10 CFR 71.75 (d)(1)(i), ISO 2919:1999(E) Class 4 impact test, along with the leak rate test specified in 49 CFR 173.469(a)(4)(i). The other test unit was subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469 (b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests, as specified in ANSI N14.5-2014.The measured leak rates were converted to standard condition leak rates as specified in ASTM E 493. The determined standardized leak rates from the test and calculation for both test units met the requirements for special form certification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Path-Integrated Stereo X-Ray Digital Image Correlation: Resolving the Violation of Conservation of Intensity

In this study, x-ray imaging addresses many challenges with visible light imaging in extreme environments, where optical diagnostics such as digital image correlation (DIC) and particle image velocimetry (PIV) suffer biases from index of refraction changes and/or cannot penetrate visibly occluded objects. However, conservation of intensity—the fundamental principle of optical image correlation algorithms—may be violated if ancillary components in the X-ray path besides the surface or fluid of interest move during the test. The test series treated in this work sought to characterize the safe use of fiber-epoxy composites in aerospace and aviation industries during fire accident scenarios. Stereo X-ray DIC was employed to measure test unit deformation in an extreme thermal environment involving a visibly occluded test unit, incident surface heating to temperatures above 600°C, and flames and soot from combusting epoxy decomposition gasses. The objective of the current work is to evaluate two solutions to resolve the violation of conservation of intensity that resulted from both the test unit and the thermal chamber deforming during the test. The first solution recovered conservation of intensity by pre-processing the path-integrated X-ray images to isolate the DIC pattern of the test unit from the thermal chamber components. These images were then correlated with standard, optical DIC software. The second solution, called Path-Integrated Digital Image Correlation (PI-DIC), modified the fundamental matching criterion of DIC to account for multiple, independently-moving components contributing to the final image intensity. The PI-DIC algorithm was extended from a 2D framework to a stereo framework and implemented in a custom DIC software. Both solutions accurately measured the cylindrical shape of the undeformed test unit, recovering radii values of R = 76.20±0.12 mm compared to the theoretical radius of R theor = 76.20 mm. During the test, the test unit bulged asymmetrically as decomposition gasses pressurized the interior and eventually burned in a localized jet. Both solutions measured the heterogeneous radius of this bulge, which reached a maximum of approximately R = 91 mm, with a discrepancy of 2–3% between the two solutions. Two solutions that resolve the violation of conservation of intensity for path-integrated X-ray images were developed. Both were successfully employed in a stereo X-ray DIC configuration to measure deformation of an aluminum-skinned, fiber-epoxy composite test unit in a fire accident scenario.

47 OTHER INSTRUMENTATION↗
NASA NTRS1972

Structural testing of concorde aircraft: Further report on United Kingdom tests

A summary of tests conducted on the Concorde aircraft nacelle structure is presented. The tests were conducted as a part of the structural development and certification program. The nacelle structural specimens are described. The problems associated with the intake testing and engine-bay and nozzle testing are discussed.

