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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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A test bed was fabricated to demonstrate hydrogen/oxygen propulsion technology readiness for the Initial Operating Capabilities (IOC) space station application and for use as a means to test evolving technology for the growth station. The test bed, its function, and plans for future testing are discussed.
Lewis Research Center of NASA, with support from Rocketdyne, was engaged in non-real time computer simulation effort for the Space Station Freedom Electric Power System (EPS) EASY5, a simulation package, is used as the primary tool for this activity. Early in the design of the EPS, two test beds were set up at Lewis. The Integrated Test Bed (ITB), that combines and upgrades these test beds, is in the planning stage. The test beds are designed to functionally represent many of the components of the EPS and their interconnections. The simulation effort is primarily directed towards these test beds. Model verification is performed using test bed data.
Regenerative processes for the revitalization of spacecraft atmospheres and reclamation of waste waters are essential for making long-term manned space missions a reality. Processes studied include: static feed water electrolysis for oxygen generation, Bosch carbon dioxide reduction, electrochemical carbon dioxide concentration, vapor compression distillation water recovery, and iodine monitoring. The objectives were to: provide engineering support to Marshall Space Flight Center personnel throughout all phases of the test program, e.g., planning through data analysis; fabricate, test, and deliver to Marshall Space Flight Center an electrochemical carbon dioxide module and test stand; fabricate and deliver an iodine monitor; evaluate the electrochemical carbon dioxide concentrator subsystem configuration and its ability to ensure safe utilization of hydrogen gas; evaluate techniques for recovering oxygen from a product oxygen and carbon dioxide stream; and evaluate the performance of an electrochemical carbon dioxide concentrator module to operate without hydrogen as a method of safe haven operation. Each of the tasks were related in that all focused on providing a better understanding of the function, operation, and performance of developmental pieces of environmental control and life support system hardware.
Lewis Research Center of NASA, with support from Rocketdyne, has engaged in a nonreal-time computer simulation effort for the Space Station Freedom Electric Power System (EPS). EASYS, a simulation package, is used as the primary tool for this activity. Early in the design of the EPS, two test beds were set up at Lewis. The Integrated Test Bed (ITB) that combines and upgrades these test beds is in the planning stage. The test beds are designed to functionally represent many of the components of the EPS and their interconnections. The simulation effort is primarily directed towards these test beds. Model verification is performed using test bed data.
Renewable energy sources and their integration with other power sources to support remote communities is of interest for Mars applications as well as Earth communities. The National Science Foundation (NSF), NASA, and the Department of Energy (DOE) have been jointly supporting development of a 100 kW cold weather wind turbine through grants and SBIRs independently managed by each agency but coordinated by NASA. The NSF grant addressed issues associated with the South Pole application and a 3 kW direct drive unit is being tested there in anticipation of the 100 kW unit operation. The DOE-NREL contract focused on development of the 100 kW direct drive generator. The NASA SBIR focused on the development of the 100 kW direct drive wind turbine. The success of this effort has required coordination and team involvement of federal agencies and the industrial partners. Designs of the wind turbine and component performance testing results will be presented. Plans for field testing of wind turbines, based on this design, in village energy systems in Alaska and in energy production at the South Pole Station will be discussed. Also included will be a discussion of terrestrial and space use of hybrid energy systems, including renewable energy sources, such as the wind turbine, to support remote communities.
Mars Tumbleweed is a concept for an autonomous rover that would achieve mobility through use of the natural winds on Mars. The wind-blown nature of this vehicle make it an ideal platform for conducting random surveys of the surface, scouting for signs of past or present life as well as examining the potential habitability of sites for future human exploration. NASA Langley Research Center (LaRC) has been studying the dynamics, aerodynamics, and mission concepts of Tumbleweed rovers and has recently developed a prototype Mars Tumbleweed Rover for demonstrating mission concepts and science measurement techniques. This paper will provide an overview of the prototype design, instrumentation to be accommodated, preliminary test results, and plans for future development and testing of the vehicle.
