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At least 1,117 records · Page 62

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗

Large Payload Ground Transportation and Test Considerations

Many spacecraft concepts under consideration by the National Aeronautics and Space Administration’s (NASA’s) Evolvable Mars Campaign take advantage of a Space Launch System payload shroud that may be 8 to 10 meters in diameter. Large payloads can theoretically save cost by reducing the number of launches needed--but only if it is possible to build, test, and transport a large payload to the launch site in the first place. Analysis performed previously for the Altair project identified several transportation and test issues with an 8.973 meters diameter payload. Although the entire Constellation Program—including Altair—has since been canceled, these issues serve as important lessons learned for spacecraft designers and program managers considering large payloads for future programs. A transportation feasibility study found that, even broken up into an Ascent and Descent Module, the Altair spacecraft would not fit inside available aircraft. Ground transportation of such large payloads over extended distances is not generally permitted, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 67 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA’s Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure—roads, bridges, airframes, and buildings—necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications. Although this paper focuses on the canceled Altair spacecraft as a case study, the issues identified here have wide applicability to other large payloads, including concepts under consideration for NASA’s Evolvable Mars Campaign.

Rucker, Michelle A.↗

Near Earth Asteroid Scout Solar Sail Engineering Development Unit Test Suite

The Near Earth Asteroid (NEA) Scout project is a 6U reconnaissance mission to investigate a near Earth asteroid utilizing an 86m(sub 2) solar sail as the primary propulsion system. This will be the largest solar sail NASA has launched to date. NEA Scout is currently manifested on the maiden voyage of the Space Launch System in 2018. In development of the solar sail subsystem, design challenges were identified and investigated for packaging within a 6U form factor and deployment in cis-lunar space. Analysis was able to capture understanding of thermal, stress, and dynamics of the stowed system as well as mature an integrated sail membrane model for deployed flight dynamics. Full scale system testing on the ground is the optimal way to demonstrate system robustness, repeatability, and overall performance on a compressed flight schedule. To physically test the system, the team developed a flight sized engineering development unit with design features as close to flight as possible. The test suite included ascent vent, random vibration, functional deployments, thermal vacuum, and full sail deployments. All of these tests contributed towards development of the final flight unit. This paper will address several of the design challenges and lessons learned from the NEA Scout solar sail subsystem engineering development unit. Testing on the component level all the way to the integrated subsystem level. From optical properties of the sail material to fold and spooling the single sail, the team has developed a robust deployment system for the solar sail. The team completed several deployments of the sail system in preparation for flight at half scale (4m) and full scale (6.8m): boom only, half scale sail deployment, and full scale sail deployment. This paper will also address expected and received test results from ascent vent, random vibration, and deployment tests.

Lockett, Tiffany Russell↗

Aeromechanics Analysis of a Distortion-Tolerant Fan with Boundary Layer Ingestion

A propulsion system with Boundary Layer Ingestion (BLI) has the potential to significantly reduce aircraft engine fuel burn. But a critical challenge is to design a fan that can operate continuously with a persistent BLI distortion without aeromechanical failure -- flutter or high cycle fatigue due to forced response. High-fidelity computational aeromechanics analysis can be very valuable to support the design of a fan that has satisfactory aeromechanic characteristics and good aerodynamic performance and operability. Detailed aeromechanics analyses together with careful monitoring of the test article is necessary to avoid unexpected problems or failures during testing. In the present work, an aeromechanics analysis based on a three-dimensional, time-accurate, Reynolds-averaged Navier-Stokes computational fluid dynamics code is used to study the performance and aeromechanical characteristics of the fan in both circumferentially-uniform and circumferentially-varying distorted flows. Pre-test aeromechanics analyses are used to prepare for the wind tunnel test and comparisons are made with measured blade vibration data after the test. The analysis shows that the fan has low levels of aerodynamic damping at various operating conditions examined. In the test, the fan remained free of flutter except at one near-stall operating condition. Analysis could not be performed at this low mass flow rate operating condition since it fell beyond the limit of numerical stability of the analysis code. The measured resonant forced response at a specific low-response crossing indicated that the analysis under-predicted this response and work is in progress to understand possible sources of differences and to analyze other larger resonant responses. Follow-on work is also planned with a coupled inlet-fan aeromechanics analysis that will more accurately represent the interactions between the fan and BLI distortion.

