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At least 1,261 records · Page 70

Venting of a Water/Inhibited Propylene Glycol Mixture in a Vacuum Environment-Characterization and Representative Test Results

A planned use of the Orion space vehicle involves its residence at the International Space Station for six months at a time. One concept of operations involves temporarily venting portions of the idle Orion active thermal control system (ATCS) during the docked phase, preventing freezing. The venting would have to be reasonably complete with few, if any, completely filled pockets of frozen liquid. Even if pockets of frozen liquid did not damage the hardware during the freezing process, they could prevent the system from filling completely prior to its reactivation. The venting of single component systems in a space environment has been performed numerous times and is well understood. Local nucleation occurs at warm, relatively massive parts of the system, which creates vapor and forces the bulk liquid out of the system. The remnants of the liquid will freeze, then evaporate over time through local heating. Because the Orion ATCS working fluid is a 50/50 mixture of water and inhibited propylene glycol, its boiling behavior was expected to differ from that of a pure fluid. It was thought that the relatively high vapor pressure water might evaporate preferentially, leaving behind a mixture enriched with the low vapor pressure propylene glycol, which would be vaporization ]resistant. Owing to this concern, a test was developed to compare the evaporation behavior of pure water, a 50/50 mixture of water and inhibited propylene glycol, and inhibited propylene glycol. The test was performed using room temperature fluids in an instrumented thin walled stainless steel vertical tube. The 1 in x 0.035 in wall tube was instrumented with surface thermocouples and encased in closed cell polyurethane foam. Reticulated polyurethane foam was placed inside the tube to reduce the convection currents. A vacuum system connected to the top of the tube set the pressure boundary condition. Tests were run for the three fluids at back pressures ranging from 1 to 18 torr. During each test, the mass of the test article was measured as it changed over time, as was its temperature and backpressure. The tests were successful. Somewhat surprisingly, the results showed that the evaporation behavior of the three fluids had more similarities than differences. The 50/50 mixture evaporated similarly to the pure water - albeit at a slower rate. The test results indicate that our extensive space - based experience with venting of single component fluids can be applied to the problem of Orion ATCS venting as long as the appropriate puts, takes, and caveats are applied.

Ungar, Eugene K.↗

Sensitivity of Depth-Integrated Satellite Lidar to Subaqueous Scattering

A method is presented for estimating subaqueous integrated backscatter from the CALIOP lidar. The algorithm takes into account specular reflection of laser light, laser scattering by wind-generated foam as well as sun glint and solar scattering from the foam Analyses show that the estimated subaqueous integrated backscatter is most sensitive to the estimate of transmittance used in the atmospheric correction, and is very insensitive to the estimate of wind speed used. As a case study, CALIOP data over Tampa Bay were compared to MODIS 645 nm remote sensing reflectance, which previously has been shown to be nearly linearly related to turbidity. The results indicate good correlation on nearly all CALIOP clear-free dates during the period 2006 through 2007, particularly those with relatively high atmospheric transmittance. When data are composited over the entire period the correlation is reduced but still statistically significant, an indication of variability in the biogeochemical composition in the water. Overall, the favorable results show promise for the application of satellite lidar integrated backscatter in providing information about subsurface backscatter properties, which can be extracted using appropriate models

Barton, Jonathan S.↗

Multilayer Composite Pressure Vessels

A method has been devised to enable the fabrication of lightweight pressure vessels from multilayer composite materials. This method is related to, but not the same as, the method described in gMaking a Metal- Lined Composite-Overwrapped Pressure Vessel h (MFS-31814), NASA Tech Briefs, Vol. 29, No. 3 (March 2005), page 59. The method is flexible in that it poses no major impediment to changes in tank design and is applicable to a wide range of tank sizes. The figure depicts a finished tank fabricated by this method, showing layers added at various stages of the fabrication process. In the first step of the process, a mandrel that defines the size and shape of the interior of the tank is machined from a polyurethane foam or other suitable lightweight tooling material. The mandrel is outfitted with metallic end fittings on a shaft. Each end fitting includes an outer flange that has a small step to accommodate a thin layer of graphite/epoxy or other suitable composite material. The outer surface of the mandrel (but not the fittings) is covered with a suitable release material. The composite material is filament- wound so as to cover the entire surface of the mandrel from the step on one end fitting to the step on the other end fitting. The composite material is then cured in place. The entire workpiece is cut in half in a plane perpendicular to the axis of symmetry at its mid-length point, yielding two composite-material half shells, each containing half of the foam mandrel. The halves of the mandrel are removed from within the composite shells, then the shells are reassembled and bonded together with a belly band of cured composite material. The resulting composite shell becomes a mandrel for the subsequent steps of the fabrication process and remains inside the final tank. The outer surface of the composite shell is covered with a layer of material designed to be impermeable by the pressurized fluid to be contained in the tank. A second step on the outer flange of each end fitting accommodates this layer. Depending on the application, this layer could be, for example, a layer of rubber, a polymer film, or an electrodeposited layer of metal. If the fluid to be contained in the tank is a gas, then the best permeation barrier is electrodeposited metal (typically copper or nickel), which can be effective at a thickness of as little as 0.005 in (.0.13 mm). The electrodeposited metal becomes molecularly bonded to the second step on each metallic end fitting. The permeation-barrier layer is covered with many layers of filament-wound composite material, which could be the same as, or different from, the composite material of the inner shell. Finally, the filament-wound composite material is cured in an ov

