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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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Development and testing of alternator assembly, pump motor, boiler, condenser, and electrical control for SNAP 8 space power system
Assembly and subsystem testing for Mariner Mars spacecraft model and advanced planetary mission technology
The progress during the sixth quarterly period is reported on construction and assembly of a test facility to determine the high temperature emittance properties of candidate thermal protection system materials for the space shuttle. This facility will provide simulation of such reentry environment parameters as temperature, pressure, and gas flow rate to permit studies of the effects of these parameters on the emittance stability of the materials. Also reported are the completed results for emittance tests on a set of eight Rene 41 samples and one anodized titanium alloy sample which were tested at temperatures up to 1600 F in vacuum. The data includes calorimetric determinations of total hemispherical emittance, radiometric determinations of total and spectral normal emittance, and pre- and post-test room temperature reflectance measurements.
The Apollo 13 lithium hydroxide canister test was conducted to evaluate emergency measures designed to enable the Apollo 13 crew to use command module lithium hydroxide canisters in the lunar module. The test verified the effectiveness of the emergency system and established that the canisters in the command module would provide ample carbon dioxide removal for the return of the Apollo 13 crew. The time interval between canister changes on the flight was also determined in the test. This reduced power demand on the lunar module by eliminating the need for telemetry in determining canister replacement times. Details of the canister modifications were relayed to the flight crew and a replica of the test system was assembled in the flight vehicle. Graphs of the parameters which were measured during the simulation are presented.
One of the key elements of the flexible rolled-up solar array system is a mechanism to deploy, retract, and store the flexible solar-cell arrays. The selection of components, the design of the mechanism assembly, and the tests that were performed are discussed. During 6 months in orbit, all mission objectives were satisfied, and inflight performance has shown good correlation with preflight analyses and tests.
Four iron-less armature torque motors, four Hall device position sensor assemblies, and two test fixtures were fabricated. The design approach utilized samarium cobalt permanent magnets, a large airgap, and a three-phase winding in a stationary ironless armature. Hall devices were employed to sense rotor position. An ironless armature torque motor having an outer diameter of 4.25 inches was developed to produce a torque constant of 65 ounce-inches per ampere with a resistance of 20.5 ohms. The total weight, including structural elements, was 1.58 pounds. Test results indicated that all specifications were met except for generated voltage waveform. It is recommended that investigations be made concerning the generated voltage waveform to determine if it may be improved.
A program to design, develop, fabricate and assemble a one-man, self-contained, solid electrolyte oxygen regeneration system (SX-1) incorporating solid electrolyte electrolyzer drums was completed. The SX-1 is a preprototype engineering model designed to produce 0.952 kg (2.1 lb)/day of breathable oxygen (O2) from the electrolysis of metabolic carbon dioxide (CO2) and water vapor. The CO2 supply rate was established based on the metabolic CO2 generation rate for one man of 0.998 kg (2.2 lb)/day. The water supply rate (0.254 kg (0.56 lb)/day) was designed to be sufficient to make up the difference between the 0.952 kg (2.1 lb)/day O2 generation specification and the O2 available through CO2 electrolysis, 0.726 kg (1.6 lb)/day. The SX-1 was successfully designed, fabricated and assembled. Design verification tests (DVT) or the CO Disproportionators, H2 separators, control instrumentation, monitor instrumentation, water feed mechanism were successfully completed. The erratic occurrence of electrolyzer drum leakage prevented the completion of the CO2 electrolyzer module and water electrolyzer module DVT's and also prevented the performance of SX-1 integrated testing. Further development work is required to improve the solid electrolyte cell high temperature seals.
Design analysis of a microbial load monitor system flight engineering model was presented. Checkout of the card taper and media pump system was fabricated as well as the final two incubating reading heads, the sample receiving and card loading device assembly, related sterility testing, and software. Progress in these areas was summarized.
A pre-package prototype unit having domestic hot water and room solar heating capability that uses air as the collector fluid is described. This system is designed to be used with a small single-family dwelling where a roof mounted collector array is not feasible. The prototype unit is an assemble containing 203 square feet of effective collector surface with 113 cubic feet of rock storage. The design of structure and storage is modular, which permits expansion and reduction of the collector array and storage bed in 68 square feet and 37 cubic feet increments respectively. The system is designed to be transportable. This permitted assemble and certification testing in one area and installation in another area without tear down and reassemble. Design, installation, operation, performance and maintenance of this system are described.
Components for an orbiting camera payload system (OCPS) include the large format camera (LFC), a gas supply assembly, and ground test, handling, and calibration hardware. The LFC, a high resolution large format photogrammetric camera for use in the cargo bay of the space transport system, is also adaptable to use on an RB-57 aircraft or on a free flyer satellite. Carrying 4000 feet of film, the LFC is usable over the visible to near IR, at V/h rates of from 11 to 41 milliradians per second, overlap of 10, 60, 70 or 80 percent and exposure times of from 4 to 32 milliseconds. With a 12 inch focal length it produces a 9 by 18 inch format (long dimension in line of flight) with full format low contrast resolution of 88 lines per millimeter (AWAR), full format distortion of less than 14 microns and a complement of 45 Reseau marks and 12 fiducial marks. Weight of the OCPS as supplied, fully loaded is 944 pounds and power dissipation is 273 watts average when in operation, 95 watts in standby. The LFC contains an internal exposure sensor, or will respond to external command. It is able to photograph starfields for inflight calibration upon command.