Propulsion Aeroelasticity↗

Phase retrieval camera for testing NGST optics

The NGST Phase Retrieval Camera (PRC) is a portable wavefront sensor useful for optical testing in high-vibration environments. Primary applications of the PRC are testing and experimenting with NGST technology demonstrator mirrors, along with exploring other wavefront sensing and control problems not easily studied using WCT. An overview of the hardware and testing results will be presented.

NGST↗

Study of new flight test techniques

The modification and testing of a small electromechanical vibrator are described. The vibrator was designed for the flutter testing of aircraft wings and was built to specifications that make it compatible with the X-29 experimental aircraft. The device uses alternating electromagnetic forces to move a magnetic mass and produce vibration. Its unconventional way of producing vibration avoids the need for complex mechanisms and makes efficient use of space and weight.

Deam, D.↗

Energy Finite Element Analysis for Computing the High Frequency Vibration of the Aluminum Testbed Cylinder and Correlating the Results to Test Data

The Energy Finite Element Analysis (EFEA) is a finite element based computational method for high frequency vibration and acoustic analysis. The EFEA solves with finite elements governing differential equations for energy variables. These equations are developed from wave equations. Recently, an EFEA method for computing high frequency vibration of structures either in vacuum or in contact with a dense fluid has been presented. The presence of fluid loading has been considered through added mass and radiation damping. The EFEA developments were validated by comparing EFEA results to solutions obtained by very dense conventional finite element models and solutions from classical techniques such as statistical energy analysis (SEA) and the modal decomposition method for bodies of revolution. EFEA results have also been compared favorably with test data for the vibration and the radiated noise generated by a large scale submersible vehicle. The primary variable in EFEA is defined as the time averaged over a period and space averaged over a wavelength energy density. A joint matrix computed from the power transmission coefficients is utilized for coupling the energy density variables across any discontinuities, such as change of plate thickness, plate/stiffener junctions etc. When considering the high frequency vibration of a periodically stiffened plate or cylinder, the flexural wavelength is smaller than the interval length between two periodic stiffeners, therefore the stiffener stiffness can not be smeared by computing an equivalent rigidity for the plate or cylinder. The periodic stiffeners must be regarded as coupling components between periodic units. In this paper, Periodic Structure (PS) theory is utilized for computing the coupling joint matrix and for accounting for the periodicity characteristics.

Vlahopoulos, Nickolas↗

Slow dynamics in a single bead with mechanical conditioning and transient heating

The contact stiffness of an aluminum bead confined between two slabs diminishes upon mechanical conditioning, and then recovers like log(t) after the conditioning ceases. Here that structure is evaluated for its response to transient heating and cooling, with and without accompanying conditioning vibrations. It is found that, under heating or cooling alone, stiffness changes are mostly consistent with temperature dependent material moduli; there is little or no slow dynamics. Hybrid tests in which vibration conditioning is followed by heating or cooling lead to recoveries that begin like log(t) and then become more complex. On subtracting the known response to heating or cooling alone we discern the influence of higher or lower temperatures on slow dynamic recovery from vibrations. It is found that heating accelerates the initial log(t) recovery, but by an amount more than predicted by an Arrhenius model of thermally activated barrier penetrations. Furthermore, transient cooling has no discernable effect, in contrast to the Arrhenius prediction that it slows recovery.