DeLay, Tom↗

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗

Flexible Shields for Protecting Spacecraft Against Debris

A report presents the concept of Flexshield a class of versatile, lightweight, flexible shields for protecting spacecraft against impacts by small meteors and orbiting debris. The Flexshield concept incorporates elements of, but goes beyond, prior spacecraft-shielding concepts, including those of Whipple shields and, more recently, multi-shock shields and multi-shock blankets. A shield of the Flexshield type includes multiple outer layers (called bumpers in the art) made, variously, of advanced ceramic and/or polymeric fibers spaced apart from each other by a lightweight foam. As in prior such shields, the bumpers serve to shock an impinging hypervelocity particle, causing it to disintegrate vaporize, and spread out over a larger area so that it can be stopped by an innermost layer (back sheet). The flexibility of the fabric layers and compressibility of the foam make it possible to compress and fold the shield for transport, then deploy the shield for use. The shield can be attached to a spacecraft by use of snaps, hook-and-pile patches, or other devices. The shield can also contain multilayer insulation material, so that it provides some thermal protection in addition to mechanical protection.

Christiansen, Eric L.↗

Lightweight, Self-Deployable Wheels

Ultra-lightweight, self-deployable wheels made of polymer foams have been demonstrated. These wheels are an addition to the roster of cold hibernated elastic memory (CHEM) structural applications. Intended originally for use on nanorovers (very small planetary-exploration robotic vehicles), CHEM wheels could also be used for many commercial applications, such as in toys. The CHEM concept was reported in "Cold Hibernated Elastic Memory (CHEM) Expandable Structures" (NPO-20394), NASA Tech Briefs, Vol. 23, No. 2 (February 1999), page 56. To recapitulate: A CHEM structure is fabricated from a shape-memory polymer (SMP) foam. The structure is compressed to a very small volume while in its rubbery state above its glass-transition temperature (Tg). Once compressed, the structure can be cooled below Tg to its glassy state. As long as the temperature remains <Tg the structure remains compacted (in a cold hibernated state), even when the external compressive forces are removed. When the structure is subsequently heated above Tg, it returns to the rubbery state, in which a combination of elasticity and the SMP effect cause it to expand (deploy) to its original size and shape. Once thus deployed, the CHEM structure can be rigidified by cooling below Tg to the glassy state. The structure could be subsequently reheated above Tg and recompacted. The compaction/deployment/rigidification cycle could be repeated as many times as needed.

Chmielewski, Artur↗

Efficient Design and Analysis of Lightweight Reinforced Core Sandwich and PRSEUS Structures

Design, analysis, and sizing methods for two novel structural panel concepts have been developed and incorporated into the HyperSizer Structural Sizing Software. Reinforced Core Sandwich (RCS) panels consist of a foam core with reinforcing composite webs connecting composite facesheets. Boeing s Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) panels use a pultruded unidirectional composite rod to provide axial stiffness along with integrated transverse frames and stitching. Both of these structural concepts are ovencured and have shown great promise applications in lightweight structures, but have suffered from the lack of efficient sizing capabilities similar to those that exist for honeycomb sandwich, foam sandwich, hat stiffened, and other, more traditional concepts. Now, with accurate design methods for RCS and PRSEUS panels available in HyperSizer, these concepts can be traded and used in designs as is done with the more traditional structural concepts. The methods developed to enable sizing of RCS and PRSEUS are outlined, as are results showing the validity and utility of the methods. Applications include several large NASA heavy lift launch vehicle structures.