The Aeroflightdynamics Directorate (AMRDEC) conducted a simulation to examine the performance of the Comanche Contact Analog world-referenced symbology displayed on the Comanche HIDSS when compared with a compressed symbology design similar to that specified by the former MIL-STD 1295. Six experimental test pilots flew one modified ADS-33 maneuver (hover turn, bob-up), an unusual attitude recovery, and two terrain flight tactical tasks in the NASA Vertical Motion Simulator (VMS). Analysis of the pilot objective performance data and subjective data showed the following results. Objective test results showed that 1295 symbology yielded more rapid maneuvering in the hover turn bob-up than Contact Analog symbology. The average margin of difference in the time to complete the maneuver was approximately two seconds, which was statistically significant. There were no significant differences measured between symbology sets with respect to altitude or position performance measures for all other maneuvers. The NOE target ID task data showed improved accuracy in determining heading to target when using Contact Analog over MIL-STD-1295. Subjective test results, including handling qualities ratings (HQRs) and NASA-TLX workload ratings, showed small but consistent advantages of 1295 symbology over Contact Analog for most parameters. For the bob-up maneuver, 1295 symbology handling qualities were rated Desired for lateral position error and time to complete whereas Contact Analog was rated adequate. The average HQRs for all other maneuvers were rated the same for both symbology sets. Pilot comments and the results of an online questionnaire more strongly favored 1295 over Contact Analog. Repeated comments from all six pilots led to a focus on design issues with six Contact Analog symbols. Those symbols were the heading tape, horizon line, radar altitude six-second predictor, the position of the torque symbol, the absence of a hover position cue, and the widespread positioning of the symbology to the outer edges of the display field-of-view. Pilots rated the present design of three of the six symbols as having safety-of-flight implications. Those symbols were the heading tape, horizon line, and six-second predictor. To summarize, test results showed no objective data that would warrant restricting experimental test pilots from flying constrained tasks. Small but consistent advantages were recorded for the MILSTD-1295 symbology design when executing ADS-33 constrained tasks. No general performance differences were recorded for the operational maneuvers (NOE, contour flight modes) except for the azimuth-to-target task, which favored the Contact Analog heading tape design. There were consistent and strong pilot comments supporting the MIL-STD-1295 design over Contact Analog in both this current simulation and in Comanche Sim I. Three Contact Analog symbols warrant modification and further evaluation to mitigate safety-of-flight implications noted by participating test pilots. A plan for symbology redesign and testing was developed. However, the Comanche program was cancelled by Department of Army in February 2004.
The transition from low earth orbit Extravehicular Activity (EVA) for construction and maintenance activities to planetary surface EVA on asteroids, moons, and, ultimately, Mars demands a new spacesuit system. NASA's development of that system has resulted in dramatically different pumping requirements from those in the current spacesuit system. Hamilton Sundstrand, Cascon, and NASA are collaborating to develop and mature a pump that will reliably meet those new requirements in space environments and within the design constraints imposed by spacesuit system integration. That collaboration, which began in the NASA purchase of a pump prototype for test evaluation, is now entering a new phase of development. A second generation pump reflecting the lessons learned in NASA's testing of the original prototype will be developed under Hamilton Sundstrand internal research funding and ultimately tested in an integrated Advanced Portable Life Support System (APLSS) in NASA laboratories at the Johnson Space Center. This partnership is providing benefit to both industry and NASA by supplying a custom component for EVA integrated testing at no cost to the government while providing test data for industry that would otherwise be difficult or impossible to duplicate in industry laboratories. This paper discusses the evolving collaborative process, component requirements and design development based on early NASA test experience, component stand alone test results, and near term plans for integrated testing at JSCs.
NASA s plans for Extravehicular Activity (EVA) portable life support systems for future exploration missions result in different design requirements than those which led to the combined fan / pump / separator in the current ISS Extravehicular Mobility Unit (EMU). To meet these new requirements, NASA contracted with Hamilton Sundstrand to provide two new prototype fans designed to meet anticipated future system requirements. Based on design trade studies, a high speed fan with mechanical bearing support of the rotating elements and a novel non-metallic barrier canned motor design was developed and implemented in the deliverable prototypes. The prototypes, which used two different bearing lubricants, have been extensively tested in both stand-alone and integrated system tests in NASA laboratories and proven to meet the anticipated performance requirements. Subsequently, they have been subjected to post test inspection and analysis in Hamilton Sundstrand laboratories to assess the effects of integrated operation and resultant exposure to vent loop contaminants. Results have confirmed expectations that one of the lubricants would be superior in this application and the prototype fans have been reassembled with new bearings with the superior lubricant. They have now been returned to the Johnson Space Center for further testing and maturation as part of NASA s PLSS 2.0 integrated test effort. This paper will discuss the test history of these units, resulting test data, the results of post test evaluation, and plans for further testing in the near future.
The standard method for defining static equivalent structural load factors for components is based on Mile s equation. Unless test data is available, 5% critical damping is assumed for all components when calculating loads. Application of this method to electrical cable tie-down hardware often results in high loads, which often exceed the capability of typical tie-down options such as cable ties and P-clamps. Random vibration testing of electrical cables was used to better understand the factors that influence component loads: natural frequency, damping, and mass participation. An initial round of vibration testing successfully identified variables of interest, checked out the test fixture and instrumentation, and provided justification for removing some conservatism in the standard method. Additional testing is planned that will include a larger range of cable sizes for the most significant contributors to load as variables to further refine loads at cable tie-down points. Completed testing has provided justification to reduce loads at cable tie-downs by 45% with additional refinement based on measured cable natural frequencies.