36 MATERIALS SCIENCE↗

VTS Dynamic Model and Experimental Validation for Vibration Suppression

High Q-factor superconducting radio-frequency (SRF) cavities are extremely sensitive to mechanical vibrations, which can cause an uncontrolled shift of the electromagnetic resonance frequency, with detrimental effects on the cavity performance. To avoid this phenomenon (i.e. microphonics) the dynamic behavior of the assembly must be studied, to design vibration suppression systems. In this paper, the numerical model of the Vertical Test Stand (VTS) insert adopted at the Fermi National Accelerator Laboratory for cold tests was studied, in the framework of the experimental characterization of Dark SRF cavities conducted by the SQMS (Superconducting Quantum Materials and Systems) center. Due to the complexity of the assembly, experimental activity is of utmost importance to validate the model. Thus, vibration testing was performed on the actual system, and a good correlation between numerical and experimental results was found. Additionally, two different setups were compared, with and without implementing a preliminary passive vibration suppression system, to assess its effectiveness in reducing the microphonics phenomenon. The obtained results allowed for the design of an improved isolation system, which will be the subject of future experimental testing.

43 PARTICLE ACCELERATORS↗

Dampers for Stationary Labyrinth Seals

Vibration dampers have been invented that are incorporated as components within the stationary labyrinth seal assembly. These dampers are intended to supplement other vibration-suppressing features of labyrinth seals in order to reduce the incidence of high-cycle-fatigue failures, which have been known to occur in the severe vibratory environments of jet engines and turbopumps in which labyrinth seals are typically used. A vibration damper of this type includes several leaf springs and/or a number of metallic particles (shot) all held in an annular seal cavity by a retaining ring. The leaf springs are made of a spring steel alloy chosen, in conjunction with design parameters, to maintain sufficient preload to ensure effectiveness of damping at desired operating temperatures. The cavity is vented via a small radial gap between the retaining ring and seal housing. The damping mechanism is complex. In the case of leaf springs, the mechanism is mainly friction in the slippage between the seal housing and individual dampers. In the case of a damper that contains shot, the damping mechanism includes contributions from friction between individual particles, friction between particles and cavity walls, and dissipation of kinetic energy of impact. The basic concept of particle/shot vibration dampers has been published previously; what is new here is the use of such dampers to suppress traveling-wave vibrations in labyrinth seals. Damping effectiveness depends on many parameters, including, but not limited to, coefficient of friction, mode shape, and frequency and amplitude of vibrational modes. In tests, preloads of the order of 6 to 15 lb (2.72 to 6.8 kilograms) per spring damper were demonstrated to provide adequate damping levels. Effectiveness of shot damping of vibrations having amplitudes from 20 to 200 times normal terrestrial gravitational acceleration (196 to 1,960 meters per square second) and frequencies up to 12 kHz was demonstrated for shot sizes from 0.032 to 0.062 in. (0.8 to 1.6 millimeters) at fill levels of from 70 to 95 percent.

El-Aini, Yehia↗

In-Sodium Testing of a Prototype Thermoacoustic Power Sensor for Sodium-Cooled Fast Reactors