Bednarcyk, Brett A.↗

Debris Impact Detection Instrument for Crewed Modules

When micrometeoroid or debris impacts occur on a space habitat, crew members need to be quickly informed of the likely extent of damage, and be directed to the impact location for possible repairs. This is especially important because the outer walls of pressurized volumes are often not easily accessible, blocked by racks or cabinets. The goal of the Habitat Particle Impact Monitoring System (HIMS) is to develop a fully automated, end-to-end particle impact detection system for crewed space exploration modules. The HIMS uses multiple passive, thin film piezo-polymer vibration sensors to detect impacts on a surface, and computer processing of the acoustical signals to characterize the impacts. Development and demonstration of the HIMS is proceeding in concert with NASA's Habitat Demonstration Unit (HDU) Project. The HDU Project is designed to develop and test various technologies, configurations, and operational concepts for exploration habitats. This paper describes the HIMS development, initial testing, and HDU integration efforts. Initial tests of the system on the HDU were conducted at NASA s 2010 and 2011 Desert Research and Technologies Studies (Desert-RATS or D-RATS). The HDU lab module, as seen from above, has an open circular floorplan divided into eight wedge-shaped Segments. The side wall of the module -- the surface used for this technology demonstration -- is a hard fiberglass composite covered with a layer of sprayed-on foam insulation. Four sensor locations were assigned near the corners of a rectangular pattern on the wall of one segment of the HDU lab module. The flat, self-adhesive sensors were applied to the module during its initial outfitting. To study the influence of the wall s construction (thickness and materials), three sets of four sensors were installed at different layer depths: on the interior of the module s wall, on the exterior of the same wall, and on the exterior of the foam insulation. The signal produced when a vibration passes through a sensor is first sent through a pre-amplifier. The amplified signal then is sent to the data acquisition and data processing systems. The vibration data from the sensors are then processed and reduced to a form suitable for presentation to the crew.

Opiela, J.↗

Nutrient Considerations for Plants Grown Under Space Flight Conditions

We present here results on the analysis of 100 mL medium samples extracted from sterilized foam (Smithers-Oasis, Kent OH) used to support the growth of both dicotyledonous (Haplopappus gracilis, n=75) and monocotyledonous (Hemerocallis cv Autumn Blaze, n=25) aseptic plants in NASA's Plant Growth Unit (PGU) during the 5-day CHROMEX-01 Space Shuttle flight (March 1989, STS-29). At recovery, the medium remaining within each of the five floral foam blocks (for both the space flight and ground control experiments) was extracted under vacuum, filtered and subjected to elemental analyses. Concentration levels of some elements remained the same, while some decreased and others increased. A unique aspect of this experiment was that all plants were either aseptic tissue culture generated plantlets or sterile seedling clones, and the design of the PGU facilitated the maintenance of asepsis throughout the mission (confirmed by postflight microbial sampling). This permitted the elimination of microbial considerations in the interpretation of the data. The significance of these findings for growing plants in altered gravity environments are discussed.

Levine, Howard G.↗

Material Model Evaluation of a Composite Honeycomb Energy Absorber

A study was conducted to evaluate four different material models in predicting the dynamic crushing response of solid-element-based models of a composite honeycomb energy absorber, designated the Deployable Energy Absorber (DEA). Dynamic crush tests of three DEA components were simulated using the nonlinear, explicit transient dynamic code, LS-DYNA . In addition, a full-scale crash test of an MD-500 helicopter, retrofitted with DEA blocks, was simulated. The four material models used to represent the DEA included: *MAT_CRUSHABLE_FOAM (Mat 63), *MAT_HONEYCOMB (Mat 26), *MAT_SIMPLIFIED_RUBBER/FOAM (Mat 181), and *MAT_TRANSVERSELY_ANISOTROPIC_CRUSHABLE_FOAM (Mat 142). Test-analysis calibration metrics included simple percentage error comparisons of initial peak acceleration, sustained crush stress, and peak compaction acceleration of the DEA components. In addition, the Roadside Safety Verification and Validation Program (RSVVP) was used to assess similarities and differences between the experimental and analytical curves for the full-scale crash test.

Jackson, Karen E.↗

Test Analysis Correlation of the Single Stringer Bending Tests for the Space Shuttle ET-137 Intertank Stringer Crack Investigation