Observations of surviving reentry debris on the ground and research performed by Hyperschall Technologie Göttingen (HTG) [1] indicated that significantly more glass fiber-reinforced polymer (GFRP) and carbon fiber-reinforced polymer (CFRP) components survive reentry than current models predict. NASA’s Orbital Debris Program Office conducted a series of tests to evaluate the accuracy of material demise models for reentering orbital debris used in NASA’s Object Reentry Survival Analysis Tool (ORSAT) and Debris Assessment Software (DAS). Testing is planned in a multi-phase series to allow for quick quantification of results as well as refinement of methods resulting from lessons learned during early phases. The Phase 1 tests discussed here validated ORSAT models for homogeneous metals, provided an efficient quantification of composite material demisability properties like mass loss rate and overall time to demise, and identified potential failure modes, which are currently not well understood. Phase 2 tests will be used to further understand mass loss rates and modes of both thermal and mechanical failure in composite materials. The authors exposed 95 samples of aluminum, CFRP, Kevlar fiber-reinforced polymer, GFRP, and sheets of G10 fiberglass to conditions approximating the reentry environment using an inductively coupled plasma (ICP) torch facility. The cylindrical CFRP samples were exposed to the atmospheric pressure plasma, at both the end and the midpoint, to investigate the difference in demisability between parts with exposed edges, like panels, and parts with no edges, such as carbonoverwrapped pressure vessels (COPVs). In a non-oxidative environment, no composite materials demised within the 5-minute test time. In the oxidative, elevated heat flux environment, CFRP samples demised between 210 s and 270 s. For the first 100 s of insertion time, most of the mass loss was due to pyrolysis of resin, creating an approximately bi-linear mass-loss rate curve with time. In a non-oxidative environment, carbon filaments were observed to unravel from some of the CFRP end-burned samples; however, this effect did not seem to affect the overall time to demise for the samples significantly. These results indicate that both GFRP and CFRP components survive reentry with significantly more remaining mass than current models predict.
NASA Langley Research Center (LaRC) awarded contract NAS1-20467 to the Space Dynamics Laboratory at Utah State University (SDL/USU) to develop instrumentation for the Sounding of the Atmosphere using Broadband Emission Radiometry (SABER) investigation. This report is submitted in compliance with the contract statement of work, DRD item 19, and the requirements of the “SABER Test and Calibration Plan” (SDL/97-069). It describes the test, data analysis, and results of ground calibration. SDL/USU is responsible for ground calibration testing, data collection, and publication of this report. The data analysis and results shown in this report, however, are a shared effort between SDL/USU, GATS, and LaRC.
This report describes the results of a field demonstration of the proposed surface sampling techniques and plan for the multi-year Canister Deposition Field Demonstration (CDFD). The CDFD will evaluate salt deposition rates on three commercial 32PTH2 NUHOMS welded stainless steel storage canisters in Advanced Horizontal Storage Modules. Exposure testing is planned for up to 10 years and will incorporate periodic surface sampling campaigns. The goal of the planned dust sampling and analysis is to determine important environmental parameters that impact the potential occurrence of stress corrosion cracking on spent nuclear fuel (SNF) dry storage canisters. Specifically, measured dust deposition rates and deposited particle sizes will improve parameterization of dust deposition models employed to predict the potential occurrence and timing of stress corrosion cracks on the stainless steel SNF canisters. Previously, a preliminary sampling plan was developed, identifying possible sampling locations on the canister surfaces and sampling intervals; possible sampling methods were also described. Building from previous work, this report documents hand sampling from a spent nuclear fuel canister on a transfer skid mockup designed by Sandia National Laboratories. The sampling took place from a boom lift and salts were collected from mounted sample plates. The results of these efforts are presented in this report and compared to previous laboratory-controlled tests. The information obtained from the CDFD will be critical for ongoing efforts to develop a detailed understanding of the potential for stress corrosion cracking of SNF dry storage canisters.