Harpur, N.↗
DOE OSTI2018

Advanced Hydrogen Fueling Station Supply: Tube Trailers

Air Products and Chemicals, Inc. (Air Products) is reporting on the results of a DOE-funded program to develop and validate Advanced Hydrogen Fueling Station hydrogen tube trailers to support hydrogen and fuel cell market applications. The project involved the engineering design and development of a new composite over-wrapped pressure vessel to increase the pressure capability of tube trailers to deliver hydrogen to greater than 8500 psi (586 bar). The new composite over-wrapped pressure vessel tube trailer was expected to provide improved delivery technology and reduce the cost of transporting hydrogen from central hydrogen production sources. The project aimed to meet or exceed DOE’s 2020 delivery targets for tube trailer hydrogen distribution. A gated approach was taken for the project, with early project Go/No-Go decision points. Specific goals for this four-stage product development project included: Preliminary Study, Modeling, and Analysis: Complete a preliminary design analysis and cost viability of a >8500 psi (586 bar) hydrogen storage vessel with an appropriate frame and chassis configuration for a complete trailer to US DOT requirements; Develop New Tube Size for >8500 psi (586 bar) Vessel: Fabricate tubes for test units, perform testing, and submit test results for a DOT Special Permit; Design, fabricate, and test a delivery trailer unit; Deploy the delivery trailer to hydrogen stations and collect data. Work conducted under DE-EE0006524 established costs for US DOT Type III vessels at 8500 psi (586 bar), 12500 psi (862 bar), and 14000 psi (965 bar) with manufactured water volumes up to 375 liters. Trailer module designs were established for the maximum US DOT design limits and for Air Products’ design limit of a 40-foot trailer length that addresses California hydrogen fueling station ingress and egress operating constraints. Conceptual trailer designs were not capable of achieving the DOE 2020 capacity and cost targets, but they did exceed the DOE pressure target of 500 bar. Based on new trailer cost and simulated operating performance, the 8500 psi (586 bar) new trailer design is not feasible in comparison to Air Products’ DOT-approved 7500 psi (520 bar) trailer design in operation today. Also, the project was expected to incur significantly higher product development costs associated with new US DOT vessel development and approval. Alternative trailer design concepts were explored that included 700 bar compression-less mobile fueling that could be promising for early-market hydrogen infrastructure fueling station placement and development and niche military applications. Due to the economic and budget challenges identified in the feasibility phase of the program, Air Products, in agreement with the Department of Energy, decided to terminate this development program.

08 HYDROGEN↗
NASA NTRS1990

Acquisition of the QPSK demodulator in the presence of interference

The acquisition behavior of the tracking and data relay satellite system (TDRSS) receiver (a quadrative phase-shift keying (QPSK) demodulator using a dither lock detector) in the presence of interference from another user has been analyzed using a simulation model. The demodulator is composed of an automatic gain control, a QPSK Costas loop, a frequency sweep unit, lock test units, and a control unit. The simulation model has been tested for the following variables: signal and interference Doppler frequencies and phase offsets (with respect to initial voltage control oscillator setup), signal-to-interference ratio (SIR), and signal I/Q power ratio. The simulation results are discussed.

Ghazvinian, Farzad↗
NASA NTRS1985

10 kW solar array switching unit performance test results

Solar array switching unit (SASU) technology is an attractive candidate for output power regulation of solar arrays. It offers greater efficiency, lower parts count, modularity and expandability. Since the SASU has switching frequencies upwards of 15 kHz, it was necessary to determine the performance characteristics of the SASU with a real solar array and to assess the impact of long lead lengths on the switching characteristics. To accommodate these requirements, TRW developed a 10 kW, 120 volt SASU which was tested for steady state and transient resistive and converter type loadings. The results of these tests are presented and discussed in this paper.

Fleck, G. W.↗
DOE OSTI2019

Reactive jet and cyclonic attrition analysis of ilmenite in chemical looping combustion systems

In chemical looping combustion (CLC), the chosen oxygen carrier’s (OC) reactivity maintenance and attrition propensity play key roles in determining its lifetime in such systems. Jet and cyclonic attrition are two main mechanisms of attrition in CLC systems, which typically use fluidized beds and cyclones. In contrast to standardized tests, that assess attrition characteristics under ambient and non-reacting conditions, a realistic evaluation must include the behavior under relevant high temperatures and cyclic oxidation-reduction. In this study, separate jet and cyclonic attrition test units were constructed to investigate the effects of temperature, fuel gas concentration and velocity on the performance of ilmenite, a natural ore-based OC in CLC. Testing showed that thermal and chemical effects were crucial to accurately determine the performance of ilmenite. For experiments conducted between 820°C and 970°C, the intermediate temperature of 895°C provided the best balance between high reactivity and material durability. Additionally, fuel gas concentration affected particle morphology evolution. Iron migration to the surface of the ilmenite particle was enhanced at higher fuel gas concentrations and resulted in reduced attrition rate, presumably due to sintering of the more highly reduced enriched iron phase on the particle surface. The laboratory jet and cyclonic attrition evaluation test units tested in this study can be used to investigate multiple parameters relevant for OC performance, including the degree of reduction, oxygen carrying capacity, attrition resistance, agglomeration, and optimum material operability conditions, as well as to extrapolate test data to determine OC replacement costs in a commercial CLC system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Test Report for the Regulatory Testing of the Welded Isotek-SFC-W-3 Special Form Capsule