On November 5, 2010, Space Shuttle mission STS-133 was scrubbed due to a hydrogen leak at the Ground Umbilical Carrier Plate (GUCP). After the scrub, a crack in the foam thermal protection system (TPS) was observed on the External Tank (ET) near the interface between the liquid oxygen (LOX) tank and the Intertank. When the damaged foam was removed, two 9-in. long cracks were found on the feet of Intertank stringer S7-2, and the stringer failure was the cause of the TPS crack. An investigation was conducted to determine the root cause of the cracks, establish a remedy/repair for the stringers, and provide flight rationale for the damaged tank, ET-137. The Space Transportation System (STS) Super Lightweight ET (SLWT) is comprised of two propellant tanks (an aft liquid hydrogen (LH2) tank and a forward LOX tank) and an Intertank. The Intertank serves as the structural connection between the two propellant tanks and also functions to receive and distribute all thrust loads from the solid rocket boosters . The Intertank is a stiffened cylinder structure consisting of eight mechanically joined panels (two integrally-stiffened, machined thrust panels to react the booster loads and six stringer-stiffened skin panels). There are one main ring frame, four intermediate ring frames, and forward and aft flange chords that mate to the respective propellant tanks.. The skin/stringer panels utilize external hat-section stringers that are mechanically attached with rivets along most of their length and with specialty fasteners, such as GP Lockbolts and Hi-Loks, at the forward and aft ends where the stringers attach to the flange chords. During the STS-133 Intertank stringer crack investigation, cracks were found on a total of five stringers. All of the cracks were at the LOX end, in the feet of the stringers, and near the forward fasteners (GP Lockbolts). Video of tanking for the November 5 launch attempt was used to determine that the TPS failure, and thus the stringer failure, occurred as the LOX liquid level crossed the LOX tank / Intertank interface ring frame. Hence, cryogenically-induced displacements were suspected as a contributing cause of the stringer cracks. To study the behavior of Intertank stringers subjected to similar displacements, static load tests of individual stringers, colloquially known as "single stringer bending tests" were performed. Approximately thirty stringers were tested, many of which were cut from the partially completed Intertank for what would have been ET-139. In addition to the tests, finite element (FE) analyses of the test configuration were also performed. In this paper, the FE analyses and test-analysis correlation for stringer test S6-8 are presented. Stringer S6-8 is a "short chord" configuration with no doubler panels.

Phillips, Dawn R.↗

Stringer Bending Test Helps Diagnose and Prevent Cracks in the Space Shuttle's External Tank

Space Shuttle Discovery's last mission, STS-133, was scheduled to launch on November 5, 2010. Just hours before liftoff, a hydrogen leak at an umbilical connection scrubbed the launch attempt. After the scrub, further inspection revealed a large crack in the foam insulation covering the External Tank, ET-137. Video replay of the launch attempt confirmed the crack first appeared as cryogenic propellants were being loaded into the ET. When the cracked foam was removed, technicians found the underlying stringer had two 9-inch-long cracks. Further inspection revealed a total of 5 of the 108 ET stringers had cracked. NASA and Lockheed Martin immediately launched an aggressive campaign to understand the cracks and repair the stringers in ET-137, targeting February 2011 as the new launch date for STS-133. Responsibilities for the various aspects of the investigation were widely distributed among NASA centers and organizations. This paper will focus on lab testing at Marshall Space Flight Center (MSFC) in Huntsville, Alabama that was intended to replicate the stringer failure and gauge the effect of proposed countermeasures.

Saxon, Joseph B.↗

Integrated Structural/Acoustic Modeling of Heterogeneous Panels

A model for the dynamic response of heterogeneous media is presented. A given medium is discretized into a number of subvolumes, each of which may contain an elastic anisotropic material, void, or fluid, and time-dependent boundary conditions are applied to simulate impact or incident pressure waves. The full time-dependent displacement and stress response throughout the medium is then determined via an explicit solution procedure. The model is applied to simulate the coupled structural/acoustic response of foam core sandwich panels as well as aluminum panels with foam inserts. Emphasis is placed on the acoustic absorption performance of the panels versus weight and the effects of the arrangement of the materials and incident wave frequency.

Bednarcyk, Brett, A.↗

Chemical Kinetics of the TPS and Base Bleeding During Flight Test

The present research deals with thermal degradation of polyurethane foam (PUF) during flight test. Model of thermal decomposition was developed that accounts for polyurethane kinetics parameters extracted from thermogravimetric analyses and radial heat losses to the surrounding environment. The model predicts mass loss of foam, the temperature and kinetic of release of the exhaust gases and char as function of heat and radiation loads. When PUF is heated, urethane bond break into polyol and isocyanate. In the first stage, isocyanate pyrolyses and oxidizes. As a result, the thermo-char and oil droplets (yellow smoke) are released. In the second decomposition stage, pyrolysis and oxidization of liquid polyol occur. Next, the kinetics of chemical compound release and the information about the reactions occurring in the base area are coupled to the CFD simulations of the base flow in a single first stage motor vertically stacked vehicle configuration. The CFD simulations are performed to estimate the contribution of the hot out-gassing, chemical reactions, and char oxidation to the temperature rise of the base flow. The results of simulations are compared with the flight test data.