Several fuel and material irradiation experiments have been planned for the U.S. Department of Energy Advanced Gas Reactor Fuel Development and Qualification Program, which supports the development and qualification of tristructural isotropic (TRISO) coated particle fuel for use in high-temperature gas-cooled reactors. The goals of these experiments are to provide irradiation performance data to support fuel process development, qualify fuel for normal operating conditions, support development of fuel performance models and codes, and provide irradiated fuel and materials for post-irradiation examination and safety testing. Originally planned and named as separate fuel experiments, but subsequently combined into a single test train. AGR-5/6/7 will test low-enriched uranium oxycarbide (UCO – a heterogeneous mixture of uranium oxide and uranium carbide) TRISO fuel. The AGR-5/6 portion of the experiment will provide data to support qualification of the selected reference fuel design, while the AGR-7 portion will serve as a margin test, irradiating the fuel beyond normal operating conditions. During irradiation, the temperature in each capsule is controlled by varying the helium / neon gas mixture flowing through the capsule until the desired thermocouple temperature is reached. Further adjustments can be made by changing the lobe power and the neutron filter. Three neutron filters are available to use as the experiment burns up the fissionable fuel. A thermal finite element model has been created for the five capsules comprising the AGR-5/6/7 experiment. Heat rates from a physics analysis are imported into the model along with fast neutron fluence. Graphite shrinkage due to the fast neutron fluence is incorporated into the model. Gas gaps change as a function of fast neutron fluence. Radiation heat transfer is a major contributor in this model. This is a large model with more than 1 million finite element brick elements. More than 150 different parts are modeled in the finite element model and communicate with each other from a heat transfer sense. More than 50 thermocouples are used in the experiment and are compared to actual measurements. The experiment is composed of five separate stainless steel capsules all welded together. This paper presents a method used to predict the gas mixture in the event that all of the thermocouples fail in a particular capsule. Curve fitting of heat rates from previous cycles and projecting them into the future is the basis of the method.
The operating characteristics of large diameter rolling-element bearings in the ultra high speed regimes expected in advanced turbine engines for high performance aircraft were investigated. A high temperature lubricant, DuPont Krytox 143 AC, was evaluated at bearing speeds to 3 million DN. Compared to the results of earlier, similar tests using a MIL-L-23699 (Type II) lubricant, bearings lubricated with the high density Krytox fluid showed significantly higher power requirements. Additionally, short bearing lives were observed when this fluid was used with AISI M50 bearings in an air atmosphere. The primary mode of failure was corrosion initiated surface distress (fatigue) on the raceways. The potential of a case-carburized bearing to sustain a combination of high-tangential and hertzian stresses without experiencing race fracture was also investigated. Limited full scale bearing tests of a 120 mm bore ball bearing at a speed of 25,000 rpm (3 million DN) indicated that a carburized material could sustain spalling fatigue without subsequent propagation to fracture. Planned life tests of the carburized material had to be aborted, however, because of apparent processing-induced material defects.
Tests are planned in the 15cm x 15cm supersonic wind tunnel at NASA Glenn to demonstrate the applicability of micro-ramp flow control to the management of shock wave boundary layer interactions. These tests will be used as a database for computational fluid dynamics (CFD) validation and Design of Experiments (DoE) design information. Micro-ramps show potential for mechanically simple and fail-safe boundary layer control.
Both AoA and MDM measurements can be made using an optical system that relies on photogrammetry. Optical measurements are being requested by customers in wind tunnels with increasing frequency due to their non-intrusive nature and recent hardware and software advances that allow measurements to become near real time. The NASA Ames Research Center Unitary Plan Wind Tunnel is currently developing a system based on photogrammetry to measure model deformation and model angle of attack. This paper describes the new system, its development, its use on recent tests and plans to further develop the system.
Flow Boiling in Microgap Coolers (FBMC) is a thermal management technique that provides embedded, on-site heat removal for power dense electronic components and systems. The dielectric coolant undergoes liquid-to-vapor phase change as it passes through channels integrated within or between devices. By facilitating direct contact between the coolant and heat-generating devices and relying on phase change, the system provides tight temperature control, hot spot mitigation, very high heat transfer coefficients, and low pumping power. Ground tests demonstrated removal of high heat fluxes (up to 500 kW/m2), very high coefficients of performance (up to 40 W of heat transferred per W of pumping power), and consistent performance across five evaporator orientations under the appropriate conditions. As a follow-on study and to better assess the role of gravity on such two-phase systems, the FBMC payload was developed and flown twice aboard the Blue Origin New Shepard space vehicle in January and May 2019. Each flight exposed the payload to weightlessness (150 seconds below 0.01 g) and shorter periods of high-g during ascent (up to 3 g) and descent (up to 5 g). The flow boiling performance was consistent independent of the acceleration levels, which provides confidence that such systems will provide consistent performance when tested on the ground, orbiting or traveling through weightlessness, and operating on the surface of the Moon, Mars, and other planetary bodies. Details of the flight results, payload development, flight environment, and planned future testing will be presented.