The major component fabrication program was completed. Assembly and system testing of the pulsed electron beam annealing machine are described. The design program for the transport reached completion, and the detailed drawings were released for fabrication and procurement of the long lead time components.
The objective of this experiment was to demonstrate electrical power generation using a small free-piston Stirling engine and linear alternator in conjunction with a parabolic solar collector. A test bed collector, formerly used at the JPL Table Mountain Observatory, was renovated and used to obtain practical experience and to determine test receiver performance. The collector was mounted on a two-axis tracker, with a cold water calorimeter mounted on the collector to measure its efficiency, while a separate, independently tracking radiometer was used to measure solar insolation. The solar receiver was designed to absorb energy from the collector, then transfer the resulting thermal energy to the Stirling engine. Successful testing of receiver/collector assembly yielded valuable inputs for design of the Stirling engine heater head.
Early studies of flat-plate arrays have projected costs on the order of $50/square meter for installed array support structures. This report describes an optimized low-cost frame-truss structure that is estimated to cost below $25/square meter, including all markups, shipping an installation. The structure utilizes a planar frame made of members formed from light-gauge galvanized steel sheet and is supposed in the field by treated-wood trusses that are partially buried in trenches. The buried trusses use the overburden soil to carry uplift wind loads and thus to obviate reinforced-concrete foundations. Details of the concept, including design rationale, fabrication and assembly experience, structural testing and fabrication drawings are included.
Data from the thematic mapper scan mirror assembly (SMA) acceptance test are presented. Documentation includes: (1) a list of the acceptance test discrepancies; (2) flight 1 SMA test data book; (3) flight 1 SMA environmental report; (4) the configuration verification index; (5) the flight 1 SMA test failure reports; (6) the flight 1 data tapes log; and (7) the requests for deviation/waivers.
The fabrication of a one-person Electrochemical Depolarized Carbon Dioxide Concentrator subsystem incorporating advanced electrochemical, mechanical, and control and monitor instrumentation concepts is discussed. This subsystem included an advanced liquid cooled unitized core composite cell module and integrated electromechanical components. Over 1800 hours with the subsystem with removal efficiencies between 90%. and 100%; endurance tests with a Fluid Control Assembly which integrates 11 gas handling components of the subsystem; and endurance testing of a coolant control assembly which integrates a coolant pump, diverter valve and a liquid accumulator were completed.
A shingle-type photovoltaic module has been designed and developed to meet the requirements of specifications for residential applications. The module is ideally suited for installation directly to the sheathing of a sloping, south-facing roof of a residential, industrial, or commercial building. The design requirements are examined, taking into account also module safety requirements. Aspects of module design and analysis are discussed, giving attention to installation details, solar cells and electrical circuit design, the encapsulation system, substrate lamination, and the module-to-module interconnecting cable. Details of module assembly experience and test and outdoor exposure experience are also considered.
A multihundred kilowatt Regenerative Fuel Cell for use in a space station is envisioned. Three 0.508 sq ft (471.9 cm) active area multicell stacks were assembled and endurance tested. The long term performance stability of the platinum on carbon catalyst configuration suitability of the lightweight graphite electrolyte reservoir plate, the stability of the free standing butyl bonded potassium titanate matrix structure, and the long life potential of a hybrid polysulfone cell edge frame construction were demonstrated. A 18,000 hour demonstration test of multicell stack to a continuous cyclical load profile was conducted. A total of 12,000 cycles was completed, confirming the ability of the alkaline fuel cell to operate to a load profile simulating Regenerative Fuel Cell operation. An orbiter production hydrogen recirculation pump employed in support of the cyclical load profile test completed 13,000 hours of maintenance free operation. Laboratory endurance tests demonstrated the suitability of the butyl bonded potassium matrix, perforated nickel foil electrode substrates, and carbon ribbed substrate anode for use in the alkaline fuel cell. Corrosion testing of materials at 250 F (121.1 C) in 42% wgt. potassium identified ceria, zirconia, strontium titanate, strontium zirconate and lithium cobaltate as candidate matrix materials.
The results of an evaluation of the ignition characteristics of the gaseous oxygen (Gox)/Ethanol propellant combination are presented. Ignition characterization was accomplished through the analysis, design, fabrication and testing of a spark initiated torch igniter and prototype 620 lbF thruster/igniter assembly. The igniter was tested over a chamber pressure range of 74 to 197 psia and mixture ratio range of 0.778 to 3.29. Cold (-92 to -165 F) and ambient (44 to 80 F) propellant temperatures were used. Spark igniter ignition limits and thruster steady state and pulse mode, performance, cooling and stability data are presented. Spark igniter ignition limits are presented in terms of cold flow pressure, ignition chamber diameter and mixture ratio. Thruster performance is presented in terms of vacuum specific impulse versus engine mixture ratio. Gox/Ethanol propellants were shown to be ignitable over a wide range of mixture ratios. Cold propellants were shown to have a minor effect on igniter ignition limits. Thruster pulse mode capability was demonstrated with multiple pulses of 0.08 sec duration and less.