The ultimate goal of this project is to develop and demonstrate a thermoacoustic power sensor (TAPS) for Sodium-Cooled Fast Reactors (SFRs), with potential application also envisioned to other nuclear technologies such as Lead-Cooled Fast Reactors (LFRs), Molten Salt Reactors (MSRs), in addition to Light Water Reactors (LWRs). The project was led by Westinghouse Electric Company, LLC (Westinghouse) and carried out in collaboration with Argonne National Laboratory (ANL) and the University of Pittsburgh. A TAPS is a passive (self-powered), non-invasive (wireless) sensor envisioned for measuring key parameters, such as local temperature and neutron flux, in a nuclear reactor core. The sensor generates pressure waves (i.e., sound waves) with a frequency and amplitude dependent upon nuclear operating conditions (coolant temperature or power changes). The acoustic waves are able to travel through the core and associated structures, and reach to the sensor network placed outside and/or inside of the reactor vessel. These sensors require a very small amount of power which, during loss of power events, can be provided, for example, by harvesting gamma radiation energy, thus resulting in a monitoring system that can function both during normal operation and during loss of power events. Westinghouse and the University of Pittsburgh designed and fabricated TAPS prototypes for Argonne National Laboratory (ANL) to carry out in-sodium testing to evaluate the effects of sodium on the TAPS and the performance of the TAPS technique in sodium. Argonne received a TAPS prototype from Westinghouse, and the prototype was modified such that it can be installed into a test vessel and function in sodium at elevated temperature without potentially leaking. A water mockup test apparatus was constructed to validate proper working of the prototype. An instrumentation and control (I&C) system, running on the National Instruments (NI) LabView platform, was developed to: 1) operate both the water mockup test and the in-sodium test facility; and 2) process and analyze the received acoustic signals from an array of accelerometers and the Argonne sodium-submersible high-temperature acoustic sensor. The prototype was successfully tested in a water bath at different temperatures. Water mockup tests demonstrated that the TAPS prototype is working properly and its resonance frequency changes linearly with the coolant (water) temperature. A TAPS test apparatus was constructed and integrated with the upgraded Under-Sodium Viewing (USV) sodium test facility. The integrated USV-TAPS sodium test facility has been operational. The TAPS prototype and a high-temperature sodium-submersible acoustic sensor (SSAS) developed by Argonne were both installed inside the TAPS test vessel. Being operated within argon cover gas under ambient conditions, the TAPS prototype demonstrated that it was functioning properly with a resonance frequency at 1407.2 Hz, which was successfully detected by the accelerometers mounted on the external wall of the vessel and the high-temperature SSAS installed inside the vessel. After successfully transferring sodium into the vessel, in-sodium tests of the prototype were conducted. Tests of the TAPS prototype demonstrated that the resonance frequency of the TAPS changes linearly with respect to the temperature difference between the interior of the TAPS and bulk sodium. The early tests showed that the TAPS prototype could not establish a continuous and consistent resonance in sodium. The resonance diminished before the prototype reached its operating temperature. A signal postprocessor was added to the DAQ module latterly to isolate interferences, enhance signal conditioning, improve peak detection, and generate resonance frequency versus temperature plots. After testing in molten sodium and immersion at higher temperature for several weeks, the TAPS prototype was able to establish a continuous resonance. Performance evaluation of the TAPS prototype was then conducted in sodium. The tests included the investigation of 1) the effects of the temperature difference between the TAPS and bulk sodium, 2) the effects of sodium flowrate; and 3) the performance of the different sensor-receiver systems positioned inside or outside the vessel. Results of a test demonstrated that, with limited sodium circulation, a continuous and consistent resonance of the TAPS prototype was established occasionally. The tests also demonstrated that, because of the nature of detection principles and mounting methods, the high temperature SSAS is more affected by acoustic noise, while accelerometers are more affected by vibrations, in the test environment. It is unknown why the TAPS prototype only occasionally established a continuous and consistent resonance when the TAPS temperature reached its operating temperature in molten sodium, and why it ultimately failed to resonate at all. A failure modes assessment was conducted and a few potential causes of failure were identified. Different post in-sodium tests were conducted to obtain additional information potentially relevant to the cause of the failure. Nondestructive evaluation techniques are suggested to examine the internal integrity as well as the gas mixture of the prototype. If they prove inconclusive, the prototype should be cut open to conduct a thorough inspection of its internal integrity and determine the state of the gas mixture.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

A comparison of measured and predicted test flow in an expansion tube with air and oxygen test gases

Simultaneous time-resolved measurements of temperature, density, pitot pressure, and wall pressure in both air and O2 test gases were obtained in the Langley pilot model expansion tube. These tests show nonequilibrium chemical and vibrational relaxation significantly affect the test-flow condition. The use of an electromagnetic device to preopen the secondary diaphragm before the arrival of the primary shock wave resulted in an improvement in the agreement between the measured pitot pressure and the value inferred from measured density and interface velocity. Boundary-layer splitter plates used to reduce the wall boundary layer show that this disagreement in the measured and inferred pitot pressures is not a result of boundary-layer effects.