Two prototypes the welded ISOTEK-SFC-W-3 special form capsules (SFCs) of the same design were evaluated to determine if the requirements of Title 49, Code of Federal Regulations (CFR), Part 173.469, Tests for Special Form Class 7 (Radioactive) Materials, were met. The results of the special form tests are documented in this test report. This report describes the special form testing activities performed on the two welded ISOTEK-SFC-W-3 capsules. The test units were designated as TU-1 and TU-2. TU-1 was subjected to leak testing, percussion testing, and impact testing. TU-1 was leak tested using the leak rate test specified in 49 CFR 173.469(a)(4)(i). The impact test on TU-1 was conducted according to the requirements in 49 CFR 173.469 (b)(1). The percussion test that was carried out on TU-1 was conducted in accordance with 49 CFR 173.469 (b)(2). TU-2 was subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469(b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests, as specified in American National Standards Institute (ANSI) N14.5-2014. The measured leak rates were converted to standard condition leak rates as specified in American Society for Testing and Measurement (ASTM) E 493. The determined standardized leak rates obtained from the test and the calculations for all the test units met the requirements for special form certification. The testing was performed under the direction of the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Test Report for the Qualification Testing of the ORNL-SFC-W-1 Special Form Capsule

Three prototypes the ORNL-SFC-W-1 special form capsules (SFCs) of the same design were evaluated to determine if the requirements of Title 49, Code of Federal Regulations (CFR), Part 173.469, Tests for Special Form Class 7 (Radioactive) Materials, were met. The results of the special form tests are documented in this test report. This report describes the special form testing activities performed on the three ORNL-SFC-W-1 capsules. The test units were designated as TU-1, TU-2 and TU-3. TU-1 was subjected to leak testing, impact testing and percussion testing. TU-1 was leak tested using the leak rate test specified in 49 CFR 173.469(a)(4)(i). The impact test was conducted according to the requirements in 49 CFR 173.469 (b)(1). The percussion test that was carried out on TU-1 was conducted in accordance with 49 CFR 173.469 (b)(2). Both TU-2 and TU-3 were subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469(b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests as specified in American National Standards Institute (ANSI) N14.5-2014.The measured leak rates were converted to standard condition leak rates as specified in American Society for Testing and Measurement (ASTM) E 493. The determined standardized leak rates obtained from the test and the calculations for all the test units met the requirements for special form certification. The testing was performed under the direction of the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP).

42 ENGINEERING↗
NASA NTRS1993

The 2.5 inch nickel-hydrogen development

The topics covered are presented in viewgraph form and include the following: reasons for developing a 2.5 in. nickel-hydrogen cell; the 2.5 in. nickel-hydrogen development history; RNHC-6-1 cell design; RNHC-6-1 charge voltage at 0.6 A; RNHC-6-1 discharge voltage at 3.0 A; RNHC-6-1 qualification testing; flight unit testing; RNHC-6-1 technical data; technical data for the SAR-10027 Battery; and RNHC-10-1 life test.