Osipov, Viatcheslav↗

Space Shuttle Solid Rocket Booster Debris Assessment

The Space Shuttle Columbia Accident revealed a fundamental problem of the Space Shuttle Program regarding debris. Prior to the tragedy, the Space Shuttle requirement stated that no debris should be liberated that would jeopardize the flight crew and/or mission success. When the accident investigation determined that a large piece of foam debris was the primary cause of the loss of the shuttle and crew, it became apparent that the risk and scope of - damage that could be caused by certain types of debris, especially - ice and foam, were not fully understood. There was no clear understanding of the materials that could become debris, the path the debris might take during flight, the structures the debris might impact or the damage the impact might cause. In addition to supporting the primary NASA and USA goal of returning the Space Shuttle to flight by understanding the SRB debris environment and capability to withstand that environment, the SRB debris assessment project was divided into four primary tasks that were required to be completed to support the RTF goal. These tasks were (1) debris environment definition, (2) impact testing, (3) model correlation and (4) hardware evaluation. Additionally, the project aligned with USA's corporate goals of safety, customer satisfaction, professional development and fiscal accountability.

Kendall, Kristin↗

Fiber Reinforced Composite Cores and Panels

A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips, and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins. Continuously wound strips or strip sections may be continuously fed either longitudinally or laterally into molding apparatus which may receive skin materials to form reinforced composite panels.

Day, Stephen W.↗

Slocum-TREC Thermal Glider

JPL is now teaming with Teledyne-Webb-Research to produce the first thermal glider that uses PCM for direct buoyancy control (not electronic pumps) and to produce all other required electricity. TWR has increased electrical production total efficiency from 0.45 to 0.61. JPL performed over 6000 cycles (2.4 years) of accelerated life testing of a piston accumulator. Design, fabrication, and testing will be performed in 2012, with deployment by Rutgers University in late 2012. The proposed goal of the ocean endurance tests was 3 months, but will be extended to at last 1 year. The piston accumulator was cycled over 6,000 times in a three-month period in order to simulate continuous glider life of about 2.4 years, The life test data suggests that we might accumulate roughly 0.5 cc of gas in the oil bladders for each cycle. PCM canisters will be fabricated with a compressed aluminum foam core, 7.5% foam selected (< 42 minutes to freeze anticipated) An Axi 5345/18 3-Phase AC alternator selected for power generation, 61% energy storage efficiency A 4-Cell A123 Energy Storage Systems battery selected for energy storage, buss voltage 14.4 to 12.5 V (13.2 V nominal) Glider deployment expected in late 2012

energy harvesting↗

Reliability and Probabilistic Risk Assessment - How They Play Together

PRA methodology is one of the probabilistic analysis methods that NASA brought from the nuclear industry to assess the risk of LOM, LOV and LOC for launch vehicles. PRA is a system scenario based risk assessment that uses a combination of fault trees, event trees, event sequence diagrams, and probability and statistical data to analyze the risk of a system, a process, or an activity. It is a process designed to answer three basic questions: What can go wrong? How likely is it? What is the severity of the degradation? Since 1986, NASA, along with industry partners, has conducted a number of PRA studies to predict the overall launch vehicles risks. Planning Research Corporation conducted the first of these studies in 1988. In 1995, Science Applications International Corporation (SAIC) conducted a comprehensive PRA study. In July 1996, NASA conducted a two-year study (October 1996 - September 1998) to develop a model that provided the overall Space Shuttle risk and estimates of risk changes due to proposed Space Shuttle upgrades. After the Columbia accident, NASA conducted a PRA on the Shuttle External Tank (ET) foam. This study was the most focused and extensive risk assessment that NASA has conducted in recent years. It used a dynamic, physics-based, integrated system analysis approach to understand the integrated system risk due to ET foam loss in flight. Most recently, a PRA for Ares I launch vehicle has been performed in support of the Constellation program. Reliability, on the other hand, addresses the loss of functions. In a broader sense, reliability engineering is a discipline that involves the application of engineering principles to the design and processing of products, both hardware and software, for meeting product reliability requirements or goals. It is a very broad design-support discipline. It has important interfaces with many other engineering disciplines. Reliability as a figure of merit (i.e. the metric) is the probability that an item will perform its intended function(s) for a specified mission profile. In general, the reliability metric can be calculated through the analyses using reliability demonstration and reliability prediction methodologies. Reliability analysis is very critical for understanding component failure mechanisms and in identifying reliability critical design and process drivers. The following sections discuss the PRA process and reliability engineering in detail and provide an application where reliability analysis and PRA were jointly used in a complementary manner to support a Space Shuttle flight risk assessment.

Safie, Fayssal M.↗