Aaggard, K. V.↗

Low-frequency noise reduction of lightweight airframe structures

The results of an experimental study to determine the noise attenuation characteristics of aircraft type fuselage structural panels were presented. Of particular interest was noise attenuation at low frequencies, below the fundamental resonances of the panels. All panels were flightweight structures for transport type aircraft in the 34,050 to 45,400 kg (75,000 to 100,000 pounds) gross weight range. Test data include the results of vibration and acoustic transmission loss tests on seven types of isotropic and orthotropically stiffened, flat and curved panels. The results show that stiffness controlled acoustically integrated structures can provide very high noise reductions at low frequencies without significantly affecting their high frequency noise reduction capabilities.

Getline, G. L.↗

Experimental Investigation of Launch Vehicle Transient Input Simulation in Payload Tests

The technique of electronically simulating the structural dynamics of a launch vehicle in transient tests of payloads using multiple vibration excitation systems was investigated. The development of computer programs to determine transfer functions, synthesize shaker forcing functions, and control vibration exciters is described. A demonstration test using the techniques was described and results are presented. The evaluation of the potential for applying this technique to large Shuttle payloads is discussed.

Rader, P.↗

MELDI2 Do No Harm Test Series

Mars 2020 will fly the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) sensor suite consisting of a total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer embedded in the thermal protection system (TPS). Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020's predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12" by 12" test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuum/ cycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation. This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

Heatshield↗

Spacecraft Micro-Vibration: A Survey of Problems, Experiences, Potential Solutions, and Some Lessons Learned

Predicting, managing, controlling, and testing spacecraft micro-vibrations due to on-board internal disturbance sources is a formidable multi-disciplinary systems engineering challenge, especially for those observatories hosting extremely sensitive optical sensor payloads with stringent requirements on allowable Line-of-Sight (LOS) jitter. In this paper some specific spacecraft micro-vibration engineering challenges will be introduced and described. Technical background context is provided with the inclusion of several illustrative examples of NASA and ESA missions (both past and present) where dynamic interactions have to be addressed and which have demanding payload instrument LOS jitter requirements. A general modeling, analysis, simulation, and test approach to address and solve the overall problem of spacecraft micro-vibrations is outlined. Recommended rules of thumb are presented to provide guidance for analysts on where to initiate and how to approach a new spacecraft micro-vibration design problem. A set of experience based spacecraft micro-vibration lessons learned are also presented in the hope they can be leveraged on new system development projects to help overcome unfamiliarity with previously identified micro-vibration technical pitfalls and challenges.

Alvarez-Salazar, Oscar S.↗

Testing of Heat Flux Sensors at Cryogenic Temperatures

Normally, in order to characterize multilayer insulation installed onto a test tank, the boil-off of the tank is measured and then heat loads from structural and fluid penetrations are calculated from temperature measurements throughout the system. For the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig testing, it was determined that this approach would have significant uncertainties (over 50%) and that another method was needed to characterize the heat load through the blanket. Heat flux sensors are widely used to measure heat loads and characterize insulation systems at room temperature, however, the heat fluxes measured are usually two orders of magnitude higher than high performance MLI. Three different heat flux sensors were initially checked out on a liquid hydrogen calorimeter. One was chosen for actual implementation and 20 sensors were ordered. Of those sensors, calibration was attempted on 7 of the sensors. The results from testing and calibration are discussed.

cryogenic fluid management↗

Line-of-sight performance improvement with reaction-wheel isolation

Design techniques used to isolate and damp vibrations from the reaction control wheels assembly (RCA) from the structural dynamics of the Hubble Space Telescope are described. The four RCAs can generate sufficient torque for large maneuvers and precision control during fine pointing. The RCAs are to operate continuously during observations and thereby pose the potential of inducing jitter. The image stability must be constrained to less than 0.007 arcsec rms per 24 hr and pointing accuracy must be 0.01 arcsec for 100 hr. Vibration-producing characteristics of the RCAs are identified, and test results are provided from measurements of the magnitudes of the associated disturbances. Design features and test results for the vibration isolators employed with the RCAs to effect viscous damping of RCA axial perturbations are presented. The dampers are expected to reduce jitter effects of RCA operation by a half.

Rodden, J. J.↗