Cook, William D.↗
NASA NTRS2003

Increasing software testability with standard access and control interfaces

Testing is the most common method of determining whether a software system satisfies its requirements. Traditionally, testing starts with the detailed examination of individual functions or methods, progresses through the integration of functions or methods into subsystems, and ends with testing the functionality and behavior of the completely integrated system. At each stage of testing, the amount of functionality and behavior of the artifact being tested is increasingly limited. One reason for this is that it becomes impossible to test all paths through the system within a reasonable amount of time. However, another reason for this progressive decrease of test coverage has to do with increasingly limited control of and visibility into the state of the artifact being tested. During unit test, it is rather simple to control the inputs of individual functions or methods or view their internal state - modem development environments provide adequate facilities for doing so. However, these facilities do not scale up to the testing of partially or completely integrated systems. Control of and visibility into the system's state is then limited to the input and output facilities provided by the software itself as well as the hardware on which the software is hosted during the test. These facilities are usually insufficient to precisely control the state of individual components or sets of components of the system; they are also inadequate to the task of displaying on demand the state of specific components. We describe an approach to improving the testability of complex software systems with software constructs modeled after the hardware JTAG bus, used to provide visibility and controllability in testing digital circuits.

Tamir, Yuval↗
DOE OSTI2016

Google Test MPI Listener

Google Test MPI Listener is a plugin for the Google Test c++ unit testing library that organizes test output of software that uses both the MPI parallel programming model and Google Test. Typically, such output is ordered arbitrarily and disorganized, making difficult the process of interpreting test output. This plug organizes output in MPI rank order, enabling easy interpretation of test results.

Oxberry, Geoffrey↗
DOE OSTI2022

Final Scientific/Technical Report-FREE-piston Zero Emissions Refrigerator (FREEZER)

The FREE-piston Zero Emissions Refrigerator (FREEZER™) is a natural refrigerant Stirling-cycle cooler developed by AMSC in partnership with Heatcraft, targeted as a replacement refrigeration system for walk-in coolers or freezers found commonly in restaurants, convenience stores, supermarkets, etc. The FREEZER™, combined with a closed-loop CO2 heat-transfer system, had the goal to provides an efficient (Target COP = 1.4), zero ODP (Ozone Depletion Potential) and near zero GWP (Global Warming Potential) refrigeration solution with no synthetic, flammable, or toxic refrigerants. Other near zero GWP refrigeration systems do not exist at the scale and performance level of FREEZER. ARPA-E Continuation Funding enabled the design and fabrication of one Advanced Development Unit (ADU) cooler and two Field Test Unit (FTU) coolers, and a new revised Field Test Unit (new FTU). Heatcraft was to extensively test the various coolers at their facilities, which closely simulate real-world conditions. The original plan was to install and operate FREEZER FTUs alongside a traditional cooling solution at one or more customer locations to obtain data on direct performance comparisons with existing commercial refrigeration systems. Success in this FREEZER refinement and field-test project will establish the basis for a new class of environmentally friendly refrigeration systems that will revolutionize the industry. The hardware developed under the program is shown below in Figure 1. Five Stirling-cycle machines were built within the program, with a sixth cooler still under construction. The original DU and the ADU coolers met the performance target with a coefficient of performance (COP) of 1.2. The FTU was underperforming during the initial tuning of the free-piston Stirling cycle dynamics when there was a catastrophic failure of the fasteners on pressure boundary. This caused a pause to the program while the failure mechanism was investigated. The root cause was an inadequate flange design that allowed an excessive cyclic loading on the fasteners, leading to a fatigue failure. It was determined that existing FTU design could not be reasonably salvaged in a safe manner, and that fact, combined with the lower-than-expected performance of the new experimental heat exchanger modules lead to the design of the “new FTU” with a more conventional shell-and-tube heat exchanger design which should get close to the design target COP of 1.4, but have a higher overall machine cost. The program ran out of time before the fabrication of the new FTU was completed, but AMSC is still working on the cooler, with the majority of the parts fabricated, and hopes to have the unit under test sometime in early 2022, after which it will be shipped to Heatcraft for additional testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